SM Wa380-5l A52001-Up Cebm009703

CEBM009703
Shop
Manual
WA380-5L
WHEEL LOADER
SERIAL NUMBERS WA380-5L A52001 and UP
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
April 2009 Copyright 2009 Komatsu

Printed in USA DataKom Publications Division
00-13
FOREWORD CONTENTS
12
CONTENTS 00
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE AND FUNCTION AND MAINTENANCE STANTARDS . . . . . . . . . . . . . . . 10-1
20 STANDARD VALUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 d WA380-5L
FOREWORD
The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add
● Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
● 00-1 3 ● 00-11 3 ● 10-3 3 ● 10-31 3
● 00-2 3 ● 00-12 3 ● 10-4 3 ● 10-32 3
● 00-2-1 3 ● 00-13 3 ● 10-5 3 ● 10-33 3
● 00-2-2 3 ● 00-14 3 ● 10-6 3 ● 10-34 3
● 00-2-3 3 ● 00-15 3 ● 10-7 3 ● 10-35 3
● 00-2-4 3 ● 00-16 3 ● 10-8 3 ● 10-36 3
● 00-2-5 3 ● 00-17 3 ● 10-9 3 ● 10-37 3
● 00-2-6 3 ● 00-18 3 ● 10-10 3 ● 10-38 3
● 00-2-7 3 ❍ 00-19 3 ● 10-11 3 ● 10-39 3
● 00-2-8 3 ❍ 00-20 3 ● 10-12 3 ● 10-40 3
● 00-2-9 3 ❍ 00-21 3 ● 10-13 3 ● 10-41 3
● 00-2-10 3 ❍ 00-22 3 ● 10-14 3 ● 10-42 3
❍ 00-2-11 3 ● 10-15 3 ● 10-43 3
❍ 00-2-12 3 01-1 ● 10-16 3 ● 10-44 3
❍ 00-2-13 3 ● 01-2 3 ● 10-17 3 ● 10-45 3
❍ 00-2-14 3 01-3 1 ● 10-18 3 ● 10-46 3
❍ 00-2-15 3 ● 01-4 3 ● 10-19 3 ● 10-47 3
❍ 00-2-16 3 ● 01-5 3 ● 10-20 3 ● 10-48 3
❍ 00-2-17 3 ● 01-6 3 ● 10-21 3 ● 10-49 3
❍ 00-2-18 3 ● 01-7 3 ● 10-22 3 ● 10-50 3
● 00-3 3 ● 01-8 3 ● 10-23 3 ● 10-51 3
● 00-4 3 ● 01-9 3 ● 10-24 3 ● 10-52 3
● 00-5 3 ● 01-10 3 ● 10-25 3 ● 10-53 3
● 00-6 3 ❍ 01-11 3 ● 10-26 3 ● 10-54 3
● 00-7 3 ❍ 01-12 3 ● 10-27 3 ● 10-55 3
● 00-8 3 ● 10-28 3 ● 10-56 3
● 00-9 3 ● 10-1 3 ● 10-29 3 ● 10-57 3
● 00-10 3 ● 10-2 3 ● 10-30 3 ● 10-58 3
WA380-5L WA700-3L 00-2-1 3

FOREWORD
● 10-59 3 ● 10-92 3 ● 10-125 3 ● 10-158 3
● 10-60 3 ● 10-93 3 ● 10-126 3 ● 10-159 3
● 10-61 3 ● 10-94 3 ● 10-127 3 ● 10-160 3
● 10-62 3 ● 10-95 3 ● 10-128 3 ● 10-161 3
● 10-63 3 ● 10-96 3 ● 10-129 3 ● 10-162 3
● 10-64 3 ● 10-97 3 ● 10-130 3 ● 10-163 3
● 10-65 3 ● 10-98 3 ● 10-131 3 ● 10-164 3
● 10-66 3 ● 10-99 3 ● 10-132 3 ● 10-165 3
● 10-67 3 ● 10-100 3 ● 10-133 3 ● 10-166 3
● 10-68 3 ● 10-101 3 ● 10-134 3 ● 10-167 3
● 10-69 3 ● 10-102 3 ● 10-135 3 ● 10-168 3
● 10-70 3 ● 10-103 3 ● 10-136 3 ● 10-169 3
● 10-71 3 ● 10-104 3 ● 10-137 3 ● 10-170 3
● 10-72 3 ● 10-105 3 ● 10-138 3 ● 10-171 3
● 10-73 3 ● 10-106 3 ● 10-139 3 ● 10-172 3
● 10-74 3 ● 10-107 3 ● 10-140 3 ● 10-173 3
● 10-75 3 ● 10-108 3 ● 10-141 3 ● 10-174 3
● 10-76 3 ● 10-109 3 ● 10-142 3 ● 10-175 3
● 10-77 3 ● 10-110 3 ● 10-143 3 ● 10-176 3
● 10-78 3 ● 10-111 3 ● 10-144 3 ● 10-177 3
● 10-79 3 ● 10-112 3 ● 10-145 3 ● 10-178 3
● 10-80 3 ● 10-113 3 ● 10-146 3 ● 10-179 3
● 10-81 3 ● 10-114 3 ● 10-147 3 ● 10-180 3
● 10-82 3 ● 10-115 3 ● 10-148 3 ● 10-181 3
● 10-83 3 ● 10-116 3 ● 10-149 3 ● 10-182 3
● 10-84 3 ● 10-117 3 ● 10-150 3 ● 10-183 3
● 10-85 3 ● 10-118 3 ● 10-151 3 ● 10-184 3
● 10-86 3 ● 10-119 3 ● 10-152 3 ● 10-185 3
● 10-87 3 ● 10-120 3 ● 10-153 3 ● 10-186 3
● 10-88 3 ● 10-121 3 ● 10-154 3 ● 10-187 3
● 10-89 3 ● 10-122 3 ● 10-155 3 ● 10-188 3
● 10-90 3 ● 10-123 3 ● 10-156 3 ● 10-189 3
● 10-91 3 ● 10-124 3 ● 10-157 3 ● 10-190 3
00-2-2 3 WA380-5L
FOREWORD
● 10-191 3 ● 10-224 3 ● 10-257 3 ● 10-290 3
● 10-192 3 ● 10-225 3 ● 10-258 3 ● 10-291 3
● 10-193 3 ● 10-226 3 ● 10-259 3 ● 10-292 3
● 10-194 3 ● 10-227 3 ● 10-260 3 ● 10-293 3
● 10-195 3 ● 10-228 3 ● 10-261 3 ● 10-294 3
● 10-196 3 ● 10-229 3 ● 10-262 3 ● 10-295 3
● 10-197 3 ● 10-230 3 ● 10-263 3 ● 10-296 3
● 10-198 3 ● 10-231 3 ● 10-264 3 ● 10-297 3
● 10-199 3 ● 10-232 3 ● 10-265 3 ● 10-298 3
● 10-200 3 ● 10-233 3 ● 10-266 3 ● 10-299 3
● 10-201 3 ● 10-234 3 ● 10-267 3 ● 10-300 3
● 10-202 3 ● 10-235 3 ● 10-268 3 ● 10-301 3
● 10-203 3 ● 10-236 3 ● 10-269 3 ● 10-302 3
● 10-204 3 ● 10-237 3 ● 10-270 3 ● 10-303 3
● 10-205 3 ● 10-238 3 ● 10-271 3 ● 10-304 3
● 10-206 3 ● 10-239 3 ● 10-272 3 ● 10-305 3
● 10-207 3 ● 10-240 3 ● 10-273 3 ● 10-306 3
● 10-208 3 ● 10-241 3 ● 10-274 3 ● 10-307 3
● 10-209 3 ● 10-242 3 ● 10-275 3 ● 10-308 3
● 10-210 3 ● 10-243 3 ● 10-276 3 ❍ 10-309 3
● 10-211 3 ● 10-244 3 ● 10-277 3 ❍ 10-310 3
● 10-212 3 ● 10-245 3 ● 10-278 3 ❍ 10-311 3
● 10-213 3 ● 10-246 3 ● 10-279 3 ❍ 10-312 3
● 10-214 3 ● 10-247 3 ● 10-280 3 ❍ 10-313 3
● 10-215 3 ● 10-248 3 ● 10-281 3 ❍ 10-314 3
● 10-216 3 ● 10-249 3 ● 10-282 3 ❍ 10-315 3
● 10-217 3 ● 10-250 3 ● 10-283 3 ❍ 10-316 3
● 10-218 3 ● 10-251 3 ● 10-284 3 ❍ 10-317 3
● 10-219 3 ● 10-252 3 ● 10-285 3 ❍ 10-318 3
● 10-220 3 ● 10-253 3 ● 10-286 3 ❍ 10-319 3
● 10-221 3 ● 10-254 3 ● 10-287 3 ❍ 10-320 3
● 10-222 3 ● 10-255 3 ● 10-288 3 ❍ 10-321 3
● 10-223 3 ● 10-256 3 ● 10-289 3 ❍ 10-322 3
WA380-5L 00-2-3 3
FOREWORD
❍ 10-323 3 ❍ 10-356 3 ( ) 20-14 1 ( ) 20-47 1
❍ 10-324 3 ❍ 10-357 3 ( ) 20-15 1 ( ) 20-48 1
❍ 10-325 3 ❍ 10-358 3 ( ) 20-16 1 ( ) 20-49 1
❍ 10-326 3 ❍ 10-359 3 ( ) 20-17 1 ( ) 20-50 1
❍ 10-327 3 ❍ 10-360 3 ( ) 20-18 1
❍ 10-328 3 ❍ 10-361 3 ( ) 20-19 1 ( ) 20-101 1
❍ 10-329 3 ❍ 10-362 3 ( ) 20-20 1 ( ) 20-102 1
❍ 10-330 3 ❍ 10-363 3 ( ) 20-21 1 ( ) 20-103 1
❍ 10-331 3 ❍ 10-364 3 ( ) 20-22 1 ( ) 20-104 1
❍ 10-332 3 ❍ 10-365 3 ( ) 20-23 1 ( ) 20-105 1
❍ 10-333 3 ❍ 10-366 3 ( ) 20-24 1 ( ) 20-106 1
❍ 10-334 3 ❍ 10-367 3 ( ) 20-25 1 ( ) 20-107 1
❍ 10-335 3 ❍ 10-368 3 ( ) 20-26 1 ( ) 20-108 1
❍ 10-336 3 ❍ 10-369 3 ( ) 20-27 1 ( ) 20-109 1
❍ 10-337 3 ❍ 10-370 3 ( ) 20-28 1 ( ) 20-110 1
❍ 10-338 3 ❍ 10-371 3 ( ) 20-29 1 ( ) 20-111 1
❍ 10-339 3 ❍ 10-372 3 ( ) 20-30 1 ( ) 20-112 1
❍ 10-340 3 ❍ 10-373 3 ( ) 20-31 1 ( ) 20-113 1
❍ 10-341 3 ❍ 10-374 3 ( ) 20-32 1 ( ) 20-114 1
❍ 10-342 3 ( ) 20-33 1
❍ 10-343 3 ● 20-1 3 ( ) 20-34 1 ( ) 20-201 1
❍ 10-344 3 ● 20-2 3 ( ) 20-35 1 ( ) 20-202 1
❍ 10-345 3 ● 20-3 3 ( ) 20-36 1 ( ) 20-203 1
❍ 10-346 3 ● 20-4 3 ( ) 20-37 1 ( ) 20-204 1
❍ 10-347 3 ● 20-5 3 ( ) 20-38 1 ( ) 20-205 1
❍ 10-348 3 ● 20-6 3 ( ) 20-39 1 ( ) 20-206 1
❍ 10-349 3 ● 20-7 3 ( ) 20-40 1 ( ) 20-207 1
❍ 10-350 3 ● 20-8 3 ( ) 20-41 1 ( ) 20-208 1
❍ 10-351 3 ● 20-9 3 ( ) 20-42 1 ( ) 20-209 1
❍ 10-352 3 ● 20-10 3 ( ) 20-43 1 ( ) 20-210 1
❍ 10-353 3 ( ) 20-11 1 ( ) 20-44 1 ( ) 20-211 1
❍ 10-354 3 ( ) 20-12 1 ( ) 20-45 1 ( ) 20-212 1
❍ 10-355 3 ( ) 20-13 1 ( ) 20-46 1 ( ) 20-213 1
00-2-4 3 WA380-5L
FOREWORD
( ) 20-214 1 ( ) 20-247 1 ( ) 20-327 1 ( ) 20-360 1
( ) 20-215 1 ( ) 20-248 1 ( ) 20-328 1 ( ) 20-361 1
( ) 20-216 1 ( ) 20-249 1 ( ) 20-329 1 ( ) 20-362 1
( ) 20-217 1 ( ) 20-250 1 ( ) 20-330 1 ( ) 20-363 1
( ) 20-218 1 ( ) 20-251 1 ( ) 20-331 1 ( ) 20-364 1
( ) 20-219 1 ( ) 20-252 1 ( ) 20-332 1 ( ) 20-365 1
( ) 20-220 1 ( ) 20-333 1 ( ) 20-366 1
( ) 20-221 1 ( ) 20-301 1 ( ) 20-334 1 ( ) 20-367 1
( ) 20-222 1 ( ) 20-302 1 ( ) 20-335 1 ( ) 20-368 1
( ) 20-223 1 ( ) 20-303 1 ( ) 20-336 1 ( ) 20-369 1
( ) 20-224 1 ( ) 20-304 1 ( ) 20-337 1 ( ) 20-370 1
( ) 20-225 1 ( ) 20-305 1 ( ) 20-338 1 ( ) 20-371 1
( ) 20-226 1 ( ) 20-306 1 ( ) 20-339 1 ( ) 20-372 1
( ) 20-227 1 ( ) 20-307 1 ( ) 20-340 1 ( ) 20-373 1
( ) 20-228 1 ( ) 20-308 1 ( ) 20-341 1 ( ) 20-374 1
( ) 20-229 1 ( ) 20-309 1 ( ) 20-342 1 ( ) 20-375 1
( ) 20-230 1 ( ) 20-310 1 ( ) 20-343 1 ( ) 20-376 1
( ) 20-231 1 ( ) 20-311 1 ( ) 20-344 1 ( ) 20-377 1
( ) 20-232 1 ( ) 20-312 1 ( ) 20-345 1 ( ) 20-378 1
( ) 20-233 1 ( ) 20-313 1 ( ) 20-346 1 ( ) 20-379 1
( ) 20-234 1 ( ) 20-314 1 ( ) 20-347 1 ( ) 20-380 1
( ) 20-235 1 ( ) 20-315 1 ( ) 20-348 1 ( ) 20-381 1
( ) 20-236 1 ( ) 20-316 1 ( ) 20-349 1 ( ) 20-382 1
( ) 20-237 1 ( ) 20-317 1 ( ) 20-350 1 ( ) 20-383 1
( ) 20-238 1 ( ) 20-318 1 ( ) 20-351 1 ( ) 20-384 1
( ) 20-239 1 ( ) 20-319 1 ( ) 20-352 1 ( ) 20-385 1
( ) 20-240 1 ( ) 20-320 1 ( ) 20-353 1 ( ) 20-386 1
( ) 20-241 1 ( ) 20-321 1 ( ) 20-354 1 ( ) 20-387 1
( ) 20-242 1 ( ) 20-322 1 ( ) 20-355 1 ( ) 20-388 1
( ) 20-243 1 ( ) 20-323 1 ( ) 20-356 1 ( ) 20-389 1
( ) 20-244 1 ( ) 20-324 1 ( ) 20-357 1 ( ) 20-390 1
( ) 20-245 1 ( ) 20-325 1 ( ) 20-358 1 ( ) 20-391 1
( ) 20-246 1 ( ) 20-326 1 ( ) 20-359 1 ( ) 20-392 1
WA380-5L 00-2-5 3
FOREWORD
( ) 20-393 1 ( ) 20-426 1 ( ) 20-459 1 ( ) 20-531 1
( ) 20-394 1 ( ) 20-427 1 ( ) 20-460 1 ( ) 20-532 1
( ) 20-395 1 ( ) 20-428 1 ( ) 20-533 1
( ) 20-396 1 ( ) 20-429 1 ( ) 20-501 1 ( ) 20-534 1
( ) 20-397 1 ( ) 20-430 1 ( ) 20-502 1 ( ) 20-535 1
( ) 20-398 1 ( ) 20-431 1 ( ) 20-503 1 ( ) 20-536 1
( ) 20-399 1 ( ) 20-432 1 ( ) 20-504 1 ( ) 20-537 1
( ) 20-400 1 ( ) 20-433 1 ( ) 20-505 1 ( ) 20-538 1
( ) 20-401 1 ( ) 20-434 1 ( ) 20-506 1 ( ) 20-539 1
( ) 20-402 1 ( ) 20-435 1 ( ) 20-507 1 ( ) 20-540 1
( ) 20-403 1 ( ) 20-436 1 ( ) 20-508 1 ( ) 20-541 1
( ) 20-404 1 ( ) 20-437 1 ( ) 20-509 1 ( ) 20-542 1
( ) 20-405 1 ( ) 20-438 1 ( ) 20-510 1 ( ) 20-543 1
( ) 20-406 1 ( ) 20-439 1 ( ) 20-511 1 ( ) 20-544 1
( ) 20-407 1 ( ) 20-440 1 ( ) 20-512 1 ( ) 20-545 1
( ) 20-408 1 ( ) 20-441 1 ( ) 20-513 1 ( ) 20-546 1
( ) 20-409 1 ( ) 20-442 1 ( ) 20-514 1 ( ) 20-547 1
( ) 20-410 1 ( ) 20-443 1 ( ) 20-515 1 ( ) 20-548 1
( ) 20-411 1 ( ) 20-444 1 ( ) 20-516 1 ( ) 20-549 1
( ) 20-412 1 ( ) 20-445 1 ( ) 20-517 1 ( ) 20-550 1
( ) 20-413 1 ( ) 20-446 1 ( ) 20-518 1 ( ) 20-551 1
( ) 20-414 1 ( ) 20-447 1 ( ) 20-519 1 ( ) 20-552 1
( ) 20-415 1 ( ) 20-448 1 ( ) 20-520 1 ( ) 20-553 1
( ) 20-416 1 ( ) 20-449 1 ( ) 20-521 1 ( ) 20-554 1
( ) 20-417 1 ( ) 20-450 1 ( ) 20-522 1 ( ) 20-555 1
( ) 20-418 1 ( ) 20-451 1 ( ) 20-523 1 ( ) 20-556 1
( ) 20-419 1 ( ) 20-452 1 ( ) 20-524 1 ( ) 20-557 1
( ) 20-420 1 ( ) 20-453 1 ( ) 20-525 1 ( ) 20-558 1
( ) 20-421 1 ( ) 20-454 1 ( ) 20-526 1 ( ) 20-559 1
( ) 20-422 1 ( ) 20-455 1 ( ) 20-527 1 ( ) 20-560 1
( ) 20-423 1 ( ) 20-456 1 ( ) 20-528 1 ( ) 20-561 1
( ) 20-424 1 ( ) 20-457 1 ( ) 20-529 1 ( ) 20-562 1
( ) 20-425 1 ( ) 20-458 1 ( ) 20-530 1
00-2-6 3 WA380-5L
FOREWORD
( ) 20-701 1 ( ) 20-734 1 ( ) 20-767 1 ( ) 20-800 1
( ) 20-702 1 ( ) 20-735 1 ( ) 20-768 1 ( ) 20-801 1
( ) 20-703 1 ( ) 20-736 1 ( ) 20-769 1 ( ) 20-802 1
( ) 20-704 1 ( ) 20-737 1 ( ) 20-770 1 ( ) 20-803 1
( ) 20-705 1 ( ) 20-738 1 ( ) 20-771 1 ( ) 20-804 1
( ) 20-706 1 ( ) 20-739 1 ( ) 20-772 1 ( ) 20-805 1
( ) 20-707 1 ( ) 20-740 1 ( ) 20-773 1 ( ) 20-806 1
( ) 20-708 1 ( ) 20-741 1 ( ) 20-774 1 ( ) 20-807 1
( ) 20-709 1 ( ) 20-742 1 ( ) 20-775 1 ( ) 20-808 1
( ) 20-710 1 ( ) 20-743 1 ( ) 20-776 1 ( ) 20-809 1
( ) 20-711 1 ( ) 20-744 1 ( ) 20-777 1 ( ) 20-810 1
( ) 20-712 1 ( ) 20-745 1 ( ) 20-778 1 ( ) 20-811 1
( ) 20-713 1 ( ) 20-746 1 ( ) 20-779 1 ( ) 20-812 1
( ) 20-714 1 ( ) 20-747 1 ( ) 20-780 1 ( ) 20-813 1
( ) 20-715 1 ( ) 20-748 1 ( ) 20-781 1 ( ) 20-814 1
( ) 20-716 1 ( ) 20-749 1 ( ) 20-782 1 ( ) 20-815 1
( ) 20-717 1 ( ) 20-750 1 ( ) 20-783 1 ( ) 20-816 1
( ) 20-718 1 ( ) 20-751 1 ( ) 20-784 1 ( ) 20-817 1
( ) 20-719 1 ( ) 20-752 1 ( ) 20-785 1 ( ) 20-818 1
( ) 20-720 1 ( ) 20-753 1 ( ) 20-786 1 ( ) 20-819 1
( ) 20-721 1 ( ) 20-754 1 ( ) 20-787 1 ( ) 20-820 1
( ) 20-722 1 ( ) 20-755 1 ( ) 20-788 1 ( ) 20-821 1
( ) 20-723 1 ( ) 20-756 1 ( ) 20-789 1 ( ) 20-822 1
( ) 20-724 1 ( ) 20-757 1 ( ) 20-790 1 ( ) 20-823 1
( ) 20-725 1 ( ) 20-758 1 ( ) 20-791 1 ( ) 20-824 1
( ) 20-726 1 ( ) 20-759 1 ( ) 20-792 1 ( ) 20-825 1
( ) 20-727 1 ( ) 20-760 1 ( ) 20-793 1 ( ) 20-826 1
( ) 20-728 1 ( ) 20-761 1 ( ) 20-794 1 ( ) 20-827 1
( ) 20-729 1 ( ) 20-762 1 ( ) 20-795 1 ( ) 20-828 1
( ) 20-730 1 ( ) 20-763 1 ( ) 20-796 1 ( ) 20-829 1
( ) 20-731 1 ( ) 20-764 1 ( ) 20-797 1 ( ) 20-830 1
( ) 20-732 1 ( ) 20-765 1 ( ) 20-798 1
( ) 20-733 1 ( ) 20-766 1 ( ) 20-799 1 ( ) 20-901 1
WA380-5L 00-2-7 3
FOREWORD
( ) 20-902 1 ( ) 20-1004 1 ( ) 20-1037 1 ● 30-13 3
( ) 20-903 1 ( ) 20-1005 1 ( ) 20-1038 1 ● 30-14 3
( ) 20-904 1 ( ) 20-1006 1 ( ) 20-1039 1 ● 30-15 3
( ) 20-905 1 ( ) 20-1007 1 ( ) 20-1040 1 ● 30-16 3
( ) 20-906 1 ( ) 20-1008 1 ( ) 20-1041 1 ● 30-17 3
( ) 20-907 1 ( ) 20-1009 1 ( ) 20-1042 1 ● 30-18 3
( ) 20-908 1 ( ) 20-1010 1 ( ) 20-1043 1 ● 30-19 3
( ) 20-909 1 ( ) 20-1011 1 ( ) 20-1044 1 ● 30-20 3
( ) 20-910 1 ( ) 20-1012 1 ( ) 20-1045 1 ● 30-21 3
( ) 20-911 1 ( ) 20-1013 1 ( ) 20-1046 1 ● 30-22 3
( ) 20-912 1 ( ) 20-1014 1 ( ) 20-1047 1 ● 30-23 3
( ) 20-913 1 ( ) 20-1015 1 ( ) 20-1048 1 ● 30-24 3
( ) 20-914 1 ( ) 20-1016 1 ( ) 20-1049 1 ● 30-25 3
( ) 20-915 1 ( ) 20-1017 1 ( ) 20-1050 ● 30-26 3
( ) 20-916 1 ( ) 20-1018 1 ( ) 20-1051 1 ● 30-27 3
( ) 20-917 1 ( ) 20-1019 ( ) 20-1052 1 ● 30-28 3
( ) 20-918 1 ( ) 20-1020 1 ( ) 20-1053 1 ● 30-29 3
( ) 20-919 1 ( ) 20-1021 1 ( ) 20-1054 1 ● 30-30 3
( ) 20-920 1 ( ) 20-1022 1 ( ) 20-1055 1 ● 30-31 3
( ) 20-921 1 ( ) 20-1023 1 ( ) 20-1056 1 ● 30-32 3
( ) 20-922 1 ( ) 20-1024 1 ● 30-33 3
( ) 20-923 1 ( ) 20-1025 1 ● 30-1 3 ● 30-34 3
( ) 20-924 1 ( ) 20-1026 1 ● 30-2 3 ● 30-35 3
( ) 20-925 1 ( ) 20-1027 1 ● 30-3 3 ● 30-36 3
( ) 20-926 1 ( ) 20-1028 1 ● 30-4 3 ● 30-37 3
( ) 20-927 1 ( ) 20-1029 1 ● 30-5 3 ● 30-38 3
( ) 20-928 1 ( ) 20-1030 1 ● 30-6 3 ● 30-39 3
( ) 20-929 1 ( ) 20-1031 1 ● 30-7 3 ● 30-40 3
( ) 20-930 1 ( ) 20-1032 1 ● 30-8 3 ● 30-41 3
( ) 20-1033 1 ● 30-9 3 ● 30-42 3
( ) 20-1001 1 ( ) 20-1034 1 ● 30-10 3 ● 30-43 3
( ) 20-1002 1 ( ) 20-1035 1 ● 30-11 3 ● 30-44 3
( ) 20-1003 1 ( ) 20-1036 1 ● 30-12 3 ● 30-45 3
00-2-8 3 WA380-5L
FOREWORD
● 30-46 3 ( ) 30-79 2 ( ) 30-112 2 ( ) 30-145 2
● 30-47 3 ( ) 30-80 2 ( ) 30-113 2 ( ) 30-146 2
● 30-48 3 ( ) 30-81 2 ( ) 30-114 2 ( ) 30-147 2
● 30-49 3 ( ) 30-82 2 ( ) 30-115 2 ( ) 30-148 2
● 30-50 3 ( ) 30-83 2 ( ) 30-116 2 ( ) 30-149 2
● 30-51 3 ( ) 30-84 2 ( ) 30-117 2 ( ) 30-150 2
● 30-52 3 ( ) 30-85 2 ( ) 30-118 2 ( ) 30-151 2
● 30-53 3 ( ) 30-86 2 ( ) 30-119 2 ( ) 30-152 2
● 30-54 3 ( ) 30-87 2 ( ) 30-120 2 ( ) 30-153 2
● 30-55 3 ( ) 30-88 2 ( ) 30-121 2 ( ) 30-154 2
● 30-56 3 ( ) 30-89 2 ( ) 30-122 2 ( ) 30-155 2
● 30-57 3 ( ) 30-90 2 ( ) 30-123 2 ( ) 30-156 2
● 30-58 3 ( ) 30-91 2 ( ) 30-124 2 ( ) 30-157 2
● 30-59 3 ( ) 30-92 2 ( ) 30-125 2 ( ) 30-158 2
● 30-60 3 ( ) 30-93 2 ( ) 30-126 2 ( ) 30-159 2
● 30-61 3 ( ) 30-94 2 ( ) 30-127 2 ( ) 30-160 2
● 30-62 3 ( ) 30-95 2 ( ) 30-128 2 ( ) 30-161 2
● 30-63 3 ( ) 30-96 2 ( ) 30-129 2 ( ) 30-162 2
● 30-64 3 ( ) 30-97 2 ( ) 30-130 2 ( ) 30-163 2
● 30-65 3 ( ) 30-98 2 ( ) 30-131 2 ( ) 30-164 2
● 30-66 3 ( ) 30-99 2 ( ) 30-132 2 ( ) 30-165 2
( ) 30-67 2 ( ) 30-100 2 ( ) 30-133 2 ( ) 30-166 2
( ) 30-68 2 ( ) 30-101 2 ( ) 30-134 2 ( ) 30-167 2
( ) 30-69 2 ( ) 30-102 2 ( ) 30-135 2 ( ) 30-168 2
( ) 30-70 2 ( ) 30-103 2 ( ) 30-136 2 ( ) 30-169 2
( ) 30-71 2 ( ) 30-104 2 ( ) 30-137 2 ( ) 30-170 2
( ) 30-72 2 ( ) 30-105 2 ( ) 30-138 2 ( ) 30-171 2
( ) 30-73 2 ( ) 30-106 2 ( ) 30-139 2 ( ) 30-172 2
( ) 30-74 2 ( ) 30-107 2 ( ) 30-140 2 ( ) 30-173 2
( ) 30-75 2 ( ) 30-108 2 ( ) 30-141 2 ( ) 30-174 2
( ) 30-76 2 ( ) 30-109 2 ( ) 30-142 2 ( ) 30-175 2
( ) 30-77 2 ( ) 30-110 2 ( ) 30-143 2 ( ) 30-176 2
( ) 30-78 2 ( ) 30-111 2 ( ) 30-144 2 ( ) 30-177 2
WA380-5L 00-2-9 3
FOREWORD
( ) 30-178 2 ( ) 30-211 2 ( ) 30-244 2 ❍ 40-12 3
( ) 30-179 2 ( ) 30-212 2 ( ) 30-245 2 ❍ 40-13 3
( ) 30-180 2 ( ) 30-213 2 ( ) 30-246 2 ❍ 40-14 3
( ) 30-181 2 ( ) 30-214 2 ( ) 30-247 2 ❍ 40-15 3
( ) 30-182 2 ( ) 30-215 2 ( ) 30-248 2 ❍ 40-16 3
( ) 30-183 2 ( ) 30-216 2 ( ) 30-249 2 ❍ 40-17 3
( ) 30-184 2 ( ) 30-217 2 ( ) 30-250 2 ❍ 40-18 3
( ) 30-185 2 ( ) 30-218 2 ( ) 30-251 2 ❍ 40-19 3
( ) 30-186 2 ( ) 30-219 2 ( ) 30-252 2 ❍ 40-20 3
( ) 30-187 2 ( ) 30-220 2 ( ) 30-253 2 ❍ 40-21 3
( ) 30-188 2 ( ) 30-221 2 ( ) 30-254 2 ❍ 40-22 3
( ) 30-189 2 ( ) 30-222 2 ( ) 30-255 2 ❍ 40-23 3
( ) 30-190 2 ( ) 30-223 2 ( ) 30-256 2 ❍ 40-24 3
( ) 30-191 2 ( ) 30-224 2 ( ) 30-257 2 ❍ 40-25 3
( ) 30-192 2 ( ) 30-225 2 ( ) 30-258 2 ❍ 40-26 3
( ) 30-193 2 ( ) 30-226 2 ( ) 30-259 2 ❍ 40-27 3
( ) 30-194 2 ( ) 30-227 2 ( ) 30-260 2 ❍ 40-28 3
( ) 30-195 2 ( ) 30-228 2 ( ) 30-261 2 ❍ 40-29 3
( ) 30-196 2 ( ) 30-229 2 ( ) 30-262 2 ❍ 40-30 3
( ) 30-197 2 ( ) 30-230 2 ( ) 30-263 2 ❍ 40-31 3
( ) 30-198 2 ( ) 30-231 2 ( ) 30-264 2 ❍ 40-32 3
( ) 30-199 2 ( ) 30-232 2 ❍ 40-33 3
( ) 30-200 2 ( ) 30-233 2 ❍ 40-1 3 ❍ 40-34 3
( ) 30-201 2 ( ) 30-234 2 ❍ 40-2 3 ❍ 40-35 3
( ) 30-202 2 ( ) 30-235 2 ❍ 40-3 3 ❍ 40-36 3
( ) 30-203 2 ( ) 30-236 2 ❍ 40-4 3 ❍ 40-37 3
( ) 30-204 2 ( ) 30-237 2 ❍ 40-5 3 ❍ 40-38 3
( ) 30-205 2 ( ) 30-238 2 ❍ 40-6 3 ❍ 40-39 3
( ) 30-206 2 ( ) 30-239 2 ❍ 40-7 3 ❍ 40-40 3
( ) 30-207 2 ( ) 30-240 2 ❍ 40-8 3 ❍ 40-41 3
( ) 30-208 2 ( ) 30-241 2 ❍ 40-9 3 ❍ 40-42 3
( ) 30-209 2 ( ) 30-242 2 ❍ 40-10 3 ❍ 40-43 3
( ) 30-210 2 ( ) 30-243 2 ❍ 40-11 3 ❍ 40-44 3
00-2-10 3 WA380-5L
FOREWORD
❍ 40-45 3 ❍ 40-78 3 ❍ 40-111 3 ❍ 40-144 3
❍ 40-46 3 ❍ 40-79 3 ❍ 40-112 3 ❍ 40-145 3
❍ 40-47 3 ❍ 40-80 3 ❍ 40-113 3 ❍ 40-146 3
❍ 40-48 3 ❍ 40-81 3 ❍ 40-114 3 ❍ 40-147 3
❍ 40-49 3 ❍ 40-82 3 ❍ 40-115 3 ❍ 40-148 3
❍ 40-50 3 ❍ 40-83 3 ❍ 40-116 3 ❍ 40-149 3
❍ 40-51 3 ❍ 40-84 3 ❍ 40-117 3 ❍ 40-150 3
❍ 40-52 3 ❍ 40-85 3 ❍ 40-118 3 ❍ 40-151 3
❍ 40-53 3 ❍ 40-86 3 ❍ 40-119 3 ❍ 40-152 3
❍ 40-54 3 ❍ 40-87 3 ❍ 40-120 3 ❍ 40-153 3
❍ 40-55 3 ❍ 40-88 3 ❍ 40-121 3 ❍ 40-154 3
❍ 40-56 3 ❍ 40-89 3 ❍ 40-122 3 ❍ 40-155 3
❍ 40-57 3 ❍ 40-90 3 ❍ 40-123 3 ❍ 40-156 3
❍ 40-58 3 ❍ 40-91 3 ❍ 40-124 3 ❍ 40-157 3
❍ 40-59 3 ❍ 40-92 3 ❍ 40-125 3 ❍ 40-158 3
❍ 40-60 3 ❍ 40-93 3 ❍ 40-126 3 ❍ 40-159 3
❍ 40-61 3 ❍ 40-94 3 ❍ 40-127 3 ❍ 40-160 3
❍ 40-62 3 ❍ 40-95 3 ❍ 40-128 3 ❍ 40-161 3
❍ 40-63 3 ❍ 40-96 3 ❍ 40-129 3 ❍ 40-162 3
❍ 40-64 3 ❍ 40-97 3 ❍ 40-130 3 ❍ 40-163 3
❍ 40-65 3 ❍ 40-98 3 ❍ 40-131 3 ❍ 40-164 3
❍ 40-66 3 ❍ 40-99 3 ❍ 40-132 3 ❍ 40-165 3
❍ 40-67 3 ❍ 40-100 3 ❍ 40-133 3 ❍ 40-166 3
❍ 40-68 3 ❍ 40-101 3 ❍ 40-134 3 ❍ 40-167 3
❍ 40-69 3 ❍ 40-102 3 ❍ 40-135 3 ❍ 40-168 3
❍ 40-70 3 ❍ 40-103 3 ❍ 40-136 3 ❍ 40-169 3
❍ 40-71 3 ❍ 40-104 3 ❍ 40-137 3 ❍ 40-170 3
❍ 40-72 3 ❍ 40-105 3 ❍ 40-138 3 ❍ 40-171 3
❍ 40-73 3 ❍ 40-106 3 ❍ 40-139 3 ❍ 40-172 3
❍ 40-74 3 ❍ 40-107 3 ❍ 40-140 3 ❍ 40-173 3
❍ 40-75 3 ❍ 40-108 3 ❍ 40-141 3 ❍ 40-174 3
❍ 40-76 3 ❍ 40-109 3 ❍ 40-142 3 ❍ 40-175 3
❍ 40-77 3 ❍ 40-110 3 ❍ 40-143 3 ❍ 40-176 3
WA380-5L 00-2-11 3
FOREWORD
❍ 40-177 3 ❍ 40-210 3 ❍ 40-243 3 ❍ 40-276 3
❍ 40-178 3 ❍ 40-211 3 ❍ 40-244 3 ❍ 40-277 3
❍ 40-179 3 ❍ 40-212 3 ❍ 40-245 3 ❍ 40-278 3
❍ 40-180 3 ❍ 40-213 3 ❍ 40-246 3 ❍ 40-279 3
❍ 40-181 3 ❍ 40-214 3 ❍ 40-247 3 ❍ 40-280 3
❍ 40-182 3 ❍ 40-215 3 ❍ 40-248 3 ❍ 40-281 3
❍ 40-183 3 ❍ 40-216 3 ❍ 40-249 3 ❍ 40-282 3
❍ 40-184 3 ❍ 40-217 3 ❍ 40-250 3 ❍ 40-283 3
❍ 40-185 3 ❍ 40-218 3 ❍ 40-251 3 ❍ 40-284 3
❍ 40-186 3 ❍ 40-219 3 ❍ 40-252 3 ❍ 40-285 3
❍ 40-187 3 ❍ 40-220 3 ❍ 40-253 3 ❍ 40-286 3
❍ 40-188 3 ❍ 40-221 3 ❍ 40-254 3 ❍ 40-287 3
❍ 40-189 3 ❍ 40-222 3 ❍ 40-255 3 ❍ 40-288 3
❍ 40-190 3 ❍ 40-223 3 ❍ 40-256 3 ❍ 40-289 3
❍ 40-191 3 ❍ 40-224 3 ❍ 40-257 3 ❍ 40-290 3
❍ 40-192 3 ❍ 40-225 3 ❍ 40-258 3 ❍ 40-291 3
❍ 40-193 3 ❍ 40-226 3 ❍ 40-259 3 ❍ 40-292 3
❍ 40-194 3 ❍ 40-227 3 ❍ 40-260 3 ❍ 40-293 3
❍ 40-195 3 ❍ 40-228 3 ❍ 40-261 3 ❍ 40-294 3
❍ 40-196 3 ❍ 40-229 3 ❍ 40-262 3 ❍ 40-295 3
❍ 40-197 3 ❍ 40-230 3 ❍ 40-263 3 ❍ 40-296 3
❍ 40-198 3 ❍ 40-231 3 ❍ 40-264 3 ❍ 40-297 3
❍ 40-199 3 ❍ 40-232 3 ❍ 40-265 3 ❍ 40-298 3
❍ 40-200 3 ❍ 40-233 3 ❍ 40-266 3 ❍ 40-299 3
❍ 40-201 3 ❍ 40-234 3 ❍ 40-267 3 ❍ 40-300 3
❍ 40-202 3 ❍ 40-235 3 ❍ 40-268 3 ❍ 40-301 3
❍ 40-203 3 ❍ 40-236 3 ❍ 40-269 3 ❍ 40-302 3
❍ 40-204 3 ❍ 40-237 3 ❍ 40-270 3 ❍ 40-303 3
❍ 40-205 3 ❍ 40-238 3 ❍ 40-271 3 ❍ 40-304 3
❍ 40-206 3 ❍ 40-239 3 ❍ 40-272 3 ❍ 40-305 3
❍ 40-207 3 ❍ 40-240 3 ❍ 40-273 3 ❍ 40-306 3
❍ 40-208 3 ❍ 40-241 3 ❍ 40-274 3 ❍ 40-307 3
❍ 40-209 3 ❍ 40-242 3 ❍ 40-275 3 ❍ 40-308 3
00-2-12 3 WA380-5L
FOREWORD
❍ 40-309 3 ❍ 40-342 3 ❍ 40-375 3 ❍ 40-408 3
❍ 40-310 3 ❍ 40-343 3 ❍ 40-376 3 ❍ 40-409 3
❍ 40-311 3 ❍ 40-344 3 ❍ 40-377 3 ❍ 40-410 3
❍ 40-312 3 ❍ 40-345 3 ❍ 40-378 3 ❍ 40-411 3
❍ 40-313 3 ❍ 40-346 3 ❍ 40-379 3 ❍ 40-412 3
❍ 40-314 3 ❍ 40-347 3 ❍ 40-380 3 ❍ 40-413 3
❍ 40-315 3 ❍ 40-348 3 ❍ 40-381 3 ❍ 40-414 3
❍ 40-316 3 ❍ 40-349 3 ❍ 40-382 3 ❍ 40-415 3
❍ 40-317 3 ❍ 40-350 3 ❍ 40-383 3 ❍ 40-416 3
❍ 40-318 3 ❍ 40-351 3 ❍ 40-384 3 ❍ 40-417 3
❍ 40-319 3 ❍ 40-352 3 ❍ 40-385 3 ❍ 40-418 3
❍ 40-320 3 ❍ 40-353 3 ❍ 40-386 3 ❍ 40-419 3
❍ 40-321 3 ❍ 40-354 3 ❍ 40-387 3 ❍ 40-420 3
❍ 40-322 3 ❍ 40-355 3 ❍ 40-388 3 ❍ 40-421 3
❍ 40-323 3 ❍ 40-356 3 ❍ 40-389 3 ❍ 40-422 3
❍ 40-324 3 ❍ 40-357 3 ❍ 40-390 3 ❍ 40-423 3
❍ 40-325 3 ❍ 40-358 3 ❍ 40-391 3 ❍ 40-424 3
❍ 40-326 3 ❍ 40-359 3 ❍ 40-392 3 ❍ 40-425 3
❍ 40-327 3 ❍ 40-360 3 ❍ 40-393 3 ❍ 40-426 3
❍ 40-328 3 ❍ 40-361 3 ❍ 40-394 3 ❍ 40-427 3
❍ 40-329 3 ❍ 40-362 3 ❍ 40-395 3 ❍ 40-428 3
❍ 40-330 3 ❍ 40-363 3 ❍ 40-396 3 ❍ 40-429 3
❍ 40-331 3 ❍ 40-364 3 ❍ 40-397 3 ❍ 40-430 3
❍ 40-332 3 ❍ 40-365 3 ❍ 40-398 3 ❍ 40-431 3
❍ 40-333 3 ❍ 40-366 3 ❍ 40-399 3 ❍ 40-432 3
❍ 40-334 3 ❍ 40-367 3 ❍ 40-400 3 ❍ 40-433 3
❍ 40-335 3 ❍ 40-368 3 ❍ 40-401 3 ❍ 40-434 3
❍ 40-336 3 ❍ 40-369 3 ❍ 40-402 3 ❍ 40-435 3
❍ 40-337 3 ❍ 40-370 3 ❍ 40-403 3 ❍ 40-436 3
❍ 40-338 3 ❍ 40-371 3 ❍ 40-404 3 ❍ 40-437 3
❍ 40-339 3 ❍ 40-372 3 ❍ 40-405 3 ❍ 40-438 3
❍ 40-340 3 ❍ 40-373 3 ❍ 40-406 3 ❍ 40-439 3
❍ 40-341 3 ❍ 40-374 3 ❍ 40-407 3 ❍ 40-440 3
WA380-5L 00-2-13 3
FOREWORD
❍ 40-441 3 ❍ 40-474 3 ❍ 40-507 3 ❍ 40-540 3
❍ 40-442 3 ❍ 40-475 3 ❍ 40-508 3 ❍ 40-541 3
❍ 40-443 3 ❍ 40-476 3 ❍ 40-509 3 ❍ 40-542 3
❍ 40-444 3 ❍ 40-477 3 ❍ 40-510 3 ❍ 40-543 3
❍ 40-445 3 ❍ 40-478 3 ❍ 40-511 3 ❍ 40-544 3
❍ 40-446 3 ❍ 40-479 3 ❍ 40-512 3 ❍ 40-545 3
❍ 40-447 3 ❍ 40-480 3 ❍ 40-513 3 ❍ 40-546 3
❍ 40-448 3 ❍ 40-481 3 ❍ 40-514 3 ❍ 40-547 3
❍ 40-449 3 ❍ 40-482 3 ❍ 40-515 3 ❍ 40-548 3
❍ 40-450 3 ❍ 40-483 3 ❍ 40-516 3 ❍ 40-549 3
❍ 40-451 3 ❍ 40-484 3 ❍ 40-517 3 ❍ 40-550 3
❍ 40-452 3 ❍ 40-485 3 ❍ 40-518 3 ❍ 40-551 3
❍ 40-453 3 ❍ 40-486 3 ❍ 40-519 3 ❍ 40-552 3
❍ 40-454 3 ❍ 40-487 3 ❍ 40-520 3 ❍ 40-553 3
❍ 40-455 3 ❍ 40-488 3 ❍ 40-521 3 ❍ 40-554 3
❍ 40-456 3 ❍ 40-489 3 ❍ 40-522 3 ❍ 40-555 3
❍ 40-457 3 ❍ 40-490 3 ❍ 40-523 3 ❍ 40-556 3
❍ 40-458 3 ❍ 40-491 3 ❍ 40-524 3 ❍ 40-557 3
❍ 40-459 3 ❍ 40-492 3 ❍ 40-525 3 ❍ 40-558 3
❍ 40-460 3 ❍ 40-493 3 ❍ 40-526 3 ❍ 40-559 3
❍ 40-461 3 ❍ 40-494 3 ❍ 40-527 3 ❍ 40-560 3
❍ 40-462 3 ❍ 40-495 3 ❍ 40-528 3 ❍ 40-561 3
❍ 40-463 3 ❍ 40-496 3 ❍ 40-529 3 ❍ 40-562 3
❍ 40-464 3 ❍ 40-497 3 ❍ 40-530 3 ❍ 40-563 3
❍ 40-465 3 ❍ 40-498 3 ❍ 40-531 3 ❍ 40-564 3
❍ 40-466 3 ❍ 40-499 3 ❍ 40-532 3 ❍ 40-565 3
❍ 40-467 3 ❍ 40-500 3 ❍ 40-533 3 ❍ 40-566 3
❍ 40-468 3 ❍ 40-501 3 ❍ 40-534 3 ❍ 40-567 3
❍ 40-469 3 ❍ 40-502 3 ❍ 40-535 3 ❍ 40-568 3
❍ 40-470 3 ❍ 40-503 3 ❍ 40-536 3 ❍ 40-569 3
❍ 40-471 3 ❍ 40-504 3 ❍ 40-537 3 ❍ 40-570 3
❍ 40-472 3 ❍ 40-505 3 ❍ 40-538 3 ❍ 40-571 3
❍ 40-473 3 ❍ 40-506 3 ❍ 40-539 3 ❍ 40-572 3
00-2-14 3 WA380-5L
FOREWORD
❍ 40-573 3 ❍ 40-606 3 ❍ 40-639 3 ❍ 40-672 3
❍ 40-574 3 ❍ 40-607 3 ❍ 40-640 3 ❍ 40-673 3
❍ 40-575 3 ❍ 40-608 3 ❍ 40-641 3 ❍ 40-674 3
❍ 40-576 3 ❍ 40-609 3 ❍ 40-642 3 ❍ 40-675 3
❍ 40-577 3 ❍ 40-610 3 ❍ 40-643 3 ❍ 40-676 3
❍ 40-578 3 ❍ 40-611 3 ❍ 40-644 3
❍ 40-579 3 ❍ 40-612 3 ❍ 40-645 3 ❍ 50-1 3
❍ 40-580 3 ❍ 40-613 3 ❍ 40-646 3 ❍ 50-2 3
❍ 40-581 3 ❍ 40-614 3 ❍ 40-647 3 ❍ 50-3 3
❍ 40-582 3 ❍ 40-615 3 ❍ 40-648 3 ❍ 50-4 3
❍ 40-583 3 ❍ 40-616 3 ❍ 40-649 3 ❍ 50-5 3
❍ 40-584 3 ❍ 40-617 3 ❍ 40-650 3 ❍ 50-6 3
❍ 40-585 3 ❍ 40-618 3 ❍ 40-651 3 ❍ 50-7 3
❍ 40-586 3 ❍ 40-619 3 ❍ 40-652 3 ❍ 50-8 3
❍ 40-587 3 ❍ 40-620 3 ❍ 40-653 3 ❍ 50-9 3
❍ 40-588 3 ❍ 40-621 3 ❍ 40-654 3 ❍ 50-10 3
❍ 40-589 3 ❍ 40-622 3 ❍ 40-655 3 ❍ 50-11 3
❍ 40-590 3 ❍ 40-623 3 ❍ 40-656 3 ❍ 50-12 3
❍ 40-591 3 ❍ 40-624 3 ❍ 40-657 3 ❍ 50-13 3
❍ 40-592 3 ❍ 40-625 3 ❍ 40-658 3 ❍ 50-14 3
❍ 40-593 3 ❍ 40-626 3 ❍ 40-659 3 ❍ 50-15 3
❍ 40-594 3 ❍ 40-627 3 ❍ 40-660 3 ❍ 50-16 3
❍ 40-595 3 ❍ 40-628 3 ❍ 40-661 3 ❍ 50-17 3
❍ 40-596 3 ❍ 40-629 3 ❍ 40-662 3 ❍ 50-18 3
❍ 40-597 3 ❍ 40-630 3 ❍ 40-663 3 ❍ 50-19 3
❍ 40-598 3 ❍ 40-631 3 ❍ 40-664 3 ❍ 50-20 3
❍ 40-599 3 ❍ 40-632 3 ❍ 40-665 3 ❍ 50-21 3
❍ 40-600 3 ❍ 40-633 3 ❍ 40-666 3 ❍ 50-22 3
❍ 40-601 3 ❍ 40-634 3 ❍ 40-667 3 ❍ 50-23 3
❍ 40-602 3 ❍ 40-635 3 ❍ 40-668 3 ❍ 50-24 3
❍ 40-603 3 ❍ 40-636 3 ❍ 40-669 3 ❍ 50-25 3
❍ 40-604 3 ❍ 40-637 3 ❍ 40-670 3 ❍ 50-26 3
❍ 40-605 3 ❍ 40-638 3 ❍ 40-671 3 ❍ 50-27 3
WA380-5L 00-2-15 3
FOREWORD
❍ 50-28 3 ❍ 50-61 3 ❍ 50-94 3 ❍ 50-127 3
❍ 50-29 3 ❍ 50-62 3 ❍ 50-95 3 ❍ 50-128 3
❍ 50-30 3 ❍ 50-63 3 ❍ 50-96 3 ❍ 50-129 3
❍ 50-31 3 ❍ 50-64 3 ❍ 50-97 3 ❍ 50-130 3
❍ 50-32 3 ❍ 50-65 3 ❍ 50-98 3 ❍ 50-131 3
❍ 50-33 3 ❍ 50-66 3 ❍ 50-99 3 ❍ 50-132 3
❍ 50-34 3 ❍ 50-67 3 ❍ 50-100 3 ❍ 50-133 3
❍ 50-35 3 ❍ 50-68 3 ❍ 50-101 3 ❍ 50-134 3
❍ 50-36 3 ❍ 50-69 3 ❍ 50-102 3 ❍ 50-135 3
❍ 50-37 3 ❍ 50-70 3 ❍ 50-103 3 ❍ 50-136 3
❍ 50-38 3 ❍ 50-71 3 ❍ 50-104 3 ❍ 50-137 3
❍ 50-39 3 ❍ 50-72 3 ❍ 50-105 3 ❍ 50-138 3
❍ 50-40 3 ❍ 50-73 3 ❍ 50-106 3 ❍ 50-139 3
❍ 50-41 3 ❍ 50-74 3 ❍ 50-107 3 ❍ 50-140 3
❍ 50-42 3 ❍ 50-75 3 ❍ 50-108 3 ❍ 50-141 3
❍ 50-43 3 ❍ 50-76 3 ❍ 50-109 3 ❍ 50-142 3
❍ 50-44 3 ❍ 50-77 3 ❍ 50-110 3 ❍ 50-143 3
❍ 50-45 3 ❍ 50-78 3 ❍ 50-111 3 ❍ 50-144 3
❍ 50-46 3 ❍ 50-79 3 ❍ 50-112 3 ❍ 50-145 3
❍ 50-47 3 ❍ 50-80 3 ❍ 50-113 3 ❍ 50-146 3
❍ 50-48 3 ❍ 50-81 3 ❍ 50-114 3 ❍ 50-147 3
❍ 50-49 3 ❍ 50-82 3 ❍ 50-115 3 ❍ 50-148 3
❍ 50-50 3 ❍ 50-83 3 ❍ 50-116 3 ❍ 50-149 3
❍ 50-51 3 ❍ 50-84 3 ❍ 50-117 3 ❍ 50-150 3
❍ 50-52 3 ❍ 50-85 3 ❍ 50-118 3 ❍ 50-151 3
❍ 50-53 3 ❍ 50-86 3 ❍ 50-119 3 ❍ 50-152 3
❍ 50-54 3 ❍ 50-87 3 ❍ 50-120 3 ❍ 50-153 3
❍ 50-55 3 ❍ 50-88 3 ❍ 50-121 3 ❍ 50-154 3
❍ 50-56 3 ❍ 50-89 3 ❍ 50-122 3 ❍ 50-155 3
❍ 50-57 3 ❍ 50-90 3 ❍ 50-123 3 ❍ 50-156 3
❍ 50-58 3 ❍ 50-91 3 ❍ 50-124 3 ❍ 50-157 3
❍ 50-59 3 ❍ 50-92 3 ❍ 50-125 3 ❍ 50-158 3
❍ 50-60 3 ❍ 50-93 3 ❍ 50-126 3 ❍ 50-159 3
00-2-16 3 WA380-5L
FOREWORD
❍ 50-160 3 ❍ 50-193 3 ❍ 50-226 3 ❍ 50-259 3
❍ 50-161 3 ❍ 50-194 3 ❍ 50-227 3 ❍ 50-260 3
❍ 50-162 3 ❍ 50-195 3 ❍ 50-228 3 ❍ 50-261 3
❍ 50-163 3 ❍ 50-196 3 ❍ 50-229 3 ❍ 50-262 3
❍ 50-164 3 ❍ 50-197 3 ❍ 50-230 3 ❍ 50-263 3
❍ 50-165 3 ❍ 50-198 3 ❍ 50-231 3 ❍ 50-264 3
❍ 50-166 3 ❍ 50-199 3 ❍ 50-232 3
❍ 50-167 3 ❍ 50-200 3 ❍ 50-233 3 90-1 2
❍ 50-168 3 ❍ 50-201 3 ❍ 50-234 3 90-2
❍ 50-169 3 ❍ 50-202 3 ❍ 50-235 3 90-3
❍ 50-170 3 ❍ 50-203 3 ❍ 50-236 3 90-4
❍ 50-171 3 ❍ 50-204 3 ❍ 50-237 3 90-5 2
❍ 50-172 3 ❍ 50-205 3 ❍ 50-238 3 90-6 2
❍ 50-173 3 ❍ 50-206 3 ❍ 50-239 3 90-7 2
❍ 50-174 3 ❍ 50-207 3 ❍ 50-240 3 90-8 2
❍ 50-175 3 ❍ 50-208 3 ❍ 50-241 3 90-9 2
❍ 50-176 3 ❍ 50-209 3 ❍ 50-242 3 90-10 2
❍ 50-177 3 ❍ 50-210 3 ❍ 50-243 3 90-11 2
❍ 50-178 3 ❍ 50-211 3 ❍ 50-244 3 90-12 2
❍ 50-179 3 ❍ 50-212 3 ❍ 50-245 3 90-13 2
❍ 50-180 3 ❍ 50-213 3 ❍ 50-246 3 90-14 2
❍ 50-181 3 ❍ 50-214 3 ❍ 50-247 3 90-15 2
❍ 50-182 3 ❍ 50-215 3 ❍ 50-248 3 90-16 2
❍ 50-183 3 ❍ 50-216 3 ❍ 50-249 3 90-17 2
❍ 50-184 3 ❍ 50-217 3 ❍ 50-250 3 90-18 2
❍ 50-185 3 ❍ 50-218 3 ❍ 50-251 3 90-19 2
❍ 50-186 3 ❍ 50-219 3 ❍ 50-252 3 90-20 2
❍ 50-187 3 ❍ 50-220 3 ❍ 50-253 3 90-21 2
❍ 50-188 3 ❍ 50-221 3 ❍ 50-254 3 90-22 2
❍ 50-189 3 ❍ 50-222 3 ❍ 50-255 3 90-23 2
❍ 50-190 3 ❍ 50-223 3 ❍ 50-256 3 90-24 2
❍ 50-191 3 ❍ 50-224 3 ❍ 50-257 3 90-25 2
❍ 50-192 3 ❍ 50-225 3 ❍ 50-258 3 90-26 2
WA380-5L 00-2-17 3
FOREWORD
90-27 2
90-28 2
90-29 2
90-30 2
90-31 2
90-32 2
90-33 2
90-34 2
90-35 2
90-36 2
90-37 2
90-38 2
90-39 2
90-40 2
90-41 2
90-42 2
90-43 2
90-44 2
90-45 2
90-46 2
00-2-18 3 WA380-5L
FOREWORD SAFETY
12
SAFETY 00
SAFETY NOTICE 00
IMPORTANT SAFETY NOTICE 00
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 00
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke
Mistakes in operation are extremely dangerous. Read the only in the areas provided for smoking. Never smoke
OPERATION & MAINTENANCE MANUAL carefully while working.
BEFORE operating the machine.
PREPARATIONS FOR WORK 00
1. Before carrying out any greasing or repairs, read all the

