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Sebm025405 PDF
Sebm025405 PDF
• This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
© 2005
All Rights Reserved 00-1
Printed in Japan 03-05 (03) (5)
00
CONTENTS
No. of page
01 GENERAL ......................................................................................... 01-1
00-2 WA430-5
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following marks. It is requested that necessary
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20-258 (1) 20-319 (1) 20-381 (1) 20-502 (1) 20-562 (1)
20-259 (1) 20-320 (1) 20-382 (1) 20-503 (1) 20-563 (1)
20-260 (1) 20-321 (1) 20-383 (1) 20-504 (1) 20-564 (1)
20-261 (1) 20-322 (1) 20-384 (1) 20-505 (1) 20-565 (1)
20-262 (1) 20-323 (1) 20-385 (1) 20-506 (1) 20-566 (1)
20-263 (1) 20-324 (1) 20-386 (1) 20-507 (1) 20-567 (1)
20-264 (1) 20-325 (1) 20-387 (1) 20-508 (1) 20-568 (1)
20-265 (1) 20-326 (1) 20-388 (1) 20-509 (1) 20-569 (1)
20-266 (1) 20-327 (1) 20-389 (1) 20-510 (1) 20-570 (1)
z 20-267 (5) 20-328 (1) 20-390 (1) 20-512 (1) 20-571 (1)
c 20-267 -1 (5) 20-329 (1) 20-391 (1) 20-513 (1) 20-572 (1)
20-268 (1) 20-330 (1) 20-392 (1) 20-514 (1) 20-573 (1)
20-269 (1) 20-331 (1) 20-393 (1) 20-515 (1) 20-574 (1)
20-270 (1) 20-332 (4) 20-394 (1) 20-516 (1) 20-575 (1)
20-271 (1) 20-333 (4) 20-395 (1) 20-517 (1) 20-576 (1)
20-272 (1) 20-334 (1) 20-396 (1) 20-518 (1) 20-577 (1)
20-273 (1) 20-335 (1) 20-397 (1) 20-519 (1) 20-578 (1)
20-274 (1) 20-336 (1) 20-398 (1) 20-520 (1) 20-579 (1)
20-275 (1) 20-337 (1) 20-399 (1) 20-521 (1) 20-580 (1)
20-276 (1) 20-338 (1) 20-400 (1) 20-522 (1) 20-582 (1)
20-277 (1) 20-340 (1) 20-401 (1) 20-523 (1) 20-583 (1)
20-278 (1) 20-341 (1) 20-402 (1) 20-524 (1) 20-584 (1)
20-279 (1) 20-342 (1) 20-403 (1) 20-525 (1) 20-585 (1)
20-280 (1) 20-343 (1) 20-404 (1) 20-526 (1) 20-586 (1)
z 20-281 (5) 20-344 (1) 20-406 (1) 20-527 (1) 20-587 (1)
20-282 (1) 20-345 (1) 20-407 (1) 20-528 (1) 20-588 (1)
20-283 (1) 20-346 (1) 20-408 (1) 20-529 (1) 20-589 (1)
20-284 (1) 20-347 (1) 20-409 (1) 20-530 (1) 20-590 (1)
20-285 (1) 20-348 (1) 20-410 (1) 20-531 (1) 20-591 (1)
20-286 (1) 20-350 (1) 20- 411 (1) 20-532 (1) 20-592 (1)
20-287 (1) 20-351 (1) 20-412 (1) 20-533 (1) 20-593 (1)
20-288 (1) 20-352 (1) 20-413 (1) 20-534 (1) 20-594 (1)
20-289 (1) 20-353 (1) 20-414 (1) 20-535 (1) 20-595 (1)
z 20-290 (5) 20-354 (1) 20-415 (1) 20-536 (1) 20-596 (1)
z 20-291 (5) 20-355 (1) 20-416 (1) 20-537 (1) 20-597 (1)
z 20-292 (5) 20-356 (1) 20-418 (1) 20-538 (1) 20-598 (1)
z 20-293 (5) 20-357 (1) 20-419 (1) 20-539 (1) 20-599 (1)
c 20-293 -1 (5) 20-358 (1) 20-420 (1) 20-540 (1) 20-600 (1)
c 20-293 -2 (5) 20-360 (1) 20-422 (1) 20-541 (1) 20-601 (1)
z 20-294 (5) 20-361 (1) 20-423 (1) 20-542 (1) 20-602 (1)
20-295 (1) 20-362 (1) 20-424 (4) 20-543 (1) 20-603 (1)
20-301 (4) 20-363 (1) 20-425 (1) 20-544 (1) 20-604 (1)
20-302 (1) 20-364 (1) 20-426 (1) 20-545 (1) 20-605 (1)
20-303 (4) 20-365 (1) 20-427 (4) 20-546 (1) 20-701 (4)
20-304 (1) 20-366 (1) 20-428 (4) 20-547 (1) 20-702 (4)
20-305 (1) 20-367 (1) 20-429 (1) 20-548 (1) 20-704 (1)
20-306 (1) 20-368 (1) 20-430 (1) 20-549 (1) 20-705 (1)
20-307 (1) 20-369 (1) 20-431 (1) 20-550 (1) 20-706 (1)
20-308 (1) 20-370 (1) 20-432 (1) 20-551 (1) 20-707 (1)
20-309 (1) 20-371 (1) 20-433 (1) 20-552 (1) 20-708 (1)
20-310 (1) 20-372 (1) 20-434 (1) 20-553 (1) 20-709 (1)
20- 311 (1) 20-373 (1) 20-435 (1) 20-554 (1) 20-710 (1)
20-312 (1) 20-374 (1) 20-436 (1) 20-555 (1) 20- 711 (1)
20-313 (1) 20-375 (1) 20-437 (1) 20-556 (1) 20-712 (1)
20-314 (1) 20-376 (1) 20-438 (1) 20-557 (1) 20-713 (1)
20-315 (1) 20-377 (1) 20-439 (1) 20-558 (1) 20-714 (1)
20-316 (1) 20-378 (1) 20-440 (1) 20-559 (1) 20-715 (1)
20-317 (1) 20-379 (1) 20-441 (4) 20-560 (1) 20-716 (1)
20-318 (1) 20-380 (1) 20-501 (1) 20-561 (1) 20-717 (1)
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20-718 (1) z 20-780 (5) 20-930 (1) z 30- 27 (5) z 30- 86 (5)
20-719 (1) z 20-781 (5) 20-931 (1) z 30- 28 (5) z 30- 87 (5)
20-720 (1) z 20-782 (5) 20-932 (1) z 30- 29 (5) z 30- 88 (5)
20-721 (1) 20-783 (1) 20-933 (1) z 30- 30 (5) z 30- 89 (5)
20-722 (1) 20-801 (4) 20-934 (1) z 30- 31 (5) z 30- 90 (5)
20-723 (1) 20-802 (3) 20-935 (1) z 30- 32 (5) z 30- 91 (5)
20-724 (1) 20-803 (3) 20-936 (1) z 30- 33 (5) z 30- 92 (5)
20-725 (1) 20-804 (3) 20-937 (1) c 30- 34 (5) z 30- 93 (5)
20-726 (1) 20-805 (3) 20-938 (1) z 30- 35 (5) z 30- 94 (5)
20-727 (1) 20-806 (3) c 20-1001 (5) z 30- 36 (5) z 30- 95 (5)
20-728 (1) 20-807 (3) c 20-1002 (5) z 30- 37 (5) z 30- 96 (5)
20-730 (1) 20-808 (3) c 20-1003 (5) z 30- 38 (5) z 30- 97 (5)
20-731 (1) 20-809 (3) c 20-1004 (5) z 30- 39 (5) z 30- 98 (5)
20-732 (1) 20-810 (3) c 20-1005 (5) z 30- 40 (5) z 30- 99 (5)
20-733 (1) 20- 811 (3) c 20-1006 (5) z 30- 41 (5) z 30-100 (5)
20-734 (1) 20-812 (3) c 20-1007 (5) z 30- 42 (5) z 30-101 (5)
20-735 (1) 20-813 (3) c 20-1008 (5) z 30- 43 (5) z 30-102 (5)
20-736 (1) 20-814 (3) c 20-1009 (5) z 30- 44 (5) z 30-103 (5)
20-737 (1) 20-815 (3) c 20-1010 (5) z 30- 45 (5) z 30-104 (5)
20-738 (1) 20-816 (3) c 20-1011 (5) z 30- 46 (5) z 30-105 (5)
20-739 (1) 20-817 (3) c 20-1012 (5) z 30- 47 (5) z 30-106 (5)
20-740 (1) 20-818 (3) c 20-1013 (5) z 30- 48 (5) z 30-107 (5)
20-742 (4) 20-819 (3) c 20-1014 (5) z 30- 49 (5) z 30-108 (5)
20-743 (1) 20-820 (3) c 20-1015 (5) z 30- 50 (5) z 30-109 (5)
20-744 (1) 20-821 (3) c 20-1016 (5) z 30- 51 (5) z 30- 110 (5)
20-745 (1) 20-822 (3) c 20-1017 (5) z 30- 52 (5) z 30- 111 (5)
20-746 (4) 20-823 (3) c 20-1018 (5) z 30- 53 (5) z 30- 112 (5)
20-747 (1) 20-824 (3) c 20-1019 (5) z 30- 54 (5) z 30- 113 (5)
20-748 (1) 20-825 (3) c 20-1020 (5) z 30- 55 (5) z 30- 114 (5)
20-749 (1) 20-826 (3) c 20-1021 (5) z 30- 56 (5) z 30- 115 (5)
20-750 (1) 20-827 (3) c 20-1022 (5) z 30- 57 (5) z 30- 116 (5)
20-751 (1) 20-828 (4) c 20-1023 (5) z 30- 58 (5) z 30- 117 (5)
20-752 (1) 20-901 (1) z 30- 59 (5) z 30- 118 (5)
20-754 (4) 20-902 (1) z 30- 1 (5) z 30- 60 (5) z 30- 119 (5)
20-755 (1) 20-904 (1) z 30- 2 (5) z 30- 61 (5) z 30-120 (5)
20-756 (4) 20-905 (1) 30- 3 (2) z 30- 62 (5) z 30-121 (5)
20-757 (1) 20-906 (1) 30- 4 (2) z 30- 63 (5) z 30-122 (5)
20-758 (4) 20-907 (1) 30- 5 (2) z 30- 64 (5) z 30-123 (5)
20-759 (1) 20-908 (1) 30- 6 (2) z 30- 65 (5) z 30-124 (5)
20-760 (1) 20-909 (1) z 30- 7 (5) z 30- 66 (5) z 30-125 (5)
20-761 (1) 20-910 (1) z 30- 8 (5) z 30- 67 (5) z 30-126 (5)
20-762 (1) 20- 911 (1) z 30- 9 (5) z 30- 68 (5) z 30-127 (5)
20-763 (1) 20-912 (1) c 30- 10 (5) z 30- 69 (5) z 30-128 (5)
20-764 (1) 20-913 (1) z 30- 11 (5) z 30- 70 (5) z 30-129 (5)
20-765 (1) 20-914 (1) z 30- 12 (5) z 30- 71 (5) z 30-130 (5)
20-766 (1) 20-915 (1) z 30- 13 (5) z 30- 72 (5) z 30-131 (5)
20-767 (1) 20-916 (1) z 30- 14 (5) z 30- 73 (5) z 30-132 (5)
20-768 (1) 20-917 (1) z 30- 15 (5) z 30- 74 (5) z 30-133 (5)
20-769 (1) 20-918 (1) z 30- 16 (5) z 30- 75 (5) z 30-134 (5)
20-770 (1) 20-920 (1) z 30- 17 (5) z 30- 76 (5) z 30-135 (5)
20-771 (1) 20-921 (1) z 30- 18 (5) z 30- 77 (5) z 30-136 (5)
20-772 (1) 20-922 (1) z 30- 19 (5) z 30- 78 (5) z 30-137 (5)
20-773 (1) 20-923 (1) z 30- 20 (5) z 30- 79 (5) z 30-138 (5)
20-774 (1) 20-924 (1) z 30- 21 (5) z 30- 80 (5) z 30-139 (5)
20-775 (1) 20-925 (1) z 30- 22 (5) z 30- 81 (5) z 30-140 (5)
20-776 (1) 20-926 (1) z 30- 23 (5) z 30- 82 (5) z 30-141 (5)
20-777 (1) 20-927 (1) z 30- 24 (5) z 30- 83 (5) z 30-142 (5)
20-778 (1) 20-928 (1) z 30- 25 (5) z 30- 84 (5) z 30-143 (5)
z 20-779 (5) 20-929 (1) z 30- 26 (5) z 30- 85 (5) z 30-144 (5)
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WA430-5 00-2-5
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
Sealing surface
mm mm Nm kgm
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
00-13
FOREWORD STANDARD TIGHTENING TORQUE
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 10-04
01 GENERAL
WA430-5 01-1
GENERAL GENERAL ASSEMBLY DRAWING
01-2 WA430-5
(3)
GENERAL SPECIFICATIONS
SPECIFICATIONS
Tread mm 2,200
Min. ground clearance mm 460
Max. height of bucket hinge pin mm 4,250
Dumping clearance (tip of BOC) mm 3,125/3,210
Dumping reach (tip of BOC) mm 1,110/1,065
Steering angle deg 40
Bucket tilt angle (travel posture) deg 50
Bucket tilt angle (max. height) deg 64
Bucket dump angle (max. height) deg 48
Digging depth (10° dump) (tip of BOC) mm 320/365
WA430-5 01-3
(3)
GENERAL SPECIFICATIONS
SPECIFICATIONS
Model SAA6D125E-3
4-cycle, water-cooled, serial 6-cylinder,
Type direct injection type with supercharger and air cooling
aftercooler
No. of cylinders - bore x stroke mm 6 - 125 x 150
Piston displacement l {cc} 11.0 {11,040}
N mode P mode
Flywheel horsepower kW {HP}/rpm 140/1,720 162/2,000
Engine
{190/1,720} {220/3,000}
Maximum torque Nm {kgm}/rpm 932/1,400 932/1,400
{95/1,400} {95/1,400}
Min. fuel consumption ratio g/kWh {g/HPh} 213{157} 213{157}
High idling speed rpm 1,900 ± 50 2,230 ± 50
Low idling speed rpm 750 (+50/0) 750 (+50/0)
Starting motor 24 V 7.5 kW
Alternator 24 V 35 A
Battery (*1) 24 V 112 Ah x 2 pcs. (145F51)
3-element, 1-stage, 1-phase
Torque converter 3-element, 1-stage, 2-phase (with lockup clutch)
Multple-shaft power shift, helical gear and spur gear, con-
Power train
stant-mesh type
Transmission Multiple plate disc type, hydrualically actuated, modula-
tion type
Reduction gear Spiral bevel gear, splash lubrication type
Differential Straight bevel gear type
Final drive Planetary gear 1-stage, splash lubrication type
Drive type Front and rear wheel drive
Axle
01-4 WA430-5
GENERAL SPECIFICATIONS
l /min
Hydraulic system
• Delivery 48
Cooling fan pump
• Type Variable displacement piston type
Type Reciprocating piston type
Steering cylinder
WA430-5 01-5
GENERAL SPECIFICATIONS
01-6 WA430-5
(3)
GENERAL WEIGHT TABLE
WEIGHT TABLE
★ This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WA430-5
WA430-5 01-7
(3)
GENERAL WEIGHT TABLE
Unit: kg
Machine model WA430-5
Battery (each) 36
Operator’s Cab (OP) 700
Operator’s seat 36
Air conditioner unit (OP) 12.5
Floor board 313
Oil cooler 3.9
Torque convertor oil cooler 21
Cooling fan drive pump 25
Cooling fan drive motor 13
01-8 WA430-5
(3)
GENERAL LIST OF LUBRICANT AND COOLANT
SAE30
SAE10W
Engine oil pan Engine oil
SAE10W-30
SAE15W-40
SAE 10W
SAE 5W-30
Unit: l
WA430-5
CAPACITY
Specified Refill
WA430-5 01-9
GENERAL LIST OF LUBRICANT AND COOLANT
NOTICE
Use only diesel fuel.
The engine mounted on this machine employs a high-pressure fuel injection device to obatain
good fuel consumption and good exahaust gas characteristics. For this reason, it requires high
precision for the parts and good lubrication.
If kerosene or other fuel with low lubricating ability is used, there will be a significant drop in
durability.
01-10 WA430-5
10 STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD
WA430-5 10-1
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
Specifications
Torque converter oil
Radiator Oil cooler After cooler cooler
Core type CF19-4 CF40-1 AL-CFT PTO-OL
*1
Fin pitch (mm) 4.0/2 4.5/2 4.0/2 100 X 558 X 12 Step
Total heat radiating area (m²) 66.30 4.22 17.55 1.291
Pressure valve opening pressure 68.6
(kPa {kg/cm²}) {0.7} — — —
10-2 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ENGINE MOUNT, TRANSMISSION MOUNT
Unit: mm
WA430-5 10-3
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
Outline
• The power from engine (3) is transmitted • The power from the transmission output shaft
through the engine flywheel to torque con- passes through center drive shaft (6), front
verter (2). The turbine in the torque converter is drive shaft (7) and rear drive shaft (5), and is
connected to the input shaft of transmission (1). transmitted to front axle (8) and rear axle (4) to
• The transmission has 6 hydraulically operated drive the wheels.
clutches. These provide 4 FORWARD and
REVERSE speeds.
10-4 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
WA430-5 10-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
10-6 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
Outline
1. Front axle
2. Differential • The power from engine (15) is transmitted
3. Wet-type multiple-disc brake through the flywheel to torque converter (16).
4. Final drive The torque converter uses oil as a medium to
5. Front drive shaft vary the transmission torque according to the
6. Center drive shaft. change in the load. It transmits the power to
7. Parking brake (wet-type multiple-disc) the transmission input shaft.
8. Transmission (multiple-shaft) The power from the engine passes through
9. Rear drive shaft the torque converter pump drive gear and is
10. Rear tire transmitted to steering pump (20), switch pump
11. Final drive (21), cooling fan drive pump (22), transmission
12. Wet-type multiple-disc brake and torque converter charging pump (17), work
13. Differential equipment hydraulic pump (18), and PPC
14. Rear axle pump (19) to drive these pumps.
15. Engine
• Transmission (8) operates the directional valves
16. Torque converter
and speed valves in the transmission to actuate
17. Torque converter charging pump
the 6 hydraulically operated clutches and select
18. Work equipment hydraulic pump
one of the 4 FORWARD or REVERSE speeds.
19. Pilot pump
• Parking brake (7) is applied by an electromag-
20. Steering pump
netic valve that is actuated when the parking
21. Switch pump
brake switch is operated. It is a wet-type multi-
22. Cooling fan drive pump
ple-disc brake installed to the front of the out-
23. Flange bearing
put shaft to stop the machine.
24. Front tire
25. Torque converter lock-up clutch • The power from the output shaft of transmis-
sion (8) is transmitted to the front and rear
axles. At the front, the power is transmitted to
front axle (1) through center drive shaft (6),
flange bearing (23), and front drive shaft (5).
At the rear, it is transmitted to rear axle (14)
through rear drive shaft (9).
• The power transmitted to front axle (1) and rear
axle (14) is reduced by the pinion gear in differ-
entials (2) and (13), and is transmitted through
the differential mechanism to the sun gear
shaft.
• The power from the sun gear is further reduced
by planetary-type final drive (11) and is trans-
mitted to the wheels through the axle shaft.
WA430-5 10-7
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DRIVE SHAFT (PROPELLER SHAFT)
10-8 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER, TRANSMISSION PIPING
WA430-5 10-9
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
Without lock-up clutch
1. Flywheel 6. Pump
2. Drive case (Number of teeth: 72) 7. PTO drive gear (Number of teeth: 97)
3. Boss 8. Stator shaft
4. Turbine 9. Transmission input shaft
5. Stator
Specifications
Type 3-element, 1-stage, 1-phase
Stall torque ratio 2.93
10-10 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
Unit: mm
No. Check item Criteria Remedy
-0.00
Width 3 -0.10 2.7
3 Wear of stator shaft
seal ring
Thickness 4.3 ±0.1 3.9 Replace
WA430-5 10-11
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
• The torque converter is installed between the • The oil passes through the main relief valve and
engine and transmission. its pressure is adjusted by the torque con-
The power from the engine goes from flywheel verter relief valve so that it is less than the set
(1) and enters drive case (2). pressure. It then enters inlet port A, passes
Drive case (2), pump (3), and PTO gear (4) are through the passage in stator shaft (1), and
each fixed by bolts and are rotated directly by flows to pump (2).
the rotation of the engine. The oil is given centrifugal force by pump (2).
The power from pump (3) uses oil as a medium It then enters turbine (3) and transmits the
to rotate turbine (5) and transmit the power to energy of the oil to the turbine.
transmission input shaft (7) through the boss The oil from turbine (3) is sent to stator (4),
(6). and enters the pump (2) again. However, part
The power from drive case (2) passes through of the oil is sent from stator (4) through outlet
PTO gear (4) and is used as the power to drive port B to the cooler.
the gear pump.
10-12 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
Specifications
Type 3-element, 1-stage, 2-phase
Stall torque ratio 2.78
WA430-5 10-13
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
10-14 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
Unit: mm
No. Check item Criteria Remedy
-0.01
Width 5 -0.04 4.5
6 Wear of clutch housing
seal ring
Thickness 6 ±0.15 5.85
-0.00
Width 3.95 -0.1 3.55
7 Wear of stator shaft
seal ring
Thickness 4.6 ±0.1 4.14
WA430-5 10-15
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
• When the lock-up clutch is disengaged, the con- • When the lock-up clutch is engaged, drive case
nection of drive case (3) and turbine (6) is dis- (3) and turbine (6) are connected and form one
connected, and the torque converter functions unit. Stator (9) is rotated by the rotation of
as normal. pump (4) and turbine (6).
The power generated by the engine is transmit- The power generated by the engine is transmit-
ted from flywheel (1) to clutch housing (2), and ted from flywheel (1) to clutch housing (2), and
rotates drive case (3) and pump (4) as one unit. rotates drive case (3) and pump (4) as one unit.
The power from pump (4) uses oil as a medium In addition, drive case (3) and turbine (6) are
to rotate turbine (6) and transmits the power connected by the lock-up clutch, so the power
from turbine (6) to transmission input shaft (8) is transmitted directly from turbine (6) to trans-
through boss (7). mission input shaft (8) without using oil as a
The power from drive case (3) passes through medium.
PTO gear (5) and is used as the power to drive The power from drive case (3) passes through
the gear pump. PTO gear (5) and is used as the power to drive
the gear pump.
10-16 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TORQUE CONVERTER
Flow of oil
WA430-5 10-17
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
10-18 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
WA430-5 10-19
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
10-20 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
No. Check item Criteria Remedy
Tolerance Standard Clearance
Standard size
Clearance between PTO driven Shaft Hole clearance limit
1 gear shaft and bearing (F)
ø 55 +0.030 0. 00 -0.045 - —
+0.011 -0.015 -0.011
WA430-5 10-21
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
10-22 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
1. Spacer 6. F clutch
2. Thrust washer 7. F gear (Number of teeth: 40)
3. R gear (Number of teeth: 31) 8. Thrust washer
4. R clutch 9. Spacer
5. F, R cylinder 10. Transmission input shaft
Unit: mm
No. Check item Criteria Remedy
WA430-5 10-23
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
1. Spacer 6. F clutch
2. Thrust washer 7. F gear (Number of teeth: 40)
3. R gear (Number of teeth: 31) 8. Thrust washer
4. R clutch 9. Spacer
5. F, R cylinder 10. Transmission input shaft
Unit: mm
No. Check item Criteria Remedy
10-24 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
No. Check item Criteria Remedy
WA430-5 10-25
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
10-26 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
Operation of clutch
Clutch engaged Clutch disengaged
• The oil sent from the transmission valve passes • The oil sent from the transmission valve is shut
through the passage inside shaft (1), goes to off, so the pressure of the oil acting on the back
the back face of piston (6), and actuates piston face of piston (6) drops.
(6). • Piston (6) is returned to its original position by
• When piston (6) is actuated, separator plate (2) wave spring (7), and shaft (1) and clutch gear (4)
and friction plate (3) are pressed together, so are separated.
shaft (1) and clutch gear (4) form one unit, and • When the clutch is disengaged, the oil at the
transmit the power. back face of the piston is drained through oil
When this happens, the oil is drained from oil drain hole (5) by centrifugal force to prevent the
drain hole (5), but the amount of oil drained is clutch from remaining partially engaged.
less than the amount of oil supplied, so there is
no influence on the operation of the clutch.
WA430-5 10-27
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
FORWARD 1ST
Operation
• In the case of FORWARD 1st, F clutch (3) and 1st • 1st clutch (9) is engaged, so the power trans-
clutch (9) are engaged. The power transmitted mitted to 1st, 4th cylinder gear (7) goes through
from the torque converter to input shaft (1) is 1st clutch (9) and is transmitted from 1st gear
transmitted to output shaft (22). (10) to 2nd, 3rd cylinder gear (16). From here, it
• The clutch discs of F clutch (3) and 1st clutch (9) passes through lower shaft (20), output gear
are fixed by the hydraulic pressure applied to (19), and output gear (21), and is transmitted to
the clutch piston. output shaft (22).
• The power from the torque converter goes from
input shaft (1) through F clutch (3) to F gear (2),
and is transmitted to 1st, 4th cylinder gear (7).
10-28 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
FORWARD 2ND
Operation
• In the case of FORWARD 2nd, F clutch (3) and • 2nd clutch (17) is engaged, so the power trans-
2nd clutch (17) are engaged. The power trans- mitted to 2nd gear (18) goes through 2nd clutch
mitted from the torque converter to input shaft (17) and is transmitted to 2nd, 3rd cylinder gear
(1) is transmitted to output shaft (22). (16). From here, it passes through lower shaft
• The clutch discs of F clutch (3) and 2nd clutch (20), output gear (19), and output gear (21), and
(17) are fixed by the hydraulic pressure applied is transmitted to output shaft (22).
to the clutch piston.
• The power from the torque converter goes from
input shaft (1) through F clutch (3) to F gear (2),
and is transmitted through 1st, 4th cylinder
gear (7), upper shaft (12), and idler gear (11) to
2nd gear (18).
WA430-5 10-29
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
FORWARD 3RD
Operation
• In the case of FORWARD 3rd, F clutch (3) and • 3rd clutch (15) is engaged, so the power trans-
3rd clutch (15) are engaged. The power trans- mitted to 3rd gear (14) goes through 3rd clutch
mitted from the torque converter to input shaft (15) and is transmitted to 2nd, 3rd cylinder gear
(1) is transmitted to output shaft (22). (16). From here, it passes through lower shaft
• The clutch discs of F clutch (3) and 3rd clutch (20), output gear (19), and output gear (21), and
(15) are fixed by the hydraulic pressure applied is transmitted to output shaft (22).
to the clutch piston.
• The power from the torque converter goes from
input shaft (1) through F clutch (3) to F gear (2),
and is transmitted through 1st, 4th cylinder
gear (7) to 3rd gear (14).
10-30 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
FORWARD 4TH
Operation
• In the case of FORWARD 4th, F clutch (3) and • 4th clutch (8) is engaged, so the power trans-
4th clutch (8) are engaged. The power transmit- mitted to 1st, 4th cylinder gear (7) goes through
ted from the torque converter to input shaft (1) 4th clutch (8) and is transmitted from 4th gear
is transmitted to output shaft (22). (6) to 4th gear (13). From here, it passes
• The clutch discs of F clutch (3) and 4th clutch (8) through lower shaft (20), output gear (19), and
are fixed by the hydraulic pressure applied to output gear (21), and is transmitted to output
the clutch piston. shaft (22).
• The power from the torque converter goes from
input shaft (1) through F clutch (3) to F gear (2),
and is transmitted to 1st, 4th cylinder gear (7).
WA430-5 10-31
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION
REVERSE 1ST
Operation
• In the case of REVERSE 1st, R clutch (4) and 1st • 1st clutch (9) is engaged, so the power trans-
clutch (9) are engaged. The power transmitted mitted to 1st, 4th cylinder gear (7) goes through
from the torque converter to input shaft (1) is 1st clutch (9) and is transmitted from 1st gear
transmitted to output shaft (22). (10) to 2nd, 3rd cylinder gear (16). From here, it
• The clutch discs of R clutch (4) and 1st clutch (9) passes through lower shaft (20), output gear
are fixed by the hydraulic pressure applied to (19), and output gear (21), and is transmitted to
the clutch piston. output shaft (22).
• The power from the torque converter goes from
input shaft (1) through R clutch (4) to R gear (5).
The direction of rotation is reversed by idler
gear (23), and is transmitted through idler gear
(11) and upper shaft (12) to 1st, 4th cylinder
gear (7).
10-32 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
A: 2nd clutch oil pressure detection port 1. ECMV (for 2nd clutch)
B: 3rd clutch oil pressure detection port 2. ECMV (for 3rd clutch)
C: 1st clutch oil pressure detection port 3. ECMV (for 1st clutch)
D: 4th clutch oil pressure detection port 4. ECMV (for 4th clutch)
E: R clutch oil pressure detection port 5. ECMV (for R clutch)
F: F clutch oil pressure detection port 6. ECMV (for F clutch)
G: Main relief oil pressure detection port 7. Parking brake solenoid valve
H: Torque converter relief oil pressure detection port 8. Main relief, torque converter
I : Parking brake oil pressure detection port relief valve
9. Last-chance filter
10-34 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
A: 2nd clutch oil pressure detection port 1. ECMV (for 2nd clutch)
B: 3rd clutch oil pressure detection port 2. ECMV (for 3rd clutch)
C: 1st clutch oil pressure detection port 3. ECMV (for 1st clutch)
D: 4th clutch oil pressure detection port 4. ECMV (for 4th clutch)
E: R clutch oil pressure detection port 5. ECMV (for R clutch)
F: F clutch oil pressure detection port 6. ECMV (for F clutch)
G: Main relief oil pressure detection port 7. Parking brake solenoid valve
H: Torque converter relief oil pressure detection port 8. Main relief, torque converter
J: Parking brake oil pressure detection port relief valve
9. Last-chance filter
WA430-5 10-34-1
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
ECMV
F R 1st 2nd 3rd 4th
Gear
speed range
F1 c c
F2 c c
F3 c c
F4 c c
R1 c c
R2 c c
R3 c c
R4 c c
Outline
WA430-5 10-35
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
A: 2nd clutch oil pressure detection port 1. ECMV (for 2nd clutch)
B: 3rd clutch oil pressure detection port 2. ECMV (for 3rd clutch)
C: 1st clutch oil pressure detection port 3. ECMV (for 1st clutch)
D: 4th clutch oil pressure detection port 4. ECMV (for 4th clutch)
E: R clutch oil pressure detection port 5. ECMV (for R clutch)
F: F clutch oil pressure detection port 6. ECMV (for F clutch)
G: Lock-up clutch oil pressure detection port 7. ECMV (for lock-up clutch)
H: Main relief oil pressure detection port 8. Parking brake solenoid valve
I : Torque converter relief oil pressure detection port 9. Main relief, torque converter
K: Parking brake oil pressure detection port relief valve
10. Last-chance filter
10-36 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
A: 2nd clutch oil pressure detection port 1. ECMV (for 2nd clutch)
B: 3rd clutch oil pressure detection port 2. ECMV (for 3rd clutch)
C: 1st clutch oil pressure detection port 3. ECMV (for 1st clutch)
D: 4th clutch oil pressure detection port 4. ECMV (for 4th clutch)
E: R clutch oil pressure detection port 5. ECMV (for R clutch)
F: F clutch oil pressure detection port 6. ECMV (for F clutch)
G: Main relief oil pressure detection port 7. Parking brake solenoid valve
H: Torque converter relief oil pressure detection port 8. Main relief, torque converter
J: Parking brake oil pressure detection port relief valve
9. Last-chance filter
WA430-5 10-36-1
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
ECMV
Lock
F R 1st 2nd 3rd 4th up
Gear
speed range
F1 c c
F2 c c
F3 c c c
F4 c c c
R1 c c
R2 c c
R3 c c c
R4 c c c
Outline
WA430-5 10-37
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
10-38 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
WA430-5 10-39
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Actuation of ECMV
• The ECMV is controlled by the command cur- 1. Before shifting gear (when draining) (range
rent from the controller to the proportional A in graph)
solenoid and the fill switch output signal. When no current is flowing to proportional
The relationship between ECMV proportional solenoid (1), pressure control valve spool (3)
solenoid command current and the clutch input drains the oil at clutch port A through drain
pressure and fill switch output signal is as port T.
shown in the diagram below. When this happens, there is no hydraulic force
Range A: Before shifting gear acting on oil pressure detection valve spool (4),
(when draining) so fill switch (6) goes OFF.
Range B: During filling
Range C: Pressure adjustment
Range D: During filling (during trigger)
Range E: Fill started
Range F: Fill completed
10-40 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
WA430-5 10-41
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
10-42 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
WA430-5 10-43
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
10-44 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Operation
WA430-5 10-45
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
FLOW VALVE
Operation
10-46 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE
AXLE
FRONT AXLE
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler port/level plug
8. Drain plug
10-48 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE
REAR AXLE
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler port/level plug
8. Drain plug
WA430-5 10-49
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
FRONT DIFFERENTIAL
10-50 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
No. Check item Criteria Remedy
WA430-5 10-51
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
REAR DIFFERENTIAL
10-52 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
No. Check item Criteria Remedy
WA430-5 10-53
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
10-54 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
LIMITED-SLIP DIFFERENTIAL
FRONT
1. Plate
2. Disc
3. Pinion (Number of teeth: 12)
4. Washer
5. Side gear (Number of teeth: 24)
6. Bevel pinion
7. Shaft
8. Pressure ring
10-56 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
3
9 Thickness of plate
±0.02 3.0
3.1
+0.04
10 Thickness of disc 3 -0.03 2.95
4
11 Thickness of washer ±0.05 3.8
4.1
WA430-5 10-57
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
REAR
1. Plate
2. Disc
3. Pinion (Number of teeth: 12)
4. Washer
5. Side gear (Number of teeth: 24)
6. Bevel pinion
7. Shaft
8. Pressure ring
10-58 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit
3
9 Thickness of plate
±0.02 2.9
3.1
+0.04
10 Thickness of disc 3 -0.03 2.95
2
11 Thickness of washer ±0.03 1.8
2.1
WA430-5 10-59
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
10-60 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD DIFFERENTIAL
2. When there is imbalance between drive Difference in wheel drive force for each type of dif-
force of left and right wheels [Road surface ferential when wheel on one side slips
condition (friction coefficient) and load for left and Wheel drive force
right wheels are not uniform and it is easier for (when one wheel is slipping)
wheel on one side to slip] Slipping Locked Total
Example 1. When digging, and wheel on one side is wheel wheel (ratio)
on soft surface Limited slip differ- 3.64
Example 2. When clearing snow, and wheel on one 1 2.64
ential (1.82)
side is on snow and wheel on other side is on
Normal differential 1 1 2 (1)
asphalt
Example 3. When traveling on slope, and there is
imbalance between load on left and right wheels On road surfaces where the wheel on one side is
The power from the transmission is divided likely to slip, the limited slip differential increases
equally to the left and right by the differential gear. the drive force by 1.82 times more than the nor-
However, when the drive force exceeds the wheel mal differential.
slip limit on the side where the wheel is slipping,
the amount of the force exceeding the wheel slip
limit passes through the brake and case at the rear When turning
face of the side gear and is transmitted to the brake
The differential gears built into a limited-slip differ-
on the opposite side (locked side) and is sent to
ential are the same as the gears used in a normal
the wheel on the locked side.
differential, so the difference in rotation between
If this excess portion of the drive force becomes
the inside and outside wheels when turning the
greater than the braking force, the differential
machine can be generated smoothly.
starts to work.
WA430-5 10-61
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
FRONT
10-62 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between pinion gear size Clearance limit
6 Shaft Hole
bearing and shaft
Replace
+0.013 -0 -0.025 -
ø 40 +0.002 -0.012 -0.002 —
WA430-5 10-63
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD FINAL DRIVE
REAR
10-64 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between pinion gear size Clearance limit
6 Shaft Hole
bearing and shaft
Replace
+0.013 -0 -0.025 -
ø 40 +0.002 -0.012 -0.002 —
WA430-5 10-65
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD FINAL DRIVE
Outline
10-66 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN
1. Front axle
2. Front frame
Outline
3. Rear axle
4. Rear frame • The front frame and rear frame are joined
through a bearing by the center hinge pin. In
addition, the left and right steering cylinders
are connected to the front and rear frames,
and the articulation angle of the frame (the
steering radius) is adjusted by the movement of
the cylinder.
10-68 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN
Unit: mm
No. Check item Criteria Remedy
WA430-5 10-69
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN
10-70 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between upper hinge size Clearance limit
1 Shaft Hole
pin and rear frame
-0.030 +0.071 0.066 -
ø80 -0.049 +0.036 0.120 —
Standard size
Shim value for upper hinge and
14 retainer
2.5
WA430-5 10-71
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING PIPING
STEERING PIPING
10-72 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING COLUMN, ORBIT-ROLL
WA430-5 10-73
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
10-74 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
A : To steering cylinder
B : To steering cylinder
Pa : From orbit-roll
Pb: To orbit-roll
P1 : From steering pump
P2 : From switch pump
PB: To work equipment circuit
T : To tank
Unit: mm
No. Check item Criteria Remedy
136.1 N 114.7 N
8 Demand spool return spring 75.1 68.5 {13.88 kg} — {11.7 kg}
182 kN 145 kN
9 Relief valve spring 24.0 22.19 {18.6 kg} — {14.8 kg}
2.26 N 1.77 N
10 Check valve return spring 21.6 17.0 {0.23 kg} — {0.18 kg}
WA430-5 10-75
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
Function
• The overload relief valve is installed to the
steering valve. If the cylinder is subjected to
impact when the steering valve is at neutral
and abnormal pressure is generated, this valve
functions as a safety valve and relieves the
circuit to prevent the damage to the cylinder
or hydraulic piping. If negative pressure forms
at the cylinder end, it functions as a suction
valve to prevent the formation of any vacuum.
10-76 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• When pilot poppet (4) opens, the pressure • If negative pressure forms at port A, check
behind poppet (1) drops, so poppet (1) moves valve poppet (3) opens because of the differ-
and seats pilot poppet (4). ence in area between diameters d3 and d4.
When this happens, the oil flows from port B
to port A to prevent any vacuum from forming.
WA430-5 10-77
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
• The steering relief valve is inside the steering
valve. It sets the maximum pressure in the
steering circuit when the steering valve is
being operated. In other words, when the
steering valve is operated, if the pressure in
the steering circuit goes above the set pressure
of this valve, it relieves the oil from the valve,
and by relieving the oil, actuates the flow con-
trol spool of the demand valve and drains the
oil going to the steering circuit.
10-78 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• When the pressure in the circuit rises and • When flow control spool (6) moves, the oil
reaches the pressure set by adjustment screw from the steering pump is drained and the oil
(1) and spring (2), pilot poppet (4) opens and from the switch pump is relieved to the main
drains the oil. control valve to prevent the pressure in the
• When this happens, the balance between the steering circuit from going above the set pres-
pressures in pressure-receiving chamber (I) and sure.
the pressure-receiving chamber (II) is lost and
flow control spool (6) moves to the left in the
direction of the arrow ().
WA430-5 10-79
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
10-80 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• When steering spool (2) is pushed (operated), • The merged oil passes through notches c and
pressure-receiving chamber (II) and the drain d, pushes up load check valve (4), and flows to
circuit are shut off, and at the same time, notch the cylinder. The return oil from the cylinder
c opens. passes through notch e and enters the drain cir-
• As a result, the pressure in pressure-receiving cuit.
chamber (II) rises, and flow control spool (1) is • When this happens, the pressure before pass-
moved to the right in the direction of the arrow ing through notch c goes to pressure-receiv-
() until notch h closes. ing chamber (I) and the pressure after passing
through notch c goes to pressure-receiving
• The passage from port B to the main control chamber (II). Flow control spool (1) is actuated
valve is shut off, so the oil from the switch so that the difference in pressure on both sides
pump pushes up merge check valve (3) and the of notch c is maintained at a constant value.
oil is merged with the oil from the steering • Therefore, an oil flow matching the degree of
pump at port A. opening of notch c is discharged from the cyl-
inder port. These pressure differences (control
pressure) are set by spring (5).
WA430-5 10-81
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• No extra oil is needed from the switch pump, • The oil from the steering pump passes through
so the pressure of the steering pump rises notches c and d, pushes up load check valve
until notch g closes and shuts off the merge (4), and flows to the cylinder. The return oil
passage at port B. from the cylinder passes through notch e and
• The difference in pressure on both sides of enters the drain circuit.
notch c is controlled only by notch f. The • Notch g is closed, so the oil from the switch
excess oil from the steering pump is drained to pump is sent from port B to the main control
the drain circuit from notch f. (When this hap- valve.
pens, notch g is completely closed.)
10-82 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
FLOW AMP
WA430-5 10-83
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• When the oil flows to port PiA, the pressure • Port PiB is connected to the drain circuit
inside the cap at end A rises and moves steer- through the Orbit-roll valve, so the oil flowing
ing spool (1) in the direction of the arrow. to end B is drained.
• The oil entering for port PiA passes through • The pressure generated at port PiA is propor-
the hole in spring seat (3), through orifice (7) in tional to the amount of oil flowing in, so steer-
steering spool (1), and then flows to the oppo- ing spool (1) moves to a position where the
site end (B end). opening of the flow amp notch balances the
pressure generated with the force of return
spring (4).
10-84 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
WA430-5 10-85
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
• The steering wheel is not being operated, so • When the pressures at ports A and B rise, flow
steering spool (1) does not move. control spool (4) is moved to the left in the
• The oil from the steering pump enters port A. direction of the arrow (), and the oil from the
The oil from the switch pump enters port B. steering pump passes through port C of the
spool and is drained.
The oil from the switch pump passes through
port D and all flows to the main control valve.
10-86 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
Turning right
• When the steering wheel is turned to the right, • The oil at the opposite ends of the left and
the control linkage is actuated and steering right cylinders passes through load check
spool (1) moves to the left in the direction of valve (3) of the steering spool and is drained.
the arrow (). • The oil from the switch pump enters port B,
• The oil from the steering pump enters port A, goes through flow control spool (2), pushes
goes through flow control spool (2) and flows open check valve (5), and merges with the oil
to steering spool (1). It then pushes open load from the steering pump.
check valve (4) of the spool, and flows to the
bottom end of the left cylinder and the rod end
of the right cylinder to turn the machine to the
right.
WA430-5 10-87
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING VALVE
Turning left
• When the steering wheel is turned to the left, • The oil at the opposite ends of the left and
the control linkage is actuated and steering right cylinders passes through load check
spool (1) moves to the right in the direction of valve (4) of the steering spool and is drained.
the arrow (). • The oil from the switch pump enters port B,
• The oil from the steering pump enters port A, goes through flow control spool (2), pushes
goes through flow control spool (2) and flows open check valve (5), and merges with the oil
to steering spool (1). It then pushes open load from the steering pump.
check valve (3) of the spool, and flows to the
rod end of the left cylinder and the bottom end
of the right cylinder to turn the machine to the
left.
10-88 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ORBIT-ROLL VALVE
ORBIT-ROLL VALVE
WA430-5 10-89
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ORBIT-ROLL VALVE
Outline
10-90 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ORBIT-ROLL VALVE
WA430-5 10-91
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ORBIT-ROLL VALVE
10-92 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STOP VALVE
STOP VALVE
WA430-5 10-93
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING PUMP, SWITCH PUMP
10-94 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING PUMP, SWITCH PUMP
Unit: mm
No. Check item Criteria Remedy
Standard Discharge
Speed Discharge discharge amount
Model (rpm) pressure amount limit
(MPa {kg/cm²} (l/min) (l/min) —
Discharge amount
— Oil: SAE 10WCD
Oil temperature: 45 - 55°C SAL(3)50 112 105
20.6
2,500 {210}
SAL(3)56 128 119
WA430-5 10-95
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EMERGENCY STEERING PUMP (OP)
Function
• The emergency steering pump is installed to
the transmission together with the emergency
steering motor. If the engine stops or if the oil
pressure in the steering circuit drops below
the set pressure, it supplies oil to the steering
circuit.
Unit: mm
No. Check item Criteria Remedy
Standard Discharge
Speed Discharge discharge
Discharge amount pressure amount limit —
(rpm) (MPa {kg/cm²} amount (l/min)
— Oil: SAE 10WCD (l/min)
Oil temperature: 45 - 55°C
3,500 20.6 67.6 62.4
{210}
10-96 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EMERGENCY STEERING MOTOR (OP)
1. Terminal E
2. Terminal M
Function
• If there is an abnormal drop in the oil pressure
in the steering circuit, the emergency steering
motor receives a signal from the transmission
controller and drives the emergency pump.
Specifications
Type DC motor
WA430-5 10-97
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between mounting size Clearance limit
1 pin and bushing at connection Shaft Hole
of frame and cylinder rod
-0 +0.142 0.080 -
ø50 -0.025 +0.080 0.167 —
10-98 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING CYLINDER
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between piston rod size Clearance limit
1 Shaft Hole
and bushing
5 Tightening torque of cylinder 1.42 ± 0.14 kNm {145 ± 14.5 kgm} (Width across flats: 55 mm) Tighten
piston
WA430-5 10-99
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD JOYSTICK STEERING LEVER (OP)
10-100 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING LEVER (OP)
1. Body 5. Retainer
2. Piston 6. Lever
3. Lever 7. Potentiometer
4. Disc 8. Connector
Function
WA430-5 10-101
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING LEVER (OP)
Unit: mm
No. Check item Criteria Remedy
Free length
X Installed Installed Free Installed Replace
1 Spring Outside length load length load spring if
diameter damaged of
5.88 N 4.71 N deformed
49 x ø7.0 25 —
{0.6 kg} {0.48 kg}
2 Spring 45.8 x ø15.5 32 73.5 N — 58.8 N
{7.5 kg} {6.0 kg}
10-102 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD STEERING SWITCH VALVE (OP)
Operation
WA430-5 10-103
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE PIPING
BRAKE PIPING
10-104 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE PIPING
WA430-5 10-105
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
BRAKE VALVE (LEFT)
10-106 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between pedal size clearance limit
5 Shaft Hole
mount hole and pin
WA430-5 10-107
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
10-108 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between pedal size clearance limit
8 Shaft Hole
mount hole and pin
WA430-5 10-109
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
Outline
• There are two brake valves installed in parallel When brake is applied (left brake valve)
at the bottom front of the operator's compart-
ment. They are actuated when the pedal is • When pedal (7) is depressed, spool (10) is
depressed. pushed up by rod (8) and spring (9), and closes
• When the right pedal is depressed, oil is sent to drain port c. The oil from the pump and accu-
the brake cylinder and the brake is applied. mulator flows from port E to port F.
• When the left pedal is depressed, oil is sent to • Port F of the left brake valve and port PP of the
the right pedal and the brake is applied in the right brake valve are connected by a hose, so
same way as when the right pedal is depressed. the oil flowing into port F flows to pilot port PP
• In addition, when the left brake pedal is of the right brake valve.
depressed, the transmission cut-off switch actu- • The oil entering pilot port PP passes through
ates the transmission solenoid valve electrically orifice d and enters port G, pushes piston (11)
to set the transmission to neutral. and the spring pushes spool (3) down to apply
Operation the brake in the same way as when the right
brake valve is depressed.
When brake is applied (right brake valve)
Upper portion
• When pedal (1) is depressed, the operating
effort is transmitted through rod (2) and spring
(4) to spool (3). When spool (3) goes down,
drain port a is closed and the oil from the
pump and accumulator flows from port A to
port C to actuate the rear brake cylinder.
Lower portion
• When pedal (1) is depressed, the operating
effort is transmitted through rod (2) and spring
(4) to spool (3). When spool (3) goes down,
plunger (6) moves spool (5) down. When this
happens, drain port b is closed and the oil from
the pump and accumulator flows from port B to
port D to actuate the front brake cylinder.
10-110 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
WA430-5 10-111
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE VALVE
Upper portion
• When pedal (1) is let back and the operating
effort on the top of the spool is removed, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (3)
up, drain port a is opened, the oil from the
brake cylinder flows to the hydraulic tank return
circuit, and the rear brake is released.
Lower portion
• When the pedal is let back, at the same time as
spool (3) in the upper portion moves up, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (5),
drain port b is opened, the oil from the brake
cylinder flows to the tank return circuit, and the
front brake is released.
10-112 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CHARGE VALVE
CHARGE VALVE
WA430-5 10-113
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CHARGE VALVE
1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. PPC (EPC*) relief valve (R2)
5. Relief valve (H1)
Function
• The charge valve acts to maintain the oil from
the pump at the specified pressure and to
charge the accumulator.
• When the oil pressure reaches the specified
pressure, the oil from the pump is connected
to the drain circuit to reduce the load on the
pump.
10-114 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CHARGE VALVE
Operation
1. When oil is not being supplied to accumu- 2. When oil is being supplied to accumulator
lator (cut-out condition)
1) Cut-in condition
• The pressure at port B is higher than the set
• When the pressure at port B goes below the
pressure of relief valve R1, so piston (2) is
set pressure of relief valve R1, piston (2) is
forcibly pushed up by the oil pressure at
pushed back down by spring (8), valve seat
port B and poppet (1) opens, and port C
(9) and poppet (1) are put in tight contact,
and port T are connected.
and port C and port T are shut off.
• The spring chamber at the right end of
• The spring chamber at the right end of
spool (6) is connected to port C of relief
spool (6) is also shut off from port T, so the
valve R1, so it is the tank pressure.
pressure rises. The pressure at port P also
• The oil from the pump enters port P and a rises in the same way.
low pressure equivalent to the load of • At the moment the pressure at port P goes
spring (5) pushes spool (6) to the right, then above the pressure of port B (accumulator
flows from port A to the PPC valve, orbit- pressure), the supply of oil to the accumula-
roll and fan pump. tor starts. In this case, it is determined by
At the same time, it also passes through the size (area) of orifice (7) and the pres-
orifices (7), (4), and (3), and returns to the sure difference generated on both sides of
tank. the orifice (equivalent to the load of spring
(5)). A fixed amount is supplied, regardless
of the speed of the engine, and the
remaining oil flows to port A.
WA430-5 10-115
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CHARGE VALVE
10-116 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ACCUMULATOR (FOR BRAKE)
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
Specifications
• The accumulator is installed between the Gas used : Nitrogen gas
charge valve and brake valve. Amount of gas : 2,850 cc
The area between cylinder (3) and free piston Charge pressure: 3.43 ± 0.1 MPa {35 ± 1.0 kg/cm²}
(4) is charged with nitrogen gas. The compres- (at 20°C)
sion ability of this gas is used to absorb the
pulse of the hydraulic pump and to ensure
that there is power to carry out braking and
operate the machine if the engine stops.
WA430-5 10-117
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ACCUMULATOR (FOR BRAKE)
1. Top cover
2. Piston
3. Cylinder
4. End cover
5. Core
Function
Specifications
• This is installed between the brake valve and Gas used : Nitrogen gas
the brake cylinder. The area between cylinder Amount of gas : 46 cc
(3) and free piston (2) is charged with nitrogen Charge pressure: 0.29 ± 0.05 MPa {3 ± 0.5 kg/cm²}
gas. The compression ability of this gas is used (at 50°C)
to ensure that there is power to carry out brak-
ing and operate the machine.
10-118 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE
BRAKE
FRONT
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Discs (x3)
10-120 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE
Unit: mm
No. Check item Criteria Remedy
Outline
• The front brake has a wet-type multiple-disc
structure, and consists of piston (3), inner ring
(5), discs (9), outer ring (8), and spring (4).
• The brake cylinder consists of differential hous-
ing (1) and bearing carrier (2), and piston (3) is
assembled in it.
Inner ring (5) and outer ring (8) are joined to
the spline portion of axle housing (7).
• Discs (9) have a lining adhered to both sides.
They are assembled between inner ring (5) and
outer ring (8), and are joined by the spline of
sun gear shaft (6).
WA430-5 10-121
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE
REAR
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Discs (x3)
10-122 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE
Unit: mm
No. Check item Criteria Remedy
Outline
• The rear brake has a wet-type single-disc struc-
ture, and consists of piston (3), inner ring (5),
disc (9), outer ring (8), and spring (4).
• The brake cylinder consists of differential hous-
ing (1) and bearing carrier (2), and piston (3) is
assembled in it.
Inner ring (5) and outer ring (8) are joined to
the spline portion of axle housing (7).
• Disc (9) has a lining stuck to both sides. It is
assembled between inner ring (5) and outer
ring (8), and is joined by the spline of sun gear
shaft (6).
WA430-5 10-123
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BRAKE
Outline
When brake is applied When brake is released
• When the brake pedal is depressed, pressure oil • When the oil pressure is released, piston (2) is
P goes from the hydraulic tank through the returned to its original position by the force of
pump and brake charge valve. It acts on the spring (8), a gap is formed between inner ring
piston inside the brake cylinder and the piston (3) and outer ring (5), and discs (4) become free.
slides. Lattice shape grooves are cut into the lining
Therefore, piston (2) stops the rotation of discs stuck to disc (4), and when disc (4) is rotating,
(4) fitted between inner ring (3) and outer ring oil flows in the grooves and carries out cooling
(5), and applies the brake to the machine. of the lining.
10-124 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE CONTROL
Outline
• The parking brake is a wet-type multiple disc • While the parking brake is being applied (when
brake built into the transmission. It is installed the solenoid is OFF), the signal from the trans-
to the bearing portion of the output shaft. It is mission controller to the transmission solenoid
applied mechanically by the pushing force of a valve is cut by the neutralizer signal, and the
spring, and is released by hydraulic power. transmission is held at neutral.
• When the parking brake switch (1) in the opera- • Parking brake emergency release valve (2) is
tor's compartment is turned ON, the hydraulic installed to release the parking brake if it is
pressure is shut off by parking brake solenoid necessary to move the machine when trouble
valve (4) installed to transmission control has occurred in the engine or drive system
valve (3), and the parking brake is applied. and the machine remains stopped (the parking
When the parking brake switch is turned OFF, brake remains applied).
the parking brake is released by the hydraulic
pressure of the cylinder.
WA430-5 10-125
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
10-126 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE
Unit: mm
No. Check item Criteria Remedy
13 Wave spring load 1,106 N {112.8 kg} ±57 N 940 N {95.9 kg}
(height : 3.2mm) {±5.8 kg}
WA430-5 10-127
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE SOLENOID VALVE
10-128 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE SOLENOID VALVE
Operation
Parking brake applied (solenoid OFF) Parking brake released (solenoid ON)
• When the parking brake switch in the operator's • When the parking brake switch is turned OFF,
compartment is turned ON, the solenoid is the solenoid is turned ON and spool (5) moves
turned OFF and spool (5) is pushed to the left by to the right. When this happens, the pressure
spring (4). When this happens, the circuit oil from the pump goes from port P through
between pump port P and parking brake port A the inside of spool (5) and flows from port A to
is closed and the pressure oil from the pump the parking brake. At the same time, port T is
does not flow to the parking brake. closed and the oil is not drained. As a result,
• At the same time, the oil from the parking brake the spring inside the parking brake is pushed
flows from port A to port T, and is drained. back by the hydraulic force and the parking
As a result, the discs inside the parking brake brake is released.
are pushed by the spring and the parking brake
is applied.
WA430-5 10-129
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE EMERGENCY RELEASE VALVE
1. Grip
2. Valve
A : From accumulator
B : To parking brake solenoid
Outline
• The parking brake emergency release valve is
installed between the brake circuit accumula-
tor and the parking brake solenoid. It is possi-
ble to open this valve manually if no pressure
oil can be supplied from the transmission
pump because of engine failure or other fail-
ure. This makes it possible to supply pressure
from the brake circuit accumulator to the
parking brake cylinder.
10-130 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC PIPING
HYDRAULIC PIPING
10-132 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC PIPING
WA430-5 10-133
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC PIPING
Outline
1. Work equipment valve
2. Bucket cylinder • The hydraulic system consists of the work
3. Steering valve equipment circuit and steering circuit. The
4. Hydraulic oil tank work equipment circuit controls the operation
5. Breather of the bucket and attachments.
6. PPC valve • The oil from hydraulic tank (4) is sent by work
7. Cooling fan pump equipment pump (11) to work equipment valve
8. Steering switch pump (1). If the bucket and lift arm spools of the work
9. Oil cooler equipment valve are in the HOLD position, the
10. Torque converter oil cooler oil is sent through the drain circuit of the work
11. Torque converter oil pressure, work equipment equipment valve, filtered by the filter in the
oil pressure, pilot control pump hydraulic tank, and returned to the tank.
12. PPC accumulator • If the work equipment control lever is operated,
13. Charge valve the bucket or lift arm spool of the PPC valve (6)
14. E. C. S. S. valve moves to operate each spool of the work equip-
15. Steering cylinder ment valve (1) hydraulically. Then, the oil flows
16. E. C. S. S. accumulator from the work equipment valve to lift arm cylin-
17. Lift arm cylinder der (17) or bucket cylinder (2) to move the lift
18. Emergency steering pump arm or bucket.
19. Emergency steering motor • The maximum pressure in the hydraulic circuit
20. Cooling fan motor is controlled with the relief valve in the work
equipment valve. The bucket cylinder circuit is
equipped with the safety-suction valve for pro-
Note: If EPC valve is installed, change "PPC valve" tection of the circuit.
to "EPC valve" when reading. • PPC accumulator (12) is installed to the PPC
pilot circuit so that the lift arm can be lowered
to the ground even while the engine is stopped.
• Hydraulic tank is pressurized, enclosed, and
equipped with breather (5) having the relief
valve. Certain pressure is applied to this tank to
prevent generation of negative pressure in the
tank and cavitation in the pump.
• If the vehicle cannot be steered normally
because of a stall of the engine, a trouble in the
steering pump, oil leakage from the piping, etc.,
emergency steering motor (19) drives emer-
gency steering pump (18) so that the vehicle
can be steered.
• Fan motor (20) installed to the radiator is driven
hydraulically and variably with fan motor drive
pump (7).
10-134 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL LEVER
10-136 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL LEVER
WA430-5 10-137
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
10-138 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD HYDRAULIC TANK
Breather
1. Nut
2. Filter element
3. Poppet
4. Sleeve
WA430-5 10-139
(3)
STRUCTURE AND FUNCTION, TORQUE CONVERTER CHARGING, WORK
MAINTENANCE STANDARD EQUIPMENT, AND PILOT CONTROL PUMPS
10-140 WA430-5
STRUCTURE AND FUNCTION, TORQUE CONVERTER CHARGING, WORK
MAINTENANCE STANDARD EQUIPMENT, AND PILOT CONTROL PUMPS
Unit: mm
No. Check item Criteria Remedy
SAL(3)90
4 Side clearance 0.10 - 0.15
SAL(3)90 0.19
SAL(3)90
Clearance between inside 0.069 - 0.149
5 diameter of plain bearing and SAL(3)90 0.20 Replace
outside diameter of gear shaft
SAL(1)20 0.06 - 0.119
SAL(3)90
6 Driving depth of pin 14
SAL(3)90 -0 —
-0.5
SAL(1)20 10
Standard Discharge
Speed Discharge discharge amount
Model (rpm) pressure amount limit
(MPa {kg/cm²} (l/min) (l/min)
Discharge amount —
— Oil: SAE10WCD SAL(3)90 20.6 {210} 208 192
Oil temperature: 45 - 55°C
SAL(3)90 2,500 20.6 {210} 208 192
WA430-5 10-141
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC RELIEF VALVE
1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
Outline
• The PPC relief valve is installed in the charge
valve between the PPC pump and PPC valve.
While the PPC valve is not in operation or when
abnormal pressure is generated in the PPC cir-
cuit, the PPC relief valve relieves the oil sent
from the pump to protect the pumps and cir-
cuits.
10-142 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC RELIEF VALVE
Operation
• The relief valve is installed to the charge valve • If the pressure in port B lowers, a pressure dif-
and ports A and C are connected to the pump ference is made between ports A and B
circuit and drain circuit respectively. because of the orifice of main valve (1). As a
The oil flows through the orifice of main valve result, main valve (1) is opened by the pressure
(1) and fills port B. in port A and the oil in port A is drained and
Pilot poppet (4) is seated at valve seat (3). relieved into port C.
• If the pressure in ports A and B reaches the set
level, pilot poppet (4) opens and the pressure in
port B is released through port D into port C,
and the pressure in port B lowers consequently.
WA430-5 10-143
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD E. C. S. S. VALVE (OP)
E. C. S. S. VALVE (OP)
10-144 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD E. C. S. S. VALVE (OP)
1. Main spool
2. Solenoid valve
3. Flow control valve
4. Shuttle valve
5. Charge valve
WA430-5 10-145
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
T : Drain port (To the tank) P2 : From the switch pump (steering valve)
A1: To the bucket cylinder head P1A : From the P1 port of the PPC valve
A2: To the lift arm cylinder head P1B : From the P2 port of the PPC valve
B1: To the bucket cylinder bottom P2A : From the P3 port of the PPC valve
B2: To the lift arm cylinder bottom P2B : From the P4 port of the PPC valve
P1 : From the work equipment pump
1. Solenoid valve
10-146 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
WA430-5 10-147
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
10-148 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
2. 3-spool valve
T : Drain port (To the tank) P2 : From the switch pump (Steering valve)
A1: To the attachment cylinder P1A : From the attachment PPC valve
A2: To the bucket cylinder head P1B : From the attachment PPC valve
A3: To the lift arm cylinder head P2A : From the P1 port of the PPC valve
B1: To the attachment cylinder P2B : From the P3 port of the PPC valve
B2: To the bucket cylinder bottom P3A : From the P2 port of the PPC valve
B3: To the lift arm cylinder bottom P3B : From the P4 port of the PPC valve
P1 : From the work equipment pump
1. Solenoid valve
WA430-5 10-149
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
10-150 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
WA430-5 10-151
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
3. Relief valve
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjusting screw
10-152 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
4. Safety-suction valve
Operation
WA430-5 10-153
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
5. Suction valve
(2) Operation as suction valve
• If negative pressure is generated in port A, the
pressure in port D becomes negative since
those ports are connected to each other.
• Since the tank pressure of port B is applied to
port E, the safety valve receives oil pressure e
corresponding to the area difference between
d2 and d1.
• Accordingly, oil pressure is applied in the open-
ing direction of the valve and oil pressure a is
applied in the closing direction of suction valve
(1).
• If the pressure in port A lowers to near 0, it is
lower than oil pressure e.
• When oil pressure e becomes larger than the 1. Main poppet
total of oil pressure a and the force of valve 2. Sleeve
spring (5), suction valve (1) opens and the oil 3. Spring
flows from port B to port A to prevent genera-
tion of negative pressure in port A.
Function
Operation
10-154 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
6. Cut-off valve
Function
Standard Hi c ± ±
specifica-
tion vehi- S c ± c
cle Lo c c c
Operation
WA430-5 10-155
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
2) When work equipment pump pressure is (3) When solenoid valve is turned ON
higher than cut-off pressure • Since port SP is connected to the drain circuit,
• If the work equipment pump pressure reaches the pilot oil flows along the arrows.
the cut-off pressure, cut-off valve (2) is opened • Then, differential pressure is generated in
by the oil pressure in chamber a and then the unload valve (3) and it opens unload valve (3).
oil in chamber b of unload valve (3) is drained • Accordingly, the oil from switching pump (the
through chamber c of cut-off valve (2). oil from the steering valve) is always drained,
• Since the oil in chamber d of unload valve (3) regardless of the level of the work equipment
flows through orifices e and f to chamber b, the port pressure.
oil pressure in chamber d lowers and unload
valve (3) opens.
• Accordingly, the oil from the switching pump is
drained.
10-156 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Operation
• The oil goes into the port A from the pump and • Although the oil coming from the PPC pump
the maximum pressure is being stipulated by goes into the port L of the PPC valve, as the lift
the relief valve (1). arm lever and the bucket lever are being set to
• As for the bucket spool (2), a bypass circuit is the holding position, the oil return to the
being opened for holding purpose and the oil hydraulic oil tank through the PPC relief valve.
coming from the port A passes around the
spool to flow into the port B.
• As for the lift arm spool (3) also, a bypass circuit
is being opened to make the neutral state and
the oil coming from the port B passes around
the spool to return to the tank through the drain
circuit.
WA430-5 10-157
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Operation
• When the lift arm lever (4) is pulled, the oil • After that, oil flow to the port D and further to
flows from the port L to the port N of the PPC the cylinder bottom.
valve and, from there, it goes into the port S of • The oil from the PPC valve flows through check
the work equipment control valve. valve (13) into port L of the PPC valve. Since
• Also, oil of the port T flow into the drain circuit the lift arm and bucket control levers are in the
passing through the port M. The pressurized hold position, however, the oil returns through
oil of the port S pushes the lift arm spool (3) to PPC relief valve (12) to the hydraulic tank.
the UP position.
• The oil coming from the pump passes through
the bypass circuit of the bucket spool (2) to flow
to the bypass circuit of the spool (3).
• Since the bypass circuit is being closed by the
spool (3), the oil pushes open the check valve
(5).
10-158 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Operation
• When the lift arm lever (4) is pushed, the oil • After that, oil flow to the port E and further to
flows from the port L to the port M of the PPC the cylinder head.
valve and, from there, it goes into the port T of • On the other hand, the oil in the cylinder bot-
the work equipment control valve. tom goes into the drain port F through the port
• Also, oil of the port S flow into the drain circuit. D to return to the tank. As the result, the lift
The pressurized oil of the port T pushes the lift arm goes down.
arm spool (3) to the LOWER position.
• The oil coming from the pump passes through
the bypass circuit of the bucket spool (2) to flow
to the bypass circuit of the spool (3).
• Since the bypass circuit is being closed by the
spool (3), the oil pushes open the check valve
(5).
WA430-5 10-159
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
10-160 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Operation
• When the bucket lever (6) is pushed, the pres-
surized oil form the port L of the PPC valve • On the other hand, the oil in the bucket cylinder
flows into the port V of the work equipment bottom flow into the drain port F through the
control valve through the port Q. port G to return to the tank. As the result, the
bucket dumps.
• Also, the oil from the port R flows to the drain
circuit.
• The pressurized oil from the port V moves the
bucket spool (2) to the DUMP position.
• Since the oil coming from the pump is being
closed by the spool (2), the oil from the port A
pushes the check valve (7) to let it open.
• The oil coming from the check valve (7) flows
into the bucket cylinder head through the port
H.
WA430-5 10-161
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
Operation
• When the bucket lever (6) is pulled, the pressur- • The oil coming from the check valve (7) flows
ized oil form the port L of the PPC valve flows into the bucket cylinder bottom through the
into the port R of the work equipment control port G.
valve through the port P. • On the other hand, the oil in the bucket cylinder
• Also, the oil from the port V flows to the drain head flow into the drain port F through the port
circuit. H to return to the tank. As the result, the
The pressurized oil from the port R moves the bucket tilts.
bucket spool (2) to the TILT position.
• Since the oil coming from the pump is being
closed by the spool (2), the oil from the port A
pushes the check valve (7) to let it open.
10-162 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
10-164 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
1. Spool 9. Ring
2. Metering spring 10. Plate
3. Centering spring 11. Retainer
4. Spring 12. Piston
5. Retainer 13. Body
6. Solenoid 14. Ball
7. Rod 15. Detent spring
8. Lever 16. Retainer
WA430-5 10-165
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
Operation
1. When in NEUTRAL
(1) PPC valve for bucket (2) PPC valve for lift arm
• Ports PA and PB of the bucket control valve and • Ports PA and PB of the lift arm control valve
ports P1 and P2 of the PPC valve are connected and ports P3 and P4 of the PPC valve are con-
through fine control hole f of spool (1) to the nected through fine control hole f of spool (1)
drain chamber D. to the drain chamber D.
10-166 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
WA430-5 10-167
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
• If lever (8) begins to return, the force of center- • If lever (8) and rod (7) push down piston (12)
ing spring (3) and the pressure in port P1 push and retainer (11) pushes down spool (1), fine
up spool (1). control hole f is disconnected from drain cham-
• As a result, fine control hole f is connected to ber D and connected to pump pressure cham-
drain chamber D and the oil in port P1 is ber PP.
released. • Accordingly, the pilot oil from the main pump
• If the pressure in port P1 lowers too much, flows through fine control hole f and port P1
spool (1) is pushed down by metering spring (2) into chamber PB and pushes the control valve
and fine control hole f is disconnected from spool.
drain chamber D and connected to pump pres- • The oil returning from chamber PA flows
sure chamber PP almost simultaneously. Then, through port P2 and fine control f' into drain
the pump pressure is applied until the pressure chamber D.
in port P1 is restored to the level corresponding
to the position of the lever.
• When the control valve spool returns, the oil in
drain chamber D flows in through fine control
hole f of the valve which is not in operation and
then flows through port P2 into chamber PA.
10-168 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
5. When lift arm is FLOATED 6. When FLOAT state of lift arm is reset
• If rod (7) and piston (12) on the LOWER side of • Lever (8) is returned from the FLOAT position by
port P3 are pushed down by lever (8), ball (14) pushing it down with a force greater than the
touches projection a of rod (7) in the middle of attractive force of solenoid (6) and retainer (5).
the stroke (The detent starts to operate). • The FLOAT state also can be reset and the lever
• If rod (7) is pushed in further, ball (14) pushes can be returned to the neutral position by turn-
up retainer (16) supported on detent spring (15) ing off the current in solenoid (6) (demagnetiz-
and escapes out to go over projection a of the ing the solenoid).
piston. • The lift arm RAISE and bucket TILT operations
• At this time, rod (7) on the opposite side is are carried out similarly to the above.
pushed up by spring (4) through retainer (11).
• If rod (7') is pushed up and the current is flow-
ing in solenoid (6), retainer (5) is attracted by
solenoid (6).
• Accordingly, rod (7') is kept pushed up and the
FLOAT state is kept even if the lever is released.
• At the same time, the control valve is also
moved to the FLOAT position and kept at that
position.
WA430-5 10-169
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE
10-170 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE
1. Spool 9. Plate
2. Metering spring 10. Retainer
3. Centering spring 11. Piston
4. Spring 12. Body
5. Retainer 13. Ball
6. Solenoid 14. Detent spring
7. Rod 15. Retainer
8. Disc
WA430-5 10-171
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE
OPERATION
1. At NEUTRAL
(1) PPC Valve for Bucket (2) PPC Valve for Lift arm
• PA and PB ports of the control valve for bucket • PA and PB ports of the control valve for lift arm
and P1 and P2 ports of the PPC valve lead to and P3 and P4 ports of the PPC valve lead to
the drain chamber D through the fine control the drain chamber D through the fine control
hole f of the spool (1). hole f of the spool (1).
10-172 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE
2. At Fine Control
(Neutral ➞ Fine Control)
• When the rod (7) and the piston (11) are pressed
with the disc (8), the retainer (10) is also
pressed, and the spool (1) is pressed with the
metering spring (2) and moves downward.
• When the fine control hole f is interrupted from
the drain chamber D as a result of the down-
ward movement, it leads to the pump pressure
chamber PP almost at the same time. Then,
pilot pressure oil of the main pump is sent from
the P4 port to the PB port through the fine con-
trol hole f.
• When the pressure is increased at the port P4,
the spool (1) is pushed back, and when the fine
control hole f is interrupted from the pump
pressure chamber PP, it leads to the drain
chamber D almost at the same time, and the
pressure is released from the P4 port.
• Therefore, the spool (1) rises and falls so that
pressure at the P4 port balances with force of
the metering spring.
The positional relations between the retainer
(10) and the body (12) (the fine control hole f is
at the intermediate position between the drain
chamber D and the pump pressure chamber
PP) do not change until the retainer (10) gets to
the spool (1).
• Since the metering spring (2) is tightened in
proportion to control lever stroke, pressure at
the P4 port rises in proportion to the control
lever stroke.
• Therefore, the control valve spool moves to the
position where pressure of the PB chamber (the
same as pressure at the P4 port) balances with
force of the return spring of the control valve
spool.
WA430-5 10-173
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE
10-174 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PPC VALVE
WA430-5 10-175
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EPC SOLENOID VALVE (OP)
WA430-5
10-176 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EPC SOLENOID VALVE (OP)
Function Operation
• The EPC valve consists of the proportional sole- 1. When the signal current is 0 (Coil is demagne-
noid section and the hydraulic valve section. tized)
• On the receiving signal current from the pump • While the signal current from the controller is
controller, the EPC valve generates an EPC out- not flowing in coil (10), coil (10) is demagne-
put pressure in proportion to the signal current tized.
and applies it to the control valve. • Accordingly, spool (7) is pressed by spring (8)
a. Output pressure P to the right.
b. Current i • Port P is closed and the hydraulic oil from the
control pump does not flow in the control valve.
c. Control Valve
WA430-5 10-177
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD EPC SOLENOID VALVE (OP)
2. When signal current is small (Coil is magnetized 3. When signal current is maximum (Coil is mag-
in fine control mode) netized in full operation.
• If a small signal current flows in coil (10), coil • If the signal current flows in coil (10), coil (10) is
(10) is magnetized and a thrust to the left is gen- magnetized.
erated in plunger (11). • Since the signal current is at maximum, the
• Push pin (9) pushes spool (7) to the left and the thrust in plunger (11) becomes maximum.
hydraulic oil from port P flows in port C. • Accordingly, push pin (9) presses spool (7) to
• The pressure in port C rises. If the total of the the left.
force applied to face a of spool (7) and the load • As a result, the maximum hydraulic oil flows
of spring (8) exceeds the thrust of plunger (11), from port P to port C and the pressure in the
spool (7) is pushed to the right. circuit between the EPC valve and control valve
• Ports P and C are disconnected from each other becomes highest.
and port C and port T are connected to each • At this time, port T is closed and the oil does
other simultaneously. not flow in the tank.
• As a result, spool (7) moves to the right or left
until the thrust of plunger (11) is balanced with
the total of the pressure in port c and the load
of spring (8).
• Accordingly, the pressure in the circuit between
the EPC valve and control valve is controlled in
proportion to the signal current.
a Control valve
10-178 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SHUT OFF VALVE (OP)
Function
A : To EPC valve • If the signal from the controller is turned on, the
P : From pilot circuit pump (Pump from EPC) shut-off valve is turned on to connect the oil
T : To hydraulic tank path from the pilot circuit pump to the EPC
valve.
WA430-5 10-179
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ATTACHMENT PPC VALVE (OP)
1. Spool 6. Plate
2. Metering spring 7. Retainer
3. Centering spring 8. Body
4. Piston 9. Filter
5. Lever
10-180 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ATTACHMENT PPC VALVE (OP)
Unit: mm
No. Check item Criteria Remedy
WA430-5 10-181
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ATTACHMENT PPC VALVE (OP)
Operation
10-182 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ATTACHMENT PPC VALVE (OP)
WA430-5 10-183
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR
Specifications
Model : LMF28
Capacity : 28.0 cc/rev
Rated speed : 1,400 rpm
Rated flow : 40 l/min
Cracking pressure of check valve : 0.044 MPa {0.45 kg/cm²}
10-184 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR
Unit: mm
No. Check item Criteria Remedy
WA430-5 10-185
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR
1. HYDRAULIC MOTOR
Function
• This hydraulic motor is a swash plate-type axial
piston motor, which converts the pressure of
the hydraulic oil sent from the hydraulic pump
into revolution.
Principle of operation
10-186 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR
2. SUCTION VALVE
(2) When pump is stopped
Function
• If the engine is stopped and the input revolution
• If the fan pump stops, the hydraulic oil does not of the fan pump lowers to 0 rpm, the hydraulic
flow into the motor. Since the motor continues oil from the pump is not supplied to port P any
revolution because of the force of inertia, how- more. As the hydraulic oil is not supplied to the
ever, the pressure on the outlet side of the MA side of the motor, the motor speed lowers
motor rises. gradually to stop.
• When the oil stops flowing in from inlet port P, • If the motor shaft is revolved by the force of
the suction valve sucks in the oil on the outlet inertia while the oil flow in the port P is reduc-
side and supplies it to the port MA where there ing, the oil in port T on the outlet side is sent by
is not sufficient oil to prevent cavitation. the suction valve to the MA side to prevent cav-
itation.
Operation
WA430-5 10-187
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR
3. OPERATION OF REVOLUTION
DIRECTION CHANGEOVER
VALVE
(1) When ON-OFF solenoid for changeover (2) When ON-OFF solenoid for changeover
valve is turned OFF valve is turned ON
• If ON-OFF solenoid (1) for changeover valve is • If ON-OFF solenoid (1) for changeover valve is
turned "OFF", the hydraulic oil from the pump is turned "ON", ON-OFF changeover valve (2)
blocked by ON-OFF changeover valve (2) and changes to let the hydraulic oil from the pump
port C is connected to the tank circuit. flow through port C into spool chamber D.
• Accordingly, changeover spool (3) is pushed by • The hydraulic oil in chamber D pushes
changeover spool spring (4) to the right to open changeover spool (3) against changeover spool
motor port MA and then the hydraulic oil flows spring (4). As a result, motor port MB opens
in to revolve the motor forward (clockwise). and the hydraulic oil flows in to revolve the
motor in reverse (counterclockwise).
10-188 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
1. Bleeder
10-190 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
1. Shaft
2. Oil seal
3. Case
4. Rocker cam
5. Shoe
6. Piston
7. Cylinder block
8. Valve plate
9. Spring
10. Servo piston
WA430-5 10-191
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
Function
• This pump converts the revolution and torque • The oil in each cylinder of cylinder block (7) can
of the engine transmitted from its shaft into be drawn and discharged through valve plate
hydraulic energy and discharges hydraulic oil (8).
according to the load.
• The discharge amount can be changed by
changing the swash plate angle.
Structure
10-192 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
Operation
1. Operation of pump
• Shaft (1) and cylinder block (7) revolve together • If center line X of rocker cam (4) is in the direc-
and shoe (5) slides on plane A. As rocker cam tion of the axis of cylinder block (7) (Swash
(4) slants around ball (11) at this time, angle α plate angle = 0), the difference between vol-
between the center line X of rocker cam (4) and umes E and F in cylinder block (7) is 0 and oil is
axis of cylinder block (7) changes. Angle α is not sucked or discharged (The swash plate
called the swash plate angle. angle is not reduced to 0 actually, however).
• If the angle between the center line X of rocker • In short, swash plate angle α is in proportion to
cam (4) and the axis of cylinder block (7) is α, the discharge of the pump.
plane A works as a cam for shoe (5).
• Accordingly, each piston (6) slides inside cylin-
der block (7) and makes difference between vol-
umes E and F in cylinder block (7) and the oil is
drawn and discharged by the difference.
• In short, if cylinder block (7) revolves and vol-
ume of chamber E is reduced, the oil is dis-
charged. On the other hand, the volume of
chamber F is increased and the oil is sucked.
(The figure shows the end of suction process of
chamber F and the end of discharge process of
chamber E.)
WA430-5 10-193
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
2. Control of discharge
10-194 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
SERVO VALVE
1. Plug
2. Lever
3. Retainer
4. Seat
5. Spool
6. Piston
7. Sleeve
WA430-5 10-195
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
10-196 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
SAFETY VALVE
Function
WA430-5 10-197
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
10-198 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between bushing size clearance limit
7 and pin at each end of bucket Shaft Hole
link
-0.036 +0.207 0.156 -
ø 85 -0.090 +0.120 0.297 1.0
+2.8 +1.5
18 Joint of bucket link and bucket 112.5 -0.5 116 0 0.7 - 5.5
-0 +3
19 Joint of lift cylinder and frame 90 -0.5 93.5 +0 3.5 - 7.0
WA430-5 10-199
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET
BUCKET
1. Bucket
2. Bolt-on cutting edge
3. Bucket tooth
Unit: mm
No. Check item Criteria Remedy
10-200 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, LIFT ARM KICK-OUT
1. Proximity switch
2. Bucket cylinder rod
3. Lever
4. Plate
Unit: mm
No. Check item Criteria Remedy
10-202 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, LIFT ARM KICK-OUT
WA430-5 10-203
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, LIFT ARM KICK-OUT
• When lift arm (3) is lower than the set position • If lift arm control lever (7) is moved to the raise
of the lift arm kick-out, plate (2) is not on the position, lift arm spool (8) is moved to the posi-
detection plane of proximity switch (1). Lift arm tion of the arrow and held at that position by
kick-out relay (4) is turned off and the current the coil turned on by detent solenoid (6). As a
flows in detent solenoid (6) of PPC valve (5) and result, lift arm control lever (7) is held at the
the coil is turned on. RAISE position and lift arm (3) is raised.
10-204 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, LIFT ARM KICK-OUT
WA430-5 10-205
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, LIFT ARM KICK-OUT
• When the bucket is tilted more than the set • If bucket control lever (7) is moved to the TILT
position of the bucket leveler, lever (2) is on the position, DUMP spool (8) is moved to the posi-
detection plane of proximity switch (1) and tion of the arrow and held at that position by
proximity switch (1) lights up. At this time, the coil turned on by detent solenoid (6). As a
bucket positioner relay (4) is turned on and the result, bucket control lever (7) is held at the TILT
current flows in detent solenoid (6) of PPC valve position and the bucket is tilted.
(5) and the coil is turned on.
10-206 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD BUCKET POSITIONER, LIFT ARM KICK-OUT
WA430-5 10-207
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
BUCKET CYLINDER
Unit: mm
No. Check item Criteria Remedy
Tolerance
Name of Standard Standard Clearance
cylinder size clearance limit
Clearance between Shaft Hole
1 piston rod and Replace
bushing -0.036 +0.257 0.084 - bushing
Lift arm ø 90 0.647
-0.090 +0.048 0.347
10-208 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD CAB
CAB
1. Front glass
2. Front windshield wiper
3. Rear windshield wiper
4. Door
5. Air conditioner filter (If equipped)
6. Antenna (If equipped)
WA430-5 10-209
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD AIR CONDITIONER (OP)
10-210 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
WA430-5 10-211
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
• This machine monitoring system is equipped • The machine monitoring system consists of the
with the service mode function to facilitate the machine monitor proper, buzzer, and switches
troubleshooting work for respective controllers that are used for inputting data to the machine
(including the machine monitor itself) on the monitor proper, sensors, respective controller
network. The description below applies to the on the network, and relevant switches and sen-
contents of the main functions. sors.
4. Tuning
This function is to be used for compensation
and adjustment of the installation errors and
dispersions in the manufacturing processes of
individual parts of sensors, proportional elec-
tromagnetic valves.
10-212 WA430-5
(5)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
Load meter
WA430-5 10-213
(5)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
Sensing functions
10-214 WA430-5
(5)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
WA430-5 10-215
(5)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
10-216 WA430-5
(5)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
Monitor mode SW
Compensation Compensation
signal
Emergency steering self-
Automatic pre-heating start signal
checks
T/M trigger resetting signal Learning control
Machine model Machine model Machine model
selection selection selection
Tire selection Tire selection Tire selection
Tire compensation Tire compensation Tire compensation
Communication Communication
Controller specification
selection selection
Option specification Option selection Option selection
FNR lever or seesaw SW signal FNR indications
WA430-5 10-217
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
MACHINE MONITOR
SPEED METER SPECIFICATIONS
10-218 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
1. Torque converter oil temperature gauge 23. Battery fluid level caution lamp
2. Torque converter oil temperature caution lamp 24. Battery charging circuit caution lamp
3. Engine water temperature gauge 25. Steering oil pressure caution lamp
4. Engine water temperature caution lamp 26. Emergency steering pilot lamp
5. Speedometer or engine tachometer 27. Character display
6. Direction indicator pilot lamp (left) 28. Engine mode pilot lamp
7. Headlamp high beam pilot lamp 29. Semi-auto digging pilot lamp
8. Direction indicator pilot lamp (right) 30. Pre-heating pilot lamp
9. Hydraulic oil temperature caution lamp 31. Auto greasing pilot lamp
10. Hydraulic oil temperature gauge 32. Joy-stick pilot lamp
11. Remaining fuel level caution lamp 33. FNR changeover pilot lamp
12. Fuel gauge 34. Shift indicator
13. Centralized warning lamps 35. Auto shifting pilot lamp
14. Brake oil pressure caution lamp 36. Lock up pilot lamp
15. Engine oil pressure caution lamp 37. Shift hold pilot lamp
16. Engine oil level caution lamp 38. Shift lever position pilot lamp
17. Engine water level caution lamp 39. Brake oil level caution lamp
18. Air cleaner clogging caution lamp 40. Transmission oil filter clogging caution lamp
19. Parking brake pilot lamp 41. Bucket load indication
20. Brake oil temperature caution lamp 42. Work indication
21. Fan reverse rotation pilot lamp 43. Addition mode: Gross load indication
22. Maintenance caution lamp Subtraction mode: Residual amount indica-
tion
WA430-5 10-219
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation status
Engine in
Engine stopped operation
Indication color
Night time
Concentrated warning
Concentrated warning
Individual indications
Individual indications
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
Category No. Items Device
: Occurs. Operating conditions
Remarks
—: Does
not occur.
To be turned on by
Concen- respective controllers
trated Concentrated
When an error occurs U U U U U U U U Red and message will be
13 LED indicated simulta-
warning warning lamp neously.
lamp
Other cases than above — — — — — — —
10-220 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation status
Engine in
Engine stopped
operation
Indication color
Concentrated warning
Concentrated warning
Night time
Individual indications
Individual indications
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
Category No. Items Device Operating conditions Remarks
: Occurs.
—: Does
not occur.
Upper digits: F, N, R
Lower digits: Speed stages
Indication will be main- Speed stage indication
Actual gear shift 9 segment
34 stage LED — tained until the starting — — — — — — — will not be made while
key is turned OFF when a at the "N" stage.
combination error has
occurred.
Normal voltage — — — — — — —
When the abnormality
was detected while the
Other 24 Battery charge LED Charging trouble AB00AMA Red engine is stopped, the
symbols alarm will continue after
starting the engine also.
When an abnormality is
detected AB00L6 — — — Red
WA430-5 10-221
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation status
Engine in
Engine stopped
operation
Indication color
Concentrated warning
Concentrated warning
Night time
Individual indications
Individual indications
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
Category No. Items Device
: Occurs. Operating conditions
Remarks
—: Does
not occur.
When an abnormality is
detected — — — DHE4L6 — — — —
Normal (CLOSE) — — — — — — —
When the abnormality
When sensor 1 is being was detected while the
Air cleaner — — — — — AA1ANX Red
18 clogging
LED blinded (OPEN) engine is stopped, the
alarm will continue after
When an abnormality is starting the engine also.
detected with sensor 1 — — — DHA4KA — — — —
25 (when the S/T oil LED When the S/T oil pressure checking of emergency
pressure is nor-
mal)
dropped (CLOSE) & when
the engine revolution is — — DDS5L6 Red steering is in progress
and when the S/T oil
(Optional) 500rpm or more pressure is found too
low during self-checking
of emergency steering,
the indicator will be
turned ON.
Normal — — — — — — —
2V or less — — — — D61AZK Red
Battery fluid level
23 (Optional) LED When this option is not
installed — — — — — — —
When an abnormality is
detected — — — DJBAKX — — — DJBAKX —
10-222 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation status
Engine in
Engine stopped
operation
Indication color
Concentrated warning
Concentrated warning
Night time
Individual indications
Individual indications
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
Category No. Items Device Operating conditions Remarks
: Occurs.
—: Does
not occur.
Not in operation/Not
installed — — — — — — —
In operation — — — — Green
Auto greasing
31 (Optional) LED
The tank is empty — — — — Green
1Hz 1Hz
Abnormal — — — — Green
2Hz 2Hz
Normal — — — — — — —
22 Maintenance LED
Less than 30 hours after
maintenance — — U — — U — Simultaneously, the
message display will
monitor indicate the content.
Less than 30 hours before The indicator will light
maintenance for 30 sec. only after the
or maintenance time has — — U — — U Red starting key is turned
come ON.
WA430-5 10-223
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation status
Engine in
Engine stopped
operation
Indication color
Concentrated warning
Concentrated warning
Night time
Individual indications
Individual indications
Message indication
Message indication
dimming
Warning buzzer
Warning buzzer
Category No. Items Device Operating conditions Remarks
: Occurs.
—: Does
not occur.
As indi- As indi-
The fan is in reverse rota- Orange Will indicate the state
21 Fan reverse LED tion — — cated at — — cated at where the fan is in for-
rotation right right ward/reverse rotation.
As indi- As indi-
Fan SW and SOL are not in
conformity — — cated at — — cated at Orange
Other right right
symbols When the load meter indi-
5 Load meter cation is being made U U U U U U U U —
41 (Load meter spec- Liquid crystal Calculation results will
42 ification) display be shown in figures.
When the load meter indi-
cation is not being made — — — — — — —
43 (Optional)
When an abnormality is
detected (Rear) — — — DGR2KA — — — DGR2KA —
Priority degrees of the buzzer sound: Repetitive () > Intermittent (✩) > Cancellation of operation > Confirmation of receiving the operation
10-224 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Check the settings or change the settings of the rotary switches, dip switches and check or change the
option setting in the following cases:
In case it becomes necessary to remove the machine monitor once and when reinstalling it
In case the machine monitor has been replaced with a new monitor
In case the tire size has been changed (speed compensation settings)
In case the optional equipment is being installed or being removed
Setting statuses of respective switches can be checked on the real time monitor under the service mode.
Refer to the "Real time monitoring function".
WA430-5 10-225
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
When making settings, turn off the power supply and remove the machine monitor in advance. Refer to
the Chapter "Disassembly and Assembly" when removing the machine monitor.
Make settings of respective switches (SW1, 2, 3, 5 and 6) according to the instructions.
When turning the rotary switches, turn them gently using a precision plus head type screwdriver, etc.
With the rotary switches, the triangular projection is the arrow mark for setting.
When changing the settings of the dip switches, move them gently using a precision minus head type
screwdriver, etc.
When inserting a tool inside the grommeted hole, be careful not to touch any other parts than the targeted
switch.
As for the option setting, the settings can be changed or checked using the "Option Setting" under the ser-
vice mode. (Refer to the Section "Initial Setting/Adjustment". page10-241 and above)
Depending on the type of the option, it becomes necessary to make the initial state setting. (Refer to the
Section "Initial Setting/Adjustment".)
As for the initial stage adjustment, the adjustment can be made by the "Tuning" under the service mode.
(Refer to the Section "Initial Setting/Adjustment".)
1. Precautions
When making settings, observe the instructions.
When moving the switches, move them gently using a precision screwdriver, etc.
When inserting a tool inside the grommeted hole, be careful not to touch any other parts than the tar-
geted switch.
Be careful not to let dust and any other foreign substance enter into the equipment.
After finishing the setting work, be sure to insert the grommets back to their original positions securely.
2. When making the machine model selection settings (Setting of the rotary switch [SW1])
Since a single type of machine monitor is being applied to many machine models, it is necessary make
the setting for the machine model to which the machine monitor has been installed.
When the machine monitor has been replaced, it becomes necessary to make machine model selection
setting by the rotary switch [SW1] to let the system make proper controls for the machine model to
which the machine monitor has been installed.
Adjustment procedures
Make the setting indicated in the following Table to fit to the machine model to which the machine mon-
itor has been installed.
10-226 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
4. When making the speedometer/tachometer indication changeover setting and tire size selection setting
(Setting of the rotary switch [SW3])
Since the machine monitor is being set to the tire size of standard tires for speed calculations, when the
tire size has been changed, it becomes necessary to adjust to the new tire size by the rotary switch
[SW3] for compensation of the speed indications.
Adjustment procedures
Make the setting according to the following Table to fit to the tire size.
Meter indication SW3 Tire size Remarks
changeover
km/h indication 0 Small diameter tire
Making the speedometer/tachometer indication changeover setting means to change the indication content
of the speed meter located in the central section of the monitor.
Changeover from the speedometer to (engine) tachometer can also be made using the "option setting".
After the above setting is made, the indication unit of the travel distance integrating meter (odometer) will
become according to the setting made as above.
Since the MPH indication is only for the countries employing the non-SI-unit only, do not make the MPH
indication setting for machines being used in countries employing the SI-unit.
In case other tires than the above or when the speed indications deviate from the actual speed by wears of
the tires, it is possible to make tire compensations using the "option setting".
5. When making necessary setting when the engine controller is installed (Setting of the dip switch [SW5-
1])
Make the setting as follows and do not change it.
Setting position of the SW5-1 in case of machines not equipped with the KOMATSU Common Rail
engine (WA430-5 ): "OFF"
6. When making necessary setting for the work equipment/joy-stick controller (Setting of the dip switch
[SW5-2])
When the work equipment/joy-stick controller is newly installed or removed, make the setting as fol-
lows.
Setting position of the SW5-2 in case the controller has been removed: "OFF"
Setting position of the SW5-2 in case the controller has been newly installed: "ON"
WA430-5 10-227
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Setting position of the SW5-4 in the case the use of the 3rd gear speed lockup, 4th gear speed, and 4th
gear speed lockup is prohibited: "OFF"
Setting position of the SW5-4 in the case the use of the 3rd gear speed lockup, 4th gear speed, and 4th
gear speed lockup is permitted: "ON"
9. When making the setting of the dip switch [SW6-1]
Make the setting as follows and do not change it.
Setting position of the SW6-1: "OFF"
10-228 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
***: Indicates which sequence number of fault history counting from the top.
######: Indicates the error code.
$$$: Indicates the number of times of occurrence of the subject error code
%%%%%: Indicates the elapsed time from the initial occurrence of the same electric fault (the value
deducting the service meter value when the electric fault initially occurred from the current service
meter value).
@@@@@: Indicates the elapsed time from last occurrence of the same electric fault (the value
deducting the service meter value when the electric fault last occurred from the current service
meter value).
When the indication is showing the currently occurring electric fault, the error code flashes. Up to
max. 20 error codes can be memorized.
2) Machine fault history
Use this function to check the machine fault history of respective controllers being memorized by
the machine monitor. Regarding the error code being used in the machine fault history, refer to the
Chapter "Troubleshooting".
The machine fault history indications on the character display are as follows.
***: Indicates which sequence number of fault history counting from the top.
######: Indicates the error code.
$$$: Indicates the number of times of occurrence of the subject error code.
%%%%%: Indicates the service meter value at the time of initial occurrence of the same machine
fault.
@@@@@: Indicates the service meter value at the time of last occurrence of the same machine
fault.
When the indication is showing the currently occurring machine fault, the error code flashes. As for
the error codes of the machine fault, up to several error codes can be memorized.
WA430-5 10-229
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-230 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA430-5 10-231
(5)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
2. Operation methods
10-232 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA430-5 10-233
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
3) Selection of displaying the fault history of electric system and clearing the entire fault history of
electric system (second layer)
A current fault is displayed prior to the restored ones.
Pressing the > SW displays the next older fault.
Pressing the < SW displays the next newer fault.
After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the
entire fault history of electric system of the relevant controller.
Pressing the SW changes the screen to the [Select displaying abnormalities in electric system]
screen on the first layer.
Pressing the SW changes the screen to the [Clear individually the fault history of electric system]
or [Clear the fault history of electric system] screen.
* If the history consisted of one fault, pressing the switch does not change the screen to that for all-
out clearing (but change the screen to that for individual clearing).
4) Clearing individually the fault history of electric system, and clearing the entire fault history of elec-
tric system (the third layer)
Select YES or NO with the < or > SW.
Cursor (_) blinks on the selected item. Pressing the SW changes the display as follows, with the
history reset if YES was selected, or not if NO was selected:
1 If No (cancel) was selected, the display returns to the [Display the fault history of electric
system] screen of the relevant fault (i.e., the screen before entering the [Clearing individually
(entirely) the fault history of electric system] screen).
2 If YES (clear ) was selected, the display returns to the [Display the fault history of electric
system] screen of a fault next to the relevant fault. If the fault history to be shown exhausts, the
screen returns to the [Select displaying the fault history of electric system] screen.
By default, the cursor is on NO (no reset) to prevent resetting by error.
A current fault cannot be cleared. If it was selected, a peep sounds for one second to notify that the
operation is cancelled.
If a fault was cleared, peeps sound (on for 0.1 sec. - off for 0.1 sec. - on for0.1 sec.) to notify that the
operation has been accepted.
If the entire history was cleared, it is considered to have been cleared even if it consisted of only
one fault .
10-234 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA430-5 10-235
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-236 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA430-5 10-237
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-238 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA430-5 10-239
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
The maintenance interval time is set when the machine is shipped as in the following table:
Interval for
Items replacement (h) Items shown ID numbers
10-240 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation
1. Press the SW and < SW for more than five seconds to go to the [ID Entry] screen.
2. Enter ID with the < and > SW, and press the SW to go to the screen for service persons.
3. Press the < and > SW to display the [Select the real-time monitor] screen, then press the SW to fix the
screen.
10-242 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
4. Press the SW, and the [Select the information displayed on monitor panel] screen appears. Pressing
the < or > SW display the screens [Select the information of the transmission controller], [Select the
information of the engine controller], [Select the information of the working machine controller], and
[Select the 2-item display] in order.
5. Pressing the SW, while each selection screen is shown, displays the [One-item display] screen or the
[Select information on 2-item display] screen.
In the case of 1-item display, pressing the < and > SW changes the items shown in turn, displaying the infor-
mation each controller has.
WA430-5 10-243
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
How to Enter an ID
After the screen was changed from another, “00000” is shown.
Enter a number 0-9 in the cursor position.
The cursor is at the highest digit first. Each time the < or > SW was pressed, the number changes by 1
within a range 0-9.
If the desired number was entered, press the SW.
The cursor moves to the second highest digit. Repeat the procedures mentioned above until the last num-
ber is filled in the lowest digit.
If the lowest digit was entered, press the SW, and the screen changes to that for displaying/selecting the
second item. Alternately, pressing the SW returns the screen to that for displaying/selecting two items.
In the case of 2-item display, enter the IDs of the information to be displayed, and the two items are shown
simultaneously. The IDs shown are the same as those on the 1-item display screen.
6. In the case of 1-item display, pressing the < and > SW changes the items shown in turn, displaying the
information each controller has.
10-244 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
40800 Calculated load weight MES LOAD 0.01t 0.00-50.00 Monitor Calculated
value
Switch on
30802 Rotary switch position SW1,SW2,SW3 --- 0-F Monitor
the rear
Switch on
30904 Dip switch position SW5-1,SW5-2 --- OFF.ON Monitor
the rear
Switch on
30905 Dip switch position SW5-3,SW5-4 --- OFF.ON Monitor
the rear
Switch on
30906 Dip switch position SW6-1,SW6-2 --- OFF.ON Monitor
the rear
Switch on
30907 Dip switch position SW6-3,SW6-4 --- OFF.ON Monitor
the rear
See separate
40900 Input signal D_IN_0-7 D-IN--0-----7 --- 10101010 Monitor
sheet
See separate
40901 Input signal D_IN_8-15 D-IN--8-----15 --- 10101010 Monitor
sheet
See separate
40902 Input signal D_IN_16-23 D-IN-16-----23 --- 10101010 Monitor
sheet
See separate
40903 Input signal D_IN_24-31 D-IN-24-----31 --- 10101010 Monitor
sheet
40904 Input signal D_IN_32-39 D-IN-32-----39 --- 10101010 Monitor See separate
sheet
T/M controller
Shows part No. of
20201 Part No. of T/M controller’s ROM TRANSM ROM --- --- T/M ---
ROM
41000 Target speed of fan pump FAN PUMP 1rpm 0-3000 T/M Calculated
value
WA430-5 10-245
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
41400 Fan pump EPC current FAN EPC 1mA 0-1000 TM L63-36
41500 T/M oil temperature ECMV OIL TEMP 1°C 24-131 TM L61-9
Calculated
41700 Selection of shift mode SHIFT MODE --- H/M/L TM
value
Calculated
41808 F fill time FILL TIME F 10msec 0-2550 TM
value
Calculated
41806 R fill time FILL TIME R 10msec 0-2550 TM
value
10-246 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Work
41904 R.H. J/S EPC current RH J/S EPC 1mA 0-1000 L73-26
equipment
Work
41905 L.H. J/S EPC current LH J/S EPC 1mA 0-1000 L73-36
equipment
Work
41906 3rd valve 1 EPC current 3RD EPC1 1mA 0-1000 L73-25
equipment
Work
41907 3rd valve 2 EPC current 3RD EPC2 1mA 0-1000 L73-35
equipment
Lever potentiometer-voltage lift Work
42000 BOOM POT1 0.01V 0.00-5.00 L71-19
arm 1 equipment
Lever potentiometer-voltage lift Work
42001 arm 2 BOOM POT2 0.01V 0.00-5.00 equipment L71-13
42004 Lever potentiometer-voltage J/S 1 J/S POT1 0.01V 0.00-5.00 Work L71-9
equipment
Work
42005 Lever potentiometer-voltage J/S 2 J/S POT2 0.01V 0.00-5.00 L71-3
equipment
Lever potentiometer-voltage 3rd Work
42006 3RD POT1 0.01V 0.00-5.00 L71-20
valve 1 equipment
42007 Lever potentiometer-voltage 3rd 3RD POT2 0.01V 0.00-5.00 Work L71-14
valve 2 equipment
Work
06002 Lift arm angle BOOM ANG 1° -41-46 L71-8
equipment
Work
40401 Lift arm bottom pressure BTM PRESS 0.01MPa 0.00-50.00 --- No function
equipment
0-256000
42100 Number of times of lift arm lever BOOM LVR 1000 (incremental Work Calculated
operation equipment value
step=1000)
0-256000
Number of times of bucket lever Work Calculated
42101 BUCKET LVR 1000 (incremental
operation equipment value
step=1000)
0-256000
Number of times of 3rd lever oper- Work Calculated
42102 3RD LVR 1000 (incremental
ation equipment value
step=1000)
40910 Input signal D_IN_0-7 D-IN--0------7 --- 10101010 Work See separate
equipment sheet
Work See separate
40911 Input signal D_IN_8-15 D-IN--8-----15 --- 10101010
equipment sheet
Work See separate
40912 Input signal D_IN_16-23 D-IN-16-----23 --- 10101010
equipment sheet
Work See separate
40913 Input signal D_IN_24-31 D-IN-24-----31 --- 10101010
equipment sheet
Work See separate
40917 Output signal D_IN_0-6 D-OUT-0------6 --- 1010101
equipment sheet
40916 Output signal SOL/0-0-5 SOL/0-0------5 --- 101010 Work See separate
equipment sheet
WA430-5 10-247
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
How to read input signals (D-IN--0------7) How to read output signals (D-OUT-0------7)
The signal input into controller by ON/OFF switch is The signal output from controller by ON/OFF switch
shown as [D-IN-*] (* represents input No.). is shown as [D-OUT-*] (* represents output No.).
The display shows it as follows: The display shows it as follows:
10-248 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA430-5 10-249
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Connector
I/O signal Displayed item No. Pin No. ON/OFF logic
T/M Controller
D-IN-0 S/T pressure switch (N.O.) L61 23 Pressure normal=ON (GND)/OFF (OPEN)
Abnormal pressure (drop down)=ON (GND)/
D-IN-1 S/T pressure switch (N.C.) L61 17 OFF (OPEN)
D-IN-2 T/M cut-off switch L61 11 Switched pressed=ON (GND)/OFF (OPEN)
D-IN-3 T/M cut-off set switch L61 5 Switched pressed=ON (GND)/OFF (OPEN)
D-IN-4 E. C. S. S. change-over switch (OP) L61 24 Switched pressed=ON (GND)/OFF (OPEN)
D-IN-5 Lock-up change-over switch (OP) L61 18 Switched pressed=ON (GND)/OFF (OPEN)
D-IN-6 Kick-down switch L61 12 Switched pressed=ON (GND)/OFF (OPEN)
D-IN-7 Engine power mode E L61 6 P mode=ON (GND)/OFF (OPEN)
D-IN-8 Shift range 1st L63 10 1st gear=ON (24V)/OFF (OPEN)
D-IN-9 Shift range 2nd L63 20 2nd gear=ON (24V)/OFF (OPEN)
D-IN-10 Shift range 3rd L63 30 3rd gear=ON (24V)/OFF (OPEN)
D-IN-11 Shift range 4th L63 40 4th gear=ON (24V)/OFF (OPEN)
D-IN-12 J/S shift up (OP) L63 9 Switch pressed=ON (24V)/OFF (OPEN)
D-IN-13 J/S shift down (OP) L63 19 Switch pressed=ON (24V)/OFF (OPEN)
Electric (emergency steering) man-
D-IN-14 ual switch (OP) L63 29 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-17 Right seesaw & J/S F (OP) L62 25 Forward=ON (24V)/OFF (OPEN)
D-IN-18 Right seesaw & J/S N (OP) L62 15 Neutral=ON (24V)/OFF (OPEN)
D-IN-19 Right seesaw & J/S R (OP) L62 5 Reverse=ON (24V)/OFF (OPEN)
D-IN-20 Direction lever F L62 36 Forward=ON (24V)/OFF (OPEN)
D-IN-21 Direction lever N L62 26 Neutral=ON (24V)/OFF (OPEN)
D-IN-22 Direction lever R L62 16 Reverse=ON (24V)/OFF (OPEN)
D-IN-23 Neutralizer (P/B) signal L62 6 Parking switch ON=(24V)/OFF (OPEN)
D-IN-24 E-POC FILL F L62 37 Fill switch ON=(GND)/OFF (OPEN)
D-IN-25 E-POC FILL R L62 27 Fill switch ON=(GND)/OFF (OPEN)
D-IN-26 E-POC FILL 1st L62 17 Fill switch ON=(GND)/OFF (OPEN)
D-IN-27 E-POC FILL 2nd L62 7 Fill switch ON=(GND)/OFF (OPEN)
D-IN-28 E-POC FILL 3rd L62 13 Fill switch ON=(GND)/OFF (OPEN)
D-IN-29 E-POC FILL 4th L62 3 Fill switch ON=(GND)/OFF (OPEN)
D-IN-30 E-POC FILL L/U L62 2 Fill switch ON=(GND)/OFF (OPEN)
D-IN-31 Shift hold switch L62 38 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-32 No item L62 28 ON (GND)/OFF (OPEN)
Electric (emergency steering) relay
SOL/0-0 (OP) L63 7 Output ON (24V)/OFF (OPEN)
10-250 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Connector
I/O signal Displayed item No. Pin No. ON/OFF logic
WA430-5 10-251
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Connector
I/O signal Displayed item No. Pin No. ON/OFF logic
10-252 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
After checking those conditions on the real-time monitor, check the engine speed
Conditions Real-time monitor item Component ID
Engine speed ENG SPEED Machine monitor 01001
Check the T/M controller first to see if any abnormality was found and to see if an error was issued.
If no error was detected, check the status of input signals on the real-time monitor.
1. Check the cut-off selection switch
Item Real-time monitor item Pin position ID
D-IN-2 D-IN--0------7 L61-11 40905
40905:**0****
The third digit is [0] if the T/M cut-off selection switch has recognized itself as not ON.
Item Real-time monitor item Pin position ID
D-IN-2 D-IN--0------7 L61-11 40905
40905:**1****
On the contrary, the digit is [1] if the switch has recognized itself as ON.
If [0] continues after you operated the switch, you can consider that the cut-off selection switch system
is abnormal.
WA430-5 10-253
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
40905:***0***
The fourth digit is [0] if the T/M cut-off set switch has recognized itself as not ON.
Item Real-time monitor item Pin position ID
D-IN-3 D-IN--0------7 L61-11 40905
40905:***1***
On the contrary, the digit is [1] if the switch has recognized itself as ON.
If [0] continues after you operated the switch, you can consider that the cut-off set switch is abnormal.
41100:*.**MPa
If the pressure does not change after you stepped on/released the cut-off brake, you can consider that
the sensor system is abnormal.
If you stepped on the left-hand brake fully, about 5.00Mpa {51kg/cm²} of pressure should be shown.
If you released the brake, a value less than 0.5Mpa {5kg/cm²} should be shown.
The pressure may change when you stepped on the brake even when the engine is stopped if some
pressure remains in accumulator; if no pressure remains in it, a value less than 0.5Mpa {5kg/cm²}
should be shown.
41100: 1.50MPa
Set the cut-off position ([1.50] was selected arbitrarily).
Setting cut-off causes the pressure taken into memory when the set switch being pressed was
released.
2) Check the cut-off pressure just set on the real-time monitor.
Item Real-time monitor item Pin position ID
T/M cut-off pressure CUT OFF Calculated value 41200
41200: 1.50MPa
The result is accepted if the value is substantially the same with the value previously set.
Although, if the cut-off pressure has been set to less than 0.49Mpa{5kg/cm²}, 0.49Mpa{5kg/cm²}
shall be adopted as the set value; if the cut-off pressure has been set to more than 4.5Mpa{45kg/
cm²}, 4.5Mpa{45kg/cm²} shall be adopted as the set value.
10-254 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
1. Outline
For the load meter, there are addition mode, subtraction mode, data display mode, calibration mode
and calculation stop mode, and each mode can be selected with the monitor panel mode selector
switch. If a printer (OP) is connected to the load meter, it is possible to print out measurement data.
2. Operating Method
WA430-5 10-255
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
3. Weight Calculation However, the real measured value (D) of lift arm
Since the pressure sensor (A) mounted on the pressure has characteristics shown in the figure
bottom side of the lift arm cylinder and the below because operations of the tires and the
pressure sensor (B) mounted on the head side work equipment cause spring effect to the
detect operating pressures (P) of the lift arm, machine.
and also the lift arm angle sensor (C) calculates
positions of the center of gravity, the load
meter calculates weight (W) of load.
10-256 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
The lift arm angle ranges from -10° to -30°. (The range between below horizontal and above touching
Condition 1 the ground)
The lift arm angle increases more than 0.1° in 0.1 second. (The lift arm started moving upward at a
Condition 2 fixed speed.)
The lift arm angle incseases less than 0.5° in 0.5 seconds. (The lift arm lifting speed reduced below
Condition 1 fixed value.)
Condition 2 The lift arm moves downward. (When lift arm lowering operation is done, the calculation is finished.)
Condition 3 The lift arm angle became up to +20° (The calculation stops at high position.)
The lift arm lifting speed changed suddenly. (The speed reduced below 70% in comparison with the
Condition 4 previous angular velocity.)
Calculation count Calculating time (sec.) Weight calculating and displaying methods
Weight is displayed by only one calculation. In this case, the weight
1 time only 1.5 - 2.5 display flashes to inform the operator that the calculating time is
short and the calculation accuracy is not enough.
2 times 2.5 - 3.5 Averaged weight of the two calculations is displayed.
3 times or more 3.5 - The averaged weight of the latest three calculations is displayed.
WA430-5 10-257
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
• When the addition mode is selected, • When the subtraction mode is selected,
"TOTAL LOADED" (1) is displayed, and each "REMAINING TARGET"(1) is displayed, and
calculated bucket load (3) is added to the the calculated bucket load (3) is reduced
total load display (2). from the residual quantity display (2).
• Weights of any five kinds of object materi- • Weights of any five kinds of object materials
als can be independently accumulated and can be independently accumulated and dis-
displayed. For selection of object materi- played. For selection of object materials, the
als, the five kinds from A to E can be five kinds from A to E are selected and set
selected and set in the display of work in the display of work object materials (4).
object materials (4).
• Values up to 9999t are displayed in the total ★ For the detail of display and calculation
load display (2) unless data are cleared with methods of bucket load display (3) larger
the load meter sub-total switch. Values up than the residual quantity (2), see the para-
to 999.9t are displayed in units of 0.1t, and graph of "Operation of Load Meter" in the
when the value is over 1000t, the decimal Operation and Maintenance Manual.
point disappears and values are displayed ★ For the detail of residual quantity display,
in units of 1t. see the paragraph of "Total Load Display
and Residual Quantity Display."
★ For the detail of total load display, see the
paragraph of "Total Load Display and Resid-
ual Quantity Display."
10-258 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Total Load Display and Residual Quantity Display Load Meter Cancel Switch
To be displayed with
- -99.5 -99.9 decimal point
To be displayed with
decimal point (round-
-99.4 - -0.1 -**.* ing off the second
fractions)
To be displayed with
decimal point (round-
0 - 999.4 ***.* ing off the second
fractions)
To be displayed in
integers only (count- • When this switch (1) is pressed during the
999.5 - 9999.4 **** ing factions of 0.5 and calculated weight display holding time (15
over as a unit and cut-
ting away the rest) seconds after calculation), the bucket load is
judged not to be loaded and the calculation
To be displayed in
9999.5 - 9999 integers only. is cancelled. The display of total load (or
residual quantity) is also cancelled to be
increased (or decreased), and returns to the
Unit of Calculated Weight
previous value.
• All calculated weights are displayed in the
SI unit (metric ton). When "MPH" is
Load Meter Sub-total Switch
selected to display machine speed with the
rotary switch on the back of the monitor,
however, it is possible to change the unit to
short ton by setting the optional device in
the service mode. In this case, weights are
printed out in short ton as well.
WA430-5 10-259
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-260 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
WA430-5 10-261
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
6. Printout (OP)
★ This function is available only when the printer (OP) is connected.
Output formats of the load meter can be selected from three (A, B and C) output modes. Output for-
mats of each mode are as follows:
★ For the output mode selection and output methods refer to the paragraph of "Operation of Load
Meter" in the Operation and Maintenance Manual.
Mode A (Total printout) Mode B (Sub-total printout) Mode C (Operation record printout)
• Machine Model, Serial number • Machine Model, Serial number • Machine Model, Serial number
• Printing time and date • Printing time and date • Record starting time and date, Service
• Sub-total data of loading (Kind, Num- • Loading data (Load weight) meter
ber of loading times, Load weight) • Loading sub-total data (Kind, Number • Record ending (printing) time and
• Total data of loading (Total number of of loading times, Load weight) data, Service meter
loading times, Total load weight) • Loading total data (Total number of • Subtotal data of loading (Kind, Num-
loading times, Total load weight) ber of loading times, Load weight)
• Total data of loading (Total number of
loading times, Total load weight)
• Maintenance time (Maintenance items,
remaining time)
Material: D Maintenance
1: 1.43t 2: 2.27t Engine oil 250h
3: 2.05t 4: 3.38t Transmission oil 1000h
Total: 4 times 9.04t Hydraulic oil 2000h
Axle oil 2000h
Material: E Engine oil filter 250h
1: 3.48t 2: 2.94t Transmission oil filter 500h
3: 3.64t 4: 1.97t Hydraulic oil filter 1000h
5: 2.79t Axle pivot pin 500h
Total: 5 times 14.82t Bobm pin 100h
Steering cylinder pin 250h
Center hinge pin 1000h
10-262 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
No-load Calibration
★ For the calibrating method, see the paragraph
• This calibration is for canceling such weight of Inspection and Adjustment of Load Meter in
difference peculiar to machine as work equip- the Volume of Inspection and Adjustment.
ment weight, etc. and is intended to compen-
sate offset error (B) from standard value (A) as
shown in the figure below.
8. Calculation Stop
This function stops the calculating function of
the load meter. During the calculation stop,
the load meter display disappears, and the
travel speed display or the engine speed dis-
play appears and the data is not added to the
total data. To resume the calculation, select
the Addition Mode or the Subtraction Mode.
★ For how to stop calculation, refer to the
paragraph of "Operation of Load Meter" in
the Operation and Maintenance Manual.
WA430-5 10-263
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Machine setting
Setting of machine serial number
1. Hold down the SW and < SW for 5 seconds or 4. Enter the machine serial number.
more, and change to the [ID entry screen].