precautions given on the decals which are fixed to the 1. Before adding oil or making repairs, park the machine
machine. on hard, level ground, and block the wheels or tracks to
prevent the machine from moving.
2. When carrying out any operation, always wear safety
shoes and helmet. Do not wear loose work clothes, or 2. Before starting work, lower blade, ripper, bucket or any
clothes with buttons missing. other work equipment to the ground. If this is not
● Always wear safety glasses when hitting parts with a possible, insert the safety pin or use blocks to prevent
hammer. the work equipment from falling. In addition, be sure to
● Always wear safety glasses when grinding parts with a lock all the control levers and hang warning signs on
grinder, etc. them.
3. When disassembling or assembling, support the

3. If welding repairs are needed, always have a trained,
machine with blocks, jacks or stands before starting
experienced welder carry out the work. When carrying
work.
out welding work, always wear welding gloves, apron,
glasses, cap and other clothes suited for welding work..
4. Remove all mud and oil from the steps or other places
WARNING! Never modify, weld, cut, or drill used to get on and off the machine. Always use the
on any part of a ROPS handrails, ladders or steps when getting on or off the
structure. Doing so may machine. Never jump on or off the machine. If it is
weaken the structure which impossible to use the handrails, ladders or steps, use a
could lead to possible failure in stand to provide safe footing.
a rollover situation
PRECAUTIONS DURING WORK 00
1. When removing the oil filler cap, drain plug or

4. When carrying out any operation with two or more
hydraulic pressure measuring plugs, loosen them slowly
workers, always agree on the operating procedure
to prevent the oil from spurting out. Before
before starting. Always inform your fellow workers
disconnecting or removing components of the oil, water
before starting any step of the operation. Before starting
or air circuits, first remove the pressure completely from
work, hang UNDER REPAIR signs on the controls in
the circuit.
the operator's compartment.
2. The water and oil in the circuits are hot when the engine
5. Keep all tools in good condition and learn the correct
is stopped, so be careful not to get burned. Wait for the
way to use them.
oil and water to cool before carrying out any work on
the oil or water circuits.
6. Decide a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their
WA380-5L 00-3 3
FOREWORD SAFETY
3. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in
position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. Gasoline or other fuels should never be used to clean parts. Clean part with appropriate solvents.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed
correctly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any
measurements.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
15. When jump starting the machine, only use a machine of similar size and voltage. Never use a arc welder or other electrical
generating equipment to jump start the machine. Carefully review the safety and procedures for jump starting the
machine.
00-4 d WA380-5L
FOREWORD GENERAL
12
GENERAL 00
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 judgements. Make sure you
understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards
when inspecting disassembled parts.
STANDARD VALUE TABLE

This section explains the standard values for new machine and judgement criteria for testing, adjusting and
troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts
in troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at
completion of the checks and repairs.
TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
DIAGRAMS AND SCHEMATICS
This section has the foldout drawings for the machine.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
WA380-5L 00-5 d
FOREWORD HOW TO READ THE SHOP MANUAL
12
HOW TO READ THE SHOP MANUAL 00
VOLUMES 00 REVISIONS 00
Shop manuals are issued as a guide to carrying out repairs. Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows: between the title page and SAFETY page.
Chassis volume: Issued for every machine model SYMBOLS 00
Engine volume: Issued for each engine series

So that the shop manual can be of ample practical use,
Electrical volume: Each issued as one to cover all models important places for safety and quality are marked with the
Attachment volume: Each issued as one to cover all models following symbols.
These various volumes are designed to avoid duplication of

information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment Special safety precautions are
be available. Safety necessary when performing the
work.
DISTRIBUTION AND UPDATING 00
Special technical precautions or

other precautions for preserving
Any additions, amendments or other changes will be sent to ★ Caution
standards are necessary when per-
your distributors. Get the most up-to-date information before
forming the work.
you start any work.
Weight of parts or systems.
FILING METHOD 00
Weight
Caution necessary when selecting
hoisting wire or when working
1. See the page number on the bottom of the page. File the posture is important, etc.
pages in correct order. Places that require special
2. Following examples show how to read the page number: Tightening
attention for tightening torque
Example: torque
during assembly.
10 - 3 Places to be coated with adhesives

Coat
and lubricants etc.
Item number (10. Structure and Function)
Places where oil, water or fuel
Oil, water
Consecutive page number for each item must be added, and the capacity.
Places where oil or water must be
3. Additional pages: Additional pages are indicated by a Drain drained, and quantity to be
hyphen (-) and numbered after the page number. File as drained.
in the example.
Example:
10-4
10-4-1
Added pages
10-4-2
10-5
REVISED EDITION MARK 00
When a manual is revised, an edition mark (bcd…) is

recorded on the bottom outside corner of the pages.
00-6 3 WA380-5L
FOREWORD HOISTING INSTRUCTIONS
12
HOISTING INSTRUCTIONS 00
HOISTING 00
can result. Hooks have maximum strength at the middle
portion.
WARNING! Heavy parts (25 kg or more)
must be lifted with a hoist etc.
In the DISASSEMBLY AND
ASSEMBLY section, every
part weighing 25 kg or more is
indicated clearly with the sym-
bol.
● If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made: 3. Do not sling a heavy load with one rope alone, but sling
1. Check for removal of all bolts fastening the part to the with two or more ropes symmetrically wound on to the
relative parts. load.
2. Check for existence of another part causing interface
with the part to be removed. WARNING! Slinging with one rope may
cause turning of the load dur-
ing hoisting, untwisting of the
WIRE ROPES 00
rope, or slipping of the rope

from its original winding posi-
1. Use adequate ropes depending on the weight of parts to tion on the load, which can
be hoisted, referring to the table below: result in a dangerous accident
Wire ropes
4. Do not sling a heavy load with ropes forming a wide
(Standard “Z” or “S” twist ropes without galvanizing) hanging angle from the hook. When hoisting a load with
Rope diameter Allowable load two or more ropes, the force subjected to each rope will
increase with the hanging angles. The table below
mm kN tons shows the variation of allowable load (kg) when hoist-
ing is made with two ropes, each of which is allowed to
10 9.8 1.0 sling up to 1000 kg vertically, at various hanging angles.
When two ropes sling a load vertically, up to 2000 kg of
11.2 13.7 1.4 total weight can be suspended. This weight becomes
1000 kg when two ropes make a 120° hanging angle. On
12.5 15.7 1.6 the other hand, two ropes are subject to an excessive
14 21.6 2.2 force as large as 4000 kg if they sling a 2000 kg load at a
lifting angle of 150°.
16 27.5 2.8
18 35.3 3.6
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
WA380-5L 00-7 3
FOREWORD PUSH PULL COUPLER
12
PUSH PULL COUPLER 00
WARNING! Before carrying out the following work,

release the residual pressure from the
hydraulic tank. For details, see TESTING
AND ADJUSTING, Releasing residual pres-
sure from hydraulic tank.
WARNING! Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows
out when the hose is disconnected. Accord-
ingly, prepare an oil receiving container.
TYPE 1 00
DISCONNECTION 00
1. Release the residual pressure from the hydraulic tank. For details,
see TESTING AND ADJUSTING, Releasing residual pressure from
hydraulic tank.
2. Hold the adapter (1) and push the hose joint (2) into the mating
adapter (3). The adapter can be pushed in about 3.5 mm. Do not hold
the rubber cap portion (4).
3. After the hose joint (2) is pushed into the adapter (3), press the
rubber cap portion (4) against the adapter until it clicks.
4. Hold the hose adapter (1) or hose (5) and pull it out. Since some
hydraulic oil flows out, prepare an oil receiving container.
CONNECTION 00
1. Hold the hose adapter (1) or hose (5) and insert it in the mating
adapter (3), aligning them with each other. Do not hold the rubber
cap portion (4).
2. After inserting the hose in the mating adapter, pull it back to check
its connecting condition. When the hose is pulled back, the rubber
cap portion moves toward the hose about 3.5 mm. This does not
indicate an abnormality.
00-8 d WA380-5L
TYPE 2 00
DISCONNECTION 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
2. Hold in the condition in Step 1, and turn the lever (4) to the right -
clockwise.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the mouthpiece of the tightening portion and push body (2) in
straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
WA380-5L 00-9 d
12
TYPE 3 00
DISCONNECTION 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until sliding prevention ring (1) contacts surface a of the
hexagonal portion at the male end.
2. Hold in the condition in Step 1, and push until the cover (3) contacts
surface a of the hexagonal portion at the male end.
3. Hold in the condition in Steps 1 and 2, and pull out the whole body
(2) to disconnect it.
CONNECTION 00
1. Hold the mouthpiece of the tightening portion and push the body (2)
in straight until the slide prevention ring (1) contacts surface a of the
hexagonal portion at the male end to connect it.
00-10 d WA380-5L
FOREWORD COATING MATERIALS
12
COATING MATERIALS 00
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
● Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
● Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene ● Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
● Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g ● Used for anti-loosening and sealant pur-
container
poses for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive ● Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
Adhesives
500 g
Polyethylene
LT-4 790-129-9040 250 g ● Used as sealant for machined holes.
container
Holtz ● Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
● Quick hardening type adhesive.
Three
Polyethylene ● Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container ● Used mainly for adhesion of metals, rub-
1735
bers, plastics and woods.
● Quick hardening type adhesive.
Aron- ● Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 ● Used mainly for adhesion of rubbers,
plastics and metals.
● Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc ● Used at joint portions subject to high tem-
648-50 container
perature.
● Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
● Features: Resistance to heat
Gasket ● Used as sealant for flange surfaces and bolts
sealant at high temperature locations; used to
LG-3 790-129-9070 1 kg Can prevent seizure.
● Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
WA380-5L 00-11 d
FOREWORD COATING MATERIALS
Category Code Part No. Quantity Container Main applications, features

● Features: Resistance to water, oil
● Used as sealant for flange surface, thread.
● Also possible to use as sealant for flanges
LG-4 790-129-9020 200 g Tube
with large clearance.
● Used as sealant for mating surfaces of final
drive case, transmission case.
● Used as sealant for various threads, pipe
Polyethylene joints, flanges.
LG-5 790-129-9080 1 kg
container ● Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
Gasket ● Features: Silicon based, resistant to heat,
sealant cold.
LG-6 09940-00011 250 g Tube ● Used as sealant for flange surface, thread.
● Used as sealant for oil pan, final drive case,
etc.
● Features: Silicon based, quick hardening
type.
LG-7 09920-00150 150 g Tube
● Used as sealant for flywheel housing, intake
manifold, oil pan, thermostat housing, etc.
Three
● Used as heat-resisting sealant for repairing
bond 790-129-9090 100 g Tube
engines.
1211
● Used as lubricant for sliding parts (to
LM-G 09940-00051 60 g Can
Molybdenum
prevent squeaking).
disulphide
lubricant
● Used to prevent seizure or scuffing of the

LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
● Used as lubricant for linkage, bearings, etc.
SYG2-400LI
SYG2-350LI
G2-LI SYG2-400LI-A Various Various ● General purpose type
SYG2-160LI
SYGA160CNLI
SYG2-400CA
SYG2-350CA
● Used for normal temperature, light load
SYG2-400CA-A
G2-CA Various Various bearing at places in contact with water or
Grease SYG2-160CA
steam.
SYG2-
160CNCA
disulphide lubricant
Molybdenum
400 g (10 per

SYG2-400M Belows type ● Used for places with heavy load.
case)
00-12 d WA380-5L
FOREWORD STANDARD TIGHTENING TORQUE
12
STANDARD TIGHTENING TORQUE 00
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 00
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter of bolt Width across flats
mm mm Nm lbf ft
6 10 11.8 - 14.7 8.70 - 10.84
8 13 27 - 34 19.91 - 25.07
10 17 59 - 74 43.51 - 54.57
12 19 98 - 123 72.28 - 90.72
14 22 153 - 190 112.84 - 140.13
16 24 235 - 285 173.32 - 210.20
18 27 320 - 400 236.02 - 295.02
20 30 455 - 565 335.59 - 416.72
22 32 610 - 765 449.91 - 564.23
24 36 785 - 980 578.98 - 722.81
27 41 1150 - 1440 848.19 - 1062.09
30 46 1520 - 1910 1121.09 - 1408.74
33 50 1960 - 2450 1445.62 - 1807.02
36 55 2450 - 3040 1807.02 - 2242.19
39 60 2890 - 3630 2131.55 - 2677.35
Thread diameter of bolt Width across flats
mm mm Nm lbf ft
6 10 5.9 - 9.8 4.35 - 7.22
8 13 13.7 - 23.5 10.10 - 17.33
10 14 34.3 - 46.1 25.29 - 34.00
12 27 74.5 - 90.2 54.94 - 66.52
WA380-5L 00-13 d
12
TIGHTENING TORQUE OF HOSE NUTS 00
Use these torques for hose nuts.

Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm lbf ft
02 14 19 19.6 - 29.4 14.5 - 21.7
03 18 24 29.4 - 68.6 21.7 - 50.6
04 22 27 58.9 - 98.1 44.4 - 72.4
05 24 32 107.9 - 166.7 79.6 - 123.0
06 30 36 147.1 - 205.9 108.5 - 151.9
10 33 41 147.1 - 245.1 108.5 - 180.8
12 36 46 196.2 - 294.2 144.7 - 217.0
14 42 55 245.2 - 343.2 180.9 - 253.1
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 00
Use these torques for split flange bolts.

mm mm Nm kgm
10 14 59 - 74 43.51 - 54.57
12 17 98 - 123 72.28 - 90.72
16 22 235 - 285 173.32 - 210.20
TIGHTENING TORQUE FOR FLARED NUTS 00
Use these torques for flared part of nut.

mm mm Nm lbf ft
14 19 24.5 ± 4.9 18.0 ± 3.6
18 24 49 ± 19.6 36.1 ± 14.4
22 27 78.5 ± 19.6 57.8 ± 14.4
24 32 137.3 ± 29.4 101.2 ± 21.6
30 36 176.5 ± 29.4 130.1 ± 21.6
33 41 196.1 ± 49 144.6 ± 36.1
36 46 245.2 ± 49 180.8 ± 36.1
42 55 294.2 ± 49 216.9 ± 36.1
00-14 d WA380-5L
12
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS 00
★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {lbf ft})
Norminal No.
mm mm Range Target
02 14 35 - 63 {25.81 - 46.46} 44 {32.45}
03, 04 20 84 - 132 {61.95 - 97.35} 103 {75.96}
Varies depending on
05, 06 24 128 - 186 {94.40 - 137.18} 157 {115.79}
type of connector.
10, 12 33 363 - 480 {267.73 - 354.02} 422 {311.25}
14 42 746 - 1010 {550.22 - 744.93} 883 {651.26}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS 00
★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {lbf lb})
Norminal No.
mm mm Range Target
08 08 14 5.88 - 8.82 {4.33 - 6.50} 7.35 {5.42}
10 10 17 9.8 - 12.74 {7.22 - 9.39} 11.27 {8.31}
12 12 19 14.7 - 19.6 {10.84 - 14.45} 17.64 {13.01}
14 14 22 19.6 - 24.5 {14.45 - 18.07} 22.54 {16.62}
16 16 24 24.5 - 34.3 {18.07 - 25.29} 29.4 {21.68}
18 18 27 34.3 - 44.1 {25.29 - 32.52} 39.2 {28.91}
20 20 30 44.1 - 53.9 {32.52 - 39.75} 49.0 {36.14}
24 24 32 58.8 - 78.4 {43.36 - 57.82} 68.6 {50.59}
30 30 32 93.1 - 122.5 {68.66 - 90.35} 107.8 {79.50}
33 33 _ 107.8 - 147.0 {79.50 - 108.42} 124.4 {91.75}
36 36 36 127.4 - 176.4 {93.96 - 130.10} 151.9 {112.03}
42 42 _ 181.3 - 240.1 {133.72 - 177.08} 210.7 {155.40}
52 52 _ 274.4 - 367.5 {202.38 - 271.05} 323.4 {238.52}
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE
SEAL TYPE) 00
★ 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 {lbf ft}) Face seal type
type
Nominal Width
Nominal thread
size of hose across flats Thread size Root diameter (mm)
Range Target size - Threads per
(mm) (Reference)
inch, Thread series
34 - 54 {25.0 - 39.8} 44 {32.4} - 9/16 - 18UN 14.3
02 19
34 - 63 {25.0 - 46.4} 44 {32.4} 14 - -
22 54 - 93 {39.8 - 68.5} 74 {54.5} - 11/16 -16UN 17.5
03
24 59 - 98 {43.5 - 72.2} 78 57.5} 18 - -
04 27 84 - 132 {61.9 - 97.3} 103 {75.9} 22 13/16 - 16UN 20.6
05 32 128 - 186 {94.4 - 137.1} 157 {115.7} 24 1 - 14UNS 25.4
06 36 177 - 245 {130.5 - 180.7} 216 {159.3} 30 1 3/16 - 12UN 30.2
(10) 41 177 - 245 {130.5 - 180.7} 216 {159.3} 33 - -
(12) 46 197 - 294 {145.3 - 216.8} 245 {180.7} 36 - -
(14) 55 246 - 343 {181.4 - 252.9} 294 {216.8} 42 - -
WA380-5L 00-15 d
FOREWORD ELECTRIC WIRE CODE
12
ELECTRIC WIRE CODE 00
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS 00
Copper wire
Nominal num- Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
ber (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE 00
Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yellow & Green & Blue & Yel-
Color — Black & Red
Blue Yellow Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-16 d WA380-5L
FOREWORD CONVERSION TABLES
12
CONVERSION TABLES 00
METHOD OF USING THE CONVERSION TABLE 00
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
● Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as b, then draw a horizontal line from b.
B. Locate the number 5 in the row across the top, take this as c, then draw a perpendicular line down from c.
C. Take the point where the two lines cross as d. This point d gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.
B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
c
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
d
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
b
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
WA380-5L 00-17 d
12
Millimeters to Inches 1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound 1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-18 d WA380-5L
12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon 1 L = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
WA380-5L 00-19 d
12
kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 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
00-20 d WA380-5L
12
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 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
WA380-5L 00-21 d
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column 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.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

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

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

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

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-22 d WA380-5L
01 GENERAL
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2
WEIGHT TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
GENERAL ASSEMBLY DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
WA380-5L 01-1
GENERAL SPECIFICATIONS
12
SPECIFICATIONS
Machine model WA380-5L
Serial number A52001 and up
Operating weight 16,150 kg (35,604 lb.)

Weight
Distribution (front) 7,785 kg (17,163 lb.)

Distribution (rear) 8,365 kg (18,441 lb.)
Bucket capacity (piled) 3.3 m³ (4.3 yd³)

Rated load 5,280 kg (11,640 lb.)
Travel speed - km/h (mph): Normal mode Power mode
FORWARD 1st 4.8 (3.0) 6.3 (3.9)

FORWARD 2nd 8.5 (5.3) 11.4 (7.0 )
FORWARD 3rd 15.3 (9.5) 20.2 (12.5 )
Performance
FORWARD 4th 24.7 (15.3) 31.5 (19.6 )

REVERSE 1st 5.2 (3.2) 6.7 (4.2 )
REVERSE 2nd 9.1 (5.7) 11.8 ( 7.3)
REVERSE 3rd 16.2 (10.0) 21.0 (13.0 )
REVERSE 4th 25.5 (15.8) 32.5 (20.2 )
Max. rimpull FORWARD kN {lbf} 130 {29,225} 168 {37,768}

REVERSE kN{lbf} 122 {27,426} 158 {35,520}
Gradeability 25 deg
(Center of outside wheel) 5,620 mm (18 ft. 5 in.)

Min. turning radius
(tip of BOC) 6,540 / 6,580 mm (21 ft. 5 in. / 21 ft. 7 in.)
Overall length (with BOC) 8,235 mm (27 ft. 0 in.)

Overall width (chassis) 2,695 mm (8 ft. 10 in.)
Bucket width (with bolt-on cutting edge) 2,905 mm (9 ft. 6 in.)
Overall height (top of cab) 3,315 mm ( 10 ft. 10 in.)
Overall height (bucket raised) 5,565 mm (18 ft. 3 in.)
Wheelbase 3,300 mm (10 ft. 9 in.)
Dimensions
Tread 2,160 mm (7 ft. 0 in.)

Minimum ground clearance 390 mm (1ft. 3 in.)
Height of bucket hinge pin 4,030 mm (12 ft. 1 in.)
Dumping clearance (cutting edge tip) 2,885 mm / 2,800 mm (9 ft. 6 in. / 9 ft. 2 in.)
Dumping reach (cutting edge tip) 1,165 mm / 1,210 mm (3 ft. 10 in. / 4 ft. 0 in.)
Steering angle 40
Bucket dump angle 49
Bucket tilt angle (travel posture) 50
Bucket tilt angle (max. height) 65
Digging depth (10° dump angle)/(tip of BOC) 310 mm / 360 mm (1 ft. / 1 ft. 2 in.)
01-2 3 WA380-5L
Model Komatsu SAA6D114E-2 diesel engine

Type 4-cycle, water cooled, in-line, 6-cylinder, direct injection with turbocharger, aftercooler
No. of cylinders - bore x stroke 6 - 114 mm (4.5 in.) x 135 mm (5.3 in.)
Piston displacement 8.27 L (504 in³)
Normal mode Power mode
Flywheel horsepower @ 136 kW (182 HP) 140kW (187 HP)

1730 rpm (normal mode)
2000 rpm (power mode)
Engine
Maximum torque (gross) @ 1400 rpm 882 N•m (651 lbf ft.) 882 N•m (651 lbf ft.)
High idle 1,900 ±50 rpm 2,240 ± 50 rpm

Low idle 900 ± 50 rpm 900 ± 50 rpm
Fuel consumption ratio 219 g/kW •h 219 g/kW •h

(163 g/HP•h) (163 g/HP•h)
Starting motor 24 V, 7.5 kW

Alternator 24 V, 35 A
Battery 24 V, 170 Ah x 2 (165G51)
Torque converter 3-element, single-stage, single-phase
Transmission 3-element, 1-stage, 2-phase (with lockup clutch)
Power train
multiple-shaft, power shift, helical gear and spur gear, constant-mesh type, multiple plate
disc type, hydraulically actuated modulation type
Reduction gear Spiral bevel gear, splash lubrication
Differential Straight bevel gear
Final drive Planetary gear, single stage, splash lubrication
Drive type Front / rear wheel drive

Axle
Front axle Fixed frame semifloating type

Rear axle Center pin support semifloating type
Tire 20.5-25-16 PR
Tire/Wheel
Wheel rim 17.00-25-1.7 WTB

Inflation pressure
Front tire 3.5 kgf/cm2 (49.8 lbf/in2)
Rear tire 3.5 kgf/cm2 (49.8 lbf/in2)
Main brakes 4-wheel brakes, front and rear-wheel independent system control, sealed wet-type disc
brake, hydraulically controlled with hydraulic power servo-assisted booster
Brakes
Parking brake Speed change gear output shaft braking, wet-type disc brake, hydraulically released
spring type
WA380-5L 01-3 1

Steering system
Type Articulated steering
Structure Hydraulic control
Torque converter pump

Type Gear type
Delivery 181 liters/min (48 gal/min)
Steering pump
Type Gear type
Hydraulic pump
Hydraulic pump
Type Gear type
Switching pump
Type Gear type
Pilot control pump

Type Gear type
Cooling fan pump

Type Variable displacement piston type
Type
Steering cylinder
Reciprocating piston type

Cylinder inner diameter 80 mm (3.2 in.)
Piston rod diameter 45 mm (1.8 in.)
Stroke 442 mm (17.4 in.)
Max. length between pins 1,209 mm (47.6 in.)
Min. length between pins 767 mm (30.2 in.)
Type Reciprocating piston type

Boom cylinder

Cylinder

Min. length between pins 1,337 mm (52.6 in.)
Type Reciprocating piston type

Bucket cylinder

Min. length between pins 1,155 mm (45.5 in.)
01-4 3 WA380-5L
Work equipment control valve

Type 2-Spool type
Control valve
210 kgf/cm2 (2,986.9 lbf/in2)

Hydraulic system
Set pressure
Steering valve
Type Spool type
Set pressure 160 kgf/cm2 (2,275.7 lbf/in2)
Cooling fan motor

Motor
Type Fixed-displacement piston type

equipment
Link type Single link

Work
bucket edge type Flat edge with top BOC
WA380-5L 01-5 3
GENERAL WEIGHT TABLE
WEIGHT TABLE
★ This weight table is a guide for use when transporting or handling components.
Unit: kg (lb.)
Serial No. A52001 and up
Engine (without coolant and oil) 870 (1,918)
Radiator (without coolant) 77 (170)
Transmission (including torque converter) 767 (1,691)
Transmission (including torque converter, with lockup clutch) 803 (1,770)
Center drive shaft 25 (55)
Front drive shaft 22 (49)
Rear drive shaft 9.8 (22)
Front axle 911 (2,008)
Rear axle 892 (1,967)
Axle pivot (rear axle) 102 (225)
Wheel (each) 110 (243)
Tire, each 207 (456)
Steering valve 24 (53)
Steering cylinder assembly, each 28 (62)
Orbit roll 5.7 (13)
Emergency steering pump (OP) 2.6 (6)
Emergency steering motor (OP) 13 (29)
Brake valve (R.H.) 8.5 (19)
Brake valve (L.H.) 5.3 (12)
Hydraulic tank (without hydraulic oil) 171 (377)
Torque converter, work equipment, PPC pump (3 tandem pump) 35 (77)
Steering, switching pump (2 tandem pump) 29 (78)
PPC valve 3 (7)
Work equipment control valve 72 (159)
Boom cylinder assembly (each) 158 (348)
Bucket cylinder assembly 172 (379)
Engine hood 160 (353)
Front frame 1,439 (3,172)
Rear frame 1,275 (2,811)
Bucket link 55 (121)
Bell crank 316 (697)
Boom (including bushing) 1,074 (2,878)
Bucket (width: 2,905 mm, with BOC) 1,618 (3,567)
Counterweight 1,200 (2,646)
Fuel tank (without fuel) 180 (397)
01-6 3 WA380-5L
GENERAL WEIGHT TABLE
Unit: kg (lb.)
Serial No. A52001 and up
Battery (each) 36 (79)
Cab 700 (1,543)
Air conditioner unit 12.5 (28)
Operator’s seat 36 (79)
Floor board 313 (690)
Oil cooler 3.5 (8)
Torque converter oil cooler 21 (46)
Cooling fan drive pump 25 (55)
Cooling fan drive motor 13 (29)
WA380-5L 01-7 3
GENERAL FUEL, COOLANT AND LUBRICANTS
FUEL, COOLANT AND LUBRICANTS

★ For details of notes (Notes 1, 2, etc.) in the table, see the Operation & Maintenance Manual.
★ As engine oil for the engine oil pan, SAE10W30 (API CH-4, CI-4) may be used instead of SAE10W30DH, and
SAE15W40 (API CH-4, CI-4) may be used instead of SAE15W40DH.
01-8 3 WA380-5L
Unit: liter (qt.)