Entering ID
At transition to the screen, “50000” or “set
2. Use the < and > SW to enter ID, and press the numeric value” is displayed on the screen.
SW to enter the service person screen. Enter a numeric value 0 to 9 at the cursor posi-
tion.
The cursor appears on the highest-order posi-
tion, and 0 to 9 is displayed one by one each
time the >, /, or < SW is pressed.
When a target numeric value is displayed, press
the SW.
The cursor moves to the second digit. Follow
the same procedure to enter up to the lowest-
order digit, and press the SW.
If a numeric value is changed, the operation
acceptance completion sound is output.
If an incorrect numeric value is entered, use the
SW to return to the [Select Setting] screen
once, and repeat the procedure from the begin-
3. Use the < and > SW to display the [machine ning.
serial No. entry] screen, and press the SW to
decide the machine serial number.
10-264 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
J/S lever, work equipment controller, J/S EPC valve Adjustment of J/S steering
Lift arm angle sensor and machine monitor Adjustment of load meter lift arm angle
WA430-5 10-267
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-268 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Operation method
4. After a target controller is selected, press and
1. Operate the monitor mode switch to select a
release the monitor mode switch ( ). The set-
service mode option.
ting state for each option appears as follows.
Pressing the monitor mode switch changes the
option setting as follows.
WA430-5 10-269
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
(1) Hold down the SW and < SW for 5 seconds or more at the same time, and change to the ID
entry screen. (Figure 1)
(2) Use the < and > SW to enter ID, and press the SW to enter the service person screen.
(3) Use the < and > SW to display the sensor initialization selection screen (Figure 2), and press
the SW to decide the value.
(4) Use the < and > SW to display the T/M initial learning screen (Figure 3) of set item 1.
(5) Depress the switch, and the transmission initial learning setting screen (Fig. 4-1 or Fig. 4-
2) appears.
(6)-1 If the initial learning has not been carried out, the initial learning incompletion (reset) screen
(Fig. 4-1) appears.
(6)-2 If the initial learning has been carried out, the initial learning completion screen (Fig. 4-2)
appears.
(7) To reset the initial learning, depress the switch to display the initial learning reset screen
(Fig. 5).
(8)-1 To reset the initial learning, select YEW with the < switch and depress the switch.
After the switch is depressed, if the initial learning incompletion (reset) screen (Fig. 4-1)
appears, the initial learning is reset.
(8)-2 If you do not need to reset the initial learning, select NO and depress the switch.
After the switch is depressed, the screen before the ž switch was depressed (Fig. 4-1 or
Fig. 4-2) appears and resetting is cancelled.
If the initial learning is necessary, carry out (1) - (5), and then carry out the resetting operation (up to (8)-1)
once while either the screen in (6)-1 or the screen in (6)-2 is displayed.
10-270 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
1. Carry out initial learning operation at the state of the machine mentioned above. (Do not stop the engine.)
2. Check that the oil temperature of transmission is in the range of 55 - 70°C on the real-time monitor.
If it is outside of the specified range, be sure to carry it out within the specified temperature range.
★ If the initial learning is carried out at the temperature outside of the specified range, it may cause
time lag and gear shift shock.
3. Shift the transmission by operating the gear shift lever and directional lever.
Gear range N2 F2 F1 F2 F3 F4 F3 F2 N2 R2 N2
Holding time 5 sec 5 sec 5 sec 3 sec 3 sec 3 sec 3 sec 3 sec 3 sec 3 sec 3 sec
After holding each gear speed for the time specified or more, shift gears to the next range.
Operate the engine at low idling, place the shift mode switch in the MANUAL position, and the transmission cut-off switch in the
OFF position (the lockup switch in the OFF position).
Carry out shifting operation while driving the machine actually or while depressing the brake pedal.
★ When setting to N2 initially, operate the directional lever by placing it in the N position following the
F2 or R2 position.
Even if the shift lever is changed to 2 after placing the directional lever in N, the gear will not
change. Therefore, operate the directional lever by placing it in the N position after setting the gear
shift lever to 2.
When the directional lever is placed in the N position at the shift lever in other than 2, place the
directional lever in the F or R position and then operate the directional lever in the N position fol-
lowing F2 or R2.
★ Hold the shift lever for the specified holding time or more for each speed of gear range.
If the gear shift lever is operated for the holding time or less, completion of initial learning (display
of TUNED) will not appear.
4. Check that completion of initial learning (display of TUNED) appears on the initial learning of transmis-
sion setting screen on the real-time monitor.
5. When the initial learning is not carried out (display of INITIAL STATUS), repeat operations mentioned
in 3 and 4 until completion of initial learning (display of TUNED) appears.
WA430-5 10-271
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
1. Hold down the SW < SW for 5 seconds or 4. Press the < and > SW to display the [Work
more at the same time, and change to the [ID Equipment Lift Arm Angle Adjustment] screen
Entry] screen. of set item 2.
2. After the ID is entered using the < and > SW, 5. Press the SW here; the [Work Equipment Lift
press the SW to enter the service person Arm Angle Set] screen appears.
screen.
10-272 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Item setting
1. Hold down the < and > SW for 5 seconds or more at he same time, and change to the [ID Entry] screen.
2. Use the < and > SW to enter ID, and press the SW to enter the service person screen.
3. Use the < and > SW to display the [Sensor Initial Setting Selection] screen, and press the SW to
decide the value.
4. Use the < and > SW to display the [Work Equipment EPC Adjustment] screen on set items 4 to 7.
Lift arm up: No.4
Lift arm down: No.5
Bucket tilt: No.6
Bucket dump: No.7
3-valve extension: No.8
3-valve reduction: No.9
Set the value individually.
5. Press the SW here; the [Work Equipment EPC Setting] screen appears.
WA430-5 10-273
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-274 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
Bucket tilt
1. Dump the bucket to lower the lift arm, and lift the front tires. Tilt the bucket by degrees in the engine
high idling state. (Lower the machine.)
2. Return the lever by fine operation to stop the bucket (tire floating), then hold the lever at that position.
3. Press the SW here; the EPC command value is read, and a difference between the read value and ref-
erence value is stored as an offset value.
4. The buzzer sounds twice (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the SW is pressed as the lever stroke is in the dump direction, the buzzer sounds for 1 second,
and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains displayed.
6. When the SW is pressed as the lever is at the neutral position, the adjustment value is cleared, and
the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC Adjust-
ment] screen.
7. When the SW is pressed, the work equipment EPC dispersion correction is ended even if it is in
progress of processing.
Bucket dump
1. Adjust the bucket to the horizontal level without load, and lower the bucket by degrees in the engine
high idling state.
2. Return the lever by fine operation to stop the lift arm, then hold the lever at that position.
3. Press the SW here; the EPC command value is read, and a difference between the read value and ref-
erence value is stored as an offset value.
4. The buzzer sounds twice (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the SW is pressed as the lever stroke is in the tilt direction, the buzzer sounds for 1 second,
and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains displayed.
6. When the SW is pressed as the lever is at the neutral position, the adjustment value is cleared, and
the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC Adjust-
ment] screen.
3-valve extension
1. Extend three valves by degrees in the engine high idling state.
2. Return the lever by fine operation. After the cylinder of three valves stops, hold the lever at that posi-
tion.
3. Press the SW here; the EPC command value is read, and a difference between the read value and ref-
erence value is stored as an offset value.
4. The buzzer sounds twice, (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the SW is pressed as the lever stroke is in the fastening direction, the buzzer sounds for 1 sec-
ond, and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains displayed.
6. When the SW is pressed as the lever is at the neutral position, the adjustment value is cleared, and
the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC Adjust-
ment] screen.
7. When the SW is pressed, the work equipment EPC dispersion correction is ended even if it is in
progress of processing.
3-valve reduction
1. Reduce three valves by degrees in the engine high idling state.
2. Return the lever by fine operation. After the cylinder of three valves stops, hold the lever at that posi-
tion.
3. Press the SW here; the EPC command value is read, and a difference between the read value and ref-
erence value is stored as an offset value.
4. The buzzer sounds twice, (two short tones), and the menu returns to the [Work Equipment EPC Adjust-
ment] screen. The setting is then completed.
5. When the SW is pressed as the lever stroke is in the extension direction, the buzzer sounds for 1 sec-
ond, and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains displayed.
6. When the SW is pressed as the lever is at the neutral position, the adjustment value is cleared, and
the buzzer sounds twice (two short tones). The menu then returns to the [Work Equipment EPC Adjust-
ment] screen.
7. When the SW is pressed, the work equipment EPC dispersion correction is ended even if it is in
progress of processing.
WA430-5 10-275
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
1. Push and hold the SW and > switch simulta- 4. Display the screen for adjusting items No. 4 — 6
neously for 5 seconds to go to the "Input ID" of the work equipment EPC with the < switch
screen. and > switch.
10-276 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
< Adjustment of each EPC lever > [Adjustment of position of lift arm RAISE
[Adjustment of position of lift arm LOWER detent]
(FLOAT) detent] Perform the following procedure with the
1) -1. Lower the lift arm to the ground. engine stopped.
2) -1. Stop and hold the lift arm lever before the 1) -2. Lower the lift arm to the ground.
FLOAT detent position. 2) -2. Stop and hold the lift arm lever before the
3) -1. Push the SW at this time. The lever voltage RAISE detent position.
is read and the standard value is changed and 3) -2. Push the SW at this time. The lever voltage
saved. is read and the standard value is changed and
4) -1. The buzzer sounds twice. The screen for saved.
adjusting the work equipment EPC appears and 4) -2. The buzzer sounds twice. The screen for
the adjustment is completed. adjusting the work equipment EPC appears and
the adjustment is completed.
Screen for adjusting work equipment EPC 5) -2. At this time, if the SW is pushed while the
lever output voltage is below the standard value
(out of design range), the buzzer sounds for 1 sec-
ond and the screen for setting work equipment
EPC does not change. The adjustment is can-
celled in this case.
WA430-5 10-277
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
10-278 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
2. Use the < and > SW to enter ID, and press the
SW to enter the service person screen.
WA430-5 10-279
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
2. Use the < and > SW to enter ID, and press the 5. Press the SW here; the [Work Equipment Lift
SW to enter the service person screen. Arm Angle Setting] screen appears.
3. Use the < and > SW to display the [Sensor Ini- 6. Adjust the lift arm to the highest position with-
tialization Setting] screen, and press the SW out load.
to decide the value. 7. Press the SW here; the lift arm angle sensor
value is read, and a difference between the
read result and reference value is stored as an
offset value.
8. The buzzer sounds twice (two short tones), and
the menu returns to the [Lift Arm Angle Adjust-
ment] screen. The setting is then completed.
9. Press the SW; the lift arm angle correction is
ended even if it is in progress of processing.
10-280 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
1. Hold down the SW < SW for 5 seconds or 4. Use the < and > SW to display the [Work
more at the same time, and change to the [ID Equipment Lift Arm Angle Adjustment] screen
Entry] screen. of set item 17.
2. Use the < and > SW to enter ID, and press the 5. Press the SW here; the [Work Equipment Lift
SW to enter the service person screen. Arm Angle Setting] screen appears.
3. Use the < and > SW to display the [Sensor Ini- 6. Adjust the lift arm to the lowest position with-
tialization Setting] screen, and press the SW out load. (Lift arm cylinder stroke end)
to decide the value. 7. Press the SW here; the lift arm angle sensor
value is read, and a difference between the
read result and reference value is stored as an
offset value.
8. The buzzer sounds twice (two short tones), and
the menu returns to the [Lift Arm Angle Adjust-
ment] screen. The setting is then completed.
9. Press the SW; the lift arm angle correction is
ended even if it is in progress of processing.
WA430-5 10-281
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
AMP070-20P [CN-L51]
Pin No. Specifications I/O Group Setting state Signal name WA430-5 Remarks
4 NSW power (+24V) I — Power +24V NSW power (+24V) NSW power (+24V)
5 NSW power (+24V) I — Power +24V NSW power (+24V) NSW power (+24V)
15 Sensor power output O — Sensor power Lift arm pressure Lift arm pressure For load meter
(+24V) sensor power sensor power (Spare for STD)
Sensor power output Lift arm angle sen- Lift arm angle sen- For load meter
16 (+5V) O — Sensor power sor power sor power (Spare for STD)
10-282 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
AMP070-18P(1) [CN-L52]
Pin No. Specifications I/O Group Setting state Signal name WA430-5 Remarks
Pin No. Specifications I/O Group Setting state Signal name WA430-5 Remarks
WA430-5 10-283
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
AMP070-18P(2) [CN-L54]
Pin No. Specifications I/O Group Setting state Signal name WA430-5 Remarks
AMP070-12P(2) [CN-L55]
Pin No. Specifications I/O Group Setting state Signal name WA430-5 Remarks
A_IM_2(High resistance
1 I J A/I Fuel level sensor Fuel level sensor
input)
A_IM_4(High resistance Torque converter oil Torque converter oil
2 I J A/I
input) temperature sensor temperature sensor
Engine coolant tem- Engine coolant tem-
A_IM_6(High resistance
3 input) I K A/I perature sensor (for perature sensor (for
auto pre-heating) auto pre-heating)
Lift arm pressure Lift arm pressure
4 A_IM_8(0 - 5V) I L A/I For load meter
sensor (rod) sensor (rod)
Battery fluid level
5 A_IM_10(0 - 14V) — — Battery fluid level A (OPT) OPT
10-284 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
AMP070-12P(3) [CN-L56]
Pin No. Specifications I/O Group Setting state Signal name WA430-5 Remarks
Machine monitor-T/
1 S_NET(+) I/O N S-NET M, and work equip- S_NET+
ment controller
Machine monitor-T/
2 S_NET(+) I/O N S-NET M, and work equip- S_NET+
ment controller
Machine monitor-T/
3 CAN+ I/O P CAN M, and work equip- CAN+
ment controller
4 S_NET(-) O N S-NET S_NET GND S_NET-
10 (NC)
11 (NC)
12 (NC)
AMP070-14P(2) [CN-L57]
Pin No. Specifications I/O Group Setting state Signal name WA430-5 Remarks
1 (NC) — — ---
RS232_C serial
2 RS232C_1_RTS I/O Q ---
communication
3 RS232C_1_RD I Q RD PC RX For monitoring(PC)
4 RS232C_2_RD I R RD NC ---
10 RS232C_1_SG O Q ---
11 RS232C_2_SG O R NC ---
12 RS232C_2_TX O R TX NC ---
14 (NC) — —
WA430-5 10-285
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD MACHINE MONITOR
AMP040-8P [CN-L58]
Pin No. Specifications I/O Group Setting state Signal name WA430-5 Remarks
Pin No. Specifications I/O Group Setting state Signal name WA430-5 Remarks
Specifications
2 16 Posi rotary SW2 I — selection ---
Speed indicator
Speed indicator
3 16 Posi rotary SW3 I — switch and OPT tire switch
selection
Common rail Common rail
1 26 Posi dip SW1 I — engine controller engine controller
selection selection
10-286 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA430-5 10-287
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
Control Function
When the engine speed is 1000 rpm or above, switching between the auto-shift up and down in the
auto-shift mode is implemented according to a travel speed mode selected from the “Table - Auto Shift
Point List” stored in the transmission controller’s memory. Here, selection of a shift mode is done by
referencing the signals from the forward-reverse lever, shift lever and travel speed sensor.
1) Shift lever at 1st to 4th speeds
This function limits the maximum gear speed (range of speed change) available for the automatic
gear speed change.
Start at the 2nd speed is usually employed in the auto-shift mode. Thus, when the shift lever is at
the 4th speed, the shift up/down is performed in the range of the 2nd and 4th speeds. It is, however,
done at the 1st speed when the kick down function is used.
10-288 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA430-5 10-289
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
4th speed (when lockup is More than 10.5 km/h 4th speed (after lockup is *1
turned ON) canceled)
*1: When the lockup is canceled from kick-down switch, it can be turned on only when:
The torque converter lockup switch is turned on once and then turned off again,
Travel speed is increased from less than the lockup ON speed to above the ON speed (both indicated in the Auto-Shift
Point List).
1-5 Transmission Protection Function
In order to protect the transmission, several restrictions are laid down in F-R shift of the forward-reverse
lever during high-speed travel.
10-290 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA430-5 10-291
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
4L/U4T/C(H) Zone III & 18.0 and up Zone III & 18.0 and up 2
When direction switch is shifted (1) (F) NR
4L/U4T/C(M) Zone III & 16.5 and up Zone III & 16.5 and up 2
4L/U4T/C(L) Zone III & 15.0 and up Zone III & 15.0 and up 2
4L/U3T/C(H) Zone III & 13.0 - 18.0 Zone III & 13.0 - 18.0 2
4L/U3T/C(M) Zone III & 13.0 - 16.5 Zone III & 13.0 - 16.5 2
4L/U3T/C(L) Zone III & 13.0 - 15.0 Zone III & 13.0 - 15.0 2
4T/C3T/C(H) Zone III & 13.0 - 18.0 Zone III & 13.0 - 18.0 2
4
4T/C3T/C(M) Zone III & 13.0 - 16.5 Zone III & 13.0 - 16.5 2
4T/C3T/C(L) Zone III & 13.0 - 15.0 Zone III & 13.0 - 15.0 2
3T/C3T/C(H)No gear Zone III & 13.0 - 18.0
speed change
Zone III & 13.0 - 18.0 2
3T/C3T/C(M) No
gear speed change
Zone III & 13.0 - 16.5 Zone III & 13.0 - 16.5 2
10-292 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA430-5 10-293
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
(2) Set up of cutoff 5 After the flashing for 2.5 seconds, the brake position is stored on mem-
point ory (your setting is held after the key is turned off).
1 Push and release the T/M cutoff set switch.
2 The indicator built in the T/M cutoff switch will flash for 2.5 seconds.
3 While the flashing continued, push and release the T/M cutoff set switch
again.
Reset procedure
4 As the flashing is ended, the cutoff point is set as the default left brake
pressure. The setup cancel buzzer is sounded.
5 The setup (default) value is stored on memory (the set value is held after
the key is turned off).
4) Output conditions for the buzzer, indicator (main monitor) and indicator built in the T/M cutoff
switch
Output condition Indicator built in the T/M Buzzer sound Cutoff point
cutoff switch
Control is done based on
When T/M cutoff switch is ON Comes on Not available the value stored in previous
operation
While T/M cutoff point is Setup complete buzzer is Pressure at your releasing
being set Flashes sounded as the set switch is the set switch is stored
released
When T/M cutoff switch is ON Goes off Not available No control is provided.
but error is present on sensor Stored value is not changed.
A separation of 0.20MPa (2kg/cm²) is provided between the cutoff IN pressure (causing T/M to neu-
tral) and OUT (reset) pressure.
Example: When 0.98MPa (10kg/cm²) is set on the pressure sensor
Cutoff IN pressure = 0.98MPa (10kg/cm²)
Cutoff OUT pressure = 0.78MPa (8kg/cm²)
10-294 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
System Diagram
WA430-5 10-295
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
Normal operation is
available when fixed to Switching between forward and
Gear speed change becomes
When steering Manual shift N. Error is warned at reverse becomes available from the
available from the lever.
column is any position other than lever.
selected N.
10-296 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
System Diagram
WA430-5 10-297
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
10-298 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA430-5 10-299
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
6. E. C. S. S. Function (OP)
This function automatically controls ON or OFF of the accumulator sealed with high-pressure gas as
well as relief of hydraulic oil of the work equipment taking into consideration of traveling state of the
machine. This system is intended at providing enhanced operator comfort by reducing rocking of the
machine body, preventing load shifts and improving work efficiency through the elasticity-based con-
trol of vertical motion of the work equipment.
10-300 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA430-5 10-301
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
The emergency steering ON signal at the self-check is output for 3 seconds maximum. If the moni-
tor detects presence of the emergency steering operating pressure within 3 seconds, the monitor
sends the emergency steering operation detection signal to the network. Upon output of this sig-
nal, the transmission controller ends the self-check of the emergency steering.
If the above signal is not sent within 3 seconds, the controller warns an error.
10-302 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
Engine water temperature, operating oil temperature and oil temperature of the torque converter
detected by the machine monitor are sent to the transmission controller via the network. Upon
receiving above information, the transmission controller turns on a fan revolution suitable to the
temperature and engine speed by controlling the swash plate of the hydraulic pump by use of elec-
tric current.
WA430-5 10-303
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
Output from reverse Reverse fan Output from Output from fan
rotation SOL (before rotation switch Engine speed reverse rota- pump EPC Monitor indicator
switch operation) tion SOL
OFF OFFON ON MIN rotation OFFON
OFF ONOFF Stopped (less OFF Normal BlinkingOFF
ON OFFON than 500 rpm) ON MIN rotation BlinkingON
ON ONOFF OFF Normal ONOFF
OFF OFFON OFF Normal OFFBlinking
OFF ONOFF Started (500 rpm OFF Normal BlinkingOFF
ON OFFON or above) ON * BlinkingON
ON ONOFF ON * ONBlinking
*: Output from the fan pump EPC while the fan is in reverse rotation
Engine speed Less than 1,500 rpm 1,500 rpm or above
EPC control MIN rotation MAX rotation
10-304 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
The switch pump cutoff signal is output when digging operation is turned on from the kick down switch.
WA430-5 10-305
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
3) Protect alarm cancel condition: In any of the following cases, output of the protect alarm is stopped
and normal control is restored.
b When matching is established between the input instruction and output instruction from the
gearshift lever (shift switch).
c When a shift above the one specified with the output instruction is selected from the gearshift
lever (shift switch).
4) Operations restricted while the shift down protect is turned on: As long as the protect is turned on,
hold and kick down operations are disabled.
T/M output shaft speed and travel speed Protection travel speed (km/h)
WA430-5 (small diameter tire) WA430-5 (large diameter tire)
2,658 33.2 36.0
T/M output shaft
speed converted to 1,846 23.0 25.0
travel speed (rpm)
1,107 13.8 15.0
11. Troubleshooting
The transmission controller self diagnoses the system by monitoring the input/output signals con-
stantly.
If any errors are found in the self-diagnosis, the controller sends the error information to the machine
monitor via the network. The machine monitor allows you to check the errors.
10-306 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
WA430-5 10-307
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
10-308 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
5) Kickdown function
1) Kickdown during manual shift
The kickdown switch can be operated only at the forward 2nd-speed (F2). Operation of the kick-
down switch is ignored at other than forward 2nd-speed.
When the directional lever (or FNR switch) is shifted to other than F or the directional lever (or FNR
switch) is shifted to R, the gear speed is changed to 2nd-speed.
When the gear shift lever is changed to other than 2nd-speed, the speed is changed to the range
corresponding to the lever position.
2) Kickdown during auto-shift
The kickdown switch functions regardless of the directional and gear shift lever positions.
The gear speed shifted by the kickdown switch operation changes according to the travel speed as
shown in the following table.
After shifting by kickdown, shift the speed according to the list of normal auto-shift points after the
expiration of the time that the speed cannot be shifted or when the directional lever is operated.
Speed range Travel speed Speed range after shift- Time that speed cannot
ing be shifted
2nd-speed Whole range 1st-speed 5 seconds
Less than 10.5 km/h 1st-speed 5 seconds
3rd-speed Less than 10.5 - 25 km/h 2nd-speed 4 seconds
25 km/h or higher No shifting (3-speed) ---
Less than 10.5 km/h 1st-speed 5 seconds
4th-speed Less than 10.5 - 35 km/h 3rd-speed 4 seconds
35 km/h or higher No shifting (4-speed) ---
Less than 10.5 km/h 1st-speed 5 seconds
3rd-speed (at lockup)
10.5 km/h or higher 3rd-speed (lockup released) *1
Less than 10.5 km/h 1st-speed 5 seconds
4th-speed (at lockup)
10.5 km/h or higher 4th-speed (lockup released) *1
*1: When the lockup is released by kickdown switch operation, lockup must not be applied again until the following conditions
occur:
● Change the torque converter lockup switch from OFF to ON temporarily.
● The travel speed less than that with the lockup ON in the list of the auto shift points changes to the speed exceeding it.
WA430-5 10-309
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
At a low temperature, the oil viscosity is high and the pump load torque increases against the engine
starting torque and the engine start ability becomes poor. As for the corrective action, when starting
the engine at a low temperature, bypass oil inside the pump to reduce load to the pump, so that the
engine start ability will improve.
The bypass solenoid operation signal outputting conditions are shown in the table below. When Con-
ditions 1 to 4 are all satisfied, the bypass solenoid operation signal is output.
Condition 1 Starting Signal C is switched on or 10 seconds after the signal is switched on to off.
Condition 2 Engine water temperature: Less than -15°C.
Condition 3 Engine speed condition A (for prevention of hunting)).
Condition 4 Solenoid energizing time: Less than 30 seconds (total operating time after the starting switch is set to
"ON")
10-310 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROLSYSTEM
TRANSMISSION CONTROLSYSTEM
WA430-5
10-312 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROLSYSTEM
WA430-5 10-313
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROLSYSTEM
10-314 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROLSYSTEM
WA430-5 10-315
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
10-316 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD TRANSMISSION CONTROLLER
DEUTSCH-40P(1) [CN-L62]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 NC Output 21 S_NET Input/Output
2 ECMV fill switch L/U Input 22 CAN0_L Input/Output
3 ECMV fill switch 4th Input 23 CAN1_L Input/Output
4 232C_RxD Input 24 Write-to-flash-memory enable signal Input
5 Right FNR (J/S) forward-reverse R Input 25 Right FNR (J/S) forward-reverse F Input
6 Neutralizer (P/B) signal Input 26 Forward-reverse lever N Input
7 ECMV fill switch 2nd Input 27 ECMV fill switch R Input
8 NC Output 28 NC Input
9 Engine speed pulse unlatched output Output 29 Pulse GND —
10 Engine speed signal (+) Input 30 NC Input
11 NC Output 31 S_NET GND —
12 CAN shield — 32 CAN0_H Input/Output
13 ECMV fill switch 3rd Input 33 CAN1_H Input/Output
14 232_TxD Output 34 RS232C GND —
15 Right FNR (J/S) forward-reverse N Input 35 Right FNR (J/S) switch Input
16 Forward-reverse lever R Input 36 Forward-reverse lever F Input
17 ECMV fill switch 1st Input 37 ECMV fill switch F Input
18 NC Output 38 Shift hold switch Input
19 Travel speed pulse unlatched output Output 39 Pulse GND —
20 Travel speed signal (+) Input 40 NC Input
DEUTSCH-40P(2) [CN-L63]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 VB (controller power) Input 21 GND (controller ground) Input
2 VIS (solenoid power) Input 22 VIS (solenoid power) Input
3 SOL_COM (common solenoid ground) Input 23 SOL_COM (common solenoid ground) Input
4 Back lamp relay Output 24 Key switch signal Input
5 ECMV F Output 25 ECMV 1st Output
6 ECMV 2nd Output 26 ECMV 4th Output
7 Electric emergency steering relay Output 27 Switch pump cutoff relay Output
8 Indicator built in T/M cutoff switch Output 28 Reverse fan pump rotation SOL Output
9 J/S shift up switch Input 29 Electric emergency steering operation sw Input
10 Gearshift lever 1st speed Input 30 Gearshift lever 3rd speed Input
11 VB (controller power) Input 31 GND (controller ground) Input
12 VIS (solenoid power) Input 32 GND (controller ground) Input
13 SOL_COM (common solenoid ground) Input 33 GND (controller ground) Input
14 Key switch signal Input 34 NC —
15 ECMV R Output 35 ECMV L/U Output
16 ECMV 3rd Output 36 Fan pump EPC Output
17 E. C. S. S. Output 37 Neutral output Output
18 Low temperature bypass relay Output 38 Fan pump neutral SOL Output
19 J/S shift down switch Input 39 Starter switch C-terminal Input
20 Gearshift lever 2nd speed Input 40 Gearshift lever 4th speed Input
WA430-5 10-317
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
10-318 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
WA430-5 10-319
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
Function table
Operator’s Controller Controller Movement at
action input output machine
Safety lock lever Safety lock lever Work equipment Hydraulic power
switch Neutral lock valve
Raise ON OFF Active
(FREE) (CLOSE) (OPEN)
Lower OFF ON Inactive
(LOCK) (OPEN) (24V)
10-320 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
2) Detent control
Lift arm kick-out control
Operating the lift arm lever to reach the RAISE detent range allows a detent-on signal to be output from
the work equipment controller.|
This enables the lift arm lever to be maintained in the RAISE state even when the lever is released.
When the lift arm is raised and an input signal of the lift arm angle sensor approaches the top angle,
detent is cancelled and the lift arm stops rising. At this same time, the work equipment controller grad-
ually slows down the lift arm RAISE EPC (referred to as modulation control) to prevent excessive
impact from arising upon stoppage of the lift arm motion.
Detent can be cancelled (manually) by operating the work equipment lever toward the neutral position
side, in which case, EPC performs ordinary control according to how much the lever was moved.
WA430-5 10-321
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
10-322 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
Functions
The remote positioner stops after slowing down at the lift arm RAISE/LOWER position.
The work equipment controller constantly detects the lift arm angle (position) based upon the direction
in which the lever is operated and data from the arm angle potentiometer.
To stop the lift arm RAISE operation (when the RAISE selection switch is turned on)
Operating the lift arm lever to enter RAISE detent and allowing the lift arm to be raised before the set
position cancels lift arm RAISE detent, which starts modulation control for stopping the lift arm.
The lift arm can be manually raised in all cases except for the RAISE detent position.
If RAISE is not selected (when the selection switch is turned off), only kick-out is enabled.
To stop lift arm LOWER operation (when the LOWER selection switch is turned on)
Place the lift arm lever at the "FLOAT detent" position. The lift arm starts slowing down at 10 degrees
before the set position, and FLOAT detent is canceled 4 degrees before the set position to perform mod-
ulation control for stopping the lift arm.
Retain the lift arm lever at that position to restart lowering it.
If LOWER is not selected (when the LOWER selection switch is turned off), only FLOAT detent is enabled.
If the lift arm angle is above the horizontal position when the lever is placed in the detent position, only
FLOAT detent is enabled.
Selection mode
RAISE and
RAISE stop LOWER stop LOWER stop
Selection switch
RAISE selection switch ON(●) OFF({) ON(●)
LOWER selection switch OFF({) ON(●) ON(●)
Indicator output
Lamp on (SW ON) : ●
Lamp off (SW OFF) : {
Stop position
For RAISE For LOWER
Model
WA430 0° - +47.0° 0° - -42.1°
0°: Horizontal lift arm position
WA430-5 10-323
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
Control items
RAISE position setting
1 Remote positioner RAISE stop control RAISE lift arm stop (selection switch = on)
RAISE selection switch = On (remote positioner RAISE stop enabled)
Enabled if:
Work equipment lever (lift arm) stroke = Neutral (within ±10%)
1)Raise the lift arm to the position to be set.
2)Press the remote positioner RAISE position setting switch and
release it.
3) If the setting position where the switch was released is within the
applicable range, the angle attained when the switch was released
Setting procedure is tentatively saved, and the setting completion buzzer beeps twice.
Otherwise, the setting cancellation buzzer beeps.
Setting of remote
2 positioner RAISE 4)The RAISE indicator blinks (for 2.5 seconds).
stop angle point 5)The setting is saved after the indicator blinks for 2.5 seconds (the
setting mode completed). (The set status is maintained even after
the equipment is keyed off.)
1)During the 2.5-second interval in setting step 4 above (while the
RAISE indicator is blinking), press the remote positioner RAISE
position setting switch again, and release it.
Resetting procedure 2)As the indicator stops blinking, set the RAISE stop position point to
"0°" (horizontal). The setting cancellation buzzer beeps.
3)The set value is saved (as the default value). (The set status is main-
tained even after the equipment is keyed off.)
10-324 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
1 Remote positioner LOWER stop control LOWER lift arm stop (selection switch = ON)
LOWER selection switch = ON
Enabled if: (remote positioner LOWER stop enabled)
Work equipment lever (lift arm) stroke = Neutral (within ±10%)
1. Lower the lift arm to the position to be set.
2. Press the remote positioner LOWER position setting switch and
release it.
3. If the setting position where the switch was released is within the
Setting procedure applicable range, the angle attained when the switch was released
is tentatively saved, and the setting completion buzzer beeps
Setting of remote
2 positioner LOWER twice. Otherwise, the setting cancellation buzzer beeps.
stop angle point 4. The LOWER indicator blinks (for 2.5 seconds).
5. The setting is saved after the indicator blink
1. During the 2.5-second interval in setting step 4 above (while
the LOWER indicator is blinking), press the remote posi-
tioner LOWER position setting switch again, and release it.
Resetting procedure 2. As the indicator stops blinking, set the LOWER stop position point
to "0°" (horizontal). The setting cancellation buzzer beeps.
3. The set value is saved (as the default value). (The set status is
maintained even after the equipment is keyed off.)
Remote positioner selection switch = On; Setting cancellation Controlled with the
Position setting switch = ON; Comes on. buzzer beeps upon value saved previously.
Lift arm angle = Outside the setting range. releasing setting switch. The value stored is not
altered.
WA430-5 10-325
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
10-326 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
2 When the lift arm lever was placed in the detent position after semi-auto digging had started:
AUTO-TILT does not start if the lift arm RAISE speed does not drop due to failure of loading into
the bucket (after the lift arm continued to be raised at 1 deg/sec for 0.5 seconds).
AUTO-TILT starts when the bucket stops being raised (after being raised at 1 deg/sec for 0.5 sec-
onds).
WA430-5 10-327
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
10-328 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
1) Steering control
Steering control with the joystick provides an articulation speed according to how the joystick lever
is moved.
A more fine steering range is provided for the "Lo" mode then the "Hi" mode for the joystick.
2) Modulation control
Steering with the joystick applies modulation control in order to reduce impact that may be experi-
enced when operation is started or finished.
A greater degree of modulation control is provided for the "Lo" for more impact reduction.
This modulation control enables steering of the machine even during traveling at a high speed, as it
improves response of the machine toward lever operation according to the machine speed.
WA430-5 10-329
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
5. Calibration function
1) EPC calibration
This is an adjusting function to reduce variances of the starting points of the lift arm, bucket and joy-
stick due to cumulative errors with the electric lever, EPC valve and main valve.
2) Sensor adjustment
This function provides offset adjustment for errors due to installation of the lift arm angle potenti-
ometer to enable the position data of the work equipment to be correctly detected.
3) Calibrating method
Calibration is performed in the service mode on the monitor panel. See the "Equipment Monitoring"
section for details.
6. Troubleshooting
The work equipment controller constantly monitors the I/O signal status and provides a self-diagnosis
function for the system. If any abnormalities are detected through self-diagnosis, it outputs fault infor-
mation via the equipment-monitoring network. In case of faulty occurrences, you can check the status
with the equipment-monitoring function.
10-330 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
10-332 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM (OP)
WA430-5 10-333
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROLLER
10-334 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD WORK EQUIPMENT CONTROLLER
DEUTSCH-40P(1) [CN-L72]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 NC Output 21 S_NET Input/Output
2 Remote positioner lifting select SW Input 22 CAN0_L Input/Output
3 Remote positioner lowering select SW Input 23 CAN1_L Input/Output
4 232C_RxD Input 24 Flash memory write enable signal Input
5 NC Input 25 NC Input
6 NC Input 26 NC Input
7 NC Input 27 NC Input
8 NC Output 28 NC Input
9 NC Output 29 Pulse GND —
10 Engine rev. signal Input 30 NC Input
11 NC Output 31 S_NET GND —
12 CAN shield — 32 CAN0_H Input/Output
13 Remote positioner lifting set SW Input 33 CAN1_H Input/Output
14 232_TxD Output 34 RS232C GND —
15 NC Input 35 NC Input
16 NC Input 36 NC Input
17 NC Input 37 NC Input
18 NC Output 38 Remote positioner lowering select SW Input
19 NC Output 39 Pulse GND —
20 Vehicle speed signal Input 40 NC Input
DEUTSCH-40P(2) [CN-L73]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 Controller power Input 21 GND (controller ground) Input
2 Solenoid power Input 22 Solenoid power Input
3 SOL_COM (common solenoid ground) Input 23 SOL_COM (common solenoid ground) Input
4 NC Output 24 KEY_SIG Input
5 Bucket tilting EPC Output 25 Third EXT EPC Output
6 Lift arm lifting EPC Output 26 J/S right EPC Output
7 J/S EPC cut-off relay Output 27 Lift arm lever manual detention of float Output
8 Remote positioner lifting indicator Output 28 Bucket and lift arm neutral lock solenoid Output
9 Semiautomatic loading hard mode SW Input 29 NC Input
10 J/S speed select SW Input 30 Bucket cylinder tilt SW Input
11 VB (controller power) Input 31 GND (controller ground) Input
12 VIS (solenoid power) Input 32 GND (controller ground) Input
13 SOL_COM (common solenoid ground) Input 33 GND (controller ground) Input
14 KEY_SIG Input 34 Reserve —
15 Bucket dumping EPC Output 35 Third RET EPC Output
16 Lift arm lowering EPC Output 36 J/S left EPC Output
17 Lift arm lever automatic detection of lifting Output 37 Magnetic detention of bucket lever tilt pos Output
18 Remote positioner lowering indicator Output 38 NC Output
19 Semiautomatic loading soft mode SW Input 39 NC Input
20 Bucket cylinder horizontal SW Input 40 NC Input
WA430-5 10-335
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ELECTRIC TRANSMISSION CONTROL
10-336 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ELECTRIC TRANSMISSION CONTROL
Functions
1 Selection of forward, reverse or N (neutral) It is performed from the forward-reverse lever
2 Selection of gear speed It is done from the gearshift lever
Shift down is available from this switch, too, without resorting to
the gearshift lever. In the manual shift mode, forward move at
the 2nd speed alone can be shifted down to the 1st speed. When
3 Kick down switch the auto-shift mode is selected, shift down is carried out accord-
ing to the gear speed and travel speed being selected prior to
operation of this is operated.
When the auto-shift is selected, this switch maintains the gear
4 Hold switch speed of the time when the switch is depressed without allowing
shift up accompanying increased travel speed.
You can cause the transmission to neutral by turning on the
5 Transmission cutoff function transmission cutoff switch and depressing the left brake pedal.
Transmission cutoff position adjusting You can specify any pedal depression depth for turning on the
6 function transmission cutoff function.
It allows you to enable or disable the transmission cutoff func-
7 Transmission cutoff switching function tion. When the function is disabled, the left brake pedal offers
the same braking function as that of the right brake pedal.
It shifts the transmission to neutral as long as the parking brake
8 Neutralizer is in operation. It prevents seizure of the parking brake that can
result from travelling while the parking brake is in operation.
This function disables startup of the engine from the starter
switch when the forward-reverse lever is not at N (neutral). This
9 Neutral safety function function is provided to prevent accidents due to unexpected
starting of the machine.
As the reverse travel is started, this function turns on the back
10 Alarm function lamp and back horn buzzer to alert nearby people.
WA430-5 10-337
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ELECTRIC TRANSMISSION CONTROL
COMBINATION SWITCH
Overview
• The forward-reverse lever and the gearshift lever switch have 3 positions and 4 positions, respectively.
Independent switches do not have the detent mechanism. This mechanism is provided on the combi-
nation switch body. Each switch is positioned with two pins and then fixed to the combination switch
with three screws. Moving a lever to a desired position turns on the corresponding switch connected
via the shaft to conduct current to the designated circuit.
Functions
1 Forward-reverse lever switch Used for switching between for forward, reverse and neutral.
2 Gearshift lever switch Used for switching gear speed.
3 Gearshift lever stopper Used for preventing the gearshift lever get into the 3rd or 4th
speed.
4 Turn signal It is a signal to be turned ON at right or left turn.
5 Self-cancel This function returns the turn signal lever to neutral position
after right or left turn is complete.
6 Lamp switch Used to turn ON the tail lamp, front lamp or parking lamp.
7 Dimmer switch Used to turn ON the travel or low beam.
8 Hazard switch Used to turn ON blinking of the right and left turn signals at the
same time.
9 Emergency blinking pilot lamp It starts blinking with emergency blinking lamp.
10 Parking brake switch Used to turn ON (activation) or OFF (deactivation) the parking
brake.
10-338 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ELECTRIC TRANSMISSION CONTROL
Operation
• The forward-reverse lever (1) and the gearshift
lever shaft (2) on the combination switch are
united with the magnet (3). Thus, as the lever
(1) is moved, the magnet (3) is moved, too.The
control switch (5) with the built-in hall IC (4) is
attached under the magnet (3). A hall IC (4) is
provided on the board for respective positions.
• If you set the forward-reverse lever (1) at F posi-
tion, the magnet comes right above the hall IC
(4) of the control switch at F position. Thus,
magnetism of the magnet (3) is irradiated to the
hall IC (4) through the clearance and case (6).
• Since the hall IC (4) is inside the magnetism
detection circuit, the circuit detects magnetism
from the magnet (3) and then sends the F posi-
tion signal to the current amplifier circuit.
Receiving this signal, the current amplifier cir-
cuit outputs the signal to operate the transmis-
sion.
WA430-5 10-339
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD KICK DOWN, HOLD SWITCH
Functions
• Being installed on the lift arm-operating lever,
switch A (1) and switch B (4) function as the kick
down switch and hold switch, respectively.
• When the load meter (optional) is provided,
switch A and switch B are installed on the
bucket-operating lever. In this case, switch A
and B function as the cancel switch and sub-
total switch, respectively.
• Contact of both switches A and B resets auto-
matically, namely it is closed only when the
switches are depressed.
10-340 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ENGINE STARTING CIRCUIT
Function
Adoption of the neutral safety circuit assured safety
when starting the engine.
• The engine cannot start except when the
forward-reverse lever is in the N (neutral)
position.
• When the right FNR selector switch (OPT) is
in the ON position, the engine cannot start
except when the right FNR switch (OPT) is
in the N (neutral) position.
• When the J/S (joystick steering) (OPT) is in
the ON position, the engine cannot start
except when the FNR switch of J/S lever is
in the N (neutral) position and also the J/S
lever is in the N (neutral) position.
WA430-5 10-341
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ENGINE STARTING CIRCUIT
Operation
1. When the starting switch is in the [ON] position • When the J/S steering (OPT) is used, lower
• If you place the starting switch in the [ON] the J/S arm rest and place the J/S selector
position, the terminals B and BR of starting switch in the ON position. Then, current
switch close. Current flows from the bat- flows from the J/S selector switch to the
tery, and goes through the starting switch exchange relay coil to operate the relay. If
and battery relay coil to grounding, closing the FNR switch of the J/S lever is in the N
the battery relay contacts. By this opera- (neutral) position and the J/S lever is in the
tion, every circuit of the machine is pow- N (neutral) position, the T/M controller out-
ered. puts current to the exchange relay. It goes
At this time, the current from ACC terminal through the exchanger relay to the neutral
of starting switch flows to timer relay, then safety relay coil, consequently making the
contacts close for 3 seconds, then current current flow between the terminals 3 and 5
flows to the pull side coil of fuel cut sole- of the neutral safety relay.
noid. The current from ACC terminal of (When the J/S steering is mounted, the J/S
starting switch also flows to hold side coil of flip switch and J/S selector switch are
fuel cut solenoid. So, by hold side coil after mounted instead of the right FNR selector
pull side coil is magnetized, fuel can be sup- switch in the figure above, and the J/S lever
plied to engine. Provision of starting engine FNR switch is mounted instead of right FNR
is completed. switch.)
2. Neutral safety circuit 3. When the starting switch is in the [Start] posi-
• If you place the forward-reverse lever at the tion
N (neutral) position, and then, current flows • If you place the starting switch in the [Start]
from the N contact of forward-reverse lever position, and then, current goes from the
and goes through the exchange relay to the terminal B of starting switch, terminal C, ter-
neutral safety relay coil. As a result, the minal 3 of neutral safety relay, and terminal
current is carried between the terminals 3 5 to the starter, starting the engine.
and 5 of neutral safety relay. • Except when the forward-reverse lever is in
• When the right FNR switch (OPT) is used the N (neutral) position, the right FNR
(when the right FNR selector switch is in the switch is the N (neutral) position (when the
ON position), current flows from the right right FNR switch is used), or the J/S lever
FNR selector switch to the exchange relay FNR switch is in the N (neutral) position and
coil to operate the relay. If the right FNR also the J/S lever is in the N (neutral) posi-
switch is in the N (neutral) position at that tion, the neutral safety relay, not allowing
time, the T/M controller outputs current to the engine to start.
the exchange relay. It flows from the T/M
controller to the exchange relay and finally
it reaches the neutral safety relay coil. As a
result, the current is carried between the
terminals 3 and 5 of neutral safety relay.
10-342 WA430-5
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ENGINE STOP CIRCUIT
Operation
• The current from ACC terminal of starting
switch to hold side coil of fuel cut solenoid is
cutoff when starting is turned off. Fuel supply to
engine is shut off.
When the fuel supply is stopped, the engine
reduces its speed and stops. Then, the power
generation of the alternator stops to shut off
voltage supply from the terminal R of the alter-
nator. In addition, the current from the terminal
BR of starting switch is shut off. Consequently,
the battery relay contact opens to shut down
the power supplied to every circuit of the
machine.
WA430-5 10-343
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PREHEATING CIRCUIT
PREHEATING CIRCUIT
(AUTOMATIC PREHEATING SYSTEM)
Outline Operation
• The automatic preheating system is being • When the starting switch is turned ON, the
installed to improve the engine starting capabil- machine monitor is started up. At this time, if
ity in cold weather areas. This system is capa- the coolant temperature is 0°C or less, the
ble of shortening the preheating time and, at machine monitor makes to contact the coil of
the same time, it is capable of making auto- the preheating relay to the earth and the pre-
matic setting of the preheating time matching heating relay operates to let the heater relay
the current coolant temperature, by merely operate to start preheating by the electric intake
turning the starting switch. air heater.
• When the starting switch is turned ON, the pre- • The operating time of the preheating process is
heating pilot lamp on the machine monitor as shown below.
lights and the electric intake air heater starts
preheating the intake air.
As for the preheating time, the coolant temper-
ature is detected by the coolant temperature
sensor and the controller being built into the
machine monitor carries out the preheating
time setting.
• While the pilot lamp is lighting, preheating is in
progress and keep the starting switch at the ON
state. If the starting switch is turned to the
START position, the preheating process is can-
celled.
10-344 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD ENGINE POWER MODE SELECTOR CIRCUIT
Function
• When the power mode selector switch is set to The accelerator pedal hi-idle stopper motor
"POWER", the stroke restriction of the accelera- cable extends completely under the state, and
tor pedal will be released and the engine power the stopper limiting the stroke of the accelera-
will be controlled. Also, when the switch is set tor pedal is released. Then, the power mode is
to "NORMAL", the stroke of the accelerator selected.
pedal will be limited and the work fuel con-
• When the power mode selector switch is set to
sumption will be reduced.
"NORMAL", the relay coil will be demagnetized.
• Switching signals are input into the transmis-
• The current from the fuse flows to the accelera-
sion controller, and gear speed and travel
tor pedal hi-idle stopper motor terminals A-C,
speed suitable for the power mode are selected
to the engine power mode relay terminals 6-3
at the time of automatic shifting.
and to the motor to rotate the motor. (The cable
will contract.)
Operation • When the motor rotates, the Terminal D will
• When the power mode selector switch is set to rotate at the same time. When the non-continue
"POWER", current will flow from the fuse to the portion of the Terminal D comes to the Terminal
engine power mode relay, to the power mode C, the circuit from the Terminal A to Terminal C
selector switch and to the ground and will ener- will open and the current from the fuse to the
gize the relay coil. motor will be interrupted. Though the motor
• The current from the fuse flows to the accelera- tries to continue rotating by inertia, both poles
tor pedal hi-idle stopper motor terminals A-B, of the motor will be short-circuited with the
to the engine power mode relay terminals 5-3 ground and the motor will stop rotating when
and to the motor to rotate the motor. (The cable the continue portion of the Terminal D touches
will expand.) the Terminal C.
The accelerator pedal hi-idle stopper motor
• When the motor rotates, the terminal D will
cable contracts completely under the state, and
rotate at the same time. When the non-continue
the stopper limits the stroke of the accelerator
portion of the Terminal D comes to the Terminal
pedal.
B, the circuit from the Terminal A to Terminal B
will open and the current from the fuse to the
motor will be interrupted. Though the motor
tries to continue rotating by inertia, both poles
of the motor will be short-circuited with the
ground and the motor will stop rotating when
the continue portion of the Terminal D touches
the Terminal B
WA430-5 10-345
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
10-346 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
WA430-5 10-347
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
2) When the parking brake is in the OFF (release) position before placing the starting switch in the ON
position
10-348 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
3. When the main brake oil pressure lowers (emergency brake operates)
WA430-5 10-349
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
SENSORS
ENGINE SPEED SENSOR
SPEED SENSOR
1. Coil 4. Housing
2. Magnet 5. Connector
3. Terminal
Function
10-350 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Function
• This sensor is mounted to the engine block.
The diaphragm detects oil pressure, and when
it reaches below the specified value, the switch
is turned ON.
1. Connector 3. Float
2. Bracket 4. Switch
Function
• This sensor is mounted to the side surface of
the oil pan. The float lowers when the oil level
reaches below the specified level, turning OFF
the switch.
WA430-5 10-351
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
10-352 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Sensor
2. Lead
3. Connector
Function
WA430-5 10-353
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
10-354 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
WA430-5 10-355
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Shaft 4. Rotor
2. Housing 5. Connector
3. Bearing
Function
10-356 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Indicator 3. Adapter
2. Spring 4. Connector
Function
WA430-5 10-357
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Sensor 3. Connector
2. Lead
Function
10-358 WA430-5
(3)
STRUCTURE AND FUNCTION,
MAINTENANCE STANDARD SENSORS
1. Body 4. Packing
2. Connector 5. Pin
3. Filter
Function
WA430-5 10-359
(3)
20 TESTING AND ADJUSTING
★ Note the following when making judgements using the standard value tables for testing, adjusting,
or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the
machine from the factory and is given for reference. It is used as a guideline for judging the progress
of wear after the machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on
the results of various tests. It is used for reference together with the state of repair and the history of
operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on level
ground, insert the safety pins, and use blocks to prevent the machine from moving.
WARNING! When carrying out work together with other workers, always use signals and do not
let unauthorized people near the machine.
WARNING! When checking the water level, always wait for the water to cool down. If the radia-
tor cap is removed when the water is still hot, the water will spurt out and cause
burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
WA430-5 20-1
(1)..
TESTING AND ADJUSTING TESTING AND ADJUSTING DATA
0
Engine speed
Low idling speed (P Mode) rpm 750 +50
0 —
Rated revolving speed (N Mode) rpm 1,720 —
Rated revolving speed (P Mode) rpm 2,000 —
0°C (Without starting aid) rpm Min. 100 —
Necessary starting speed
-20°C (With starting aid) rpm Min. 85 —
kPa Max. 2.94 7.47
Intake resistance At all speed
{mmH2O} {300} {762}
kPa Min. 80 60
Boost pressure At rated horsepower
{mmHg} {600} {450}
Intake and exhaust system
20-2 WA430-5
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Category Item Measurement Condi- Unit Standard Value For New Service Limit Value
tions Machine
N - FOR-
Operating effort WARD, • Engine Stopped N {kg} 5.9 +4.9
-3.0 {0.6 +0.5
-0.3 } Max. 16.7 {1.7}
Direc- REVERSE
• Measure at center
tional lever N - FOR- of lever knob
Travel WARD, mm 35 ± 10 35 ± 20
REVERSE
1st - 2nd • Engine stopped 5.9 +4.9
-3.0 {0.6 +0.5
-0.3 } Max. 16.7 {1.7}
Operating effort 2nd - 3rd • Measure at center N {kg} 5.9 +4.9
{0.6 +0.5 } Max. 16.7 {1.7}
-3.0 -0.3
of lever knob
Speed 3rd - 4th 5.9 +4.9
-3.0 {0.6 +0.5
-0.3 } Max. 16.7 {1.7}
lever 1st - 2nd 35 ± 10 35 ± 20
Travel 2nd - 3rd mm 35 ± 10 35 ± 20
3rd - 4th 35 ± 10 35 ± 20
HOLD →RAISE • Engine speed: Low Max. 12.8 {1.3} * Max. 19.6 {2.0} *
idling
RAISE →HOLD • Hydraulic oil tem- Max. 14.7 {1.5} Max. 22.6 {2.3}
perature:
HOLD →LOWER Max. 12.8 {1.3} * Max. 19.6 {2.0} *
45 - 55 ° C
Lift arm
LOWER →HOLD — —
Operating Max. 15.7 {1.6} Max. 23.5 {2.4}
LOWER →FLOAT N {kg}
effort
• Flat, horizontal,
straight, dry paved
road surface 6.9 ∼ 12.6
Operating effort N {kg} Max. 19.6 {2.0}
• Engine speed: Low {0.7 - 1.3}
idling (Bucket
Steering empty)
wheel
• Engine speed: High
Turning speed (Not including play) idling Turns 3.7 ± 0.4 3.7 ± 0.4
• Left lock - right lock
• Engine speed:
Low idling Low idling
4.4 ± 0.4 Max. 7.2
• Hydraulic oil
Operat- temperature: P mode Sec. 3.1 ± 0.3 Max. 5.1
ing time 45 - 55 ° C
High idling • Left lock -
Right lock N mode 3.2 ± 0.3 Max. 5.3
WA430-5 20-3
(1)..
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Brake
pedal
Tire mm
Clearance of wheel TEW00003
lock ring C 2 - 10 —
20-4 WA430-5
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
WA430-5 20-5
(1)..
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
• Engine stopped
MPa
• Keep brake pedal depressed at {kg/cm2}
Drop in
brake pres- 4.9 MPa {50 kg/cm2} and mea- Max. 98 {1.0} Max. 98 {1.0}
sure sure drop in oil pressure after 5
min.
20-6 WA430-5
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
TEW01360
WA430-5 20-7
(1)..
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Work equipment relief • Hydraulic oil temperature: 45 - 55 ° C MPa 20.6 ± 0.49 +0.49 +5
20.6 -1.27 210 -13 }
pressure • Run engine at high idling. {kg/cm2} {210 ± 5}
Lowering time
N mode 4.0 ± 0.5 Max. 5.4
Bucket full
stroke To stroke end
N mode 2.1 ± 0.3 Max. 2.9
Backward
From level position P mode 1.8 ± 0.3 Max. 2.5
mm
20-8 WA430-5
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
WA430-5 20-9
(1)..
TESTING AND ADJUSTING
When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, inset
the safety pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let unautho-
rized people near the machine.
When checking the water level, always wait for the water to cool down. If the radiator cap is
removed when the water is still hot, the water will spurt out and cause burns.
Be careful not to get caught in the fan, fan belt or other rotating parts.
WA430-5 20-101
(1)......
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Water temperature,
oil temperature, B 799-101-1502 Digital thermometer 1 –99.9 - 1,299 ° C
exhaust temperature
20-102 WA430-5
(1)
(5)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
WARNING! Put blocks under the tires. 2. Measuring torque converter stall speed.
1) Switch to the monitoring function of Ser-
vice Mode 1 and use the 2-item simulta-
WARNING! Before starting measure- neous monitoring function to display the
ment, check that there is no one in the following 2 items. For details, see SPE-
surrounding area. CIAL FUNCTIONS OF MACHINE MONI-
TOR in the TROUBLESHOOTING section.
★ Monitoring items
★ Measure the engine speed under the follow- (1) Code No. 01001: Engine speed
(2) Code No. 40100: Torque converter oil
ing conditions.
temperature
• Coolant temperature: Within operating
range
• Hydraulic temperature: 45 - 55 ° C
• Torque converter oil temperature:
60 - 80 ° C
BWW100101
WA430-5 20-103
(1)......
TESTING AND ADJUSTING MEASURING ENGINE SPEED
3. Measuring hydraulic stall speed: 6) Run the engine at high idling, stall the
1) Switch to the monitoring function of Ser- torque converter, extend the boom cylin-
vice Mode 1 and use the 2-item simulta- der or bucket cylinder at the same time to
neous monitoring function to display the relieve the circuit, and measure the
following 2 items. For details, see SPE- engine speed.
CIAL FUNCTIONS OF MACHINE MONI- ★ Do not keep the stall condition for more
TOR in the TROUBLESHOOTING section. than 20 seconds. Make sure that the
★ Monitoring items torque converter oil temperature does not
(1) Code No. 01001: Engine speed exceed 120 ° C.
(2) Code No. 04401: Hydraulic oil temperature
BWW10012
20-104 WA430-5
(1)
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
Sym- Part
Part No. Qty Remarks
bol Name
BPW10341
Handy
1 799-201-9001 Smoke 1
Checker Bosch index:
G 0-9
Commer-
2 cially avail- Smoke 1
meter
able
BPW10022
WA430-5 20-105
(5)
(1)......
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
Sym Part
Part No. Qty Remarks
bol Name
Digital
tempera-
B 799-101-1502 1 -99.9 - 1,299 ° C
ture
gauge
1. Remove the adiabatic cover, then remove 3. When measuring the exhaust temperature at
exhaust temperature measurement plug (1) . torque converter stall, do as follows.
• To prevent overheating of the torque con-
verter, stabilize the exhaust temperature
at full stall (torque converter stall +
hydraulic stall), then stall the torque con-
verter only and measure the temperature.
1) Start the engine and raise the cooling
water temperature to the operating range.
2) Turn the transmission cut-off selector
switch OFF and depress the left brake
securely.
3) Place the directional lever at F4 or R4.
• Turn the transmission manual switch
ON and place the speed lever at F4
2. Install sensor (2) and connect to digital tem- and R4.
perature gauge B. 4) Release the parking brake.
★ Be careful not to let the wiring harness of 5) Depress the accelerator pedal gradually
the temperature gauge touch the high- to raise the engine speed to full throttle,
temperature portion. stall the torque converter, and extend
boom cylinder or bucket cylinder at the
same time to relieve the circuit.
★ Continue until the exhaust tempera-
ture is around the standard value of
650 ° C
20-106 WA430-5
(1)
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
WA430-5 20-107
(1)......
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
20-108 WA430-5
(1)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
3 Adapter:
1 795-502-1590 1
D sion Kit part No.:
gauge 795-502-1205
2 795-502-1360 Adapter 1 — 21.6 ± 2.9 Nm {2.2 ± 0.3 kgm}
WA430-5 20-109
(1)......
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
20-110 WA430-5
(1)
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
BWW11012
WA430-5 20-111
(1)......
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
20-112 WA430-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
Sym- Part
bol Part No. Name Remarks
P 795-471-1200 Gauge
WA430-5 20-113
(1)......
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
4) Put the tip of dial gauge P in contact with 7) Check that fuel infectin timing line (a) on
the top center of the piston, then set the the fuel infection pump is aligned with
scale on dial gauge P to 0 when the piston line (b) on the fuel infection pump body.
is at the top dead center.
★ Rotate the crankshaft in the normal
direction and in the reverse direction
to align the top dead center.
★ Record the value indicated by the
short indicator on dial gauge P.
20-114 WA430-5
(1)
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
WA430-5 20-115
(1)......
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
20-116 WA430-5
(1)
TESTING AND ADJUSTING ADJUSTING ENGINE STOP MOTOR LEVER
1. Temporarily install ball joint (3) to cable (2) of 4. Tighten all bolts and nuts.
engine stop moter (1) (tighten fully, then turn
back approx. 1/2 turn), then install a ball joint
to the stop lever of the fuel infection pump.
3. Adjust so that clearance a between stop lever 1) When the engine is running, check visu-
(4) of the fuel infection pump and STOP stop- ally that there is slack in the engine stop
per (5) is 0.5 - 1.5 mm. motor cable, and that the stop lever of the
Carry out the adjustment with nut (6) holding fuel injection pump is fully returned to the
the cable to the bracket, or make fine adjust- RUN position.
ments by changing the amount that ball joint 2) Check again that the clearance between
(3) is screwed in. the stop lever and the STOP stopper is 0.5
- 1.5 mm when the engine is stopped.
★ The engine stop motor has limit swithes
built in at both ends of the cable stroke.
★ Engine stop motor stroke: 35 mm
Fuel injection pump stop lever stroke: 30 mm
WA430-5 20-117
(1)......
TESTING AND ADJUSTING ADJUSTING ENGINE STOP MOTOR LEVER
20-118 WA430-5
(1)
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL
1. Adjust the installed length of accelerator 2. Press the accelerator pedal to the end in the
cable (3) so that inclination X of pedal (2) will power mode and insert a steel sheet 0.2 mm
be 48 ° when lever (1) is pressed against the thick to W between stopper (4) on the engine
low idling stopper of the engine. side and lever (1).
• Installed length of cable
Pedal side y: 150 mm 3. Under the above condition, adjust the bolt
Lever side z: 256 mm length so that pedal (2) will touch stopper bolt
★ Screw in the cable and joint more (5) when a force of 29.4 - 49 N {3 - 5 kg} is
than 6 mm. applied to the end of pedal (2).
• Height of stopper bolt (Standard) h: 54 mm
WA430-5 20-119
(1)......
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL
1. Operate the mode selector switch to select 4. Start the engine and adjust stopper bold (4)
the normal mode. [Motor cable (1) is short- so that the high idling speed in the normal
ened.] mode will be 1900 ± 50 rpm, then tighten
• Installed length x: 140 mm locknut (5).
• Check the clearance between stopper (2)
and lever (3).
Clearance b: 1.0 mm"
20-120 WA430-5
(1)
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SENSOR
WA430-5 20-121
(1)......
TESTING AND ADJUSTING TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
BWW10037
WARNING! Wait for the temperature
of the oil to go down before installing
or removing the measuring equip-
ment.
Gauge
No. Measuring Oil Pressure MPa {kg/cm2}
1 Main relief pressure 5.9 {60}
2 Torque converter relief pressure 5.9 {60}
3 Torque converter outlet pressure 0.98 {10}
BPW10038
4 Transmission F clutch pressure 5.9 {60}
5 Transmission R clutch pressure 5.9 {60}
Torque converter lock-up clutch
6 5.9 {60}
pressure (Lock-up specification)
7 Transmission 4th clutch pressure 5.9 {60}
8 Transmission 1st clutch pressure 5.9 {60}
20-122 WA430-5
(1)
(5)
TESTING AND ADJUSTING TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
BWW10097
BPW10040
WA430-5 20-123
(1)......
TESTING AND ADJUSTING TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
3. Measuring torque converter relief pressure 4. Measuring torque converter outlet pressure
(inlet) 1) Remove oil pressure measurement plug (3)
1) Install hose [1] to oil pressure measure- and install tee C4, nipple [1] and hose [2].
ment nipple (2).
BPW10040
20-124 WA430-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
WA430-5 20-125
(1)......
TESTING AND ADJUSTING DRAWING OF SPECIAL TOOL
Tool C4
20-126 WA430-5
(1)
PROCEDURE FOR FLUSHING TORQUE CONVERTER, TRANSMISSION
TESTING AND ADJUSTING HYDRAULIC CIRCUIT
Transmission case: 54 l
WA430-5 20-127
(1)......
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE
TESTING AND ADJUSTING FAILS
20-128 WA430-5
(1)
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE
TESTING AND ADJUSTING FAILS
3. Depending on the direction for moving the 4. Depress the brake pedal securely.
machine (forward or reverse), remove 2 5. Start the engine, release the parking brake,
ECMV solenoids (3) and install plug K. then release the brake pedal gradually to
• FORWARD: F solenoid and 2nd solenoid allow the machine to start, and move the
• REVERSE: R solenoid and 2nd solenoid machine.
★ If there is any mistake in the selection of ★ If a failure in the electrical system makes
the solenoid to remove, there is danger it impossible to release the parking brake,
that the transmission may be damaged. release the parking brake manually. For
details, see MANUAL RELEASE METHOD
★ Install plus K with the protruding surface
FOR PARKING BRAKE.
facing the ECMV. Check also that there is
an O-ring installed to the mating surface.
★ Be careful not to let any dirt or mud get
WARNING! Remove the blocks from
inside the removed solenoid or valve.
under the tires.
BWG10005
WA430-5 20-129
(1)......
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING CONTROL
Testing
1. Start the engine, operate the steering wheel,
and set the front and rear frames straight.
2. Check the looseness of locknut (2), or stopper
bolt (1).
3. Start the engine and measure clearance
between the front frame and rear frame stop- TKW00897
per when the steering wheel is turned fully to
the left and right.
★ When measureing the clearance, check
that the end face of the spool of stop
valve (3) is in contact with the head of the 2
3
stopper bolt. 1 TKW00897
Adjusting
1. Adjust the stopper bolt.
1) Screw in stopper bolt (1) to make it the
minimum length.
2) Run the engine at low idling and operate
the steering slowly to contact the frame
stopper.
3) Turn the stopper bolt until the head of
stopper bolt (1) contacts the end face of
the spool of the stop valve (3).
4) Set the machine facing straight, and stop
the engine.
5) Loosen stopper bolt (1) 8.5 turns, then
lock it in position with locknut (2).
6) Carry out steps 1) thru 5) for both the left
and right sides.
2. Start the engine and measure clearance a
between the front frame and rear frame stop-
per when the steering wheel is turned fully to
the left and right.
★ When measuring the clearance, check
that the end face of the spool of stop
valve (3) is in contact with the head of the
stopper bolt.
20-130 WA430-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING OIL PRESSURE
Measuring
BPW10040
WA430-5 20-131
(5)
(1)......
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING OIL PRESSURE
Adjusting
BWW10066
20-132 WA430-5
(1)
TESTING AND ADJUSTING TESTING HYDRAULIC FAN
Sym-
Part No. Part Name Qty Remarks
bol
Measurement
J 799-205-1100 Multi- 1 range:
tachometer
6-99,999.9rpm
WA430-5 20-133
(5)
(1)......
TESTING AND ADJUSTING MEASURING BRAKE OIL PRESSURE
Sym- Part
bol Part No. Name Qty Remarks
Brake
1 793-605-1001 1 ---
test kit
2 790-101-1430 Coupler 1 ---
BWW10073
3 790-101-1102 Pump 1 ---
H M20 x 1.5
4 799-301-1720 Adapter 1
(Rc1/8)
5 799-101-5160 Nipple 1 ---
6 799-401-2220 Hose 1 L: 5 m
7 790-261-1130 Coupling 1 ---
20-134 WA430-5
(1)
TESTING AND ADJUSTING MEASURING BRAKE OIL PRESSURE
WA430-5 20-135
(1)......
TESTING AND ADJUSTING TESTING WEAR OF WHEEL BRAKE DISC
BWW10076
20-136 WA430-5
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE CIRCUIT
• Raise the lift arm and put blocks under the lift
arm, and then remove front frame cover (1).
WA430-5 20-137
(1)......
TESTING AND ADJUSTING TESTING WEAR OF PARKING BRAKE DISC
Transmission case: 54 l
BPW10045
20-138 WA430-5
(1)
TESTING AND ADJUSTING MANUAL RELEASE METHOD FOR PARKING BRAKE
1. Remove 2 plugs (1). (left and right) • Refilling with oil (transmission case)
★ Approx. 20 l of oil will come out from the After carrying out the manual release method
plug mount, so prepare a container to for the parking brake, add oil through the oil
catch it. filler to the specified level. Run the engine to
circulate the oil through the system, then
★ After releasing the parking brake, coat the
check the oil again.
plug with gasket sealant (LG-5) and
tighten it.
WA430-5 20-139
(1)......
TESTING AND ADJUSTING TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
C Pressure BPW10070
Digital
gauge:
type
790-261-1203 1 58.8 MPa
hydrau-
lic tester {600 kg/
cm2}
799-401-3300 Nipple 1 —
3
02896-11012 O-ring 1 —
Measuring
• Hydraulic oil temperature: 45 - 55 ° C 4. Measure the accumulator charge cut-in pres-
sure.
WARNING! Put blocks under the tires.
Start the engine, run at low idling, and mea-
sure the oil pressure when the brake oil pres-
sure warning pilot lamp on the maintenance
WARNING! Stop the engine, then monitor goes out.
depress the brake pedal at least 100 5. Measure the accumulator charge cut-out
times to release the pressure inside pressure.
the accumulator circuit. After the accumulator charge cut-in, the pres-
sure rises. Measure the oil pressure at the
point where the oil pressure gauge indicator
1. Disconnect accumulator inlet hose (1) on the
suddenly drops after rising.
left side of the rear frame.
2. Install tool C3 to nipple (2) at charge valve
end, then assemble hose (1) again.
20-140 WA430-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
Adjusting
★ When the accumulator charge cut-out pres-
sure is adjusted, the cut-in pressure also
changes because of the valve area ratio.
1. Loosen locknut (4) of accumulator charge cut-
out valve (3), then turn adjustment screw (5)
to adjust.
★ Turn the adjustment screw to adjust as
follows.
• To INCREASE the pressure, turn
CLOCKWISE.
• To DECREASE the pressure, turn
COUNTERCLOCKWISE.
★ Amount of adjustment for one turn of
adjustment screw: 5.59 MPa {57 kg/cm2}
WA430-5 20-141
(1)......
TESTING AND ADJUSTING TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE
Measuring
1. PPC pump basic pressure
1) Remove oil pressure pickup plug (1) (M10
x 1.25) from the bottom of the accumula-
tor at the left front in the rear frame.
20-142 WA430-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORKING EQUIPMENT PPC OIL PRESSURE
2) Remove oil pressure measurement plug ★ After completion of the adjustment, check
(R 1/8) of the circuit to be measured, then the accumulator charge cut-in pressure
fit nipple [1] and hose [2] and install oil and cut-out pressure again. For details,
pressure gauge C1 (5.9 MPa {60 kg/cm2}). see TESTING AND ADJUSTING ACCU-
MULATOR CHARGE PRESSURE.
★ Plug A: Lift arm RAISE
Plug B: Lift arm LOWER, FLOAT
Plug C: Bucket TILT
Plug D: Bucket DUMP
BWW01192
WA430-5 20-143
(1)......
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
BWW01193
20-144 WA430-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
WA430-5 20-145
(1)......
TESTING AND ADJUSTING TESTING AND ADJUSTING BUCKET POSITIONER
Mounting nut:
14.7 - 19.6 Nm {1.5 - 2.0 kgm}
BWW01209
20-146 WA430-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING LIFT ARM KICK-OUT
2. After stopping the engine, measure dimen- ★ After adjusting, operate the lift arm lever
sion a between the center of proximity switch and check that the proximity switch is
(1) and the top of plate (2). actuated normally.
★ Standard dimension a: 0 - 5 mm
BDW00235
WA430-5 20-147
(1)......
TESTING AND ADJUSTING CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP
Proximity
Switch
Actuation Lights Up Goes Out
Pilot Lamp
Detector When detector is positioned at detection surface of When detector has moved away from detection surface
Position proximity switch of proximity switch
Bucket Posi-
tioner TEW00167 TEW00168
Lift Arm
Kick-out
20-148 WA430-5
(1)
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
BWW10306
WA430-5 20-149
(1)......
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
20-150 WA430-5
(1)
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
WA430-5 20-151
(1)......
TESTING AND ADJUSTING TESTING AND ADJUSTING LOAD METER
20-152 WA430-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING LOAD METER
2) Press ( ) on monitor panel mode selector Performing Calibration for Load (Zero Point
switch 1 to display LOAD METER. Adjustment)
(Supplementary Explanations)
WA430-5 20-153
(1)......
TESTING AND ADJUSTING TESTING AND ADJUSTING LOAD METER
4) Press ( ) on monitor panel mode selector 8) When the lift arm is lowered, the display
switch 1. EMPTY BUCKET appears on the changes to STEP 2 RAISE TO TOP. It is
lower line. ready to perform calibration for load.
9) Raise the lift arm to its uppermost posi-
tion by following the prompts. When rais-
ing the lift arm, perform operation as
close as to that of actual work.
20-154 WA430-5
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING LOAD METER
13) Input the weight value on the screen for 17) Press ( ) on monitor panel mode selector
entering targets. switch 1. When the monitor accepts the
The weight calculated from the last data entry, two short beeps are sounded and
appears on the screen. The cursor is now calibration for load setting is completed.
on 10 tons. When chaging the last target The display is restored to a normal view
weight 7.1t to7.5t (loaded weight at step of a service meter and clock.
7) of this time, input procedure is as
folows.
WA430-5 20-155
(1)......
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
1. Bleeding air from fan motor circuit 3. Bleeding air from cylinders
1) Open the radiator grill, then remove cov- 1) Start the engine and run at idling for
ers (1) and (2). approx. 5 minutes.
2) Run the engine at low idling, then raise
and lower the lift arm 4 - 5 times in suc-
cession.
★ Operate the piston rod to a point
approx. 100 mm before the end of its
stroke. Do not relieve the circuit under
any circumstances.
3) Run the engine at full throttle and repeat
Step 2). After that, run the engine at low
idling, and operate the piston rod to the
end of its stroke to relieve the circuit.
4) Repeat Steps 2) and 3) to bleed the air
from the bucket and steering cylinders.
★ When the cylinder has been replaced,
2) Connect air bleed hose [1] to nipple (3) at bleed the air before connecting the
the inlet port of the motor. piston rod.
20-156 WA430-5
(1)
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
TESTING AND ADJUSTING RELEASING
RELEASING REMAINING
REMAINING PRESSURE
PRESSURE IN HYDRAULIC
IN TRAVEL DAMPER CIRCUIT
WA430-5 20-157
(1)......
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN TRAVEL DAMPER CIRCUIT
Max. coolant temp. (During operation) Max. HST oil temp. (During operation)
Segment color W G G G G R R Segment color G G G G G R R
1 2 3 4 5 6 7 1 2 3 4 5 6 7
SAE30
Min. 150 Min. 80
Low idling
kPa {Min. 1.5} {Min. 0.8}
Oil pressure
{kg/cm2} 290 - 490 Min. 180
High idling
{3.0 - 5.0} {Min. 1.8}
SAE10W
Low idling Min. 100 Min. 70
{Min. 1.0} {Min. 0.7}
• High idling kPa Min. 79.8 Min. 60
Boost pressure
• T/C stall {mmHq} {Min. 600} {Min. 450}
• High idling
Max. 650 Max. 700
Exhaust gas • T/C stall °C
temperature
Ambient temperature - -
When shifting transmission to FORWARD or REVERSE, apply the brake securely.
Engine rated 2.76 - 2.96 2.76 - 2.96
Main relief speed {28.2 - 30.2} {28.2 - 30.2}
pressure 2.64 - 2.84 2.64 - 2.84
Low idling
Transmission, Torque converter
WA430-5 20-159
(1)......
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN TRAVEL DAMPER CIRCUIT
WA430-5 #60001-
<>: Reference value
Standard Measure-
value for Service
Item Conditions Unit new limit value
ment Pass Fail
results
machine
Lock frame with safety bar
Steering
Steering relief • Hydraulic oil temperature: 45 - 55°C MPa 16.21 - 17.19 15.72 - 17.19
pressure • Engine high idling {kg/cm2} {165 - 175} {160 - 175}
• Torque converter oil temperature:
60 - 80°C MPa Min. 2.27 Min. 2.27
Inlet pressure
{kg/cm2} {Min. 23.1} {Min. 23.1}
• Engine low idling
Parking brake
MEMO
20-160 WA430-5
(1)
TROUBLESHOOTING
WA430-5 20-201
(1)......
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the
machine. However, a short cut to effective troubleshooting is to ask the operator various questions to form
some idea of possible causes of the failure that would produce the reported symptoms.
2) Check for any external leakage of oil from
1. When carrying out troubleshooting, do not the piping or hydraulic equipment.
hurry to disassemble the components. If com- 3) Check the travel of the control levers.
ponents are disassembled immediately after 4) Check the stroke of the control valve
a failure occurs: spool.
• Parts that have no connection with the 5) Other maintenance items can be checked
failure or other unnecessary parts will be externally, so check any item that is con-
disassembled. sidered to be necessary.
• It will become impossible to find the 4. Confirming the failure.
cause of the failure. Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
It will also cause a waste of man hours, parts,
as a problem with the method of operation,
or oil and grease. At the same time, it will
etc.
also lose the confidence of the user or opera-
tor. For this reason, when carrying out trou- ★ When operating the machine to re-enact
bleshooting, it is necessary to carry out the troubleshooting symptoms, do not
thorough prior investigation and to carry out carry out any investigation or measure-
troubleshooting in accordance with the fixed ment that may make the problem worse.
procedure. 5. Troubleshooting
2. Points to ask the user or operator. Use the results of the investigation and
1) Have any other problems occurred apart inspection in Steps 2 - 4 to narrow down the
from the problem that has been reported? causes of the failure, then use the trouble-
2) Was there anything strange about the shooting flowchart to locate the position of
machine before the failure occurred? the failure exactly.
3) Did the failure occur suddenly, or were ★ The basic procedure for troubleshooting
there problems with the machine condi- is as follows.
tion before this? 1) Start from the simple points.
4) Under what conditions did the failure 2) Start from the most likely points.
occur? 3) Investigate other related parts or
5) Had any repairs been carried out before information.
the failure? When were these repairs car- 6. Measures to remove root cause of failure.
ried out? Even if the failure is repaired, if the root cause
6) Has the same kind of failure occurred of the failure is not repaired, the same failure
before? will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting. problem occurred. Then, remove the root
1) Check the oil level. cause.
20-202 WA430-5
(1)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
WA430-5 20-203
(1)......
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be
carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed
at improving the quality of repairs. For this purpose, it gives sections on 'Handling electric equipment'
and 'Handling hydraulic equipment' (particularly hydraulic oil).
20-204 WA430-5
(1)
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
WA430-5 20-205
(1)......
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
20-206 WA430-5
(1)
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
• Connecting connectors
(1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating
portion).
2) Check that there is no deformation,
faulty contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or
breakage to the outside of the connec-
tor.
★ If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry
cloth. If any water has gotten 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.
WA430-5 20-207
(1)......
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
20-208 WA430-5
(1)
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
WA430-5 20-209
(1)......
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tape, or
vinyl bags to prevent any dirt or dust from
entering. Never leave any openings opened or
blocked with a rag, this could cause particles or
dirt to get into the system.
Drain all oil into a container and not unto the
ground and be sure to follow the proper envi-
ronmental regulation for any disposal of oil.
20-210 WA430-5
(1)
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and
secondary flushing is carried out with the spec-
ified hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment
(pump, control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultra fine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
WA430-5 20-211
(1)......
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
— Repair or replace
15. Check for abnormal noise, smell — Repair
16. Check for oil leakage
— Repair
20-212 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
20-214 WA430-5
(1)
(5)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
BWW10513
WA430-5 20-215
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
BWW10326
20-216 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA430-5 20-217
(3)
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
Operator Mode
★ No. 2 - No. 8 give an endless display accord-
ing to the operation of the switch.
★ When a failure occurs, the screen changes
automatically to No. 9, regardless of the dis-
play screen.
★ Regardless of the display screen, if no switch
is operated for more than 30 seconds, the
screen automatically changes as follows.
• Goes to No. 1: If there is no failure
• Goes to No. 9: If there is no failure
★ From No. 10 the screen changes to No. 1 with
the switch operation, and if no switch is oper-
ated for more than 10 seconds, the screen
automatically changes to No. 9.
Service Mode 1
★ No. 11 - No. 19 give an endless display
according to the operation of the switch.
★ Once the ID is input and confirmed, it remains
effective until the starting switch is turned
OFF.
Control switches
Control of the machine monitor display is all car-
ried out with machine monitor mode selector
switches (1) and (2).
The following functions are provided for the but-
tons of each switch.
1. ◊: Select, Run
2. ■: Cancel, Release, Select (YES/NO screen
only)
3. >: Right, Next, Continue
4. <: Left, Previous, Return
20-218 WA430-5
(1)
(5)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
BWW10311
★ For details, see the OPERATION AND MAINTENANCE MANUAL, Handling Load Meter.
WA430-5 20-219
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
3. Travel distance aggregate display function ★ The replacement interval can be set using
From the normal service meter display, press Service Mode 1.
the [◊] switch to display the odometer. 5. Telephone number input function
• On machines without a load meter, this The telephone number set inside the machine
display is shown first. monitor can be input, corrected, or cancelled
★ For details, see the OPERATION AND by operating the switches.
MAINTENANCE MANUAL, Machine Mon- ★ When action code [E03] is displayed, the
itor and Other Functions. telephone number is displayed at the
same time as [CALL].
★ For details, see the OPERATION AND
MAINTENANCE MANUAL, Machine Mon-
itor and Other Functions.
BWW10312
BWW10314
BWW10313
BWW10315
20-220 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
E03 Displayed • Stop engine and machine immediately and contact serviceman.
WA430-5 20-221
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
10. Failure code display function ★ With the service code display function,
While the action code is being displayed on the following data are displayed.
the machine monitor, press the [>] button A. Failure code (location code + problem
once to display the failure codes for the exist- code)
ing failures. B. Controller codes
★ The failure codes detected in the past are MON: Machine monitor
divided into failures of the electrical sys- TM : Transmission controller
tem and the mechanical system and are WRK: Work equipment controller
recorded as trouble data. (For details, see C. System with problem
Service Mode 1.)
★ If more than one failure is occurring,
press the [>] button once more to display
the other failure codes.
★ After pressing the [>] button to display all
the existing failures, press the [>] button
once more to return to the service meter
display screen. BJH10102
If the [>] button is pressed once more, the
failure codes will be displayed again from
the beginning.
If the switch is not operated for 3 seconds,
the display will switch automatically to
the action code screen.
20-222 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA430-5 20-223
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
DB90KK Work equipment controller power source Drop in power source voltage, input (KK) WRK E03
circuit
DB92KK Solenoid power source circuit Drop in power source voltage, input (KK) WRK E03
DB95KX Sensor power source circuit Input signal outside range (KX) WRK E03
(DFA0KM) Work equipment lever neutral position con- Mistaken operation or mistaken setting (KM) WRK E00
firmation signal
Water temperature sensor (High tempera-
DGE2KX Input signal outside range (KX) MON E01
ture)
Water temperature sensor (Low tempera-
DGE3L6 * See separate table (L6) MON E01
ture)
DGF1KX Transmission oil temperature sensor Input signal outside range (KX) TM —
DGH2KX Hydraulic tank Input signal outside range (KX) MON E01
20-224 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
DW7BKA Reverse rotation solenoid valve for fan Disconnection (KA) TM E01
pump
Reverse rotation solenoid valve for fan
DW7BKB Short circuit (KB) TM E01
pump
DW7CKA Switch pump solenoid Disconnection (KA) TM E01
DW7CKB Switch pump solenoid Short circuit (KB) TM E01
DW7DKA EPC solenoid valve for fan pump Disconnection (KA) TM E01
DW7DKB EPC solenoid valve for fan pump Short circuit (KB) TM E01
DX16KA EPC valve for fan pump Disconnection (KA) TM E01
DX16KB EPC valve for fan pump Short circuit (KB) TM E01
DXH1KA ECMV (E-POCV) for lock-up clutch Disconnection (KA) TM E01
DXH1KB ECMV (E-POCV) for lock-up clutch Short circuit (KB) TM E01
DXH4KA ECMV (E-POCV) for 1st clutch Disconnection (KA) TM E03
DXH4KB ECMV (E-POCV) for 1st clutch Short circuit (KB) TM E03
DXH5KA ECMV (E-POCV) for 2nd clutch Disconnection (KA) TM E03
DXH5KB ECMV (E-POCV) for 2nd clutch Short circuit (KB) TM E03
DXH6KA ECMV (E-POCV) for 3rd clutch Disconnection (KA) TM E03
DXH6KB ECMV (E-POCV) for 3rd clutch Short circuit (KB) TM E03
DXH7KA ECMV (E-POCV) for R clutch Disconnection (KA) TM E03
DXH7KB ECMV (E-POCV) for R clutch Short circuit (KB) TM E03
DXH8KA ECMV (E-POCV) for F clutch Disconnection (KA) TM E03
DXH8KB ECMV (E-POCV) for F clutch Short circuit (KB) TM E03
DXHHKA ECMV (E-POCV) for 4th clutch Disconnection (KA) TM E03
DXHHKB ECMV (E-POCV) for 4th clutch Short circuit (KB) TM E03
DXHJKA 3rd lever EXTEND EPC solenoid Disconnection (KA) WRK E03
DXHJKB 3rd lever EXTEND EPC solenoid Short circuit (KB) WRK E03
DXHKKA 3rd lever RETRACT EPC solenoid Disconnection (KA) WRK E03
WA430-5 20-225
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
20-226 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
L6 Engine speed signal, terminal C signal, signals for oil pressure switch, water temperature switch, etc. do not
match operating condition or stopped condition of machine
L8 Analog signals for 2 systems do not match
LC Speed signals for 2 systems do not match
LD Switch has been kept pressed for abnormally long time
LH Fill signal is OFF when command current to ECMV is ON
WA430-5 20-227
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
3) Inputting, confirming ID
Operate the buttons to input the ID.
★ ID: 6491
• [>] button: Number at cursor goes up.
• [<] button: Number at cursor goes down.
• [◊] button: Number at cursor is con-
firmed. BJH10104
• [■] button: Returns to initial screen (see
Note).
Note: When the cursor is at the left edge, the
screen returns to the normal screen
(operator mode).
If the cursor is not at the left edge, the
cursor returns to the left edge.
★ If more than 60 seconds passes before the
switch on the ID input screen is operated,
the screen returns automatically to the
normal screen.
20-228 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA430-5 20-229
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
1) Menu selection
Select the display function for ELECTRIC
FAULT trouble data on the menu screen
of Service Mode 1.
★ The total number of trouble data
items recorded in memory is dis-
played in the [**] portion. (Recorded
up to a maximum of 20 items)
20-230 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA430-5 20-231
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
20-232 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA430-5 20-233
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
20-234 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA430-5 20-235
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
20-236 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA430-5 20-237
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
20-238 WA430-5
(1)
(3)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA430-5 20-239
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
Monitor Panel
Input/
Monitoring
No. Code Output Display Item Content of ON/OFF Switch
Signal
D-IN-0 Head lamp Head lamp lights up ON=(24V)/OFF(OPEN)
D-IN-2 Starting switch output Starting motor started = ON(24V)/OFF(OPEN)
1 40900
D-IN-4 Auto grease A Tank empty or abnormal = ON(24V)/OFF(OPEN)
D-IN-5 Auto grease B Operating or abnormal = ON(24V)/OFF(OPEN)
D-IN-12 Turn signal right Right turn signal lights up = ON(24V)/OFF(OPEN)
D-IN-13 Turn signal left Left turn signal lights up = ON(24V)/OFF(OPEN)
2 40901
D-IN-14 ◊ Switch input Switch pressed = ON(24V)/OFF(OPEN)
D-IN-15 ■ Switch input Switch pressed = ON(24V)/OFF(OPEN)
D-IN-16 Brake oil pressure (Front) Oil pressure normal = ON(GND)/(OPEN)
3 40902 D-IN-17 Brake oil pressure (Rear) Oil pressure normal = ON(GND)/(OPEN)
D-IN-20 Air cleaner clogging No clogging = ON(GND)/(OPEN)
D-IN-26 Parking brake Parking brake applied = ON(GND)/(OPEN)
D-IN-27 Engine water level Water level normal = ON(GND)/(OPEN)
4 40903 D-IN-28 Engine oil pressure Drop in oil pressure = ON(GND)/(OPEN)
D-IN-29 Engine oil level Oil level normal = ON(GND)/(OPEN)
D-IN-30 Emergency steering motor normal Emergency steering motor actuated = ON(GND)/(OPEN)
D-IN-32 Load meter sub-total switch Switch pressed = ON(GND)/(OPEN)
D-IN-33 Load meter cancel switch Switch pressed = ON(GND)/(OPEN)
D-IN-34 High beam switch High beam = ON(GND)/(OPEN)
5 40904 D-IN-36 Service function 2 Switch pressed = ON(GND)/(OPEN)
D-IN-37 > Switch input Switch pressed = ON(GND)/(OPEN)
D-IN-38 < Switch input Switch pressed = ON(GND)/(OPEN)
D-IN-39 Drop in steering pressure Oil pressure normal = ON(GND)/(OPEN)
20-240 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
Monitor Panel
Input/
Monitoring
No. Output Display Item Content of ON/OFF Switch
Code
Signal
D-IN-0 Steering pressure switch (N.O.) Pressure normal(exists)ON=(GND)/OFF(OPEN)
D-IN-1 Steering pressure switch (N.C.) Pressure normal(lowered)ON=(GND)/OFF(OPEN)
D-IN-2 Transmission cut-off switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-3 Transmission cut-off set switch Switch pressed = ON(GND)/OFF(OPEN)
1 40905
D-IN-4 Travel damper selector switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-5 Lock-up selector switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-6 Kick-down switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-7 Engine power mode Power mode = ON(GND) /(OPEN)
D-IN-8 Shift range 1st 1st = ON(24V)/OFF(OPEN)
D-IN-9 Shift range 2nd 2nd = ON(24V)/OFF(OPEN)
D-IN-10 Shift range 3rd 3rd = ON(24V)/OFF(OPEN)
D-IN-11 Shift range 4th 4th = ON(24V)/OFF(OPEN)
2 40906
D-IN-12 Joystick shift up Switch pressed = ON(24V)/OFF(OPEN)
D-IN-13 Joystick shift down Switch pressed = ON(24V)/OFF(OPEN)
D-IN-14 Electric emergency steering manual switch Switch pressed = ON(24V)/OFF(OPEN)
D-IN-15 Starting switch output Starting motor started = ON(GND)/OFF(OPEN)
D-IN-16 Right FNR (Joystick) selector switch Switch pressed = ON(24V)/OFF(OPEN)
D-IN-17 Right seesaw switch & joystick FORWARD FORWARD = ON(24V)/OFF(OPEN)
D-IN-18 Right seesaw switch & joystick Neutral NEUTRAL = ON(24V)/OFF(OPEN)
D-IN-19 Right seesaw switch & joystick REVERSE REVERSE = ON(24V)/OFF(OPEN)
3 40907
D-IN-20 Direction lever FORWARD FORWARD = ON(24V)/OFF(OPEN)
D-IN-21 Direction lever Neutral NEUTRAL = ON(24V)/OFF(OPEN)
D-IN-22 Direction lever REVERSE REVERSE = ON(24V)/OFF(OPEN)
D-IN-23 Neutralizer (Parking brake) signal Parking switch ON = ON(24V)/OFF(OPEN)
D-IN-24 F clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-25 R clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-26 1st clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-27 2nd clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
4 40908
D-IN-28 3rd clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-29 4th clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-30 Lock-up clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-31 Shift hold switch Switch pressed = ON(GND)/OFF(OPEN)
D-OUT-0 Backup lamp relay Output ON (24V)/OFF(GND)
5 40915
D-OUT-1 Transmission cut-off indicator Output ON (24V)/OFF(GND)
SOL/O-0 Electric emergency steering relay Output ON (24V)/OFF(GND)
SOL/O-1 E.C.S.S. relay Output ON (24V)/OFF(GND)
SOL/O-2 Switch pump cut-off Output ON (24V)/OFF(GND)
6 40914
SOL/O-3 Neutral output Output ON (24V)/OFF(GND)
SOL/O-4 Fan pump reverse rotation solenoid Output ON (24V)/OFF(GND)
SOL/O-5 Fan pump neutral solenoid Output ON (24V)/OFF(GND)
WA430-5 20-241
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
Monitor Panel
Input/
Monitoring
No. Output Display Item Content of ON/OFF Switch
Code
Signal
D-IN-0 Joystick ON/OFF selector switch Joystick (right FNR) selected = ON(24V)/(OPEN)
1 40910 Working position = ON(24V)/LOCK position =
D-IN-1 Work equipment safety lock lever switch
OFF(OPEN)
Joystick Hi speed selected = ON(GND)/
D-IN-8 Joystick speed Hi/Lo selector switch
OFF(OPEN)
D-IN-9 Bucket proximity switch (horizontal) Horizontal position = ON(GND)/OFF(OPEN)
2 40911 D-IN-10 Bucket full stroke switch Stroke end position = ON(GND)/OFF(OPEN)
D-IN-12 Semi auto digging hard switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-13 Semi auto digging soft switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-28 Remote positioner RAISE set switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-29 Remote positioner LOWER set switch Switch pressed = ON(GND)/OFF(OPEN)
3 40913
D-IN-30 Remote positioner RAISE selector switch Switch pressed = ON(GND)/OFF(OPEN)
D-IN-31 Remote positioner LOWER selector switch Switch pressed = ON(GND)/OFF(OPEN)
D-OUT-1 Remote positioner RAISE switch Output ON (24V)/OFF(GND)
4 40917
D-OUT-2 Remote positioner LOWER lamp Output ON (24V)/OFF(GND)
SOL/O-0 Joystick EPC cut relay Output ON (24V)/OFF(GND)
SOL/O-1 Detent lift arm RAISE Output ON (24V)/OFF(GND)
5 40916 SOL/O-2 Detent lift arm FLOAT Output ON (24V)/OFF(GND)
SOL/O-3 Detent TILT Output ON (24V)/OFF(GND)
SOL/O-4 Work equipment neutral lock solenoid Output ON (24V)/OFF(GND)
20-242 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
• Adjustment items
1) Setting initial training of transmission 7) Adjusting 3-tandem valve EPC valve (cylin-
2) Adjusting lift arm angle sensor der extension)
(RAISE) (for EPC lever) 8) Adjusting 3-tandem valve EPC valve (cylin-
3) Adjusting lift arm RAISE EPC valve der retraction)
4) Adjusting lift arm LOWER EPC valve 9) Adjusting joystick steering calibration
5) Adjusting bucket TILT EPC valve (right)
6) Adjusting bucket DUMP EPC valve 10) Adjusting joystick steering calibration (left)
11) Adjusting lift arm angle sensor (RAISE) (for
load meter)
12) Adjusting lift arm angle sensor (LOWER)
(for load meter)
BWW10324
★ For details, see STRUCTURE AND FUNCTION, Settings needed when installing optional equipment.
20-244 WA430-5
(1)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
Table of filter and oil replacement interval set items [when shipping]
No. Item Code Display Replacement Interval
1 Engine oil 01 ENG OIL 500
2 Engine oil filter 02 ENG OIL FILTER 500
3 Fuel filter 03 FUEL FILTER 500
4 Corrosion resistor 06 CORR RESISTOR 1000
5 Transmission oil 12 TM OIL 1000
6 Transmission oil filter 13 TM OIL FILTER 1000
7 Hydraulic filter 04 HYD OIL FILTER 2000
8 Hydraulic tank breather element 05 BREATHER ELE 2000
9 Axle oil 15 AXLE OIL 2000
10 Hydraulic oil 10 HYD OIL 2000
WA430-5 20-245
(1)......
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
BWW10328
20-246 WA430-5
(1)
(3)
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONITOR
WA430-5 20-247
(1)......
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
Procedure of troubleshooting
If a phenomenon considered to be a failure occurs in the machine, select a proper troubleshooting No.
according to the following procedure, and then read the corresponding troubleshooting procedure.
3. Procedure of troubleshooting to be taken when action code is not displayed and error code is recorded:
If a error code is not recorded in the monitor panel (EMMS), a failure that the machine cannot find out
by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon considered to be failures again and select the same phenomenon
from the "Phenomena considered to be failures" table, and then carry out troubleshooting related to
that phenomenon in "TM mode", "MON mode", "WRK mode", or "E mode".
WA430-5 20-249
(1)......
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
20-250 WA430-5
(1)
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
Troubleshooting
No. Phenomena considered to be failures Error TM WRK MON H E (Engine)
code mode mode mode mode mode
Failures related to work equipment controller (WRK mode)
Defective semi-automatic digging SOFT selection
31 switch system WRK-9
53 The air cleaner clogging indicator lamp does not light MON-4
ON
The engine oil pressure caution lamp does not light
54 ON MON-5
55 The engine oil level caution lamp does not light ON MON-6
60 The steering oil pressure caution lamp does not light MON-11
ON
WA430-5 20-251
(1)......
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
Troubleshooting
No. Phenomena considered to be failures Error TM WRK MON H E (Engine)
code mode mode mode mode mode
Failures related to monitor panel (MON mode)
Input fault in monitor panel mode switch 1 [■] (Panel
61 SW1) MON-12
86 The lift arm moves slowly or the lift arm rising force is H-16
insufficient
When rising, the lift arm comes to move slowly at
87 H-17
specific height
The lift arm cylinder cannot hold down the bucket
88 H-18
(The bucket rises in the air)
89 Hydraulic drifts of the lift arm occur often H-19
90 The lift arm wobbles during operation H-20
20-252 WA430-5
(1)
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
Troubleshooting
No. Phenomena considered to be failures Error TM WRK MON H E (Engine)
code mode mode mode mode mode
Failures related to hydraulic and mechanical system (H mode)
The bucket comes to operate slowly in he midst of tilt-
94 ing-back H-24
99 The control levers of lift arm and bucket do not move H-29
smoothly and heavy
Failures related to electrical system (E mode)
100 The engine power modes cannot be selected E-4
101 The front wiper does not function E-5
102 The rear wiper does not function E-6
103 The side wiper does not function (If equipped) E-7
104 The wind washer does not function E-8
105 The headlamp (Lo beam) does not light on E-9
106 The headlamp (Hi beam) does not function E-10
107 The clearance lamp does not light on (Small lamp) E-11
108 The turn signal does not blink E-12
109 The horn does not sound E-13
110 The air conditioner does not work or does not stop E-14
WA430-5 20-253
(1)......
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
5. Method of using troubleshooting table (TM mode, WRK mode, MON mode, E mode)
Controller
Action Code Error Code
Code Trouble Trouble displayed in trouble data
Panel display Panel display Panel display
Description of • Condition when monitor panel or controller detected trouble.
Trouble
Controller • Action to take to protect system or equipment when monitor or controller detected trouble.
Reaction
Effect on • Condition that appeared as problem on machine when action (given above) was taken by monitor panel or
Machine controller.
20-254 WA430-5
(1)
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
6. Method of reading matrix-type troubleshoot- 1. Steering wheel does not turn ←Problem
ing chart (H mode) (example)
Ask the operator the following questions.
Step 1. Ask operator questions • Did the problem suddenly start?
Yes = Equipment related to steering broken
The questions to ask the operator are given • Was there previously any symptom, such as heaviness
under the problem. If the answer to the ques- of the steering wheel?
tion matches the content given, the cause Yes = Wear of equipment related to steering, defective
given after the arrow is the probable cause. seal
Keeping the content of the questions in mind,
read the matrix and proceed with Step 2 and Checks before troubleshooting (example)
Step 3 to pinpoint the correct cause. • Is the oil level in the hydraulic tank correct? Is the type
of oil correct?
Step 2. Checks before troubleshooting • Is there any leakage of oil from the steering valve or
Before measuring the oil pressure or starting Orbit-roll?
• Has the safety bar been removed from the frame?
the troubleshooting, confirm the checks
before starting items, check for leakage of oil,
or for loose bolts. <Example 1>
This will prevent wasting time when trouble- Remedy
shooting. No.
Problems
The items given under Checks before trouble-
Steering wheel does not turn in either direction (left
shooting are checks that are particularly 1
and right)
important to make about the condition of the In Item 1, movement of work equipment is abnor-
machine before starting the actual trouble- 2
mal
shooting. Steering wheel turns only in one direction (left or
3
right)
Step 3. Method of reading matrix 4 Steering wheel is heavy and does not turn
1) Operate the machine when carrying out
troubleshooting of the items in the Trou- <Example 2>
bleshooting column. If any problems Cause
occur as the result of the troubleshooting, a b c d e
put a check against the item.
Remedy ∆
★ When carrying out the troubleshoot- X C A X
ing, check the easier items first. It is Problems X
not necessary to follow the number 1 ❍ ❍ ❍ ❍
order. 2 ● ●
2) Find the matching cause in the Causes 3 ❍ ❍
column. 4 ❍ ❍
If a problem is found, the ❍ marks on the
5 ❍ ❍
same line as the troubleshooting are the
causes. (In Troubleshooting item 2 in the
same diagram on the right the cause is c
or e.)
When there is one ❍ mark
Carry out troubleshooting for the other
items marked with ❍ in the same Causes
column to check if the problem occurs,
then make repairs.
When there are two ❍ marks
Go to Step 3) to narrow down the cause.
WA430-5 20-255
(1)......
CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLE-
TROUBLESHOOTING SHOOTING CHARTS
7) Remedy
After narrowing down the common
causes, taken the action given in the rem-
edy line.
X: Replace ∆: Repair A: Adjust C: Clean
20-256 WA430-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
X Type Connector
Number
of Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
BWP04702
2 799-601-7020
BWP04703
3 BWP04704 799-601-7030
BWP04705
4 BWP04706 799-601-7040
20-258 WA430-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04708
BWP04707
6 799-601-7050
BWP04709 BWP04710
8 799-601-7060
BWP04711
BWP04712
12 799-601-7310
BWP04713 BWP04714
14 799-601-7070
WA430-5 20-259
(1)......
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04715
16 BWP04716 799-601-7320
20-260 WA430-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
BWP04718
2 BWP04717 799-601-7090
BWP04719 BWP04720
3 799-601-7110
BWP04723 BWP04724
6 799-601-7130
WA430-5 20-261
(1)......
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S Type Connector
Number
of Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
BWP04728
8 BWP04727 799-601-7140
BWP04731 BWP04732
12 (white) 799-601-7350
BWP04733 BWP04734
16 (white) 799-601-7330
20-262 WA430-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S Type Connector
Number
of Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
BWP04736
BWP04735
10 (blue) —
— —
BWP04737 BWP04738
12 (blue) 799-601-7160
BWP04739 BWP04740
16 (blue) 799-601-7170
WA430-5 20-263
(1)......
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04742
BWP04741
5 799-601-2710
BWP04743 BWP04744
9 799-601-2950
BWP04745 BWP04746
13 799-601-2720
20-264 WA430-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04748
BWP04747
17 799-601-2730
BWP04749 BWP04750
21 799-601-2740
WA430-5 20-265
(1)......
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04752
BWP04751
8 799-601-7180
BWP04753 BWP047544
12 799-601-7190
BWP04755 BWP04756
16 799-601-7210
BWP04757 BWP04758
20 799-601-7220
20-266 WA430-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
10 799-601-7510
WA430-5 20-267
(1)......
(5)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DRC26 Series connector
Number
of Pins T-adapter
Body (plug) Body (receptacle) Part Number
24 799-601-9360
40
799-601-9350
(A)
40
799-601-9350
(B)
20-267-1 WA430-5
(5)
(5)
(4)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L Type Connector
Number
of Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
BWP04770
2 BWP04769 —
— —
PA Type Connector
Number
of Pins T-adapter Part
Male (Female housing) Female (Male housing)
Number
BWP04772
9 BWP04771 —
— —
BWP04774
10 BWP04773 799-601-3460
— —
20-268 WA430-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04776
BWP04775
2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 BWP04777 BWP04778 —
BWP04779 BWP04780
4 —
Part number: 08027-10410 (Natural color) Part number: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
BWP04781 BWP04782
6 —
Part number: 08027-10610 (Natural color) Part number: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
WA430-5 20-269
(1)......
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
BWP04784
BWP04783
8 —
Part number: 08027-10810 (Natural color) Part number: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
BWP04786
5 BWP04785 799-601-7360
— —
BWP04788
6 BWP04787 799-601-7370
— —
20-270 WA430-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9210
799-601-9210
799-601-9220
799-601-9220
WA430-5 20-271
(1)......
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9230
799-601-9230
799-601-9240
799-601-9240
20-272 WA430-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9250
799-601-9250
799-601-9260
799-601-9260
WA430-5 20-273
(1)......
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9270
799-601-9270
799-601-9280
799-601-9280
20-274 WA430-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9290
799-601-9290
WA430-5 20-275
(1)......
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part number: 08192-13200 (normal type) Part number: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part number: 08192-14200 (normal type) Part number: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part number: 08192-16200 (normal type) Part number: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
20-276 WA430-5
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9080
Part number: 08192-1820 <Galpha>@ (nor- Part number: 08192-1810 <Galpha>@ (nor-
mal type) mal type)
08192-2820 <Galpha>@ (fine 08192-2810 <Galpha>@ (fine
wire type) wire type)
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
Part number: 08192-1920 <Galpha>@ (nor- Part number: 08192-1910 <Galpha>@ (nor-
mal type) mal type)
08192-2920 <Galpha>@ (fine 08192-2910 <Galpha>@ (fine
wire type) wire type)
WA430-5 20-277
(1)......
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DTM Series connector
Number
of Pins T-adapter Part
Body (plug) Body (receptacle)
Number
2 799-601-9010
1 —
Part number: 08192-31200 (Contact size #12) Part number: 08192-31100 (Contact size #12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-278 WA430-5
(1)
TROUBLESHOOTING T-ADAPTER TABLE
T-ADAPTER TABLE
★ The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring
harness checker assemblies are shown in the lines.
KIT No.
799-601-3000
799-601-6000
799-601-7000
799-601-8000
799-601-9000
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-5500
799-601-6500
799-601-7500
799-601-9200
799-601-9300
799-601-7100
799-601-7400
799-601-9100
—
Port No. Connector type Pin No.
WA430-5 20-279
(1)......
TROUBLESHOOTING T-ADAPTER TABLE
KIT No.
799-601-3000
799-601-6000
799-601-7000
799-601-8000
799-601-9000
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-5500
799-601-6500
799-601-7500
799-601-9200
799-601-9300
799-601-7100
799-601-7400
799-601-9100
—
Port No. Connector type Pin No.
20-280 WA430-5
(1)
TROUBLESHOOTING T-ADAPTER TABLE
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Port No. Connector type Pin No.
WA430-5 20-281
(1)......
(5)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
A21 Yazaki 2 Water temperature sensor (Vehicle with automatic air W-3
conditioner)
Inside temperature sensor (Vehicle with automatic air
A22 Yazaki 2 conditioner) U-2
20-282 WA430-5
(1)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
C48 AMP040 16 A/C control AMP (Vehicle with automatic air conditioner) D-9
C49 SWP 8 Left Servomotor R-1
C50 SWP 8 Right Servomotor M-3
C51 Yazaki 2 Diode (Vehicle with automatic air conditioner) M-3
CAN1 DT-T 3 Resistor O-1 F-1 K-7 B-2
CAN2 DT-T 3 Resistor R-9 J-9 K-7 B-2
CL1 S 8 Intermediate connector A-4 E-7
CL2 S (L) 12 Intermediate connector (Wiper motor) A-4
Intermediate connector (Vehicle with automatic air
CL5 S (W) 16 M-2
conditioner)
CL6 M 6 Intermediate connector (Vehicle with automatic air M-2 B-3 C-5
conditioner)
CL6 DT-T (G) 12 Intermediate connector (Monitor panel controller) W-4 K-4 C-4
CL7 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-2 B-4 K-4 C-5
CL8 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-1 B-4 C-5
CL9 DT-T (Gr) 8 Intermediate connector (Monitor panel controller) O-1 B-4 K-4 C-6 B-5
WA430-5 20-283
(1)......
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
CL10 DT-T (Gr) 8 Intermediate connector (Monitor panel controller) O-1 B-3 K-3 C-3
CL20 DT-T 2 Intermediate connector (Monitor panel controller) N-2
CN55 DT-T 2 Intermediate connector (Backup buzzer) K-9 P-2 V-8
COMBI M 3 Front combination lamp (Right) A-6 W-3
COMBI M 3 Front combination lamp (Left) E-1 W-2
DIODE DT-T 2 Diode (Parking brake solenoid) AG-8 P-8
DL DT-T (Gr) 12 Connector (S-NET) U-8 I-9 K-5 K-5
E01 DT-T 2 Intermediate connector (Starting motor) AC-1 W-4 B-1
E02 Terminal 1 Alternator R AD-3 X-5
E03 Terminal 1 Alternator B AD-4 X-5
E04 Terminal 1 Alternator E AD-3 X-5
E05 Terminal 1 Engine heater relay AC-8 Q-9 E-4
E06 Terminal 1 Engine heater relay AC-9 Q-9 F-4
E07 Terminal 1 Engine heater relay Q-9 F-4
E08 DT-T 2 Engine water temperature sensor (Monitor) AD-3 O-8
E09 DT-T 2 Engine water temperature sensor (Preheater) AA-1 O-8 B-3
E10 DT-T 2 Air conditioner compressor magnet clutch AA-5
E14 Terminal 1 Ground (Rear frame) AB-1 X-5 A-1
E26 DT-T 2 Engine oil level sensor AC-1 P-8
E27 DT-T 2 Engine speed sensor AC-7 L-8
E28 DT 2 Diode (Engine heater relay) Z-1 O-8 B-2
E29 Terminal 1 Engine oil pressure switch Y-5 P-8
E30 Terminal 1 Starting motor B AB-1 X-4
E33 DT-T 2 Dust indicator Z-3 P-8
E35 SWP 8 Engine stop motor Z-1 B-2
E36 Terminal 1 Air compressor magetic clutch Z-5
ER-1 DT-T (G) 12 Intermediate connector (Engine) AC-1 P-5 D-3
ER-3 DT-T (Gr) 8 Intermediate connector (Engine) AD-2 L-7 O-5 C-3
F01 M 6 Intermediate connector (R.H. Front lamp) A-5 U-3
F02 M 6 Intermediate connector (L.H. Front lamp) D-1 U-2
F03 Terminal 1 Horn (303 Hz) A-1 W-2
F04 Terminal 1 Horn (303 Hz) A-1 W-1
F05 Terminal 1 Horn (303 Hz) C-1 W-1
F06 Terminal 1 Horn (303 Hz) B-1 W-1
F07 DT-T 2 Switching pump cut-off solenoid C-1 R-8
F09 DT-T 3 Bucket positioner proximity switch A-3 Q-7 B-4
F10 DT-T 3 Bucket positioner proximity switch (STD) A-3 Q-6 B-4
F13 DT-T 2 Lift arm damper solenoid C-1 R-8
F14 DT-T 2 Diode (Damper solenoid) D-1 R-7
F15 DT-T 3 Lift arm angle signal (For load meter) A-2 B-3 M-8
F16 DT-T 3 Lift arm bottom signal (For load meter) B-1 B-3 M-8
F17 DT-T 3 Lift arm rod signal (For load meter) B-1 B-3 M-8
F18 DT-T 3 Lift arm angle sensor (For boom EPC) A-5 H-7
F19 DT-T 3 Bucket positioner proximity switch (For bucket EPC) A-3 I-7
F20 DT-T 2 Lift arm RAISE EPC A-2 G-7
F21 DT-T 2 Lift arm LOWER EPC A-1 G-7
20-284 WA430-5
(1)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
WA430-5 20-285
(1)......
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
20-286 WA430-5
(1)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
L73 DRC 40 Lift arm bucket and joystick controller R-9 J-8 B-8
L88 DT-T (Gr) 8 Engine mode selector motor P-1 B-8
L92 DT-T 3 Intermediate connector (Pump bypass) R-9 J-6
L93 Relay 5 Pump bypass relay R-9 J-6
L100 Terminal 1 Ground (Floor) R-1 I-1 K-1 J-1 B-6
L101 S (W) 16 Intermediate connector (Relay sub-unit) T-9 D-2 I-7 E-8
L102 S (L) 16 Intermediate connector (Relay sub-unit) T-9 D-2 J-7 E-7
L103 S (W) 16 Intermediate connector (Relay sub-unit) S-9 E-2 J-7
L104 S (W) 16 Intermediate connector (Relay sub-unit) T-9 E-2 L-7 E-7
L105 S (W) 12 Intermediate connector (Relay sub-unit) T-9 F-2 E-6
L106 S (W) 16 Intermediate connector (Relay sub-unit) S-9 F-2 K-7
L111 — 5 Turn signal lamp and hazard relay X-7 I-9
L112 — 5 Air cleaner clogging relay W-7 I-9
L113 — 5 Steering selector relay W-8 D-1 J-9 F-8
L114 — 5 Automatic preheater relay V-8 J-9 F-7
L115 — 5 Engine controller power supply relay V-9 F-7
L116 — 4 Neutral safety relay W-7 D-1 J-9 F-7
L117 — 4 Backup lamp relay W-7 E-1 J-9
L118 — 4 Stop lamp relay V-8 K-9
L119 — 4 Horn relay V-8 K-9
L120 — 4 Parking brake relay V-8 E-1
L123 — 5 Lift arm detent relay (STD) X-9 L-9 F-6
L124 — 5 Bucket detent relay (STD) W-9 L-9 F-6
L125 — 5 Lift arm damper relay V-9 E-1
L126 — 4 Emergency steering relay X-8 F-1
L127 — 4 Front working lamp relay X-7 K-9
L128 — 4 Rear working lamp relay X-9 K-9
L129 — 4 Rear glass heater relay V-9
L130 — 4 Transmission pump cut-off relay V-9 F-1
L131 — 5 Engine stop motor relay X-9 F-6
L141 Relay 5 Printer relay T-1
L142 DT-T 2 Diode (Printer) W-3
L143 DT-T 2 Diode (Printer) W-4
L144 DT-T 2 Diode (Printer) W-4
L145 DT-T 2 Diode (Printer) W-4
L146 DT-T 2 Diode (Printer) S-1
L147 DT-T 2 Diode (Printer) T-1
LC.PS DT-T 2 Torque converter lockup solenoid (OPT) AJ-5 N-8
LC.SW DT 2 Torque converter lockup fill switch (OPT) AJ-5 P-8
LL5 DT 3 Intermediate connector (Vehicle with joystick) Q-1 F-5
LL6 DT-T (Gr) 12 Intermediate connector (Vehicle with joystick) Q-1 E-4
LL7 DT-T (G) 12 Intermediate connector (Vehicle with joystick) Q-1 J-7 E-4 K-5
LL8 DT-T (Gr) 8 Intermediate connector (Joystick switch) R-1 K-2 C-1
LR1 DTHD#12 1 Intermediate connector (Slow-blow fuse) X-2 I-2 D-5
LR2 DT-T (G) 12 Intermediate connector (Engine) J-7 K-4 D-5
LR4 L 2 Intermediate connector (Slow-blow fuse) X-1 I-2 E-5
WA430-5 20-287
(1)......