WA380-5L
CAPACITY
Specified Refill
Engine oil pan 37 (39) 32 (34)
Transmission case 62 (65.5) 54 (57)
Hydraulic system 186 (196.5) 129 (136.3)
Axle (each) 38 (40) 38 (40)
Fuel tank 300 (317) —
Cooling system 36 (38) —
API: American Petroleum Institute ASTM: American Society of Testing and Materials
NLGI: National Lubricating Grease Institute SAE: Society of Automotive Engineers
Specified Capacity: Total amount of oil, including oil piping.

Refill Capacity: Amount of oil needed to refill system during normal maintenance.
Other equipment may be necessary when operating the machine at temperatures below -20° C (-4° F). Consult your Komatsu
distributor for specific needs.
NOTICE
Use only diesel fuel.
The engine mounted on this machine employs electronic control and a high-pressure fuel injection device to obtain
good fuel consumption and good exhaust characteristics. For this reason, high-precision parts and good lubrication are
required. If kerosene or other fuel with low lubricating qualities is used, there will be a significant drop in durability.
Remark
Use only diesel fuel only.
This engine uses an electronically controlled high-pressure fuel injection system to obtain good fuel economy
and low emissions. For this reason, it requires high precision parts and good lubrication. If kerosene or other
fuel with low lubricating ability is used, there will be a big drop in durability.
Note 1: Power train of oil has different properties from engine oil. Be sure to use the recommended oil.
Note 2: Axle oil AXO80 has the function of preventing squealing from the brakes and LSD (Limited Slip Differential). Only
AXO80 is recommended, use Komatsu genuine AXO80 or equivalent.
Note 3: When the ambient temperature is higher than 45°C (113°F) and the machine operation hour is longer than 12 hours/
day, then the use of EO50-CD instead of AXO80 is recommended. Squealing of the brakes may occur with EO50-
CD, but there is no problem with the brake performance or durability.
Note 4: Hyper grease (G2-T, G2-TE) has a high performance. When it is necessary to improve the lubricating ability of
grease in order to prevent squeaking of pins and bushings, the use of G2-T or G2-TE is recommended.
Note 5: Supercoolant (AF-NAC)
● Coolant has the important function of preventing corrosion as well as preventing freezing. Even in areas where freez-
ing is not an issue, the use of antifreeze coolant is essential. Komatsu machines are supplied with Komatsu Super-
coolant (AF-NAC). Komatsu Supercoolant (AF-NAC) has excellent anticorrosion, antifreeze, and cooling properties
and can be used continuously for 2 years or 4000 hours. Komatsu Supercoolant (AF-NAC) is strongly recommended
wherever available.
● When the machine is shipped from the factory, it may be filled with coolant containing 30% or more Supercoolant
(AF-NAC). In this case, no adjustment is needed for temperatures down to -10°C (14°F). (never dilute with water)
● To maintain the anticorrosion properties of Supercoolant (AF-NAC), always keep the density of Supercoolant
between 30% and 68%.
WA380-5L 01-9 3
Ratio When Diluting Super Coolant With Water.
Min. atmospheric °C -10 -15 -20 -25 -30

temperature °F 14 5 -4 -13 -22
Liters 10.8 12.6 14.4 16.2 18.0

Amount of antifreeze
US gal 2.85 3.33 3.80 4.28 4.76
Liters 25.2 23.4 21.6 19.8 18.0

Amount of water
US gal 6.66 6.18 5.71 5.23 4.75
Ratio % 30 36 41 46 50
• Use distilled water for the cooling system water.

• Komatsu recommends the use of an antifreeze density gauge to control the mixing proportions.
• Prepare the following: Container should hold a minimum of 50 liters (13.21 US gal) capacity to mix the coolant.
Note 6: For machines equipped with the antislip differential axle, select oil from the table below.
Maker Brand (antislip differential) Brand (conventional differential) Remarks

SHELL DONAX TD 5W-30 DONAX TT or TD North American Manufactured DONAX
TD 20W-40 must not be used on antislip
differential
ESSO TORQUE FLUID 50 North American manufactured product must
not be used on antislip differential.
MOBIL MOBIL 424 MOBIL 424
FUCHS RENOGEAR HYDRA ZF 20W-40
01-10 3 WA380-5L
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING
Item Unit WA380-5L
A Overall length mm (in.) 8,235 (324)
B Overall height mm (in.) 3,315 (130.5)
C Overall height with raised bucket mm (in.) 5,565 (219)
D Overall width mm (in.) 2,695 (106)
E Minimum ground clearance mm (in.) 390 (15.4)
F Bucket width mm (in.) 2,905 (114.4)
G Dumping clearance (tip of BOC) mm (in.) 2,885 / 2,800 (113.6 / 110.2)
H Dumping reach (tip of BOC) mm (in.) 1,165 / 1,210 (45.9 / 47.6)
I Bucket dump angle deg. 45
WA380-5L 01-11 3
GENERAL GENERAL ASSEMBLY DRAWING
01-12 3 WA380-5L
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
12G1
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7
ENGINE MOUNT, TRANSMISSION MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
POWER TRAIN SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
Without Torque Converter Lockup Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10
With Torque Converter Lock-up Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
DRIVE SHAFT (PROPELLER SHAFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
TORQUE CONVERTER, TRANSMISSION PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Without Lock-up Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Path Of Power Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
With Lock-up Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Path Of Power Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Lock-up Clutch Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Lock-up Clutch Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Oil Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
F and R Clutches: Without Lock-up Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
F and R Clutches: With Lock-up Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
1st and 4th Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
2nd and 3rd Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Clutch Engaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Clutch Disengaged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Forward 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Forward 2nd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Forward 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
Forward 4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-39
Reverse 1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
WA380-5L 10-13
STRUCTURE, FUNCTION AND
TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41

Without Lock-up Clutch (Transmission S/N 110643) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
Without Lock-up Clutch (Transmission S/N 110644 and up) . . . . . . . . . . . . . . . . . . . . . 10-42
With Lock-up Clutch (Transmission S/N 110643) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
With Lock-up Clutch (Transmission S/N 110644 and up) . . . . . . . . . . . . . . . . . . . . . . . 10-45
Electronic Control Modulation Valve (ECMV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-47
ECMV for Speed Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
Outline of ECMV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
ECMV and Proportional Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
ECMV and Fill Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
ECMV Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
ECMV for Lock-up Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
Main Relief, Torque Converter Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
Flow Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
Front Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-57
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
Front Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
Rear Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
Limited Slip Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
Operation of Limited Slip Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-65
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
AXLE MOUNTING, CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-72
STEERING PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
STEERING COLUMN, ORBIT ROLL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
Overload Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
Steering Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
Steering Relief Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Demand Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
Flow amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
Steering Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
Turning Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
Turning Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
ORBIT-ROLL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
10-23 WA380-5L
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
Connection Between the Hand Pump and Sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
Function of Center Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-95
STOP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
STEERING PUMP, SWITCH PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-99
EMERGENCY STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101
EMERGENCY STEERING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
JOYSTICK STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
Joystick PPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107
Steering Switch Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
Brake Valve - Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
Brake Valve - Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
CHARGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-122
PPC RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
ACCUMULATOR - BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-127
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-127
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
PARKING BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-133
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-133
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
Parking Brake Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
Parking Brake Emergency Release Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
HYDRAULIC PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
WA380-5L 10-33
WORK EQUIPMENT CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142

For PPC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-142
For EPC Valve (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-143
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-144
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145
TORQUE CONVERTER CHARGING, WORK EQUIPMENT,
AND PILOT CONTROL PUMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
PPC RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
E.C.S.S. VALVE (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
WORK EQUIPMENT CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-153
2-Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-153
3-Spool Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160
Safety-suction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-161
Suction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
Cut-off Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-163
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-163
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-163
Work Equipment Control Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-165
NEUTRAL Position of Lift Arm and Bucket Spools . . . . . . . . . . . . . . . . . . . . . . . 10-165
RAISE Position for Lift Arm Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-166
LOWER Position of Lift Arm Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167
FLOAT Position of Lift Arm Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168
DUMP Position for Bucket Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-169
TILT Position for Bucket Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
WORK EQUIPMENT PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-172
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-174
PPC VALVE (FOR MULTI FUNCTION MONO LEVER) . . . . . . . . . . . . . . . . . . . . . . . 10-178
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180
EPC SOLENOID VALVE (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-183
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
SHUT OFF VALVE (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
ATTACHMENT PPC VALVE (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190
COOLING FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
Model: LMF28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
Hydraulic Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-194
Suction Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-195
Operation of Revolution Direction Changeover Valve . . . . . . . . . . . . . . . . . . . . . . 10-196
10-43 WA380-5L
COOLING FAN MOTOR DRIVE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198

Model: LPV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-198
Servo Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-204
Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206
WORK EQUIPMENT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-208
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210
BUCKET POSITIONER, BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211
Bucket Positioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
Boom Kick-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
Proximity Switch Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-213
When Lift Arm Is Raised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-213
When Bucket Is Tilted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-215
WORK EQUIPMENT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-218
Lift Arm Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-218
Bucket Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-218
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-221
Air Conditioner Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-221
MACHINE MONITORING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-222
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-222
Individual Circuit Diagrams of the Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 10-224
Starting and Lighting Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-224
Load Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-224
Sensing Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-225
Power Supply and Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-226
Automatic Preheating Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-227
MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230
Speedometer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-230
Load Meter Specification (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-231
Table of Monitor Indication Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-232
Setting the Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-239
Service Mode Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-242
Items Related To The Fault History Of Electric System . . . . . . . . . . . . . . . . . . . . . 10-246
Items Related to the Fault History Of Machine System . . . . . . . . . . . . . . . . . . . . . 10-248
Items Related to Maintenance Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-250
Real-Time Monitoring Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-252
Real-Time Monitoring Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-254
Load Meter Function (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-264
Machine Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-274
Setting Necessary For Option Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-275
Optional Device Setting For Machine Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-276
Adjustment for Each EPC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-284
TRANSMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-302
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-302
Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-303
Electric Circuit Diagram (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-326
Electric Circuit Diagram (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-328
TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-330
WORK EQUIPMENT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-332
WA380-5L 10-53
System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-332

Electric Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-346
WORK EQUIPMENT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-348
ELECTRIC TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-350
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-351
Combination Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-352
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-352
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-352
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-353
KICK DOWN, HOLD SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-354
Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-354
ENGINE STARTING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-355
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-355
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-356
ENGINE STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-357
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-357
PREHEATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-358
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-358
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-358
ENGINE POWER MODE SELECTOR CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-359
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-359
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-359
PARKING BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-360
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-360
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-364
Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-364
Engine Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-365
Engine Oil Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-365
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-366
Coolant Temperature - For Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-366
Torque Converter Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-366
Hydraulic Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-366
Transmission Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-366
Brake Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-366
Coolant Temperature - Preheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-366
Transmission Cut-off Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-367
Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-368
Fuel Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-369
Lift Arm Angle Sensor (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-370
Air Cleaner Clogging Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-371
Load Meter Pressure Sensor (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-371
Battery Electrolyte Level Sensor(If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-372
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-373
10-63 WA380-5L
MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
1. Radiator 5. Reservoir tank

2. After cooler 6. Cooling fan
3. Oil cooler 7. Cooling fan motor
4. Torque converter oil cooler
Specifications
Radiator Oil cooler After cooler Torque converter oil
cooler
Core type CF19-4 CF40-1 AL-CFT PTO-OL
Fin pitch (mm) 4.0/2 4.5/2 4.0/2 —
Total heat radiating area (m²) 60.08 2.90 17.55 1.291
Pressure valve opening pressure 68.6 — —
(kPa {kg/cm²}) {0.7} —
Vacuum valve opening pressure 0 ~ 4.9 — —

(kPa {kg/cm²}) {0 ~ 0.05} —
WA380-5L 10-73
ENGINE MOUNT, TRANSMISSION MOUNT MAINTENANCE STANDARD
ENGINE MOUNT, TRANSMISSION MOUNT
No. Check item Criteria Remedy
1 Clearance between transmission

1 - 1.5 mm (0.039 - 0.059 inch) Adjust
mount bracket and adjustment bolt
A 245 - 308.7 N•m (25 - 31.5 kgf m) {181 - 228 lbf ft}
Torque Values
B 490 - 608 N•m (50 - 62 kgf m) {361 - 448 lbf ft}
10-83 WA380-5L
MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
1. Transmission 4. Rear axle 7. Front drive shaft

2. Torque converter 5. Rear drive shaft 8. Front axle
3. Engine 6. Center drive shaft
● The power from engine (3) is transmitted through the engine flywheel to torque converter (2). The turbine in the torque
converter is connected to the input shaft of transmission (1).
● The transmission has 6 hydraulically operated clutches. These provide 4 FORWARD and REVERSE speeds.
● The power from the transmission output shaft passes through center drive shaft (6), front drive shaft (7) and rear drive
shaft (5), and is transmitted to front axle (8) and rear axle (4) to drive the wheels.
WA380-5L 10-93
POWER TRAIN SYSTEM DIAGRAM MAINTENANCE STANDARD
POWER TRAIN SYSTEM DIAGRAM
Without Torque Converter Lockup Clutch
10-103 WA380-5L
MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM
With Torque Converter Lock-up Clutch
WA380-5L 10-113
POWER TRAIN SYSTEM DIAGRAM MAINTENANCE STANDARD
1 Front axle 14 Rear axle
2 Differential 15 Engine
3 Wet-type multiple-disc brake 16 Torque converter
4 Final drive 17 Torque converter charging pump
5 Front drive shaft 18 Work equipment hydraulic pump
6 Center drive shaft 19 Pilot pump
7 Parking brake (wet-type multiple-disc) 20 Steering pump
8 Transmission (multiple-shaft) 21 Switch pump
9 Rear drive shaft 22 Cooling fan drive pump
10 Rear tire 23 Flange bearing
11 Final drive 24 Front tire
12 Wet-type multiple-disc brake 25 Torque converter lock-up clutch
13 Differential
Outline
● Power from engine (15) is transmitted through the flywheel to torque converter (16).
The torque converter uses oil as a medium to vary the transmission torque according to the change in the load. It transmits
the power to the transmission input shaft.
The power from the engine passes through the torque converter pump drive gear and is transmitted to steering pump (20),
switch pump (21), cooling fan drive pump (22), transmission and torque converter charging pump (17), work equipment
hydraulic pump (18), and PPC pump (19) to drive these pumps.
● Transmission (8) operates directional valves and speed valves in the transmission to actuate six hydraulically operated
clutches and select one of the 4 FORWARD or REVERSE speeds.
● Parking brake (7) is applied by an electromagnetic valve that is actuated when the parking brake switch is operated. It is a
wet-type multiple-disc brake installed to the front of the output shaft to stop the machine.
● Power from the output shaft of transmission (8) is transmitted to the front and rear axles. At the front, 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).
● Power transmitted to front axle (1) and rear axle (14) is reduced by the pinion gear in differentials (2) and (13), and is
transmitted through the differential mechanism to the sun gear shaft.
● Power from the sun gear is further reduced by planetary-type final drive (11) and is transmitted to the wheels through the
axle shaft.
10-123 WA380-5L
MAINTENANCE STANDARD DRIVE SHAFT (PROPELLER SHAFT)
DRIVE SHAFT (PROPELLER SHAFT)
1 Front drive shaft A 245.0 - 309.0 N•m (25.0 - 31.5 kgf m) {181 - 228 lbf ft}
2 Flange bearing B 98.0 - 122.5 N•m (10.0 - 12.5 kgf m) {lbf ft}
3 Center drive shaft C 823.0 - 1029.0 N•m (84.0 - 105.0 kgf m) {lbf ft}
4 Rear drive shaft
Outline
● Power from the transmission output shaft passes through center drive shaft (3), front drive shaft (1), and rear drive shaft
(4), and is transmitted to the front axle and rear axle.
● When the body is articulated, or when the machine is traveling and there is ground surface shock, or when there is shock
during operations, the position of the transmission and the front and rear axles changes. The transmission is designed so
that even if the position of the components changes as a result of such shock, power can be transmitted without damage to
any parts. With this design, the drive shafts have universal joints and flange bearings that enable them to handle any
changes in the angle and length.
WA380-5L 10-133
TORQUE CONVERTER, TRANSMISSION PIPING MAINTENANCE STANDARD
TORQUE CONVERTER, TRANSMISSION PIPING
1. Hydraulic oil tank 6. Filter
2. Steering, switch pump 7. Transmission converter oil cooler
3. Torque converter charging, work equipment, pilot 8. Transmission

control pumps
4. Torque converter 9. Oil filter
5. Torque converter control valve 10. Oil fill pipe
10-143 WA380-5L
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
Without Lock-up Clutch
1. Flywheel 6. Pump
2. Drive case (Number of teeth: 72) 7. PTO drive gear (Number of teeth: 97)
3. Boss 8. Stator shaft
4. Turbine 9. Transmission input shaft
5. Stator
Specifications
Type 3-element, 1-stage, 1-phase
Stall torque ratio 3.27
WA380-5L 10-153
TORQUE CONVERTER MAINTENANCE STANDARD
Unit: mm
Standard size Tolerance Repair limit

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

4 0.17~0.44
and drive gear
A Torque Value 58.8 - 73.5 N•m (6.0 - 7.5 kgf m) {43 - 54 lbf ft}
B Torque Value 27.5 - 34.3 N•m (2.8 - 3.5 kgf m) {20 - 25 lbf ft}
10-163 WA380-5L
Path Of Power Transmission

Power Flow
● Torque converter is installed between the engine and transmission.
Power from the engine goes from flywheel (1) and enters drive case
(2).
Drive case (2), pump (3), and PTO gear (4) are each fixed by bolts
and are rotated directly by the rotation of the engine.
The power from pump (3) uses oil as a medium to rotate turbine (5)
and transmit the power to transmission input shaft (7) through the
boss (6).
The power from the drive case (2) passes through the PTO gear (4)
and is used as the power to drive the gear pump.
Oil Flow
● Oil passes through the main relief valve and its pressure is adjusted
by the torque converter relief valve so that it is less than the set
pressure. It then enters inlet port A, passes through the passage in
stator shaft (1), and flows to pump (2).
The oil is given centrifugal force by pump (2). It then enters turbine
(3) and transmits the energy of the oil to the turbine.
The oil from turbine (3) is sent to stator (4), and enters the pump (2)
again. However, part of the oil is sent from stator (4) through outlet
port B to the cooler.
WA380-5L 10-173
With Lock-up Clutch
10-183 WA380-5L
1. Flywheel 6. Stator 11. Transmission input shaft
2. Clutch housing (Number of teeth: 7. Pump 12. One-way clutch

72)
3. Boss (Number of teeth: 90) 8. PTO drive gear (Number of teeth: 97) 13. Race
4. Turbine 9. Stator shaft 14. Disc
5. Drive case 10. Guide 15. Piston
Specifications
Type 3-element, 1-stage, 2-phase

Stall torque ratio 2.98
WA380-5L 10-193
10-203 WA380-5L
Unit:mm

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

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

13 0.17~0.44
PTO gear
Torque Values
A 27.5 - 34.3 N•m (2.8 - 3.5 kgf m) {20 - 25 lbf ft}
B 58.8 - 73.5 N•m (6.0 - 7.5 kgf m) {43 - 54 lbf ft}
C 147.1 - 176.5 N•m (15 - 18 kgf m) {109 - 130 lbf ft}
WA380-5L 10-213
Path Of Power Transmission

Lock-up Clutch Disengaged
● When the lock-up clutch is disengaged, the connection of drive case
(3) and turbine (6) is disconnected, and torque converter functions
as normal.
Power generated by the engine is transmitted from flywheel (1) to
clutch housing (2), and rotates drive case (3) and pump (4) as one
unit.
Power from pump (4) uses oil as a medium to rotate turbine (6) and
transmits the power from turbine (6) to transmission input shaft (8)
through boss (7).
Power from drive case (3) passes through PTO gear (5) and is used
as power to drive the gear pump.
Lock-up Clutch Engaged

● When the lock-up clutch is engaged, drive case (3) and turbine (6)
are connected and form one unit. Stator (9) is rotated by the rotation
of pump (4) and turbine (6).
Power generated by the engine is transmitted from flywheel (1) to
clutch housing (2), and rotates drive case (3) and pump (4) as one
unit. In addition, drive case (3) and turbine (6) are connected by the
lock-up clutch, so the power is transmitted directly from turbine (6)
to transmission input shaft (8) without using oil as a medium.
Power from drive case (3) passes through PTO gear (5) and is used
as power to drive the gear pump.
10-223 WA380-5L
Oil Flow
● Oil passes through the main relief valve and its pressure is adjusted
by the torque converter relief valve so that it is less than the set
pressure. It then enters inlet port A, passes through the passage in
stator shaft (1) and guide (2), and flows to pump (3).
Oil is given centrifugal force by pump (3). The oil then enters the
turbine (4) and transmits the energy of the oil to turbine (4).
Oil from the turbine (4) is sent to stator (5), and enters pump (3)
again. However, part of the oil is fed to the torque converter oil
cooler from stator (5) passing through outlet port B.
WA380-5L 10-233
TRANSMISSION MAINTENANCE STANDARD
TRANSMISSION
10-243 WA380-5L
MAINTENANCE STANDARD TRANSMISSION
1. Steering, switch, cooling fan pump mounting section 5. Main relief, torque converter relief valve
2. Torque converter oil pressure, work equipment oil, 6. Transmission case (Front)
pressure, pilot control pump mounting section 7. Transmission oil filter
3. Transmission case (Rear) 8. Oil level gauge
4. Transmission control valve 9. Flow valve
Torque Values
a. 98 - 123 N•m (10 - 12.5 kgf m) {72 - 91 lbf ft} e. 58.8 - 73.5 N•m (6.0 - 7.5 kgf m) {43 - 54 lbf ft}
b. 12.7 - 13.7 N•m (1.3 - 1.4 kgf m) {112 - 121 lbf in} f. 44.1 - 53.93 N•m (4.5 - 5.5 kgf m) {33 - 40 lbf ft}
c. 34.3 - 63.7 N•m (3.5 - 6.5 kgf m) {25 - 47 lbf ft} g. 2.9 - 5.9 N•m (0.3 - 0.6 kgf m) {26 - 52 lbf in}
d. 265 - 363 N•m (27 - 37 kgf m) {196 - 268 lbf ft} h. 29.4 - 39.2 N•m (3 - 4 kgf m) {22 - 29 lbf ft}
WA380-5L 10-253
10-263 WA380-5L
1. PTO driven gear (Number of teeth: 89) 9. Output shaft

2. PTO drive gear (Number of teeth: 97) 10. Parking brake
3. Torque converter 11. Front coupling
4. Transmission input shaft 12. Lower shaft
5. F clutch 13. 2nd clutch
6. 4th clutch 14. Upper shaft
7. 3rd clutch 15. 1st clutch
8. Rear coupling 16. R clutch
WA380-5L 10-273
Torque Values
A. 98 - 123 N•m (10 - 12.5 kgf m) {72 - 91 lbf ft}

B. 490 - 608 N•m (50 - 62 kgf m) {361 - 448 lbf ft}
10-283 WA380-5L
Unit: mm
Tolerance Standard Clearance
Standard size
Shaft Hole clearance limit
Clearance between PTO driven +0.030 0. 00 -0.045 ~
1 ø 55 —
gear shaft and bearing (F) +0.011 -0.015 -0.011
Clearance between PTO driven 0. 00 +0.030
2 ø 100 0 ~ 0.045 —
gear bearing and housing (R) -0.015 +0.035
Clearance between PTO driven +0.025 0. 00 -0.037 ~
3 ø 45 —
gear shaft and bearing (R) +0.009 -0.012 -0.009
Clearance between PTO driven 0. 00 +0.030
4 ø 85 0 ~ 0.045 —
Clearance between the input 0. 00 +0.030
5 ø 110 0 ~ 0.045 —
shaft bearing and the housing (R) -0.015 +0.035
Clearance between the input 0. 00 +0.030
6 ø 110 0 ~ 0.045 —
shaft bearing and the housing (F) -0.015 +0.035
Clearance between the upper 0. 00 +0.030
7 ø 110 0 ~ 0.045 —
shaft bearing and the housing (R) -0.015 +0.035
Clearance between the upper 0.00 +0.030
8 ø 120 0 ~ 0.045 —
shaft bearing and the housing (F) -0.015 +0.035
Clearance between the lower 0.00 0. 00 -0.035 ~
9 ø 100 —
shaft bearing and the housing (R) -0.018 -0.035 0.018
Clearance between the lower 0.00 0. 00 -0.035 ~
10 ø 120 —
shaft bearing and the housing (F) -0.018 -0.035 0.018
Clearance between the output 0.00 -0.018 -0.058 ~
11 ø 130 —
shaft bearing and the housing (R) -0.020 -0.058 0.002
Clearance between the output +0.030 0. 00 -0.045 ~
12 ø 75 —
shaft and the bearing (R) +0.011 -0.015 -0.011
Clearance between the output 0.00 -0.018 -0.058 ~
13 ø 130 — Replace
shaft bearing and the housing (F) -0.020 -0.058 0.002
Clearance between the output +0.035 0. 00 -0.055 ~
14 ø 85 —
shaft and the bearing (F) +0.013 -0.020 -0.013
Standard size Tolerance Clearance limit
Inner diameter of the seal ring
contact surface +0.050
ø 60 ø 60.1
+0.035
+0.076
15 Width of the seal ring groove 3.2 3.5
+0.035
Width of the seal ring 3.1 ±0.05 2.8
0.00
Thickness of the seal ring 2.29 2.1
-0.100
Inner diameter of the seal ring +0.050
ø 50 ø 50.1
contact surface +0.035
+0.076
Width of the seal ring groove 3.2 3.5
16 +0.035
Width of the seal ring 3.1 ±0.05 2.8
0.00
Thickness of the seal ring 2.29 2.1
-0.100
Inner diameter of the oil seal slid- 0.00
17 ø 95 ø 94.8
ing surface of the coupling (R) -0.087
Inner diameter of the oil seal slid- 0.00
18 ø 95 ø 94.8
ing surface of the coupling (F) -0.087
Standard clearance Clearance limit
Clearance between the retainer 0.71 ~ 1.49
19 —
and the housing Standard shim thickness: 1.10
Clearance between the cage and 0.79 ~ 1.51
20 —
the case Standard shim thickness: 1.15
WA380-5L 10-293
1. PTO driven gear (Number of teeth: 79)

2. R idler gear (Number of teeth: 28)
3. Spacer
4. Strainer
Standard size Tolerance Standard Clearance

Shaft Hole clearance limit
5 Clearance between PTO driven ø 65 +0.030 0. 00 -0.045 ~ —

gear shaft and bearing (F) +0.011 -0.015 -0.011
6 Clearance between PTO driven ø 120 0. 00 +0.030 0 ~ 0.045 —
gear bearing and housing (F) -0.015 +0.035
7 Clearance between PTO driven ø 50 +0.020 0. 00 -0.032 ~ — Replace
gear shaft and bearing (R) +0.009 -0.012 -0.009
8 Clearance between PTO driven ø 90 0. 00 +0.030 0 ~ 0.045 —
9 Clearance between R idler gear ø 50 +0.027 0. 00 -0.039 ~ —
bearing and case +0.002 -0.012 -0.002
10 Clearance between R idler gear ø 80 0. 00 -0.021 -0.051 ~
bearing and R idler gear -0.016 -0.051 -0.005
A Torque Value 98 - 123 N•m (10 - 12.5 kgf m) {72 - 91 lbf ft}
Outline Combination of clutch and reduction gear ratio table

Speed step Using clutch Reduction gear ratio
● The transmission is installed after the torque converter. The F1 F X 1st 4.095
power from the torque converter enters into the transmission F2 F X 2nd 2.311
from the transmission input shaft.
F3 F X 3rd 1.265
● The transmission transfers power from the transmission input
F4 F X 4th 0.706
shaft to the output shaft after changing the speed into forward 1
speed through 4 speed or into reverse 1 speed through 4 speed R1 R X 1st 3.834
by combination of the F • R clutch and 4 pieces of the speed R2 R X 2nd 2.163
clutch. R3 R X 3rd 1.185
R4 R X 4th 0.661
10-303 WA380-5L
F and R Clutches: Without Lock-up Clutch
A: R clutch oil port C: Lubricating oil port

B: F clutch oil port
1. Spacer 6. F clutch
2. Thrust washer 7. F gear (Number of teeth: 40)
3. R gear (Number of teeth: 31) 8. Thrust washer
4. R clutch 9. Spacer
5. F • R cylinder 10. Transmission input shaft
No. Check item Criteria Unit: mm Remedy
Standard Tolerance Standard Clearance

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

13 Separator plate
Distortion — 0.1 0.15

14 Friction plate
Load of wave spring 1,010 N ±101 N 859 N
15
(Height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
16 Warp of spring plate 1.4 ±0.2 1.2
Thickness of thrust washer of F
17 3 ±0.1 2.7
and R clutches
18 End play of R gear 0.30 ~ 0.70
19 End play of F gear 0.24 ~ 0.76
WA380-5L 10-313
F and R Clutches: With Lock-up Clutch
A: R clutch oil port C: Lubricating oil port

B: F clutch oil port D: Lock-up clutch oil port
1. Spacer 6. F clutch
2. Thrust washer 7. F gear (Number of teeth: 40)
3. R gear (Number of teeth: 31) 8. Thrust washer
4. R clutch 9. Spacer
5. F • R cylinder 10. Transmission input shaft

11 ø 60 —
part of shaft (F) +0.020 -0.015 -0.020
12 ø 60 —
part of shaft (R) +0.011 -0.015 -0.011
Thickness 1.7 ±0.05 1.5

13 Separator plate

14 Friction plate
Load of wave spring 1,010 N ±101 N 859 N
15
(Height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
16 Warp of spring plate 1.4 ±0.2 1.2
Thickness of thrust washer of F
17 3 ±0.1 2.7
and R clutches
18 End play of R gear 0.30 ~ 0.70
19 End play of F gear 0.24 ~ 0.76
10-323 WA380-5L
1st and 4th Clutch
A. 1st clutch oil port C. Lubricating oil port

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

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

Clearance at press-fitting portion +0.035 0. 00 -0.050 ~
11 ø 55 —
of 1st • 4th clutch shaft bearing (F) +0.025 -0.015 -0.025
Clearance at press-fitting portion +0.039 0. 00 -0.054 ~
12 ø 60 —
of 1st • 4th clutch shaft bearing (R) +0.020 -0.015 -0.020
Thickness 1.7 ±0.05 1.5

13 Separator plate

14 Friction plate
Load of wave spring 1,010 N ±101N 859 N
15
(height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
Thickness of 1st • 4th clutch thrust
16 3 ±0.1 2.7
washer
Thickness of 1st clutch thrust
17 3 ±0.1 2.7
washer
18 End play of 1st gear 0.26 ~ 0.74
19 End play of 4th gear 0.28 ~ 0.72
WA380-5L 10-333
2nd and 3rd Clutch
A: 2nd clutch oil port C: Lubricating oil port

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

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

Clearance at outside diameter of
+0.050 0. 00 -0.065 ~
11 press-fitting portion of 2nd•3rd ø 55 —
+0.040 -0.015 -0.040
clutch shaft bearing (F)
Clearance at outside diameter of
+0.039 0. 00 -0.054 ~
12 press-fitting portion of 2nd•3rd ø 55 —
+0.020 -0.015 -0.020
clutch shaft bearing (R)
Thickness 1.7 ±0.05 1.5

13 Separator plate Replace
Thickness 2.2 ±0.08 1.6

14 Friction plate
Load of wave spring 1,010 N ±101N 859 N
15
(height: 2.2 mm) {103 kg} {±10.3 kg} {87.6 kg}
Thickness of 2nd•3rd clutch
16 3 ±0.1 2.7
thrust washer
17 End play of 2nd gear 0.26 ~ 0.74
18 End play of 3rd gear 0.28 ~ 0.72
10-343 WA380-5L
Clutch Operation
Clutch Engaged
● The oil sent from the transmission valve passes through the passage
inside shaft (1), goes to the back face of piston (6), and actuates the
piston (6).
● When the piston (6) is actuated, the separator plate (2) and friction
plate (3) are pressed together, so shaft (1) and clutch gear (4) form
one unit, and transmit the power.
When this happens, the oil drains through the oil drain hole (5).
Because the amount of oil drained is less than the amount of oil
supplied, clutch operation is not affected.
Clutch Disengaged
● The oil sent from the transmission valve is shut off, so the pressure
of the oil acting on the back face of piston (6) drops.
● Piston (6) is returned to its original position by wave spring (7), and
shaft (1) and clutch gear (4) are separated.
● When the clutch is disengaged, the oil at the back face of the piston
is drained through oil drain hole (5) by centrifugal force to prevent
the clutch from remaining partially engaged.
★ Oil drain hole (5) is provided only in the 1st, 2nd, 3rd, and 4th
clutches.
WA380-5L 10-353
Forward 1st
Operation
● In the case of FORWARD 1st, F clutch (3) and 1st clutch (9) are engaged. Power transmitted from the torque converter to
input shaft (1) is transmitted to output shaft (22).
● The clutch discs of the F clutch (3) and 1st clutch (9) are fixed by the hydraulic pressure applied 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 to
1st•4th cylinder gear (7).
● 1st clutch (9) is engaged, so the power transmitted to 1st•4th cylinder gear (7) goes through 1st clutch (9) and is transmit-
ted from 1st gear (10) to 2nd•3rd cylinder gear (16). From here, it passes through the lower shaft (20), output gear (19),
and output gear (21), and is transmitted to output shaft (22).
10-363 WA380-5L
Forward 2nd
Operation
● In the case of FORWARD 2nd, F clutch (3) and 2nd clutch (17) are engaged. The power transmitted from the torque con-
verter to input shaft (1) is transmitted to output shaft (22).
● The clutch discs of F clutch (3) and 2nd clutch (17) are fixed by the hydraulic pressure applied 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).
● 2nd clutch (17) is engaged, so the power transmitted to 2nd gear (18) goes through 2nd clutch (17) and is transmitted to
2nd•3rd cylinder gear (16). From here, it passes through lower shaft (20), output gear (19), and output gear (21), and is
transmitted to output shaft (22).
WA380-5L 10-373
Forward 3rd
Operation
● In the case of FORWARD 3rd, F clutch (3) and 3rd clutch (15) are engaged. The power transmitted from the torque con-
● The clutch discs of F clutch (3) and 3rd clutch (15) are fixed by the hydraulic pressure applied 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).
● 3rd clutch (15) is engaged, so the power transmitted to 3rd gear (14) goes through 3rd clutch (15) and is transmitted to
2nd•3rd cylinder gear (16). From here, it passes through lower shaft (20), output gear (19), and output gear (21), and is
transmitted to output shaft (22).
10-383 WA380-5L
Forward 4th
Operation
● In the case of FORWARD 4th, F clutch (3) and 4th clutch (8) are engaged. The power transmitted from the torque con-
● The clutch discs of F clutch (3) and 4th clutch (8) are fixed by the hydraulic pressure applied 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 to
1st•4th cylinder gear (7).
● 4th clutch (8) is engaged, so the power transmitted to 1st•4th cylinder gear (7) goes through 4th clutch (8) and is transmit-
ted from 4th gear (6) to 4th gear (13). From here, it passes through the lower shaft (20), output gear (19), and output gear
(21), and is transmitted to output shaft (22).
WA380-5L 10-393
Reverse 1st
Operation
● In the case of REVERSE 1st, R clutch (4) and 1st clutch (9) are engaged. The power transmitted from the torque converter
to input shaft (1) is transmitted to the output shaft (22).
● The clutch discs of R clutch (4) and 1st clutch (9) are fixed by the hydraulic pressure applied to the clutch piston.
● The power from the torque converter goes from the input shaft (1) through the R clutch (4) to the R gear (5). The direction
of rotation is reversed by the idler gear (23), and is transmitted through the idler gear (11) and upper shaft (12) to 1st•4th
cylinder gear (7).
● 1st clutch (9) is engaged, so power transmitted to 1st•4th cylinder gear (7) goes through 1st clutch (9) and is transmitted
from 1st gear (10) to 2nd•3rd cylinder gear (16). From here, it passes through lower shaft (20), output gear (19), and
output gear (21), and is transmitted to output shaft (22).
10-403 WA380-5L
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE

Without Lock-up Clutch (Transmission S/N 110643)
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 relief valve
J. Parking brake oil pressure detection port 9. Filter
Torque Values
a: 7.8 - 9.8 N•m (0.8 - 1.0 kgf m) {69 - 87 lbf in} d: 15.7 - 19.2 N•m (1.6 - 2.0 kgf m) {139 - 170 lbf in}
b: 44.1 - 53.9 N•m (4.5 - 5.5 kgf m) {33 - 40 lbf ft} e: 6.9 - 9.8 N•m (0.7 - 1.0 kgf m) {61 - 87 lbf in}
c: 34.3 - 44.1 N•m (3.5 -4.5 kgf m) {25 - 33 lbf ft} f: 19.6 - 24.5 N•m (2.0 - 2.5 kgf m) {173 - 217 lbf in}
WA380-5L 10-413
TRANSMISSION CONTROL VALVE MAINTENANCE STANDARD
Without Lock-up Clutch (Transmission S/N 110644 and up)
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 relief valve
J. Parking brake oil pressure detection port 9. Filter
Torque Values
c: 34.3 - 44.1 N•m (3.5 -4.5 kgf m) {25 - 33 lbf ft} f: 47.0 - 53.9 N•m (4.8 - 5.5 kgf m) {35 - 40 lbf ft}
10-423 WA380-5L
ECMV actuation table

ECMV
Gear F R 1st 2nd 3rd 4th

speed range
F1
F2
F3
F4
R1
R2
R3
R4
Outline
● The oil from the pump passes through the flow valve, is filtered by the oil filter, enters the transmission control valve, and
is separated into the main relief circuit and clutch actuation circuit.
● The oil pressure adjusted by the main relief valve and flowing to the clutch actuation circuit passes through the filter and
actuates the clutch and parking brake. The oil relieved by the main relief valve is supplied to the torque converter.
● When the transmission shifts gear, the ECMV uses the command current from the transmission controller to raise the
clutch oil pressure smoothly in order to reduce the transmission shock. In addition, it keeps the clutch pressure constant
when the machine is traveling.
● By switching the F, R, and 1st•4th ECMVs, adjusted oil pressure is supplied to the selected clutch to provide the necessary
speed range.
WA380-5L 10-433
With Lock-up Clutch (Transmission S/N 110643)
G. Lock-up clutch oil pressure detection port 7. ECMV (for lock-up clutch)
H. Main relief oil pressure detection port 8. Parking brake solenoid valve
J. Torque converter relief oil pressure detection port 9. Main relief, torque converter relief valve
K. Parking brake oil pressure detection port 10. Filter
Torque Values
c: 34.3 - 44.1 N•m (3.5 -4.5 kgf m) {25 - 33 lbf ft} f: 19.6 - 24.5 N•m (2.0 - 2.5 kgf m) {173 - 217 lbf in}
10-443 WA380-5L
With Lock-up Clutch (Transmission S/N 110644 and up)
G. Lock-up clutch oil pressure detection port 7. ECMV (for lock-up clutch)
H. Main relief oil pressure detection port 8. Parking brake solenoid valve
J. Torque converter relief oil pressure detection port 9. Main relief, torque converter relief valve
K. Parking brake oil pressure detection port 10. Filter
Torque Values
c: 34.3 - 44.1 N•m (3.5 -4.5 kgf m) {25 - 33 lbf ft} f: 47.0 - 53.9 N•m (4.8 - 5.5 kgf m) {35 - 40 lbf ft}
WA380-5L 10-453
ECMV actuation table (with lock-up clutch)
ECMV
Lock
F R 1st 2nd 3rd 4th
Gear up
speed range
F1
F2
F3
F4
R1
R2
R3
R4
Outline
● The oil from the pump passes through the flow valve, is filtered by the oil filter, enters the transmission control valve, and
is separated into the main relief circuit and clutch actuation circuit.
● The oil pressure adjusted by the main relief valve and flowing to the clutch actuation circuit passes through the filter and
actuates the clutch and parking brake. The oil relieved by the main relief valve is supplied to the torque converter.
● When the transmission shifts gear, the ECMV uses the command current from the transmission controller to raise the
clutch oil pressure smoothly in order to reduce the transmission shock. In addition, it keeps the clutch pressure constant
when the machine is traveling.
● By switching the F, R, and 1st•4th ECMVs, adjusted oil pressure is supplied to the selected clutch to provide the necessary
speed range.
● When traveling in 3rd or 4th, the lock-up ECMV is actuated at a speed greater than the set speed of the transmission
controller.
10-463 WA380-5L
Electronic Control Modulation Valve (ECMV)
A: To clutch 1. Connector for fill switch
P: From pump 2. Connector for proportional solenoid
T: Drain 3. Oil pressure detection valve
Dr: Drain 4. Fill switch
P1: Clutch oil pressure detection port 5. Proportional solenoid
P2: Pilot oil pressure detection port 6. Pressure control valve
Torque Values
P1 14.7 +2.9/-0 N•m (1.5 +0.3/-0 kgf m) (11 +2/-0 lbf ft} a 49.0 ±5.0 N•m (5.0 ±0.5 kgf m) {36 ±4 lbf ft}
P2 14.7 +2.9/-0 N•m (1.5 +0.3/-0 kgf m) (11 +2/-0 lbf ft}
WA380-5L 10-473
ECMV for Speed Clutch

Outline of ECMV
● The ECMV (Electronic Control Modulation Valve) consists of two
components: the pressure control valve and the fill switch.
● Pressure control valve
The proportional solenoid receives the flow of electricity sent from
the transmission controller, and the pressure control valve converts
this into hydraulic pressure.
● Fill switch
The fill switch detects when the clutch is filled with oil. It has the
following functions.
A. When the clutch is filled with oil, it sends a signal (fill signal)
at the same time to the controller to inform the controller that
the filling is completed.
B. While oil pressure is applied to the clutch, it outputs a signal

(fill signal) to the controller to inform the controller of the
existence of the oil pressure.
Range A: Before shifting gear (when draining)

Range B: Start of fill (during trigger)
Range C: Completion of fill
Range D: Pressure adjustment
Range E: During filling
ECMV and Proportional Solenoid

● There is one proportional solenoid installed to each ECMV.
It generates propulsion force as shown in the diagram below according to the command current from the controller.
Propulsion force generated by the proportional solenoid acts on the pressure control valve spool and generates oil pressure
as shown in the following diagrams. In this way, the command current flow is controlled and the propulsion force varies to
actuate the pressure control valve and control the oil flow and oil pressure.
Characteristics of proportional solenoid current - propulsion
force
10-483 WA380-5L
Characteristics of propotional solenoid propulsion - oil

pressure
ECMV and Fill Switch

● There is one fill switch installed to each ECMV.
When the filling of the clutch is completed, the fill switch is turned
on by the clutch pressure. With this signal, the oil pressure starts the
build-up.
ECMV Actuation
● ECMV is controlled by the command current from the controller to
the proportional solenoid and the fill switch output signal.
The relationship between ECMV proportional solenoid command
current and the clutch input pressure and fill switch output signal is
as shown in the diagram below.
Range A: Before shifting gear (when draining)

Range B: Start of fill (during trigger)
Range C: Completion of fill
Range D: Pressure adjustment
Range E: During filling
★ The logic is so designed that the controller will not recognize

completion of filling even if the fill switch is turned ON in the
triggering range (range D).
1. Before shifting gear (when draining) (range A in graph).

When no current is flowing to proportional solenoid (1), pressure
control valve spool (3) drains the oil at clutch port A through drain
port T.
When this happens, there is no hydraulic force acting on oil
pressure detection valve spool (4), so fill switch (6) goes OFF.
WA380-5L 10-493
2. Start of fill (when trigger command is input to pressure control

valve) (ranges B and C in graph).
When there is no oil inside the clutch, if current is applied to
proportional solenoid (1), oil pressure is applied in chamber B to
balance with the force of the solenoid, and pressure control valve
(3) is pushed to the left. As a result, pump port P and clutch port A
open, and oil starts to fill the clutch. When the clutch is filled with
oil, oil pressure detection switch (4) is actuated, and fill switch (6)
comes ON.
3. Adjusting pressure (range D in graph).

When electric current flows to proportional solenoid (1), the
solenoid generates a propulsion force proportional to the current.
The total of this propulsion force of the solenoid and the propulsion
force of the oil pressure at the clutch port and the reaction force of
pressure control valve spring (2) is adjusted so that it is balanced.
ECMV for Lock-up Clutch

Outline
● The ECMV sets the lock-up clutch hydraulic pressure to a specified
pressure, and also switches the lock-up clutch.
It has a modulation wave pattern, which engages the lock-up clutch
smoothly, and reduces the shock when shifting gear. Furthermore, it
prevents the generation of peak torque in the power train. As a
result, the machine gives a good ride, and the durability of the
power train is greatly increased.
10-503 WA380-5L
Operation
When Traveling In Torque Converter Drive
● When the machine is traveling in torque converter drive, no electric

current is flowing to proportional solenoid (1).
Pressure control valve (3) drains the oil from clutch port A through
drain port T, and the lock-up clutch is released. At the same time,
there is no hydraulic force acting on oil pressure detection valve
(4), so fill switch (6) goes OFF.
When Traveling In Direct Drive

(Changing from Torque Converter Drive Direct Drive)
1. During filling.
When the transmission shifts to direct drive (lock-up), if current is
applied to proportional solenoid (1) by an electric signal, oil pres-
sure is applied in chamber B to balance with the force of the sole-
noid, and pressure control valve (3) is pushed to the left. As a result,
pump port P and clutch port A open, and oil starts to fill the clutch.
When the clutch is filled with oil, oil pressure detection switch (4)
is actuated, and fill switch (6) comes ON.
2. Adjusting pressure.
When electric current flows to proportional solenoid (1), the
solenoid generates a propulsion force proportional to the current.
The total of this propulsion force of the solenoid and the propulsion
force of the oil pressure at the clutch port and the reaction force of
pressure control valve spring (2) is adjusted so that it is balanced.
WA380-5L 10-513
Main Relief, Torque Converter Relief Valve
A: Drain (torque converter relief) 1. Body
B: Drain 2. Piston
C: From pump 3. Torque convertor relief valve
D: Drain 4. Piston
E: To torque converter 5. Main relief valve
P1: Main relief oil pressure detection port
P2: Torque converter oil pressure detection port
Torque Values
a. 44.1 - 53.9 N•m (4.5 - 5.5 kgf m) {33 - 40 lbf ft}
10-523 WA380-5L
Unit: mm

Clearance between main relief -0.035 +0.013 0.035 ~

6 ø 28 0.078
valve and valve body -0.045 0 0.058
Clearance between torque
-0.035 +0.013 0.035 ~
7 converter relief valve and valve ø 22 0.078
-0.045 0 0.058
body
Standard size Repair limit

Replace
Free Installed Installed Installed
Free length
length length load load
392 N 373 N
8 Main relief valve spring (outer) 122 81.3 118.3
{40.0 kg} {38.0 kg}
329N 312 N
9 Main relief valve spring (inner) 108 81.3 104.8
{33.5 kg} {31.8 kg}
Torque converter relief valve 134 N 128 N
10 50 43 48.5
spring {13.7 kg} {13.0 kg}
Outline
Torque converter relief valve
The torque converter relief valve is installed in the torque converter inlet port circuit. It acts to keep the oil pressure in the
torque converter inlet port circuit at or below the set pressure and protects the torque converter from abnormally high pressure.
Set pressure: 0.86 MPa (8.83 kg/cm²) {122 psi} (cracking pressure)
Main relief valve
The main relief valve maintains the oil pressure in the transmission and parking brake at the set pressure.
Set pressure: 2.86 MPa (29.2 kg/cm²) {415 psi} (engine at rated speed)
Operation
Torque converter relief valve
● The oil relieved from the main relief valve flows from port C into
the torque converter, and at the same time, passes through orifice B
of spool (2) and enters port D.
When the oil fills the circuit to the torque converter, the oil pressure
starts to rise.
● When the oil pressure in the circuit to the torque converter rises, the
oil entering port D pushes piston (9). The reaction compresses
valve spring (3), and moves spool (2) to the right to open port C and
port E.
When this happens, the oil from port C is relieved to port E and is
drained to the oil tank.
The oil pressure at port C at this point is 0.86 MPa (8.83 kg/cm²)
{122 psi} (cracking pressure)
WA380-5L 10-533
Main relief valve
● The oil from the hydraulic pump passes through the filter, enters
port A of the main relief valve, and then passes through orifice a in
spool (6) and enters chamber B.
When the oil from the pump fills the circuit, the oil pressure starts
to rise.
● When the oil pressure in the circuit rises, the oil entering port B
pushes piston (4). The reaction compresses valve spring (7) and
moves spool (6) to the left to open port A and port C.
When this happens, the oil from the pump is relieved from port A to
port C, and flows from port C into the torque converter.
The oil pressure at port A at this point is 2.86 MPa (29.2 kg/cm²)
{415 psi} (engine at rated speed).
10-543 WA380-5L
Flow Valve
A. To transmission valve circuit 1. Valve body
B. From pump 2. Valve spool
C. To transmission lubrication circuit a. Torque Value: 58.8 - 78.5 N•m (6.0 - 8.0 kgf m) {43 - 58 lbf ft}

Clearance between flow control -0.020 +0.013 0.020 ~
3 25 0.06
valve and body -0.030 0 0.043
Standard size Repair limit Replace

Installed Installed Installed
Free length Free length
length load load
79.5 N 75.5 N
4 Flow control valve spring 63.8 47 {8.11 kgf} 61.9 {7.7 kgf}
(18 lbf) (17 lbf)
Operation
● Oil from the pump flows to the transmission valve circuit, but if it goes above the specified amount, the flow valve acts to
send it to the transmission lubrication circuit.
● If the flow of oil from the pump goes above the specified amount, valve spool (2) moves and directs part of the oil from
the pump to the transmission lubrication circuit.
WA380-5L 10-553
AXLE MAINTENANCE STANDARD
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
10-563 WA380-5L
MAINTENANCE STANDARD AXLE
Rear Axle
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler port/level plug
8. Drain plug
WA380-5L 10-573
DIFFERENTIAL MAINTENANCE STANDARD
DIFFERENTIAL
Front Differential
1. Pinion gear (Number of teeth: 12) A. 157 - 196 N•m (16 - 20 kgf m) {116 - 145 lbf ft}
2. Shaft B. 490 - 608 N•m (50 - 62 kgf m) {361 - 448 lbf ft}
3. Bevel gear (Number of teeth: 41) C. 2.9 - 5.9 N•m (0.3 - 0.6 kgf m) {26 - 52 lbf in}
4. Sun gear shaft D. 245 - 309 N•m (25 - 31.5 kgf m) {181 - 228 lbf ft}
5. Bevel pinion (Number of teeth: 10) E. 127 - 176 N•m (13 - 18 kgf m) {94 - 130 lbf ft}
6. Side gear (Number of teeth: 24)
10-583 WA380-5L
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
No. Check Item Criteria Remedy
7 Differential gear backlash 0.18 ~ 0.23 Adjust
Standard size Tolerance Repair Limit
8 Pinion gear washer thickness 3 ±0.08 2.8 Replace
9 Side gear washer thickness 4 ±0.05 3.8
34.3 ~ 51.0 N•m {25 ~ 38 lbf ft.}
10 Bevel gear starting rotation force
Outside diameter of bevel gear
Shim thickness (one side) at differential
11 0.3 ~ 1.25
side bearing carrier portion
Adjust
12 Bevel gear backlash 0.030 ~ 0.041
13 Pinion gear end play 0.19
Shim thickness at differential housing
14 1.49 ±0.36
and cage assembly
WA380-5L 10-593
Rear Differential
1. Pinion gear (Number of teeth: 12) A. 157 - 196 N•m (16 - 20 kgf m) {116 - 145 lbf ft}
2. Shaft B. 490 - 608 N•m (50 - 62 kgf m) {361 - 448 lbf ft}
3. Bevel gear (Number of teeth: 41) C. 2.9 - 5.9 N•m (0.3 - 0.6 kgf m) {26 - 52 lbf in}
4. Sun gear shaft D. 245 - 309 N•m (25 - 31.5 kgf m) {181 - 228 lbf ft}
5. Bevel pinion (Number of teeth: 10) E. 127 - 176 N•m (13 - 18 kgf m) {94 - 130 lbf ft}
6. Side gear (Number of teeth: 24)
10-603 WA380-5L
Unit:mm
7 Backlash of differential gear 0.13 ~ 0.18

Adjust
13.7 ~ 37.2 N•m {10 ~ 27 lbf ft.}
8 Starting torque of bevel gear
(At outside surface of bevel gear)
9 Pinion gear washer thickness 3 ±0.08 2.8 Replace
10 Side gear washer thickness 4 ±0.05 3.8
Thickness of shim at differential

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

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

14 1.05 ± 0.35
housing and gauge assembly
WA380-5L 10-613
Outline
● The power from the engine passes through the torque converter,
transmission, and drive shafts, and is transmitted to the front and
rear axles.
● Inside the axle, the power is transmitted from bevel pinion (1) to
bevel gear (5) and the direction is changed 90°. It is also reduced
and passes through pinion gear (4) and is transmitted to sun gear
shaft (2).
● The power of the sun gear is further reduced by the planetary gear
type final drive and is transmitted to the axle shaft and wheels.
When traveling in a straight line
● When traveling in a straight line, the rotating speed of the left and
right wheels is the same, so pinion gear (4) inside the differential
assembly does not rotate. The power of carrier (6) passes through
pinion gear (4) and side gear (3), and is transmitted equally to the
left and right sun gear shafts (2).
When turning
● When turning, the rotating speed of the left and right wheels is
different, so pinion gear (4) and side gear (3) inside the differential
transmit the power of carrier (6) to sun gear shaft (2) while rotating
in accordance with the difference between the left and right rotating
speeds.
10-623 WA380-5L
Limited Slip Differential
1. Plate
2. Disc
3. Pinion
4. Washer
5. Side gear
6. Bevel pinion
7. Shaft
8. Pressure ring
9. Case
WA380-5L 10-633
10-643 WA380-5L
Unit: mm
2
1 Washer thickness ±0.03 1.8
2.1
3
2 Plate thickness ±0.02 2.9
3.1
+0.04
3 Disc thickness 3 2.95
-0.03
Standard Standard Clearance
Shaft Hole
Clearance between spider and size Clearance limit
4
differential pinion gear -0.110 +0.050 0.110 ~
30 0.3
-0.160 +0 0.210
Piston assembly of differential housing -0.110 +0.079 0.110 ~
5 290.5 —
(housing, piston) -0.191 +0 0.270
Piston assembly portion of bearing -0.111 +0.081 0.111 ~
6 311 —
carrier (piston, carrier) -0.190 +0 0.271
Replace
-0 -0.045 -0.085 ~
Outer race 150 —
Clearance at -0.016 -0.085 -0.029
7
differential side bearing +0.059 -0 -0.079 ~
Inner race 100 —
+0.037 -0.020 -0.037
-0 -0.050 -0.075 ~
Outer race 150 —
Clearance of bearing at -0.020 -0.075 -0.030
8
pinion shaft gear end +0.039 -0 -0.054 ~
Inner race 70 —
+0.020 -0.015 -0.020
-0 -0.048 -0.088 ~
Clearance of bearing at Outer race 140 —
-0.018 -0.088 -0.030
9 pinion shaft coupling
end +0.039 -0 -0.054 ~
Inner race 65 —
+0.020 -0.015 -0.020
10 Backlash between case and plate 0 ~ 0.4
11 Clearance between disc and plate 0.2 ~ 0.6
12 Backlash between side gear and disc 0.13 ~ 0.36
End play (one end) of side gear in axial

13 0.15 ~ 0.35
direction
Operation of Limited Slip Differential

Power transmitted from the transmission is transmitted from bevel gear (6) to case (9), pressure ring (8), shaft (7), pinion (3),
and gear (5), and is divided to the left and right shafts.
The brake system, consisting of discs (2) and plates (1) is installed at the rear face of side gear (5). A brake torque is generated
that is proportional to the torque transmitted from pressure ring (8) to shaft (7).
This brake torque acts to limit the rotation in relation to side gear (5) and case (9), so it is difficult for left and right side gears
(5) to rotate mutually and the operation of the differential is limited.
WA380-5L 10-653
Brake torque generation mechanism of left and right side gears (5).
Shaft (7) is supported at the cam surface cut into the facing surfaces of
left and right pressure rings (8).
The power (torque) transmitted from pressure rings (8) to shaft (7) is
transmitted at the cam surface, but force Fa separating left and right
pressure rings (8) is generated in proportion to the torque transmitted
according to the angle of this cam surface.
This separation load Fa acts on the brake at the rear face of left and right
side gears (5) and generates the brake torque.
When traveling in a straight line
1. When there is no imbalance between drive force of left and right

wheels [Road surface condition (friction coefficient) and load for
left and right wheels are uniform and load on bucket is centered
exactly].
The power from the transmission is divided equally to the left and
right by the differential gear. In this case, the wheel slip limit of the
left and right wheels is the same, so even if the power from the
transmission exceeds the wheel slip limit, both wheels will slip and
the differential will not be actuated.
There is no load on the brake at the rear face of the side gears.
2. When there is imbalance between drive force of left and right

wheels [Road surface condition (friction coefficient) and load for
left and right wheels are not uniform and it is easier for wheel on
one side to slip].
Example 1: When digging, and wheel on one side is on a soft
surface
Example 2: When clearing snow, and wheel on one side is on
snow and wheel on other side is on asphalt.
Example 3: When traveling on a slope, and there is an imbalance
between load on left and right wheels
The power from the transmission is divided equally to the left and
right by the differential gear. However, when the drive force
exceeds the wheel 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 face of the side gear and is
transmitted to the brake on the opposite side (locked side) and is
sent to the wheel on the locked side.
If this excess portion of the drive force becomes greater than the
braking force, the differential starts to work.
10-663 WA380-5L
Difference in wheel drive force for each type of differential when wheel on one side slips.
Wheel drive force (when one wheel is slipping)
Slipping wheel Locked wheel Total (ratio)
2.64
Limited slip differential 1 3.64 (1.82)
(Front)
Normal differential 1 1 2 (1)
On road surfaces where the wheel on one side is likely to slip, the anti-slip differential increases the drive force by 1.82 times
more than the normal differential.
When turning
The differential gears built into a anti-slip differential are the same as
the gears used in a normal differential, so the difference in rotation
between the inside and outside wheels when turning the machine can be
generated smoothly.
WA380-5L 10-673
FINAL DRIVE MAINTENANCE STANDARD
FINAL DRIVE
1. Planet gear (No. of teeth: 26) A. 662 - 829 N•m (67.5 - 84.5 kgf m) {488 - 611 lbf ft}
2. Planetary carrier B. 823 - 1029 N•m (84 - 105 kgf m) {607 - 759 lbf ft}
3. Axle shaft C. 127 - 176 N•m (13 - 18 kgf m) {94 - 130 lbf ft}
4. Ring gear (No. of teeth: 69)
5. Sun gear shaft (No. of teeth: 15)
10-683 WA380-5L
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
Tolerance
size Clearance limit
Shaft Hole
+0.013 -0 -0.025 ~ Replace

Clearance between pinion gear
6 40 —
bearing and shaft +0.002 -0.012 -0.002
Clearance between axle housing +0.100 +0.100 -0.100 ~
7 358 —
and ring gear +0.030 +0 0.070
Clearance between oil seal and
8 Max. 0.2 Adjust
housing
+0.500 -0.072 -0.050 ~
Housing 215 —
Press-fitting portion of +0.300 -0 -0.372
9
axle shaft seal -0 -0.300 -0.500 ~
Shaft 180 —
-0.063 -0.500 -0.0237
-0 -0.045 -0.085~
Clearance at Outer race 180 —
-0.025 -0.085 -0.020
10 press-fitting portion of Replace
axle housing bearing +0.045 -0 -0.065 ~
Inner race 120 —
+0.023 -0.020 -0.023
+0.025 -0.012 -0.077 ~
Clearance at Outer race 157.162 —
+0 -0.052 -0.012
11 press-fitting portion of
axle housing bearing +0.059 +0.025 -0.059 ~
Inner race 98.425 —
+0.037 +0 -0.012
12 End play of axle shaft 0 ~ 0.1 Adjust
+0.025 +0.207 0.120 ~

13 Clearance of guide pin 12 — Replace
+0.007 +0.145 0.200
WA380-5L 10-693
FINAL DRIVE MAINTENANCE STANDARD
Outline
● The final drive reduces the speed of the power from the engine and
increases the drive force.
● Ring gear (4) is press fitted to the axle housing and is fixed in
position by a pin.
● Power transmitted from the differential and passing through sun
gear shaft (5) has its speed reduced by the planetary gear
mechanism and the drive force increased.
The increased drive force passes through planetary carrier (2) and
axle shaft (3) and is transmitted to the wheels.
10-703 WA380-5L
MAINTENANCE STANDARD FINAL DRIVE
MEMORANDUM
WA380-5L 10-713
AXLE MOUNTING, CENTER HINGE PIN MAINTENANCE STANDARD
AXLE MOUNTING, CENTER HINGE PIN
1. Front axle A. 1029 ±98 N•m (105 ±10 kgf m) {759 ±72 lbf ft}
2. Front frame B. 824 - 1030 N•m (84 - 105 kgf m) {608 - 760 lbf ft}
3. Rear axle C. 823 - 1029 N•m (84 - 105 kgf m) {607 - 759 lbf ft}
4. Rear frame
Outline
● 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 (steering radius) is adjusted by
the movement of the cylinder.
10-723 WA380-5L
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN
A. 98 - 123 N•m (10 - 12.5 kgf m) {72 - 91 lbf ft}
B. 245 - 309 N•m (25 - 31.5 kgf m) {181 - 228 lbf ft}
1 Thrust plate thickness 22 ±0.5 —
+0.3
2 Wave plate thickness 5 —
-0.1
Standard Tolerance Standard Clearance Replace

Clearance between hole and -0.050 +0.472 0.050 ~

3 ø190 —
shaft at front support end -0.122 0 0.594
Clearance between hole and -0.005 +0.552 0.055 ~
4 ø170 —
shaft at rear support end -0.124 +0.050 0.594
WA380-5L 10-733
AXLE MOUNTING, CENTER HINGE PIN MAINTENANCE STANDARD
A. 206 ±20 N•m (21 ±2 kgf m) {152 ±15 lbf ft}
10-743 WA380-5L
MAINTENANCE STANDARD AXLE MOUNTING, CENTER HINGE PIN
Tolerance
size Clearance limit
Shaft Hole
Clearance between upper hinge -0.030 +0.071 0.066 ~

1 ø80 —
pin and rear frame -0.049 +0.036 0.120
2 ø80 —
pin and spacer (small) -0.049 +0.030 0.109
Clearance between upper hinge -0.030 -0 0.015 ~
3 ø80 —
pin and bearing -0.049 -0.015 0.049
4 ø80 —
pin and spacer (large) -0.049 +0 0.079
Clearance between rear frame -0.036 +0.071 0.072 ~
5 ø95 —
and spacer (large) -0.071 +0.036 0.142
Clearance between front frame 0 -0.048 -0.088 ~
6 ø130 —
and upper hinge bearing -0.025 -0.088 -0.023
Replace
Clearance between lower hinge -0.030 +0.067 0.057 ~
7 ø80 —
pin and rear frame bushing -0.076 +0.027 0.143
Clearance between lower hinge -0.030 -0 -0.015 ~
8 ø80 —
pin and bearing -0.076 -0.015 -0.076
Clearance between front frame 0 -0.048 -0.088 ~
9 ø130 —
and lower hinge bearing -0.025 -0.088 -0.023
Clearance between rear frame +0.089 +0.054 -0.089 ~
10 ø95 —
and bushing +0.054 +0 0
Clearance at seal press-fitting +0.17 +0.054 -0.17 ~
11 ø105 —
portion of lower hinge pin +0.08 +0 -0.026
Height of upper hinge spacer

12 22.5 ±0.1 —
(small)
Height of upper hinge spacer
13 56 ±0.1 —
(large)
Standard size
Shim value for upper hinge and

14 2.5
retainer
Shim value for upper hinge and
15 2.5
retainer
Shim value for lower hinge and
16 2
retainer Adjust
20 ±2 N•m {15 ±2 lbf ft.} (When adjusting shim)
Tightening torque for upper hinge
17
retainer mounting bolt
98 ~ 123 N•m {72 ~ 91 lbf ft.} (Final value)
20 ±2 N•m {15 ±2 lbf ft.} (When adjusting shim)

Tightening torque for lower hinge
18
retainer mounting bolt
98 ~ 123 N•m {72 ~ 91 lbf ft.} (Final value)
WA380-5L 10-753
STEERING PIPING MAINTENANCE STANDARD
STEERING PIPING
1. Work equipment valve 8. Steering pump

2. Steering valve 9. Steering cylinder (left)
3. Steering cylinder (right) 10. Orbit-roll
4. Hydraulic oil tank 11. Stop valve (right)
5. Emergency steering pump 12. Stop valve (left)
6. Emergency steering motor 13. PPC accumulator
7. Switch pump
10-763 WA380-5L
MAINTENANCE STANDARD STEERING COLUMN, ORBIT ROLL
STEERING COLUMN, ORBIT ROLL
1. Steering wheel 5. Orbit-roll

2. Steering column
3. Tilt lever A. 49 - 62 N•m (4.9 - 6.4 kgf m) {36 - 46 lbf ft}
4. Joint B. 29.4 ±2.9 N•m (3.0 ±0.3 kgf m) {22 ±2 lbf ft}
Unit:mm

Clearance between steering size Shaft Hole Clearance limit
6 Replace
shaft and column bearing
0 +0.15
19 0.05 ~ 0.23 0.4
-0.08 -0.05
WA380-5L 10-773
STEERING VALVE MAINTENANCE STANDARD
STEERING VALVE
10-783 WA380-5L
MAINTENANCE STANDARD STEERING VALVE
1. Overload relief valve

2. Check valve
3. Steering spool
4. Flow control spool
5. Main relief valve
A. To steering cylinder
B. To steering cylinder
Pa. From orbit-roll
Pb. To orbit-roll
P1. From steering pump
P2. From switch pump
PB. To work equipment circuit
T. To tank
Unit:mm
Free Installed Free Installed

Installed load
length length length load
56.9N 47.1 N
6 Steering spool return spring 37.2 32.0 {5.8 kgf} — {4.8 kgf}
{13 lbf} {11 lbf}
9.3±4.9 N 7.85 N
7 Poppet spring 20.9 13.2 {0.95±0.5 kgf} — {0.8 kgf}
{34 ozf} {28 ozf} Replace
136.1 N 114.7 N
8 Demand spool return spring 75.1 68.5 {13.88 kgf} — {11.7 kgf}
{31 lbf} {26 lbf}
182 N 145 N
9 Relief valve spring 24.0 22.19 {18.6 kgf} — {14.8 kgf}
{41 lbf} {33 lbf}
2.26 N 1.77 N
10 Check valve return spring 21.6 17.0 {0.23 kgf} — {0.18 kgf}
{8 ozf} {6 ozf}
WA380-5L 10-793
Overload Relief Valve

1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
Function
● The overload relief valve is installed to the 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 damage to the cylinder or
hydraulic piping. If negative pressure forms at the cylinder end, it
functions as a suction valve to prevent formation of any vacuum.
Operation
Functioning as relief valve
● Port A is connected to the cylinder circuit and port B is connected

to the drain circuit. Oil passes through center of the hole in poppet
(1) and acts on diameters d1 and d2, which have different areas.
Check valve poppet (3) and relief valve poppet (2) are securely
seated.
● When the pressure at port A reaches the set pressure of the relief
valve, pilot poppet (4) opens, and the oil flows around pilot poppet
(4), passes through the drill hole, and flows to port B.
10-803 WA380-5L
● When pilot poppet (4) opens, the pressure behind poppet (1) drops,
so poppet (1) moves and seats pilot poppet (4).
● The pressure on the inside is lower than the pressure at port A, so

relief valve poppet (2) opens. When this happens, the oil flows
from port A to port B to prevent any abnormal pressure.
Functioning as a suction valve
● If negative pressure forms at port A, check valve poppet (3) opens

because of the difference 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.
Steering Relief Valve

1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
● The steering relief valve is inside the steering valve. It sets the
maximum pressure in the steering circuit when the steering valve is
being operated. In other words, when the steering valve is operated,
if the pressure in the steering circuit goes above the set pressure of
this valve, it relieves the oil from the valve, and by relieving the oil,
actuates the flow control spool of the demand valve and drains the
oil going to the steering circuit.
WA380-5L 10-813
Steering Relief Valve Operation
● When the pressure in the circuit rises and reaches the pressure set by adjustment screw (1) and spring (2), pilot poppet (4)
opens and drains the oil.
● When this happens, the balance between the pressures in pressure-receiving chamber (I) and the pressure-receiving cham-
ber (II) is lost and flow control spool (6) moves to the left in the direction of the arrow ().
● When flow control spool (6) moves, the oil from the steering pump is drained and the oil from the switch pump is relieved
to the main control valve to prevent the pressure in the steering circuit from going above the set pressure.
10-823 WA380-5L
Demand Valve Operation

When steering spool is in neutral
● The oil from the steering pump enters port A; the oil from the switch pump enters port B.
● When steering spool (2) is at neutral, pressure-receiving chamber (II) is connected to the drain circuit through orifice b; in
addition, notch c is closed.
● Because notch c is closed, the pressure of the oil at port A and port B rises, and this pressure passes through orifice a, is
taken to pressure-receiving chamber (I) and moves flow control spool (1) to the left in the direction of the arrow ().
● When the pressure in the pressure-receiving chamber (I) reaches a certain value (set by spring (5)), notch f opens and the
oil from the steering pump is relieved to the drain circuit; in addition, notch g closes, so all the flow of oil from the switch
pump goes to the main control valve.
WA380-5L 10-833
When steering spool is operated
Engine Running At Low Speed
● When steering spool (2) is pushed (operated), pressure-receiving chamber (II) and the drain circuit are shut off, and at the
same time, notch c opens.
● As a result, the pressure in pressure-receiving chamber (II) rises, and flow control spool (1) is moved to the right in the
direction of the arrow () until notch h closes.
● The passage from port B to the main control valve is shut off, so the oil from the switch pump pushes up merge check
valve (3) and the oil is merged with the oil from the steering pump at port A.
● The merged oil passes through notches c and d, pushes up load check valve (4), and flows to the cylinder. The return oil
from the cylinder passes through notch e and enters the drain circuit.
● When this happens, the pressure before passing through notch c goes to pressure-receiving chamber (I) and the pressure
after passing through notch c goes to pressure-receiving chamber (II). Flow control spool (1) is actuated so that the differ-
ence in pressure on both sides of notch c is maintained at a constant value.
● Therefore, an oil flow matching the degree of opening of notch c is discharged from the cylinder port. These pressure dif-
ferences (control pressure) are set by spring (5).
10-843 WA380-5L
Engine Running At High Speed
● No extra oil is needed from the switch pump, so the pressure of the steering pump rises until notch g closes and shuts off
the merge passage at port B.
● The difference in pressure on both sides of notch c is controlled only by notch f. The excess oil from the steering pump is
drained to the drain circuit from notch f. (When this happens, notch g is completely closed.)
● The oil from the steering pump passes through notches c and d, pushes up load check valve (4), and flows to the cylinder.
The return oil from the cylinder passes through notch e and enters the drain circuit.
● Notch g is closed, so the oil from the switch pump is sent from port B to the main control valve.
WA380-5L 10-853
Flow amp
1. Steering spool 5. Cap A. From Orbit-roll valve

2. Valve housing (body) 6. Capscrew B. From Orbit-roll valve
3. Spring seat 7. Orifice C. Passage (inside housing)
4. Return spring
Operation of flow amp

1. Spool at neutral (Orbit-roll valve not actuated
● When the Orbit-roll valve is not actuated, both pilot port PiA and pilot port PiB are connected through the Orbit-roll to the
drain (return) circuit, so steering spool (1) is kept at neutral by return spring (4).
10-863 WA380-5L
2. Spool actuated (oil flows to port PiA).
● When the oil flows to port PiA, the pressure inside the cap at end A rises and moves steering spool (1) in the direction of
the arrow.
● Oil entering for port PiA passes through the hole in spring seat (3), through orifice (7) in steering spool (1), and then flows
to the opposite end (B end).
● Port PiB is connected to the drain circuit through the Orbit-roll valve, so the oil flowing to end B is drained.
● Pressure generated at port PiA is proportional to the amount of oil flowing in, so steering spool (1) moves to a position
where the opening of the flow amp notch balances the pressure generated with the force of return spring (4).
WA380-5L 10-873
3. Spool returning (steering wheel stopped)
● When the steering wheel (Orbit-roll valve) is stopped, ports PiA and PiB are both connected to the drain circuit through
the Orbit-roll valve. For this reason, steering spool (1) is returned to the neutral position by return spring (4).
10-883 WA380-5L
Steering Valve Operation

Neutral
● The steering wheel is not being operated, so steering spool (1) does not move.
● The oil from the steering pump enters port A. The oil from the switch pump enters port B.
● When the pressures at ports A and B rise, flow control spool (4) is moved to the left in the direction of the arrow (), and
the oil from the steering pump passes through port C of the spool and is drained.
Oil from the switch pump passes through port D and flows to the main control valve.
WA380-5L 10-893
Turning Right
● When the steering wheel is turned to the right, the control linkage is actuated and steering spool (1) moves to the left in the
direction of the arrow ().
● Oil from the steering pump enters port A, goes through flow control spool (2) and flows to steering spool (1). It then
pushes open load 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.
● Oil at the opposite ends of the left and right cylinders passes through load check valve (3) of the steering spool and is
drained.
● Oil from the switch pump enters port B, goes through the flow control spool (2), pushes open the check valve (5), and
merges with the oil from the steering pump.
10-903 WA380-5L
Turning Left
● When the steering wheel is turned to the left, the control linkage is actuated and steering spool (1) moves to the right in the
direction of the arrow ().
● Oil from the steering pump enters port A, goes through flow control spool (2) and flows to steering spool (1). It then
pushes open load 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.
● Oil at the opposite ends of the left and right cylinders passes through load check valve (4) of the steering spool and is
drained.
● Oil from the switch pump enters port B, goes through the flow control spool (2), pushes open the check valve (5), and
merges with the oil from the steering pump.
WA380-5L 10-913
ORBIT-ROLL VALVE MAINTENANCE STANDARD
ORBIT-ROLL VALVE
1. Needle bearing 5. Rotor 9. Spool

2. Center spring 6. Cover 10. Stator
3. Drive shaft 7. Center pin 11. Lower cover
4. Valve body 8. Sleeve
10-923 WA380-5L
MAINTENANCE STANDARD ORBIT-ROLL VALVE
Outline
● The steering valve is connected directly to the shaft of the steering
wheel. It switches the flow of oil from the steering pump to the left
and right steering cylinders to determine the direction of travel of
the machine.
● The orbit-roll valve, broadly speaking, consists of the following
components: rotary type spool (9) and sleeve (8), which have the
function of selecting the direction, and the Girotor set (a combina-
tion of rotor (5) and stator (10)), which acts as a hydraulic motor
during normal steering operations, and as a hand pump (in fact, the
operating force of the steering wheel is too high, so it cannot be
operated) when the steering pump or engine have failed and the
supply of oil has stopped.
Structure
● Spool (9) is directly connected to the drive shaft of the steering
wheel, and is connected to sleeve (8) by center pin (7) (it does not
contact the spool when steering wheel is at neutral) and centering
spring (2).
● The top of drive shaft (3) is meshed with center pin (7), and forms
one unit with sleeve (8), while the bottom of the drive shaft is
meshed with the spline of rotor (5) of the Girotor.
● There are four ports in valve body (4), and they are connected to the
pump circuit, tank circuit, and circuits at the head end and bottom
end of the steering cylinders. The pump port and tank port are
connected by the check valve inside the body. If the pump or engine
fail, the oil can be sucked in directly from the tank by this check
valve.
WA380-5L 10-933
ORBIT-ROLL VALVE MAINTENANCE STANDARD
Connection Between the Hand Pump and Sleeve
● The diagrams above show the connections with the sleeve ports
used to connect the suction and discharge ports of the Girotor.
● If the steering wheel has been turned to the right, ports a, c, e, g, i
and k are connected by the vertical grooves in the spool to the
pump side. At the same time, ports b, d, f, h, j, and l are connected
to the head end of the left steering cylinder in the same way.
In the condition in left figure above, ports 1, 2, and 3 are discharge
ports of the Girotor set. They are connected to ports l, b, and d, so
oil is sent to the cylinder.
Ports 5, 6, and 7 are connected and the oil flows in from the pump.
If the steering wheel is turned 90°, the condition changes to the
condition shown in the right figure above. In this case, ports 1, 2,
and 3 are the suction ports, and are connected to ports i, k, and c.
Ports 5, 6, and 7 are the discharge ports, and are connected to ports
d, f, and h.
10-943 WA380-5L
MAINTENANCE STANDARD ORBIT-ROLL VALVE
● In this way, the ports of the Girotor acting as delivery ports are
connected to ports which are connected to the end of the steering
valve spool. The ports acting as suction ports are connected to the
pump circuit.
● Adjusting delivery in accordance with angle of steering wheel:
For every 1/7 turn of the steering wheel, inner teeth of the Girotor
gear advance one position so the oil flow from the pump is adjusted
by this movement. In this way, the oil delivered from the pump is
directly proportional to the amount the steering wheel is turned.
Function of Center Spring

● Centering spring (2) consists of four layers of leaf springs crossed
to form an X shape. The springs are assembled in spool (9) and
sleeve (8) as shown in the diagram on the right.
When the steering wheel is turned, the spring is compressed and a
difference in rotation (angle variation) arises between the spool and
the sleeve.
Because of this, the ports in the spool and sleeve are connected and
oil is sent to the cylinder. When the turning of the steering wheel is
stopped, the Girotor also stops turning, so no more oil is sent to the
cylinder and the oil pressure rises.
To prevent this, when the turning of the steering wheel is stopped,
the action of the centering spring only allows it to turn by an
amount equal to the difference in angle of rotation (angle variation)
of the sleeve and spool, so the steering wheel returns to NEUTRAL
position.
WA380-5L 10-953
STOP VALVE MAINTENANCE STANDARD
STOP VALVE
1. Boot A: From orbit-roll

2. Wiper B: To steering valve
3. Seal DR: To drain
4. Poppet
5. Spring
6. Spool
7. Spring
10-963 WA380-5L
MAINTENANCE STANDARD STOP VALVE
MEMORANDUM
WA380-5L 10-973
STEERING PUMP, SWITCH PUMP MAINTENANCE STANDARD
STEERING PUMP, SWITCH PUMP

SAL (3) 45+45
1. Steering pump a. 98.1 - 122.6 N•m (10.0 - 12.5 kgf m) {72 - 90 lbf ft}
2. Switch pump b. 245.0 - 309.0 N•m (25.0 - 31.5 kgf m) {181 - 228 lbf ft}
c. 157.0 - 196.0 N•m (16.0 - 20.0 kgf m) {116 - 145 lbf ft}
d. 231.9 - 264.8 N•m (23.5 - 27.0 kgf m) {171 - 195 lbf ft}
10-983 WA380-5L
MAINTENANCE STANDARD STEERING PUMP, SWITCH PUMP
Outline
● The steering pump and switch pump are installed to the PTO shaft of the torque converter. When the shaft rotates, the
pumps are driven and supply pressure oil to the steering circuit.
● The pressure of oil supplied from the switch pump is adjusted by the steering valve, and when pressure in the steering
circuit is sufficient to meet the demand, oil from the switch pump is diverted to the work equipment hydraulic circuit.
Unit:mm

3 Side clearance
0.10 ~ 0.15 0.19
Clearance between inside

4 diameter of plain bearing and 0.06 ~ 0.149 0.20
Replace
outside diameter of gear shaft

Model
5 Driving depth of pin 0
SAL(3)45 14 —
-0.5
SAL(3)45
6 Spline rotating torque 13.8 - 23.6 N•m (1.4 - 2.4 kgf m) {10 - 17 lbf ft.}
Discharge Standard
Discharge amount Speed Discharge
Model pressure discharge
Oil: SAE 10W/CD (rpm) amount limit —
(MPa {kg/cm²} amount
— Oil temperature: 45°
~ 55° C SAL(3)45 20.6 MPa
101 liters/min 96 liters/min
(113° ~ 131° F) 2,500 (210 kg/cm²)
SAL(3)45 {27 gal/min} {25 gal/min}
{2,988 psi}
WA380-5L 10-993
EMERGENCY STEERING PUMP MAINTENANCE STANDARD
EMERGENCY STEERING PUMP

SBL (1) 21
10-1003 WA380-5L
MAINTENANCE STANDARD EMERGENCY STEERING PUMP
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

1 Side clearance
0.10 ~ 0.15 0.19
Clearance between inside

2 diameter of plain bearing and 0.060 ~ 0.119 0.20 Replace

10 —
-0.5
4 Spline rotating torque 2.0 - 4.9 N•m (0.2 - 0.5 kgf m) {18 - 43 lbf in}
5 Socket head bolt torque 245.0 - 309.0 N•m (25.0 - 31.5 kgf m) {181 - 228 lbf ft}
Standard
Speed Discharge Discharge —
Discharge amount discharge
(rpm) pressure amount limit
Oil: SAE 10W/CD amount
—
Oil temperature: 45° ~ 55° C 20.6 MPa
(113° ~ 131° F) 67.6 liters/min 62.4 liters/min
3,500 (210 kg/cm²)
{18 gal/min} {16 gal/min}
{2,988 psi}
WA380-5L 10-1013
EMERGENCY STEERING MOTOR MAINTENANCE STANDARD
EMERGENCY STEERING MOTOR
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
Rated voltage 24V
Rated output 0.9kW
10-1023 WA380-5L
MAINTENANCE STANDARD EMERGENCY STEERING MOTOR
MEMORANDUM
WA380-5L 10-1033
STEERING CYLINDER MAINTENANCE STANDARD
STEERING CYLINDER
Unit:mm
Tolerance
Clearance between mounting pin size Clearance limit
1 and bushing at connection of Shaft Hole
frame and cylinder rod
0 +0.142 0.080 ~
ø50 —
-0.025 +0.080 0.167
Clearance between mounting pin
0 +0.142 0.080 ~
2 and bushing at connection of ø50 — Replace
-0.025 +0.080 0.167
frame and cylinder bottom
Standard clearance
Width of boss Width of hinge
Connection of steering cylinder and (a + b)
3
front frame Max. 0.5
60 66
(after adjusting shim)
Connection of steering cylinder and Max. 0.5
4 60 63
rear frame (after adjusting shim)
10-1043 WA380-5L
MAINTENANCE STANDARD STEERING CYLINDER
Unit:mm
Tolerance
Clearance between piston rod and size Clearance limit
1 Shaft Hole
bushing
+0.025 +0.141 0.021 ~ Replace pin,
ø45 0.505
+0.064 -0.004 0.205 bushing
Clearance between piston rod support 0 +0.142 0.080 ~
2 ø50 1.0
shaft and bushing -0.025 +0.080 0.167
Clearance between cylinder bottom 0 +0.142 0.080 ~
3 ø50 1.0
support shaft and bushing -0.025 +0.080 0.167
4 Tightening torque of cylinder head 677 ±67.5 N•m (69 ±6.9 kgf m) {499 ±50 lbf ft.}
1.25 ± 0.13 kNm (127 ±12.7 kgf m) {950 ±130 lbf ft.}
5 Tightening torque of cylinder piston Tighten
(Width across flats: 50 mm)
Tightening torque of nipple plug on
6 9.8 ~ 12.74 Nm (1.0 - 1.3 kgf m) {87 - 113 lbf in.}
cylinder head side
WA380-5L 10-1053
JOYSTICK STEERING MAINTENANCE STANDARD
JOYSTICK STEERING
1. Shift UP switch 9. Console lock lever