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
LR9 DT-T (G) 12 Intermediate connector (Steering and brake oil pressure X-1 I-3 K-2
switch)
LR10 DT-T (Gr) 12 Intermediate connector X-1 I-3 K-3 D-5
LR13 DT-T 2 Intermediate Connecter ( Pump bypass) AE-7 L-7
W-3,
LT1 HD-24 31 Intermediate connector (Transmission) I-6 K-4
AF-2
PB.PS DT-T 2 Parking brake solenoid AI-3 P-8
PB.SW DT-T 2 Parking brake indicate switch AI-3 Q-8 P-8
R.PS DT-T 2 Transmission R clutch solenoid AJ-6 N-8
R.SW DT 2 Transmission R clutch fill switch AJ-6 O-8
R01 Terminal 1 Battery relay J-2 O-1 X-6 F-2
R02 Terminal 1 Slow-blow fuse L-2 P-1 F-3
R03 Terminal 1 Slow-blow fuse L-2 P-1 F-3
R04 Terminal 1 Battery relay L-1 O-1 X-6 F-2
R05 Terminal 1 Slow-blow fuse K-2 P-1 X-7 F-3
R06 Terminal 1 Slow-blow fuse K-2 P-1 F-3
R11 Terminal 1 Slow-blow fuse K-2 X-7 F-3
R13 L-1 O-1 X-6 F-2
R14 Terminal 1 Battery relay L-1 O-1 X-6 F-2
R15 Terminal 1 Emergency steering relay J-1 O-1
R16 Terminal 1 Emergency steering relay J-1 O-1
R22 Terminal 1 Battery G-9 T-9 F-2
R24 DT-T 2 Diode (Battery relay) I-1 P-1 F-5
R25 DT-T 2 Diode (Battery relay) I-2 J-1 P-1 F-5
R26 DT-T 2 Diode (Starting motor) I-1 P-1 F-5
R27 DT-T 2 Diode (Starting motor) I-2 P-1 F-5
R29 DT-T 2 Fan pump EPC A-6 Q-3
R30 M 6 Rear combination lamp (Left) L-5 S-8
R31 M 6 Rear combination lamp (Right) H-9 S-8
R32 DT-T 2 Coolant level sensor B-8 X-8
R33 DT-T 2 Fuel level gauge sensor K-3 U-8
R34 M 2 License lamp L-6
R36 DT-T 3 Steering pump pressure switch E-1 Q-3 V-8
R37 DT-T 3 Emergency steering pressure switch D-1 Q-2 W-8
R38 DT-T 6 Auto grease controller N-1
R39 DT-T 2 Battery level sensor L-6 T-7
R43 KES1 2 Front windshield washer G-1
R44 DT-T 2 Diode (Washer) G-1
R45 KES1 2 Rear windshield washer H-1
R46 DT-T 2 Diode (Washer) G-1
R47 DT-T 2 Hydraulic oil temperature sensor A-6 W-1
R50 Terminal 1 Ground (Rear frame) I-9 M-1 T-1 D-1
R51 DT-T 2 Emergency brake switch 1 F-1 I-1
20-288 WA430-5
(1)
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
S14 DT-T 6 Lower remote positioner ON/OFF switch (Vehicle with joy- N-8 J-1
stick)
S15 DT-T 6 Automatic digging switch (Vehicle with joystick) N-9 J-1
S16 DT-T 6 Hydraulic fan reverse switch M-9 G-2
S17 DT-T 6 Auto grease switch O-8 A-8
S19 DT-T 6 Emergency steering check switch M-9 H-2
S21 DT-T 4 Engine power mode switch M-9 G-8 C-8
S22 DT-T 4 Auto shift mode switch N-7 G-8
S31 DT 4 Starting switch N-7 G-2 K-2 L-7 D-8
S32 DT-T 2 Starting switch N-7
T20 Terminal 1 Ground AI-2 Q-4
T21 DT-T 2 Pump bypass solenoid AG-8 L-8
TC.T DT-T 2 Torque converter oil temperature sensor AH-8 Q-8 Q-8
TEL DT-T (Gr) 12 Intermediate connector (KOMTRAX) Q-1 I-9 K-1 C-5
TM.T DT-T 2 Transmission oil temperature sensor AJ-3 Q-8
WA430-5 20-289
(1)......
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-290 WA430-5
(1)
(5)
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA430-5 20-291
(1)......
(5)
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-292 WA430-5
(1)
(5)
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA430-5 20-293
(1)......
(5)
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-293-1 WA430-5
(5)
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA430-5 20-293-2
(5)......
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
20-294 WA430-5
(1)
(5)
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
WA430-5 20-295
(1)......
TROUBLESHOOTING OF TRANSMISSION
CONTROL SYSTEM
(TM MODE)
WA430-5 20-301
(1)......
(4)
TROUBLESHOOTING
Error code [DF10KA] (No input of gear shift lever signal) is displayed . . . . . . . . . . . . . . . . . . . . . . 20-364
Error code [DF10KB] (Input of multiple gear shift lever signals No input of gear shift lever signal)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366
Error code [DGF1KX] (Transmission oil temperature sensor system failure) is displayed. . . . . . . 20-368
Error code [DGR2KA] (Rear brake oil temperature sensor system disconnection) is displayed . . 20-369
Error code [DGR2KB] (Ground fault of rear brake oil temperature sensor system) is displayed . . 20-370
Error code [DHT1KX] (Transmission cut-off (Left brake pressure sensor) signal discontinuity)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-371
Error code [DLE2KA] (Engine revolution sensor system discontinuity) is displayed . . . . . . . . . . . 20-372
Error code [DLE2LC] (Engine revolution sensor failure) is displayed . . . . . . . . . . . . . . . . . . . . . . . 20-373
Error code [DLT3KA] (Speed sensor transmission output shaft revolution system discontinuity)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-374
Error code [DT20KB] (Ground fault of built-in indicator lamp system of transmission cut-off switch)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-375
Error code [DW7BKA] (Fan pump reverse solenoid system discontinuity) is displayed . . . . . . . . . 20-376
Error code [DW7BKB] (Fan pump reverse solenoid system short-circuiting) is displayed . . . . . . . 20-377
Error code [DW7CKA] (Switch pump cut-off relay discontinuity) is displayed . . . . . . . . . . . . . . . . . 20-378
Error code [DW7CKB] (Switch pump cut-off relay ground fault) is displayed . . . . . . . . . . . . . . . . . 20-379
Error code [DX16KA] (Fan pump EPC solenoid system discontinuity) is displayed . . . . . . . . . . . . 20-380
Error code [DX16KB] (Fan pump EPC solenoid system ground fault) is displayed . . . . . . . . . . . . 20-381
Error code [DXH1KA] (Lock-up clutch _ECMV (E-POCV) solenoid system discontinuity)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-382
Error code [DXH1KB] (Lock-up clutch _ECMV (E-POCV) solenoid system short-circuiting)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-383
Error code [DXH4KA] (1st_ECMV (E-POCV) solenoid system discontinuity) is displayed. . . . . . . . 20-384
Error code [DXH4KB] (1st_ECMV (E-POCV) solenoid system short-circuiting) is displayed. . . . . . 20-385
Error code [DXH5KA] (2nd_ECMV (E-POCV) solenoid system discontinuity) is displayed . . . . . . . 20-386
Error code [DXH5KB] (2nd_ECMV (E-POCV) solenoid system short-circuiting) is displayed . . . . . 20-387
Error code [DXH6KA] (3rd_ECMV (E-POCV) solenoid system discontinuity) is displayed . . . . . . . 20-388
Error code [DXH6KB] (3rd_ECMV (E-POCV) solenoid system short-circuiting) is displayed . . . . . 20-389
Error code [DXH7KA] (R_ECMV (E-POCV) solenoid system discontinuity) is displayed . . . . . . . . . 20-390
Error code [DXH7KB] (R_ECMV (E-POCV) solenoid system ground fault) is displayed . . . . . . . . . 20-391
Error code [DXH8KA] (F_ECMV (E-POCV) solenoid system discontinuity) is displayed . . . . . . . . . 20-392
Error code [DXH8KB] (F_ECMV (E-POCV) solenoid system ground fault) is displayed. . . . . . . . . . 20-393
Error code [DXHHKA] (4th_ECMV (E-POCV) solenoid system discontinuity) is displayed . . . . . . . 20-394
Error code [DXHHKB] ( 4th ECMV (E-POCV) solenoid system short-circuiting) is displayed . . . . . 20-395
Error code [DY30MA] (Motor-driven emergency steering pump failure
(malfunction in manual mode)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-396
Error code [DY30MC] (Motor-driven emergency steering pump failure
(Malfunction in manual mode)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-398
Troubleshooting code [TM-1] Discontinuity or hot short-circuiting of kickdown switch system20-400
Troubleshooting code [TM-2] Hold switch system discontinuity or hot short-circuiting . . . . . . 20-402
Troubleshooting code [TM-3] Torque converter lock-up switch system failure . . . . . . . . . . . . . 20-404
Troubleshooting code [TM-4] Neutralizer signal (Parking brake switch signal) system failure . 20-406
Troubleshooting code [TM-5] Emergency steering switch (motor-driven emergency steering
operation switch) signal system failure . . . . . . . . . . . . . . . . . . . . 20-408
Troubleshooting code [TM-6] Transmission cut-off switch system discontinuity or ground fault
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-410
Troubleshooting code [TM-7] Transmission cut-off setting switch system discontinuity
or hot short-circuiting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-411
Troubleshooting code [TM-8] Transmission cut-off (left brake sensor) signal short-circuiting . 20-412
Troubleshooting code [TM-9a] Joystick SHIFT_UP/SHIFT_DOWN siwtch system failure
(discontinuity or ground fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-413
Troubleshooting code [TM-9b] Joystick ON/OFF change over switch system failure. . . . . . . . . . 20-414
Troubleshooting code [TM-10] FNR switch mode change over switch system failure . . . . . . . . . 20-416
Troubleshooting code [TM-11] "Starting switch ""C"" (IGN_C) signal system failure . . . . . . . . . . 20-418
Troubleshooting code [TM-12] Engine power mode switch discontinuity or ground fault . . . . . 20-420
Troubleshooting code [TM-13] The engine power mode cannot be selected. . . . . . . . . . . . . . . . 20-422
20-302 WA430-5
(1)
TROUBLESHOOTING
★ Referring to TESTING AND ADJUSTING, Adjusting machine monitor, check that the rotary switches
(SW1, SW2, and SW3) and DIP switches (SW5 and SW6) on the back side of the monitor panel are set
correctly.
★ [*]: Check that the travel damper switch is turned ON. Referring to TROUBLESHOOTING, Special func-
tions of machine monitor, check that the optional selection of the travel damper is effective.
WA430-5 20-303
(1)......
(4)
TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM DIAGRAM
20-304 WA430-5
(1)
TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM DIAGRAM
WA430-5 20-305
(1)......
TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM DIAGRAM
20-306 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [1500L1]
Possible Causes and Causes Standard Values in Normal State and Remarks on Troubleshooting
Standard Values ★ Refer to Error Codes 15SAL1, 15 SBL1, 15SEL1, 15SFL1, 15SGL1 and 15SHL1.
WA430-5 20-307
(1)......
TROUBLESHOOTING ERROR CODE [15SAL1]
BWW10520
20-308 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [15SALH]
BWW10520
WA430-5 20-309
(1)......
TROUBLESHOOTING ERROR CODE [15SBL1]
BWW10520
20-310 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [15SBLH]
BWW10520
WA430-5 20-311
(1)......
TROUBLESHOOTING ERROR CODE [15SEL1]
Between L62 Gear shift lever = 1st speed Voltage 1 V and below
(17) - body Other than above Voltage 20 - 30 V
20-312 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [15SELH]
Between L62 Gear shift lever = 1st speed Voltage 1 V and below
(17) - body Other than above Voltage 20 - 30 V
WA430-5 20-313
(1)......
TROUBLESHOOTING ERROR CODE [15SFL1]
Between L62 Gear shift lever = 2nd speed Voltage 1 V and below
(7) - body Other than above Voltage 20 - 30 V
20-314 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [15SFLH]
Between L62 Gear shift lever = 2nd speed Voltage 1 V and below
(7) - body Other than above Voltage 20 - 30 V
WA430-5 20-315
(1)......
TROUBLESHOOTING ERROR CODE [15SGL1]
Between L62 Gear shift lever = 3rd speed Voltage 1 V and below
(13) - body Other than above Voltage 20 - 30 V
20-316 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [15SGLH]
WA430-5 20-317
(1)......
TROUBLESHOOTING ERROR CODE [15SHL1]
Between L62 Gear shift lever = 4th speed Voltage 1 V and below
(3) - body Other than above Voltage 20 - 30 V
20-318 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [15SHLH]
WA430-5 20-319
(1)......
TROUBLESHOOTING ERROR CODE [15SJL1]
20-320 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [15SJLH]
WA430-5 20-321
(1)......
TROUBLESHOOTING ERROR CODE [989F00]
20-322 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [B@C7NS]
WA430-5 20-323
(1)......
TROUBLESHOOTING ERROR CODE [D150KA]
BWW10522
20-324 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [D150KB]
BWW10522
WA430-5 20-325
(1)......
TROUBLESHOOTING ERROR CODE [D160KA]
BWW10523
20-326 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [D160KB]
BWW10523
WA430-5 20-327
(1)......
TROUBLESHOOTING ERROR CODE [D191KA]
20-328 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [D191KA]
WA430-5 20-329
(1)......
TROUBLESHOOTING ERROR CODE [D191KB]
20-330 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [D191KB]
WA430-5 20-331
(1)......
TROUBLESHOOTING ERROR CODE [D192KA]
20-332 WA430-5
(1)
(4)
TROUBLESHOOTING ERROR CODE [D192KB]
WA430-5 20-333
(1)......
(4)
TROUBLESHOOTING ERROR CODE [D198KB]
Description of • Ground fault in wiring harness or relay between the transmission controller and the low temperature bypass
Trouble relay
Controller Reac- • Triggers an alarm.
tion
Effect on Machine • Function to improve starting ability at low temperature (at -20 °C or lower) does not work.
Related Informa- • This function works when the kit (OP) for improving low temperature starting is installed.
tion
BWW10523
20-334 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [D198KY]
BWW10523
WA430-5 20-335
(1)......
TROUBLESHOOTING ERROR CODE [DAQ0KK]
BWW10525
20-336 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DAQ2KK]
BWW10525
WA430-5 20-337
(1)......
TROUBLESHOOTING ERROR CODE [DAQ9KQ]
20-338 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDK3KA]
Effect on Machine • Traveling is possible in steering wheel mode after the machine is stopped.
Related Informa- • Can be checked with the monitoring function (Code: 40907, D-IN-17, D-IN-18 or D-IN-19).
1 M Ω and
Between L62 (Female) (5)/L12 (Female) (4) - body Resistance
above
1) Turn starting switch OFF.
2) Disconnect connector L12.
3) Connect T-adapter.
Possible Causes Right FNR switch or multi
and Standard Val-
Between L12 (Male) function mono lever FNR Resistance 1 Ω and below
ues switch = F
(2) - (1)
Other than above Resistance 1 MΩ and above
Defective right FNR switch or
3 multi function mono lever Right FNR switch or multi
FNR switch Between L12 (Male) function mono lever FNR Resistance 1 Ω and below
(3) - (1) switch = N
Other than above Resistance 1 MΩ and above
Right FNR switch or multi
Between L12 (Male) function mono lever FNR Resistance 1 Ω and below
(4) - (1) switch = R
Other than above Resistance 1 MΩ and above
1) Turn starting switch OFF.
2) Disconnect connector L62.
3) Connect T-adapter.
4) Turn starting switch ON.
When right FNR switch mounted (Right FNR switch = On)
Right FNR switch or multi
Between L62 (25) and function mono lever FNR Voltage 20 - 30 V
body switch = F
Defective transmission and Other than above Voltage 1 V and below
4 fan pump motor controller
Right FNR switch or multi
Between L62 (15) and function mono lever FNR Voltage 20 - 30 V
body switch = N
Other than above Voltage 1 V and below
Right FNR switch or multi
Between L62 (5) and function mono lever FNR Voltage 20 - 30 V
body switch = R
Other than above Voltage 1 V and below
20-340 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDK3KA]
BWW10526
WA430-5 20-341
(1)......
TROUBLESHOOTING ERROR CODE [DDK3KB]
20-342 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDK3KB]
BWW10526
WA430-5 20-343
(1)......
TROUBLESHOOTING ERROR CODE [DDK4KA]
20-344 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDK4KA]
WA430-5 20-345
(1)......
TROUBLESHOOTING ERROR CODE [DDK4KB]
20-346 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDK4KB]
WA430-5 20-347
(1)......
TROUBLESHOOTING ERROR CODE [DDK5LD]
20-348 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDK6KA]
Wiring harness discontinuity Wiring harness between L62 (Female) (36) - L04 1 Ω and
Resistance
2 (Disconnection or defective (Female) (2) below
contact) Wiring harness between L62 (Female) (26) - L04 1 Ω and
Resistance
(Female) (3) below
Wiring harness between L62 (Female) (16) - L04 1 Ω and
(Female) (4) Resistance below
20-350 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDK6KA]
WA430-5 20-351
(1)......
TROUBLESHOOTING ERROR CODE [DDK6KB]
20-352 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDK6KB]
WA430-5 20-353
(1)......
TROUBLESHOOTING ERROR CODE [DDS5KA]
Wiring harness between R36 (Female) (A) - body Resistance 1 Ω and below
1) Turn starting switch OFF.
2) Disconnect connector L61.
3) Connect T-adapter.
4) Turn starting switch ON.
Defective transmis-
3 sion and fan pump Engine stopped Voltage 1 V and below
motor controller Between L61 (17) - body
Engine started Voltage 20 - 30 V
Engine stopped Voltage 20 - 30 V
Between L61 (23) - body
Engine started Voltage 1 V and below
20-354 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDS5KB]
WA430-5 20-355
(1)......
TROUBLESHOOTING ERROR CODE [DDT0L4]
2 Wiring harness
ground fault
Between connector L61 (Female) (14)/S22 (Female) (2) -
body Resistance 1 MΩ and above
Between connector L61 (Female) (8)/S22 (Female) (3) - body Resistance 1 MΩ and above
1) Turn starting switch OFF.
2) Disconnect connector S22.
3) Connect T-adapter.
Manual shift Resistance 1 MΩ and above
20-356 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDT0L4]
WA430-5 20-357
(1)......
TROUBLESHOOTING ERROR CODE [DDT4LD]
20-358 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDW9LD]
20-360 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDW9LD]
WA430-5 20-361
(1)......
TROUBLESHOOTING ERROR CODE [DDWLLD]
20-362 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDWLLD]
12
Related circuit diagram
For standard
WA430-5 20-363
(1)......
TROUBLESHOOTING ERROR CODE [DF10KA]
Wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors L63 and L04. 3) Connect T-adapter.
1 discontinuity
connection or
(Dis- Wiring harness between L63 (Female) (10) - L04 (Female) (5) Resistance 1 Ω and below
defective contact) Wiring harness between L63 (Female) (20) - L04 (Female) (6) Resistance 1 Ω and below
Wiring harness between L63 (Female) (30) - L04 (Female) (7) Resistance 1 Ω and below
Wiring harness between L63 (Female) (40) - L04 (Female) (8) Resistance 1 Ω and below
1) Turn starting switch OFF. 2) Disconnect connectors L63 and L04. 3) Connect T-adapter.
Between L63 (Female) (10)/L04 (Female) (5) - body Resistance 1 Ω and below
2 Wiring harness
ground fault
Between L63 (Female) (20)/L04 (Female) (6) - body Resistance 1 Ω and below
Between L63 (Female) (30)/L04 (Female) (7) - body Resistance 1 Ω and below
Between L63 (Female) (40)/L04 (Female) (8) - body Resistance 1 Ω and below
1) Turn starting switch OFF. 2) Disconnect connector L04. 3) Connect T-adapter. 4) Turn start-
ing switch ON.
20-364 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DF10KA]
BWW10528
WA430-5 20-365
(1)......
TROUBLESHOOTING ERROR CODE [DF10KB]
20-366 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DF10KB]
BWW10528
WA430-5 20-367
(1)......
TROUBLESHOOTING ERROR CODE [DGF1KX]
20-368 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DGR2KA]
WA430-5 20-369
(1)......
TROUBLESHOOTING ERROR CODE [DGR2KB]
20-370 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DHT1KX]
WA430-5 20-371
(1)......
TROUBLESHOOTING ERROR CODE [DLE2KA]
20-372 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DLE2LC]
WA430-5 20-373
(1)......
TROUBLESHOOTING ERROR CODE [DLT3KA]
20-374 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DT20KB]
WA430-5 20-375
(1)......
TROUBLESHOOTING ERROR CODE [DW7BKA]
BWW10533
20-376 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DW7BKB]
BWW10533
WA430-5 20-377
(1)......
TROUBLESHOOTING ERROR CODE [DW7CKA]
BWW10533
20-378 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DW7CKB]
WA430-5 20-379
(1)......
TROUBLESHOOTING ERROR CODE [DX16KA]
20-380 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DX16KB]
BWW10531
WA430-5 20-381
(1)......
TROUBLESHOOTING ERROR CODE [DXH1KA]
20-382 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DXH1KB]
WA430-5 20-383
(1)......
TROUBLESHOOTING ERROR CODE [DXH4KA]
20-384 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DXH4KB]
WA430-5 20-385
(1)......
TROUBLESHOOTING ERROR CODE [DXH5KA]
20-386 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DXH5KB]
WA430-5 20-387
(1)......
TROUBLESHOOTING ERROR CODE [DXH6KA]
20-388 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DXH6KB]
WA430-5 20-389
(1)......
TROUBLESHOOTING ERROR CODE [DXH7KA]
20-390 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DXH7KB]
WA430-5 20-391
(1)......
TROUBLESHOOTING ERROR CODE [DXH8KA]
20-392 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DXH8KB]
WA430-5 20-393
(1)......
TROUBLESHOOTING ERROR CODE [DXHHKA]
20-394 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DXHHKB]
WA430-5 20-395
(1)......
TROUBLESHOOTING ERROR CODE [DY30MA]
20-396 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DY30MA]
BWW10527
WA430-5 20-397
(1)......
TROUBLESHOOTING ERROR CODE [DY30MC]
20-398 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DY30MC]
BWW10527
WA430-5 20-399
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-1]
20-400 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-1]
WA430-5 20-401
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-2]
20-402 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-2]
WA430-5 20-403
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-3]
BWW10534
20-404 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-4]
20-406 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-4]
Troubleshooting Controller
code Error Code Code Trouble Neutralizer signal (parking brake switch signal) system failure
TM-4 — (TM)
Causes Standard Values in Normal State and Remarks on Troubleshooting
1) Turn starting switch OFF.
2) Disconnect connectors L62.
3) Connect T-adapter.
4) Turn starting switch ON.
When parking brake switch is
Possible Causes switched from OFF to ON (Not Voltage 1 V or below
and Standard Defective transmission released)
Values 7 and fan pump motor con- Parking brake switch = OFF
troller Voltage 1 V or below
Between L62 (6) - (Retained OFF) (Not released)
body When parking brake switch is
switched from ON to OFF Voltage 20 - 30 V
(Released)
Parking brake switch = ON
(Retained on) (Not released) Voltage 1 V or below
WA430-5 20-407
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-5]
Defective emergency 1) Turn starting switch OFF. 2) Disconnect connector L126. 3) Connect T-adapter.
2 steering relay (L126) Between L126 (Female) (3)/L126 (Female) (5) - body Resistance 1 MΩ or above
1) Turn starting switch OFF.
Defective emergency 2) Disconnect connectors R15, R16 and both power lines (100sq).
3 steering operation relay
Between relay contacts. Resistance 1 MΩ or above
1) Turn starting switch OFF.
Wiring harness disconti- 2) Disconnect connectors L63 and S19.
4 nuity (Disconnection or 3) Connect T-adapter.
defective contact) Wiring harness between L63 (Female) (29) - S19 Resistance 1 Ω or below
(Female) (1)
1) Turn starting switch OFF.
Hot short-circuiting 2) Disconnect connectors L63 and S19.
between harnesses 3) Connect T-adapter.
5 (Contacting 24-V har-
Possible Causes 4) Turn starting switch ON.
and Standard ness)
Values Between L63 (Female) ((29)/S19 (Female) (1) - body Voltage 1 V or below
1) Turn starting switch OFF.
Wiring harness ground 2) Disconnect connectors L63, L105, L126 and S19.
6 fault 3) Connect T-adapter.
Between L63 (Female) (29)/S19 (Female) (1) - body Resistance 1 MΩ or above
1) Turn starting switch OFF.
2) Disconnect connectors L63, L126 and S19.
3) Connect T-adapter.
4) Turn starting switch ON.
Between L63 (Female) (29)/L126 (Female) (1)/S19 Resistance 1 MΩ or above
Wiring harness short- (Female) (4) - body
7 circuiting
1) Turn starting switch OFF.
2) Disconnect connectors L126 and R15.
3) Connect T-adapter.
4) Turn starting switch ON.
Between L126 (5)/R15 - body Resistance 1 MΩ or above
1) Turn starting switch OFF.
2) Disconnect connector L63.
Defective transmission 3) Connect T-adapter.
8 and fan pump motor 4) Turn starting switch ON.
controller
Between L63 (29) - Emergency steering switch = ON Voltage 20 - 30 V
body Other than above Voltage 1 V or below
20-408 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-5]
BWW10527
WA430-5 20-409
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-6]
20-410 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-7]
WA430-5 20-411
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-8]
20-412 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE
TROUBLESHOOTING CODE [TM-9A]
[TM-9a]
WA430-5 20-413
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE
TROUBLESHOOTING CODE [TM-9B]
[TM-9b]
20-414 WA430-5
(1)
TROUBLESHOOTING CODE [TM-9B]
TROUBLESHOOTING CODE [TM-9b]
WA430-5 20-415
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-10]
Wiring harness disconti- Wiring harness between L62 (Female) 3% - S04 Resistance 1 Ω or below
2 nuity (Disconnection or (Female) (4)
defective contact) 1) Turn starting switch OFF. 2) Disconnect connectors L62 and S04.
3) Connect T-adapter. 4) Turn starting switch ON.
Possible Causes
and Standard Between S04 (Female) (3) - body Voltage 20 - 30 V
Values 1) Turn starting switch OFF. 2) Disconnect connectors L62 and S04.
Wiring harness hot
3 short-circuiting (Con- 3) Connect T-adapter. 4) Turn starting switch ON.
tacting 24-V harness) Between L62 (Female) 3%/S04 (Female) e - body Voltage 1 V or below
Wiring harness ground 1) Turn starting switch OFF. 2) Disconnect connectors L62, S04 and L101.
fault 3) Connect T-adapter.
4 ★ In this case, fuse A-2
blows out when the Between L62 (Female) (35)/S04 (Female) (4) - body Resistance 1 MΩ or above
switch is operated.
1) Turn starting switch OFF. 2) Disconnect connector L62.
3) Connect T-adapter. 4) Turn starting switch ON.
Defective transmission
5 and fan pump motor FNR switch mode change over
Voltage 20 - 30 V
controller Between L62 (35) - switch = ON
body
Other than above Voltage 1 V or below
20-416 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-11]
20-418 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-11]
WA430-5 20-419
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-12]
bww10166.eps
20-420 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-13]
20-422 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-13]
Troubleshoot-
ing code Error Code Controller Code
Trouble The engine power mode cannot be selected.
TM-13 — —
1) Turn starting switch OFF, 2) Disconnect connectors S21, L102 and L61, 3) Connect
T-adapter, 4) Turn starting switch ON
Wiring harness between S21 (Female) (4), L61 (Female) Voltage 1 V or below
(6), L102 (Female) (7) and body
Possible Causes Hot short-circuiting
and Standard 5 ★ In the power mode is selected in the above case, fuse B-(6) is broken.
Values between harnesses
Wiring harness between L88 (Female) (7), L102 Voltage 1 V or below
(Female) (8) and body
★ In the case, the economy mode and power mode are changed over to each other
while the power mode switch is not operated.
WA430-5 20-423
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-14]
bww10167.eps
20-424 WA430-5
(1)
(4)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-15]
Wiring harness disconti- Wiring harness between L61 (Female) (7) - S16 Resistance 1 Ω or below
2 nuity (Disconnection or (Female) (4)
defective contact) 1) Turn starting switch OFF.
2) Disconnect connectors L61 and S16.
3) Connect T-adapter.
Possible Causes Between S16 (Female) (3) and body Voltage 20 - 30 V
and Standard
Values Wiring harness hot 1) Turn starting switch OFF.
short-circuiting (Con- 2) Disconnect connectors L61 and S16.
tacting 24-V harness) 3) Connect T-adapter.
3 * In this case, fuse A-2 4) Turn starting switch ON.
blows out when the
switch is operated. Between L61 (Female) (7)/S16 (Female) (4) - body Voltage 1 V or below
WA430-5 20-425
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-16]
20-426 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-17]
Wiring harness hot Between L63 (Female) (17)/L104 (Female) (11) - body Voltage 1 V or below
1 short-circuiting
Possible Causes 1) Turn starting switch OFF.
and Standard 2) Disconnect connectors F13 and L125.
Values 3) Connect T-adapter.
4) Turn starting switch ON.
Between F13 (female) (1)/L125 (female) (5) - body Voltage Max. 1 V
1) Turn starting switch OFF.
Defective transmission 2) Disconnect connector L63.
2 and fan pump motor 3) Connect T-adapter.
controller
Between L63 (Female) (17) - body Resistance 200 - 400 Ω
BWW10538
WA430-5 20-427
(1)......
(4)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-18]
20-428 WA430-5
(1)
(4)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-19]
WA430-5 20-429
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-20]
20-430 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-21]
WA430-5 20-431
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-22]
20-432 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-23]
WA430-5 20-433
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-24]
20-434 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-25]
WA430-5 20-435
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-26]
20-436 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-27]
WA430-5 20-437
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-28]
20-438 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-29]
BWW10533
WA430-5 20-439
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [TM-30]
20-440 WA430-5
(1)
TROUBLESHOOTING OF WORK EQUIPMENT
CONTROL SYSTEM
(WRK MODE)
WA430-5 20-501
(1)......
TROUBLESHOOTING
20-502 WA430-5
(1)
TROUBLESHOOTING
Troubleshooting Code [WRK-13] Hot short-circuited lift arm RAISE magnet detent output system
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-586
Troubleshooting Code [WRK-14] Hot short-circuited lift arm FLOATING magnet detent output
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-587
Troubleshooting Code [WRK-15] Hot short-circuited bucket TILT magnet detent output system . 20-588
Troubleshooting Code [WRK-16] Hot short-circuited work equipment neutral lock solenoid output
system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-589
Troubleshooting Code [WRK-17] Hot short-circuited lift arm RAISE EPC solenoid system . . . . . . . 20-590
Troubleshooting Code [WRK-18] Hot short-circuited lift arm LOWER EPC solenoid system . . . . . 20-591
Troubleshooting Code [WRK-19] Hot short-circuited bucket TILT EPC solenoid system . . . . . . . . . 20-592
Troubleshooting Code [WRK-20] Hot short-circuited bucket DUMP EPC solenoid system . . . . . . . 20-593
Troubleshooting Code [WRK-21] Hot short-circuited 3 valves extension EPC solenoid system . . . 20-594
Troubleshooting Code [WRK-22] Hot short-circuited 3 valves retraction EPC solenoid system . . . 20-595
Troubleshooting Code [WRK-23] Hot short-circuited joystick steering right EPC solenoid system 20-596
Troubleshooting Code [WRK-24] Hot short-circuited joystick steering left EPC solenoid system. . 20-597
Troubleshooting Code [WRK-25] Defective bucket positioner, lift arm kick-out and FLOATING
holding function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-598
Troubleshooting Code [WRK-26] Defective lift arm kick-out function and cancellation. . . . . . . . . . 20-600
Troubleshooting Code [WRK-27] Defective bucket leveler function and cancellation . . . . . . . . . . . 20-602
Troubleshooting Code [WRK-28] Defective lift arm FLOATING holding and cancellation . . . . . . . . 20-604
WA430-5 20-503
(1)......
TROUBLESHOOTING WORK EQUIPMENT CONTROL SYSTEM DIAGRAM
20-504 WA430-5
(1)
TROUBLESHOOTING WORK EQUIPMENT CONTROL SYSTEM DIAGRAM
WA430-5 20-505
(1)......
TROUBLESHOOTING WORK EQUIPMENT CONTROL SYSTEM DIAGRAM
20-506 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [D193KA]
WA430-5 20-507
(1)......
TROUBLESHOOTING ERROR CODE [D193KB]
20-508 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DB90KK]
WA430-5 20-509
(1)......
TROUBLESHOOTING ERROR CODE [DB92KK]
20-510 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DB95KX]
20-512 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DB95KX]
BWW10245
WA430-5 20-513
(1)......
TROUBLESHOOTING ERROR CODE [DD1ALD]
20-514 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DD1BLD]
WA430-5 20-515
(1)......
TROUBLESHOOTING ERROR CODE [DFAOKM]
20-516 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DK59KA]
WA430-5 20-517
(1)......
TROUBLESHOOTING ERROR CODE [DK59KY]
20-518 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DK59L8]
WA430-5 20-519
(1)......
TROUBLESHOOTING ERROR CODE [DK5AKA]
20-520 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DK5AKY]
WA430-5 20-521
(1)......
TROUBLESHOOTING ERROR CODE [DK5BKA]
20-522 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DK5BKY]
WA430-5 20-523
(1)......
TROUBLESHOOTING ERROR CODE [DK5BL8]
20-524 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DK5CKA]
WA430-5 20-525
(1)......
TROUBLESHOOTING ERROR CODE [DK5CKY]
20-526 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DK5DKA]
WA430-5 20-527
(1)......
TROUBLESHOOTING ERROR CODE [DK5DKY]
20-528 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DK5DL8]
L71 (14) - Lever = Full stroke at the exten- Voltage 3.4 - 4.0 V
sion side
(21)
Lever = Full stroke at the shrink-
age side Voltage 1.1 - 1.5 V
WA430-5 20-529
(1)......
TROUBLESHOOTING ERROR CODE [DK5EKA]
20-530 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DK5EKY]
WA430-5 20-531
(1)......
TROUBLESHOOTING ERROR CODE [DK5FKA]
20-532 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DK5FKY]
WA430-5 20-533
(1)......
TROUBLESHOOTING ERROR CODE [DK5FKM]
20-534 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DK5FL8]
Possible Causes 1) Turn starting switch ON. 2) Disconnect connectors L71 and L34.
and Standard Val- 3) Connect T-adapter.
ues Wiring harness disconti- Between wiring harnesses between L71
2 nuity (Disconnection or (Female) (9), L (Female) (3) Resistance 1 Ω and below
defective contact)
Between wiring harnesses between L71
(Female) (3) - L (Female) (2) Resistance 1 Ω and below
WA430-5 20-535
(1)......
TROUBLESHOOTING ERROR CODE [DK5GKA]
20-536 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DK5GKY]
WA430-5 20-537
(1)......
TROUBLESHOOTING ERROR CODE [DKAOKA]
20-538 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DKAOKY]
Wiring harness discontinuity (Dis- 1) Turn starting switch OFF. 2) Disconnect connectors L71 and F18. 3) Connect T-adapter.
2 connection or defective contact) Wiring harness between F18 (Female) (A) - body Resistance 1 Ω and below
1) Turn starting switch OFF.
2) Disconnect connector F18.
3) Connect T-adapter.
4) Turn starting switch ON.
Between F18 (C) - (A) Voltage 4.75 - 5.25 V
Possible Causes and
Standard Values 3 Defective lift arm angle sensor At the time of boom RAISE
stroke end Voltage 3.5 - 4.0 V
Between F18 (B) - (A)
At the time of boom LOWER
Voltage 1.0 - 2.0 V
stroke end
1) Turn starting switch OFF. 2) Disconnect connector F18. 3) Connect T-adapter.
Between F18 (C) - (A) Resistance 4 - 6 kΩ
1) Turn starting switch OFF. 2) Disconnect connector L71.
3) Connect T-adapter. 4) Turn starting switch ON.
Between L71 (22) - body The whole gamut Voltage 4.75 - 5.25 V
Defective work equipment con-
4
troller At the time of the boom maxi- Voltage 3.5 - 4.0 V
mum raising
Between L71 (8) - body
At the time of the boom maxi- Voltage
1.0 - 2.0 V
mum lowering
WA430-5 20-539
(1)......
TROUBLESHOOTING ERROR CODE [DLE2LC]
20-540 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DLT3LC]
WA430-5 20-541
(1)......
TROUBLESHOOTING ERROR CODE [DUM1KB]
20-542 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DUM2KB]
WA430-5 20-543
(1)......
TROUBLESHOOTING ERROR CODE [DW4PKA]
20-544 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DW4PKB]
WA430-5 20-545
(1)......
TROUBLESHOOTING ERROR CODE [DW4QKA]
20-546 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DW4QKB]
WA430-5 20-547
(1)......
TROUBLESHOOTING ERROR CODE [DW4RKA]
20-548 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DW4RKB]
WA430-5 20-549
(1)......
TROUBLESHOOTING ERROR CODE [DW4SKA]
20-550 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DW4SKB]
WA430-5 20-551
(1)......
TROUBLESHOOTING ERROR CODE [DWM1KA]
20-552 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DWM1KB]
Possible Causes Between F26 (Male) (1) - body Resistance 1 MΩ and above
and Standard 1) Turn starting switch OFF.
Values Wiring harness 2) Disconnect connectors L73 and F26.
ground fault or 3) Connect T-adapter.
2 defective short cir-
cuit Wiring harness between L73 (Female) (28),F26 (Female) (1) Resistance 1 MΩ and above
- body
1) Turn starting switch OFF.
Defective work 2) Disconnect connector L73.
3 equipment control- 3) Connect T-adapter.
ler
Between L73 (Female) (28) - body Resistance 1 MΩ and above
WA430-5 20-553
(1)......
TROUBLESHOOTING ERROR CODE [DWN6KA]
20-554 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DWN6KB]
WA430-5 20-555
(1)......
TROUBLESHOOTING ERROR CODE [DWN7KA]
20-556 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DWN7KB]
WA430-5 20-557
(1)......
TROUBLESHOOTING ERROR CODE [DWN8KA]
20-558 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DWN8KB]
WA430-5 20-559
(1)......
TROUBLESHOOTING ERROR CODE [DXHJKA]
20-560 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DXHJKB]
WA430-5 20-561
(1)......
TROUBLESHOOTING ERROR CODE [DXHKKA]
20-562 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DXHKKB]
WA430-5 20-563
(1)......
TROUBLESHOOTING ERROR CODE [DXHLKA]
Action Code Error Code Controller Code Joystick steering right-hand EPC
Trouble solenoid system disconnection
E03 DXHLKA WRK
• Joystick steering right-hand EPC solenoid system disconnection prevents output to the joystick steering
Description of Trouble
right-hand EPC solenoid.
Controller Reaction • Stops output to the joystick steering right-hand EPC solenoid (Both sides).
• Stops output to the joystick steering right-hand EPC solenoid (Both sides).
Effect on Machine • Stops output to the joystick solenoid cutoff relay.
Related Information —
20-564 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DXHLKB]
Action Code Error Code Controller Code Joystick steering right-hand EPC
Trouble solenoid system ground fault
E03 DXHLKB WRK
• Joystick steering right-hand EPC solenoid system ground fault prevents output to the joystick steering
Description of Trouble
right-hand EPC solenoid.
• Stops output to the joystick steering right-hand EPC solenoid (Both sides).
Controller Reaction
• Stops output to the joystick solenoid cutoff relay.
Effect on Machine • Cannot operate the steering with the joystick steering lever.
Related Information —
WA430-5 20-565
(1)......
TROUBLESHOOTING ERROR CODE [DXHMKA]
Action Code Error Code Controller Code Joystick steering left-hand EPC
Trouble solenoid system disconnection
E03 DXHMKA WRK
• Joystick steering left-hand EPC solenoid system disconnection prevents output to the joystick steering
Description of Trouble
left-hand EPC solenoid.
Controller Reaction • Stops output to the joystick steering left-hand EPC solenoid (Both sides).
• Stops output to the joystick steering left-hand EPC solenoid (Both sides).
Effect on Machine • Stops output to the joystick solenoid cutoff relay.
Related Information —
20-566 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DXHMKB]
Action Code Error Code Controller Code Joystick steering left-hand EPC
Trouble solenoid system ground fault
E03 DXHMKB WRK
• Joystick steering left-hand EPC solenoid system ground fault prevents output to the joystick steering left-
Description of Trouble
hand EPC solenoid.
Controller Reaction • Stops output to the joystick steering left-hand EPC solenoid (Both sides).
• Stops output to the joystick steering left-hand EPC solenoid (Both sides).
Effect on Machine • Stops output to the joystick solenoid cutoff relay.
Related Information —
WA430-5 20-567
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-1]
Troubleshooting Code Error Code Controller Code Defective lift arm lock switch sys-
Trouble tem
WRK-1 — (WRK)
• The work equipment (Lift arm and bucket) does not operate due to incorrectly disconnected, short-cir-
Description of Trouble
cuited or grounded lift arm lock (Work equipment lock lever) switch system or cannot be locked.
Controller Reaction • No reaction.
Effect on Machine • The work equipment (Lift arm and bucket) does not operate or cannot be locked.
Related Information • Can be checked with the monitoring function (Code: 40917_D_IN_1).
20-568 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-2]
WA430-5 20-569
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-3]
20-570 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-3]
WA430-5 20-571
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-4]
Wiring harness between FS3 (Female) (11) - S12 Resistance 1 Ω and below
(Female) (5)
1) Turn starting switch OFF.
Possible Causes
and Standard 2) Disconnect connectors L72, S13, and S12.
Values Wiring harness ground 3) Connect T-adapter.
3 4) Turn starting switch ON.
fault
Between L72 (Female) (2), S13 (Female) (4), S12 1 MΩ and
Resistance
(Female) (6) - body above
1) Turn starting switch OFF.
2) Disconnect connectors L72, S13, and S12.
Hot-shorted wiring har- 3) Connect T-adapter.
4 4) Turn starting switch ON.
ness
Between L72 (Female) (2), S13 (Female) (4), S12 Voltage 1 V and below
(Female) (6) - body
1) Turn starting switch OFF.
2) Disconnect connector L72.
3) Insert T-adapter.
5 Defective work equip- 4) Turn starting switch ON.
ment controller
Between L72 Remote positioner ON/OFF switch = ON Voltage 1 V and below
(Female) (2) -
body Remote positioner ON/OFF switch = OFF Voltage 20 - 30 V
20-572 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-4]
WA430-5 20-573
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-5]
20-574 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-5]
WA430-5 20-575
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-6]
Troubleshooting Code Error Code Controller Code Defective bucket cylinder proxim-
Trouble ity switch system
WRK-6 — (WRK)
• The bucket leveler does not function due to incorrectly disconnected, grounded or short-circuited bucket
Description of Trouble
cylinder proximity switch system.
Controller Reaction • No reaction.
Effect on Machine • The bucket leveler does not function.
Related Information • Can be checked with the monitoring function (Code: 40911_D-IN-9).
Wiring harness between F09 (Female) (C) - body Resistance 1 Ω and below
1) Turn starting switch OFF.
2) Disconnect connectors L73, F09, and L104.
3) Connect T-adapter.
Wiring harness ground Between L73 (Female) (20), F09 (Female) (B), L104 (7) - 1 MΩ and
2 Resistance
fault body above
FS4 (Female) (5), F09 (Female) (A) - body
Resistance 1 MΩ and
★ Fuse A-(5) blows in this case above
Possible Causes 1) Turn starting switch OFF.
and Standard
Values 2) Disconnect connectors L73, F09, and L104.
Hot-shorted wiring har- 3) Connect T-adapter.
3 ness 4) Turn starting switch ON.
Between L73 (Female) (20), F09 (Female) (B), L104 (7) - Voltage 1 V and below
body
1) Turn starting switch OFF.
2) Disconnect connector F09.
3) Insert T-adapter.
4 Defective bucket cylinder 4) Turn starting switch ON.
proximity switch
Between F09 Bucket under level Voltage 1 V and below
(B) - (C) Bucket above level Voltage 20 - 30 V
1) Turn starting switch OFF.
2) Disconnect connector L72.
3) Insert T-adapter.
Defective work equip-
5 4) Turn starting switch ON.
ment controller
Between L72 Bucket under level Voltage 1 V and below
(20) - body Bucket above level Voltage 20 - 30 V
20-576 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-6]
WA430-5 20-577
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-7]
Troubleshooting Code Error Code Controller Code Defective bucket cylinder full
Trouble stroke detection switch system
WRK-7 — (WRK)
• The semi-automatic digging mode is not available or cannot be cancelled due to incorrectly disconnected,
Description of Trouble
grounded or short-circuited bucket cylinder full stroke detection switch system.
Controller Reaction • No reaction.
Effect on Machine • Semi-automatic general operation mode is not available or cannot be cancelled.
Related Information • Can be checked with the monitoring function (Code: 40911_D-IN-10).
Wiring harness between F19 (Female) (C) - body Resistance 1 Ω and below
1) Turn starting switch OFF.
2) Disconnect connectors L73 and F19.
3) Connect T-adapter.
Wiring harness ground 1 MΩ and
2 Between L73 (Female) (30), F19 (Female) (B) - body Resistance
fault above
FS4 (Female) (5), F19 (Female) (A) - body
Resistance 1 MΩ and
★ Fuse A-(5) blows in this case above
Possible Causes
and Standard 1) Turn starting switch OFF.
Values 2) Disconnect connectors L73 and F19.
Hot-shorted wiring har- 3) Connect T-adapter.
3 ness 4) Turn starting switch ON.
Between L73 (Female) (30), F19 (Female) (B) - body Voltage 1 V and below
1) Turn starting switch OFF.
2) Disconnect connector F19.
Defective bucket cylinder 3) Insert T-adapter.
4 full stroke detection 4) Turn starting switch ON.
switch
Between F19 Other than tilt stroke end Voltage 1 V and below
(B) - (C) Tilt stroke end Voltage 20 - 30 V
1) Turn starting switch OFF.
2) Disconnect connector L72.
3) Insert T-adapter.
Defective work equip-
5 4) Turn starting switch ON.
ment controller
Between L72 Other than tilt stroke end Voltage 1 V and below
(30) - body Tilt stroke end Voltage 20 - 30 V
20-578 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-8]
WA430-5 20-579
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-9]
20-580 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-10]
Troubleshooting Code Error Code Controller Code Defective joystick ON/OFF switch
Trouble system
WRK-10 — (WRK)
Description of Trouble • The joystick mode cannot be used or be cancelled due to defective joystick ON/OFF switch system.
Controller Reaction • No reaction.
Effect on Machine • The joystick mode cannot be used or cancelled.
Related Information • Can be checked with the monitoring function (Code: 40910_D-IN-0).
20-582 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-10]
WA430-5 20-583
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-11]
Troubleshooting Code Error Code Controller Code Defective joystick steering speed
Trouble HI/LO switch system
WRK-11 — (WRK)
• The joystick steering speed slows or accelerates (Cannot be switched between HI/LO) due to defective joy-
Description of Trouble
stick steering speed HI/LO switch system.
Controller Reaction • No reaction.
Effect on Machine • The joystick steering speed slows or accelerates (Cannot be switched between HI/LO).
Related Information • Can be checked with the monitoring function (Code: 40910_D-IN-8).
20-584 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-12]
Troubleshooting Code Error Code Controller Code Defective joystick solenoid cut
Trouble relay output system
WRK-12 — (WRK)
Description of Trouble • The joystick mode cannot be used or be cancelled due to defective joystick ON/OFF switch system.
Controller Reaction • No reaction.
Effect on Machine • The joystick steering solenoid cannot be turned OFF.
Related Information —
WA430-5 20-585
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-13]
Troubleshooting Code Error Code Controller Code Hot short-circuited lift arm RAISE
Trouble magnet detent output system
WRK-13 — (WRK)
Description of Trouble • RAISE detent cannot be cancelled due to hot short-circuited lift arm RAISE magnet detent output system.
Controller Reaction • No reaction.
• RAISE detent left turned ON.
Effect on Machine
• Normal operation is possible excluding automatic cancel of detent.
Related Information —
20-586 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-14]
Troubleshooting Code Error Code Controller Code Hot short-circuited lift arm
Trouble FLOATING magnet detent output
WRK-14 — (WRK) system
• FLOATING detent cannot be cancelled due to short-circuited lift arm FLOATING magnet detent output sys-
Description of Trouble tem.
Controller Reaction • No reaction.
• RAISE detent left turned ON.
Effect on Machine
• Normal operation is possible excluding automatic cancel of detent.
Related Information —
WA430-5 20-587
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-15]
Troubleshooting Code Error Code Controller Code Hot short-circuited bucket TILT
Trouble magnet detent output system
WRK-15 — (WRK)
Description of Trouble • TILT detent cannot be cancelled due to hot short-circuited bucket TILT magnet detent output system.
Controller Reaction • No reaction.
• TILT detent left turned ON.
Effect on Machine
• Normal operation is possible excluding automatic cancel of detent.
Related Information —
20-588 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-16]
Troubleshooting Code Error Code Controller Code Hot short-circuited work equip-
Trouble ment neutral lock solenoid output
WRK-16 — (WRK) system
• Neutral lock solenoid cannot be turned OFF due to hot short-circuited work equipment neutral lock sole-
Description of Trouble noid output system.
Controller Reaction • No reaction.
Effect on Machine • Working equipment locked even when the lock lever is free.
Related Information —
WA430-5 20-589
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-17]
Troubleshooting Code Error Code Controller Code Hot short-circuited lift arm RAISE
Trouble EPC solenoid system
WRK-17 — (WRK)
Description of Trouble • Lift arm RAISE EPC solenoid gets turned on due to hot short-circuited lift arm RAISE EPC solenoid system.
Controller Reaction • No reaction.
Effect on Machine • Lift arm raises in full speed.
Related Information —
20-590 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-18]
Troubleshooting Code Error Code Controller Code Hot short-circuited lift arm
Trouble LOWER EPC solenoid system
WRK-18 — (WRK)
• Lift arm LOWER EPC solenoid gets turned on due to hot short-circuited lift arm LOWER EPC solenoid sys-
Description of Trouble
tem.
Controller Reaction • No reaction.
Effect on Machine • Lift arm lowers in full speed.
Related Information —
WA430-5 20-591
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-19]
Troubleshooting Code Error Code Controller Code Hot short-circuited bucket TILT
Trouble EPC solenoid system
WRK-19 — (WRK)
Description of Trouble • Bucket TILT EPC solenoid gets turned on due to hot short-circuited bucket TILTEPC solenoid system.
Controller Reaction • No reaction.
Effect on Machine • Lift arm tilts in full speed.
Related Information —
20-592 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-20]
Troubleshooting Code Error Code Controller Code Hot short-circuited bucket DUMP
Trouble EPC solenoid system
WRK-20 — (WRK)
Description of Trouble • Bucket DUMP EPC solenoid gets turned on due to hot short-circuited bucket DUMP EPC solenoid system.
Controller Reaction • No reaction.
Effect on Machine • Bucket dumps in full speed.
Related Information —
WA430-5 20-593
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-21]
20-594 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-22]
WA430-5 20-595
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-23]
Troubleshooting Code Error Code Controller Code Hot short-circuited joystick steer-
Trouble ing right EPC solenoid system
WRK-23 — (WRK)
• The joystick steering right EPC solenoid gets turned on due to hot short-circuited joystick steering speed
Description of Trouble
right EPC solenoid system.
Controller Reaction • No reaction.
Effect on Machine • Steering all the way to the right is possible.
Related Information —
20-596 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-24]
Troubleshooting Code Error Code Controller Code Hot short-circuited joystick steer-
Trouble ing left EPC solenoid system
WRK-24 — (WRK)
• The joystick steering left EPC solenoid gets turned on due to hot short-circuited joystick steering speed left
Description of Trouble
EPC solenoid system.
Controller Reaction • No reaction.
Effect on Machine • Steering all the way to the left is possible.
Related Information —
WA430-5 20-597
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-25]
Troubleshooting Code Error Code Controller Code Defective bucket positioner, lift
Trouble arm kick-out and FLOATING hold-
WRK-25 — — ing function
• Bucket positioner, lift arm kick-out and lift arm FLOATING holding functions do not function due to proxim-
Description of Trouble ity switch and PPC detent circuit power supply system ground fault.
Controller Reaction • No reaction.
Effect on Machine • Bucket positioner, lift arm kick-out and FLOATING holding do not function.
Related Information —
20-598 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-25]
WA430-5 20-599
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-26]
Defective lift arm PPC 1) Turn starting switch OFF. 2) Disconnect connector L26S. 3) Connect T-adapter.
2
detent Between L26S (Male) (1) - (2) Resistance 30 - 50 Ω
1) Turn starting switch OFF. 2) Disconnect connectors L123. 3) Replace boom
positioner proximity switch (F10) with bucket leveler proximity switch (F9).
Defective lift arm posi- 4) Boom kick-out operation.
3
tioner proximity switch Boom kick-out functions
Boom kick-out proximity switch (F10) is abnormal
Boom kick-out does not function Boom kick-out proximity switch (F10) is normal
1) Turn starting switch OFF. 2) Disconnect connectors FS4, L104, L26S, and F10.
3) Connect T-adapter.
Wiring harness between FS4 (Female) (5) - F10 (Female)
(A) Resistance 1 Ω and below
Wiring harness between L104 (Female) (2) - F10 (Female)
Resistance 1 Ω and below
Wiring harness disconti- (B)
4 nuity
Wiring harness between F10 (Female) (C) - body Resistance 1 Ω and below
Wiring harness between L104 (Female) (5) - L26S (Female)
Possible Causes (1) Resistance 1 Ω and below
and Standard
Values Wiring harness between L26S (Female) (2) - body Resistance 1 Ω and below
★ Boom kick-out does not function in all items
1) Turn starting switch OFF. 2) Disconnect connectors L104, F10, and FS4.
3) Connect T-adapter.
Between L104 (Female) (2), F10 (Female) (B) - body
Resistance 1 MΩ and
★ Boom kick-out detent function is not effective in this above
case (Lever returns to neutral)
5 Wiring
harness ground Between L104 (Female) (5), L26S (Female) (1) and body
fault 1 MΩ and
★ Fuse A-2 blows and all detents will not function (Lever Resistance above
returns to neutral)
Between FS4 (Female) (5), F10 (Female) (A) - body
1 MΩ and
★ Fuse A-2 blows and all detents will not function (Lever Resistance above
returns to neutral)
1) Turn starting switch OFF. 2) Disconnect connectors L104 and F10. 3) Connect
T-adapter. 4) Turn starting switch ON.
Between L104 (Female) (2), F10 (Female) (B) - body
Voltage 1 V and below
★ Fuse of hot-shorted circuit blows in this case
6 Hot-shorted wiring har- 1) Turn starting switch OFF. 2) Disconnect connectors L104 and L26S. 3) Con-
ness
nect T-adapter. 4) Turn starting switch ON.
Between L104 (Female) (5), L26S (Female) (1) - body
★ Boom kick-out does not function in this case (Lever Voltage 1 V and below
does not return to neutral).
20-600 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-26]
WA430-5 20-601
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-27]
Defective bucket PPC 1) Turn starting switch OFF. 2) Disconnect connector L25S. 3) Connect T-adapter.
2
detent Between L25S (Male) (1) - (2) Resistance 30 - 50 Ω
1) Turn starting switch OFF. 2) Disconnect connectors L124. 3) Replace bucket
leveler proximity switch (F9) with boom kick-out proximity switch (F09).
Defective bucket leveler 4) Bucket leveler operation.
3 positioner proximity
switch Bucket leveler functions Bucket leveler proximity switch (F09) is abnormal
Bucket leveler does not function Bucket leveler proximity switch (F09) is normal
1) Turn starting switch OFF. 2) Disconnect connectors FS4, L104, L25S, and F9.
3) Connect T-adapter.
Wiring harness between FS4 (Female) (9) - F09 (Female)
(A) Resistance 1 Ω and below
Wiring harness between L104 (Female) (7) - F09 (Female)
Wiring harness disconti- (B) Resistance 1 Ω and below
4 nuity (Disconnection
and defective contact) Wiring harness between F09 (Female) (C) - body Resistance 1 Ω and below
Wiring harness between L104 (Female) (9) - L25S (Female)
Possible Causes (1) Resistance 1 Ω and below
and Standard
Values Wiring harness between L25S (Female) (2) - body Resistance 1 Ω and below
★ Bucket positioner does not function in all items
1) Turn starting switch OFF. 2) Disconnect connectors L104, F09, and FS4.
3) Connect T-adapter.
Between L104 (Female) (7), F09 (Female) (B) - body
1 MΩ and
★ Bucket leveler does not function in this case (Lever Resistance
above
returns to neutral)
5 Wiring
harness ground Between L104 (Female) (9), L25S (Female) (1) and body
fault 1 MΩ and
★ Fuse A-2 blows and all detents will not function (Lever Resistance above
returns to neutral)
Between FS4 (Female) (5), F09 (Female) (A) - body
1 MΩ and
★ Fuse A-2 blows and all detents will not function (Lever Resistance above
returns to neutral)
1) Turn starting switch OFF. 2) Disconnect connectors L104 and F09. 3) Connect
T-adapter. 4) Turn starting switch ON.
Between L104 (Female) (7), F09 (Female) (B) - body
Voltage 1 V and below
★ Fuse of hot-shorted circuit blows in this case
6 Hot-shorted wiring har- 1) Turn starting switch OFF. 2) Disconnect connectors L104 and L25S. 3) Con-
ness
nect T-adapter. 4) Turn starting switch ON.
Between L104 (Female) (9), L25S (Female) (1) - body
★ Bucket leveler does not function in this case (Lever Voltage 1 V and below
does not return to neutral).
20-602 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-27]
WA430-5 20-603
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-28]
Troubleshooting Code Error Code Controller Code Defective lift arm FLOATING hold-
Trouble ing and cancellation
WRK-28 — —
• Lift arm FLOATING holding does not function or cannot be cancelled due to defective lift arm FLOATING
Description of Trouble
PPC detent system.
Controller Reaction • No reaction.
Effect on Machine • Lift arm FLOATING holding does not function or cannot be cancelled.
Related Information —
Wiring harness between L27S (Female) (2) and body Resistance 1 Ω and below
20-604 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [WRK-28]
WA430-5 20-605
(1)......
TROUBLESHOOTING OF MONITOR SYSTEM
(MON MODE)
WA430-5 20-701
(1)......