2. Shift DOWN switch 10. Height adjustment lock lever
3. F-N-R switch 11. Angle/Position adjustment lock lever
4. Joystick steering lever 12. Console
5. Joystick ON/OFF switch 13. Block
6. Hi/Lo switch 14. Steering switch
7. Horn switch 15. Orbit-roll
8. Steering electrical lever
10-1063 WA380-5L
MAINTENANCE STANDARD JOYSTICK STEERING
Joystick PPC Valve
1. Body 5. Retainer
2. Piston 6. Lever
3. Lever 7. Potentiometer
4. Disc 8. Connector
Function
● The steering potentiometer is installed to the left side part of the floor, and is interconnected by a link to the steering end
of the joystick. When the joystick is operated in the steering direction, disc (4) is rotated through the link, pushes piston
(2) down, and rotates potentiometer (7).
● Steering lever potentiometers sense lever angle and output angle signal to HSS controller.
● Two potentiometers are attached to the steering lever and they output a signal as shown in the diagram.
WA380-5L 10-1073
JOYSTICK STEERING MAINTENANCE STANDARD
Unit: mm
No. Check Item Criteria Remedy
Installed Installed Free Installed

Free length
length load length load
5.88 N 4.71 N
1 Spring 49 x 7.0 25 {0.6 kg} — {0.48 kg} Replace a damaged or
(21 ozf)) (17 ozf)) deformed spring
73.5 N 58.8 N
2 Spring 45.8 x 15.5 32 {7.5 kg} — {6.0 kg}
(17 lbf)) (13 lbf))
10-1083 WA380-5L
MAINTENANCE STANDARD JOYSTICK STEERING
Steering Switch Valve
Item 1. 6.9 - 8.3 N•m (0.70 - 0.85 kgf m) {61 - 73 lbf in}
Operation
● Steering switch valve switches oil circuit from R.H. steering cylinder circuit to L.H. steering cylinder circuit or in reverse
according to the operated direction of steering lever.
● According to the angle of steering lever, steering switch valve controls the oil flow amount.
WA380-5L 10-1093
BRAKE PIPING MAINTENANCE STANDARD
BRAKE PIPING
10-1103 WA380-5L
MAINTENANCE STANDARD BRAKE PIPING
1. Brake valve (LH)

2. Brake valve (RH)
3. Hydraulic oil tank
4. Accumulator (for the front side)
5. Accumulator (for the rear side)
6. Accumulator (for the rear side)
7. Accumulator (for the front side)
8. Charge valve
9. Parking brake emergency release valve
10. Pilot control pump
11. Rear brake
12. Transmission control valve
13. Parking brake solenoid valve
14. Parking brake
15. Front brake
WA380-5L 10-1113
BRAKE VALVE MAINTENANCE STANDARD
BRAKE VALVE
Brake Valve - Left
T: Drain port 1. Brake pedal

A: To the RH brake valve PP 2. Rod
P: From the charge valve ACC2 3. Spool
4. Cylinder
a. 58.8 - 73.5 N•m (6.0 - 7.5 kgf m) {43 - 54 lbf ft}

b. 127.4 - 176.4 N•m (13 - 18 kgf m) {94 - 130 lbf ft}
10-1123 WA380-5L
MAINTENANCE STANDARD BRAKE VALVE
Unit:mm
Tolerance
Clearance between pedal mount size clearance limit
5 Shaft Hole
hole and pin
-0.025 +0.1 0.025 ~
ø 10 0.25
-0.075 0 0.175
Clearance between roller and -0.025 +0.1 0.025 ~
6 ø 10 0.25
pin -0.075 0 0.175

7 Outside diameter of roller
0
30 29.2
-0.5

Replace
Installed Installed Installed
Free length Free length
8 Control spring length load load
0 Nm
34.7 34.7 {0 kg} 33.7 —
(0 lbf)
40.3 Nm
9 Control spring 51.8 49.7 {4.12 kg} 50.8 —
(9 lbf)
116.4 Nm
10 Return spring 197.8 58 {11.88 kg} 178 —
(26.lbf)
16.7 Nm
11 Return spring 31.5 19.5 {1.7 kg} 28 —
(4 lbf)
WA380-5L 10-1133
Brake Valve - Right
T: Drain port 1. Brake pedal

A: To the rear brake 2. Rod
B: To the front brake 3. Piston (Pilot)
PA: From the charge valve ACC1 4. Spool
PB: From the charge valve ACC2 5. Cylinder (Upper)
PP: From the LH brake valve A 6. Spool
7. Cylinder (Lower)
a. 58.8 - 73.5 N•m (6.0 - 7.5 kgf m) {43 - 54 lbf ft}

b. 127.4 - 176.4 N•m (13 - 18 kgf m) {94 - 130 lbf ft}
10-1143 WA380-5L
Unit: mm
Tolerance
size clearance limit
Shaft Hole
Clearance between pedal mount -0.025 +0.1 0.025 ~

8 ø 10 0.25
hole and pin -0.075 0 0.175
Clearance between roller and -0.025 +0.1 0.025 ~
9 ø 10 0.25
pin -0.075 0 0.175

10 Outside diameter of roller
-0
30 29.2
-0.5
Free Installed Installed Free Installed

length length load length load Replace
0 Nm
11 Control spring 34.7 34.7 {0 kg} 33.7 —
(0 lbf)
40.3 Nm
12 Control spring 51.8 49.7 {4.12 kg} 50.8 —
(9 lbf)
116.4 Nm
13 Return spring 197.8 58 {11.88 kg} 178 —
(26.lbf)
16.7 Nm
14 Return spring 31.5 19.5 {1.7 kg} 28 —
(4 lbf)
17.7 Nm
15 Return spring 17 16.5 {1.8 kg} — —
(4 lbf)
Outline
● There are two brake valves installed in parallel at the bottom front of the operator's compartment. They are actuated when
the pedal is depressed.
● When the right pedal is depressed, oil is sent to the brake cylinder and the brake is applied.
● When the left pedal is depressed, oil is sent to the right pedal and the brake is applied in the same way as when the right
pedal is depressed.
● In addition, when the left brake pedal is depressed, the transmission cut-off switch actuates the transmission solenoid
valve electrically to set the transmission to neutral.
WA380-5L 10-1153
Operation
When brake is applied (right brake valve)
Upper portion
● When pedal (1) is depressed, the operating effort is transmitted
through rod (2) and spring (4) to spool (3). When spool (3) goes
down, drain port a is closed and 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.
When brake is applied (left brake valve)
● When pedal (7) is depressed, spool (10) is pushed up by rod (8) and
spring (9), and closes drain port c. Oil from the pump and
accumulator flows from port E to port F.
● Port F of the left brake valve and port PP of the right brake valve
are connected by a hose, so the oil flowing into port F flows to pilot
port PP of the right brake valve.
● The oil entering pilot port PP passes through orifice d and enters
port G, pushes piston (11) and the spring pushes spool (3) down to
apply the brake in the same way as when the right brake valve is
depressed.
10-1163 WA380-5L
Applying brake (right brake valve) when there is failure in

upper valve
● Even if there is leakage of oil from the upper piping, when pedal (1)
is depressed, spool (5) is moved down mechanically, so the lower
portion is actuated normally.
The brake for the upper portion is not actuated.
Applying brake (right brake valve) when there is failure in
lower valve
● Even if there is leakage of oil from the lower piping, when pedal (1)
is depressed, the lower portion is actuated normally.
Balanced operation
Upper portion
● When the oil fills the rear brake cylinder and the oil pressure
between port A and port C becomes high, the oil entering port H
through orifice e of spool (3) pushes against spring (4) and pushes
spool (3) up to shut off port A and port C. When this happens, drain
port a remains closed and the oil entering the brake cylinder is
maintained, so the brake remains applied.
Lower portion
● Spool (a) in the upper portion moves up, and at the same time as
port A and port C are shut off, the front brake cylinder is also filled
with oil and the oil pressure between port B and port D becomes
high. The oil entering port J through orifice f of spool (5) pushes up
the spool by the same amount that spool (3) moves and shuts off
port B and port D.
Drain port b is closed, so oil entering the brake cylinder is
maintained and the brake is applied.
● The pressure in the space in the upper portion is balanced with the
operating effort of the pedal, and the pressure in the space in the lower portion is balanced with the pressure in the space in
the upper portion. Spools (3) and (5) move the full stroke, and ports A - C and ports B - D are opened completely, so the
oil pressure in the space in the lower portion and the left and right brake cylinders becomes the same as the oil pressure
from the pump.
Therefore, the amount that the brake is applied can be adjusted by the amount that the pedal is depressed, up to the point
where the piston is operated fully.
WA380-5L 10-1173
Brake released (right brake valve)
Upper portion
When pedal (1) is let back and the operating effort on the top of the
spool is removed, the back pressure from the brake cylinder and the
force of the spool return spring move spool (3) up, drain port a is
opened, the oil from the brake cylinder flows to the hydraulic tank
return circuit, and the rear brake is released.
Lower portion
When the pedal is let back, at the same time as spool (3) in the upper
portion moves up, the back pressure from the brake cylinder and the
force of the spool return spring move spool (5), drain port b is opened,
the oil from the brake cylinder flows to the tank return circuit, and the
front brake is released.
10-1183 WA380-5L
MEMORANDUM
WA380-5L 10-1193
CHARGE VALVE MAINTENANCE STANDARD
CHARGE VALVE
A1: To the PPC valve

A2: Plug
ACC1: To the RH brake valve PA
ACC2: To the RH brake valve PB
To the LH brake valve P
P: From the pump
PP: To the accumulator
T: Drain
10-1203 WA380-5L
MAINTENANCE STANDARD CHARGE VALVE
1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. PPC 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.
WA380-5L 10-1213
Operation
1. When oil is not being supplied to accumulator (cut-out
condition).
● Pressure at port B is higher than the set pressure of relief valve
R1, so piston (2) is forcibly pushed up by the oil pressure at
port B and poppet (1) opens, and port C and port T are
connected.
● Spring chamber at the right end of spool (6) is connected to
port C of relief valve R1, so it is the tank pressure.
● Oil from the pump enters port P and a low pressure equivalent
to the load of spring (5) pushes spool (6) to the right, then
flows from port A to the PPC valve, orbit-roll and fan pump.
At the same time, it also passes through orifices (7), (4), and
(3), and returns to the tank.
2. When oil is being supplied to accumulator

A. Cut-in condition
● When the pressure at port B goes below the set pressure of
relief valve R1, piston (2) is pushed back down by spring
(8), valve seat (9) and poppet (1) are put in tight contact,
and port C and port T are shut off.
● The spring chamber at the right end of spool (6) is also
shut off from port T, so the pressure rises. The pressure at
port P also rises in the same way.
● At the moment pressure at port P goes above the pressure
of port B (accumulator pressure), supply of oil to the
accumulator starts. In this case, it is determined by the
size (area) of orifice (7) and pressure difference generated
on both sides of the orifice (equivalent to the load of
spring (5)). A fixed amount is supplied, regardless of
engine speed, and the remaining oil flows to port A.
10-1223 WA380-5L
B. When cut-out pressure is reached

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

● When the pressure at port P (pump pressure) goes above the
set pressure of relief valve R3, the oil from the pump pushes
against spring (10), pushes up ball (11), and sends the oil to the
tank circuit to set the maximum pressure in the brake circuit
and protect the circuit.
WA380-5L 10-1233
PPC RELIEF VALVE
1. Main valve 4. Pilot poppet
2. Spring 5. Spring
3. Valve seat 6. Screw
Outline
● The PPC relief valve is 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 circuit, the PPC relief valve relieves the oil sent from the pump to pro-
tect the pumps and circuits.
Operation
● The relief valve is installed to the charge valve and ports A and C
are connected to the pump circuit and drain circuit respectively. The
oil flows through the orifice of main valve (1) and fills port B. Pilot
poppet (4) is seated at valve seat (3).
● If the pressure in ports A and B reaches the set level, pilot poppet
(4) opens and the pressure in port B is released through port D into
port C, and the pressure in port B lowers consequently.
10-1243 WA380-5L
● If the pressure in port B lowers, a pressure difference is made

between ports A and B because of the orifice of main valve (1). As
a result, main valve (1) is opened by the pressure in port A and the
oil in port A is drained and relieved into port C.
WA380-5L 10-1253
ACCUMULATOR - BRAKE MAINTENANCE STANDARD
ACCUMULATOR - BRAKE
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function
● The accumulator is installed between the charge valve and brake
valve.
The area between cylinder (3) and free piston (4) is charged with
nitrogen gas. The compression ability of this gas is used to absorb
the pulse of the hydraulic pump and to ensure that there is power to
perform braking and operate the machine if the engine stops.
Specifications
Gas used: Nitrogen gas
Amount of gas: 2,850 cc
Charge pressure: 3.43 ±0.1 MPa (35 ±1.0 kg/cm²) {498 ±15 psi}
at 20° C (68° F)
10-1263 WA380-5L
MAINTENANCE STANDARD ACCUMULATOR - BRAKE
Function
This accumulator is installed between the brake valve and the brake
cylinder. The area between cylinder (3) and free piston (2) is charged
with nitrogen gas. The compression ability of this gas is used to ensure
that there is power to perform braking and machine operation.
1. Top cover
2. Piston
3. Cylinder
4. End cover
5. Core
Specifications
Gas used: Nitrogen gas
Amount of gas: 46 cc
Charge pressure: 0.29 ±0.05 MPa (3 ±0.5 kg/cm²) {42 ±7 psi}
at 50° C (122° F)
WA380-5L 10-1273
BRAKE MAINTENANCE STANDARD
BRAKE
Front
★ Figure shows brake with anti-slip differential.
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Discs (x 3)
10-1283 WA380-5L
MAINTENANCE STANDARD BRAKE
Unit: mm
10 Thickness of inner ring 6 ±0.1 5.5
Thickness of brake disc 6.5 ±0.15 5.7
11 Depth of lining groove 0.8 (Min.) — 0.4
Thickness of lining 1.0 0.9 (Min.) — Replace

Wear of brake outer ring disc
12 23.3 ±0.1 0.3
contact surface
Installed height Installed load Installed load
460 N (47 kg) 372 N (38 kg)

13 Spring load 6.5
{103 lbf} {84 lbf}
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 housing (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).
WA380-5L 10-1293
Rear
★ Figure shows brake with anti-slip differential.
1. Differential housing 4. Spring 7. Axle housing
2. Bearing carrier 5. Inner ring 8. Outer ring
3. Piston 6. Sun gear shaft 9. Discs (x 3)
10-1303 WA380-5L
MAINTENANCE STANDARD BRAKE
Unit: mm
10 Thickness of inner ring 6 ±0.1 5.5
Thickness of brake disc 6.5 ±0.15 5.7
11 Depth of lining groove 0.8 (Min.) — 0.4
Thickness of lining 1.0 0.9 (Min.) — Replace

Wear of brake outer ring disc
12 23.3 ±0.1 0.3
contact surface
13 Spring load Installed height Installed load Installed load
460 N (47 kg) 372 N (38 kg)

6.5
{103 lbf} {84 lbf}
Outline
● The rear brake has a wet-type, single-disc structure, and consists of piston (3), inner ring (5), disc (9), outer ring (8), and
spring (4).
● The brake cylinder consists of differential housing (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 the inner ring (5) and outer ring (8), and is joined by the
spline of sun gear shaft (6).
WA380-5L 10-1313
Operation
When brake is applied
● When the brake pedal is depressed, pressure oil P goes from the
hydraulic tank through the pump and brake charge valve. It acts on
the piston inside the brake cylinder and the piston slides.
Therefore, the piston (2) stops the rotation of discs (4) fitted
between inner ring (3) and outer ring (5), and applies the brake to
the machine.
When brake is released
● When oil pressure is released, piston (2) is returned to its original

position by the force of spring (8), a gap is formed between inner
ring (3) and outer ring (5), and discs (4) become free.
Lattice shape grooves are cut into the lining stuck to the disc (4).
When the disc (4) is rotating, oil flows in the grooves and cools the
lining.
10-1323 WA380-5L
MAINTENANCE STANDARD PARKING BRAKE CONTROL
PARKING BRAKE CONTROL
1. Parking brake switch 4. Parking brake solenoid valve
2. Parking brake emergency release valve 5. Parking brake
3. Transmission control valve
Outline
● The parking brake is a wet-type multiple disc brake built into the transmission. It is installed to the bearing portion of the
output shaft. It is applied mechanically by the pushing force of a spring, and is released by hydraulic power.
● When the parking brake switch (1) in the operator's compartment is turned ON, the hydraulic pressure is shut off by park-
ing brake solenoid valve (4) installed to transmission control valve (3), and the parking brake is applied. When the parking
brake switch is OFF, the parking brake is released by the hydraulic pressure of the cylinder.
● While the parking brake is being applied (solenoid is OFF), the signal from the transmission controller to the transmission
solenoid valve is cut by the neutralizer signal, and the transmission is held at neutral.
● Parking brake emergency release valve (2) is installed to release the parking brake if it is necessary to move the machine
when trouble has occurred in the engine or drive system and the machine remains stopped (the parking brake remains
applied).
WA380-5L 10-1333
PARKING BRAKE MAINTENANCE STANDARD
PARKING BRAKE
1. Output shaft 4. Piston 7. Disc
2. Spring 5. Parking brake oil port 8. Wave spring
3. Spring 6. Plate
OUTLINE
● The parking brake is a wet-type multiple-disc brake and is applied mechanically by a spring to apply braking force to
transmission output shaft (1).
● The tension of spring (3) uses piston (4) to push discs (7) and plates (6) together and stop output shaft (1).
● When the brake is released, oil pressure from parking brake oil port (5) actuates piston (4) to release the force pushing
discs (7) and plates (6) together.
10-1343 WA380-5L
MAINTENANCE STANDARD PARKING BRAKE
Unit: mm

length length load length load
1,113 N 1,058 N
9 Parking brake spring (outer) 94 76 (113.5 kg) 91.2 (107.8 kg)
{250 lbf} {238 lbf}
583 N 553 N
10 Parking brake spring (inner) 94 76 (59.4 kg) 91.2 (56.4 kg)
{131 lbf} {124 lbf}
Replace
Thickness 4.0 ±0.05 3.9

11 Separate plate
12 Brake disc Thickness 3.2 ±0.08 2.97
±57 N
1,106 N (112.8 kg) 940 N (95.9 kg)
13 Wave spring load (±5.8 kg)
{249 lbf} {211 lbf}
{±13 lbf}
WA380-5L 10-1353
PARKING BRAKE MAINTENANCE STANDARD
Parking Brake Solenoid Valve

Transmission No. 110643 and Down
Transmission No. 110644 and Up
1. Movable iron core

2. Coil
3. Bushing pin
4. Spring
5. Spool
6. Valve seat
7. Check valve
10-1363 WA380-5L
MAINTENANCE STANDARD PARKING BRAKE
Operation
Parking brake applied (solenoid OFF)
● When the parking brake switch in the operator's compartment is

turned ON, the solenoid is turned OFF and spool (5) is pushed to
the left by spring (4). When this happens, the circuit between pump
port P and parking brake port A is closed and the pressure oil from
the pump does not flow to the parking brake.
● At the same time, the oil from the parking brake flows from port A
to port T, and is drained. As a result, the discs inside the parking
brake are pushed by the spring and the parking brake is applied.
Parking brake released (solenoid ON)
● When the parking brake switch is turned OFF, the solenoid is

turned ON and spool (5) moves to the right. When this happens, the
pressure oil from the pump goes from port P through the inside of
spool (5) and flows from port A to the parking brake. At the same
time, port T is closed and the oil is not drained. As a result, the
spring inside the parking brake is pushed back by the hydraulic
force and the parking brake is released.
Parking Brake Emergency Release Valve

Outline
● The parking brake emergency release valve is installed between the
brake circuit accumulator and the parking brake solenoid. It is pos-
sible 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.
1. Grip
2. Valve
A. From accumulator
B. To parking brake solenoid
a: 25 ±5 N•m 2.5 ±0.5 kgf m {18 ±4 lbf ft}

b: 20 ±5 N•m 2.0 ±0.5 kgf m {15 ±4 lbf ft}
WA380-5L 10-1373
HYDRAULIC PIPING MAINTENANCE STANDARD
HYDRAULIC PIPING
10-1383 WA380-5L
MAINTENANCE STANDARD HYDRAULIC PIPING
WA380-5L 10-1393
HYDRAULIC PIPING MAINTENANCE STANDARD
1. Work equipment valve

2. Bucket cylinder
3. Steering valve
4. Hydraulic oil tank
5. Breather
6. PPC valve
7. Cooling fan pump
8. Steering switch pump
9. Oil cooler
10. Torque converter oil cooler
11. Torque converter oil pressure • work equipment oil pressure • pilot control pump
12. PPC accumulator
13. Charge valve
14. Travel damper valve
15. Steering cylinder
16. Travel damper accumulator
17. Lift arm cylinder
18. Emergency steering pump
19. Emergency steering motor
20. Cooling fan motor
Outline
● The hydraulic system consists of the work equipment circuit and steering circuit. The work equipment circuit controls the
operation of the bucket and attachments.
● The oil from hydraulic tank (4) is sent by work equipment pump (11) to work equipment valve (1). If the bucket and lift
arm spools of the work equipment valve are in the HOLD position, the oil is sent through the drain circuit of the work
equipment valve, filtered by the filter in the hydraulic tank, and returned to the tank.
● If the work equipment control lever is operated, the bucket or lift arm spool of the PPC valve (6) moves to operate each
spool of the work equipment valve (1) hydraulically. Then, the oil flows from the work equipment valve to lift arm cylin-
der (17) or bucket cylinder (2) to move the lift arm or bucket.
● The maximum pressure in the hydraulic circuit is controlled with the relief valve in the work equipment valve. The bucket
cylinder circuit is equipped with the safety-suction valve for protection of the circuit.
● 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 a 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 emergency 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).
10-1403 WA380-5L
MAINTENANCE STANDARD HYDRAULIC PIPING
MEMORANDUM
WA380-5L 10-1413
WORK EQUIPMENT CONTROL LEVER MAINTENANCE STANDARD
WORK EQUIPMENT CONTROL LEVER
For PPC Valve
1. Lift arm control lever

2. Bucket control lever
3. Kick down switch
4. Holding switch
5. Canceling switch
(When equipped with load meter)
6. Sub-totaling switch
7. Wrist rest
8. Wrist rest height adjusting lever
9. Lever stand angle adjusting lever
10. Work equipment PPC valve
11. Safety lock lever
A: 11.8 - 17.4 N•m (1.2 - 1.8 kgf m) {104 - 145 lbf in}
10-1423 WA380-5L
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL LEVER
For EPC Valve (If Equipped)
1. Lift arm control lever

2. Bucket control lever
3. Kick down switch
4. Holding switch
5. Canceling switch
6. Sub-totaling switch
7. Wrist rest
8. Wrist rest height adjusting lever
9. Lever stand tilt adjusting lever
10. EPC valve
11. Work equipment lock lever
12. Travel direction selector switch
A: 11.8 - 17.4 N•m (1.2 - 1.8 kgf m) {104 - 145 lbf in}
WA380-5L 10-1433
HYDRAULIC TANK MAINTENANCE STANDARD
HYDRAULIC TANK
1. Oil filler port 4. Sight gauge
2. Breather 5. Bypass valve
3. Hydraulic oil tank 6. Oil filter
SPECIFICATIONS
System capacity 195 liters (51.5 gal.)
Oil quantity inside the tank 129 liters (34 gal)
Bypass valve setting pressure 0.125 MPa {1.27 kg/cm²} (18 psi)
10-1443 WA380-5L
MAINTENANCE STANDARD HYDRAULIC TANK
Breather
1. Nut
2. Filter element
3. Poppet
4. Sleeve
A: 10 - 14 N•m (1.0 - 1.4 kgf m) {89 - 124 lbf in}
Prevention of negative pressure in tank

● Since the tank is pressurized and enclosed, if the hydraulic oil level
in it lowers, negative pressure is generated. At this time, poppet (3)
is opened by the differential pressure between the tank pressure and
the atmospheric pressure to prevent generation of the negative
pressure.
Set pressure of suction valve:
2.0 ± 0.03 kPa (0.02 ± 0.003 kg/cm²) {0.29 ±0.04 psi}
Prevention of pressure rise in tank
● While the hydraulic circuit is in operation, hydraulic oil level in the
tank varies as the hydraulic cylinders operate and the temperature
rises. Consequently, pressure in the tank varies, too. If pressure in
the tank rises above the set level, sleeve (4) operates to release the
pressure from the tank.
Set pressure of exhaust valve:
0.1 ± 0.015 MPa (1.0 ± 0.15 kg/cm²) {15 ±2 psi}
WA380-5L 10-1453
TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PILOT CONTROL PUMPS
TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND

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

2. Work equipment pump
3. Pilot control pump
Outline
● The torque converter charging, work equipment, and pilot control pumps are installed to the PTO shaft of the torque
converter and driven by shafts to supply oil to the transmission, work equipment, and PPC circuit.
10-1463 WA380-5L
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING, WORK EQUIPMENT, AND PI-
Unit:mm
Model Standard clearance Clearance limit Replace
SAL(3)80
4 Side clearance 0.10 ~ 0.15
SAL(3)90 0.19
SAL(1)20 0.08 ~ 0.13
SAL(3)80
Clearance between inside 0.069 ~ 0.149
5 diameter of plain bearing and SAL(3)90 0.20
SAL(1)20 0.06 ~ 0.119
Model Standard size Tolerance Repair limit
SAL(3)80
0
SAL(3)90 —
-0.5
SAL(1)20 10
7 Spline rotating torque 17.7 - 33.3 Nm (1.8 - 3.4 kgf m) {13 - 25 lbf ft.}
Standard
Speed Discharge Discharge
Model discharge
(rpm) pressure amount limit
amount
20.6 MPa
Discharge amount SAL(3)80 (210 kg/cm²)
{49 gal/min} {45 gal/min} —
Oil: SAE10W/CD {2,988 psi}
—
Oil temperature: 45° - 55° C 20.6 MPa
(113° - 131° F) SAL(3)90 208 liters/min 192 liters/min
2,500 (210 kg/cm²)
{2,988 psi}
2.9 MPa
SAL(1)20 (30 kg/cm²)
{421 psi}
WA380-5L 10-1473
PPC RELIEF VALVE MAINTENANCE STANDARD
PPC RELIEF VALVE
1. Main Valve 4. Pilot Poppet
2. Spring 5. Spring
3. Valve Seat 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 circuit, the PPC
relief valve relieves the oil sent from the pump to protect the pumps
and circuits.
★ If EPC valve is installed, change "PPC valve" to "EPC valve"
when reading.
Operation
● The relief valve is installed to the charge valve and ports A and C
are connected to the pump circuit and drain circuit respectively. Oil
flows through the orifice of main valve (1) and fills port B. Pilot
poppet (4) is seated at valve seat (3).
● If 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.
● If pressure in port B lowers, a pressure difference is made between
ports A and B because of the orifice of main valve (1). As a result,
main valve (1) is opened by the pressure in port A, and the oil in
port A is drained and relieved into port C.
10-1483 WA380-5L
MAINTENANCE STANDARD PPC RELIEF VALVE
MEMORANDUM
WA380-5L 10-1493
E.C.S.S. VALVE (If Equipped) MAINTENANCE STANDARD
E.C.S.S. VALVE (If Equipped)
1. 29.0 ±1.0 N•m (3.0 ±0.1 kgf m) {21 ±1 lbf ft}

2. 13.0 ±0.6 N•m (1.3 ±0.06 kgf m) {115 ±5 lbf in}
A: From lift arm cylinder bottom
B: From lift arm cylinder head
P: From work equipment pump
SP: To travel damper accumulator
T: To tank
10-1503 WA380-5L
MAINTENANCE STANDARD E.C.S.S. VALVE (If Equipped)
1. Main spool
2. Solenoid valve
3. Flow control valve
4. Shuttle valve
5. Charge valve
WA380-5L 10-1513
E.C.S.S. VALVE (If Equipped) MAINTENANCE STANDARD
MEMORANDUM
10-1523 WA380-5L
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
WORK EQUIPMENT CONTROL VALVE

2-Spool Valve
T: Drain port (To the tank) P2: From switch pump (steering valve)
A1: To bucket cylinder head P1A: From P1 port of PPC valve
A2: To lift arm cylinder head P1B: From P2 port of PPC valve
B1: To bucket cylinder bottom P2A: From P3 port of PPC valve
B2: To lift arm cylinder bottom P2B: From P4 port of PPC valve
P1: From work equipment pump 1. Solenoid valve
WA380-5L 10-1533
WORK EQUIPMENT CONTROL VALVE MAINTENANCE STANDARD
10-1543 WA380-5L
1. Cutoff valve assembly 7. Cutoff relief valve

2. Unload valve 8. Screen
3. Bucket spool 9. Safety valve with suction valve
4. Lift arm spool 10. Check valve
5. Check valve 11. Main relief valve
6. Suction valve
Torque Values:
A. 28 - 34 N•m (2.8 - 3.5 kgf m) {21 - 25 lbf ft} E. 441 - 490 N•m (45 - 50 kgf m) {325 - 361 lbf ft}
B. 127 - 177 N•m (13 - 18 kgf m) {94 - 130 lbf ft} F. 245 - 304 N•m (25 - 31 kgf m) {181 - 224 lbf ft}
C. 216 - 235 N•m (22 - 24 kgf m) {159 - 173 lbf ft} G. 59 - 78 N•m (6 - 8 kgf m) {44 - 58 lbf ft}
D. 11.8 - 14.7 N•m (1.2 - 1.5 kgf m) {104 - 130 lbf in}
Unit: mm

Spool return spring length length load length load
12
(For bucket)
125 N
54.8 53.5 {12.7 kg} — —
(28 lbf)
235 N
Spool return spring
13 54.8 52.2 {24 kg} — —
(For bucket and lift arm)
(53 lbf)
235 N
Spool return spring
14 30.7 26.8 {24 kg} — —
(53 lbf)
233 N
Spool return spring Replace a
15 55.3 40.0 {23.8 kg} — —
(For lift arm) damaged or
(52 lbf)
deformed
208 N spring
Spool return spring
16 86.8 83.5 {21.2 kg} — —
(For lift arm)
(47 lbf)
33.3 N
Main valve spring of main relief
17 39.5 23.2 {3.4 kg} — —
valve
(120 ozf)
259 N 208 N
18 Poppet spring of relief valve 49.3 41.9 {26.4 kg} 47.8 {21.2 kg}
(58 lbf) (47 lbf)
44.1 N
19 Check valve spring 32.6 24.5 {4.5 kg} — —
(10 lbf)
6.86 N
20 Suction valve spring 27.9 19.0 {0.7 kg} — —
(25 ozf)
WA380-5L 10-1553
MEMORANDUM
10-1563 WA380-5L
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
WA380-5L 10-1573
10-1583 WA380-5L
1. Cutoff valve assembly 7. Suction valve

2. Unload valve 8. Cutoff relief valve
3. Attachment spool 9. Screen
4. Bucket spool 10. Safety valve with suction valve
5. Lift arm spool 11. Check valve
6. Check valve 12. Main relief valve
Torque Values:
A. 28 - 34 N•m (2.8 - 3.5 kgf m) {21 - 25 lbf ft} E. 441 - 490 N•m (45 - 50 kgf m) {325 - 361 lbf ft}
B. 127 - 177 N•m (13 - 18 kgf m) {94 - 130 lbf ft} F. 245 - 304 N•m (25 - 31 kgf m) {181 - 224 lbf ft}
C. 216 - 235 N•m (22 - 24 kgf m) {159 - 173 lbf ft} G. 59 - 78 N•m (6 - 8 kgf m) {44 - 58 lbf ft}
D. 11.8 - 14.7 N•m (1.2 - 1.5 kgf m) {104 - 130 lbf in}
Unit: mm

Spool return spring length length load length load
13
(For bucket and attachment)
125 N
54.8 53.5 {12.7 kg} — —
(28 lbf)
235 N
Spool return spring
14 54.8 52.2 {24 kg} — —
(53 lbf)
235 N
Spool return spring
15 30.7 26.8 {24 kg} — —
(53 lbf)
233 N
Spool return spring Replace a
16 55.3 40.0 {23.8 kg} — —
(For lift arm) damaged or
(52 lbf)
deformed
208 N spring
Spool return spring
17 86.8 83.5 {21.2 kg} — —
(For lift arm)
(47 lbf)
33.3 N
Main valve spring of main relief
18 39.5 23.2 {3.4 kg} — —
valve
(120 ozf)
259 N 208 N
19 Poppet spring of relief valve 49.3 41.9 {26.4 kg} 47.8 {21.2 kg}
(58 lbf) (47 lbf)
44.1 N
20 Check valve spring 32.6 24.5 {4.5 kg} — —
(10 lbf)
6.86 N
21 Suction valve spring 27.9 19.0 {0.7 kg} — —
(25 ozf)
WA380-5L 10-1593
Relief Valve
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjusting screw
Function
● The relief valve is installed to the inlet of the work equipment
valve. When the oil pressure rises above the specified level, this
valve drains the oil into the hydraulic tank to limit the maximum
pressure of the work equipment circuit and protect the circuit.
Operation
● Port A is connected to the pump circuit and port C is connected to
the drain circuit. Oil passes through the orifice of main valve (1) to
fill port B. Pilot poppet (3) is contacting (seated) to valve seat (2).
● When the hydraulic pressure inside port A and port B reaches the
set pressure of pilot poppet spring (4), pilot poppet (3) opens to let
the hydraulic pressure of port B flow from port D to port C and the
pressure of port B drops.
● When the pressure at port B drops, pressure difference occurs

between port A and port B by the orifice of main valve (1) and the
main valve is pushed open to let the oil of port A pass through port
C to flow into the drain circuit, to release the abnormal pressure.
● The preset pressure can be changed by increasing or decreasing the

tension of the pilot poppet spring (4).
● To change the preset pressure, remove the cap nut to loosen the lock
nut. After that, screw-in the adjust screw (5) to raise the preset pres-
sure and loosen the adjust screw to lower the preset pressure.
10-1603 WA380-5L
Safety-suction Valve
1. Suction valve
2. Main valve
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
Function
● The safety-suction valve is in the bucket cylinder circuit in the work equipment valve. When the work equipment valve is
in neutral, if any impact is applied to the cylinder and abnormal pressure is generated, that pressure is released through
this valve to protect the cylinder.
● If negative pressure is generated in the cylinder circuit, this valve works as a suction valve.
Operation
1. Operation as safety valve

● Ports A and B are connected to the cylinder circuit and drain
circuit respectively.
● Oil pressure in port A is applied through the hole of pilot piston
(4) to port D. It is also applied through the orifice consisting of
main valve (2) and pilot piston (4) to port C.
● Pilot piston (4) is fixed to the safety valve and the diameters
(sectional areas) are set in the following order; d2 > d1 > d3 >
d4.
● When abnormal pressure is generated in port A, suction valve

(1) does not operate since d2 > d1. Main valve (2) receives the
oil pressure corresponding to the area difference between d3
and d4 of ports A and C, however, since d3 > d4.
● If the oil pressure applied to main valve (2) reaches the set
pressure of main valve spring (3), main valve (2) operates and
the oil flows from port A to port B.
WA380-5L 10-1613
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 differ-
ence between d2 and d1.
● Accordingly, oil pressure is applied in the opening 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 total of oil pres-
sure a and the force of valve spring (5), suction valve (1) opens and the oil flows from port B to port A to prevent gen-
eration of negative pressure in port A.
Suction Valve
1. Main poppet
2. Sleeve
3. Spring
Function
● The suction valve prevents generation of negative pressure in the circuit.
Operation
● If negative pressure is generated in port A (lift arm cylinder head)
(If pressure lower than the pressure in tank circuit port B is gener-
ated), main poppet (1) opens because of the area difference between
d1 and d2, then the oil flows from tank port B to cylinder port A.
10-1623 WA380-5L
Cut-off Valve
Function
● The cut-off valve is between the switching pump and work equipment valve. The cut off valve sends oil from the switch-
ing pump to the work equipment valve or drains it to control the work equipment speed according to the working condi-
tion.
● The cut-off valve is operated with the hydraulic system and the electronic governor controller.
● Operating condition of cut-off valve
Cuts off (Drains oil)
Does not operate (Sends oil to work equipment valve)
Above Below
15.7 MPa 15.7 MPa When kick down
Mode
(160 kg/cm²) (160 kg/cm²) switch is ON
{2,277 psi} {2,277 psi}
Hi
Standard specification vehicle S
Lo
Operation
1. When work equipment valve is held

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

(When solenoid valve of hyper-specification vehicle is turned OFF)
A. When work equipment pump pressure is lower than cut-off

pressure
● Similarly to the state where the work equipment valve is
held, oil of the switching pump (oil from steering valve)
pushes up check valve (1) and merges with oil from the
work equipment pump and then flows into the work
equipment valve.
WA380-5L 10-1633
B. When work equipment pump pressure is higher than cut-off

pressure
● If the work equipment pump pressure reaches the cut-off
pressure, cut-off valve (2) is opened by the oil pressure in
chamber a. The oil in chamber b of unload valve (3) is
now drained through chamber c of cut-off valve (2).
● Since the oil in chamber d of unload valve (3) flows
through orifices e and f to chamber b, the oil pressure in
chamber d lowers and unload valve (3) opens.
● Accordingly, the oil from the switching pump is drained.
C. When solenoid valve is turned ON

● Since port SP is connected to the drain circuit, the pilot oil
flows along the arrows.
● Then, differential pressure is generated in unload valve (3)
and it opens unload valve (3).
● Accordingly, the oil from switching pump (the oil from the
steering valve) is always drained, regardless of the level of
the work equipment port pressure.
10-1643 WA380-5L
Work Equipment Control Valve Operation

NEUTRAL Position of Lift Arm and Bucket Spools
Operation
● The oil goes into the port A from the pump and the maximum pressure is being stipulated by the relief valve (1).
● As for the bucket spool (2), a bypass circuit is being opened for holding purpose and the oil 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.
● Although the oil coming from the PPC pump goes into the port L of the PPC valve, as the lift arm lever and the bucket
lever are being set to the holding position, the oil returns to the hydraulic oil tank through the PPC relief valve.
WA380-5L 10-1653
RAISE Position for Lift Arm Spool
Operation
● When the lift arm lever (4) is pulled, the oil flows from the port L to the port N of the PPC valve and, from there, it goes
into the port S of the work equipment control valve.
● Also, oil of the port T flow into the drain circuit passing through the port M. The pressurized oil of the port S pushes the
lift arm spool (3) to the UP position.
● Oil 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).
● After that, oil flow to the port D and further to the cylinder bottom.
● The oil from the PPC valve flows through check valve (13) into port L of the PPC valve. Since the lift arm and bucket
control levers are in the hold position, however, the oil returns through PPC relief valve (12) to the hydraulic tank.
10-1663 WA380-5L
LOWER Position of Lift Arm Spool
Operation
● When the lift arm lever (4) is pushed, the oil flows from the port L to the port M of the PPC valve and, from there, it goes
into the port T of the work equipment control valve.
● Also, oil of the port S flow into the drain circuit. The pressurized oil of the port T pushes the lift 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).
● After that, oil flow to the port E and further to the cylinder head.
● On the other hand, the oil in the cylinder bottom goes into the drain port F through the port D to return to the tank. As the
result, the lift arm goes down.
WA380-5L 10-1673
FLOAT Position of Lift Arm Spool
Operation
● When the lift arm lever is pushed to the FLOAT position, the lift arm spool (3) further moves from the LOWER position
to the FLOAT 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
lift arm spool (3).
● Because of the spool (3), the oil in the bypass circuit flows into the drain circuit and the oil cannot push-open the check
valve.
● Also, since both of the lift arm cylinder RAISE circuit D and the LOWER circuit E are being connected to the drain cir-
cuit, the lift arm comes down by its own weight.
● As the result, while the bucket is contacting the ground surface, the bucket can move up and down when the ground sur-
face is uneven.
10-1683 WA380-5L
DUMP Position for Bucket Spool
Operation
● When the bucket lever (6) is pushed, the pressurized oil form the port L of the PPC valve flows into the port V of the work
equipment control valve through the port Q.
● 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.
● On the other hand, the oil in the bucket cylinder bottom flow into the drain port F through the port G to return to the tank.
As the result, the bucket dumps.
WA380-5L 10-1693
TILT Position for Bucket Spool
Operation
● When the bucket lever (6) is pulled, the pressurized oil form the port L of the PPC valve flows into the port R of the work
equipment control valve through the port P.
● Also, the oil from the port V flows to the drain circuit.
The pressurized oil from the port R moves the 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.
● The oil coming from the check valve (7) flows into the bucket cylinder bottom through the port G.
● On the other hand, the oil in the bucket cylinder head flow into the drain port F through the port H to return to the tank.
As the result, the bucket tilts.
10-1703 WA380-5L
MEMORANDUM
WA380-5L 10-1713
WORK EQUIPMENT PPC VALVE MAINTENANCE STANDARD
WORK EQUIPMENT PPC VALVE
P: From HST charging pump

T: To hydraulic tank
P1: To bucket TILT valve
P2: To bucket DUMP valve
P3: To lift arm RAISE valve
P4: To lift arm LOWER (FLOAT) valve
10-1723 WA380-5L
MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE
1. Spool 9. Ring
2. Metering spring 10. Plate
3. Centering spring 11. Retainer
4. Spring 12. Piston
5. Retainer 13. Body
6. Solenoid 14. Ball
7. Rod 15. Detent spring
8. Lever 16. Retainer
WA380-5L 10-1733
Operation
1. When in NEUTRAL
A. PPC valve for bucket

● Ports PA and PB of the bucket control valve and ports P1
and P2 of the PPC valve are connected through fine
control hole f of spool (1) to drain chamber D.
B. PPC valve for the lift arm

● Ports PA and PB of the lift arm control valve and ports P3
and P4 of the PPC valve are connected through fine
control hole f of spool (1) to the drain chamber D.
10-1743 WA380-5L
2. When in fine control (NEUTRAL Fine control)