(4)
TROUBLESHOOTING
Troubleshooting Code [MON-1] The parking brake indicator lamp does not light up
when the parking brake switch is turned ON (The parking brake
indicator switch circuit suffers a ground fault). . . . . . . . . . . . . . . 20-762
Troubleshooting Code [MON-2] The brake oil pressure caution lamp does not light up
when the emergency brake is applied (Front circuit) . . . . . . . . . 20-764
Troubleshooting Code [MON-3] The brake oil pressure caution lamp does not light up
when the emergency brake is applied (Rear circuit) . . . . . . . . . . 20-765
Troubleshooting Code [MON-4] The air cleaner clogging indicator lamp does not light ON . . . . 20-766
Troubleshooting Code [MON-5] The engine hydraulic caution lamp does not light ON . . . . . . . . 20-768
Troubleshooting Code [MON-6] The engine oil level caution lamp does not light ON . . . . . . . . . 20-769
Troubleshooting Code [MON-7] The engine water temperature caution lamp does not light ON 20-770
Troubleshooting Code [MON-8] The radiator water volume caution lamp does not light ON . . . 20-771
Troubleshooting Code [MON-9] The hydraulic oil temperature caution lamp does not light ON . 20-772
Troubleshooting Code [MON-10] The torque converter oil temperature caution lamp does not
light ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-773
Troubleshooting Code [MON-11] The steering hydraulic caution lamp does not light ON . . . . . . . 20-774
Troubleshooting Code [MON-12] Input fault in monitor panel mode switch 1 [■] (Panel SW1) . . . 20-775
Troubleshooting Code [MON-13] Input fault in monitor panel mode switch 1 [◊] (Panel SW2). . . . 20-776
Troubleshooting Code [MON-14] Input fault in monitor panel mode switch 2 [<] (Panel SW3) . . . 20-777
Troubleshooting Code [MON-15] Input fault in monitor panel mode switch 2 [>] (Panel SW4) . . . 20-778
Troubleshooting Code [MON-16] Defective subtotal switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-779
Troubleshooting Code [MON-17] Defective cancel switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-780
Troubleshooting Code [MON-18] Defective bottom pressure sensor (Hot short fault). . . . . . . . . . . 20-781
Troubleshooting Code [MON-19] Defective head sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-782
Troubleshooting Code [MON-20] The alarm buzzer does not sound or stop (disconnection or
short circuit with chassis ground in buzzer output system) . . . . 20-783
★ Referring to TESTING AND ADJUSTING, Adjusting machine monitor, check that the rotary switches
(SW1, SW2, and SW3) and DIP switches (SW5 and SW6) on the back side of the monitor panel are set
correctly.
*: Applied to the load meter specification
20-702 WA430-5
(1)
(4)
TROUBLESHOOTING MONITOR SYSTEM DIAGRAM
20-704 WA430-5
(1)
TROUBLESHOOTING MONITOR SYSTEM DIAGRAM
WA430-5 20-705
(1)......
TROUBLESHOOTING MONITOR SYSTEM DIAGRAM
20-706 WA430-5
(1)
TROUBLESHOOTING MONITOR SYSTEM DIAGRAM
WA430-5 20-707
(1)......
TROUBLESHOOTING ERROR CODE [2F00MA]
20-708 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [2F00MA]
WA430-5 20-709
(1)......
TROUBLESHOOTING ERROR CODE [2G42ZG]
20-710 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [2G43ZG]
WA430-5 20-711
(1)......
TROUBLESHOOTING ERROR CODE [AA1ANX]
20-712 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [AA1ANX]
WA430-5 20-713
(1)......
TROUBLESHOOTING ERROR CODE [AB00L6]
20-714 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [AB00MA]
Between alternator R Engine start (Throttle : 1/2 or more) Voltage 27.5 - 29.5 V
Defective
2 alternator terminal (E02) and
machine body Engine stop Voltage 1 V or below
WA430-5 20-715
(1)......
TROUBLESHOOTING ERROR CODE [B@BAZG]
20-716 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [B@BAZK]
WA430-5 20-717
(1)......
TROUBLESHOOTING ERROR CODE [B@BCNS]
20-718 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [B@BCZK]
WA430-5 20-719
(1)......
TROUBLESHOOTING ERROR CODE [B@HANS]
20-720 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [B@CENS]
WA430-5 20-721
(1)......
TROUBLESHOOTING ERROR CODE [D182KZ]
Defective The failure code "D182KZ" is displayed. The relay (L114) is normal.
1 preheater relay
(L114) The failure code "D182KZ" is not displayed. The relay (L114) is abnormal.
1) Starting switch OFF.
2) Disconnect the connectors L51 and L114.
3) Connect a T-adaptor.
Between L114(male) (1) and (2) Resistance 100 - 500 Ω
Possible Causes
1) Starting switch OFF.
and Disconnection of
Standard 2) Disconnect the connectors L51 and L102.
harness 3) Connect a T-adapter.
Values 2 (Disconnection,
defective Harness between the fuse B. (10) and L102 (female) (1). Resistance 1 Ω and below
contact)
Harness between L51 (female) (12) and L102 (female) (2). Resistance 1 Ω and below
1) Starting switch OFF.
Ground fault of 2) Disconnect the connectors L51 and L102.
3 3) Connect a T-adapter.
harness
Machine body between L51 (female) (12) and L102 (female) (2). Resistance 1 MΩ and above
1) Starting switch OFF.
2) Disconnect the connector L51.
Defective 3) Insert a T-adaptor.
4 monitor panel
4) Starting switch ON.
Between L51 (12) - body. Voltage 20 - 30 V
20-722 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [D182KZ]
WA430-5 20-723
(1)......
TROUBLESHOOTING ERROR CODE [D5ZHL6]
20-724 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DA80L4]
WA430-5 20-725
(1)......
TROUBLESHOOTING ERROR CODE [DAF3KK]
20-726 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DAF3KK]
WA430-5 20-727
(1)......
TROUBLESHOOTING ERROR CODE [DAF5KP]
3 Defective 1) Starting switch OFF. 2) Disconnect the connector L51 and L55. 3) Insert a T-adaptor. 4)
monitor panel Starting switch ON.
Between L51 (16) - body Voltage 4.75 - 5.25 V
Between L55 (10) - When the lift arm is raised maximum. Voltage 3.5 - 4.0 V
body When the lift arm is lowered maximum. Voltage 1.0 - 2.0 V
20-728 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DAF6KP]
20-730 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DAF6KP]
WA430-5 20-731
(1)......
TROUBLESHOOTING ERROR CODE [DAFBKM]
20-732 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DAFSKQ]
WA430-5 20-733
(1)......
TROUBLESHOOTING ERROR CODE [DAQSKR]
20-734 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DBQSKR]
WA430-5 20-735
(1)......
TROUBLESHOOTING ERROR CODE [DB9SKR]
20-736 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DD15LD]
WA430-5 20-737
(1)......
TROUBLESHOOTING ERROR CODE [DD16LD]
20-738 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DD17LD]
WA430-5 20-739
(1)......
TROUBLESHOOTING ERROR CODE [DD18LD]
20-740 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DD1CLD]
20-742 WA430-5
(1)
(4)
TROUBLESHOOTING ERROR CODE [DD1CLD]
12
Related circuit diagram
WA430-5 20-743
(1)......
TROUBLESHOOTING ERROR CODE [DDS5L6]
20-744 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DDS5L6]
12
Related circuit diagram
WA430-5 20-745
(1)......
TROUBLESHOOTING ERROR CODE [DDY0LD]
20-746 WA430-5
(1)
(4)
TROUBLESHOOTING ERROR CODE [DDY0LD]
12
Related circuit diagram
WA430-5 20-747
(1)......
TROUBLESHOOTING ERROR CODE [DGE2KX]
20-748 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DGE3L6]
Ground fault of 1) Starting switch OFF. 2) Disconnect L82 and TWL. 3) Insert a T-adaptor.
3 harness
Among L55 (female) (3), E09 (female) (1) and machine body. Resistance 1 MΩ and above
1) Starting switch OFF. 2) Disconnect the connector L55. 3) Connect a T-adaptor.
Defective
4 10 °C Resistance 9 kΩ approx.
monitor panel Between L55 (female) (3) - (5)
100 °C Resistance 0.3 kΩ approx.
WA430-5 20-749
(1)......
TROUBLESHOOTING ERROR CODE [DGH2KX]
20-750 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DGT1KX]
WA430-5 20-751
(1)......
TROUBLESHOOTING ERROR CODE [DHE4L6]
20-752 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DHPCKX]
20-754 WA430-5
(1)
(4)
TROUBLESHOOTING ERROR CODE [DHPCKX]
WA430-5 20-755
(1)......
TROUBLESHOOTING ERROR CODE [DHPDKX]
Wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors L51, L55, F16 and F17.
discontinuity 3) Connect T-adapter.
Possible Causes
and 2 (Broken wires or Between L55 (Female) (4) - F17 (Female) (C) Resistance 1 Ω and below
Standard loose
Values connections) Between L51 (Female) (15) - F17 (Female) (B) Resistance 1 Ω and below
Wiring harness 1) Turn starting switch OFF. 2) Disconnect connectors L55, F16, F17. 3) Connect T-adapter.
3 ground fault
Between L55 (Female) (4), F17 (Female) (C) - body Resistance 1 MΩ and above
1) Turn starting switch OFF. 2) Disconnect connectors L51 and F17.
3) Insert T-adapter. 4) Turn starting switch ON.
20-756 WA430-5
(1)
(4)
TROUBLESHOOTING ERROR CODE [DHPDKX]
WA430-5 20-757
(1)......
TROUBLESHOOTING ERROR CODE [DKA0KX]
1) Turn starting switch OFF. 2) Disconnect connectors L51, L71 and F15.3) Connect T-adapter.
3 Wiring harness
ground fault Between L55 (Female) (10), F15 (Female) (B) - body Resistance 1 MΩ and above
1) Turn starting switch OFF.
2) Disconnect connectors L51 and L55.
3) Insert T-adapter.
4) Turn starting switch ON.
4 Defective
monitor panel Between L51 (16) - body Voltage 4.75 - 5.25 V
Between L55 (10) - With boom fully raised Voltage 3.5 - 4.0 V
body With boom fully lowered Voltage 1.0 - 2.0 V
20-758 WA430-5
(1)
(4)
TROUBLESHOOTING ERROR CODE [DV00KB]
WA430-5 20-759
(1)......
TROUBLESHOOTING ERROR CODE [DY30ME]
20-760 WA430-5
(1)
TROUBLESHOOTING ERROR CODE [DY30ME]
WA430-5 20-761
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-1]
Description of • The parking brake detector circuit remains CLOSED when the parking brake switch is operated.
Trouble
Controller • No reaction.
Reaction
Effect on • When the parking brake switch is turned ON (parking), neither the parking brake indicator lamp light up nor the
Machine parking brake is applied.
Related • Can be verified with the monitoring function (Code: 40903, D-IN-26).
Information • The state of the parking brake switch can be verified with the monitoring function (Code: 40907, D-IN-23).
Wiring harness 1) Turn starting switch OFF. 2) Disconnect connector L54 and PB.SW. 3) Connect T-adapter.
3 ground fault
Between L54 (Female), PB.SW (Female) (1) - body Resistance 1 MΩ and above
1) Turn starting switch OFF. 2) Disconnect connector L54. 3) Connect T-adapter. 4) Start engine.
When parking brake oil pressure is above
4 Defective
monitor panel Between L54 (Female) 0.6 MPa {6.1 kg/cm2}
Voltage 1 V or less
(1) - body When parking brake oil pressure is below
Possible Causes 0.34 MPa {3.5 kg/cm2} Voltage 20 - 30 V
and
Standard 1) Turn starting switch OFF. 2) Disconnect connector L01. 3) Connect T-adapter.
Values
Between L01 (Male) When parking brake switch is turned ON Resistance 1 Ω and below
(1) - (3) When parking brake switch is turned OFF Resistance 1 MΩ and above
5 Faulty parking
brake switch When parking brake switch is turned ON Resistance 1 MΩ and above
Between L01 (Male)
(2) - (3) When parking brake switch is turned OFF Resistance 1 Ω and below
Between L01 (Male)
(1) - (2) At all times Resistance 1 MΩ and above
20-762 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-1]
WA430-5 20-763
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-2]
20-764 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-3]
WA430-5 20-765
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-4]
20-766 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-4]
WA430-5 20-767
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-5]
20-768 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-6]
WA430-5 20-769
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-7]
Description of • The engine water temperature sensor circuit is always in the OPEN state.
Trouble
Controller • No reaction.
Reaction
Effect on • The engine water temperature caution lamp does not light ON.
Machine • After the engine starts, the engine water temperature gauge does not rise.
Related • Can be checked with the monitoring function (Code: 04103).
Information
20-770 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-8]
WA430-5 20-771
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-9]
Description of • The hydraulic oil temperature sensor circuit is always in the OPEN state.
Trouble
Controller • No reaction.
Reaction
Effect on • The hydraulic oil temperature caution lamp does not light ON.
Machine • After the engine starts, the hydraulic oil temperature gauge does not rise.
Related • Can be checked with the monitoring function (Code: 04401).
Information
20-772 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-10]
WA430-5 20-773
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-11]
20-774 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-12]
WA430-5 20-775
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-13]
20-776 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-14]
WA430-5 20-777
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-15]
20-778 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-16]
WA430-5 20-779
(1)......
(5)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-17]
20-780 WA430-5
(1)
(5)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-18]
WA430-5 20-781
(1)......
(5)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-19]
20-782 WA430-5
(1)
(5)
TROUBLESHOOTING TROUBLESHOOTING CODE [MON-20]
WA430-5 20-783
(1)......
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
WA430-5 20-801
(3)......
(4)
TROUBLESHOOTING H-1
• Have the wheel brake and the parking brake Clogging of strainer
been locked?
Remedy ∆ ∆ ∆ ∆ ∆ ∆ ∆
No. X X *1 *1 *1 X X X
Diagnosis X C X X X X X
1 The machine does not start at all gear speeds { { { { { { { { { { {
The machine does not start at specific gear
2 { { { { {
speeds
When the transmission oil temperature is low,
3 the charging pump or the transmission filter { {
causes abnormal noise(s)
When the transmission oil temperature rises,
4 the machine comes not to start { { { {
*1 Proceed to the paragraph of "Defective clutch and ECMV Specifying Method (Check by Failure Code)."
20-802 WA430-5
(3)
TROUBLESHOOTING H-1
Defective Clutch and ECMV Specifying Method (Check by Failure Code) Cause
★ For the checking method of failure code display, see the paragraph of "Special
Functions of Machine Monitor."
★ When replacing the ECMV for diagnosis, remove mud and dust around the ECMV Transmission ECMV
completely and clean it, and then tighten the mounting bolt with the
specified torque.
★ For the following diagnoses, start the engine and select the manual mode: a b c d e f g h i j k l
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
★ When the gear speed is N in the manual mode, the clutch of the gear speed
(Marked with O), to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch position
cannot be changed.
Remedy Failure
No. Code X X X X X X X X X X X X
Diagnosis
(1) The code is not displayed at R1~R4 but is displayed at F1~F4 15SALI { {
When the failure code is 15SALI after the diagnosis in (1), the failure
1 code comes not to be displayed when the F fill switch connector (CN-
(2) F.SW) is disconnected. When the failure code is 15SALH, the failure 15SALH {
code comes not to be displayed when the ECMV is replaced with any
one other than F clutch ECMV
(1) The code is not displayed at F1~F4 but is displayed at R1~R4 15SBLI { {
When the failure code is 15SBLI after the diagnosis in (1), the failure
2 code comes not to be displayed when the R fill switch connector (CN-
(2) R.SW) is disconnected. When the failure code is 15SBLH, the failure 15SBLH {
code comes not to be displayed when the ECMV is replaced with any
one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SELI { {
When the failure code is 15SELI after the diagnosis in (1), the failure
3 code comes not to be displayed when the 1st fill switch connector (CN-
(2) 1.SW) is disconnected. When the failure code is 15SELH, the failure 15SELH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 1st clutch ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFLI { {
When the failure code is 15SFLI after the diagnosis in (1), the failure
4 code comes not to be displayed when the 2nd fill switch connector (CN-
(2) 2.SW) is disconnected. When the failure code is 15SFLH, the failure 15SFLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 2nd clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGLI { {
When the failure code is 15SGLI after the diagnosis in (1), the failure
5 code comes not to be displayed when the 3rd fill switch connector (CN-
(2) 3.SW) is disconnected. When the failure code is 15SGLH, the failure 15SGLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 3rd clutch ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHLI { {
When the failure code is 15SHLI after the diagnosis in (1), the failure
6 code comes not to be displayed when the 4th fill switch connector (CN-
(2) 4.SW) is disconnected. When the failure code is 15SHLH, the failure 15SHLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 4th clutch ECMV
WA430-5 20-803
(3)......
TROUBLESHOOTING H-2
H-2 The lock-up clutch is not released (The engine stops) (When the lock-up clutch is provided)
Inspection before diagnosis Cause
• Is the oil level in the transmission case appropriate? a b
20-804 WA430-5
(3)
TROUBLESHOOTING H-3
a. The travel speed is slow, the thrusting force is weak, the uphill traveling power is
H-3 weak, and the gear is not shifted
Ask the operator about the following: Cause
• Has an abnormality occurred suddenly?
→ Breakage of related equipment Torque
Did any abnormal noise occur at the time and Torque Con- Torque
Converter Main Relief Parking
where? Charging verter Oil Con- Valve ECMV Transmission Brake Others
Cooler verter
• Have any abnormal signs come to occur gradu- Pump
ally?
→ Wear of related equipment, defective seal a b c d e f g h i j k l m n o p q r
Clogging of breather
Clogging of strainer
Engine degradation
dragged?
• Are the tire air pressure and the tread shape
appropriate?
• Is the operating method correct?
Note: When the inspection result was "Engine
Degradation," proceed to Engine System
Troubleshooting (S Mode).
Remedy C ∆ ∆ ∆ ∆ ∆ ∆ ∆ C ∆
No. X X X *1 *1 X X Note
Diagnosis X X X X X X X X X X
1 Any abnormality occurs at all gear speeds { { { { { { { { { { { { { { {
Any abnormality occurs at specific gear
2
speeds { { { {
When the transmission oil temperature is low,
3 the charging pump or the transmission filter { {
causes any abnormal noise
4 The torque converter oil temperature rises { { { { { { { { { { {
abnormally high
5 The transmission oil level rises or falls { { { { {
Metal (Aluminum, copper, iron, etc.) powers
6 are adhered to the transmission filter or the { { {
strainer
The engine low idling and high idling speeds
7 { { {
are measured to be abnormal
8 When the stall speed of The speed is high { { { { { { { { { {
the torque converter is
9 measured The speed is low {
The oil pressure
10 drops as the tempera- { { { {
ture rises
The oil pressure is
11 { { { { { { { { {
low at all gear speeds
When the ECMV output
(Clutch) oil pressure is The oil pressure is
12 measured low at specific gear { { { {
speeds
The oil pressure does
13 not become stable as { {
the gauge touches the
oil
When the torque converter relief (Inlet) oil
14 pressure is measured, the oil pressure is low. { { {
(Nos. 11~13 are normal.)
When the oil pressure at the torque converter
15 outlet is measured, the oil pressure is low. {
(No. 14 is normal.)
*1 Proceed to the paragraph of "Defective clutch and ECMV Specifying Method (Check by Failure Code)."
WA430-5 20-805
(3)......
TROUBLESHOOTING H-3
Defective Clutch and ECMV Specifying Method (Check by Failure Code) Cause
★ For the checking method of failure code display, see the paragraph of "Special
Functions of Machine Monitor."
★ When replacing the ECMV for diagnosis, remove mud and dust around the ECMV Transmission ECMV
completely and clean it, and then tighten the mounting bolt with the
specified torque.
★ For the following diagnoses, start the engine and select the manual mode: a b c d e f g h i j k l
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
★ When the gear speed is N in the manual mode, the clutch of the gear speed
(Marked with O), to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch position
cannot be changed.
Remedy Failure
No. Code X X X X X X X X X X X X
Diagnosis
(1) The code is not displayed at R1~R4 but is displayed at F1~F4 15SALI { {
When the failure code is 15SALI after the diagnosis in (1), the failure
1 code comes not to be displayed when the F fill switch connector (CN-
(2) F.SW) is disconnected. When the failure code is 15SALH, the failure 15SALH {
code comes not to be displayed when the ECMV is replaced with any
one other than F clutch ECMV
(1) The code is not displayed at F1~F4 but is displayed at R1~R4 15SBLI { {
When the failure code is 15SBLI after the diagnosis in (1), the failure
2 code comes not to be displayed when the R fill switch connector (CN-
(2) R.SW) is disconnected. When the failure code is 15SBLH, the failure 15SBLH {
code comes not to be displayed when the ECMV is replaced with any
one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SELI { {
When the failure code is 15SELI after the diagnosis in (1), the failure
3 code comes not to be displayed when the 1st fill switch connector (CN-
(2) 1.SW) is disconnected. When the failure code is 15SELH, the failure 15SELH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 1st clutch ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFLI { {
When the failure code is 15SFLI after the diagnosis in (1), the failure
4 code comes not to be displayed when the 2nd fill switch connector (CN-
(2) 2.SW) is disconnected. When the failure code is 15SFLH, the failure 15SFLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 2nd clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGLI { {
When the failure code is 15SGLI after the diagnosis in (1), the failure
5 code comes not to be displayed when the 3rd fill switch connector (CN-
(2) 3.SW) is disconnected. When the failure code is 15SGLH, the failure 15SGLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 3rd clutch ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHLI { {
When the failure code is 15SHLI after the diagnosis in (1), the failure
6 code comes not to be displayed when the 4th fill switch connector (CN-
(2) 4.SW) is disconnected. When the failure code is 15SHLH, the failure 15SHLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 4th clutch ECMV
20-806 WA430-5
(3)
TROUBLESHOOTING H-3
H-3 b. The torque converter lock-up clutch is not let in (If the lock-up clutch is equipped)
Check of abnormality
• Oil pressure of main relief valve
• Oil pressure of lock-up clutch
• Traveling speed
Remedy ∆
No. Diagnosis Self-diagnosis X X X X C X
Display of T/M Controller X
1 The main relief valve oil pressure is low {
2 No. 1 is normal but the lock-up clutch oil pressure is low or 0 { { { { {
3 The oil pressure is normal in No. 2 {
Letting the lock-up clutch in takes
4 a long time 15SJLH {
WA430-5 20-807
(3)......
TROUBLESHOOTING H-4
H-4 Shocks are large at the times of starting and shifting gear
Remedy C ∆ ∆
No. X X *1 *2 *1 *1 X X *2
Diagnosis X X X
1 Shocks are large at all gear speeds { { { { { { { {
2 Shocks are large at specific gear speeds { { { { { {
★ Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
*1 Proceed to the paragraph of "Defective Clutch and ECMV Specifying Method (Check by Failure Code)."
*2 Proceed to the paragraph of "Troubleshooting of Transmission Controller System (TM Mode)."
20-808 WA430-5
(3)
TROUBLESHOOTING H-4
Defective Clutch and ECMV Specifying Method (Check by Failure Code) Cause
★ For the checking method of failure code display, see the paragraph of "Special
Functions of Machine Monitor."
★ When replacing the ECMV for diagnosis, remove mud and dust around the ECMV Transmission ECMV
completely and clean it, and then tighten the mounting bolt with the specified
torque.
★ For the following diagnoses, start the engine and select the manual mode: a b c d e f g h i j k l
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
★ When the gear speed is N in the manual mode, the clutch of the gear speed
(Marked with O), to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch position
cannot be changed.
Remedy Failure
No. Code X X X X X X X X X X X X
Diagnosis
(1) The code is not displayed at R1~R4 but is displayed at F1~F4 15SALI { {
When the failure code is 15SALI after the diagnosis in (1), the failure
1 code comes not to be displayed when the F fill switch connector (CN-
(2) F.SW) is disconnected. When the failure code is 15SALH, the failure 15SALH {
code comes not to be displayed when the ECMV is replaced with any
one other than F clutch ECMV
(1) The code is not displayed at F1~F4 but is displayed at R1~R4 15SBLI { {
When the failure code is 15SBLI after the diagnosis in (1), the failure
2 code comes not to be displayed when the R fill switch connector (CN-
(2) R.SW) is disconnected. When the failure code is 15SBLH, the failure 15SBLH {
code comes not to be displayed when the ECMV is replaced with any
one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SELI { {
When the failure code is 15SELI after the diagnosis in (1), the failure
3 code comes not to be displayed when the 1st fill switch connector (CN-
(2) 1.SW) is disconnected. When the failure code is 15SELH, the failure 15SELH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 1st clutch ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFLI { {
When the failure code is 15SFLI after the diagnosis in (1), the failure
4 code comes not to be displayed when the 2nd fill switch connector (CN-
(2) 2.SW) is disconnected. When the failure code is 15SFLH, the failure 15SFLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 2nd clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGLI { {
When the failure code is 15SGLI after the diagnosis in (1), the failure
5 code comes not to be displayed when the 3rd fill switch connector (CN-
(2) 3.SW) is disconnected. When the failure code is 15SGLH, the failure 15SGLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 3rd clutch ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHLI { {
When the failure code is 15SHLI after the diagnosis in (1), the failure
6 code comes not to be displayed when the 4th fill switch connector (CN-
(2) 4.SW) is disconnected. When the failure code is 15SHLH, the failure 15SHLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 4th clutch ECMV
WA430-5 20-809
(3)......
TROUBLESHOOTING H-5
H-5 Time lag is large at the times of starting and shifting gear
Remedy C ∆ ∆
No. X X *1 *1 X X *2
Diagnosis X X X
1 Time lag is large at all gear speeds { { { { { { {
2 Time lag is large at specific gear speeds { { { {
When the transmission oil temperature is low,
3 any abnormal noise occurs from the charging { {
pump or the transmission filter
The torque converter oil temperature is heated
4 { { { {
abnormally high
The oil pressure is low { { { { {
5 When the ECMV output at all gear speeds
(Clutch) oil pressure is
measured The oil pressure is low
6 { { {
at specific gear speeds
★ Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting
wastes of pressure control valve spool.
*1 Proceed to the paragraph of "Defective Clutch and ECMV Specifying Method (Check by Failure Code)."
*2 Proceed to the paragraph of "Troubleshooting of Transmission Controller System (TM Mode)."
20-810 WA430-5
(3)
TROUBLESHOOTING H-5
Defective Clutch and ECMV Specifying Method (Check by Failure Code) Cause
★ For the checking method of failure code display, see the paragraph of "Special
Functions of Machine Monitor."
★ When replacing the ECMV for diagnosis, remove mud and dust around the ECMV Transmission ECMV
completely and clean it, and then tighten the mounting bolt with the
specified torque.
★ For the following diagnoses, start the engine and select the manual mode: a b c d e f g h i j k l
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
★ When the gear speed is N in the manual mode, the clutch of the gear speed
(Marked with O), to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch position
cannot be changed.
Remedy Failure
No. Code X X X X X X X X X X X X
Diagnosis
(1) The code is not displayed at R1~R4 but is displayed at F1~F4 15SALI { {
When the failure code is 15SALI after the diagnosis in (1), the failure
1 code comes not to be displayed when the F fill switch connector (CN-
(2) F.SW) is disconnected. When the failure code is 15SALH, the failure 15SALH {
code comes not to be displayed when the ECMV is replaced with any
one other than F clutch ECMV
(1) The code is not displayed at F1~F4 but is displayed at R1~R4 15SBLI { {
When the failure code is 15SBLI after the diagnosis in (1), the failure
2 code comes not to be displayed when the R fill switch connector (CN-
(2) R.SW) is disconnected. When the failure code is 15SBLH, the failure 15SBLH {
code comes not to be displayed when the ECMV is replaced with any
one other than R clutch ECMV
(1) The code is not displayed at F2, F3, and F4 but is displayed at F1 15SELI { {
When the failure code is 15SELI after the diagnosis in (1), the failure
3 code comes not to be displayed when the 1st fill switch connector (CN-
(2) 1.SW) is disconnected. When the failure code is 15SELH, the failure 15SELH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 1st clutch ECMV
(1) The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFLI { {
When the failure code is 15SFLI after the diagnosis in (1), the failure
4 code comes not to be displayed when the 2nd fill switch connector (CN-
(2) 2.SW) is disconnected. When the failure code is 15SFLH, the failure 15SFLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 2nd clutch ECMV
(1) The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGLI { {
When the failure code is 15SGLI after the diagnosis in (1), the failure
5 code comes not to be displayed when the 3rd fill switch connector (CN-
(2) 3.SW) is disconnected. When the failure code is 15SGLH, the failure 15SGLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 3rd clutch ECMV
(1) The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHLI { {
When the failure code is 15SHLI after the diagnosis in (1), the failure
6 code comes not to be displayed when the 4th fill switch connector (CN-
(2) 4.SW) is disconnected. When the failure code is 15SHLH, the failure 15SHLH {
code comes not to be displayed when the ECMV is replaced with any
one other than the 4th clutch ECMV
WA430-5 20-811
(3)......
TROUBLESHOOTING H-6
Clogging of breather
Clogging of strainer
Engine degradation
Remedy C ∆ ∆ ∆ ∆ ∆ ∆ C ∆
No. X X Note
Diagnosis X X X X X X X X X
When the transmission oil temperature is low, the
1 charging pump or the transmission filter causes any { {
abnormal noise
Traveling speed, braking force and uphill travelling
2 power do not occur at all gear speeds { { { { { { { { { { {
20-812 WA430-5
(3)
TROUBLESHOOTING H-7
steering valve
• Breakage of steering gear box and steering linkage
Defect inside
• Is the frame safety lever off?
• Has the steering linkage been properly adjusted?
Demand spool
Safety valve
Remedy ∆ ∆ ∆ ∆ ∆ ∆
No.
Diagnosis X X X X X X
1 The steering wheel does not turn both right and left { { { { {
2 The work equipment operates abnormally in No. 1 {
3 The steering wheel turns either right or left { {
4 The steering wheel is too heavy to turn { { { {
5 The steering circuit oil pressure does not rise at all { {
★ Since the steering circuit is closely related to the work equipment circuit, check how the work equip-
ment operates when the steering is felt abnormal.
WA430-5 20-813
(3)......
TROUBLESHOOTING H-8
The hydraulic oil return side filter is clogged or the bypass valve is defective
The hydraulic pump is defective
Inspection before diagnosis
Demand spool
Safety valve
Remedy ∆ ∆A ∆ ∆ ∆ ∆C ∆C A ∆
No.
Diagnosis X X X X X X X X
1 The steering wheel is heavy to turn both right and left { { { { {
2 The steering wheel is heavy to turn right or left { {
3 The steering wheel is heavy when the engine rotates slowly { {
When the engine rotates at full throttle, the boom raising speed is
4 {
insufficient
5 The steering wheel is heavy and jerks {
6 The hydraulic oil temperature is heated abnormary high {
7 The steering circuit oil pressure is low { { { {
8 The oil pressure rises in the pipe on the steering cylinder return side { {
20-814 WA430-5
(3)
TROUBLESHOOTING H-9
Defect inside steering cylinder (Cylinder inner plane, piston seal, nut, bolt)
The steering valve is defective
• Play of center hinge pin bearing, steering cylinder pin and bushing?
• Irregular tire air pressure?
• Play of steering wheel?
Check of Abnormality
• Operate the machine in a safe place and check how the steering wheel fluc-
tuates under which conditions
★ When the steering wheel fluctuates and is heavy as well, see "H-8, The
steering wheel is heavy."
Remedy ∆ A ∆ ∆
No.
Diagnosis X X X
1 When traveling, the machine fluctuates on rough roads { { {
When the steering wheel is turned quickly in operation or travel, the
2 {
machine fluctuates
3 When accelerated in travel, the machine fluctuates { { {
4 When the engine starts, the machine fluctuates {
WA430-5 20-815
(3)......
TROUBLESHOOTING H-12
H-12 The brake does not work or does not work well
7 An airflow is observed in bleeding air from the brake circuit, and the {
brake returns to normal after the bleeding
8 Brake oil leaks abnormally from the axle during inspection {
9 Much metal powders are mixed in the axle oil {
The brake pedal leg-power and stroke are normal, but the brake does
10 { { { {
not work well
11 The brake does not work often when the engine is stopped { { { {
12 The accumulator is not charged, and a buzzer sounds { { {
13 The brake works after some time lag {
20-816 WA430-5
(3)
TROUBLESHOOTING H-13
2 When the brake pedal is released, oil is drained from the air bleeder, {
the circuit pressure drops and the brake is released
The four wheels are jacked up, the axle is placed on a table, the
3 engine is stopped, the parking brake is released and the tires are { {
rotated by hand but a specific tire hardly rotates
WA430-5 20-817
(3)......
TROUBLESHOOTING H-14
Remedy ∆ ∆ ∆ ∆
No. ∆
Diagnosis X X X X
1 When the parking brake switch is off, the parking brake is not released { { { { {
When the parking brake switch is off, the brake is not applied even if
2 the engine stops {
3 When the parking brake switch is on, the parking brake does not work { {
well
• The parking brake is not released even if the emergency parking brake release valve is opened. The
following causes are considered:
a. Defective operation of emergency parking brake release valve
b. Insufficient gas pressure of accumulator for brake or breakage of piston seal
20-818 WA430-5
(3)
TROUBLESHOOTING H-15
WA430-5 20-819
(3)......
TROUBLESHOOTING H-16
H-16 The lift arm moves slowly or the lift arm rising force is insufficient
3 When the oil temperature rises in No. 1, the lift arm speed {
becomes very slow
4 The hydraulic pump is causing an abnormal noise { {
When the engine is at full throttle, the steering operation is
5 light and too fast {
20-820 WA430-5
(3)
TROUBLESHOOTING H-17
H-17 When rising, the lift arm comes to move slowly at specific height
Cause
• Expansion of lift arm cylinder tube or damage inside
★ For other abnormal phenomena during lift arm rise, see "H-16. The lift arm moves slowly or the lift arm rising force is insufficient."
H-18 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)
See "H-16. The lift arm moves slowly or the lift arm rising force is insufficient."
Cause
• Defective seat of suction valve on the lift arm cylinder rod side of work equipment valve
• Oil leak from lift arm cylinder piston seal
The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm control lever in the
"HOLD" position.
★ Frequent hydraulic drifts → The suction valve on the lift arm cylinder rod side is defective
WA430-5 20-821
(3)......
TROUBLESHOOTING H-21
H-21 When the control lever is switched from "HOLD" to "RAISE," the lift arm falls temporarily
Check of Phenomenon
• When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the lift arm falls temporarily due
to its own weight. When the control lever is completely set to "RAISE," the lift arm returns to normal.
Cause
• Improper adhesion of lift arm spool check valve of the work equipment valve
20-822 WA430-5
(3)
TROUBLESHOOTING H-22
WA430-5 20-823
(3)......
TROUBLESHOOTING H-23
Defective operation of safety valve (With suction valve) on bucket cylinder bottom side
Check of Abnormality
• Make sure in an actual operation that the tilting-back force is insufficient.
• Measure the operating speed of the bucket, and make sure referring to
the criterion value table that the speed is abnormal
Remedy C ∆ ∆ ∆ ∆ ∆Α ∆ ∆
No.
Diagnosis ∆ X X X X X X X X X
1 The lift arm rising force and speed are abnormal, and the bucket { { { { { {
tilting force and speed are abnormal
The lift arm rising force and speed are normal, and the bucket tilt-
2 { { { {
ing force and speed are abnormal
When the oil temperature rises in No. 1, the bucket speed
3 {
becomes worse
4 The hydraulic pump is causing an abnormal noise { {
When the engine is at full throttle, the steering operation is light
5 {
and too fast
20-824 WA430-5
(3)
TROUBLESHOOTING H-24
Cause
• Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see "H-23. The bucket moves slowly or the tilting-back force is insuffi-
cient."
See "H-23. The bucket moves slowly or the tilting-back force is insufficient."
Cause
• Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
• Oil leak from bucket cylinder piston seal
Check of Abnormality
• Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically
Cause
• Oil leak in bucket cylinder
• Improper adhesion of safety valve (With suction valve) on the bottom side
• Improper oil tight of bucket spool
WA430-5 20-825
(3)......
TROUBLESHOOTING H-27
H-27 The bucket wobbles during travel with cargo (The work equipment valve is set to "HOLD")
Cause
• Defective seal of bucket cylinder piston
• Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal phenomena, refer to
diagnoses for relevant abnormal phenomena.
H-28 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily
Check of Phenomenon
• When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the bucket falls temporarily due
to its own weight. When the control lever is completely set to "TILT," the bucket returns to normal.
Cause
• Improper adhesion of bucket spool check valve of the work equipment valve
20-826 WA430-5
(3)
TROUBLESHOOTING H-29
H-29 The control levers of lift arm and bucket do not move smoothly and heavy
Remedy ∆ ∆ C
No.
Diagnosis X X X ∆
1 When the machine is loaded and the oil pressure rises, the levers { { { { {
come not to move smoothly
2 The levers come not to move smoothly as the oil pressure rises { { { { {
The levers partly come not to move smoothly during operation
3 irrespective of oil pressure and oil temperature {
WA430-5 20-827
(3)......
TROUBLESHOOTING H-30
H-30 ECSS does not work, and there is pitcing and bouncing
Remedy
No. X X X X
Problems
Speed (3 km/h) for start of actuation of ECSS is greatly out of
1 adjustment ! !
20-828 WA430-5
(3)
(4)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
WA430-5 20-901
(1)......
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM
20-902 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE:
TROUBLESHOOTING CODE: [E-1-A]
[E-1-a]
Troubleshooting Code Error Code Controller Code The engine does not start. (Start-
Trouble ing system)
E-1-a) — —
Description of Trouble The starting motor system is defective, and the engine does not start.
Controller Reaction —
Effect on Machine The starting motor system is defective, and the engine does not start.
Check that the fuses A-2 and B-2 are not blown. (If they are blown, check if the related harness is short-cir-
Related Information
cuited with the ground.).
20-904 WA430-5
(1)
TROUBLESHOOTING [E-1-a]
TROUBLESHOOTING CODE: [E-1-A]
Troubleshooting Code Error Code Controller Code The engine does not start.
Trouble (Starting system)
E-1-a) — —
Causes Standard Value in Normal State and Remarks on Troubleshooting
1) Stating switch OFF. 2) Disconnect the connector TEL.
3) Connect a T-adapter.
Harness between TEL (female) (7) and 1 Ω and
Disconnection between Resistance
TEL (female) (8) below
6 short connector (TEL) and
related harness 1) Stating switch OFF. 2) Disconnect the connectors TEL and L116.
3) Connect a T-adapter.
Harness between TEL (male) (8) and L116 1 Ω and
Resistance
(female) (3) below
1) Stating switch OFF. 2) Disconnect the connectors L79 and L116.
3) Connect a T-adapter. 4) Shifter switch "Neutral."
5) Starting switch "Start."
Between L113 (4) and machine body. Voltage 20 - 30 V
Between L113 (3) and machine body. Voltage 20 - 30 V
1 V and
Between L113 (1) and machine body. Voltage
below
1) Stating switch OFF. 2) Disconnect the relays L113 and L116.
3) Connect a T-adapter.
Harness between L113 (female) (3) and 1 Ω and
Disconnection between relay Resistance
7 (L113) and related harness L116 (female) (1). below
Between the relays L113 (male) (1) and
(2). Resistance 200 - 400 Ω
Possible Causes and Stan- 1) Stating switch OFF. 2) Disconnect the connectors L101 and L102.
dard Values 3) Connect a T-adapter.
Harness between L101 (female) (12) and Resistance 1 Ω and
L102 (female) (12). below
1) Stating switch OFF. 2) Disconnect the connectors L102 and E01.
3) Connect a T-adapter.
Harness between L102 (female) (14) and
E01 (female) (1).
Continuity Yes
Disconnection between relay ★ Measure the continuity from L102
8 (14) side in the diode range.
(L116) and related harness
1) Stating switch OFF. 2) Disconnect the relay L116. 3) Connect a T-
adapter.
Between the relays L116 (male) (1) and
Resistance 200 - 400 Ω
(2).
1) Stating switch OFF. 2) Disconnect the connector L04.
3) Connect a T-adapter. 4) Starting switch "ON."
Among L04 (1), (3) and machine body. Voltage 20 - 30 V
9 Disconnection between shift 1) Stating switch OFF. 2) Disconnect the connectors L04 and FS4.
switch and related harness
3) Connect a T-adapter.
Harness between L04 (female) (1) and Resistance 1 Ω and
FS4 (female) (2). below
1) Stating switch OFF. 2) Disconnect the connector R26.
3) Connect a T-adapter.
Between R26 (male) (2) and (1).
Disconnection among ★ Measure the continuity from the (2)
10 diodes R26, R27 and related Continuity Yes
harness side in the diode range.
★ Measure the continuity from the (1)
side in the diode range. Continuity No
★ The diode R26 can be replaced.
WA430-5 20-905
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE:
TROUBLESHOOTING CODE: [E-1-A]
[E-1-a]
Troubleshooting Code Error Code Controller Code The engine does not start.
Trouble (Starting system)
E-1-a) — —
Causes Standard Value in Normal State and Remarks on Troubleshooting
1) Stating switch OFF. 2) Disconnect the connector R27.
3) Connect a T-adapter.
Between R27 (male) (2) and (1).
★ Measure the continuity from the (2)
Continuity Yes
side in the diode range.
★ Measure the continuity from the (1)
Continuity No
side in the diode range.
★ The diode R27 can be replaced.
1) Stating switch OFF. 2) Disconnect the connectors L102, R26 and R27.
Disconnection among 3) Connect a T-adapter.
10 diodes R26, R27 and related
harness Harness between L102 (female) (14) and 1 Ω and
Resistance
R26 (female) (2). below
Harness between L102 (female) (14) and 1 Ω and
Resistance
R27 (female) (2). below
1) Stating switch OFF. 2) Disconnect the connectors E01, R26 and R27.
3) Connect a T-adapter.
Harness between E01 (female) (1) and 1 Ω and
R26 (female) (1). Resistance below
Harness between E01 (female) (1) and 1 Ω and
Resistance
R27 (female) (1). below
1) Stating switch OFF. 2) Disconnect the connectors FS2 and FS4.
3) Connect a T-adapter. 4) Starting switch ON.
Between FS3 (1) and machine body. Voltage 20 - 30 V
Between FS4 (2) and machine body. Voltage 20 - 30 V
Between FS2 (1) and machine body. Voltage 20 - 30 V
Among FS1 (1), (2) and machine body. Voltage 20 - 30 V
Possible Causes and Stan-
dard Values 1) Stating switch OFF. 2) Disconnect the connectors LR1 and LR4.
3) Connect a T-adapter. 4) Starting switch ON.
Between LR1 (1) and machine body. Voltage 20 - 30 V
Among LR4 (1), (2) and machine body. Voltage 20 - 30 V
1) Stating switch OFF. 2) Disconnect the connectors FS1, FS2, LR1 and LR4.
3) Connect a T-adapter.
Harness between FS1 (female) (1) and 1 Ω and
Resistance
LR1 (male) (1). below
11 Disconnection between fuse
Harness between FS1 (female) (2) and 1 Ω and
and related harness Resistance
LR4 (male) (1). below
Harness between LR4 (male) (2) and FS2 Resistance 1 Ω and
(female) (1). below
1) Stating switch ON. 2) Slow blow fuse (firm power supply).
Among terminal R02, R03 and machine Resistance 1 Ω and
body. below
1) Starting switch OFF. 2) Disconnect the flow blow fuse (firm power
supply) terminal R02 and the battery relay terminal R01.
Harness between the flow blow fuse
(firm power supply) terminal R02 and the Resistance 1 Ω and
below
battery relay terminal R01
1) Starting switch OFF. 2) Disconnect the flow blow fuse (firm power
supply) terminal R05 and the battery relay terminal R04.
Harness between the flow blow fuse
(firm power supply) terminal R05 and the Resistance 1 Ω and
battery relay terminal R04 below
20-906 WA430-5
(1)
TROUBLESHOOTING [E-1-a]
TROUBLESHOOTING CODE: [E-1-A]
WA430-5 20-907
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE:
TROUBLESHOOTING CODE: [E-1-B]
[E-1-b]
20-908 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE:
TROUBLESHOOTING CODE: [E-1-B]
[E-1-b]
WA430-5 20-909
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-2]
20-910 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-2]
WA430-5 20-911
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-3]
Related Information When any error code appears, diagnose the machine referring to the error code "D182KZ" related to the mon-
itor. The monitoring function (Code : 04104) enables to check engine water temperature.
Possible Causes and In case other than the above two paragraphs, the slow blow fuse will
Standard Values be blown.
1) Starting switch OFF. 2) Disconnect the connector E09. 3) Connect a
T-adapter.
Defective engine water tempera-
5 ture sensor Between E09 At the time of 10 °C Resistance 7 - 11 kΩ
(male) (A) and (B) At the time of 100 °C Resistance 0.1 - 0.5 kΩ
1) Starting switch OFF. 2) Disconnect the connectors L55 and TWH. 3)
Ground fault of harness (Engine Insert a T-adapter.
6 water temperature sensor sys-
tem) Among L55 (female) (3), E09 (A) and
machine body Resistance 1 MΩ and above
The machine does not operate normally. The preheater relay (L114) is
normal.
1) Starting switch OFF. 2) Disconnect the connectors L151 and L114.
Disconnection of harness (Dis- 3) Connect a T-adapter.
9 connection, defective contact)
(Preheater relay system) Harness between L114 (female) (2) and Resistance 1 Ω and below
L51 (female) (12)
20-912 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-3]
BWW11066
WA430-5 20-913
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-4]
20-914 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-4]
Troubleshooting Code Error Code Controller Code The engine power modes
Trouble cannot be selected.
E-4 — —
Causes Standard Value in Normal State and Remarks on Troubleshooting
1) Starting switch OFF. 2) Disconnect the connectors S21, L102 and
L61. 3) Connect a T-adapter. 4) Starting switch ON.
Among S21 (female) (4), L61 (female) (6), 1 V and
Voltage
L102 (female) (7) and machine body below
Possible Causes and Stan- ★ In the above case, the fuse B-(6) will be blown when the power
dard Values 5 Hot short-circuit of harness mode is selected.
Among L88 (female) (7), L102 (female) (8) 1 V and
and machine body Voltage below
★ In the above case, the economy mode is changed to the power
mode, and the power mode is changed to the economy mode
automatically without operation.
WA430-5 20-915
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-5]
20-916 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-5]
Troubleshooting Code Error Code Controller Code The front wiper does not func-
Trouble tion
E-5 — —
Causes Standard Value in Normal State and Remarks on Troubleshooting
1) Turn starting switch OFF.
2) Disconnect connectors L21, L31, and C12.
3) Connect T-adapter.
Harness between L21 (Female) (2) -
Resistance 1 Ω and below
L31 (Female) (4)
Between L21 (Female) (2), L31
(Female) (4) - body Resistance 1 MΩ and above
WA430-5 20-917
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-5]
20-918 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-6]
Between L21 (Female) (8), C15 (Female) (3) - Resistance 1 MΩ and above
body
20-920 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-6]
WA430-5 20-921
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-7]
Troubleshooting Code Error Code Controller Code The side wiper does not function
Trouble (If equipped)
E-7 — —
Description of Trouble • Since a fault occurs in the side wiper, switch, or harness, the side wiper does not function.
Controller Reaction —
Effect on Machine • The side wiper does not function.
Related Information —
Between C43 (Female) (3), FS4 (Female) (7) - Resistance 1 MΩ and above
and body
20-922 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-8]
Troubleshooting Code Error Code Controller Code The wind washer does not func-
Trouble tion
E-8 — —
• Since a fault occurs in the window washer motor, switch, timer (Front only), or harness, the wind washer
Description of Trouble
does not function.
Controller Reaction —
Effect on Machine • The wind washer does not function.
• When the wiper function is normal (When the wiper function is also abnormal, first diagnose the wiper
Related Information
function fault in E-9).
WA430-5 20-923
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-8]
Troubleshooting Code Error Code Controller Code The wind washer does not func-
Trouble
E-8 — — tion
20-924 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-8]
WA430-5 20-925
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-9]
Troubleshooting Code Error Code Controller Code The headlamp (Lo beam) does
Trouble not light on
E-9 — —
• Since a disconnection (Ground fault) occurs in the switch, lamp, or harness in the headlamp system, the
Description of Trouble
headlamp (Lo beam) does not light on.
Controller Reaction —
Effect on Machine • The headlamp (Lo beam) does not light on.
Related Information —
20-926 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-9]
Troubleshooting Code Error Code Controller Code The headlamp (Lo beam) does
Trouble
E-9 — — not light on
WA430-5 20-927
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-9]
20-928 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-10]
Troubleshooting Code Error Code Controller Code The headlamp (Hi beam) does not
Trouble function
E-10 — —
• Since a disconnection (Ground fault) occurs in the switch, lamp, or harness in the headlamp system, the
Description of Trouble
headlamp (Hi beam) does not light on.
Controller Reaction —
Effect on Machine • The headlamp (Hi beam) does not light on.
Related Information —
WA430-5 20-929
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-10]
Troubleshooting Code Error Code Controller Code The headlamp (Hi beam) does
Trouble
E-10 — — not light on
20-930 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-11]
Troubleshooting Code Error Code Controller Code The clearance lamp does not light
Trouble on (Small lamp)
E-11 — —
• Since a disconnection (Ground fault) occurs in the switch, lamp, or harness in the clearance lamp system,
Description of Trouble
the clearance lamp does not light on.
Controller Reaction —
Effect on Machine • The clearance lamp does not light on (Small lamp).
Related Information —
Possible Causes and Harness between L02 (Female) (1) - FS4 Resistance 1 Ω and below
Standard Values (Female) (11)
Between L02 (Female) (1) - FS4 (Female) (11)
harness - body Resistance 1 MΩ and above
Between L02 (Female) (2) - FS5 (Female) (4) Resistance 1 MΩ and above
harness - body
Harness disconnection Harness between L02 (Female) (2) - COMB1
Resistance 1 Ω and below
or ground fault right (female) (1)
★ Fuses A-1, A-14, and
3 Between FS5 (Female) (2) - COMB1 right Resistance 1 MΩ and above
A-15 blow at occur- (Female) (1) harness - body
rence of a ground
Harness between FS5 (Female) (3) - COMB1 Resistance
fault. 1 Ω and below
right (Female) (1)
Between FS5 (Female) (3) - COMB1 right
Resistance 1 MΩ and above
(Female) (1) harness - body
Harness between FS5 (Male) (1) - (2) (Includ- Resistance
ing fuse A-13) 1 Ω and below
Between FS5 (Male) (1) - (2) harness - body Resistance 1 MΩ and above
Harness between FS5 (Male) (1) - (3) (Includ- Resistance 1 Ω and below
ing fuse A-12)
Between FS5 (Male) (1) - (3) harness - body Resistance 1 MΩ and above
Between COMB (Female) (Left and right) (3) - Resistance
body 1 Ω and below
WA430-5 20-931
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-12]
20-932 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-12]
WA430-5 20-933
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-13]
1 Horn relay fault Between L119 (2) - body (Horn switch: ON) Voltage 1 V and below
Between L119 (5) - body (Horn switch: ON) Voltage 20 - 30 V
1) Turn starting switch OFF.
2) Disconnect connector L119.
3) Connect T-adapter.
Between L119 (Male) (1) - (2) (Coil resistance) Resistance 200 - 400 Ω
Between L119 (Male) (3) - (5) (Between pints) Resistance 1 MΩ and above
1) Turn starting switch ON.
Between horn switch pin - body (Horn Voltage 1 V and below
switch: ON)
Between horn switch pin - body (Horn Voltage 20 - 30 V
2 Horn switch fault switch: OFF)
Possible Causes and
Standard Values 1) Turn starting switch OFF.
2) Disconnect the horn switch pin.
Between horn switch pin - body (Switch: Resistance 1 Ω and below
ON)
1) Turn starting switch ON.
3 Horn fault
Between horn pin - body (Horn switch: ON) Resistance 35 - 45 Ω
1) Turn starting switch OFF.
2) Disconnect the horn pin, horn switch pin, and connectors L103 and FS4.
3) Connect T-adapter.
Harness between FS4 (Female) (1) - L103
Resistance 1 Ω and below
(Female) (9), (11)
Harness disconnection Between FS4 (Female) (1), L103 (Female) (9), Resistance
or ground fault 1 MΩ and above
(11) - body
4 ★ Fuse A-1 blows at
Harness between horn switch pin - L103
occurrence of a
(Female) (10) Resistance 1 Ω and below
ground fault.
Between horn switch pin, L103 (Female) (10) Resistance
1 MΩ and above
- body
Harness between horn pin - L103 (Female)
Resistance 1 Ω and below
(12)
Between horn pin, L103 (Female) (12) - body Resistance 1 MΩ and above
20-934 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-13]
WA430-5 20-935
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-14]
Troubleshooting Code Error Code Controller Code The air conditioner does not work
Trouble or does not stop.
E-14 — —
Description of Trouble The air conditioning system is out of order, and the air conditioner does not work or does not stop.
Controller Reaction —
Effect on Machine The air conditioner does not work or does not stop.
This troubleshooting is only for the connection between the air conditioner and the operator cab. For trou-
Related Information
bleshooting of air conditioner body, refer to the Shop Manual of Air Conditioner.
1) Starting switch OFF. 2) Disconnect the connectors A7, A8, A9, A10, A11 and
A14. 3) Connect a T-adapter.
20-936 WA430-5
(1)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-14]
Troubleshooting Code Error Code Controller Code The air conditioner does not
Trouble
E-14 — — work or does not stop.
WA430-5 20-937
(1)......
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-14]
20-938 WA430-5
(1)
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE
(S MODE)
WA430-5 20-1001
(5)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
(a)
Questions
[A] (b)
(c)
(d)
(e)
[B]
Check items
[C]
i
shooting
Trouble-
ii
iii
20-1002 WA430-5
(5)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
)
[Questions] Section, ask the user, and mark
n
ctio
the Cause column with to use as reference
inje
for locating the cause of the failure. However,
sive
do not use this when marking calculations to
zle
renc
xces
ner
narrow down the causes.
noz
ent
erfe
er li
p (e
*2. Use the in the Cause column as reference
g
ion
m
imin
d
for [Degree of use (Operated for long period)]
, int
pum
e
n
ject
l
i
er e
, cyl
in the [Questions] section as reference.
rger
on t
d in
ion
lean
ring
As a rule, do not use it when calculating be
cha
ecti
ject
eize
included if necessary to determine the order
air c
urbo
r inj
ston
e in
s
for troubleshooting.
,
rope
ged
ctiv
ged
n pi
ed t
Defe
Clog
Clog
Wor
Seiz
Imp
*1 Confirm recent repair history
*2 Degree of use Operated for long period
WA430-5 20-1003
(5)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
d)
ad
n)
• Excessive injection of fuel
eize
d he
ctio
er s
inje
r an
lung
at
arge
sive
e se
e
ck, p
renc
xces
zzle
och
valv
p (ra
ent
n no
turb
erfe
p (e
lve,
r
r
e
inde
lem
uffle
imin
ranc
, int
pum
pum
ctio
een
f va
er e
, cyl
ed m
rger
inje
clea
on t
etw
ct o
ion
ion
lean
ring
cha
air b
ecti
zed
onta
ject
ject
lve
logg
Legend
air c
urbo
r inj
r va
, sei
ston
e in
e in
c
e of
: Possible causes (judging from Questions and check items)
d, c
e
rope
rope
ged
ctiv
ctiv
ged
ctiv
: Most probable causes (judging from Questions and Check items)
n pi
ed t
she
kag
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-1004 WA430-5
(5)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
Five causes
Step 1
Three symptoms
Step 2
Step 3
WA430-5 20-1005
(5)
TROUBLESHOOTING S-1
uck)
temperature
er st
20° C 1.28 1.26 1.24 1.23 1.22
nk
seat
0° C 1.29 1.27 1.25 1.24 1.23
lung
ping
ater
el t a
ery
–10° C 1.30 1.28 1.26 1.25 1.24
alve
ck, p
ir he
r
el pi
in fu
filte
batt
ve, v
ent
p (ra
in fu
r
• The specific gravity should exceed the value for the
uze
r
ake
hole
le
inde
ted
lem
n
ing
nozz
f val
i
p ga
a
pum
l int
charging rate of 70% in the above table.