● If rod (7) and piston (12) are pushed by lever (8), retainer (11)
is pushed and spool (1) is also pushed down through metering
spring (2).
● Accordingly, fine control hole f is disconnected from drain
chamber D and connected to pump pressure chamber PP
almost simultaneously, and then the pilot oil of the main pump
flows from port P1 to port PB.
● If pressure in port P1 rises, spool (1) is pushed back and fine
control hole f is disconnected from pump pressure chamber PP
and connected to drain chamber D almost simultaneously to
release the pressure in port P1.
● As a result, spool (1) moves up and down to balance the force
of metering spring (2) with the pressure in port P1.
The positional relationship between spool (1) and body (13)
(where fine control hole f is between drain chamber D and
pump pressure chamber PP) does not change until retainer (11)
comes in contact with spool (1).
● Since metering spring (2) is compressed in proportion to the
stroke of the control lever, the pressure in port P1 rises in
proportion to the stroke of the control lever.
● Accordingly, the control valve spool moves to a position at
which the pressure in the chamber PB (equal to the pressure in
port P1) is balanced with the force of the control valve spool
return spring.
3. When in fine control (When control lever is returned)

● If lever (8) begins to return, the force of centering spring (3)
and the pressure in port P1 push up spool (1).
● As a result, fine control hole f is connected to drain chamber D
and the oil in port P1 is released.
● If pressure in port P1 lowers too much, spool (1) is pushed
down by metering spring (2) and the fine control hole f is
disconnected from drain chamber D and connected to pump
pressure chamber PP almost simultaneously. Then, the pump
pressure is applied until the pressure 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.
WA380-5L 10-1753
4. When lever is operated to stroke end

● If lever (8) and rod (7) push down piston (12) and retainer (11)
pushes down spool (1), fine control hole f is disconnected from
drain chamber D and connected to pump pressure chamber PP.
● Accordingly, the pilot oil from the main pump flows through
fine control hole f and port P1 into chamber PB and pushes the
control valve spool.
● The oil returning from chamber PA flows through port P2 and
fine control f' into drain chamber D.
5. When lift arm is FLOATED

● If rod (7) and piston (12) on the LOWER side of port P3 are
pushed down by lever (8), ball (14) touches projection a of rod
(7) in the middle of the stroke (The detent starts to operate).
● If rod (7) is pushed in further, ball (14) pushes up retainer (16)
supported on detent spring (15) and escapes out to go over
projection a of the piston.
● At this time, rod (7) on the opposite side is pushed up by spring
(4) through retainer (11).
● If rod (7) is pushed up and the current is flowing 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.
6. When FLOAT state of lift arm is reset

● Lever (8) is returned from the FLOAT position by pushing it
down with a force greater than the attractive force of solenoid
(6) and retainer (5).
● The FLOAT state also can be reset and the lever can be
returned to the neutral position by turning off the current in
solenoid (6) (demagnetizing the solenoid).
● The lift arm RAISE and bucket TILT operations are performed
similarly to the above.
10-1763 WA380-5L
MEMORANDUM
WA380-5L 10-1773
PPC VALVE (FOR MULTI FUNCTION MONO LEVER) MAINTENANCE STANDARD
PPC VALVE (FOR MULTI FUNCTION MONO LEVER)
P: From PPC accumulator
P1: To bucket TILT valve
P2: To bucket DUMP valve
P3: To lift arm RAISE valve
P4: To lift arm LOWER (FLOAT) valve
10-1783 WA380-5L
MAINTENANCE STANDARD PPC VALVE (FOR MULTI FUNCTION MONO LEVER)
1. Spool 9. Plate
2. Metering spring 10. Retainer
3. Centering spring 11. Piston
4. Spring 12. Body
5. Retainer 13. Ball
6. Solenoid 14. Detent spring
7. Rod 15. Retainer
8. Disc
WA380-5L 10-1793
Operation
1. At NEUTRAL
A. PPC Valve for Bucket

● PA and PB ports of the control valve for bucket and P1
and P2 ports of the PPC valve lead to the drain chamber D
through the fine control hole f of the spool (1).
B. PPC Valve for Lift arm

● PA and PB ports of the control valve for lift arm and P3
and P4 ports of the PPC valve lead to the drain chamber D
through the fine control hole f of the spool (1).
10-1803 WA380-5L
MAINTENANCE STANDARD PPC VALVE (FOR MULTI FUNCTION MONO LEVER)
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 drain chamber
D as a result of downward 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 P4 port to PB port
through fine control 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, spool (1) rises and falls so that pressure at the P4
port balances with force of the metering spring. The positional
relations between retainer (10) and body (12) (fine control hole
f is at the intermediate position between drain chamber D and
the pump pressure chamber PP) do not change until retainer
(10) gets to spool (1).
● Since 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 (same as pressure at the P4 port)
balances with force of the return spring of the control valve
spool.
3. At Fine Control (When the control valve is returned)

● As the disc (8) begins to be returned, the spool (1) is pushed
upward by the force of the centering spring (3) and by the pres-
sure at the P4 port.
● Therefore, the fine control hole f leads to the drain chamber D
and pressured oil is released from the P4 port.
● When pressure at the P4 port drops too much, the spool (1) is
pushed downward with the metering spring (2) and the fine
control hole f is interrupted from the drain chamber D and
leads to the pump pressure chamber PP almost at the same
time. And the pump pressure is supplied through the fine con-
trol hole f until the pressure at the P4 port rises to the pressure
according to the lever position.
● When the control valve spool returns, oil flows in through the
fine control hole f’ of the valve on the non-moving side from
the drain chamber D and is led to the PA chamber through the
P3 port for replenishment.
WA380-5L 10-1813
4. At Full Stroke
● When disc (8) and rod (7) push piston (11) down and retainer
(10) pushes spool (1) down, fine control hole f is interrupted
from drain chamber D and leads to pump pressure chamber PP.
Therefore, pilot pressure oil from the main pump passes
through the fine control hole f and is led to the PB chamber
from P4 port to push the control valve spool.
● The return oil from PA chamber flows to drain chamber D
through P3 port and the fine control hole f.
5. At FLOAT
● When rod (7) and piston (11) on P4 port LOWER side are
pushed downward with disc (8), ball (13) touches rod (7)
protrusion a halfway in the stroke (start of detent operation).
● When rod (7) is pushed down more, the ball pushes retainer
(15) being held with detent spring (14) upward and escapes
outside and then rides over piston protrusion a.
● At this time, rod (7') on the opposite side is pushed up with
spring (4) through retainer (11').
● Also, rod (7') is pushed up further, and when solenoid (6) is
energized, retainer (5) is adsorbed to solenoid (6).
● Therefore, rod (7') remains pushed up and keeps FLOAT even
if the lever is no longer supported by hand.
● At the same time, the control valve also strokes to the FLOAT
position and comes to remain floated.
6. When FLOAT is released

● To return the disc from the FLOAT position, press it down with
a force more than the adsorbing force between the solenoid (6)
and retainer (5).
● Or demagnetize the solenoid (6), and the FLOAT position is
released and the lever returns to the neutral position.
● To raise the lift arm or to tilt the bucket, take same procedures.
10-1823 WA380-5L
MAINTENANCE STANDARD EPC SOLENOID VALVE (If equipped)
EPC SOLENOID VALVE (If equipped)
1. Bucket TILT EPC 7. Spool P: From control pump
2. Bucket DUMP EPC 8. Spring T: To tank
3. Lift arm RAISE EPC 9. Push pin C1: Bucket TILT
4. Lift arm LOWER EPC 10. Coil C2: Bucket DUMP
5. Block 11. Plunger C3: Lift arm RAISE
6. Body 12. Connector C4: Lift arm LOWER
5.88 - 11.7 N•m (0.6 - 1.2 kgf m) 22.5 - 34.3 N•m (2.3 - 3.5 kgf m) 9.8 - 12.7 N•m (.01 - 1.3 kgf m)
a: b: c:
{52 - 104 lbf in} {17 - 25 lbf lb} {87 - 112 lbf in}
WA380-5L 10-1833
EPC SOLENOID VALVE (If equipped) MAINTENANCE STANDARD
Function
● The EPC valve consists of the proportional solenoid section and the
hydraulic valve section.
● On the receiving signal current from the pump controller, the EPC
valve generates an EPC output pressure in proportion to the signal
current and applies it to the control valve.
Operation
1. When the signal current is 0 (Coil is demagnetized)
● While the signal current from the controller is not flowing in
coil (10), coil (10) is demagnetized.
● Accordingly, spool (7) is pressed by spring (8) to the right.
● Port P is closed and the hydraulic oil from the control pump
does not flow in the control valve.
● The oil from the work equipment control valve is drained
through parts C and T.
10-1843 WA380-5L
MAINTENANCE STANDARD EPC SOLENOID VALVE (If equipped)
2. When signal current is small (Coil is magnetized in fine control

mode)
● If a small signal current flows in coil (10), coil (10) is magne-
tized and a thrust to the left is generated in plunger (11).
● Push pin (9) pushes spool (7) to the left and the hydraulic oil
from port P flows in port C.
● The pressure in port C rises. If the total of the force applied to
face a of spool (7) and the load of spring (8) exceeds the thrust
of plunger (11), spool (7) is pushed to the right.
● Ports P and C are disconnected from each other, then port C
and port T are simultaneously connected to each other.
● 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, pressure in the circuit between the EPC valve and
control valve is controlled in proportion to the signal current.
● a: Control valve
3. When signal current is maximum (Coil is magnetized in full

operation.
● If the signal current flows in coil (10), coil (10) is magnetized.
Since the signal current is at maximum, the thrust in plunger
(11) becomes maximum.
● Accordingly, push pin (9) presses spool (7) to the left.
● As a result, the maximum hydraulic oil flows from port P to
port C and pressure in the circuit between the EPC valve and
control valve becomes highest.
● At this time, port T is closed and oil does not flow into the
tank.
WA380-5L 10-1853
SHUT OFF VALVE (If equipped) MAINTENANCE STANDARD
SHUT OFF VALVE (If equipped)
a: 6.86 - 7.85 N•m (0.7 - 0.8 khf m) {61 - 69 lbf in}

b: 47.1 - 53.9 N•m (4.8 - 5.5 khf m) {35 - 40 lbf lb}
A: To EPC valve
P: From pilot circuit pump (Pump from EPC)
Function
● If the signal from the controller is turned on, the shut-off valve is turned on to connect the oil path from the pilot circuit
pump to the EPC valve
10-1863 WA380-5L
MAINTENANCE STANDARD SHUT OFF VALVE (If equipped)
MEMORANDUM
WA380-5L 10-1873
ATTACHMENT PPC VALVE (If equipped) MAINTENANCE STANDARD
ATTACHMENT PPC VALVE (If equipped)
T: To the tank P1: To the service valve

P: From the main pump P2: To the service valve
1. Spool 6. Plate
2. Metering spring 7. Retainer
3. Centering spring 8. Body
4. Piston 9. Filter
5. Lever
a: 13.2 ±1.47 N•m (1.35 ±0.15 kgf m) {117 ±13 lbf in}
b: 10.3 ±1.47 N•m (1.05 ±0.15 kgf m) {91 ±13 lbf in}
10-1883 WA380-5L
MAINTENANCE STANDARD ATTACHMENT PPC VALVE (If equipped)
Unit: mm
Free length
x
Outside diameter
Replace a
38.0 N 30.4 N
damaged or
10 Center ring spring 41.1 X 15.5 28.4 {3.88 kg} — {3.1 kg}
deformed
(137 ozf) (109 ozf)
spring.
Replace a
16.7 N 13.3 N
damaged or
11 Metering spring 22.7 X 8.10 22.0 {1.70 kg} — {1.36 kg}
deformed
(60 ozf) (48 ozf)
spring.
WA380-5L 10-1893
ATTACHMENT PPC VALVE (If equipped) MAINTENANCE STANDARD
Operation
1. At the neutral position
● The ports A and B of the control valve and the ports P1 and P2
of the PPC valve are being connected to the drain chamber D
through the fine control hole of the spool (1).
2. At the fine control position (Neutral fine control)

● When the piston (4) is pushed by the lever (5), the retainer (7)
is pushed and the spool (1) also is pushed trough the metering
spring (2) to move to the lower side.
● When the fine control hole f is shut off from the drain chamber
D by the above, it connects to the pressure chamber PP of the
pump almost simultaneously and the pilot pressure oil of the
main pump is led from the P1 port to the A port through the
fine control hole f.
● When the pressure at the P1 port goes up, the spool (1) is
pushed back and, when the fine control hole f is shut off from
the pressure chamber PP of the pump, it connects to the drain
chamber D almost simultaneously to release the pressure at the
P1 port.
● By the above structure, the spool (1) moves up and down so
that the power of the metering spring (2) and the P1 port pres-
sure may balance.
● Until the retainer (7) hits the spool (1), the positional relation
between the spool (1) and the body (8) (the fine control hole
comes to the intermediate potion between the drain chamber D
and the pressure chamber of the pump) does not change.
● Therefore, since the metering spring (2) is compressed in proportion to the control lever stroke, the pressure at the P1
port also rises in proportion to the control lever stroke.
● By the above, control valve spool moves to the position where pressure of the chamber A (same pressure to P1 port)
balances to the force of control valve spool return spring.
10-1903 WA380-5L
MAINTENANCE STANDARD ATTACHMENT PPC VALVE (If equipped)
3. At the fine control position (When the control lever is returned)

● When lever (5) is started to be returned, by the power of
centering spring (3) and by pressure of the P1 port, spool (1) is
pushed up. By the above, fine control hole f connects to drain
chamber D to release pressurized oil from the P1 port.
● In case pressure of the P1 port drops excessively, spool (1) is
pushed down by metering spring (2) and the fine control hole f
is shut off from drain chamber D, connecting to drain chamber
D almost simultaneously to supply pump pressure PP until the
pressure of P1 port returns to the pressure corresponding to the
lever position.
● When the control valve spool returns, the oil in drain chamber
D flows through fine control hole f' of the valve which is not
moving to be led to B chamber through the P2 port to refill the
oil.
4. At full stroke
● When lever (5) pushes down piston (4) and when the retainer
pushes down spool (1), the fine control hole f is shut off from
drain chamber D, and then it connects to pressure chamber PP
of the pump.
● Therefore, pilot pressure oil coming from the main pump
passes through fine control hole f to be led to chamber A
through P1 port to push the control valve spool.
● The return oil from chamber B passes through the P2 port and
fine control hole f’ to flow into drain chamber D.
WA380-5L 10-1913
COOLING FAN MOTOR MAINTENANCE STANDARD
COOLING FAN MOTOR

Model: LMF28
a: 11.8 - 14.7 N•m (1.1 - 1.5 kgf m) {104 - 130 lbf in}
b: 27 - 34 N•m (2.8 - 3.5 kgf m) {20 - 25 lbf ft}
c: 98 - 123 N•m (10 - 12.5 kgf m) {72 - 91 lbf ft}
P: From fan pump

T: From cooler to tank
TC: To tank
Specifications
Model: LMF28
Capacity: 28.0 cc/rev
Rated speed: 1,400 rpm
Rated flow: 40 liters/min {10.5 gal/min}
Cracking pressure of check valve: 0.044 MPa (0.45 kg/cm²) {6 psi}
10-1923 WA380-5L
MAINTENANCE STANDARD COOLING FAN MOTOR
1. Output shaft 8. End cover

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

Free length
x
Outside diameter
Replace a
3.43 N 2.55 N
damaged or
10 Check valve spring 13.0 x 6.5 7.0 {0.35 kg} — {0.26 kg}
deformed
(12 ozf) (9 ozf)
spring
a Torque Value 44.1 - 63.7 N•m (4.5 - 6.5 kgf m) {33 - 47 lbf ft}
WA380-5L 10-1933
Hydraulic Motor
Function
● This hydraulic motor is a swash-plate, axial piston motor. It converts pressure of the hydraulic oil sent from the hydraulic
pump into revolution.
Principle of Operation
● The oil sent from the hydraulic port flows through the valve plate
(7) into cylinder block (5). This oil can flow on only one side of the
Y-Y line connecting the top dead center and bottom dead center of
the stroke of piston (4).
● The oil sent to one side of cylinder block (5) presses pistons (4) (2
or 3 pieces) and generates force F1 (F1 kg = P kg/cm² x π/4 D2
cm²).
● This force is applied to the thrust plate (2). Because the thrust plate
(2) is fixed to the angle of Eo degrees to the output shaft (1), the
force is divided into components F2 and F3.
● The radial component F3 generates torque against the Y-Y line

connecting the top dead center and bottom dead center
(T = F3 x ri).
● The resultant of this torque [T = Σ (F3 x ri)] rotates the cylinder
block (5) through the piston.
● Since the cylinder block (5) is coupled with the output shaft by
means of spline, the output shaft revolves to transmit the torque.
10-1943 WA380-5L
Suction Valve
Function
● If the fan pump stops, hydraulic oil does not flow into the motor.
Since the motor continues revolution because of the force of inertia,
pressure on the outlet side of the motor rises.
● When oil stops flowing in from inlet port P, the suction valve sucks
in oil on the outlet side and supplies it to port MA where there is
not sufficient oil to prevent cavitation.
Operation
1. When pump is started

● If the hydraulic oil from the pump is supplied to port P and the
pressure on the MA side rises and starting torque is generated
in the motor, the motor starts revolution. The oil on the outlet
MB side of the motor returns through port T to the tank.
2. When pump is stopped

● If the engine is stopped and input revolution of the fan pump
lowers to 0 rpm, hydraulic oil from the pump is not supplied to
port P any more. As hydraulic oil is not supplied to the MA
side of the motor, the motor speed lowers gradually to stop.
● If the motor shaft is revolved by the force of inertia while the
oil flow in port P is reducing, oil in port T on the outlet side is
sent by suction valve to the MA side to prevent cavitation.
WA380-5L 10-1953
Operation of Revolution Direction Changeover Valve
1. When ON-OFF solenoid for changeover valve is turned OFF

● If ON-OFF solenoid (1) for changeover valve is turned "OFF",
hydraulic oil from the pump is blocked by ON-OFF
changeover valve (2) and port C is connected to the tank
circuit.
● Accordingly, changeover spool (3) is pushed by changeover
spool spring (4) to the right to open motor port MA and then
the hydraulic oil flows in to revolve the motor forward
(clockwise).
2. When ON-OFF solenoid for changeover valve is turned ON

● If ON-OFF solenoid (1) for changeover valve is turned "ON",
ON-OFF changeover valve (2) changes to let the hydraulic oil
from the pump flow through port C into spool chamber D.
● Hydraulic oil in chamber D pushes changeover spool (3)
against changeover spool spring (4). As a result, motor port
MB opens and hydraulic oil flows in to revolve the motor in
reverse (counterclockwise).
10-1963 WA380-5L
MEMORANDUM
WA380-5L 10-1973
COOLING FAN MOTOR DRIVE PUMP MAINTENANCE STANDARD
COOLING FAN MOTOR DRIVE PUMP

Model: LPV
10-1983 WA380-5L
MAINTENANCE STANDARD COOLING FAN MOTOR DRIVE PUMP
P: EPC valve main pressure TO: Drain

PS: Suction port of pump PHO: Discharge port of pump
1. Bleeder
Torque Values
a: 7.8 - 9.8 N•m (0.8 - 1.0 kgf m) {69 - 87 lbf in}
b: 11.8 - 14.7 N•m (1.2 - 1.5 kgf m) {104 - 130 lbf in}
c: 9.8 - 12.7 N•m (1.0 - 1.3 kgf m) {87 - 112 lbf in}
d: 68.6 - 83.3 N•m (7.0 - 8.5 kgf m) {51 - 61 lbf ft}
e: 107.8 - 142.2 N•m (11.0 - 14.5 kgf m) {80 - 105 lbf ft}
f: 27.4 - 34.3 N•m (2.8 - 3.5 kgf m) {20 - 25 lbf ft}
g: 59.0 - 74.0 N•m (6.0 - 7.5 kgf m) {44 - 55 lbf ft}
h: 98.0 - 123.0 N•m (10.0 - 12.5 kgf m) {72 - 91 lbf ft}
WA380-5L 10-1993
1. Shaft 6. Piston
2. Oil seal 7. Cylinder block
3. Case 8. Valve plate
4. Rocker cam 9. Spring
5. Shoe 10. Servo piston
Torque Values:
a: 34.3 - 44.1 N•m (3.5 - 4.5 kgf m) {25 - 33 lbf ft}
b: 19.6 - 24.5 N•m (2.0 - 2.5 kgf m) {15 - 18 lbf ft}
10-2003 WA380-5L
Function
● This pump converts the revolution and torque of the engine transmitted from its shaft into hydraulic energy and discharges
hydraulic oil according to the load.
● The discharge amount can be changed by changing the swash plate angle.
Structure
● Cylinder block (7) is supported on shaft (1) through spline a. Shaft (1) is supported on the front and rear bearings.
● The end of piston (6) has a concave sphere, which holds shoe (5) as a spherical bearing.
● Rocker cam (4) has plane A. Shoe (5) is kept pressed against plane A and slide circularly. Rocker cam (4) slides around
ball (11).
● Piston (6) moves axially and relatively in each cylinder of cylinder block (7).
● Cylinder block (7) revolves relatively against valve plate (8), sealing the hydraulic oil. The hydraulic pressure on the
revolving surface of the cylinder block is balanced properly.
● The oil in each cylinder of cylinder block (7) can be drawn and discharged through valve plate (8).
WA380-5L 10-2013
Operation
1. Pump Operation
● Shaft (1) and cylinder block (7) revolve together and shoe (5)
slides on plane A. As rocker cam (4) slants around ball (11) at
this time, angle α between the center line X of rocker cam (4)
and axis of cylinder block (7) changes. Angle α is called the
swash plate angle.
● If the angle between the center line X of rocker cam (4) and the
axis of cylinder block (7) is α, plane A works as a cam for shoe
(5).
● Accordingly, each piston (6) slides inside cylinder block (7)
and makes difference between volumes 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 volume of chamber
E is reduced, the oil is discharged. On the other hand, 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.)
● If center line X of rocker cam (4) is in the direction of the axis
of cylinder block (7) (Swash plate angle = 0), the difference
between volumes E and F in cylinder block (7) is 0 and oil is
not sucked or discharged (The swash plate angle is not reduced
to 0 actually, however).
● In short, swash plate angle α is in proportion to the discharge
of the pump.
10-2023 WA380-5L
2. Discharge Control
● If swash plate angle α is increased, the difference between vol-
umes E and F, or discharge Q, is increased. Swash plate angle
Eo is changed with servo piston (10).
● Servo piston (10) is reciprocated linearly by the signal pressure
of the servo valve. This linear motion is transmitted to rocker
cam (4). Rocker cam (4) supported on ball (11) rocks around
ball (11).
WA380-5L 10-2033
Servo Valve
1. Plug P: EPC valve main pressure
2. Lever T: Drain
3. Retainer PE: Control piston pressure
4. Seat PH: Pump discharge pressure
5. Spool
6. Piston a: 27.4 - 34.3 N•m (2.8 - 3.5 kgf m) {20 - 25 lbf ft}
7. Sleeve b: 5.9 - 8.8 N•m (0.6 - 0.9 kgf m) {52 - 78 lbf in}
10-2043 WA380-5L
Function
● The servo valve controls the relationship between the current input
to the EPC valve and the swash plate angle as shown to the right.
● The output oil of the EPC valve flows in the piston chamber to push
piston (6). Piston (6) pushes spool (5) until it is balanced with the
spring.
● Then, the cut of spool (5) intersects the piston pressure path to the
pump discharge pressure path and the discharge oil is sent to the
servo piston.
● The servo piston is pushed up by the rocker cam. Then, position
feedback is applied and the lever moves in the direction to com-
press the spring.
● If spool (5) is pushed back, pump discharge circuit is disconnected
from the servo piston circuit and the pressure in the servo piston
chamber lowers and the rocker cam returns toward the maximum swash plate angle.
● These processes are repeated to fix the swash plate to the position at which the EPC output pressure is balanced with the
spring force.
● Accordingly, as the EPC output pressure increases or decreases, the swash plate angle narrows or widens.
WA380-5L 10-2053
Safety Valve
Function
● The discharge pressure of the fan pump rises when the engine is
started and when the fan is reversed to stop.
● The safety valve is installed to protect the fan system circuit.
● If the discharge pressure rises above the cracking pressure of the
safety valve, the seat of the safety valve opens to release the oil into
the drain path to prevent generation of abnormally high pressure in
the discharge port.
10-2063 WA380-5L
MEMORANDUM
WA380-5L 10-2073
WORK EQUIPMENT LINKAGE MAINTENANCE STANDARD
WORK EQUIPMENT LINKAGE
1. Bucket 3. Bucket Cylinder 5. Lift Arm
2. Bell Crank 4. Lift Cylinder 6. Bucket Link
10-2083 WA380-5L
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
Unit: mm
Tolerance
size clearance limit
Shaft Hole
Clearance between bushing and -0.036 +0.207 0.156 ~
7 ø 85 1.0
pin at each end of bucket link -0.090 +0.120 0.297
8 ø 85 1.0
pin of joint of lift arm and bucket -0.090 +0.120 0.297
9 ø 95 1.0
pin of joint of lift arm and frame -0.090 +0.120 0.297
Clearance between bushing and
-0.036 +0.207 0.156 ~
10 pin of joint of bucket cylinder bot- ø 110 1.0
-0.090 +0.120 0.297
tom and frame
Clearance between bushing and Replace if pin has
-0.036 +0.207 0.156 ~
11 pin of joint of bucket cylinder rod ø 110 1.0 scuff mark
-0.090 +0.120 0.297
and lever
-0.036 +0.245 0.181 ~
12 pin of joint of bell crank and lift ø 120 1.0
-0.090 +0.145 0.335
arm
-0.036 +0.207 0.156 ~
13 pin of joint of lift cylinder rod and ø 95 1.0
-0.090 +0.120 0.297
lift arm
-0.036 +0.207 0.156 ~
14 pin of joint of lift cylinder bottom ø 95 1.0
-0.090 +0.120 0.297
and frame
Width of boss Width of hinge
Standard
Standard Standard clearance
Tolerance Tolerance
size size
Joint of bucket cylinder and 0
15 110 114 ±1.5 2.5~6.0
frame -0.5
+3 Replace (Insert
16 Joint of lift arm and frame 122 — 129 7.0~10.0
+0 shims on both
+1.5 sides so that
17 Joint of lift arm and bucket 106 — 108 2.0~3.5
0 clearance will be
+2.8 +1.5 1.5 mm or less on
18 Joint of bucket link and bucket 112.5 116 0.7~5.5 each side)
-0.5 0
0 +3
19 Joint of lift cylinder and frame 90 93.5 3.5~7.0
-0.5 +0
Joint of bell crank and bucket +2.8
20 112.5 117 ±1.5 1.7~6.5
link -0.5
Replace
+2
21 Joint of bell crank and lift arm 220 223 ±0.5 0.5~3.5
0
Adjust clearance
Joint of bucket cylinder and bell 0
22 110 117 ±1.5 5.5~9.0 on each side to
crank -0.5
1.5 mm or less
Adjust clearance
23 Joint of lift arm and lift cylinder 100 — 106 ±1.5 4.5~7.5 on each side to
2.0 mm or less
WA380-5L 10-2093
BUCKET MAINTENANCE STANDARD
BUCKET
1. Bucket
2. Bolt-on cutting edge
3. Bucket tooth
Unit:mm
4 Wear of bucket tooth 50 18.5 Replace
Clearance of fitting part of bucket Adjust or

5 Max. 0.5 —
tooth replace
Turn over or
6 Wear or cutting edge 93 —
replace
a 637.0 - 852.6 N•m (67 - 87 kgf m) {470 - 629 lbf ft}
b 618.0 N•m (63 kgf m) {456 lbf ft}
10-2103 WA380-5L
MAINTENANCE STANDARD BUCKET POSITIONER, BOOM KICK-OUT
BUCKET POSITIONER, BOOM KICK-OUT
1. Proximity switch
2. Bucket cylinder rod
3. Lever
4. Plate
Clearance of bucket positioner

5 3 ~ 5 mm (0.118 ~ 0.197 in)
switch
Adjust
Clearance of lift arm kick-out
6 3 ~ 5 mm (0.118 ~ 0.197 in)
switch
14.7 - 19.6 N•m (1.5 3 ~ 5 mm
a - 2.0 kgf m) {11 - 15 (0.118 ~
lbf ft} 0.197 in)
WA380-5L 10-2113
BUCKET POSITIONER, BOOM KICK-OUT MAINTENANCE STANDARD
Bucket Positioner
● The bucket positioner is operated electrically and used to return the
bucket control lever from the TILT position to the HOLD position
to obtain proper digging angle automatically when the bucket is
moved from the DUMP position to any bucket angle before the
TILT position.
● Lever (3) is bolted to bucket cylinder rod (2) and proximity switch
(1) is bolted to the cylinder.
● If the bucket control lever is moved from the DUMP position
toward the TILT position, the bucket cylinder rod moves to the
front side of the vehicle body and lever (3) moves forward, too.
When proximity switch (1) leaves lever (3) at any point, the switch
operates to return the bucket control lever to the neutral position.
Boom Kick-out
● The lift arm kick-out is operated electrically and used to return the
lift arm control lever to the hold position to stop the lift arm when
the lift arm moves to any position before the maximum position.
● Plate (4) is fixed to the lift arm and proximity switch (1) is fixed to
the frame.
If the lift arm control lever is moved from the lower position to the
raise position, the lift arm is raised. When the proximity switch and
plate come near each other at any point, the switch operates to
return the lift arm control lever to the hold position.
10-2123 WA380-5L
Proximity Switch Operation

When Lift Arm Is Raised
● When lift arm (3) is lower than the set position of the lift arm kick-out, plate (2) is not on the detection plane of proximity
switch (1). Lift arm kick-out relay (4) is turned off and the current flows in detent solenoid (6) of PPC valve (5) and the
coil is turned on.
● If lift arm control lever (7) is moved to the raise position, lift arm spool (8) is moved to the position of the arrow and held
at that position by the coil turned on by detent solenoid (6). As a result, lift arm control lever (7) is held at the RAISE
position and lift arm (3) is raised.
WA380-5L 10-2133
● If lift arm (3) is raised to the set position of the kick-out, or if plate (2) reaches the detection plane of proximity switch (1),
proximity switch (1) lights up and lift arm kick-out relay (4) is turned on. As a result, the circuit of detent solenoid (6) of
PPC valve (5) is turned off and the coil is turned off. Accordingly, held lift arm spool (8) receives the reaction force of
spring (9) and returns lift arm control lever (7) to the neutral position.
When part to be detected is apart from detection plane of proximity switch

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

Pilot lamp of proximity switch ON
Lift arm kick-out relay switch circuit ON
PPC valve detent solenoid circuit OFF
PPC valve detent solenoid OFF
10-2143 WA380-5L
When Bucket Is Tilted

● When the bucket is tilted more than the set position of the bucket leveler, lever (2) is on the detection plane of proximity
switch (1) and proximity switch (1) lights up. At this time, bucket positioner relay (4) is turned on and the current flows in
detent solenoid (6) of PPC valve (5) and the coil is turned on.
● If bucket control lever (7) is moved to the TILT position, DUMP spool (8) is moved to the position of the arrow and held
at that position by the coil turned on by detent solenoid (6). As a result, bucket control lever (7) is held at TILT position
and the bucket is tilted.
WA380-5L 10-2153
● If the bucket is tilted to the set position of the bucket leveler, or if lever (2) leaves the detection plane of proximity switch
(1), the lamp of proximity switch (1) goes off and the bucket positioner relay (4) turns off. As a result, the circuit of detent
solenoid (6) of PPC valve (5) is turned off and the coil is turned off.
Held dump spool (8) receives the reaction force of spring (9) and returns bucket control lever (7) to the NEUTRAL
position.
When part to be detected is apart from detection plane of proximity switch

Pilot lamp of proximity switch ON
Bucket positioner relay switch circuit ON
PPC valve detent solenoid circuit ON
PPC valve detent solenoid ON
When part to be detected is on detection plane of proximity switch

Pilot lamp of proximity switch OFF
Bucket positioner relay switch circuit OFF
PPC valve detent solenoid circuit OFF
PPC valve detent solenoid OFF
10-2163 WA380-5L
MEMORANDUM
WA380-5L 10-2173
WORK EQUIPMENT CYLINDER MAINTENANCE STANDARD
WORK EQUIPMENT CYLINDER
Lift Arm Cylinder
Bucket Cylinder
10-2183 WA380-5L
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
Unit: mm
Tolerance
Name of Standard Standard Clearance
cylinder size clearance limit
Shaft Hole
-0.036 +0.257 0.084 ~

Clearance between Lift arm ø 90 0.647
-0.090 +0.048 0.347 Replace
1 piston rod and
-0.036 +0.257 0.084 ~ bushing
bushing Bucket ø 90 0.647
-0.090 +0.048 0.347
-0.036 +0.35 0.236 ~
Clearance between Lift arm ø 95 1.0
-0.090 +0.20 0.440
2 piston rod support
shaft and bushing -0.036 +0.207 0.156 ~
Bucket ø 110 1.0
-0.090 +0.120 0.297 Replace pin
Clearance between -0.036 +0.207 0.156 ~ and bushing
Lift arm ø 95 1.0
cylinder bottom -0.090 +0.120 0.297
3
support shaft and -0.036 +0.207 0.156 ~
bushing Bucket ø 110 1.0
-0.090 +0.120 0.297
Tightening torque of Lift arm 250 ±24.5 N•m (25.5 ±2.5 kgf m) {184 ±18 lbf ft.}
4
cylinder head Bucket 343 ±34.3 N•m (35.0 ±3.5 kgf m) {253 ±25 lbf ft.}
Tightening torque of Lift arm 294 ±29.4 N•m (30.0 ±3.0 kgf m) {217 ± 22 lbf ft.}
5 Retighten
cylinder piston Bucket 294 ±29.4 N•m (30.0 ±3.0 kgf m) {217 ± 22 lbf ft}
Tightening torque of Lift arm 58.9 - 73.6 N•m (6.0 - 7.5 kgf m) {43 - 54 lbf ft.}
6 fixed screw of
cylinder piston Bucket 58.9 - 73.6 N•m (6.0 - 7.5 kgf m) {43 - 54 lbf ft.}
WA380-5L 10-2193
CAB MAINTENANCE STANDARD
CAB
1. Front glass
2. Front windshield wiper
3. Rear windshield wiper
4. Door
5. Air conditioner filter
10-2203 WA380-5L
MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
Air Conditioner Piping
1. Air outlet duct 7. Air compressor

2. Fresh air suction duct 8. Hot water return piping
3. Inside air suction filter 9. Refrigerant piping
4. Inside-Fresh air changeover damper 10. Hot water take-off piping
5. Receiver tank 11. Air conditioner unit
6. Air conditioner condenser 12. Floor duct
WA380-5L 10-2213
MACHINE MONITORING SYSTEM MAINTENANCE STANDARD
MACHINE MONITORING SYSTEM
Outline
● The machine monitor system uses the sensors and other devices installed to various parts of the machine to observe the
condition of the machine. It processes this information swiftly and displays it on the monitor panel to inform the operator
of the condition of the machine.
● The machine monitor is available in two different specifications, the standard specification and load meter specification.
As to the load meter specification, machine monitor functions are being supplemented to carry out the necessary load
meter calculations and relevant indications, with an optional printer for printing the calculated data of the load meter.
● The indications of the machine monitor will be made under the normal mode and under the service mode.
● The machine monitor has ON/OFF output function of automatic preheating which assists with the starting of the engine.
● Normal mode indications are those which are usually being made for ordinary use by machine operators. The description
below applies to the contents of the main indications.
1. Items which are always indicated.

● Meters (Travel speedometer or engine tachometer)
● Gauges (Engine cooling water temperature gauge, torque converter oil temperature gauge, hydraulic oil temperature
gauge and fuel level gauge)
● Pilot indications
● Service meter
A. Load meter specification items which are always indicated

(Items which are indicated in addition to the standard spec. indications).
● Weight calculated by the load meter
● Time
2. Items which will be indicated only when some abnormality occurs.

● Cautions
● Action code indications (When the machine monitor mode changeover switch (>) is depressed and released while the
action code is being indicated, the failure code (6 digits) will be indicated.)
3. When the time comes to change the filter or oil, necessary items for the filter change or oil change will be indicated on the
character display. (Maintenance monitoring functions).
4. In addition, this system is equipped with the functions to indicate the travel distance integrating meter (odometer), to reset
the filter • oil changing time, to select the telephone number inputting language and to adjust the illuminance of the night
time illumination for the machine monitor, by use of the character display and its operation switch, the machine monitor
mode changeover switch.
A. Other functions under the load meter specification.

With the load meter specification system, functions necessary to make changeovers of the load meter indication
mode, to make changeovers of the printer output mode, to execute calibration of the load meter, and to adjust the
clock time are being supplemented in addition to the standard specification functions.
10-2223 WA380-5L
MAINTENANCE STANDARD MACHINE MONITORING SYSTEM
● This machine monitoring system is equipped with the service mode function to facilitate the troubleshooting work for
respective controllers (including the machine monitor itself) on the network. The description below applies to the contents
of the main functions.
1. Electric fault history
This function will indicate the electric fault history data of respective controllers being memorized by the machine
monitor. Also, it can be used to delete the data.
2. Machine fault history

This function will indicate the machine fault history and machine fault history data of respective controllers being
memorized by the machine monitor.
3. Real time monitor

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

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

This function is being used to effect the settings of this machine monitor before shipment from our factory.
● The machine monitoring system consists of the machine monitor proper, buzzer, and switches that are used for inputting
data to the machine monitor proper, sensors, respective controller on the network, and relevant switches and sensors.
WA380-5L 10-2233
Individual Circuit Diagrams of the Machine Monitor

Starting and Lighting Functions
Load Meter
10-2243 WA380-5L
Sensing Functions
WA380-5L 10-2253
Power Supply and Network
10-2263 WA380-5L
Automatic Preheating Function
WA380-5L 10-2273
S-net input S-net signal using items
Work equipment
Machine monitor T/M controller
S-net output controller
Hydraulic oil temperature Fan pump control
Coolant temperature Fan pump control
Torque converter temperature Fan pump control
Emergency steering
Emergency steering operation signal
self-checks
Sensor adjusting mode signal Compensation Compensation

Machine monitor
Monitor mode switch signal Compensation Compensation
Emergency steering
Automatic pre-heating start signal
self-checks
Transmission trigger resetting signal Learning control
Machine model selection Machine model selection Machine model selection
Tire selection Tire selection Tire selection
Tire compensation Tire compensation Tire compensation
Controller specification Communication selection Communication selection
Option specification Option selection Option selection
FNR lever or seesaw switch signal FNR indications
FNR SOL output signal Actual speed stage indications
1, 2, 3 and 4 lever position signals 1 2 3 4 lever positions
1, 2, 3 and 4 solenoid output signal Actual speed stage indications
Transmission hold signal Indicator
Auto-shifting selection signal Indicator
Lock up selection signal Indicator

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

equipment
controller
Joy-stick neutral signal Neutral cut

Work
Buzzer signal Operation buzzer
I/O status signal Real time monitor
10-2283 WA380-5L
MEMORANDUM
WA380-5L 10-2293
MACHINE MONITOR MAINTENANCE STANDARD
MACHINE MONITOR
Speedometer Specifications
1. Torque converter oil temperature gauge 22. Maintenance caution lamp

2. Torque converter oil temperature caution lamp 23. Battery electrolyte level caution lamp
3. Engine coolant temperature gauge 24. Battery charging circuit caution lamp
4. Engine coolant temperature caution lamp 25. Steering oil pressure caution lamp
5. Speedometer or engine tachometer 26. Emergency steering pilot lamp
6. Direction indicator pilot lamp (left) 27. Character display
7. Headlamp high beam pilot lamp 28. Output mode pilot lamp
8. Direction indicator pilot lamp (right) 29. Semi-auto digging pilot lamp
9. Hydraulic oil temperature caution lamp 30. Pre-heating pilot lamp
10. Hydraulic oil temperature gauge 31. Auto greasing pilot lamp
11. Remaining fuel level caution lamp 32. Joy-stick pilot lamp
12. Fuel gauge 33. Directional selector pilot lamp
13. Centralized warning lamps 34. Shift indicator
14. Brake oil pressure caution lamp 35. Auto shift pilot lamp
15. Engine oil pressure caution lamp 36. Lock-up pilot lamp
16. Engine oil level caution lamp 37. Shift hold pilot lamp
17. Engine coolant level caution lamp 38. Shift lever position pilot lamp
18. Air cleaner clogging caution lamp 39. Brake oil level caution lamp
19. Parking brake pilot lamp 40. Transmission oil filter clogging caution lamp
20. Brake oil temperature caution lamp
21. Fan reverse rotation pilot lamp
10-2303 WA380-5L
MAINTENANCE STANDARD MACHINE MONITOR
Load Meter Specification (If Equipped)
1. Torque converter oil temperature gauge 23. Battery electrolyte level caution lamp
2. Torque converter oil temperature caution lamp 24. Battery charging circuit caution lamp
3. Engine coolant temperature gauge 25. Steering oil pressure caution lamp
4. Engine coolant temperature caution lamp 26. Emergency steering pilot lamp
5. Speedometer or engine tachometer 27. Character display
6. Direction indicator pilot lamp (left) 28. Output 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. Directional selector pilot lamp
12. Fuel gauge 34. Shift indicator
13. Centralized warning lamps 35. Auto shift 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 coolant level caution lamp 39. Brake oil level caution lamp
18. Air cleaner clogging caution lamp 40. Transmission oil filter clogging caution lamp
19. Parking brake pilot lamp 41. Bucket load indication
20. Brake oil temperature caution lamp 42. Work indication
21. Fan reverse rotation pilot lamp 43. Addition mode: Total loading weight
22. Maintenance caution lamp Subtraction mode: Indication of remaining quantity to
the targeted load
WA380-5L 10-2313
Table of Monitor Indication Items

The engine is in operation when 2 of the 3 conditions are : Turns on.
established. : Flashes. (1.6sec 50% Duty)
1. Charge is normal. ✩: Intermittent
2. Engine oil pressure is normal. (Cycle 240 msec. ON 80msec. OFF 160msec.)
3. History of occurrence of IGN_C = 24V when the starting U: According to separately set conditions.
key was turned is being registered.
Category No. Items Device Night time Operating Operation status Remarks
dimming conditions Engine stopped Engine in
operation
: Occurs.
Concentrated warning
Individual indications
Message indication
Message indication
—:
Indication color
Warning buzzer
Warning buzzer
Doesn’t
occur.
When an error To be turned on by

Concen- U U U U U U U U Red
occurs respective control-
trated Concentrated
13 LED lers and message
warning warning lamp
Other than above — — — — — — — will be indicated
lamp
simultaneously.
Back When the small
— Back light LED — — — — — — Orange
light lamp turns ON
The status will be
Engine maintained until the
revolution Pointer: starting key is
— — — — — — — —
(speed meter Movement turned OFF when a
specification) communication
error is occurring.
5
Can be
switched "0" will be indi-
Travel speed
over cated in case of
(Speed meter — — — — — — —
between communication
specification)
the engine error.
revolution.
Pointer: Other than below — — — — — — —
11 Movement
Fuel quantity
12 Indicator: 80 Ω or more — — — — Red
LED
Pointer: Other than below — — — — — — — White range:
10 Hydraulic oil Movement Warning: 50° - 110° C
9 temperature Indicator: 110° C or more
B@HANS B@HANS Red
Red range:
LED Problem detected — — — DGH2KX — — — DGH2KX — 110° - 135° C
Other than below — — — — — — — — —

Pointer: Warning: White range:
— — — — — — Red
3 Engine water Movement 102° C or more 50° - 102° C
4 temperature Indicator: Warning: Red range:
LED 105° C or more
B@BCNS B@BCNS Red
102° - 135° C
Problem detected — — — DGE2KX — — — DGE2KX —
Other than below — — — — — — — — —
Pointer: Warning: White range:
Torque — — — — — — Red
1 Movement 120° C or more 50° - 120° C
converter oil
2 Indicator: Warning: Red range:
temperature
LED 130° C or more
B@BCNS B@BCNS Red
120° - 135° C
Problem detected — — — DGE2KX — — — DGE2KX —
10-2323 WA380-5L
Category No. Items Device Night Operating conditions Operation status Remarks
time Engine stopped Engine in
dimming operation
:
Message indication
Message indication
Occurs.
Indication color
Warning buzzer
Warning buzzer
—:
Doesn’t
occur.
Turns on when the

engine revolution is
— Engine speed LED — — — — — — Green X r/min
selected under the ser-
vice mode option
Unit
Set by use of rotary
SW on the monitor
— Travel speed LED — — — — — — Green km/h or MPH
while engine revolu-
tion is not selected
Upper digits: F, N, R
Lower digits: Speed
stages. Indication will Speed stage indica-
Actual
9-segment be maintained until tion will not be
34 gear shift — — — — — — — —
LED the starting key is made while at the
stage
turned OFF when a "N" stage.
combination error
occurrs.
"F" is selected. Neu- Normally (Without
Indicated
F tral safety indication ✩ — — Green Joystick steering
at right
when engine stops and RH F*N*R
N "N" is being selected — — — — Orange signal): DDK6M
When Joystick
"R" is selected. Neu-
Indcated steering is
R tral safety indication ✩ — — Green
selected:
at right
when engine stops DDK1KM
Shift lever 4 Selecting 4th speed — — — — Green When RH F*N*R
38
positions
3 Selecting 3rd speed — — — — Green is selected: DDK-
BKM
2 Selecting 2nd speed — — — — Green Indication will be
maintained until
the starting key is
Speed 1 Selecting 1st speed — — — — Green turned OFF when a
shifting combination error
operations occurrs.
Indication will be
Selecting auto-shift — — — — Green maintained until
the starting key is
35 Auto-shift LED
turned OFF when a
Other than above — — — — — — — combination error
occurrs.
When auto-shift and Indication will be
— — — — Green
shift hold are selected maintained until
the starting key is
37 Shift hold LED
turned OFF when a
Other than above — — — — — — —
combination error
occurrs.
The LED will not
Lock up is operational — — — — — Green turn on in case of
machines without
Torque lock up mecha-
converter nism. Indication
36 LED
lock up will be maintained
(Optional) Other than above — — — — — — — until the starting
key is turned OFF
when a combina-
tion error occurrs.
WA380-5L 10-2333
time Engine stopped Engine in
dimming
operation
:
Message indication
Message indication
Occurs.
Indication color
Warning buzzer
Warning buzzer
—:
Doesn’t
occur.
Interlocked with
When blinker SW is the blinker SW
being turned ON (Hazard lamp)
6 Direction
LED (including the time — — — — Green will also turn ON
8 indicator
when the starting when the starting
key is turned OFF) key is turned
OFF.)
When high beam is
turned ON. When
the headlamp is
7 High beam LED — — — — Blue
turned ON and, also,
when the high beam
turned is ON.
When problem is
Normal voltage — — — — — — —
detected while
the engine is
24
Battery
LED Charging trouble AB00AMA Red stopped, the
charge
alarm continues
Problem detected AB00L6 — — — Red after starting the
engine also.
Normal oil level Low oil level
— — — —
(CLOSE) alarm is sounded
Other
symbols when the starting
Engine oil key is turned
16 LED
quantity Oil level is low B@BAZK ON, and the
— — — — — Red alarm continues
(OPEN)
after the engine
is started.
Normal coolant level
— — — —
Engine (CLOSE)
17 LED
coolant level Coolant level is low
— — B@BCZK — — — B@BCZK Red
(OPEN)
Normal pressure
— — — — — — — —
(OPEN)
Less than specified When problem
pressure (CLOSE) is detected while
& when the engine the engine is
Engine oil revolution is 500 stopped, the
15 LED
pressure rpm or more — — — — B@BAZG Red alarm will
and when 15 sec. or continue after
more has passed starting the
after starting the engine also.
engine
Problem detected — — — DHE4L6 — — — —
10-2343 WA380-5L
time Engine stopped Engine in operation
dimming
Message indication
Message indication
:
Indication color
Warning buzzer
Warning buzzer
Occurs.
—:
Doesn’t
occur.
Normal pressure
— — — — — — —
(CLOSE)
Less than specified
pressure (F) (OPEN)
& when the engine is
started (when detect-
ing time continues) & — — — 2G42ZG Red
when 30 sec. has
passed after starting
the engine (without
detecting time)
Less than specified
pressure (R) (OPEN)
ing time continues) & — — — 2G43ZG Red The alarm will be
Brake oil when 30 sec. has changed over, not
pressure passed after starting being cancelled by
14 LED
Accumulator the engine (without the changeover at
oil pressure detecting time) 30 sec. after starting
engine.
Other Less than specified
symbols pressure (F) (OPEN)
— — Red
ing time continues) &
during 30 sec. after
starting engine (with-
out detecting time)
Less than specified
pressure (F) (OPEN)
— — Red
ing time continues) &
during 30 sec. after
starting engine (with-
out detecting time)
Normal (CLOSE) — — — — — — — When problem is
When sensor 1 is detected while the
Air cleaner being blinded — — — — — AA1ANX Red engine is stopped,
18 LED
clogging (OPEN) the alarm continues
after starting engine
When sensor 1 detects
— — — DHA4KA — — — — also.
a problem
WA380-5L 10-2353
Category No Items Device Night time Operating conditions Operation status Remarks
dimming Engine stopped Engine in operation
: Occurs.
Message indication
Message indication
Indication color
Warning buzzer
Warning buzzer
—:
Doesn’t
occur.
When the S/T oil

pressure is normal — — — — — — —
(OPEN)
When emergency
steering signal is
Emergency input while the
steering engine is stopped,
function is the system
operational determines that
25 LED When the S/T oil self-check of
(when the S/T pressure dropped emergency
oil pressure is (CLOSE) & when — — DDS5L6 Red steering is in
normal) the engine revolution progress. When
(Optional) S/T oil pressure is
is 500rpm or more too low during
self-check of
emergency
steering, the
indicator turns
ON.
When the pump
Emergency operates (for 1 min. DY30N1 DY30N1 Green
Other steering is or more) (OPEN)
symbols normal
When the pump
26 (Emergency LED
operates (for less — — — — Green
steering pump
than 1 min.) (OPEN)
is operational)
(Optional) When the pump
— — — — — — —
stops (CLOSE)
Normal — — — — — — —
2V or less — — — — D61AZK Red
Battery fluid
23 level LED When option not
— — — — — — —
(Optional) installed
Abnormality
— — — DJBAKX — — — DJBAKX —
detected
When the parking Turns ON as the
brake is in operation — — — — Red contact OPENs
when parking
(OPEN) brake is operated.
19 Parking brake LED This indicator is
When the parking
used with parking
brake is released — — — — — — — brake dragging
(CLOSE) prevention LED.
10-2363 WA380-5L
Category No. Items Device Night Operating Operation status Remarks

time conditions Engine stopped Engine in operation
dimming
Message indication
Message indication
:
Indication color
Warning buzzer
Warning buzzer
Occurs.
—:
Doesn’t
occur.
When pre-heating
and after heating
are not made due
to a problem,
Other than below — — — — — — — including output
section failure,
Preheating alarm will not turn
on.
30 (auto LED
preheat) When pre-heating
is being made
— — — — Red
No indication
Communication when
— — — — — — —
error occurrs. communication
error occurrs.
When option not
— — — — — — —
installed
Wheel steering is
— — — — — — —
operational
Joystick is
— — — — Green
Joystick operational
32 changeover LED "Priority to the
(Optional) FNR lever" ✩ 989G00 ✩ 989G00 Green
caution
Other No indication
symbols Communication when
error occurrs
— — — — — — — communication
error occurrs.
Normal — — — — — — —
Less than 30
hours after — — U — — U — Simultaneously,
maintenance the message
Maintenance display indicates
22 LED Less than 30
monitor content. Indicator
hours before lights up 30 sec.
maintenance or — — Ur — — U Red after turning the
maintenance key to ON.
needed.
Power mode = P — — — — Green Indicates the
28 Power mode LED power mode
Other than above — — — — — — — selection.
Fan is in forward
— — — — — — —
rotation
Indicated Indicated Indicates where
The fan is in
Fan reverse — — at right — — at right Orange the fan is in
21 LED reverse rotation
rotation (*) (*) forward/reverse
Fan SW and SOL Indicated Indicated Orange rotation.
are not in — — at right — — at right
conformity (*) (*)
WA380-5L 10-2373
time Engine stopped Engine in operation
dimming
Message indication
Message indication
:
Indication color
Warning buzzer
Warning buzzer
Occurs.
—:
Doesn’t
occur.
When the load meter
5 Load meter U U U U U U U U —
indication is made Calculation
41 (Load meter
LCD When the load meter results shown in
42 specification)
indication is not being — — — — — — — — — figures.
43 (Optional)
made
Other
Symbols Other than below — — — — — — —
Brake oil When the temperature

20 LED B@C7NS B@C7NS Red
temperature rises (Rear)
When an abnormality
— — — DGR2KA — — — DGR2KA —
is detected (Rear)
Priority degrees of buzzer sound: Repetitive () > Intermittent (✩) > Cancellation of operation > Confirmation of receiving
the operation
10-2383 WA380-5L
Setting the Machine Monitor
1. Machine model selecting rotary switch [SW1]

2. Spare rotary switch [SW2]
3. Speedometer/Tachometer indication changeover and tire size selecting rotary switch [SW3]
4. Engine controller installation setting dip switch [SW5-1]
5. Work equipment/joy-stick controller installation setting dip switch [SW5-2]
6. Spare dip switch [SW5-3]
Check 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 the status of respective switches can be checked on the real time monitor under the service mode. Refer to the "Real
time monitoring function".
WA380-5L 10-2393
● When making settings, turn off the power supply and remove the machine monitor in advance. Refer to Chapter "Disas-
sembly 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 flat 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 service mode.
(Refer to the Section "Initial Setting/Adjustment" page 10-241 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 Sec-
tion "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 targeted 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
rotary switch [SW1] to let the system make proper controls for the machine model to which the monitor has been
installed.
★ Adjustment procedures:
Make the setting indicated in the following Table to fit to the machine model to which the monitor has been installed.
Machine model SW1 Remarks
WA380-5L 0
3. When making the setting of the rotary switch [SW2]

★ Make the setting as follows and do not change it.
★ Setting position of the SW2: "0"
4. When making 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.
10-2403 WA380-5L
★ Adjustment procedures:
Make setting according to the following Table to fit to the tire size.
Meter indication changeover SW 3 Tire size Remarks
km/h indication 0 Small diameter tire
MPH indication 1 Small diameter tire U.S. market only
rpm indication 2 Small diameter tire
km/h indication 3 Large diameter tire
MPH indication 4 Large diameter tire U. S. market only
rpm indication 5 Large diameter tire
Tire size WA380-5L

20.5-25 small OPT
23.5-25 large STD
★ 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 equipped with the KOMATSU Common Rail engine (WA380-5L):
"OFF"
6. When making necessary setting for the work equipment/joystick controller (Setting of the dip switch [SW5-2]).
★ When the work equipment/joystick controller is newly installed or removed, make the setting as follows:
● Setting position of SW5-2 in case the controller has been removed: "OFF".
● Setting position of SW5-2 in case the controller has been newly installed: "ON".
7. When making the setting of the dip switch [SW5-3], make the setting as follows and do not change it.
★ Setting position of SW5-3: "OFF".
10. When making the setting of the dip switch [SW6-2]make the setting as follows and do not change it.
★ Setting position of SW6-2: "OFF"
WA380-5L 10-2413
Service Mode Functions
1. Outline.
A. Electric fault history.

★ Use this function to check the electric fault history of
respective controllers being memorized by the machine
monitor. Regarding error codes being used in the electric
fault history, refer to the "Troubleshooting" Chapter.
★ When the fault is repaired and after checking and
confirming that normal operation has been restored, delete
the fault history.
★ Electric 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 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.
B. 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 "Troubleshooting"
Chapter.
★ 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.
10-2423 WA380-5L
C. Real time monitor.

★ Use this function to check the input and output signals
being recognized by respective controllers on the network.
★ The real time monitor indications on the character display
are as follows.
● ***: Indicates the item name.
● #####: Indicates the ID number allocated to each
item.
● %%%* Indicates the data.
★ When a unit is being used, the unit will be shown on the
right-hand side of the data. By designating the ID number
allocated to each item, it is also possible to have optional 2
items indicated at the same time.
★ The indications on the character display when optional 2

items are indicated at the same time are as follows.
● ***: Indicates the designated ID numbers.
● %%%* Indicates the data. When a unit is being used,
the unit will be shown on the right-hand side of the
data.
D. Tuning.
★ Use this function to make initial adjustments of the
sensors, etc. which are being installed to the machine.
★ Use this function when sensors, EPC valves or controllers
have been replaced or supplemented.
E. Changing the filter and oil changing time.

★ This function is being explained in the section "Filter and oil changing time indication on the character display"
in the Chapter "Handling" in the Operation and Maintenance Manual. Use this function when revising changing
time.
F. Settings of the optional equipment and functions.

★ Use this function to indicate the installation status of the optional equipment and to change the settings.
★ Use this function when optional equipment is installed or removed.
G. Settings of the serial number of the machine.

★ Use this function to indicate the serial number of the machine and to make new settings. Use this function for the
purposes of machine controls, etc.
H. Controller initialization.
★ Since this function is for factory use only, do not touch it.
I. Service meter setting.

★ Use this function to make the service meter settings when the machine monitor has been replaced with a new
monitor.
J. Settings for the travel distance integrating meter value.

★ Use this function to make settings for the travel distance integrating meter value of the subject machine when the
machine monitor has been replaced with a new monitor.
WA380-5L 10-2433
2. Operation Methods
10-2443 WA380-5L
ID Input Procedure
1. It is possible to increase or decrease the value at the cursor position by pressing > or < switch. Select a desired value using
these keys, then press key.
2. Repeat step 1 four times to specify the value for each of the four digits. The screen will scroll to screen 1.
3. When an incorrect value is entered, press the switch then enter the correct data starting from the hightest digit.
4. The normal screen can be restored by pressing the switch when the cursor is located at the highest digit.
5. If any switch operation is not done for 60 seconds or more during input of an ID, the screen will be restored to it’s normal
mode.
Screen 1: When normal mode is displayed, it is possible to get the ID input display by pressing the machine monitor mode
selector switch 1 ( ) and mode selector switch 2 (<) simultaneously for at least 5 seconds.
★ When the ID is entered correctly, the screen scrolls to screen 2.
Screen 2: Use (<) switch to scroll to screen .
Use (<) switch to scroll to screen 3.
Use ( ) switch to turn on the normal mode.
Use ( ) switch to display the electrical equipment failure history (refer to troubleshooting).
★ The portion indicated with displays the number of failures being stored.
Screen 3: Use (<) switch to scroll to screen 2.
Use ( ) switch to display the electrical equipment failure history (refer to troubleshooting).
★ The portion indicated with displays the number of failures being stored.
Use ( ) switch to display the real-time monitor screen (refer to troubleshooting).
Use ( ) switch to display the reduced cylinder mode screen (refer to troubleshooting).
Use ( ) switch to display the initial setting screen (refer to troubleshooting).
Use ( ) switch to display the filter/oil replacement time change screen (refer to troubleshooting).
Use ( ) switch to display the Option Set-up screen (refer to troubleshooting).
Use (<) switch to scroll to screen .
Use ( ) switch to display the machine serial number set-up screen (refer to troubleshooting).
Screen : Use (<) switch to scroll to screen 9.
DO NOT touch the ( ) switch.
★ The normal mode can be restored by turning the ignition switch off.
WA380-5L 10-2453
Items Related To The Fault History Of Electric System
1. Selection of displaying and clearing the fault history of electric system.

● The fault history is displayed in the order of occurrence with the new fault first.
● A current fault is displayed prior to the restored ones.
● Pressing the > 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 his-
tory of electric system of the relevant controller.
● Pressing the SW changes the screen to [Select displaying abnormalities in electric system] screen on the first layer.
● Pressing the SW changes the screen to [Clear individually the fault history of electric system] or [Clear the fault
history of electric system] screen.
2. Selection of displaying the fault history of electric system (first

layer).
★ Pressing > SW changes the screen to [Select initializing
function] screen.
★ Pressing < SW changes the screen to [Select displaying fault
history of vehicle system] screen.
★ Pressing SW changes the screen to ordinary or alert screen.
★ Pressing SW changes the screen to [Display abnormalities in
electric system] screen.
10-2463 WA380-5L
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 > SW displays the next older fault.
★ Pressing < SW displays the next newer fault.
★ After the oldest fault in memory was displayed, a screen is display allowing to select clearing the entire fault history
of electric system for the relevant controller.
★ Pressing SW changes the screen to [Select displaying abnormalities in electric system] screen on the first layer.
★ Pressing SW changes the screen to [Clear individual fault history of electric system] or [Clear all fault history of
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 electric 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 sys-
tem] 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 all the fault history is shown, the screen returns to [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 can-
celled.
★ If a fault was cleared, peeps sound (on for 0.1 sec. - off for 0.1 sec. - on for 0.1 sec.) to notify that the operation has
been accepted.
★ If the entire history was cleared, it is considered to have been cleared even if it consisted of only one fault .
WA380-5L 10-2473
Items Related to the Fault History Of Machine System
1. Display of the fault history of vehicle system.

★ Pressing > SW displays the next older fault.
★ Pressing < 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 SW changes the screen to [Select displaying abnormalities in machine system] screen on the first layer.
2. Selection of displaying the fault history of machine system (first

layer)
★ Pressing > SW changes the screen to [Select real-time monitor
functions] screen.
★ Pressing < SW changes the screen to [Select displaying fault
history of machine system] screen.
★ Pressing SW changes the screen to [Display abnormalities in
10-2483 WA380-5L
3. Display of the fault history of vehicle system (second layer).

★ The fault history is displayed in the order of occurrence with the newest fault first.
★ The fault history is displayed in the order of occurrence with the newest fault first.
★ Pressing > SW displays the next newer fault.
★ Pressing < SW displays the next older fault.
★ Pressing SW changes the screen to [Select displaying abnormalities in vehicle system] screen.
WA380-5L 10-2493
Items Related to Maintenance Monitor
1. Selection/display of the maintenance monitor items.

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

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

★ The display is same as that on the maintenance monitor, which is included in the functions open to operators, except
the maintenance caution lamp is turned off.
★ Pressing SW changes the screen to [Select the maintenance monitor functions] screen.
★ Pressing SW changes the screen to [Change the maintenance monitor interval time] screen.
10-2503 WA380-5L
4. Changing the maintenance interval time (third layer).

★ The change of the maintenance interval time can be set to any value within a range 0-9999h.
★ Pressing SW causes change of the time skipped, and changes the screen to [Select maintenance items] screen. In
this case, a beep sounds for one second to notify that the operation is cancelled.
How to Enter Interval Time
1. Enter a number from 0-9 in the cursor position.
2. 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.
3. If the desired number was entered, press the SW to
apply it.
4. The cursor moves to the second highest digit. Repeat the
procedures mentioned in c and d until the last number is
filled in the lowest digit.
5. After the lowest digit was entered, press the SW.
6-1. If the entered value represents the time which can be set,
the screen changes to the confirmation screen.
6-2. Otherwise, the screen does not change to the
confirmation screen but to the [Select the maintenance items] screen. In this case, a peep sounds for one
second to notify that the operation is cancelled.
7. If a wrong number was entered, return to the [Maintenance items] screen with the SW, and do the procedure
from the beginning again.
5. Confirming the changed maintenance interval time (fourth layer).

★ Select YES or NO with the < or > SW.
★ Cursor (_) blinks on the selected item. Pressing the SW
returns the display to the [Select the maintenance items]
screen, with the change applied if YES was selected, or not if
NO was selected:
★ Default of the cursor is on NO (no change) to prevent resetting
by error.
● A current fault cannot be cleared. If it was selected, a peep
sounds for one second to notify that the operation is
cancelled.
★ If the change of the time-setting was completed, peeps sound
(on for 0.1 sec. off for 0.1 sec. on for 0.1 sec.) to notify
that the operation has been accepted.
The maintenance interval time is set when the machine is shipped as in the following table:
Replacement
Items Items shown ID numbers
interval (h)
Engine oil 500 ENG OIL 01
Engine oil filter 500 ENG FILT 02
Fuel filter 500 FUEL FILT 03
Corrosion resistor 1,000 CORR RES 06
Transmission oil 1,000 TM OIL 12
Transmission oil filter 1,000 TM FILT 13
Hydraulic fluid filter 2,000 HYD FILT 04
Hydraulic oil tank breather element 2,000 HYD BREATH 05
Axle oil 2,000 AXLE OIL 15
Hydraulic fluid 2,000 HYD OIL 10
WA380-5L 10-2513
Real-Time Monitoring Function

The real-time monitor shows real-time information which the controller mounted on the vehicle has. This function is used for
checking and adjustment, diagnosis of faults of the vehicle and other purposes.
The real-time monitor shows the items and their data, classified by the controllers which have information. It shows them in
two ways: the ordinary display, and the 2-item display where two data items are shown simultaneously.
Operation
1. Press the 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.
10-2523 WA380-5L
4. Press the SW, and the [Select the information displayed on monitor panel] screen appears. Pressing the < or > SW dis-
play 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 SW, while each selection screen is shown, displays [One-item display] screen or [Select information on 2-item
display] screen.
***:. . . . . . . . . . . . . . . . . . Shows items.
%%%%%:. . . . . . . . . . . Shows data and unit (SI system)
$$$$:. . . . . . . . . . . . . . . . . Shows ID.
In the case of 1-item display, pressing the < and > SW changes the
items shown in turn, displaying the information each controller has.
How to Enter an ID
★ After the screen was changed from another, “00000” as shown.
★ Enter a number from 0 to 9 in the cursor position.
★ The cursor is at the highest digit first. Each time < or > SW is
pressed, the number changes by 1 within a range 0-9. If the desired
number was entered, then press SW.
★ The cursor moves to the second highest digit. Repeat procedures
mentioned above until the last number is filled in the lowest digit.
★ If the lowest digit was entered, then press SW, and the screen
changes to displaying/selecting the second item. Alternately, press
SW returns the screen to displaying/selecting two items.
In the 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. The case of 1-item display, pressing < and > SW changes the items shown in turn, displaying information each controller
has.
WA380-5L 10-2533
Real-Time Monitoring Items

Item ID Real-time monitoring item Item displayed Display unit Displayed range Component Terminal No. Remarks
detected
All the items are shown even if some Abridged due to SI unit A value out of
of them are not equipped depending limitation of number system so the range
on models and options. of letters. long as the displayed is
values have shown as the
units lowest (highest)
value in the
range.
Monitor panel controller
20200 Part No. of monitor’s ROM MONITOR ROM --- --- Monitor --- Shows the part No.
of monitor-panel’s
ROM
01001 Engine speed ENG SPEED 1rpm 0~3000 Transmission L62-10
40000 Travel speed SPEED km/h 0~50 Transmission L62-20
04202 Fuel level FUEL SENSOR 1% 0~100 Monitor L55-1
04401 Hydraulic oil temperature HYD TEMP 1° C 24~131 Monitor L55-7 Any temperature
lower than 24°C is
displayed as 24°C
04103 Coolant temperature COOLANT TEMP 1° C 24/131 Monitor L55-8 Any temperature
colder than 24°C is
displayed as 24°C
04104 Coolant temperature (low) COOLANT Lo 1° C -31/91 Monitor L55-3 Any temperature
colder than -31°C
is displayed as
-31°C
40100 Torque converter oil TC OIL TEMP 1° C 24/131 Monitor L55-2 Any temperature
temperature lower than 24°C is
displayed as 24°C
04302 Charging level of alternator ALTERNATOR R 0.1V 0.0/30.0 Monitor L52-18
40200 Voltage of small lamps SMALL LAMP 0.1V 0.0/30.0 Monitor L53-12
40300 Battery fluid level A BATTERY A2V 0.1V 0.0/30.0 Monitor L55-5
40301 Battery fluid level B BATTERY B2V 0.1V 0.0/30.0 Monitor L55-12
06001 Lift arm angle BOOM ANG 1° -41/46 Monitor L55-10
40400 Lift arm bottom pressure BTM PRESS 0.01MPa 0.00/50.00 Monitor L55-9
40500 Lift arm rod pressure ROD PRESS 0.01MPa 0.00/50.00 Monitor L55-4
40600 Calibration pressure CAL PRESS 0.01MPa 0.00/50.00 Monitor Calculated
value
40700 Calculated pressure MES PRESS 0.01MPa 0.00/50.00 Monitor Calculated
value
40800 Calculated load weight MES LOAD 0.01t 0.00/50.00 Monitor Calculated
value
30802 Rotary switch position SW1,SW2,SW3 --- 0-F Monitor Switch on the
rear
30904 Dip switch position SW5-1,SW5-2 --- OFF.ON Monitor Switch on the
rear
30905 Dip switch position SW5-3,SW5-4 OFF.ON Monitor Switch on the
rear
rear
rear
40900 Input signal D_IN_0-7 D-IN--0-----7 --- 10101010 Monitor See
separate
sheet
40901 Input signal D_IN_8-15 D-IN--8-----15 --- 10101010 Monitor See
separate
sheet
40902 Input signal D_IN_16-23 D-IN-16-----23 --- 10101010 Monitor See
separate
sheet
separate
sheet
separate
sheet
10-2543 WA380-5L
Item ID Real-time monitoring item Item displayed Display unit Displayed Component Terminal No. Remarks
range detected
Because of options, all items are Shortened because SI unit A value out of
listed, regardless if your model is of limited letters. system so the range
equipped with the item or not. long as the displayed is
units lowest
(highest) value
in the range.
41100 Pressure of left-hand brake LH BRAKE 0.1MPa 0.00/50.00 Transmission L61-19
41200 Transmission cut-off pressure CUT OFF 0.01MPa 0.00/50.00 Transmission Calculated
value
41300 Number of times of kick-down K/D TIMES --- --- Transmission Calculated
value
41400 Average cycle time CYCLE TIME 1 SEC --- Transmission Calculated
value
31608 F ECMV current ECMV F 1mA 0/1000 Transmission L63-5
31606 R ECMV current ECMV R 1mA 0/1000 Transmission L63-15
31602 1st-clutch ECMV current ECMV 1 1mA 0/1000 Transmission L63-25
31603 2nd-clutch ECMV current ECMV 2 1mA 0/1000 Transmission L63-6
31604 3rd-clutch ECMV current ECMV 3 1mA 0/1000 Transmission L63-16
31605 4th-clutch ECMV current ECMV 4 1mA 0/1000 Transmission L63-26
31609 L/C ECMV current ECMV LU 1mA 0/1000 Transmission L63-35
41400 Fan pump EPC current FAN EPC 1mA 0/1000 Transmission L63-36
41500 Transmission oil temperature ECMV OIL TEMP 1° C 24/131 Transmission L61-9
41600 Selection of engine mode ENGINE MODE --- P/N Transmission L61-6
41700 Selection of shift mode SHIFT MODE --- H/M/L Transmission Calculated
value
41808 F fill time FILL TIME F 10msec 0/2550 Transmission Calculated
value
41806 R fill time FILL TIME R 10msec 0/2550 Transmission Calculated
value
41802 1st-gear fill time FILL TIME 1 10msec 0/2550 Transmission Calculated
value
41803 2nd-gear fill time FILL TIME 2 10msec 0/2550 Transmission Calculated
value
41804 3rd-gear fill time FILL TIME 3 10msec 0/2550 Transmission Calculated
value
41805 4th-gear fill time FILL TIME 4 10msec 0/2550 Transmission Calculated
value
31508 F fill time FILL SW(F) --- 0/1 (Normal/ Transmission Calculated
abnormal) value
31506 R fill time FILL SW(R) --- 0/1 (Normal/ Transmission Calculated
abnormal) value
31502 1st-clutch fill time FILL SW(1) --- 0/1 (Normal/ Transmission Calculated
abnormal) value
31503 2nd-clutch fill time FILL SW(2) --- 0/1 (Normal/ Transmission Calculated
abnormal) value
31504 3rd-clutch fill time FILL SW(3) --- 0/1 (Normal/ Transmission Calculated
abnormal) value
31505 4th-gear fill time FILL SW(4) --- 0/1 (Normal/ Transmission Calculated
abnormal) value
40905 Input signal D_IN_0-7 D-IN--0------7 --- 10101010 Transmission See
separate
sheet
40906 Input signal D_IN_8-15 D-IN--8-----15 --- 10101010 Transmission See
separate
sheet
40907 Input signal D_IN_16-23 D-IN-16-----23 --- 10101010 Transmission See
separate
sheet
WA380-5L 10-2553
Item ID Real-time monitoring item Item displayed Display unit Displayed Component Terminal No. Remarks
range detected
Because of options, all items are Shortened because SI unit A value out of
listed, regardless if your model is of limited letters. system so the range
equipped with the item or not. long as the displayed is
units lowest
(highest) value
in the range.
Transmission controller (continued)
40908 Input signal D_IN_24-31 D-IN-24-----31 --- 10101010 Transmission See

separate
sheet
30202 Rear brake fluid temperature R BRAKE OIL 1° C 24/131 Transmission L61-20
40915 Output signal D_OUT_0-6 D-OUT-0------6 --- 101010 Transmission See
separate
sheet
40914 Output signal D_OUT_0-5 D-OUT-0------5 --- 101010 Transmission See
separate
Work machine controller
20202 Part No. of work equipment BOOM ROM --- --- Work --- Shows part No. of
controller’s ROM equipment ROM
41904 R.H. Joystick EPC current RH Joystick EPC 1mA 0/1000 Work L73-26
equipment
41905 L.H. Joystick EPC current LH Joystick EPC 1mA 0/1000 Work L73-36
equipment
41906 3rd valve 1 ECMV current 3RD EPC1 1mA 0/1000 Work L73-25
equipment
41907 3rd valve 2 ECMV current 3RD EPC2 1mA 0/1000 Work L73-35
equipment
42004 Lever potentiometer-voltage Joystick POT1 0.01V 0.00/5.00 Work L71-9
Joystick 1 equipment
42005 Lever potentiometer-voltage Joystick POT2 0.01V 0.00/5.00 Work L71-3
Joystick 2 equipment
01003 Engine speed ENG SPEED 1rpm 0/3000 Work L72-10
equipment
40001 Travel speed SPEED 1km/h 0/50 Work L72-20
equipment
40910 Input signal D_IN_0-7 D-IN--0------7 --- 10101010 Work See
equipment separate
sheet
40911 Input signal D_IN_8-15 D-IN--8-----15 --- 10101010 Work See
equipment separate
sheet
40912 Input signal D_IN_16-23 D-IN-16-----23 --- 10101010 Work See
equipment separate
sheet
40913 Input signal D_IN_24-31 D-IN-24-----31 --- 10101010 Work See
equipment separate
sheet
40917 Output signal D_IN_0-6 D-OUT-0------6 --- 1010101 Work See
equipment separate
sheet
40916 Output signal SOL/0-0-5 SOL/0-0------5 --- 101010 Work See
equipment separate
sheet
10-2563 WA380-5L
How to read input signals (D-IN--0------7)
★ The signal input into controller by ON/OFF switch is shown as [D-IN-*] (* represents input No.).
★ The display shows it as follows:
***:...........................................Shows items.
%%%%%:.............................Shows data and unit (SI system)
$$$$:.........................................Shows ID No.
If input status [0] or [1] is shown, Output OFF or ON is displayed,

respectively.
How to read output signals (D-OUT-0------7)
★ The signal output from controller by ON/OFF switch is shown as [D-OUT-*] (* represents output No.).
★ The display shows it as follows:
***:...........................................Shows items.
%%%%%:.............................Shows data and unit (SI system)
$$$$:.........................................Shows ID No.
If input status [0] or [1] is shown, Output OFF or ON is displayed,
respectively.
WA380-5L 10-2573
Connector
I/O signal Displayed item Pin No. ON/OFF logic
No.
Machine Monitor
D-IN-0 Head lamp L52 1 Head lamp turned ON=(24V)/OFF (OPEN)
D-IN-1 No item L52 10 ON (24V)/OFF (OPEN)
D-IN-2 IGN_C L52 2 Starter activated=(24V)/OFF (OPEN)
D-IN-4 Auto-grease A (if equipped) L52 3 Tank empty or abnormal= (24V)/OFF (OPEN)
D-IN-5 Auto-grease B (if equipped) L52 12 Operating or abnormal= (24V)/OFF (OPEN)
D-IN-12 Blinker R L52 7 Right blinker=ON (24V)/OFF (OPEN)
D-IN-13 Blinker L L52 16 Left blinker=ON (24V)/OFF (OPEN)
D-IN-14 Input from the SW L52 8 Switch pressed=ON (24V)/OFF (OPEN)
D-IN-15 Input from the SW L52 17 Switch pressed=ON (24V)/OFF (OPEN)
D-IN-16 Brake oil pressure (front) L53 1 Pressure normal=ON (GND)/OFF (OPEN)
D-IN-17 Brake oil pressure (rear) L53 7 Pressure normal=ON (GND)/OFF (OPEN)
D-IN-18 No item L53 2 ON (GND)/OFF (OPEN)
D-IN-20 Clogged air cleaner L53 3 No clogging=ON (GND)/OFF (OPEN)
D-IN-26 Parking brake L54 1 P/B in operation=ON (GND)/OFF (OPEN)
D-IN-27 Coolant level L54 10 Coolant level normal=ON (GND)/OFF (OPEN)
D-IN-28 Engine oil pressure L54 2 Dropped pressure=ON (GND)/OFF (OPEN)
D-IN-29 Engine oil level L54 11 Oil level normal=ON (GND)/OFF (OPEN)
(Emergency steering) motor normal (Emergency steering) motor activated=ON
D-IN-30 L54 3
(if equipped) (GND)/OFF (OPEN)
D-IN-31 No item --- --- ---
Load meter subtotal switch
D-IN-32 L54 4 Switch pressed=ON (GND)/OFF (OPEN)
(if equipped)
Load meter cancel switch
(if equipped)
D-IN-34 High-beam switch L54 5 High-beam=ON (GND)/OFF (OPEN)
D-IN-36 Service function 2 L54 6 ON (GND)/OFF (OPEN)
D-IN-37 Input from > SW L54 15 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-38 Input from < SW L54 7 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-39 Dropped steering pressure L54 6 Oil pressure normal=ON (GND)/OFF (OPEN)
10-2583 WA380-5L
Connector
I/O signal Displayed item Pin No. ON/OFF logic
No.
Transmission Controller
D-IN-0 Seering pressure switch (N.O.) L61 23 Pressure normal ON=(OPEN)/OFF (GND)
D-IN-1 Steering pressure switch (N.O.) L61 17 Pressure normal ON=(GND)/OFF (GND)
D-IN-2 Transmission cut-off switch L61 11 Switched pressed=ON (GND)/OFF (OPEN)
D-IN-3 Transmission cut-off set switch L61 5 Switched pressed=ON (GND)/OFF (OPEN)
E.C.S.S. change-over switch
D-IN-4 L61 24 Switched pressed=ON (GND)/OFF (OPEN)
(if equipped)
Lock-up change-over switch
D-IN-5 L61 18 Switched pressed=ON (GND)/OFF (OPEN)
(if equipped)
D-IN-6 Kick-down switch L61 12 Switched pressed=ON (GND)/OFF (OPEN)
D-IN-7 Engine power mode E L61 6 P mode=ON (GND)/OFF (OPEN)
D-IN-8 Shift range 1st L63 10 1st gear=ON (24V)/OFF (OPEN)
D-IN-9 Shift range 2nd L63 20 2nd gear=ON (24V)/OFF (OPEN)
D-IN-10 Shift range 3rd L63 30 3rd gear=ON (24V)/OFF (OPEN)
D-IN-11 Shift range 4th L63 40 4th gear=ON (24V)/OFF (OPEN)
D-IN-12 Joystick shift up (if equipped) L63 9 Switch pressed=ON (24V)/OFF (OPEN)
D-IN-13 Joystick shift down (if equipped) L63 19 Switch pressed=ON (24V)/OFF (OPEN)
Electric (emergency steering)
manual switch (if equipped)
D-IN-15 IGN_C (AFTER N SAFETY) L63 39 Starter activated=ON (24V)/OFF (OPEN)
Right FNR (Joystick) change-over switch
D-IN-16 L62 35 Switch pressed=ON (24V)/OFF (OPEN)
(if equipped)
Right seesaw and Joystick F
D-IN-17 L62 25 Forward=ON (24V)/OFF (OPEN)
(if equipped)
Right seesaw and Joystick N
D-IN-18 L62 15 Neutral=ON (24V)/OFF (OPEN)
(if equipped)
Right seesaw and Joystick R
D-IN-19 L62 5 Reverse=ON (24V)/OFF (OPEN)
(if equipped)
D-IN-20 Direction lever F L62 36 Forward=ON (24V)/OFF (OPEN)
D-IN-21 Direction lever N L62 26 Neutral=ON (24V)/OFF (OPEN)
D-IN-22 Direction lever R L62 16 Reverse=ON (24V)/OFF (OPEN)
D-IN-23 Neutralizer (Parking Brake) signal L62 6 Parking switch ON=(24V)/OFF (OPEN)
D-IN-24 E-POC FILL F L62 37 Fill switch ON=(GND)/OFF (OPEN)
D-IN-25 E-POC FILL R L62 27 Fill switch ON=(GND)/OFF (OPEN)
D-IN-26 E-POC FILL 1st L62 17 Fill switch ON=(GND)/OFF (OPEN)
D-IN-27 E-POC FILL 2nd L62 7 Fill switch ON=(GND)/OFF (OPEN)
D-IN-28 E-POC FILL 3rd L62 13 Fill switch ON=(GND)/OFF (OPEN)
D-IN-29 E-POC FILL 4th L62 3 Fill switch ON=(GND)/OFF (OPEN)
D-IN-30 E-POC FILL Lock-up L62 2 Fill switch ON=(GND)/OFF (OPEN)
D-IN-31 Shift hold switch L62 38 Switch pressed=ON (GND)/OFF (OPEN)
Electric (emergency steering) relay
SOL/0-0 L63 7 Output ON (24V)/OFF (OPEN)
(if equipped)
SOL/0-1 E.C.S.S. relay L63 17 Output ON (24V)/OFF (OPEN)
SOL/0-2 Switch pump cut-off L63 27 Output ON (24V)/OFF (OPEN)
SOL/0-3 Neutral output L63 37 Output ON (24V)/OFF (OPEN)
SOL/0-4 Fan pump reverse SOL L63 28 Output ON (24V)/OFF (OPEN)
SOL/0-5 Fan pump neutral SOL L63 38 Output ON (24V)/OFF (OPEN)
D-OUT-0 Back lamp relay L63 4 Output ON (24V)/OFF (OPEN)
D-OUT-1 Transmission cut-off indicator L63 8 Output ON (24V)/OFF (OPEN)
WA380-5L 10-2593
Connector Pin
I/O signal Displayed item ON/OFF logic
No. No.
Working equipment controller (if equipped)
D-IN-0 Joystick ON/OFF change-over switch L71 23 Joystick (right FNR) selection=ON (24V)/OFF
(OPEN)
D-IN-1 Work equipment safety-lock lever L71 17 Operating position=ON(24V)/
switch Obstruction position=OFF(OPEN)
D-IN-8 Joystick speed Hi/Lo change-over L73 10 Joystick Hi speed selection=ON (GND)/OFF
switch (OPEN)
D-IN-9 Bucket proximity switch (horizontal) L73 20 Horizontal position=ON (GND)/OFF (OPEN)
D-IN-10 Bucket full-stroke switch L73 30 Stroke end position=ON (GND)/OFF (OPEN)
D-IN-12 Semi-auto digging hard switch L73 9 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-13 Semi-auto digging soft switch L73 19 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-28 Remote positioner raise set switch L72 13 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-29 Remote positioner lower set switch L72 3 Switch pressed=ON (GND)/OFF (OPEN)
D-IN-30 Remote positioner raise selection L72 2 Switch pressed=ON (GND)/OFF (OPEN)
switch
D-IN-31 Remote positioner lower selection L72 38 Switch pressed=ON (GND)/OFF (OPEN)
switch
SOL/0-0 Joystick EPC cut relay L73 7 Output ON (24V)/OFF (GND)
10-2603 WA380-5L
Connector Pin
I/O signal Displayed item ON/OFF logic
No. No.
SOL/0-1 Detent lift arm RAISE L73 17 Output ON (24V)/OFF (GND)
SOL/0-2 Detent lift arm FLOATING L73 27 Output ON (24V)/OFF (GND)
SOL/0-3 Detent TILT L73 37 Output ON (24V)/OFF (GND)
SOL/0-4 Work equipment lock SOL L73 28 Output ON (24V)/OFF (GND)
SOL/0-5 No item L73 38 Output ON (24V)/OFF (GND)
D-OUT-1 Remote positioner raise lamp L73 8 Output ON (24V)/OFF (GND)
D-OUT-2 Remote positioner lower lamp L73 18 Output ON (24V)/OFF (GND)
WA380-5L 10-2613
(For Reference) Check Using the Real-Time Monitor
Example: Measurement of engine speed

● Measure the engine speed under the following conditions:
● Temperature of coolant: within operation range
● Temperature of hydraulic oil: 45°- 55° C (113°- 131° F)
● Temperature of power train oil: 70°- 90° C (158°- 194° F)
Use the real-time monitor first to check these conditions.