, air
iora
r
m
er e
, cyl
r, st
her
r
i
act o
tor
nato
t
tion
pum
trica
ging
• In cold areas the specific gravity must exceed the
eter
tion
tion
n
reat
filte
ring
gula
clea
injec
alter
cont
elec
or d
clog
injec
value for the charging rate of 75% in the above table.
injec
air b
eed
fuel
ston
e
r
r
a i
f
ctive
ctive
ctive
ctive
ctive
ctive
age,
ged
tive
ged
ged
tive
ged
n pi
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Leak
Defe
Clog
Clog
Clog
Clog
Wor
Replace
Replace
Replace
Replace
Replace
Replace
»Adjust
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
20-1006 WA430-5
(5)
TROUBLESHOOTING S-2
ire
or w
or
• Seizure inside engine
mot
mot
h
n
★ For seizure inside the engine, carry out the trou-
witc
stop
ctio
stop
it
bleshooting for S-4 Engine stops during opera-
nne
ery
ircu
ty s
gine
gine
tion.
batt
al co
safe
ng c
f en
f en
id
ated
itch
leno
tarti
• Failure in power train
min
r
y or
nt o
o
o
y
o t
t
rela
g sw
• Defective electrical system
men
rior
of s
t so
r
rela
gm
tme
t
ttery
dete
ttery
el cu
ar
artin
iring
artin
just
fety
djus
g ge
e ba
e ad
e ba
e sa
e or
e fu
e st
e st
ew
a
n
e
ri
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ken
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Bro
Confirm recent repair history
Questions
move out
Replace
Replace
Adjust
—
Remedy
WA430-5 20-1007
(5)
TROUBLESHOOTING S-2
d)
–30 –20 –10 0 10 20 30 40° C
eize
er s
ASTM D975 No. 2
key
lung
nk
Diesel oil
el ta
aft,
ASTM D975A
ck, p
on
No. 1
lter
e sh
in fu
pist
p (ra
or
ze fi
ng
driv
id
mot
ump
ole
pipi
leno
rain
gau
pum
nk
mp
stop
ed p
fuel
r, st
her
t so
in ta
mp
n pu
ed
ion
reat
e
filte
king
l cu
gine
l us
u
en f
fuel
ject
p
ctio
air b
feed
r fue
fuel
, lea
e en
brok
e fu
e in
inje
ent
ged
rope
ged
ged
ged
ctiv
ctiv
ctiv
ffici
ed,
ken
Clog
Defe
Clog
Defe
Clog
Clog
Defe
Insu
Seiz
Imp
Bro
Remedy
20-1008 WA430-5
(5)
TROUBLESHOOTING S-2
.)
r, etc
General causes why exhaust smoke comes out
)
tuck
but engine does not start
leve
cap
er s
y
spra
cker
• Lack of rotating force due to defective electri-
lung
tank
em
ater
e, ro
e
cal system
syst
ctiv
k, p
ery
fuel
i r he
(valv
r
r
• Insufficient supply of fuel
filte
e
defe
batt
(rac
fuel
t
le in
i
n
ke a
• Insufficient intake of air
l
tem
er
uz e
e
e r
ump
ated
zle,
elem
rain
r in
d
r ho
• Improper selection of fuel and oil
e sys
inta
p ga
n
noz
i
i
, cyl
r, st
a
rior
on p
e
ner
valv
ed
ical
ing,
h
pum
tion
reat
dete
filte
ring
l us
a
i
ectr
ject
ken
ogg
l e
njec
air b
eed
air c
r fue
uel
ston
e or
, bro
e in
e el
e, cl
f
f
rope
ged
ged
ged
ged
ged
ctiv
ctiv
ctiv
ctive
n pi
kag
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Imp
Lea
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly failed to start
Questions
found to be clogged
When feed pump gauze filter is inspected directly, it is found to
be clogged
When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
Speed does not change when operation of certain cylinders is stopped
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
WA430-5 20-1009
(5)
TROUBLESHOOTING S-3
ap
y
seat
spra
nk c
• Improper fuel used
lve
el ta
tive
nce
d va
r
er
efec
r
filte
in fu
fere
e
r lin
ung
e an
ent
ng
d
r
uze
nter
aine
pipi
e
hole
e
lem
zle,
p pl
valv
ranc
d
p ga
cylin
er, i
noz
r
er e
fuel
pum
r, st
her
clea
t of
pum
harg
n
lean
reat
filte
king
ring
ntac
ctio
tion
lve
c
air b
eed
air c
urbo
uel
, lea
inje
r va
ston
e co
njec
f
f
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
ed i
n pi
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Replacement of filters has not been carried out according to
Questions
Operation Manual
Non-specified fuel is being used
Engine oil must be added more frequently
Engine pick-up suddenly became poor
Rust and water are found when fuel tank is drained
Dust indicator lamp is red
Noise of interference is heard from around turbocharger
Blue under light load
Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Check items
clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or does not return
When compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be
outside standard value
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-1010 WA430-5
(5)
TROUBLESHOOTING S-4
c.)
r , et
• Insufficient supply of fuel
)
tuck
leve
• Overheating
er s
cker
★ If the engine is overheating and the engine
rod
lung
nk
e, r o
el ta
nt
stops, carry out troubleshooting for over-
ey
ring
ting
ck, p
ston
(valv
lter
ft, k
ui pm
in fu
heating.
a
nec
p pi
ft be
p ( ra
ze f i
ng
sha
(See S-14 Water temperature becomes too
stem
iner
con
y eq
ole
pipi
pum
in
gau
ksha
pum
e
high)
stra
nk
r tra
er h
v
e sy
in
on,
iliar
fuel
p dr
in ta
r t ra
ump
feed
cran
valv
h
gea
ion
pist
ter,
x
reat
king
pum
p au
owe
uel
ject
ed p
l
zed
i
c
zed
zed
zed
f
i
air b
ynam
fuel
, lea
f
pum
e in
in p
fuel
, sei
ent
, sei
, sei
, sei
f e
ged
ged
ged
ged
ctiv
en d
ffici
ken
ure
ken
ken
ken
ken
ken
Clog
Clog
Defe
Clog
Clog
Insu
Brok
Fail
Bro
Bro
Bro
Bro
Bro
Bro
Confirm recent repair history
Degree of use of machine Operated for long period
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Questions
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
WA430-5 20-1011
(5)
TROUBLESHOOTING S-5
p
zzle
pum
• Defective governor mechanism
d no
eed
• Defective electrical governor mechanism
p an
nd f
(engine with electrical governor)
m
nk a
nk
d pu
el ta
★
k
If hunting stops when electrical governor rod is
el ta
r
c
erno
ol ra
rnor
lter
n fee
in fu
disconnected, carry out troubleshooting for the
en fu
ze fi
gov
ontr
ove
in ta low
troubleshooting for electric system.
twee
er
hole
etw e
rain
gau
of g
t of
of c
o
k
it be
o
n
uit b
r, st
her
men
ump
ion
ion
d is
circu
reat
filte
c
erat
erat
just
r
e
fuel
ed p
c i
e
air in
air b
g sp
air in
fuel
e ad
e op
e op
ent
f e
idlin
ged
ged
ged
ged,
ctiv
ged,
ctiv
ctiv
ffici
Clog
Clog
Clog
Defe
Defe
Defe
Clog
Insu
Clog
Low
Confirm recent repair history
Degree of use of machine Operated for long period
Occurs at a certain speed range
Questions
improperly adjusted
When control rack is pushed, it is found to be heavy, or
does not return
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump gauze filter is inspected directly, it is
found to be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
20-1012 WA430-5
(5)
TROUBLESHOOTING S-6
ent
stm
y
seat
• Insufficient intake of air
spra
adju
nk
• Insufficient supply of fuel
lve
el ta
tive
e
• Improper condition of fuel injection
d va
e
renc
ctiv
r
efec
in fu
ger
fi l te
• Improper fuel used
e an
g
ent
defe
erfe
plun
le, d
i pi n
pum ainer
uze
(if non-specified fuel is used, output drops)
hol e
e
inde
lem
valv
ranc
, int
p
ge,
p ga
z
• Lack of output due to overheating
p
noz
tr
fuel
er e
pum
, cyl
her
rger
er, s
nka
t of
clea
ion
reat
lean
★ If there is overheating and lack of output,
king
ring
ntac
er li
cha
tion
t
lve
l
ject
f i
air b
carry out troubleshooting for S-14 overheat-
feed
air c
l lev
fuel
urbo
, lea
e co
r va
ston
njec
n
ing.
t fue
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
n pi
ed i
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Ben
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly
Power was lost
Gradually
Questions
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
WA430-5 20-1013
(5)
TROUBLESHOOTING S-7
d)
ad
)
• Improper condition of fuel injection
tion
eize
d he
• Excessive injection of fuel
njec
er s
at
ray
r an
e se
lung
e sp
ve i
arge
valv
essi
e
ctiv
ck, p
renc
och
er
and
(exc
defe
r lin
p ( ra
ent
turb
erfe
lve
g
r
ce
i nde
mp
lem
zle,
uffle
imin
, int
pum
een
aran
f va
u
z
er e
, cyl
n no
ed m
rger
on t
w
ct o
e cle
ion
ion
t
lean
ir be
ring
ctio
cha
ecti
onta
ject
ject
logg
valv
air c
a
inje
urbo
r inj
ston
e in
e in
c
e of
d, c
e
r
rope
rope
ged
ctiv
ctiv
ged
ctiv
n pi
ed t
she
kag
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Replace
Replace
Replace
Replace
Replace
Remedy
Correct
Adjust
Adjust
Adjust
Clean
20-1014 WA430-5
(5)
TROUBLESHOOTING S-8
r
arge
General causes why oil consumption is excessive
och
• Abnormal combustion of oil
Turb
al
d
• External leakage of oil
hea
n se
ce
em
e
oler
• Wear of lubrication system
urfa
hos
der
oke
syst
er
s
r lin
cylin
her
), br
seal
pl ug
r oi l
e
reat
k
inde
d
nd
uide
inta
n or
ter o
pi ng
eal,
n
ain
e
er e
or b
, cyl
bine
m, g
om
ar s
il pa
il dr
il pi
il fil
ing
low
ther
r
ring
in fr
n re
oole
t tur
(ste
mo
mo
mo
mo
on r
at b
brea
roke
ston
cked
al a
oil c
e fro
e fro
e fro
e fro
lve
pist
a l
n va
n se
n se
ged
n, b
n pi
t su
kag
ken
kag
kag
kag
ken
Clog
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Bro
Lea
Lea
Lea
Confirm recent repair history Bro
Degree of use of machine Operated for long period
Oil consumption suddenly increased
Engine oil must be added more frequently
Questions
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
WA430-5 20-1015
(5)
TROUBLESHOOTING S-9
end
• Improper oil used
bi ne
• Operation under excessive load
tube
r tur
ose
er
ain
arge
r lin
i l dr
r
athe
inde
h
er o
ui de
boc
lack
, bre
alve
, cyl
harg
t tur
g
is b
r
e
v
ther
o ol e
ring
valv
r
y
al a
e
rboc
oke
t
t
e
il fil
brea
oil c
f
ston
e se
e sa
lve,
t sm
u
o
t
ged
n va
ged
ged
ged
ctiv
ctiv
n pi
aus
Clog
Defe
Clog
Clog
Defe
Clog
Wor
Wor
Exh
Confirm recent repair history
Questions
None
Carry out troubleshooting for “S-7 Exhaust smoke is black”.
While oil temperature is high, oil filter caution lamp lights up
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty
with oil
Engine oil temperature rises quickly
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
20-1016 WA430-5
(5)
TROUBLESHOOTING S-10
)
tion
ge
ter
on)
njec
linka
el fil
(pist
ive i
g, fu
trol
mp
r
er
ce ss
cove
l con
pipin
d pu
n g
ng
y
p plu
p (ex
spra
f fue
ead
timi
e
fuel
f e
pum
h
pum
e
lder
nt o
tion
nsid
from
side
le ho
stme
injec
tion
eal i
el in
o
age
t i
injec
injec
nozz
adju
oil s
fuel
of fu
leak
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Defe
Defe
Leak
Defe
Defe
Defe
Defe
Exte
Confirm recent repair history
Questions
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
WA430-5 20-1017
(5)
TROUBLESHOOTING S-11
ng
• Internal leakage in cooling system
pitti
by
ade
ole m
lin er
or h
et
n d er
gask
-ring
k
bloc
ing
er
l i
head
of cy
cool
er O
, O-r
der
r lin
n oil
cylin
core
ead,
ction
linde
i
er h
r tra
oler
s in
roje
of cy
ylind
rack
owe
il co
nt p
nal c
fficie
en o
en p
en c
age
Dam
Brok
Brok
Brok
Inter
Insu
Confirm recent repair history
Questions
Remedy
20-1018 WA430-5
(5)
TROUBLESHOOTING S-12
SAE30CD
SAE10WCD
Engine oil
g
ipin
SAE10W-30CD
n
n
il pa
sor
l pa
lic p
ing
SAE15W-40CD
sen
e oi
r
alve
de o
drau
braz
nso
l
ure
d
urna
e
tor v
el se
insi
insi
d hy
n
ipe
valv
mp
il pa
ress
g, jo
on p
il
ilter
iner
gula
ipe
l lev
she
l pu
in o
lief
in o
p
oil p
stra
oil f
l
arin
, cru
e oi
e re
e re
e oi
e oi
suct
uel
i l
of o
n be
ctiv
ctiv
ctiv
ged
ged
ged
ctiv
ctiv
king
er, f
ken
Defe
Defe
Defe
Defe
Defe
Lack
Clog
Clog
Clog
Wor
Wat
Lea
Bro
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
WA430-5 20-1019
(5)
TROUBLESHOOTING S-13
seal
ng
pitti
for “S-11 Oil is in coolant, or coolant level goes
tive
down”.
e by
efec
er
cov
mad
General causes why oil level rises
or d
al
ead
t se
ole
hole
• Coolant in oil (milky white)
de h
or h
n
pum
ket
e
• Fuel in oil (diluted, and smells of diesel fuel)
ther
uipm
ace
insi
gas
ring
• Entry of oil from other component
n
surf
brea
-ring
leev
ctio
y eq
ing
k
ead
r O-
bloc
eal
s
inje
re, O
p
ump
iliar
d, h
line
r
p i
e
der
hold
rom
t
rear
side
osta
aux
hea
r co
ter p
der
cylin
f
rt in
zzle
ylin
oole
ged
erm
mp
der
fuel
a
of w
side
e no
of c
e pu
cylin
e pa
ama
e th
oil c
e of
ging
ks in
age
ctiv
ctiv
ctiv
ctiv
n, d
kag
ken
ken
Dam
Defe
Clog
Defe
Defe
Defe
Crac
Wor
Lea
Bro
Confirm recent repair history Bro
Questions
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-1020 WA430-5
(5)
TROUBLESHOOTING S-14
re
• Defective cooling circulation system
ratu
n)
ge
• Rise in oil temperature in power train
ope
ket
gau
mpe
lley
gas
t tem es not
★ Carry out troubleshooting for chassis.
ns
ure
n pu
il te
or fi
ead
erat
er o
oole
rn fa
do
alve
diat
d, h
p
tat (
vert
g
core
oil c
, wo
ittin
re v
d ra
hea
ump
mos
con
ator
by p
essu
ping
olan
ken
she
der
er p
ant
rque
ther
, bro
radi
, cru
cylin
e co
e pr
l
ade
wat
o
l i
o
s
in to
e
of c
ged
ged
ged
sm
ctiv
ctiv
ctiv
belt
ken
ken
Clog
Defe
Hole
Clog
Defe
Lack
Clog
Defe
Rise
Bro
Bro
Fan
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Coolant temperature Rises quickly
gauge Does not go down from red range
Radiator coolant level sensor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Coolant flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
is excessive
Temperature difference between top and bottom radiator tanks
is slight
Troubleshooting
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
—
Add
WA430-5 20-1021
(5)
TROUBLESHOOTING S-15
ead
etc.)
)
General causes why abnormal noise is made
ition
d)
der h
i on)
ver,
eize
f pos
ject
cylin
er le
• Abnormality due to defective parts
er s
ce
n
out o
r
• Abnormal combustion
rock
aran
r line
l ung
r and
ive
e
• Air sucked in from intake system
c
e
oard
e cle
cess
linde
alve
eren
ck, p
enc
arge
pum oz z l e
m (v
ing b
sh
x
r
g, cy
valv
f
p (ra
boch
e
r
p (e
inte
f
nn
ckla
nter
yste
divid
n rin
i ng
t of
pum
n tur
ctio
a
belt
er, i
b
lve s
ush
n
pisto
fler (
i nj e
train
wee
e
i on
i on
harg
n
m
ic va
b
n, fa
just
muf
r bet
d
r of
ject
ject
zed
r
e
a
c
ynam
z
wea
urbo
r ge
d fa
e ad
, sei
e in
of ai
side
, sei
e in
rme
rope
sive
ctiv
ged
ctiv
ct in
en d
ctiv
ed t
sing
age
s
Defe
Defo
Defe
Defe
Clog
Defe
Brok
Leak
Seiz
Imp
Exce
Mis
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Injection pump test shows that injection amount is incorrect
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-1022 WA430-5
(5)
TROUBLESHOOTING S-16
uck)
n)
Abnormal noise is made”.
ctio
tc. st
ion
inje
General causes why vibration is excessive
gne
er, e
cush
r)
fuel
r lev
isali
e
port
p
• Defective parts (abnormal wear, breakage)
ken
dam
rocke
sive
ring
in m
• Improper alignment
sup
, bro
aft (
xces
bea
alve,
a
• Abnormal combustion
r
n of
olts
t
h
t sh
m (v
klas
ain
p (e
e
ortio
w
b
utpu
d, m
syste
o
ting
bac
pum
p
int p
and
de o
g ro
oun
rain
alve
ing
ion
et jo
gine
mic v
em
ctin
ush
insi
ject
a r
fauc
e
nne
ngin
mb
f en
dyna
e in
part
r g
n co
rope
ter o
n ca
ctiv
se e
r of
ctive
ken
Defe
Wor
Wea
Wor
Imp
Cen
Loo
Defe
Bro
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idling
Check items
Check faucet joint portion of support directly for wear and play
Inspect directly for loose engine mounting bolts, broken cushion
Inspect inside of output shaft (damper) directly
When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Remove head cover and inspect directly
Injection pump test shows that injection amount is incorrect
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
WA430-5 20-1023
(5)
30 DISASSEMBLY AND ASSEMBLY
WA430-5 30-1
(5)
(2)...
DISASSEMBLY AND ASSEMBLY
30-2 WA430-5
(2)
(5)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
• Special tools that are deemed necessary for • Except where otherwise instructed, install parts
removal or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing parts
kind of information. are shown with [*1] mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
t: Special tools which cannot be substi- are intended for.
tuted, should always be used. • Marks shown in the INSTALLATION Section
q: Special tools which are very useful if stand for the following.
5
This mark indicates an amount of oil or
3) Circle mark (Q) in sketch column:
water to be added.
A circle mark means that a sketch of the spe-
cial tool is presented in the section of
Sketches for Special Tools. SKETCHES OF SPECIAL TOOLS
a Part No. of special tools starting with 79*T • Various special tools are illustrated for the con-
means that they are locally made parts and as venience of local manufacture.
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL OF PARTS
6
This mark shows oil or water to be
drained
4
This mark shows the weight of a part or a
device.
WA430-5 30-3
(2)...
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
• Special tools which are deemed necessary for • Section titled ASSEMBLY contain procedures,
disassembly and assembly of parts are listed. precautions and the know-how for the work, as
• List of the special tools contains the following well as the amount of oil or water to be added.
kind of information. • Various symbols used in ASSEMBLY Section
1) Necessity are explained and listed below.
t: Special tools which cannot be substi- • Marks shown in the INSTALLATION Section
tuted, should always be used. stand for the following.
2) Distinction of new and existing special tools This mark gives guidance or precautions
a when doing the procedure.
N: Tools with new part numbers, newly
developed for this mode.
2
This mark stands for a specific coating
R: Tools with upgraded part numbers,
agent to be used.
remodeled from already available tools
for other models. 3 This mark indicates the specified torque.
Blank: Tools already available for other models,
5
used without any modification. This mark indicates an amount of oil or
water to be added.
3) Circle mark (Q) in sketch column:
A circle mark means that a sketch of the spe- SKETCHES OF SPECIAL TOOLS
cial tool is presented in the section of
Sketches for Special Tools.
1) Various special tools are illustrated for the
convenience of local manufacture.
a Part No. of special tools starting with 79*T
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T--- xxx --- xxxx.
DISASSEMBLY
6
This mark shows oil or water to be
drained
30-4 WA430-5
(2)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
C. 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
DEW00401
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
WA430-5 30-5
(2)...
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
30-6 WA430-5
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
New/
Nece Sket
Component Symbol Part No. Part Name ssity
Q’ty remo Nature of work, remarks
del ch
Engine assembly A 790-331-1110 Wrench 1 Tightening of cylinder head bolt
790-501-5000 Unit repair stand 1
Disassembly and assembly of torque
790-501-5200 Unit repair stand 1 converter assembly
1 ★ Use C2 and C3 for lock-up speci-
790-901-2110 Bracket 1
fications only
Torque converter
C 790-901-2150 Plate 1
assembly
790-201-2230 Plate 1
2 Installation of stator shaft bearing
790-201-2750 Spacer 1
Removal and installation of pump
3 793-647-1110 Wrench 1
nut
793T-607-1240 Bracket z 2 {
1 Turning of transmission assembly
01010-81645 Bolt z 8
790-201-2170 Plate 1
3
790-201-2730 Spacer 1 Press-fitting of bearing
D
4 796-465-1120 Push tool 1
Transmission assembly
5 793-607-1110 Seal holder 1
Assembly of piston seal
6 793-607-1120 Seal holder 1
7 799-301-1500 Oil leak tester 1 Checking of piston function
793T-607-1210 Lifting tool z 2 {
F 2 Lifting up of clutch pack assembly
793-607-1230 Pin z 2
793T-607-1190 Bracket 1 {
Removal and installation of snap
1 722-14-13130 Holder 1
ring
01011-62020 Bolt 1
793T-607-1130 Push tool 1 {
3 790-101-5421 Grip 1 Press-fitting of oil seal and dust seal
01010-81240 Bolt 1
4 793T-607-1140 Spacer 1 { Press-fitting of dust seal
Parking brake assembly H
5 792T-446-1150 Push tool 1 { Installation of bearing on boss part
6 797T-423-1141 Push tool 1 { Installation of output shaft bearing
793T-512-1110 Push tool 1 {
8 790-101-5421 Grip 1 Press-fitting of oil seal and dust seal
01010-51240 Bolt 1
9 793T-607-1160 Spacer 1 { Press-fitting of dust seal
10 793T-607-1180 Push tool 1 { Press-fitting of front coupling cover
WA430-5 30-7
(5)
(2)...
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
790-201-2760 Spacer 1
793T-622-1370 Support 2 {
12 Position setting of oil seal (For front)
01016-30860 Bolt 6
Axle assembly
13 793T-522-1160 Push tool 1 { Press-fitting
rear)
of oil seal sleeve (For
H
793T-522-1140 Push tool 1 {
14 Press-fitting of bearing (For rear)
793T-522-1150 Spacer 1 {
793T-522-1170 Support 2 {
15 Position setting of oil seal sleeve
01010-30860 Bolt 6
(For rear)
22 793T-622-1610 Holder 1 N {
23 797T-423-1290 Push tool 1 { Press-fitting
side)
of bearing (differential
790-501-5000
or Unit repair stand 1
790-501-5200 Disassembly and assembly of differ-
16
790-901-2110 Bracket 1 ential assembly (For front)
790T-901-3440 Plate 1 {
796-765-1110 Push tool 1 • Press-fitting of pinion gear bearing
(For front)
17 790-201-2750 Spacer 1 • Connect push tool and spacer
01010-81240 Bolt 1
20
793T-522-1110 Push tool 1 {
793T-522-1120 Spacer 1 { Press-fitting of pinion cage dust seal
790-101-5421 Grip 1 (For rear)
01010-51240 Bolt 1
790-301-1720 Adapter 1
799-101-5002 Hydraulic kit 1
21 Checking of brake oil leakage
793-605-1001 Brake tester 1
790-101-1102 Hydraulic pump 1
No-load operating torque of anti-slip
24 796-751-1510 Wrench 1
differential
30-8 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Vacuum pump
799-703-1120
(240V) 1
WA430-5 30-9
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
D1 Bracket
F2 Lifting tool
30-10 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
H1 Bracket
H3 Push tool
WA430-5 30-11
(5)
(2)...
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H4 Spacer
H5 Push tool
30-12 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H6 Push tool
H8 Push tool
WA430-5 30-13
(5)
(2)...
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H9 Spacer
30-14 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H11 Spacer
WA430-5 30-15
(5)
(2)...
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H12 Support
30-16 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H14 Spacer
WA430-5 30-17
(5)
(2)...
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H15 Support
H16 Plate
30-18 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
WA430-5 30-19
(5)
(2)...
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
30-20 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H20 Spacer
WA430-5 30-21
(5)
(2)...
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H22 Holder
9JS02736
30-22 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
CPW11330
CPW11508
CPW11333
WA430-5 30-23
(5)
(2)...
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
[*2]
★ Adjust the accelerator pedal and the engine
stop motor lever, referring to section "Adjust-
10. Remove the four mounting bolts and then ing Accelerator Pedal and Engine Stop Lever"
remove the fuel injection pump assembly in "TESTING AND ADJUSTING."
(14).
[*3]
4 Fuel injection pump assembly:
3 Lubrication tube (9) joint bolt
30kg
(Cylinder block side):
9.8 - 12.74Nm {1.0 - 1.3kgm}
30-24 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF NOZZLE HOLDER
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDERASSEMBLY
ASSEMBLY
CPW11336
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
3. Remove the two nozzle holder mounting bolts ★ Tighten the nozzle holder mounting bolts
(3). [*1] alternately and evenly.
CPW11337
WA430-5 30-25
(5)
(2)...
REMOVAL AND INSTALLATION OF CYLINDER HEAD
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
ASSEMBLY
New/Modified
(Left) (3) and G05 (Right) (4).
Necessity
Quantity
Sketch
Symbol Part Number Part Name 5. Disconnect the intermediate connectors CN-
55 (5) and GRI (6).
A 790-331-1110 Wrench ■ 1
REMOVAL
1. Drain coolant.
CPW11301
CPW11304
CPW11302
CPW11305
30-26 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF CYLINDER HEAD
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
8. Remove the baffle (10). 11. Remove the insulator cover (14).
CPW11306 CPW11309
9. Temporarily lift the engine hood assembly 12. Remove the Muffler water drained tube (15).
and remove the two mounting bolts (11) and [*1]
(12). 13. Remove the U-clamp (16). [*2]
14. Temporarily lift the muffler assembly.
15. Remove the four bolts and nuts (17) between
the muffler and the turbocharger, and remove
the four muffler mounting bolts (18).
CWW11307
CPW11310
CPW11308
CPW11311
WA430-5 30-27
(5)
(2)...
REMOVAL AND INSTALLATION OF CYLINDER HEAD
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
ASSEMBLY
17. Disconnect the dust indicator hose (20) and 21. Disconnect the dust indicator connector E33
the air intake hose (21). [*3] (28).
★ Disconnect the air intake hose from the 22. Disconnect the engine heater relay wiring
turbocharger. harness E07 (29), E05 (30) and E06 (31). [*5]
18. Remove the band (22) and then the air
cleaner assembly (23). [*4]
CPW11314
CPW11312
CPW11315
30-28 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF CYLINDER HEAD
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
28. Remove the boost compensation tube (42). 33. Lift the air intake manifold assembly (47) and
29. Remove the heater relay and engine oil filter remove it.
4
bracket (43).
Air intake manifold assembly: 50kg
30. Remove the air cleaner bracket (44).
★ Disconnect the 2 wire clamps of the
heater relay, and then remove the air
cleaner bracket.
CPW11318
CPW11316
CPW11317
CPW11320
WA430-5 30-29
(5)
(2)...
REMOVAL AND INSTALLATION OF CYLINDER HEAD
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
ASSEMBLY
36. Remove the six fuel injection tubes (51). [*12] 41. Remove the rocker arm assembly (56). [*16]
37. Remove the spill tube (52). ★ Loosen the locknut, and then loosen
adjustment screw by 2 - 3 turns.
38. Remove the water tube (53). [*13]
CPW11324
CPW11321
42. Remove the push rod (57) and the cross head
39. Remove the head cover (54). [*14]
(58). [*17]
CPW11322 CPW11325
40. Remove the two mounting bolts and then 43. Remove the rocker housing (59). [*18]
remove the nozzle holder assembly (55).
[*15]
CPW11326
CPW11323
30-30 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF CYLINDER HEAD
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
3
[*19]
Joint bolt (Fuel filter side):
24.5 - 34.3Nm {2.5 - 3.5kgm}
3 Hose clamp:
2.9 ± 0.49Nm {0.3 ± 0.05kgm}
CJW11328
[*2]
3 U-clamp:
9.8 - 14.7Nm {1.0 - 1.5kgm}
[*3]
3
[*4]
3
Hose clamp:
Band: 9.8 - 11.76Nm {1.0 - 1.2kgm} 5.9 ± 0.49Nm {0.6 ± 0.05kgm}
[*5] [*10]
3 Nut (31):
1.86 - 2.45Nm {0.19 - 0.25kgm}
[*6]
3 Hose clamp:
3.3 ± 0.49Nm {0.34 ± 0.05kgm}
WA430-5 30-31
(5)
(2)...
REMOVAL AND INSTALLATION OF CYLINDER HEAD
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
ASSEMBLY
[*11] [*16]
★ Screw in the exhaust manifold mounting ★ Check that the ball of the adjustment screw is
bolts [1] - [3] with the fingers by 2 - 3 turns, fitted to the socket of the push rod.
and then tighten the other bolts. ★ When installing the rocket shaft, set the ball
3
toward the front of the engine. Do not set it
Mounting bolt:
upside down.
58.8 - 73.5Nm {6.0 - 7.5kgm}
★ Adjust the valve clearance, referring to sec-
tion "Adjusting Valve Clearance" in "TESTING
AND ADJUSTING."
3
CJW11329
Locknut:
53.0 - 64.7Nm {5.4 - 6.6kgm}
[*17]
Procedure for adjusting cross head
3
tighten the adjustment screw.
Sleeve nut: 3. After the adjustment screw touches the valve
22.54 - 24.5Nm {2.3 - 2.5kgm} stem, tighten it further by 20 degrees.
[*13] 4. Tighten the locknut.
3
Engine oil (SAE30)
Head cover mounting bolt:
9.8 ± 1.0Nm {1.0 ± 0.1kgm} [*18]
30-32 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF CYLINDER HEAD
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
[*19]
★ Clean the underside of the head, top of the
block, and liner with dry cloth or cloth soaked
in solvent.
★ Apply LM-P or SAE30 to the bolt threads and
underside of the bolt head. CXE00860
★ Screw the bolt into the block with the fingers
at least 2 turns.
★ Before tightening each bolt, measure its stem
length "a" and check that the result is less
than the service limit. If it is longer than the
service limit, do not use it again but replace it.
• Service limit length of bolt: Less than
171.4 mm
CDE00116
DWE00275
3
CEW00034
Cylinder head bolt:
1st time:
98.1 ± 9.8 Nm {10 ± 1 kgm}
2nd time:
156.9 - 166.7 Nm {16 - 17 kgm}
3rd time: Make marks on head bolt
and cylinder head (1) with marker,
and then tighten bolt by 90° +300 .
WA430-5 30-33
(5)
(2)...
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
New/Modified
Necessity
Quantity
Sketch
Symbol Part Number Part Name
CPW11401
799-703-1200 Service tool kit ■ 1
vacuum pump
799-703-1100 (100V) ■ 1
vacuum pump
X 799-703-1110 ■ 1
(100V)
vacuum pump
799-703-1120 ■ 1
(100V)
799-703-1400 Gas leak tester ■ 1
7. Remove the cover (6) and then the rubber (7).
REMOVAL ★ Remove the upper and opposite one.
★ Keep the caps.
Park the machine on flat ground and set
the safety bar to the frame.
30-34 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
9. Disconnect the coolant level sensor connector 15. Remove the two mounting bolts (16) of the
R32 (9). left and right, and lift the reservoir tank
10. Disconnect the transmission breather hose assembly (17) and remove it.
4
(10). [*3]
Reservoir tank assembly: 70kg
11. Disconnect the air conditioner hose clamp
(11) and then the air conditioner hose (12).
[*4]
12. Disconnect the over-flow hose (13) of the res-
ervoir tank form clamp.
CPW11407
CPW11404
CPW11405
CPW11408
CPW11406
WA430-5 30-35
(5)
(2)...
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
20. Lift the muffler assembly (22) and remove it. 24. Disconnect the dust indicator connector E33
4
(30).
Muffler assembly: 40kg
25. Disconnect the engine speed sensor connec-
tor E27 (31).
CPW11409
CPW11412
CPW11410
CPW11413
CPW11411
CPW11414
30-36 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
30. Disconnect the starting motor wiring harness 35. Disconnect the heater outlet hose (48), inlet
(39) and the B terminal E30 (40). [*9] hose (49) and the water pump inlet hose (50).
31. Disconnect the engine water temperature pre-
heater sensor connector E09 (41) and the
engine stop motor connector E35 (42).
32. Disconnect the ground wiring harness (43).
CPW11418
CPW11415
CPW11416
CPW11417
WA430-5 30-37
(5)
(2)...
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
38. Disconnect the air conditioner compressor 41. Disconnect the torque converter oil cooler
hose clamp, and then disconnect the hose outlet hose (60) and inlet hose (61), and
(54) and (55). [*4] remove the torque converter oil cooler
mounting bolt (62). [*12]
CPW11421
CPW11424
CPW11422
CPW11425
CPW11423
CPW11426
30-38 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
44. Temporarily lift the engine assembly. 48. Lift the engine assembly (66) and remove it.
45. Remove the left and right engine mounting [*15]
bolts (64). [*14] ★ Check that no wires and no pipes of the
engine are connected to the chassis side
and take care that the engine will not
interfere with the chassis side when
removing it.
CPW11430
CPW11428
CPW11429
WA430-5 30-39
(5)
(2)...
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
INSTALLATION
• Carry out installation in the reverse order to
removal. [*8]
3
[*1]
3
Nut: 2.4 - 3.0Nm {0.24 - 0.31kgm}
air intake hose clamp:
8.8 ± 0.5Nm {0.9 ± 0.05kgm}
[*9]
3 Hose band:
2.8 - 3.8Nm {0.29 - 0.39kgm} [*11]
★ Adjust the accelerator pedal and the engine
[*4] stop motor lever, referring to section "Adjust-
2
ing Accelerator Pedal and Engine Stop Lever"
O-ring and screw unit: in "TESTING AND ADJUSTING."
Compressor oil (ND-OIL8)
3 Air conditioner hoses:
[*12]
3
Screw size Tightening torque Nm {kgm}
Torque converter oil cooler hose:
M16X1.5 12 - 15 {1.2 - 1.5}
147.1 - 245.1Nm {15.0 - 25.0kgm}
M24X1.5 30 - 35 {3.1 - 3.5}
3
Others M6 bolt 8 - 12 {0.8 - 1.2}
Rear propeller shaft mounting bolt:
98.1 - 122.6Nm {10.0 - 12.5kgm}
[*5]
3
2.9 ± 0.49Nm {0.3 ± 0.05kgm}
Engine mounting bolt:
823.8 - 1,029Nm {84.0 - 105kgm}
[*6]
3
inserted smoothly.
Nut (27):
1.86 - 2.45Nm {0.19 - 0.25kgm} Refilling with air conditioner refrigerant
3
• Using tool X, refill the air conditioner circuit
Nut (28), (29): with refrigerant (R134a).
2.45 - 2.94Nm {0.25 - 0.3kgm}
30-40 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF AFTER COOLER
DISASSEMBLY AND ASSEMBLY AFTER COOLER ASSEMBLY
CPW11214
CPW11211
CPW11212
CPW11215
WA430-5 30-41
(5)
(2)...
REMOVAL AND INSTALLATION OF COOLING FAN MOTOR
DISASSEMBLY AND ASSEMBLY COOLING FAN MOTOR ASSEMBLY
6
CPW11341
Hydraulic tank: 129l
CPW11342
4. Disconnect the fan reverse solenoid connec-
tor GR2 (3).
★ When disconnecting the connector, dis-
connect the wiring harness clamp from
the fan motor assembly mounting
bracket.
INSTALLATION
• Carry out installation in the reverse order to
CPW11340 removal.
[*1]
★ Bleed air from the fan motor circuit, referring
to section "Bleeding Air from Fan Motor Cir-
cuit" in "TESTING AND ADJUSTING."
30-42 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF RADIATOR, FAN MOTOR
DISASSEMBLY AND ASSEMBLY RADIATOR, FAN MOTORAND
AND AFTER
AFTER COOLER ASSEMBLY
1. Drain coolant.
CPW11203
CPW11201
WA430-5 30-43
(5)
(2)...
REMOVAL AND INSTALLATION OF RADIATOR, FAN MOTOR
DISASSEMBLY AND ASSEMBLY RADIATOR, FAN MOTOR AND
AND AFTER
AFTER COOLER ASSEMBLY
8. Disconnect the radiator inlet hose (9), the 11. Remove the left and right radiator stays (15)
water hose (10), the after cooler inlet hose and (16).
(11) and the after cooler outlet hose (12). [*1] 12. Temporarily lift the radiator, fan motor, after
cooler assembly, remove the left and right
radiator mounting bolts (17) and (18).
CPW11204
CPW11207
CPW11208
CPW11206
30-44 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF RADIATOR, FAN MOTOR
DISASSEMBLY AND ASSEMBLY RADIATOR, FAN MOTORAND
AND AFTER
AFTER COOLER ASSEMBLY
14. Remove the after cooler assembly (20) from 3. Put the block [1] (Size: about 15cm) under the
the radiator, fan motor, after cooler assembly. torque converter oil cooler.
4
4. Lower the radiator, fan motor, and aftercooler
After cooler assembly: 30kg
assembly slowly and insert it in the radiator
4
flange.
Radiator and fan motor assembly:
★ After connecting radiator outlet hose (22),
160kg
remove block [1] under the torque con-
verter oil cooler.
CPW11210
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
2
[*3]
3
Radiator inlet hose:
Gasket sealant (Three bond Radiator mounting bolt:
120BE) 157 - 196Nm {16 - 20kgm}
1. Remove the two torque converter oil cooler Bleed air from fan motor circuit.
mounting bolts (20). • Referring to section "Bleeding Air from Fan
Motor Circuit" in "TESTING AND ADJUST-
2. Disconnect the hose (21) from the torque con- ING."
verter oil cooler.
CPW11209
WA430-5 30-45
(5)
(2)...
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION FUEL TANK ASSEMBLY
1. Drain fuel.
CPW11385
6 Fuel tank: 343l (When full level)
CPW11386
CPW11387
30-46 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION FUEL TANK ASSEMBLY
3
the left cleaning window and stop the
nylon sling with bolt [2]. Fuel tank mounting bolt:
824 - 1,030Nm {84 - 105kgm}
5
CPW11388
Fuel tank: 343 l
CWW11389
13. Lift the fuel tank assembly (11) and remove it.
CPW11391
WA430-5 30-47
(5)
(2)...
REMOVAL AND INSTALLATION OF PARKING BRAKE DISC
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISC AND PLATE
New/Modified
washer (4), the retainer (5) and the coupling
Necessity
Quantity
Sketch
(6). [*2]
Symbol Part Number Part Name
793T-607-1190 Bracket ■ 1 {
H1 772-14-13130 Holder ■ 1
01011-62020 Bolt ■ 1
CPW10767
REMOVAL
CPW11559
30-48 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF PARKING BRAKE DISC
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISC AND PLATE
6. Loosen the mounting bolts (11) of the brake 10. Use the tool H1 to push the brake disc and
cover (10) equally, and remove the cover (10) the plate inside, and remove the snap ring
and the spring (12). [*4] (16).
★ Since the mounting bolts are pressed ★ For the bolt and holder of the tool H1, the
with the brake spring, loosen them yoke mounting bolt and retainer can be
equally. used.
CWW10769 CPW11562
7. Keep the guide bolt [2] installed to the hous- 11. Remove the hub (17) and then remove the
ing (13). plates (18), the springs (19) and the discs (20).
8. Remove the bearing assembly (14). [*6]
★ 10 plates, 9 springs, and 9 discs
CPW11561
CPW10773
CPW11572
WA430-5 30-49
(5)
(2)...
REMOVAL AND INSTALLATION OF PARKING BRAKE DISC
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISC AND PLATE
INSTALLATION [*6]
★ Install the hub (17) first and then install the
• Carry out installation in the reverse order to plates (18), the springs (19) and the discs (20)
removal. in this order.
★ Be careful so that the spring (19) is not
[*1] pinched between them.
★ When installing the propeller shaft, check that
the spider cap key is perfectly nested in the
key slot of the counter yoke, and the tighten
the bolt.
3 Mounting bolt:
98 - 123Nm {10 - 12.5kgm} CWW10775
[*2]
3
system. Then check the oil level again.
Mounting bolt:
98 - 123Nm {10 - 12.5kgm} ★ When replacing any parts other than the disc
and plate, referring to section "Removal and
Installation of Parking Brake Assembly."
[*4]
[*5]
CPW10774
30-50 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND
AND TRANSMISSION ASSEMBLY
CPW11103
WA430-5 30-51
(5)
(2)...
REMOVAL AND INSTALLATION OF TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND
AND TRANSMISSION ASSEMBLY
9. Remove the guard (7) from between the 12. Disconnect the torque converter oil cooler
transmission and the front axle, and then dis- hose (13) and (14) from right of the torque
connect the center propeller shaft (8) at the converter.
transmission side. [*2]
★ Shrink the center propeller shaft.
CPW11107
CPW11104
CPW11108
CPW11105
CPW11106 CPW11109
30-52 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND
AND TRANSMISSION ASSEMBLY
16. Disconnect the following hoses from the 20. Remove the oil filler tube (31).
steering, switch and fan pump. 21. Disconnect the hoses (32) and (33) and
• (21), (22): Discharge tube remove the hydraulic oil filter (34).
• (23), (24): Discharge hose
• (25), (26): Hydraulic tank return hose
CPW11114
CPW11110
CPW11112
CPW11115
CPW11113
WA430-5 30-53
(5)
(2)...
REMOVAL AND INSTALLATION OF TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND
AND TRANSMISSION ASSEMBLY
3) Remove the transmission mounting bolts 5) Sling the transmission and engine assem-
(37) and (38) and then remove the plate bly and support the flywheel housing of
(39) and insulator (40). [*4] the engine assembly at a height of about
15 cm with block [1]. At this time, set
block [1] so that it will not damage the
brake piping of the rear axle.
CPW11118
CPW11117
CPW11119
30-54 WA430-5
(5)
(2)
REMOVAL AND INSTALLATION OF TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND
AND TRANSMISSION ASSEMBLY
4
removal.
Transmission assembly [*1]
(Without lock-up clutch): 800kg
★ When installing the propeller shaft, check that
(With lock-up clutch): 800kg
the spider cap key is perfectly nested in the
key slot of the counter yoke, and the tighten
the bolt.
CJW11122
WA430-5 30-55
(5)
(2)...
REMOVAL AND INSTALLATION OF TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND
AND TRANSMISSION ASSEMBLY
[*3]
[*4]
[*5]
★ Check that the O-ring is fitted to the torque
converter housing.
★ Using a crane and a chain block, adjust the
height and angle of the transmission assem-
bly so that the transmission will enter the
engine assembly smoothly.
5 Transmission case: 54 l
Bleeding air
• Bleed air from the fan motor circuit, referring
to section "Bleeding Air from Fan Motor Cir-
cuit" in "TESTING AND ADJUSTING."
30-56 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
New/Modified
Necessity
Quantity
1) Remove the suction tube (3).
Sketch
Symbol Part Number Part Name
2) Remove the discharge tube (4).
3) Temporarily lift the torque converter,
793T-607-1240 Bracket ● 2 {
work equipment and pilot control pump
D1 assembly (5), and remove the mounting
01010-81645 Bolt ● 8 bolt.
793T-607-1210 Lifting tool ● 2 {
F2
793-607-1230 Pin ● 2
DISASSEMBLY
1. Steering, switch and fan pump assembly CPW11148
1) Set the torque converter and transmission
assembly (1) on the block [1] and [2].
CPW11146
4) Remove the strainer (6).
CPW11149
CPW11147
WA430-5 30-57
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
CPW11150
CPW11151
CPW11152
30-58 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
(60) to (75), and then remove the wiring • (71): 2 SW (2nd clutch switch)
●
CJW11553
WA430-5 30-59
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
6. Speed sensor and oil temperature sensor 4) Remove the twenty case mounting bolts
Remove the speed sensor (27) and the trans- (30).
mission oil temperature sensor (28).
CPW11154
CPW10809
CJW11556
30-60 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
8. Torque converter assembly 2) Face the PTO side up and set the rear case
1) Face the torque converter side down and to the block.
lift the rear case assembly (31). Then, set 3) Remove the snap ring (37), the plate (38)
the block [7] below the torque converter and the woodruff thrust plate (39).
assembly (32).
★ Keep the case upright.
2) Remove the stator shaft mounting bolt
(33) and lift the rear case to remove the
torque converter assembly (33).
CPW10815
CJW11156
CPW10816
CPW10813
CPW10814
WA430-5 30-61
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
5) Remove the snap ring (35) and the plate 2) Use the tool F2 to lift the 1st speed and
(36) from the shaft (40). 4th speed clutch assembly (45) together
6) Remove the bearing (43) and the inner with the 2nd speed and 3rd speed clutch
race (59) from the shaft (40). assembly (46) and remove it.
★ Repeat the same procedures to
remove the PTO gear on the opposite
side.
Plate (36) is not installed on the oppo-
site side, however.
CWW10820
CWW10818
CPW11157
CPW10819
CPW10822
30-62 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
2) Use the puller [12] to remove the gear (51) 3) Remove the outer race (58) from the cover
and the bearing (52). (56).
3) Remove the bearing (52) and the plate
(53).
CWW10826
CJW11558
CPW10824
CPW10825
WA430-5 30-63
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
CPW10827
CPW10822
30-64 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
WA430-5 30-65
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
4) Set the PTO gear (41) to the case and 6) Attach the snap ring (34).
attach the shaft (40). ★ Repeat the same procedures to attach
the PTO gear on the opposite side.
CPW10815
3) Tighten 6 pieces of the stator shaft
mounting bolt (33).
2 Bolt: Adhesive (LT-2)
3 Bolt:
98 - 123 Nm {10 - 12.5 kgm}
CPW10813
30-66 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
3 Mounting bolt:
extension of the seal ring from the shaft
equal.
98 - 123 Nm {10 - 12.5 kgm}
2) Attach the guide bolt [9] to the front case.
3) Use the lever block to lift the rear case
assembly (31) and to attach it to the shaft
of the clutch assembly.
WA430-5 30-67
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
5) When bolt torques become equal, mea- 10. Speed sensor and oil temperature sensor
sure the clearances at four places (circular
1) Attach the oil temperature sensor (28).
2
equal division) (3-place equal division is
also acceptable) to find the average clear- Oil temperature sensor:
ance. Gasket sealant (LG-5)
3
★ To check if the bearing is not inclined,
Oil temperature sensor:
however, check if the bearing is set
29.4 - 49 Nm {3 - 5 kgm}
properly or if there is any other rea-
son where measured values differ
more than 0.15 mm. Take a proper
measure so that the bearing is not
inclined.
3 Mounting bolt:
gear then let the sensor touch the
gear by hand.
98 - 123 Nm {10 - 12.5 kgm} 2) After the sensor (27) touched the gear
(61), give the sensor a half to a turn in
8) Attach the cover (55). reverse and fix it with the locknut (62).
★ When fixing the sensor with the lock-
nut, fix the other nut with a wrench
and tighten the locknut.
30-68 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
1) Install the two guide bolts to the transmis- • (63): R SW (Reverse clutch switch)
●
2) Use the eyebolt [3] to lift and install the • (65): 4 SW (4th clutch switch)
●
3
• (69): 3 SW (3rd clutch switch)
●
(60) to (75) and install the wiring harness • (73): PB SW (Parking brake switch)
●
CJW11553
WA430-5 30-69
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
3
2) Install the level gauge (17).
Tube joint bolt:
★ Fix the upper and lower holders with
9.8 - 12.7Nm {1.0 - 1.3kgm}
a wrench so that they to not rotate,
and tighten the bolts. 2) Install the flow control valve (11).
3 Mounting bolt: 2 Mounting bolt:
12.7 - 13.7Nm {1.3 - 1.4kgm} Adhesive (LT-2)
3) Install the cover (16). 3 Mounting bolt:
3
29.4 - 39.2Nm {3.0 - 4.0kgm}
Mounting bolt:
98 - 123Nm {10 - 12.5kgm} 3) Connect the hose (10).
4) Install the transmission mount (15) and 4) Install the block (9).
(14). 5) Connect the torque converter oil tempera-
3
ture sensor connector TC.T (8).
Mounting bolt: 6) Connect the breather hose (7).
245 - 308.7Nm {25 - 31.5kgm}
CPW11150
CPW11152
CPW11151
CPW11149
30-70 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
CPW11148
CPW11147
WA430-5 30-71
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
New/Modified
1) Remove spacer (1) and thrust washer (4)
Necessity
Quantity
Sketch
and dismount forward gear (2).
Symbol Part Number Part Name
2) Dismount needle bearing (5) from the for-
ward gear.
790-201- Plate ■ 1
2170
3
790-201- Spacer ■ 1
2730
796-465-
4 Push tool ■ 1
1120
D
793-607-
5 1110 Seal holder ■ 1
DISASSEMBLY
3. End plate
When loading the clutch pack on the
1) Use C clamp [3] or the like to press end
block, take care so that the clutch pack
plate (6) and to dismount snap ring (7).
may not slip from your hands with oil
2) Dismount end plate (6).
and so that your finger may not get
caught between the block and clutch
pack.
cpw11161
30-72 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
4. Clutch plate
1) Dismount spring plate (8) from the hous-
ing.
cpw10577
cpw10574
cpw10575
CPW11163
5. Piston
Make air blow into the forward side oil hole of
the shaft and dismount piston (14).
cpw10576
WA430-5 30-73
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
cpw10586
cpw10579
3. End plate
1) Use C clamp [8] or the like to press end
plate (36) and dismount snap ring (37).
CPW11164 2) Dismount end plate (36).
CPW11165
30-74 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
cpw10589 CPW11166
cpw10590
cpw10593
8. End plate
9. Clutch plate
10. Piston
★ Disassemble procedures 8. - 10. in the
cpw10591 same manner as the procedures 3. - 5. at
the 1-spool clutch side.
WA430-5 30-75
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
CPW11168
CPW11167
4. Clutch plate
2. 3rd gear 1) Dismount plate (56), disc (57) and spring
1) Dismount thrust washer (52) and 3rd gear (58) from the housing.
(53).
cpw10599
cpw10596
CWW10977
30-76 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
cpw10600
CPW11169
7. 2nd gear
1) Dismount thrust washer (62) and 2nd gear
(63).
cpw10602
cpw10979
cpw10605
8. End plate
9. Clutch plate
10. Piston
★ Disassemble procedures 8. - 10. in the
same manner as the procedures 3. - 5. at
the 3-spool clutch side.
WA430-5 30-77
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
cjw11171
4. End plate
1) Mount end plate (72).
2) Use C clamp [13] or the like to press end
plate (72).
3) Mount snap ring (73).
cpw10607
CPW11170
30-78 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
Transmission oil
3) Mount thrust washer (12).
cpw10579
cpw10576
CwW10980
CPW10575
CPW10574
WA430-5 30-79
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
PACK ASSEMBLY
CPW11162
CJW11507
CwW10981
30-80 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
cpw11177
cpw10618
cpw10593
cpw10619
CJW11173
WA430-5 30-81
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
PACK ASSEMBLY
CWW10984 cpw10589
8. End plate
[1ST CLUTCH SIDE] 1) Mount end plate (36).
6. 1-spool side piston 2) Use C clamp [8] or the like to press end
1) Make the piston seal run in the same plate (36) and mount snap ring (37).
manner as the 4th clutch side and assem-
ble piston (42).
2) Assemble piston (42) in the same manner
as the 4th clutch side piston.
cpw10587
30-82 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
3) Assemble thrust washer (33) and snap 2) Check that the clearance d between idler
ring (32). gear (31) and thrust washer (33) is within
a standard value.
Standard value d: 0.26 - 0.74 mm
★ Measure the clearance d using a dial
gauge or clearance gauge.
cpw10586
CJW11175
CJW11174
WA430-5 30-83
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
PACK ASSEMBLY
Transmission oil
cpw10631
CJW11176
4. End plate
1) Mount end plate (91).
2. 2nd side piston 2) Use C clamp [15] or the like to press end
1) Mount 2nd side piston (85). plate (91) and mount snap ring (92).
★ Take care so that the piston seal may
not be damaged.
cpw10630
30-84 WA430-5
(5)
(2)
(3)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
cpw10979
cpw10633
WA430-5 30-85
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
8. Clutch plate
Alternately assemble plate (56), disc (57) and
spring (58) in the housing.
★ Assemble them in the same manner as
the 2nd side.
CJW11180
30-86 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK ASSEMBLY
CJW11181
WA430-5 30-87
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE
DISASSEMBLY AND ASSEMBLY PARKING BRAKE ASSEMBLY
Simplified Drawing
New/Revised
bly (7) and shim (8).
Necessity
Quantity
Part
Symbol Number Part Name
★ For the shim, check the thickness and
the number of shims.
2) Dismount dust seal (9), oil seal (10) and
793T-607-1190 Bracket ● 1 |
outer race (11) from gauge (7).
1 722-14-13130 Plate ● 1
01011-62020 Bolt ● 1
790-101-5421 Grip ● 1
4 793T-607-1140 Spacer ● 1 |
H
5 792T-446-1150 Push tool ● 1 |
6 797T-423-1141 Push tool ● 1 | cpw11182
793T-512-1110 Push tool ● 1 N |
8 01010-51240 Bolt ● 1
790-101-5421 Grip ● 1
9 793T-607-1160 Spacer ● 1 |
10 793T-607-1180 Push tool ● 1 |
DISASSEMBLY
4. Bearing assembly
1. Coupling (rear drive) 1) Dismount bearing assembly (12).
Dismount coupling (2). 2) Dismount bearing (14) from boss (13).
2. Coupling (front drive)
1) Dismount bolt (3) and dismount washer
(4) and holder (5).
2) Dismount coupling (6).
cpw10932
cpw10930
30-88 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE
DISASSEMBLY AND ASSEMBLY PARKING BRAKE ASSEMBLY
cpw10935
cpw10933
7. Piston
Use eyebolt [2] to hang and dismount piston
(18).
cpw10936
cpw11183
9. Brake housing
Use eyebolt [3] to hang and dismount brake
housing (24).
cpw11184
WA430-5 30-89
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE
DISASSEMBLY AND ASSEMBLY PARKING BRAKE ASSEMBLY
cjw11185
cpw11188
12. Outer race, oil seal (rear drive side) Liquid gasket
1) Dismount outer race (31). (Three Bond 1110B)
2) Dismount dust seal (32).
3) Dismount oil seal (33). • Lightly cover the inner face of the
housing and wipe off excess.
30-90 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE
DISASSEMBLY AND ASSEMBLY PARKING BRAKE ASSEMBLY
cpw10942 cpw11186
2) Mount gear (28) on output shaft (34). 2) Mount guide bolt [6].
★ Face the gear with a long flange to the 3) Use eyebolt [3] to mount brake housing
cpw11187
WA430-5 30-91
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE
DISASSEMBLY AND ASSEMBLY PARKING BRAKE ASSEMBLY
9js02562
cpw11189
cpw10947
cpw10950
30-92 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE
DISASSEMBLY AND ASSEMBLY PARKING BRAKE ASSEMBLY
9. Cage assembly
11. Adjusting rotation torque of output shaft with
1) Use push tool [7] to mount outer race (11)
shim
on the gauge.
1) Tighten 6 cage mounting bolts (40) tem-
porarily without setting the shim.
9.8 ± 0.98 Nm {1 ± 0.1 kgm}
2) Rotate the shaft to the right by 10 turns
and to the left by 10 turns, and then check
the tightening torque.
cjw11190 3) If the tightening torque has changed,
repeat 1) and 2).
4) When the tightening torque does not
change any more, insert the shim and
tighten 6 cage mounting bolts (40) to the
specified torque.
Cage mounting bolt (40):
98 - 123 Nm {10 - 12.5 kgm}
2) Mount gauge assembly (7). 5) Adjust the shim thickness so that the rota-
★ Do not install the shim. tion torque of the shaft becomes 0.49 -
Mounting bolt: 0.98 Nm {0.05 - 0.1kgm}.
9.8 ± 0.98 Nm {1 ± 0.1 kgm} 6) Make sure that there is no looseness after
the shim is adjusted.
★ When adjusting the shim after install- ★ Perform the above adjustment while
ing the coupling, tighten the bolts per- parking brake P.B. is not installed.
manently.
★ Perform the above adjustment while
the dust seal and oil seal S are not
10. Coupling (front drive) installed.
1) Mount coupling (6).
★ Replace O-ring (Part No. 07000 - 15140).
2) Attach holder (5) and washer (4) and
tighten bolt (3).
Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
AJS01617
WA430-5 30-93
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE
DISASSEMBLY AND ASSEMBLY PARKING BRAKE ASSEMBLY
12. Install 2 parking brake release bolts B (M12, 2) Use tool H1 to press down the plate and
L = 45 mm). to mount snap ring (19).
13. Remove the assembly of cover K and piston ★ Take care so that the spring will not
P. be loaded on the disc.
★ Do not remove cage mounting bolts (40). ★ Check that the snap ring is correctly
inserted in the groove.
cpw10935
30-94 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF PARKING BRAKE
DISASSEMBLY AND ASSEMBLY PARKING BRAKE ASSEMBLY
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
cpw10930
WA430-5 30-95
(5)
(2)...
DISASSEMBLY AND CONVERTER
TORQUE ASSEMBLY OF TORQUE CONVERTER
ASSEMBLY (STANDARD
DISASSEMBLY AND ASSEMBLY ASSEMBLY (STANDARD SPECIFICATION)
Simplified Drawing
bly in the following procedure.
New/Revised
i) Dismount pilot (4).
Necessity
Quantity
Part ii) Remove snap ring (5) and dismount
Symbol Part Name
Number
plate (1).
DISASSEMBLY
1. Perform disassembly procedure steps 1 - 8 of
Disassembly, assembly of transmission
assembly.
★ Continue the work with the torque con-
verter assembly placed on the block (or iii) Press the boss portion of turbine (6)
install the torque converter to tool C1. and dismount it from case (7).
2. Turbine and case assembly
1) Mount the eyebolt on the stator shaft and
dismount bolt (2a), then dismount stator
shaft and pump assembly (2) from turbine
case assembly (3).
cpw10378
30-96 WA430-5
(5)
(2)
DISASSEMBLY AND CONVERTER
TORQUE ASSEMBLY OF TORQUE CONVERTER
ASSEMBLY (STANDARD
DISASSEMBLY AND ASSEMBLY ASSEMBLY (STANDARD SPECIFICATION)
3. Stator 5. Gear
1) Dismount snap ring (9). Dismount gear (13) from pump (14).
2) Dismount stator (10).
6. Bearing
4. Stator shaft Dismount bearing (15) from gear (13).
Use eyebolt [1] to press it from the side of sta-
tor shaft (11) and disconnect it from pump
assembly (12).
WA430-5 30-97
(5)
(2)...
TORQUE
DISASSEMBLY AND CONVERTER ASSEMBLY
ASSEMBLY OF (STANDARD
TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY ASSEMBLY (STANDARD SPECIFICATION)
4. Stator
1) Mount stator (10).
2) Mount snap ring (9).
2. Gear
Mount gear (13) on pump (14).
Mounting bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
2
★ After having press-fit the bearing,
Seal ring: Grease (G2-LI) drop the engine oile by 6 cc and rotate
the bearing ten times.
★ Average the overhang of the seal ring.
30-98 WA430-5
(5)
(2)
DISASSEMBLY AND CONVERTER
TORQUE ASSEMBLY OF TORQUE CONVERTER
ASSEMBLY (STANDARD
DISASSEMBLY AND ASSEMBLY ASSEMBLY (STANDARD SPECIFICATION)
ii) Mount boss (18) on turbine (6). iv) Attach plate (1) and mount snap ring
2
(5).
Mounting bolt: v) Mount pilot (4).
3 2
Adhesive (LT-2)
Mounting bolt: Mounting bolt:
3
58.8 - 73.5 Nm Adhesive (LT-2)
{6.0 - 7.5 kgm} Mounting bolt:
14.7 - 34.3 Nm
{1.5 - 3.5 kgm}
2
3
Mounting bolt: Adhesive (LT-2)
Mounting bolt:
27.5 - 34.3 Nm {2.8 - 3.5 kgm}
cpw10378
WA430-5 30-99
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER ASSEMBLY
ASSEMBLY (LOCK-UP
(LOCK-UP SPECIFICATION)
Simplified Drawing
New/Revised
Necessity
Quantity
Part
Symbol Part Name
Number
C 790-901-2150 Plate ■ 1
790-201-2230 Plate ■ 1
2
790-201-2750 Spacer ■ 1
ii) Use eyebolt [4] to pull out stator shaft
3 793-647-1110 Wrench ■ 1 (5).
iii) Dismount seal ring (6) from stator
shaft (5).
DISASSEMBLY
1. Execute disassembly procedures 1. - 8. of
item "Disassembling and Assembling Trans-
mission Assembly".
★ Subsequently, perform work loading the
torque assembly on the block (or mount it
on tool C1).
2. Stator shaft and pump assembly
1) Dismount pump mounting bolt (1).
2) Use eyebolt [2] to hang stator shaft and
pump assembly (2) and dismount it from
turbine and case assembly (3).
30-100 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER
(LOCK-UP SPECIFICATION)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER ASSEMBLY (LOCK-UP SPECIFICATION)
WA430-5 30-101
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER ASSEMBLY
ASSEMBLY (LOCK-UP
(LOCK-UP SPECIFICATION)
1. Complete turbine
Mount turbine (25) on boss (27) and tighten
bolt (25a).
3 Bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
30-102 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER
(LOCK-UP SPECIFICATION)
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER ASSEMBLY (LOCK-UP SPECIFICATION)
3. Disc
Mount disc (40).
★ Coat the sliding surface of the disc with
engine oil and mount the disc.
3
Adhesive (LT-2)
1) Fine assembly of complete housing Mounting bolt:
i) Mount seal ring (39) on complete 27.5 - 34.3 Nm {2.8 - 3.5 kgm}
housing (36).
WA430-5 30-103
(5)
(2)...
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER ASSEMBLY
ASSEMBLY (LOCK-UP
(LOCK-UP SPECIFICATION)
6. Plate, snap ring ii) Mount snap ring (17) on stator (16).
Assemble spacer (24) and mount snap ring iii) Attach race free wheel association
(23). (15) to stator (16) and mount snap
ring (14).
7. Pilot
Mount pilot (22) and tighten bolt (17a).
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
58.8 - 73.5 Nm {6.0 - 7.5 kgm}
3
Adhesive (LT-2)
Mounting bolt:
58.8 - 73.5 Nm
{6.0 - 7.5 kgm}
30-104 WA430-5
(5)
(2)
TORQUE CONVERTER
DISASSEMBLY AND ASSEMBLY DISASSEMBLY ASSEMBLY
AND ASSEMBLY OF(LOCK-UP
TORQUE SPECIFICATION)
CONVERTER AS-
iii) Mount seal ring (6) on stator shaft (5). ★ When the direction of stator rota-
djw05925
WA430-5 30-105
(5)
(2)...
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FRONT AXLE ASSEMBLY
CPW11466
CPW10887
[*2]
3
CPW11468
Front propeller shaft mounting bolt:
98.1 - 122.6Nm {10 - 12.5kgm}
[*3]
30-106 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY
1. Drain the rear axle oil. 7. Disconnect the rear brake oil temperature
6
sensor wiring harness connector R56 (5), and
Rear axle housing: 40 l then remove the cover (6).
CPW11392
CPW11395
4. Lift the rear wheel (1) and remove it.
★ Remove the opposite side at the same
procedures.
WA430-5 30-107
(5)
(2)...
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY
9. Remove the bolt (8) and then remove cou- 12. Pull out the rear frame assembly toward the
pling (9). [*3] rear of the chassis and disconnect brake hose
★ If the coupling is not removed, dust seal (14). [*5]
(13) will be damaged easily in section 11.
CPW11399
CPW11396
CPW11397
CPW11400
CPW11398
30-108 WA430-5
(5)
(2)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF REAR AXLE ASSEMBLY
INSTALLATION
• Carry out installation in reverse order of
removal.
[*1]
[*2]
[*3]
[*4]
[*5]
3 Brake hose:
84 - 132Nm {8.5 - 13.5kgm}
WA430-5 30-109
(5)
(2)...
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY AXLE HOUSING
OF AXLE ASSEMBLY
HOUSING ASSEM-
Simplified Drawing
★ When one-sided housing assembly is dis-
New/Revised
Necessity
Quantity
Part mounted, load the axle assembly on block
Symbol Part Name
Number [1] so that it will not be tilted.
11 793T-622-1340 Spacer ■ 1 |
790-201-2760 Spacer ■ 1
793T-622-1370 Support ■ 2 |
12 cpw11509
01016-30860 Bolt ■ 6
793T-522-1170 Support ■ 2 |
15
01010-30860 Bolt ■ 6
3. Axle housing assembly
22 793T-622-1610 Holder ■ 1 N |
1) Temporarily hang axle housing assembly
23 797T-423-1290 Push tool ■ 1 | (8) and remove the housing mounting
bolt.
★ When dismounting the axle housing
DISASSEMBLY assembly on both left and right,
attach a counter mark to the housing
★ The subsequent photographs and illustra- and the differential case not so as to
tions are shown using the front axle assembly be mixed.
as an example. 2) Dismount axle housing assembly (8).
1. Oil drain
Dismount plug (1) and extract oil.
Need cpw10299
Need cpw10295
30-110 WA430-5
(5)
(2)
AXLE
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HOUSING
AXLE ASSEMBLY
HOUSING ASSEM-
Need cpw10300
Need cpw10303
Need cpw10301
CJW11510
Need cpw10302
WA430-5 30-111
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY AXLE HOUSING
OF AXLE ASSEMBLY
HOUSING ASSEM-
6. Axle shaft
1) Lift axle housing (14)
2) Punch and pull out the end surface of axle
shaft (15) using a copper hammer or the
like.
8. Axle housing
Dismount bearing outer races (18) and (19)
and oil seal (17) from axle housing (14).
★ Remove oil seal (17) from only the rear
axle.
30-112 WA430-5
(5)
(2)
(4)
AXLE
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HOUSING
AXLE ASSEMBLY
HOUSING ASSEM-
WA430-5 30-113
(5)
(2)...
(4)
AXLE
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HOUSING
AXLE ASSEMBLY
HOUSING ASSEM-
3) Install the tool H12 under the oil seal (17). 2) Use push tool [6] to mount oil seal (17) on
★ Adjust oil seal (17) with tool H12 so housing (14).
CJW11516
30-114 WA430-5
(5)
(2)
(4)
AXLE
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HOUSING
AXLE ASSEMBLY
HOUSING ASSEM-
4) Use tool H14 to press-fit bearing (16) in 3) Using push tool H23, press fit bearing
axle shaft (15). (26) to axle shaft (15).
★ Turning the axle housing, press fit the
bearing.
2 Periphery of bearing: Axle oil
4) Pull out tools H12 and H15 horizontally.
★ Check that oil seal (17) does not lean.
WA430-5 30-115
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY AXLE HOUSING
OF AXLE ASSEMBLY
HOUSING ASSEM-
★ If the turning force is below the standard 5) Install planetary carrier (20) to the spline
value, press fit the bearings again and of axle shaft (15) without the gear and
perform the work in step 1). place tool H22.
★ If the turning force exceeds the standard ★ Just place tool H22 on planetary car-
value, adjust it according to following rier (20). Do not tighten the bolt.
steps 2) - 4). 6) Using a depth micrometer, measure dis-
2) Hold 2 parts of axle shaft and housing tance (e) from the end of tool H22 to the
assembly (8) and sling it by 20 - 30 mm, end of the axle shaft.
as you installed the axle housing. ★ Subtract thickness (t) of tool H22
3) Rotating axle shaft (15), hit the flange with from distance (e), and let the result be
a copper hammer in the direction of the (e-t).
arrow several times to drive out axle shaft
• Shim thickness = (e-t) +0.05
(15). 0
4) Adjust the turning force to the standard 7) After determining the shim thickness,
value according to step 1). remove planetary carrier (20).
5. Planetary carrier
1) Previously assemble spacer (24) in plane-
tary carrier (20).
★ Assemble the spacer from the brake
housing side.
2) Assemble bearing (25) in gear (23) and lift
spacer (24), then assemble gear (23).
30-116 WA430-5
(5)
(2)
(4)
AXLE
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HOUSING
AXLE ASSEMBLY
HOUSING ASSEM-
3 Mounting bolt:
4) Tap on the end surface of shaft (22) and
the differential side of gear (23) and push
back bearing (25), then check that the gear 662 - 829 {67.5 - 84.5 kgm}
rotates gently.
★ Thoroughly clean and assemble the
shaft end surface and the planetary
carrier spline portion.
WA430-5 30-117
(5)
(2)...
(4)
AXLE
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HOUSING
AXLE ASSEMBLY
HOUSING ASSEM-
3) After having made the bearing run in 2) Horizontally hang axle hosing assembly
fully, check the activation turning force (8) and quietly assemble it fitting the
"X" in the drill hole h portion of axle hous- spline groove and guide bolt [10].
ing (14). ★ Assemble the axle housing assembly
★ Refer to the item of procedure 4. not to damage the brake piston sur-
Selecting shims. face and the plate surface.
• Activation turning force:
29.4 - 54.9 N {3.0 - 5.6 kg} (Front)
49.0 - 93.2 N {5.0 - 9.5 kg} (Rear)
★ If the turning force is out of the stan-
dard value, return to procedure 4.
4) Mount stand [9] of the dial gauge on axle
housing (14) and measure the end play of
the planetary carrier on the end surface of
the planetary carrier.
★ Reference value.
• End play of planetary carrier:
0 - 0.1 mm
cpw10299
30-118 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY
ASSEMBLY
New/Improved
Disconnect the tube (1).
Illustration
Necessity
Quantity
2. Oil temperature sensor (rear differential)
F/R
Symbol Product No. Product Name
1) Remove the cover (3).
2) Disconnect the connector and remove the
Unit repair oil temperature sensor (5).
790-501-5000 stand ■ 1
Unit repair
16 790-501-5200 stand ■ 1
790-901-2110 Bracket ■ 1
790T-901-3440 Plate F ■ 1 {
796-765-1110 Push tool ■ 1
F
790-201-2750 Spacer ■ 1
17
792T-423-1110 Push tool ■ 1 {
R
793T-522-1130 Push tool ■ 1 {
793T-622-1360 Push tool F ■ 1 {
18
797T-423-1290 Push tool R ■ 1 {
793T-622-1410 Push tool ■ 1
790-101-5421 Grip F ■ 1
01010-51240 Bolt ■ 1
19 3. Axle housing assembly
793T-522-1110 Push tool ■ 1 {
H Remove the axle housing assembly on the
790-101-5421 Grip R ■ 1
left and right, referring to section, "Disassem-
01010-81240 Bolt ■ 1
bling Axle Housing Assembly."
793T-622-1410 Push tool ■ 1 {
793T-622-1420 Spacer ■ 1 { 4. Differential assembly
F
790-101-5421 Grip ■ 1 Put the differential assembly (7) on the block
01010-81240 Bolt ■ 1 [1] to make it stable. (Otherwise, attach to tool
20 H16.)
793T-522-1110 Push tool ■ 1 {
★ When using tool H16, remove the cage
793T-522-1120 Spacer ■ 1 {
R assembly according to step 7.
790-101-5421 Grip ■ 1
5. Cover
01010-51240 Bolt ■ 1
Remove the cover (8).
1 790-301-1720 Adapter ■ 1
2 790-101-5002 Hydraulic kit ■ 1
21 F/R
3 793-605-1001 Brake tester ■ 1
4 790-101-1102 Hydraulic pump ■ 1
F/R
24 796-751-1510 Wrench ■ 1
ASD
DISASSEMBLY
★ The subsequent photos and illustrations
show the front differential as an example,
excluding the portions described separately.
★ For the front and rear differentials, the inter-
nal structures are the same, excluding the
appearance.
WA430-5 30-119
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
CPW10336
CPW10333
CPW10335
30-120 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
CPW10338
8. Bearing carrier
1) Temporarily lift the differential carrier
assembly (23). 2) Remove the gear cover (26) from the dif-
ferential case.
CPW10339 CPW10342
CPW11530
WA430-5 30-121
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY
2) Remove the bearing (27) from the plane 5) Remove the spherical washer (37) and
half (28). pinion gear (35) from the detached spider
shaft (36).
4) Remove the pinion gear (35), spider shaft 7) Reverse the bevel gear flange half assem-
(36), and spherical bush (37) together. bly (29) and remove the bolt. Then detach
the bevel gear (43) and bearing (27).
30-122 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY
11. Disassembly of differential carrier assembly 2) Remove the 2 plates (61) and 2 disks (62).
(Anti-slip differential specification)
★ Identify right and left parts to avoid confu-
sion.
1) Remove the cover (58).
★ Put mating marks on the cover (58)
and case (59) for reference purposes
when re-assembling.
★ The bearing (57) is attached only to
the front.
★ Front
AJS01633
★ Rear
WA430-5 30-123
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY
5) Remove the side gear (67) and pressure 10) Using push tool [8], remove outer race
ring (68). (75) from inside of case (59). (Rear)
6) Remove the 2 disks (69) and 2 plates (70). 11) Using puller [9], remove bearing (76)
7) Remove the washer (71). from bearing carrier (24). (Rear)
8) Reverse the case (59) and remove the bolt 12. Pinion gear and cage
(72) to detach the bevel gear (73). 1) Use the press to pull out the pinion gear
9) Remove bearing (74). (Front) (45) from the cage (44).
30-124 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY
2) Remove the dust seal (49), oil seal (50), 2) Use tool H17 to press the bearing inner
bearing (46), and outer races (47), (48) race (52) in the pinion gear (45).
from the cage (44).
WA430-5 30-125
(5)
(2)...
(4)
DIFFERENTIAL ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
6) Use the push-pull gauge [5] to turn the 8) Use tool H20 to press the dust seal (49) in
cage (44) and measure the activation rota- the cage (44) until its end surface
tion power. becomes equal to the one of the cage.
CPW11534
2. Coupling
Attach the coupling (19), o-ring (19a), and
holder (17a) to the pinion gear (45), and
tighten the mounting bolt (17).
★ In this case, temporarily tighten the
mounting bolt (17). After the coupling is
7) Use tool H19 to press the oil seal (50) in assembled in the differential case,
the cage (44). securely tighten the bolt.
★ Confirm that dimension C is ★ Take care not to damage the seal at inser-
10 ± 0.5 mm. tion of the coupling (19).
2 Oil seal lip unit: Grease (G2-LI) 2 Mounting bolt (At actual tightening):
Adhesive (LT-2)
30-126 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
3. Detailed assembly of differential carrier 4) Put the bevel gear (43) on the block [6],
assembly (Standard spec.) turning down the gear side.
★ Assemble the parts on the left and right 5) Attach the guide bolt [7] to the bevel gear
according to the identification determined (43).
at disassembly. 6) Lift the flange half (29), attach it to the
1) Press the bearing outer race (24a) in the bevel gear (43), and tighten the bevel gear
mounting bolt (42).
2 Mounting bolt: Adhesive (LT-2)
bearing carriers (24) on the left and right
until it reaches the carriers.
3 Mounting bolt:
Front: 245 - 309 Nm {25 - 31.5 kgm}
Rear: 157 - 196 Nm {16 - 20 kgm}
WA430-5 30-127
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
9) Attach the spider shaft (36), pinion gear 12) Attach the plane half (28) to the flange
(35), and spherical bush (37). half (29).
★ At attachment, match the index marks
set at disassembly.
3 Attachment bolt:
157 - 196 Nm {16 - 20 kgm}
CPW10343
30-128 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
2) Press the bearing outer race (24b) until it 7) Place the bevel gear (73) on the block [6]
comes into contact with the right and left with the gear side down.
bearing carriers (24) using push tool [10]. 8) Install guide bolt [7] to bevel gear (73).
(Rear) 9) Lower the case (59) and install it in the
bevel gear (73) and tighten the bevel gear
mounting bolts.
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
Front :
245 - 309 Nm {25 - 31.5 kgm}
Rear :
157 - 196 Nm {16 - 20 kgm}
5) Press fit outer race (75) to case (59). (Rear) Plate and disk: Axle oil
6) Press fit cover (58) similarly. (Rear)
9JS02261
WA430-5 30-129
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
AJS01639
AJS01636
9JS02261
12) Install the pinion gear (65) and spider
shaft (66).
AJS01637
AJS01635
30-130 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
15) Adjust the clearance between the case 17) Install the cover (58) on the case (59).
and plate. ★ Install them by aligning the mating
i) Using depth gauge [11], measure dis- marks put when disassembling
tance (d) from the end face of case ★ Bearing (57) is installed on only the
(59) to the end face of plate (61). front side.
• Distance (d): 0.2 - 0.6 mm
ii) If distance (d) is out of the standard Mounting bolt:
range, replace the plate with the one 98 - 123 Nm {10 - 12.5 kgm}
with proper thickness so that distance
(d) will be in the standard range.
★ Replace the plates on both right
and left sides so that the total
thickness of the 2 plates on each
side will be the same, and then
perform the above procedure
AJS01633
from step 10).
• Thicknesses of plates
: 3.0 mm Front (Part No. 424-22-27450)
Rear (Part No. 423-22-27450)
: 3.1 mm Front (Part No. 424-22-27460)
Rear (Part No. 423-22-27460)
WA430-5 30-131
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
5. Gear cover
Attach the gear cover (26) to the differential
case.
AJS02267
CPW10342
30-132 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
3) Attach the guide bolt [3] in the bearing 5) Use the push-pull gauge [5] to measure
carrier attachment holes on the left and the preload of the bevel gear.
right of the differential case. ★ Starting rotation power:
Front:13.7 - 37.2 Nm {1.4 - 3.8 kgm}
Rear:35.3 - 52.9 Nm {3.6 - 5.4 kgm}
★ When the starting rotation power is
outside the reference value, adjust the
shim thickness.
CPW11538
CPW11539
3 Mouning bolt:
245 - 309 Nm {25 - 31.5 kgm}
WA430-5 30-133
(5)
(2)...
(4)
DIFFERENTIAL ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
3) Securely tighten the coupling mounting 2) To obtain the back rash in the reference
bolt temporarily tightened in step 2. value, move a part of the shim of the
3
change the total thickness of the left
Mounting bolt: and light.
Front: ★ When the back rash is too high, move
823 - 1,029 Nm {84 - 105 kgm} a part of shim b to shim a.
Rear: ★ When the back rash is too low, move
490 - 608 Nm {50 - 62 kgm} a part of shim a to shim b.
CPW11541
30-134 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
DEW00910
The bevel pinion gear is too separate 1) Decrease the shim from the pinion gear and
from the gear. approach to the bevel gear.
2) Separate the bevel gear from the pinion gear
and correctly adjust the back rash.
DEW00904 DEW00908
The bevel pinion gear is too near the 1) Increase the shim of the pinion gear and sepa-
gear. rate it from the bevel gear.
2) Approach the bevel gear to the pinion gear and
correctly adjust the back rash.
DEW00905
The bevel gear is too near the pinion 1) Decrease the shim of the pinion gear and
gear. approach it to the bevel gear.
2) Separate the bevel gear from the pinion gear
and correctly adjust the back rash.
DEW00906 DEW00908
The bevel gear is too separate from the 1) Increase the shim of the pinion gear and sepa-
pinion gear. rate it from the bevel gear.
2) Approach the bevel gear to the pinion gear and
correctly adjust the back rash.
DEW00907
★ When adjusting the bevel gear in-out state, do not change the total thickness of the left and right by
moving the shim.
WA430-5 30-135
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
10. Brake 3) Attach the outer plate (11) and shaft (9),
1) Assemble the seal in the piston (16) and then tighten the bolt (10).
attach it to the differential carrier assem-
bly.
★ (15) is the brake tube joint unit.
CPW10333
CPW10335
CPW10334
11. Cover
Attach the cover (8) to the differential case (7).
3 Mounting bolt:
157 - 196 Nm {16 - 20 kgm}
CPW10332
30-136 WA430-5
(5)
(2)
(4)
DIFFERENTIAL ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL ASSEMBLY
WA430-5 30-137
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
New/Improved
and remove the bracket (5). [*2]
Illustration
Necessity
Quantity
Symbol Product No. Product Name
REMOVAL
5. Remove the center propeller shaft (6). [*3]
Park the machine on flat ground and set
the safety bar to the frame.
Lower the work equipment to the
ground completely and stop the engine.
Apply the parking brake and put the
blocks under the wheels.
CPW11433
Disconnect the battery (–) terminal in
advance.
CPW11431
30-138 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
7. Disconnect the lift arm signal connector F16 10. Disconnect the hose (22). [*6]
(9) and lift arm rod signal connector F17 (10). ★ Tag the disconnected hose so that it can
be identified.
CPW11435
CWW11438
CPW11436 CJW11439
9. Disconnect the hose (16), (17), (18), (19), (20) 12. Jack up the front frame (25). While adjusting
and (21) in the front frame side. [*5] the height, insert the block [2] on the left and
★ Tag the disconnected hoses so that it can right of the front frame.
be identified. ★ Insert the roller [3] between the block [2]
and the frame so that the front frame can
be pulled out.
CPW11437
CJW11440
WA430-5 30-139
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
13. Remove the lock bolt (26) and then pull out 17. Carefully pull out the front frame (25) forward
lower hinge pin (27). [*7] and disconnect it from the rear frame (24).
★ Confirm whether the front frame is com-
pletely disconnected from the rear frame.
★ Remove the safety bar.
★ Take care that the lower spacer of the
upper hinge does not engage with the
CPW11441 rear frame.
★ Take care of the balance at disconnection.
CWW11444
CJW11442
CJW11445
CJW11443
30-140 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY CENTER HINGE
REMOVAL AND INSTALLATION OF CENTER HINGE PIN
PIN
19. Remove the retainer (33) from the front 22. Remove the mounting bolt and then remove
frame. [*7] the retainer (36). [*7]
★ The shims are inserted between the ★ The shims are inserted between the
retainer and the frame, check the number retainer and the frame, check the number
and thickness of shims. and thickness of shims.
CJW11446 CJW11449
20. Remove the dust seal (34) from the retainer. 23. Remove the dust seal (37) from the retainer.
[*7]
★ Also remove the dust seal from the frame.
CJW11450
CJW11447
24. Remove the spacer (38) and the dust seal (39)
from the front frame.
21. Remove the bearing (35). [*7]
CJW11451
CJW11448
WA430-5 30-141
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
3 Hose (16):
84 - 132Nm {8.5 - 13.5kgm}
3 Hose (18):
177 - 245Nm {18.0 - 25.0kgm}
CJW11452
[*6]
[*7]
Assembly of the center pin
1. Install the tool K1 to the top of the upper
INSTALLATION hinge of the rear frame (24).
2. Set the bearing (40) onto the tool K4 and then
• Carry out installation in reverse order of press the bearing from upper side.
removal. ★ At pressing, use tool K4 as a guide.
★ Take care that the bearing does not
[*1] incline.
★ Adjust the shim so that the maximum of ★ Coat the grease to the bearing inside sur-
clearance between the frame and the cylinder face.
is 0.5 mm or less. ★ The bearing is clearance-adjusted. The
★ Keep clearance. bearing (40) must be replaced together
• Standard shim thickness: 3 mm with spacer (31) and (38).
2
• Shim thickness: 0.5 mm, 1.0 mm
2
Bearing inside surface:
Cylinder bush inside surface and dust Lubricant containing molybde-
seal: num disulfide (LM-P)
2
Lubricant containing molybdenum
Spacer (38) inside surface:
disulfide (LM-P)
Lubricant containing molybde-
num disulfide (LM-P)
[*2]
★ Adjust the steering linkage, referring to sec-
tion "Testing and Adjusting steering linkage"
in "TESTING AND ADJUSTING."
[*3] CJW11453
3 Center propeller shaft mounting bolt:
98.1 - 122.6Nm {10 - 12.5kgm}
[*4]
30-142 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
3. Set the bearing (35) to the lower hinge of the 7. Adjusting the shim of the retainer portion
rear frame (24). (Upper side).
4. Use the tool K1, and press the bearing (35). 1) Equally tighten the three mounting bolts
★ At pressing, use tool K4 as a guide. of the retainer (36), and select a shim so
★ Take care that the bearing does not that the maximum of clearance b between
incline. the retainer and the hinge is 0.1 mm or
★ Coat the grease to the bearing inside sur- less. Then assemble the retainer.
face. • Shim thickness class:
2
0.1 mm, 0.5 mm
3
Bearing inside surface:
Lubricant containing molybde- Mounting bolt:
num disulfide (LM-P) 20 ± 2Nm {2.0 ± 0.2kgm}
(At shim adjusting)
CJW11454
CJW11457
CJW11458
CJW11455
2
★ At pressing, turn the dust seal lip outside.
2
Mounting bolt:
Dust seal: Grease (G2L1)
Adhesive (Locktite 2701)
3 Mounting bolt:
98 - 123Nm {10 - 12.5kgm}
CJW11456
WA430-5 30-143
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
8. Adjusting the shim of the retainer portion 9. Assemble the dust seal (39) and spacer (38)
(Lower side). from lower of the front frame.
1) Equally tighten the three mounting bolts ★ At pressing, turn the dust seal lip outside.
of the retainer (33), and select a shim so ★ Assemble the spacer (38) from lower so
that the maximum of clearance b that the more largely chamfered side fac-
between the retainer and the hinge is 0.1 ing to the bearing side.
2
mm or less. Then assemble the retainer.
• Shim thickness class: Spacer inside surface:
Lubricant containing molybde-
0.1 mm, 0.5 mm
3
num disulfide (LM-P)
Mounting bolt:
20 ± 2Nm {2.0 ± 0.2kgm}
(At shim adjusting)
CJW11461
CJW11459
11. Use the puller [4] to press the bush (32) in the
lower hinge of the rear frame.
CJW11460
★ Press fit both upper and lower bushings
similarly.
CJW11462
2) After adjusting the shim, tighten all the
retainer mounting bolts with the specified
torque.
2 Mounting bolt:
Adhesive (Locktite 2701)
3 Mounting bolt:
98 - 123Nm {10 - 12.5kgm}
30-144 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CENTER HINGE PIN
CWW11463
2 Mounting bolt:
Adhesive (Locktite 2701)
3
13. Install the cover (28) to the upper hinge pin
(30), and equally tighten the three mounting Pin mounting bolt:
bolts. Then select the shim so that the clear- 206 ± 20Nm {21 ± 2kgm}
ance c between the hinge and the retainer is
0.2 mm or less, and assemble the retainer. 15. Install the lock bolt (29) of the upper hinge pin
(30).
★ Measure the three points of the clearance
between the cover and the hinge. 16. Insert the lower hinge pin (27) and install the
★ After adjusting the shim, temporarily lock bolt (26).
tighten the retainer mounting bolt so that
it does not turn.
• Shim thickness class:
0.2 mm, 0.5 mm, 1mm
3 Mounting bolt:
CPW11441
20 ± 2Nm {2.0 ± 0.2kgm}
(At shim adjusting)
CJW11464
WA430-5 30-145
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CAB ASSEMBLY
CPW11124
30-146 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CAB ASSEMBLY
2) Disconnect the connectors (7), (8) and (9) 5) Disconnect the wiring harness connectors
from center front. (14), (15) and (16) from left rear of the
• (7): LO6 cover.
• (8): LO7 (Machine monitor switch)
• (9): SO3 (Transmission cut-off switch)
CPW11128
CPW11127
CPW11143
WA430-5 30-147
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF CAB ASSEMBLY
4
[*1]
3
Cab assembly: 700kg
Mounting bolt (M12):
98 - 123Nm {10 - 12.5kgm}
CPW11130
[*2]
★ Install the shims of the thickness and quantity
recorded when they were removed.
★ If the cab assembly was removed, eliminate
the clearance with the shims.
• Shim thickness class
(At M12 bolt mounting position): 1.0 mm
• Shim thickness class
(At M20 bolt mounting position):
0.5 mm, 1.0 mm
30-148 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY CAB AND
REMOVAL AND INSTALLATION OFFLOOR FRAME
CAB AND ASSEMBLY
FLOOR FRAME
New/Modified
following procedures below.
Necessity
Quantity
Sketch
Symbol Part Number Part Name 1) Remove the washer tank under cover.
2) Disconnect the two washer hoses (1).
3) Disconnect the front window shield
799-703-1200 Service tool kit ■ 1 washer connector R43A (2) and rear win-
Vacuum pump
dow shield washer connector R45A (3).
799-703-1100 ■ 1
(100 V)
Vacuum pump
X 799-703-1110 ■ 1
(220 V)
Vacuum pump
799-703-1120 ■ 1
(240 V)
REMOVAL
4
Release the remaining pressure in the
circuit between the hydraulic cylinder Left ladder and fender assem-
and control valve, the brake accumulator bly: 90kg
circuit and the PPC accumulator circuit,
2. Remove the front left cover (5) and the rear
referring to section "Releasing Remain-
left cover (6) of the cab.
ing Pressure in Circuit" in "TESTING
AND ADJUSTING."
WA430-5 30-149
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY CAB AND
REMOVAL AND INSTALLATION OFFLOOR FRAME
CAB AND ASSEMBLY
FLOOR FRAME
CPW11131
CPW11133
30-150 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY CAB AND
REMOVAL AND INSTALLATION OFFLOOR FRAME
CAB AND ASSEMBLY
FLOOR FRAME
8. Disconnect the air conditioner hoses (23) and 12. Disconnect the hoses (29) to (35) from the left
(24) in right under the bulkhead. [*2] and right brake valves.
• (29): Left brake valve T port hose
• (30): Right brake valve T port hose
• (31): Right brake valve PA port hose
• (32): Right brake valve PB port hose
CPW11135
CPW11138
CPW11136
CPW11139
CPW11140
WA430-5 30-151
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY CAB AND
REMOVAL AND INSTALLATION OFFLOOR FRAME
CAB AND ASSEMBLY
FLOOR FRAME
3
★ Check that all the wires and pipes are dis-
connected, and then lift off the cab and Floor frame mounting nut:
floor frame assembly slowly. 1,175 - 1,470Nm {120 - 150kgm}
30-152 WA430-5
(5)
(2)
(4)
OPERATOR'SOF
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CAB GLASS (STUCK
OPERATOR'S CAB GLASS)
GLASS
New/Remodel
adhesive by the following method. Insert
Necessity
a fine wire [2] (piano wire, etc.) in the
Sketch
Q'ty
Symbol Part No. Part Name adhesive and grip its both ends with pri-
ors [3], etc. (or hold them by winding
them onto something) and cut the adhe-
1 793-498-1120 Clear plate t 2 sive with the wire.
2 2 793-498-1130 Plate t 2
X
3 793-498-1110 Magnet t 2
3 793-498-1210 Lifter (Suction cups) t 2
REMOVAL
CPW11602
a All sides of each glass of the operator's cab of
this vehicle are stuck.
a Remove the window glass to be replaced
according to the following procedure.
CPW11607
WA430-5 30-153
(5)
(2)...
(4)
OPERATOR'SOF
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CAB GLASS (STUCK
OPERATOR'S CAB GLASS)
GLASS
CPW11603
CPW11605
CPW11604
CPW11606
30-154 WA430-5
(5)
(2)
(4)
OPERATOR'SOF
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CAB GLASS (STUCK
OPERATOR'S CAB GLASS)
GLASS
CPW11614
CPW11633
CPW11615
CWW11608
CPW11613 CPW11616
WA430-5 30-155
(5)
(2)...
(4)
OPERATOR'SOF
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CAB GLASS (STUCK
OPERATOR'S CAB GLASS)
GLASS
CWW11624
CPW11609
2
times.
Paint primer: SUNSTAR PAINT (If it is applied more than 2 times, its
PRIMER 580 SUPRE performance will be lowered.)
a Parts to be coated with primer: Apply
a Do not apply the primer more than 2 the primer to the sticking surface of
times. window glass (3) and all over dimen-
(If it is applied more than 2 times, its sion (d) on both-sided adhesive tape
performance will be lowered.) (4) and operator's cab (2).
• Dimension to apply primer (d):
23 mm
30-156 WA430-5
(5)
(2)
(4)
OPERATOR'SOF
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CAB GLASS (STUCK
OPERATOR'S CAB GLASS)
GLASS
a Do not apply the primer to the 1) Break aluminum seal (10) of the outlet of
boarder about 5 mm wide between adhesive cartridge (9) and install the noz-
the black part and transparent part of zle.
the glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a If the paint primer is applied by mis-
take, wipe it off with white gasoline.
(If wrong primer is applied, the glass CPW11612
will not be stuck.)
CWW11625
2) Cut the tip of the adhesive nozzle (11) so
that dimensions ( f ) and (g) will be as fol-
lows.
• Dimension ( f ) : 10 mm
• Dimension (g): 12 mm
CPW11617
CPW11611
2
a An electric caulking gun is more effi-
Adhesive (Summer): cient.
SUNSTAR PENGUINE SEAL
580 SUPER "S"
2 Adhesive (Winter):
SUNSTAR PENGUINE SEAL
580 SUPER "W"
WA430-5 30-157
(5)
(2)...
(4)
OPERATOR'SOF
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CAB GLASS (STUCK
OPERATOR'S GLASS)
CAB GLASS
4) Remove release tape (13) of the both- a Apply adhesive (12) higher than both-
sided adhesive tape on the glass side. sided adhesive tape (4).
a Apply the adhesive evenly.
CPW11621
CWW11620
CPW11619
CPW11614
30-158 WA430-5
(5)
(2)
(4)
OPERATOR'SOF
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CAB GLASS (STUCK
OPERATOR'S CAB GLASS)
GLASS
2) Using tool X3, raise and place window 3) After sticking window glass (3), press it
glass (3) on tool X2-1 (5-mm spacer) and evenly.
stick it to the operator's cab. a Press all over the window glass to the
a Match the lines of the match tapes degree that the window glass will be
stuck in step 1. stuck to the both-sided adhesive tape.
a Do not press the window glass to
a Stick the glass within 10 minutes after
strongly.
applying the adhesive.
a Before sticking the glass, check that
the primer is applied to the surface to
which the glass will be stuck.
CPW11623
CPW11622
CWW11626
CPW11628
CWW11629
WA430-5 30-159
(5)
(2)...
(4)
OPERATOR'SOF
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CAB GLASS (STUCK
OPERATOR'S GLASS)
CAB GLASS
2) Fill the joint of the glasses with caulking 3) Remove the caulking material projected
material (15). from the joint with cardboard [8], etc.
a The usable period of the following
caulking material is 4 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
CPW11631
4) Remove the masking tapes from the win-
dow glass.
11. Remove the primer and adhesive from the
operator's cab and window glass.
a Using white gasoline, wipe off the adhe-
sive before it is dried up.
a When cleaning the glass, do not give an
impact to it.
COATING MATERIALS
Komatsu
Category Part No. Q’ty Container Main applications, featuresr
code
SUNSTAR,
PAINT 20 ml Glass • Used as primer for cab. (Using limit: 4 months)
PRIMER 580 container
SUPER
Primer
SUNSTAR,
GLASS Glass
PRIMER 580 417-926-3910 20 ml container
• Used as primer for cab. (Using limit: 4 months)
SUPER
For sticking cab glass
SUNSTAR,
PENGUINE Polyethyl- • "S" and "W" are used as adhesive for glass at high
SEAL 580 320 ml ene con- temperature (summer) and low temperature (winter)
SUPER "S" or tainer respectively. (Using limit: 4 months)
Adhesive "W"
SIKA JAPAN, Polyethyl-
SIKAFLEX 256 20Y-54-39850 310 ml ene con- • Used as adhesive for glass. (Using limit: 6 months)
HV tainer
SUNSTAR, Polyethyl-
PENGUINE
SEAL NO. 417-926-3920 320 ml ene con- • Used to seal joint of glasses (Using limit: 4 months)
Caulking tainer
2605
material
SEKISUI SILI- Polyethyl-
CONE SEAL- 20Y-54-55130 333 ml ene con- • Used to seal front window (Using limit: 6 months)
ANT tainer
30-160 WA430-5
(5)
(2)
(4)
TORQUE CONVERTER, WORK EQUIPMENT AND PILOT
DISASSEMBLY AND ASSEMBLY CONTROL
REMOVAL AND INSTALLATION PUMP
OF TORQUE ASSEMBLY
CONVERTER,
CPW11549
CPW11550
WA430-5 30-161
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY STEERING,
REMOVAL AND SWITCH OF
INSTALLATION AND FAN PUMP
STEERING, ASSEMBLY
SWITCH AND
CPW11551 CPW11553
3. Disconnect the flowing tubes and the hoses 4. Temporarily lift the steering, switch and fan
from the steering, switch and fan pump pump assembly (9), and remove the mount-
assembly. ing bolts and remove it.
4
1) Remove the suction tube (2). Steering, switch and fan pump
assembly: 55kg
CPW11552
CPW11554
INSTALLATION
• Carry out installation in reverse order of
removal.
30-162 WA430-5
(5)
(2)
(4)
STEERING
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION OFDEMAND VALVE
STEERING ASSEMBLY
DEMAND VALVE
4
Lower the work equipment to the
ground completely and stop the engine. Steering demand valve assembly:
Apply the parking brake and put the 30kg
blocks under the wheels.
INSTALLATION
CPW10856
WA430-5 30-163
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY TRAVEL OF
REMOVAL AND INSTALLATION DUMPER VALVE
TRAVEL ASSEMBLY
DUMPER VALVE
4
lift arm cylinder bottom hose (2) hydraulic
tank return hose (3). Travel dumper valve assembly:
30kg
CPW10855
CPW11555
INSTALLATION
• Carry out installation in reverse order of
removal.
30-164 WA430-5
(5)
(2)
(4)
WORK EQUIPMENT
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION VALVE ASSEMBLY
OF WORK EQUIPMENT VALVE
WA430-5 30-165
(5)
(2)...
(4)
WORK EQUIPMENT
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION VALVE ASSEMBLY
OF WORK EQUIPMENT VALVE
6. Disconnect the PPC tube for bucket side (8) 9. Disconnect the bucket cylinder head hose (17)
and lift arm side (9) from rear of the work and bottom hose (18).
equipment valve. 10. Disconnect the lift cylinder head tube (11) and
7. Loosen the mounting bolts of the work equip- bottom tube (12).
ment pump outlet tube (10), lift cylinder head ★ Remove the tubes (11) and (12) first loos-
tube (11), and bottom tube (12) up to the ened in the rear of the valve, and shift
arrow-indicated level of the drawn line. backward.
★ For tube (10), remove the clamp.
4
and lift arm head hose (14) of the travel
dumper valve. Work equipment valve assembly:
Then disconnect the travel dumper valve 80 kg
return hose (15) and work equipment valve
return hose (16).
★ Remove the bolts first loosened in the
rear of the valve and shift the work equip-
ment pump outlet tube (10) backward.
INSTALLATION
• Carry out installation in reverse order of
removal.
30-166 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF HYDRAULIC TANK
4
Park the machine on flat ground and set
Right fender: 60kg
the safety bar to the frame.
6 Hydraulic tank: 129 l 4. Lift the right ladder (6) and remove it.
CPW10848
CPW11344
CPW11345
WA430-5 30-167
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL AND INSTALLATION OF HYDRAULIC TANK
7. Disconnect the suction tube (13) of the emer- 11. Lift the hydraulic tank assembly (17) and
gency pump. remove it.
CPW11346
CPW11349
[*2]
3 Mounting bolt:
245 - 309Nm {25 - 31.5kgm}
CPW11348
30-168 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF HYDRAULIC TANK
Park the machine on flat ground and set 3. Move the machine to backward and discon-
the safety bar to the frame. nect the bucket.
4. Temporarily lift the bucket cylinder assembly
Lower the work equipment to the (3), pull out the rod pin (4). Then disconnect
ground completely and stop the engine. the cylinder rod and tilt lever. [*3]
Apply the parking brake and put the
★ Install the block [1] between the cylinder
blocks under the wheels.
bottom and frame.
Disconnect the battery (–) terminal in ★ If the shims are inserted, check the num-
advance. ber and thickness of shims.
CEW02152
CEW02153
WA430-5 30-169
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF HYDRAULIC TANK
6. Temporarily lift the lift cylinder assembly, and 11. Temporarily lift the lift arm, tilt lever and
remove the pin (5). [*4] bucket link assembly (10), and pull out the
★ If the shims are inserted, check the num- mounting pin (11). [*7]
ber and thickness of shims. ★ If the shims are inserted, check the num-
★ When lowering the lift cylinder, put the ber and thickness of shims.
block into the top of the axle. 12. Lift the lift arm, tilt lever and bucket link
4
assembly (10) and remove it.
Lift cylinder assembly: 170kg
4 Lift arm, tilt lever and bucket link
assembly: 1,600kg
DBW01810
CJW11354
CPW11352
CJW11355
CPW11353
30-170 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL AND INSTALLATION OF HYDRAULIC TANK
14. Temporarily lift the tilt lever assembly (14), 18. Pull out the dust seal (21) and bushing (22)
and pull out the mounting pin (15). from the bucket link (12). [*9]
15. Lift the tilt lever assembly (14), and remove it.
CJW11359
CJW11356
INSTALLATION
• Carry out installation in reverse order of
16. Pull out the dust seal (17) and bushing (18) removal.
from the lift arm (16). [*9]
When aligning the pin hole posi-
tion, use the rod. Absolutely do not
insert fingers into the pin hole.
[*1]
Installation of bucket link pin
CJW11357
1. Lift the bucket link, align the hole of the
mounting pin (1) and install the cord ring (23).
2. Insert shims so that clearance a is equal on
the left and right.
• Clearance a: Max. 1.5 mm
• Standard shim thickness:
1.5 mm, 3.0 mm
3. Assemble the mounting pin (1) and tighten
17. Pull out the dust seal (19) and bushing (20) the bolt (24) to lock it.
from the tilt lever (14). [*9]
Absolutely do not insert fingers
into the pin hole.
CJW11358
CJW11360
WA430-5 30-171
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF HYDRAULIC TANK
2
1.5 mm, 3.0 mm
3. Assemble the mounting pin (2) and tighten Bush inside surface:
the bolt (26) to lock it. Lubricant containing molybde-
num disulfide (LM-P)
Absolutely do not insert fingers
into the pin hole. ★ After assembling the pins, fit the grease.
2 Grease:
Lubricant containing molybde-
num disulfide (LM-P)
(LM-G or hyper white G1-T)
30-172 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF HYDRAULIC TANK
2. Assemble the mounting pin (5) and tighten 2. Assemble the mounting pin (11) and tighten
the bolt (28) to lock it. the bolt (29) to lock it.
★ Take care not to damage the pin. ★ Take care not to damage the pin.
★ Before installing the pin, apply lubricant ★ Before installing the pin, apply lubricant
containing molybdenum disulfide to the containing molybdenum disulfide to the
inside wall of the bushing. inside wall of the bushing.
★ After assembling the pins, fit the grease. ★ After assembling the pins, fit the grease.
2 Grease: 2 Grease:
Lubricant containing molybde- Lubricant containing molybde-
num disulfide (LM-P) num disulfide (LM-P)
(LM-G or hyper white G1-T) (LM-G or hyper white G1-T)
CJW11363 CJW11364
[*5]
★ Adjust the boom kick-out, referring to section
"Testing and adjusting boom kick-out" in
"TESTING AND ADJUSTING."
[*6]
★ Perform the calibration, referring to section
"Testing and adjusting load meter" in "TEST-
ING AND ADJUSTING."
[*7]
Installation of lift arm pin (Frame side)
1. Insert shims so that clearance e is equal on
the left and right.
• Clearance e: Max. 1.5 mm
• Standard shim thickness:
1.5 mm, 3.0 mm
WA430-5 30-173
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF HYDRAULIC TANK
[*8] [*9]
Installation of bucket link pin Use the hydraulic cylinder [3], press the bushes to
★ Fix the bucket link to the tilt lever using a the lift arm, tilt lever and bucket link and assem-
wire. ble the dust seal.
2
1. Align the hole of the bucket link mounting pin
Bush: Grease (G2-LI)
(13) and install the cord ring (30).
2. Assemble the mounting pin (13) and tighten ★ Apply grease to the seal and take care not to
the bolt (31) to lock it. damage the seal.
★ The following figure shows the bucket link as
Absolutely do not insert fingers an example.
into the pin hole.
2 Grease:
Lubricant containing molybde- ★ At pressing, turn the dust seal lip outside.
num disulfide (LM-P) • Mounting dimensions f : 0.25 - 0.8 mm
(LM-G or hyper white G1-T) • Mounting dimensions g : 2 - 3 mm
CJW11365 CJW11367
Greasing
• Greasing to pins.
★ Supply grease until it comes out through
the joint.
30-174 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER
New/Modified
Necessity
Quantity
Set the cylinder assembly (1) to tool U1.
Sketch
Symbol Part Number Part Name
2. Cylinder head and piston rod assembly
(Steering cylinder assembly)
790-502-1003 Repair stand 1 1) Use tool U2 to remove the cylinder head
1 (2) from the cylinder.
790-101-1102 Hydraulic pump 1
Wrench assembly
790-102-2303
(For steering) 1
2
790-330-1100 Wrench assembly 1
Socket
3 790-302-1280
(For steering) 1
CJW12051
Wrench assembly
790-102-4300 (For lift arm, 1
4 bucket)
790-101-4310 Pin 1
5 790-720-1000 Expander 1
Ring
796-720-1660 (For steering) 1
Clamp
07281-01029 (For steering) 1
2) Pull out the cylinder head and piston
Ring assembly (3) from the cylinder (4).
796-720-1680 (For lift arm) 1
6 ★ When the piston rod assembly is
07281-01589
Clamp
1 pulled out from the cylinder, oil leaks.
(For lift arm)
Prepare an oil receiver.
796-720-1690 Ring (For bucket) 1
U
Clamp
07281-02169 (For bucket) 1
• Push tool
7 790-201-1761 1
(For steering)
• Push tool
790-201-1841 1
(For lift arm)
• Push tool
790-201-1851 1
(For bucket)
01010-50816 • Bolt 1
• Plate
8 790-201-1570 1
(For steering)
• Plate
790-201-1650 1
(For lift arm)
• Plate
790-201-1660 1
(For bucket)
WA430-5 30-175
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER
3. Cylinder head and piston rod assembly (Lift 4. Piston and cylinder head (Steering cylinder
cylinder assembly and bucket cylinder assem- assembly)
bly) 1) Set the cylinder head and piston rod
1) Remove the mounting bolts of the cylin- assembly (3) to tool U1.
der head assembly (2). 2) Use tool U3 to remove the nut (5).
★ Width across flats of nut: 55 mm
Width across flats of bolt
Cylinder (mm) 3) Remove the piston assembly (6), and then
Lift cylinder 24 cylinder head assembly (2).
Bucket cylinder 30
CJW12054
CJW12052
CJW12055
CJW12053
DJW05935
30-176 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER
★ When the screw (7) is too tightened 6. Disassembly of piston assembly (Steering
and it is not removed, screw the cylinder assembly)
screw (7) into the inside once, and Remove the wear ring (9) and piston ring (10)
apply a tap to the screw unit. Then from the piston (8).
remove it.
CJW12058
DJW05936
CJW12059
CJW12056
CJW12057
WA430-5 30-177
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER
CWW11480
CJW12061
CJW12060
30-178 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER
2. Assembly of cylinder head assembly (Lift cyl- 2) Remove the piston ring (10) from tool U5,
inder assembly and bucket cylinder assem- assemble it to the piston (8).
bly) 3) Use tool U6 to tighten the piston ring
1) Use tool U7 to press the bush (17). (10).
2) Assemble the buffer ring (16). 4) Assemble the wear ring (9).
3) Assemble the rod packing (15).
4) Use tool U8 to press the dust seal (14)
and fix it with the snap ring (13).
5) Install the backup ring and O-ring (12).
CJW12064
CJW12060
CJW12062
CJW11484
CJW11484
WA430-5 30-179
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER
2) Remove the piston ring (10) from tool U5, 6. Assembly of cylinder head and piston rod
assemble it to the piston (8). assembly (Lift cylinder assembly and bucket
3) Use tool U6 to tighten the piston ring cylinder assembly)
(10). 1) Set the piston rod (19) to tool U1.
4) Assemble the wear ring (9). 2) Assemble the cylinder head assembly (2).
5) Assemble the O-ring and backup ring (11).
★ To insert the backup ring, do not put it
in the assembly unreasonably. Heat it
with hot water of about 50 - 60°C, then
insert it.
CJW12066
CJW12065
3
torque.
★ Width across flats of nut: 55 mm Screw:
2
58.9 - 73.6Nm {6 - 7.5kgm}
Piston rod screw unit:
Adhesive (Equivalent to
LOCTITE 262)
CJW12054
30-180 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER
iii) Fasten the screw at four portions iii) After processing, eliminate chips and
using drift. dusts, then carefully clean the tapped
hole part.
DJW05948
CJW12068
CJW12067
CWW11015
DJW05930
WA430-5 30-181
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER
CJW12051
4) Remove the cylinder assembly (1) from
tool U1.
Cylinder Nm {kgm}
Lift cylinder 250 ± 25 {25.5 ± 2.5}
Bucket cylinder 490 ± 49 {50 ± 5.0}
CJW12053
30-182 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF COUNTER WEIGHT
4
1. Open the grill and temporarily lift it.
Counter weight: 850kg
2. Disconnect the left and right damper gas cyl-
inders (1).
3. Disconnect the working lamp connector left
G04 (2) and right G05 (3).
★ Disconnect wiring harness clamp from
the grill.
CPW11370
CPW11368
INSTALLATION
• Carry out installation in reverse order of
removal.
[*1]
CPW11369
WA430-5 30-183
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT
New/Modified
★ If the heater hose is disconnected, the
Necessity
Quantity
Sketch
Symbol Part Number Part Name coolant leaks. Accordingly, prepare a
plug in advance.
REMOVAL
CPW11374
30-184 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT
8. Disconnect the seven intermediate connec- 10. Remove the cool and heat box assembly (19)
tors of the fuse box. and the remove relay and fuse bracket (20).
• (8): FS7 ★ When removing the cool and heat box
• (9): FS6 assembly, remove the relay mounting
• (10): FS1 plate.
• (11): FS2
• (12): FS5
• (13): FS3
• (14): FS4
CPW11377
CPW11375
CPW11376
WA430-5 30-185
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT
CPW11380
30-186 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLY AIR
REMOVAL AND CONDITIONER
INSTALLATION COMPRESSOR
OF ASSEMBLY
AIR CONDITIONER COM-
New/Modified
fixing bolt and nut (6), and remove the belt
Necessity
Quantity
Sketch
(7). [*2]
Symbol Part Number Part Name
6. Remove the belt tension adjusting bolt (5)
and fixing bolt and nut (6), and remove the air
799-703-1200 Service tool kit 1 conditioner compressor assembly (8).
Vacuum pump
799-703-1100
(100V) 1
Vacuum pump
X 799-703-1110
(220V) 1
Vacuum pump
799-703-1120 (240V) 1
799-703-1401 Gas leak detector 1 CPW11382
REMOVAL
CPW11381
WA430-5 30-187
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLY AIR
REMOVAL AND CONDITIONEROF
INSTALLATION COMPRESSOR ASSEMBLY
AIR CONDITIONER COM-
INSTALLATION
[*2]
★ Adjust the air conditioner compressor belt
tension, referring to section "Adjusting Air
Conditioner Compressor Belt tension" in
"TESTING AND ADJUSTING."
★ Using claw bar [1] to move the air conditioner
compressor bracket so that adjust the belt
tension. Then tighten the adjusting bolt (5)
and fixing bolt and nut (6).
CPW11383
30-188 WA430-5
(5)
(2)
(4)
ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY
DISASSEMBLY
1. Headrest
1) Referring to the figure, check the posi-
tions of 2 clips (2) of headrest stay (1) on
both sides.
CJH12302
WA430-5 30-189
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY
2) Apply force (b) to part (a) of each clip (2) 2. Back seat
in the direction of the arrow to turn the 1) Disconnect 3 air hoses (5) from the rear
clip and release it from part (d) of head- left of back seat (4).
rest stay (1), and then pull out up headrest
★ Before disconnecting the air hoses, check
(3).
their types.
CJH12305
CJH12303
CJH12306
CJH12304
CJF12307
30-190 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY
4) Apply force (E) to the right side of back 2) Push cushion slide stopper wire (9) down
seat (4) in the direction of the arrow. with screwdriver [1], etc.
5) Applying the force to back seat (4), pull its 3) Keeping the state in 2), pull out cushion
right side up. seat (8) forward and remove it.
6) Slide back seat (4) sideway and remove it.
CJH12310
CJH12308
4. Armrest
3. Cushion seat • The procedure for disassembling right-hand
1) Push cushion adjuster lever (7) inward armrest (10) is shown below.
and slide cushion seat (8) to the front end. (Disassemble left-hand armrest (11) simi-
larly.)
CJH12309
CJH12311
WA430-5 30-191
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY
CJH12312
CJH12315
CJH12314
30-192 WA430-5
(5)
(2)
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY
3) Remove 4 suspension cover fixing rings 6) Remove 6 plastic suspension cover clips
(19). (small) (25) and 2 plastic suspension
cover clips (large) (26).
★ Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
CJH12317
Front lower part; 2 places
7) Remove suspension cover (27).
★ If you remove the suspension cover
without performing the work in steps
5) and 6), the suspension cover may
be broken.
CJH12318
6. Rails
1) Turn over the seat assembly to set rails
(28) on the upside.
CJH12321
CJH12319
WA430-5 30-193
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY
CJH12322
CJH12324
CJH12323
CJH12323
CJH12324
30-194 WA430-5
(5)
(2)
(4)
ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY
3) Set rails (28) to the rear end and install 1 2) Install 3 metallic suspension cover clips
lock washer (30) and 1 hexagon socket (24).
head bolt (29) to each rail.
CJH12319
CJH12322
CJH12320
4) Install 4 suspension cover fixing rings
(19).
CJH12317
WA430-5 30-195
(5)
(2)...
(4)
DISASSEMBLY AND ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY
5) Install plastic plate (18) to the rear. 2) Tighten lower mounting bolt (15A) lightly
6) Install right-hand hinge cover (17). and turn armrest (10) by 180 degrees.
3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and
upper mounting bolt (15B) permanently.
CJH12326
3. Armrest
• The procedure for assembling right-hand
armrest (10) is shown below.
(Assemble left-hand armrest (11) simi-
larly.)
CJH12315
30-196 WA430-5
(5)
(2)
(4)
ASSEMBLY
DISASSEMBLY AND ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY
CJH12328
CJH12327
CJH12306
WA430-5 30-197
(5)
(2)...
(4)
OPERATOR'S SEAT
DISASSEMBLY AND ASSEMBLYDISASSEMBLY, ASSEMBLY OF OPERATOR'S SEAT ASSEMBLY
ASSEMBLY
CJH12305
6. Headrest
1) Insert headrest (3) in back seat (4).
★ Check that 2 clips (2) on both sides are
locked securely.
CJH12329
30-198 WA430-5
(5)
(2)
(4)
90 OTHERS
WA430-5 90-1
POWER TRAIN OIL CIRCUIT DIAGRAM
(WITHOUT TORQUE CONVERTER LOCKUP CLUTCH)
WA430-5 90-3
POWER TRAIN OIL CIRCUIT DIAGRAM
(WITH TORQUE CONVERTER LOCKUP CLUTCH)
WA430-5 90-5
BRAKE OIL CIRCUIT DIAGRAM
WA430-5 90-7
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WA430-5 90-9
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (FOR ELECTRIC WORK EQUIPMENT LEVER)
WA430-5 90-11
ELECTRICAL CIRCUIT DIAGRAM 1/8 (1/4)
WA430-5 90-13
(3)
ELECTRICAL CIRCUIT DIAGRAM 1/8 (2/4)
WA430-5 90-15
(3)
ELECTRICAL CIRCUIT DIAGRAM 1/8 (3/4)
WA430-5 90-17
(3)
ELECTRICAL CIRCUIT DIAGRAM 1/8 (4/4)
* 1. Serial No. : 60023 and up
WA430-5 90-19
(3)
ELECTRICAL CIRCUIT DIAGRAM 2/8 (1/4)
WA430-5 90-21
ELECTRICAL CIRCUIT DIAGRAM 2/8 (2/4)
WA430-5 90-23
ELECTRICAL CIRCUIT DIAGRAM 2/8 (3/4)
WA430-5 90-25
ELECTRICAL CIRCUIT DIAGRAM 2/8 (4/4)
* 1. Serial No. : 60023 and up
WA430-5 90-27
(3)
ELECTRICAL CIRCUIT DIAGRAM 3/8
WA430-5 90-29
(3)
ELECTRICAL CIRCUIT DIAGRAM 4/8
WA430-5 90-31
ELECTRICAL CIRCUIT DIAGRAM 5/8
WA430-5 90-33
ELECTRICAL CIRCUIT DIAGRAM 6/8
WA430-5 90-35
ELECTRICAL CIRCUIT DIAGRAM 7/8
WA430-5 90-37
ELECTRICAL CIRCUIT DIAGRAM 8/8
WA430-5 90-39