Conditions Real-time monitor item Component ID
Temperature of coolant COOLANT TEMP Machine monitor 04103
Temperature of hydraulic oil HYD TEMP Machine monitor 04401
Temperature of power train oil TC OIL TEMP Machine monitor 40100
After checking those conditions on the real-time monitor, check the engine speed
Conditions Real-time monitor item Component ID
Engine speed ENG SPEED Machine monitor 01001
(For Reference) Troubleshooting Using the Real-Time Monitor
Example: Cannot succeed in re-setting the Transmission cut-off position.

● Possible causes of disabled cut-off of Transmission include the following:
● Abnormal cut-off selection switch
● Abnormal cut-off position set switch
● Abnormal left brake pressure sensor
● Abnormal Transmission controller
Check the Transmission controller first to see if any abnormality was found and to see if an error was issued.
If no error was detected, check the status of input signals on the real-time monitor.
1. Check the cut-off selection switch

Item Real-time monitor item Pin position ID
D-IN-2 D-IN--0------7 L61-11 40905
40905:**0****
● The third digit is [0] if the Transmission cut-off selection switch has recognized itself as not ON.
D-IN-2 D-IN--0------7 L61-11 40905
40905:**1****
★ On the contrary, the digit is [1] if the switch has recognized itself as ON.
★ If [0] continues after you operated the switch, you can consider that the cut-off selection switch system is abnormal.
10-2623 WA380-5L
2. Check the cut-off set switch

D-IN-3 D-IN--0------7 L61-11 40905
40905:***0***
● The fourth digit is [0] if the Transmission cut-off set switch has recognized itself as not ON.
D-IN-3 D-IN--0------7 L61-11 40905
40905:***1***
★ On the contrary, the digit is [1] if the switch has recognized itself as ON.
★ If [0] continues after you operated the switch, you can consider that the cut-off set switch is abnormal.
3. Check the left-hand brake pressure sensor

● Check the left-hand brake pressure sensor with the engine kept operating.
Left brake pressure LH BRAKE L61-19 41100
41100:*.**MPa
● If the pressure does not change after you stepped on/released the cut-off brake, you can consider that the sensor sys-
tem is abnormal.
● If you stepped on the left-hand brake fully, about 5.00Mpa {51kg/cm²} (725 psi)of pressure should be shown.
● If you released the brake, a value less than 0.5Mpa {5kg/cm²} (73 psi) 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} (73 psi) should be shown.
4. Check the cut-off pressure set value

★ Check the set value of the pressure at which Transmission is cut off.
A. Set the cut-off position at a desired pressure by stepping on the cut-off brake, with the left-hand brake pressure sensor
kept displaying.
● Here, it is set at a pressure 1.5Mpa {15kg/cm²} (218 psi).
Left brake pressure LH BRAKE L61-19 41100
41100: 1.50MPa
● Set the cut-off position ([1.50] was selected arbitrarily).
● Setting cut-off causes the pressure taken into memory when the set switch being pressed was released.
B. Check the cut-off pressure just set on the real-time monitor.

Transmission cut-off pressure CUT OFF Calculated value 41200
41200: 1.50MPa
● The result is accepted if the value is substantially the same with the value previously set.
● Although, if the cut-off pressure has been set to less than 0.49Mpa {5kg/cm²} (71 psi), 0.49Mpa{5kg/cm²}
(71 psi) shall be adopted as the set value; if the cut-off pressure has been set to more than 4.5Mpa {45kg/cm²}
(71 psi), 4.5Mpa{45kg/cm²} shall be adopted as the set value.
WA380-5L 10-2633
Load Meter Function (If equipped)
1. Outline.
For the load meter, there are addition mode, subtraction mode, data display mode, calibration mode and calculation stop
mode, and each mode can be selected with the monitor panel mode selector switch. If a printer is connected to the load
meter, it is possible to print out measurement data.
2. Operating Method.
10-2643 WA380-5L
3. Weight Calculation.
Since the pressure sensor (A) mounted on the bottom side of the lift
cylinder and the pressure sensor (B) mounted on the head side
detect operating pressures (P) of the lift arm, and also the lift arm
angle sensor (C) calculates positions of the center of gravity, the
load meter calculates weight (W) of load.
Weight is calculated from differential pressure (C) between the

standard value (A) of lift arm pressure in unloaded state memorized
(and corrected by calibration) and the calculated value (B) of lift
arm pressure in the loaded state. Also, it is designed for improving
accuracy that weights are detected and calculated while the boom is
being lifted.
However, the real measured value (D) of lift arm pressure has
characteristics shown in the figure to the right because operations
of the tires and work equipment cause spring effect to the machine.
From the really measured value (D) in lift arm lifting operation,
value (B) is calculated according to the calculation method below.
★ Pressure fluctuates greatly and no fixed value can be measured
for 0.5 seconds after the lift arm lifting start (E) due to the shift
from the static state to an dynamic state. So, pressure cannot be
used for calculation.
★ Since the machine spring effect has periodic cycle of
approximately one second, calculated value (B) is calculated as
a mean value of every second from the lift arm lifting start to
the stop.
WA380-5L 10-2653
Judgment of Lift Arm Lifting Start

When all the following conditions are satisfied, the lift arm is judged to have started moving, and weight calculation
starts.
The lift arm angle ranges from -10° to -30°. (The range between below horizontal and above touching
Condition 1
the ground)
The lift arm angle increases more than 0.1° in 0.1 second. (The lift arm started moving upward at a fixed
Condition 2 speed.)
Judgment of Stop of Lift Arm Lifting

When any of the following conditions is satisfied, the lift arm is judged to have stopped, and a weight calculation ends.
The lift arm angle incseases less than 0.5° in 0.5 seconds. (The lift arm lifting speed reduced below fixed
Condition 1 value.)
Condition 2 The lift arm moves downward. (When lift arm lowering operation is done, the calculation is finished.)
Condition 3 The lift arm angle became up to +20° (The calculation stops at high position.)
The lift arm lifting speed changed suddenly. (The speed reduced below 70% in comparison with the
Condition 4 previous angular velocity.)
Condition 5 The calculation was performed for 7 times.
Display of Calculated Weight

Calculated weight is displayed as the average value of each calculated values.
Calculation Calculating
Weight calculating and displaying methods
count time (sec.)
1 time only 1.5 - 2.5 Weight is displayed by only one calculation. In this case, the weight 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.
10-2663 WA380-5L
4. Subtraction and Addition Modes

Addition Mode
At this mode, bucket load is added at each loading, and added value
of loads is displayed, this mode is used to grasp total workloads.
● When the addition mode is selected, "TOTAL LOADED" (1) is
displayed, and each calculated bucket load (3) is added to the
total load display (2).
● Weights of any five kinds of object materials can be
independently accumulated and displayed. For selection of
object materials, the five kinds from A to E can be selected and
set in the display of work object materials (4).
● Values up to 9999t are displayed in the total load display (2)
unless data are cleared with the load meter sub-total switch.
Values up to 999.9t are displayed in units of 0.1t, and when the
value is over 1000t, the decimal point disappears and values
are displayed in units of 1t.
★ For details of total load display, see the paragraph of "Total Load Display and Residual Quantity Display."
Subtraction Mode
This mode is for reducing each bucket load from previously set
target weight value, and is used for fixed total loading value works,
etc.
● When the subtraction mode is selected, "REMAINING
TARGET"(1) is displayed, and the calculated bucket load (3) is
reduced from the residual quantity display (2).
● Weights of any five kinds of object materials can be
independently accumulated and displayed. For selection of
object materials, the five kinds from A to E are selected and set
in the display of work object materials (4).
★ For the detail of display and calculation methods of bucket
load display (3) larger than the residual quantity (2), see
the paragraph of "Operation of Load Meter" in the
Operation and Maintenance Manual.
★ For details of residual quantity display, see the paragraph of "Total Load Display and Residual Quantity
Display."
WA380-5L 10-2673
Total Load Display and Residual Quantity Display

Actual total load Total load
Remarks
weight (t) display
- -99.5 -99.9 To be displayed with decimal point
-99.4 - -0.1 -**.* To be displayed with decimal point (rounding off the second fractions)
0 - 999.4 ***.* To be displayed with decimal point (rounding off the second fractions)
To be displayed in integers only (counting factions of 0.5 and over as a unit and cutting
999.5 - 9999.4 ****
away the rest)
9999.5 - 9999 To be displayed in integers only.
Unit of Calculated Weight

● All calculated weights are displayed in the SI unit (metric ton). When "MPH" is selected to display travel speed with
the rotary switch on the back of the monitor, however, it is possible to change the unit to short ton by setting the
optional device in the service mode. In this case, weights are printed out in short ton as well.
WARNING! In countries where the SI unit is adopted, the units of travel speed and load weight
should not be selected in any unit other than the SI unit.
Load Meter Cancel Switch

● When switch (1) is pressed during the calculated weight
display holding time (15 seconds after calculation), the bucket
load is judged not to be loaded and the calculation is cancelled.
The display of total load (or residual quantity) is also cancelled
to be increased (or decreased), and returns to the previous
value.
Load Meter Sub-total Switch

● To clear the total load display (in the addition mode), or to
clear the residual quantity display (in the subtraction mode), or
to print out displays, keep pressing switch (1) for more than 2
seconds.
Specification Operation after the switch is pressed
Without printer The total load display (or residual quantity

display) is cleared.
With printer The stored sub-total data are printed out. After
being output, the sub-total data are cleared.
10-2683 WA380-5L
Subtotal Data
● After calculating weight, the following data are stored as a set:
★ Kind of object materials
★ Each load weight
★ Total number of loading times
★ Total load weight
Memory capacity: More than 500 loading times
Automatic sub-total Function

1) When a printer is connected.
When a weight is calculated at the 501st time, data will be stored in the RAM 15 seconds later, and at the same time,
data up to 500 times will be printed out. After being printed out, the sub-total data will be cleared. After the 500th
data is stored, the following messages will be displayed on the character display: "LOAD DATA FULL" and
"CLEAR DATA" But the measurement can be continued.
2) When a printer is not connected.
When and a weight is calculated at the 501st time, data will be stored in the RAM 15 seconds later, and at the same
time, weight data of each bucket load up to 500 times will be cleared. After the 500th data is stored, the following
messages will be displayed on the character display: "LOAD DATA FULL." , "CLEAR DATA". But the measure-
ment can be continued.
Display on the Character Display after the 500th Data is Stored.
WA380-5L 10-2693
5. Cumulative Data Display Function

Data Display
● Total load weight and total number of loading times are displayed in the addition mode or in the subtraction mode.
● When "DATA" is selected on the load meter function, then
"TOTAL DATA" is displayed on the character display.
★ The time based on the hour meter in which the data were
integrated is displayed on the lower line (*****-*****h).
Example:
If 12300-12450h is displayed, the data integrated in 150 h
from 12300 h to 12450 h are displayed on the character
display.
● Press (>) or (<) on the monitor panel mode selector switch 2

and select any or all of A to E. When any of A to E is selected,
the cumulative weight (2) for each kind and the number of
loading times (3) will be displayed. When turn on all is
selected, the total cumulative weight (2) of all object materials
from A to E and the total number of loading times (3) will be
displayed.
Data Reset
● Cumulative data of any of A to E or of all object materials are reset.
● "TOTAL DATA" is displayed on the character display. Press (>) or (<) on the monitor panel mode selector switch 2,
then, select any of A to E or "turn on all" on the work object material display, and press (<>) on the mode selector
switch.
● "RESET" and "YES <> NO" are displayed on the character
display for confirmation. Since the cursor is located at the
"NO" position right after the screen changed, press (<) on the
monitor panel mode selector switch 2 to move it to the "YES"
position and press ( ) on the mode selector switch.
● When the monitor begins to operate, the buzzer will sound
"Pipi", and the service meter display appears.
★ When more than 6 hours has elapsed after the battery is
disconnected, cumulative date of the load will be deleted
from the memory. Keep this in mind when using battery
disconnection switch.
10-2703 WA380-5L
6. Printout (If equipped)

★ This function is available only when the printer is connected.
★ Output formats of the load meter can be selected from three (A, B and C) output modes. Output formats 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,
● Sub-total data of loading (Kind, ● Loading data (Load weight) Service meter
Number of loading times, Load ● Loading sub-total data (Kind, ● Record ending (printing) time and
weight) Number of loading times, Load data, Service meter
● Total data of loading (Total number weight) ● Subtotal data of loading (Kind,
of loading times, Total load weight) ● Loading total data (Total number of Number of loading times, Load
loading times, Total load weight) weight)
● Total data of loading (Total number
of loading times, Total load weight)
● Maintenance time (Maintenance
items, remaining time)
WA380-5L 10-2713
Example of Printout in each Mode (In case of WA470-5)
10-2723 WA380-5L
7.Calibration
● There are two kinds of calibrations, i.e., the noload calibration for measuring pressure when the bucket is empty and the
load calibration for measuring pressure when a known weight is loaded. When the lift arm is raised while the bucket is
fully tilted, the lift arm operating pressure without load (0kg) or with a known load weight is memorized.
● In general, accuracy can be fully secured only in calibration without load. When the center of gravity of a load is quite dif-
ferent from our preset position due to modification of the lift arm or the bucket, it is necessary to calibrate at the load.
★ The memory of calibration data is not deleted even while the battery is removed for a certain time.
No-load Calibration
● This calibration is for canceling such weight difference peculiar to
machine as work equipment weight, etc. and is intended to
compensate offset error (B) from standard value (A) as shown in
the figure to the right.
Load Calibration
● This calibration is for compensating the standard pressure in a
loaded state and is intended to perform compensation (B) of an
error from standard value (A) in the vicinity of load calibration (C)
conducted as shown in the figure to the right.
★ For the calibrating method, see the paragraph of Inspection and
Adjustment of Load Meter in the Volume of Inspection and
Adjustment.
8. Calculation Stop
This function stops the calculating function of the load meter. During the calculation stop, the load meter display disap-
pears, and the travel speed display or the engine speed display appears and the data is not added to the total data. To
resume the calculation, select the Addition Mode or the Subtraction Mode.
★ For how to stop calculation, refer to the paragraph of "Operation of Load Meter" in the Operation and Maintenance
Manual.
WA380-5L 10-2733
Machine Setting
Setting the machine serial number
1. Hold down SW and < SW for 5 seconds or more, and change to

the [ID entry screen].
2. Use < and > SW to enter ID, and press SW to enter the service
person screen.
3. Use < and > SW to display the [machine serial No. entry] screen,
and press SW to decide the machine serial number.
4. Enter the machine serial number.
5. Entering ID
At transition to the screen, “50000” or “set numeric value” is dis-
played on the screen.
Enter a numeric value 0 to 9 at the cursor position.
Cursor appears on the highest-order position, 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 beginning.
10-2743 WA380-5L
Setting Necessary For Option Mounting

When one of the options below is added or replaced, initialize sensors and solenoids using the machine monitor.
Additional or changeable options Initial adjustment items
Transmission mainframe, Transmission controller, and ECMV Transmission initial learning
Lift arm angle sensor and work equipment controller Adjustment of work equipment lift arm angle
EPC lever, work equipment controller, and work equipment EPC valve Adjustment of work equipment EPC
3 EPC levers, work equipment controller, and work equipment EPC valve Adjustment of work equipment EPC
Joystick lever, work equipment controller, Joystick EPC valve Adjustment of Joystick steering
Lift arm angle sensor and machine monitor Adjustment of load meter lift arm angle
WA380-5L 10-2753
Optional Device Setting For Machine Monitor

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

Item No. Option item English Remarks
Monitor panel controller
1 Auto grease AUTO GREASE
2 Battery electrolyte reduction sensor BAT LIQUID 4
3 Transmission clogging sensor TRANSM CLOG 4
4 Printer PRINTER
5 Lift arm high lift specifications HI LIFT
6 Speed/engine tachometer switch ENGINE RPM 1
7 Short ton switch SHORT TON 2
1 Travel dumper E.C.S.S
2 Torque converter lock-up LOCK UP
3 Emergency steering EMER STRG
4 Tire size TIRE SIZE 3
5 Spare switch AUTO RE FAN 4
6 Right FNR switch RH FNR SW
Work equipment controller
1 EPC lever EPC LEVER
2 Joystick lever JOY STICK
3 EPC 3rd lever EPC 3RD
1: Setting of speed/engine tachometer indicator switch
When rotary switch on the rear is km/h: engine rotation is displayed at engine rotation option = ADD.
When rotary switch on the rear is mph: engine rotation is displayed at engine rotation option = ADD.
When rotary switch on the rear is rpm: machine speed (km/h) is displayed engine rotation option = NO ADD.
2: Setting of load meter short ton (US ton) indicator switch
When DIP switches on the rear is mph, the indicator is switched to short ton.
MPH indicator is domestic type using the non-SI unit (mile); do not change for SI unit countries.
3: Adjustment of tire size
When speed indicator does not match the actual value because an unspecified tire is used or a tire is abraded, correct
the tires so that the speed indicator matches the actual value.
When the normal tire size is changed, use rotary switch 3 on the rear, not the adjustment function.
4: No optional items are set for this machine
10-2763 WA380-5L
Operation method
1. Operate the monitor mode switch to select a service mode option.

Pressing the monitor mode switch changes the option setting as
follows.
2. Press and release the monitor panel mode switch ( ).

The screen changes to the monitor panel option setting selectable
display.
3. When the option setting controller is not the monitor, use monitor
panel mode switch (< or >) to switch to each controller.
4. After a target controller is selected, press and release monitor mode

switch ( ). Setting state for each option appears as follows:
● ##: Displays an item number.
● ***: Displays an item name.
● Upper row: Displayed when no OPT is currently set.
● Lower row: Displayed when OPT is currently set.
● Pressing the SW changes ADD (set) or NO ADD (not set),
and the display is switched.
● If the setting is changed, the operation acceptance completion
sound (two short tones (0.1 sec. ON 0.1 sec. OFF 0.1 sec.
ON)) is output.
WA380-5L 10-2773
● To adjust the tire size, the operation and display sizes are as
follows:
★ Using the SW switches the 00% and @@%.
★ @@: Can be switched every 2% up to deflection -12 to
+12% for the setting of the DIP switches on the rear.
★ +00+02+04+06+08+10+12-02-04-
06-08-10-12 +00… .
★ When the value is changed, the operation acceptance
completion sound (two short tones (0.1 sec. ON 0.1 sec.
OFF 0.1 sec. ON)) is output.
★ Adjust the tire size only when an unspecified tire is
mounted.
5. Press and release monitor panel mode switch (); menu returns to the preceding screen.
10-2783 WA380-5L
Transmission initial learning setting
Learning for correcting the solid difference of transmission
1. Learning data reset

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

(1) Hold down SW and < SW simultaneously for 5 seconds and change to the ID entry screen (Figure 1).
(2) Use < and > SW to enter ID, and press SW to enter the service person screen.
(3) Use < and > SW to display the sensor initialization selection screen (Figure 2), and press SW to decide the value.
(4) Use < and > SW to display the Transmission initial learning screen (Figure 3) of set item 1.
(5) Press SW; the Transmission initial learning set screen (Figure 4-1 or 4-2) appears.
(6)-1 If the initial learning is not executed, the initial learning reset screen (Figure 4-1) appears.
(6)-2 If the initial learning is executed, the initial learning set screen (Figure 4-2) appears.
(7) To reset the initial learning, press SW to display the initial learning reset screen (Figure 5).
(8)-1 To reset the initial learning, select [YES] with < switch, then press SW.
After SW is pressed, if the initial learning incompletion (reset screen (Figure 4-1) appears, the initial learning is
reset.
(8)-2 If you do not need to reset the initial learning, select NO, then press the SW.
After SW is pressed, the the screen before the SW was pressed (Figure 4-1 or 4-2) appears ans resetting is
cancelled.
If the initial learning is necessary, execute (1) - (5), and then execute the resetting operation (up to (8)-1) once while either the
screen in (6)-1 or the screen in (6)-2 is displayed
WA380-5L 10-2793
2. Initial learning procedure. Preparation for machine
A. Start the engine.
B. Display the transmission oil temperature (Item ID: 41500, ECMV OIL TEMP) on the real-time monitor.
C. Operate the gear shift and directional levers to sufficiently circulate oil inside the transmission.
Gear Range N2 F2 F1 F2 F3 F4 F3 F2 N2 R2 N2
Holding Time 2 Sec. 2 Sec. 2 Sec. 2 Sec. 2 Sec. 2 Sec. 2 Sec. 2 Sec. 2 Sec. 2 Sec. 2 Sec.
● After holding each gear speed for the time specified or more, shift gears to the next range.
● Operate engine at low idle, place shift mode switch in the MANUAL position and transmission cut- off switch in the OFF
position (lockup switch in the OFF position).
D. Increase the transmission oil temperature in the range from 55° - 70° C (131° - 158° F).
★ Set oil temperature to the specified temperature while learning operation.
★ Make sure the machine is in normal condition (no faults are detected).
Initial learning procedure
A. Execute the initial learning operation at the state of the machine mentioned above. (Do not stop the engine.)
B. Use the real-time monitor to confirm that the transmission oil temperature is in the range from 55° - 70° C (131° -
158° F).
If the transmission oil temperature is outside the specified range (55° - 70° C {131° - 158° F}), 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
C. Time lag and gear shift shock.Operate the gearshift lever and forward-reverse lever to change the transmission.
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 engine at low idle, place shift mode switch in the MANUAL position and transmission cut- off switch in the OFF
position (lockup switch in the OFF position).
● Execute shifting operation while driving the machine, or while depressing the brake pedal.
★ When initially setting to N2, 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 N position and the shift lever in other than 2, place the directional
lever in F or R position and then operate the directional lever in N position following 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.
D. Check that completion of initial learning (display of TUNED) appears on the initial learning of transmission setting
screen on the real-time monitor.
E. When the initial learning is not carried out (display of INITIAL STATUS), repeat operations mentioned in 3 and 4
until completion of initial learning (display of TUNED) appears.
10-2803 WA380-5L
Adjustment of Joystick steering
1. Hold down the ■ switch and < switch for 5 seconds or more at the
same time, and change to the [ID Entry] screen.
2. After the ID is entered using the < and > switch, press the switch
to enter the service person screen.
3. Press < and > switch to display the [Sensor Initial Setup Selection]
screen, and press switch to decide the value.
4. Press the < and > switch to display the [Work Equipment Lift Arm
Angle Adjustment] screen of set item 2.
WA380-5L 10-2813
5. Press switch here; the [Work Equipment Lift Arm Angle Set]
screen appears.
6. Adjust the lift arm to the highest position without load.
7. Press switch 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. Confirm that the buzzer sounds (two short tones) twice and the
menu returns to the [Lift Arm Angle Adjustment] screen. The set-
ting is then completed.
9. Pressing ■ switch ends the lift arm angle correction even if it is performed currently.
10-2823 WA380-5L
Adjustment of work equipment EPC (If equipped)
Item setting
1. Hold down the < and > switch for 5 seconds or more at he same time, and change to the [ID Entry] screen.
2. Use the < and > switch to enter ID, and press the .. switch to enter the service person screen.
3. Use the < and > switch to display the [Sensor Initial Setting Selection] screen, and press the ■ switch to decide the value.
4. Use the < and > switch to display the [Work Equipment EPC Adjustment] screen on set items 4 to 7.
● Lift arm up: No.4
● Lift arm down: No.5
● Bucket tilt: No.6
● Bucket dump: No.7
● 3-valve extension: No.8
● 3-valve reduction: No.9
● Set the value individually.
5. Press the switch here; the [Work Equipment EPC Setting] screen appears.
WA380-5L 10-2833
Adjustment for Each EPC
Lift arm RAISE
1. Dump the bucket to lower the lift arm, and lift the front tires. Lift the lift arm (lower the machine) by degrees in the engine
high idling state.
2. Return the lever by fine operation to stop the lift arm (tire floating). Then hold the lever at that position.
3. Press the switch here; the EPC command value is read, and a difference between the read value and reference value is
stored as an offset value.
4. The buzzer sounds twice (two short tones), and the menu returns to the [Work Equipment EPC Adjustment] screen. The
setting is then completed.
5. When the switch is pressed as the lever stroke is in the down direction, the buzzer sounds for 1 second, and the
adjustment is canceled as the [Work Equipment EPC Setting] screen remains displayed.
6. When the switch is pressed as the lever is at the neutral position, the adjustment value is cleared, and the buzzer sounds
twice (two short tones). The menu then returns to the [Work Equipment EPC Adjustment] screen.
7. Press the ■ switch; the work equipment EPC dispersion correction is ended even if it is in progress of processing.
Lift arm LOWER
1. Adjust the lift arm to the horizontal level without load, and lower the lift arm by degrees in the engine high idling state.
2. Return the lever by fine operation to stop the lift arm, then hold the lever at that position.
5. When the switch is pressed as the lever stroke is 40% or more in the down direction, the buzzer sounds for 1 second,
and the adjustment is canceled as the [Work Equipment EPC Setting] screen remains displayed.
10-2843 WA380-5L
Bucket tilt
1. Dump the bucket to lower the lift arm, and lift the front tires. Tilt the bucket by degrees in the engine high idling state.
(Lower the machine.)
2. Return the lever by fine operation to stop the bucket (tire floating), then hold the lever at that position.
5. When the switch is pressed as the lever stroke is in the dump direction, the buzzer sounds for 1 second, and the
7. When the ■ switch is pressed, the work equipment EPC dispersion correction is ended even if it is in progress of
processing.
Bucket dump
1. Adjust the bucket to the horizontal level without load, and lower the bucket by degrees in the engine high idling state.
2. Return the lever by fine operation to stop the lift arm, then hold the lever at that position.
5. When the switch is pressed as the lever stroke is in the tilt direction, the buzzer sounds for 1 second, and the adjustment
is canceled as the [Work Equipment EPC Setting] screen remains displayed.
6. When the ■ switch is pressed as the lever is at the neutral position, the adjustment value is cleared, and the buzzer sounds
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 position.
4. The buzzer sounds twice, (two short tones), and the menu returns to the [Work Equipment EPC Adjustment] screen. The
5. When the switch is pressed as the lever stroke is in the fastening direction, the buzzer sounds for 1 second, and the
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 position.
4. The buzzer sounds twice, (two short tones), and the menu returns to the [Work Equipment EPC Adjustment] screen. The
5. When the switch is pressed as the lever stroke is in the extension direction, the buzzer sounds for 1 second, and the
processing.
WA380-5L 10-2853
Correction of position of work equipment EPC lever detent
Procedure for correcting position of work equipment EPC lever
Perform the following procedure with the engine stopped
1. Push and hold ■ switch and > switch simultaneously for 5 seconds
to go to the "Input ID" screen.
2. Input the ID with the < switch and > switch, then push the switch
to go to the screen for the service person.
3. Display the "Select initial setting of sensors" screen with the <
switch and > switch and enter the setting.
10-2863 WA380-5L
4. Display the screen for adjusting items No. 4 - 6 of work equipment

EPC with the < switch and > switch.
Screen for adjusting work equipment EPC
● RAISE lift arm: No. 4
● LOWER lift arm: No. 5
● Tilt bucket: No. 6
● Set these items respectively.
● Perform this correction procedure when the electric work
equipment control lever or work equipment controller is
replaced.
● This correction procedure cannot be performed if the ROM
No. of the work equipment controller in the real-time monitor
is ****R200.
5. Push the switch and the screen for setting the work equipment
EPC appears.
Screen for setting work equipment EPC.

< Adjustment of each EPC lever >
[Adjustment of position of lift arm LOWER (FLOAT) detent]
1) -1. Lower the lift arm to the ground.
2) -1. Stop and hold the lift arm lever before the FLOAT detent
position.
3) -1. Push the switch at this time. The lever voltage is read and
the standard value is changed and saved.
4) -1. The buzzer sounds twice. The screen for adjusting the work
equipment EPC appears and the adjustment is completed.
5) -1. At this time, if the switch is pushed while the lever output
voltage is below the standard value (out of the design range),
the buzzer sounds for 1 second and the screen for setting
work equipment EPC does not change. The adjustment is cancelled in this case.
The buzzer sounds twice and the screen for adjusting work equipment EPC appears again.
6) Correction of the position of the work equipment EPC lever detent can be stopped at any time by pushing the ■
switch.
[Adjustment of position of lift arm RAISE detent].

Perform the following procedure with the engine stopped.
2) -2. Stop and hold the lift arm lever before the RAISE detent position.
3) -2. Push the switch at this time. The lever voltage is read and the standard value is changed and saved.
4) -2. The buzzer sounds twice. The screen for adjusting the work equipment EPC appears and the adjustment is com-
pleted.
5) -2. At this time, if the switch is pushed while the lever output voltage is below the standard value (out of design
range), the buzzer sounds for 1 second and the screen for setting work equipment EPC does not change. The adjust-
ment is cancelled in this case.
6) Correction of the position of the work equipment EPC lever detent can be stopped at any time by pushing the ■
switch.
WA380-5L 10-2873
[Adjustment of the position of the bucket TILT detent]

Perform the following procedure with the engine stopped.
2) -3. Stop and hold the bucket lever before the TILT detent position.
3) -3. Push the switch at this time. The lever voltage is read and the standard value is changed and saved.
4) -3. The buzzer sounds twice. The screen for adjusting the work equipment EPC appears and the adjustment is
completed.
5) -3. At this time, if the switch is pushed while the lever output voltage is below the standard value (out of the
design range), the buzzer sounds for 1 second. The screen for setting the work equipment EPC does not
change. The adjustment is cancelled in this case.
6) Correction of the position of the work equipment EPC lever detent can be stopped at an time by pushing the ■
switch.
10-2883 WA380-5L
MEMORANDUM
WA380-5L 10-2893
Adjustment of Joystick steering (If equipped)
1. Hold down the ■ switch < switch for 5 seconds or more at the same
time, and change to the [ID Entry] screen.
2. Use the < and > switch to enter ID, and press the switch to enter
the service person screen.
3. Use the < and > switch to display the [Sensor Initialization Setting]
screen, and press the switch to decide the value.
4. Use < and > switch to display the [Joystick Calibration Adjustment]
screen of set item 11 or 12. (Right or left)
10-2903 WA380-5L
5. Press the switch here; the [Joystick Calibration Adjustment]

screen appears. (Right or left).
Setting of starting point (Right or left).

6. Set the engine high idling state, and set the switch speed High/Low switch to High.
(For this operation, use the stationary steering.)
7. Start the steering by right or left steering fine operation, and stop the steering. Then hold the lever at that position.
9. The buzzer sounds twice (two short tones), and the [Joystick Steering Calibration Adjustment] screen returns. The setting
is then completed.
10. When the switch is pressed as the lever is in the reverse state, the buzzer sounds for 1 second, and the adjustment is
canceled as the [Joystick Calibration Setting] screen remains displayed.
11. When the switch is pressed as the lever is at the neutral position, the adjustment value is cleared to the initial value, and
the buzzer sounds twice (two short tones). The menu then returns to the [Joystick Steering Calibration Adjustment]
screen.
12. When the ■ switch is pressed, the Joystick calibration is ended even if it is in progress of processing.
WA380-5L 10-2913
Adjustment of lift arm angle for load meter (If equipped)
Adjustment of lift arm angle (upper position)
4. Press the < and > switch to display the [Work Equipment Lift Arm
Angle Adjustment] screen on set item 16.
10-2923 WA380-5L
5. Press switch here; [Work Equipment Lift Arm Angle Setting]

screen appears.
6. Adjust the lift arm to the highest position without load.

7. Press the switch 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 Adjustment] screen. The setting
is then completed.
9. Press the ■ switch; the lift arm angle correction is ended even if it is in progress of processing.
WA380-5L 10-2933
Adjustment of lift arm angle (Lower position)
4. Use the < and > switch to display the [Work Equipment Lift Arm
Angle Adjustment] screen of set item 17.
10-2943 WA380-5L
5. Press switch here; [Work Equipment Lift Arm Angle Setting]

screen appears.
6. Adjust the lift arm to the lowest position without load. (Lift cylinder stroke end)
7. Press the switch 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 [Lift Arm Angle Adjustment] screen. The setting is
then completed.
9. Press the ■ switch; the lift arm angle correction is ended even if it is in progress of processing.
★ After the lift arm angle is adjusted, be sure to perform calibration without load.
WA380-5L 10-2953
AMP070-20P [CN-L51]
Pin No. Specifications I/O Group Setting state Signal name WA380-5L Remarks
1 --- — — --- ---
2 Small lamp power I — Power +24V --- ---
3 Small lamp power I — Power +24V --- ---
4 NSW power (+24V) I — Power +24V NSW power (+24V) NSW power (+24V)
5 NSW power (+24V) I — Power +24V NSW power (+24V) NSW power (+24V)
6 SW power (+24V) I — Power +24V SW power (+24V) SW power (+24V)
7 SW power (+24V) I — Power +24V SW power (+24V) SW power (+24V)
8 --- — — --- ---
9 GND I — GND GND GND

D_OUT_3 (+24V, sink
11 O A D/0 sink --- ---
200mA)
D_OUT_2 (+24V, sink (Auto preheating
12 O A D/0 sink ---
200mA) relay)
D_OUT_1 (+24V, sink
13 O A D/0 sink Pre-lube relay ---
200mA)
D_OUT_0 (+24V, sink Buzzer 1 Buzzer 1
14 O A D/0 sink
200mA) (Machine monitor) (Machine monitor)
Sensor power output Lift arm pressure Lift arm pressure
15 O — Sensor power For load meter
(+24V) sensor power sensor power
Sensor power output Lift arm angle sensor Lift arm angle
16 O — Sensor power For load meter
(+5V) power sensor power
10-2963 WA380-5L
AMP070-18P(1) [CN-L52]
1 D_IN_0(24V,5mA) I B D/I+24V High beam Head lamp
2 D_IN_2(24V,5mA) I B D/I+24V IGN C IGN C
3 D_IN_4(24V,5mA) I B D/I+24V Auto grease A Auto grease A (OPT) OPT
4 D_IN_6(24V,5mA) I B D/I+24V (Direction F) --- For compact type
5 D_IN_8(24V,5mA) I B D/I+24V (Direction R) --- For compact type
6 D_IN_10(24V,5mA) I B D/I+24V (Diagnosis IN A) --- Spare
7 D_IN_12(NSW24V,5mA) I C D/I+24V Blinker right Blinker right
8 D_IN_14(NSW24V,5mA) I C D/I+24V Service SW input SW input Machine monitor

operation SW
9 GND O — SIGNAL GND SIGNAL GND
10 D_IN_1(24V,5mA) I B D/I+24V IGN BR ---
11 D_IN_3(24V,5mA) I B D/I+24V IGN R1 ---
12 D_IN_5(24V,5mA) I B D/I+24V Auto grease B Auto grease B (OPT) OPT
13 D_IN_7(24V,5mA) I B D/I+24V (Direction N) --- For compact type
14 D_IN_9(24V,5mA) I B D/I+24V (HST: Hi/Lo switch) --- For compact type
15 D_IN_11(24V,5mA) I B D/I+24V (Diagnosis IN B) --- Spare
16 D_IN_13(NSW24V,5mA) I C D/I+24V Blinker left Blinker left
17 D_IN_15(NSW24V,5mA) I C D/I+24V Service SW input ■SW input Machine monitor

operation SW
18 A_IN_0(0~30V) I H A/I Alternator R Alternator R
AMP070-12P (1) [CN-L53]
Break oil pressure Break oil pressure

1 D_IN_16(24V/GND,5mA) I D D/IGND
(Front) (Front)
Break oil level
2 D_IN_18(24V/GND,5mA) I D D/IGND --- Spare
(Front)
Air cleaner clogging
3 D_IN_20(24V/GND,5mA) I D D/IGND Air cleaner clogging
1
4 D_IN_22(24V/GND,5mA) I D D/IGND (Spare) ---
Transmission filter
5 D_IN_24(24V/GND,5mA) I E D/IGND ---
clogging
6 GND O — GND Sensor GND Sensor GND
Break oil pressure
7 D_IN_17(24V/GND,5mA) I D D/IGND ---
(Rear)
8 D_IN_19(24V/GND,5mA) I D D/IGND Break oil level (Rear) --- Spare
Air cleaner clogging
9 D_IN_21(24V/GND,5mA) I D D/IGND --- Spare
2
10 D_IN_23(24V/GND,5mA) I D D/IGND (Spare) ---
Seat belt mounting
11 D_IN_25(24V/GND,5mA) I E D/IGND ---
alarm
12 A_IN_0(0~30V) I H A/I Small lamp SW Small lamp SW
WA380-5L 10-2973
AMP070-18P(2) [CN-L54]
1 D_IN_26 (24V/GND,5mA) I E D/IGND Parking brake Parking brake
2 D_IN_28 (24V/GND,5mA) I E D/IGND Engine oil pressure Engine oil pressure Spare
3 D_IN_30 (24V/GND,5mA) I E D/IGND E/G steering normal E/G steering normal

For load meter
4 D_IN_32 (24V/GND,5mA) I F D/IGND Subtotal SW Subtotal SW (OPT)
(Spare for STD)
5 D_IN_34 (24V/GND,5mA) I F D/IGND Printer output SW High-beam SW
Machine monitor
6 D_IN_36 (24V/GND,5mA) I G D/IGND Service function 2
indicator SW
Machine monitor
7 D_IN_38 (24V/GND,5mA) I G D/IGND Increment SW < SW input
operation SW
(Machine speed
8 P_IN_0 (0.5Vp-p) I M P/I --- For compact type
sensor)
9 GND O — GND GND GND
10 D_IN_27 (24V/GND,5mA) I E D/IGND Engine coolant level Engine coolant level
11 D_IN_29 (24V/GND,5mA) I E D/IGND Engine oil level Engine oil level Spare
12 N.C. I E D/IGND N.C. --- OPT

For load meter
13 D_IN_33 (24V/GND,5mA) I F D/IGND Cancel SW Cancel SW (OPT)
(Spare for STD)
Lift arm approach
14 D_IN_35 (24V/GND,5mA) I F D/IGND ---
SW
15 D_IN_37 (24V/GND,5mA) I G D/IGND Decrement SW > SW input
E/G steering opera- E/G steering opera-
16 D_IN_39 (24V/GND,5mA) I G D/IGND
tion tion
17 P_IN_1 (0.5Vp-p) I M P/I (Spare) --- Pulse input
18 (NC) — — (NC) ---
AMP070-12P(2) [CN-L55]
1 A_IM_2 (High resistance I J A/I Fuel level sensor Fuel level sensor
input)
2 A_IM_4 (High resistance I J A/I Torque converter oil Torque converter oil
input) temperature sensor temperature sensor
3 A_IM_6 (High resistance I K A/I Engine coolant tem- Engine coolant
input) perature sensor (for temperature sensor (for
auto pre-heating) auto pre-heating)
4 A_IM_8(0~5V) I L A/I Lift arm pressure sen- Lift arm pressure For load meter
sor (rod) sensor (rod)
5 A_IM_10(0~14V) — — Battery fluid level A Battery fluid level OPT
(OPT)
6 GND O — GND SIGNAL GND GND
7 A_IM_3 (High resistance I J A/I Hydraulic oil tempera- Hydraulic oil

input) ture sensor temperature sensor
8 A_IM_5 (High resistance I J A/I Engine coolant tem- Engine coolant
input) perature sensor temperature sensor Hi
9 A_IM_7 (0~5V) I L A/I Lift arm pressure sen- Lift arm pressure For load meter
sor (bottom) sensor (bottom)
10 A_IM_9 (0~5V) I L A/I Lift arm angle sensor Lift arm angle sensor For load meter
11 GND O — GND SIGNAL GND GND
12 A_IM_11 (0~14V) — — Battery fluid level B --- Spare
10-2983 WA380-5L
AMP070-12P(3) [CN-L56]
Machine monitor
~Transmission, &
1 S_NET(+) I/O N S-NET S_NET+
work equipment
controller
Machine monitor
~Transmission, &
2 S_NET(+) I/O N S-NET S_NET+
work equipment
controller
Machine monitor
~Transmission, &
3 CAN+ I/O P CAN work equipment CAN+
controller,
KOMTRAX
4 S_NET(-) O N S-NET S_NET GND S_NET-
5 S_NET(-) O N S-NET S_NET GND S_NET-
6 GND O — GND S_NET GND
7 GND O — GND CAN GND

Machine monitor~
Transmission, &
8 CAN- I/O P CAN work equipment CAN-
controller,
KOMTRAX
9 (NC)
10 (NC)
11 (NC)
12 (NC)
AMP070-14P(2) [CN-L57]
1 (NC) — — ---
RS232_C serial
2 RS232C_1_RTS I/O Q ---
communication
3 RS232C_1_RD I Q RD ü PC RX For monitoring PC
4 RS232C_2_RD I R RD NC ---
5 RS232C_2_RTS I/O R NC ---

Load meter printer
6 — — Printer BUSY For load meter
busy input
7 (NC) — — ---
RS232_C serial For load meter
8 RS232C_1_CTS I/O Q ---
communication For monitoring(PC)
9 RS232C_1_TX O Q TX ü Printer & PC TX
10 RS232C_1_SG O Q ü ---
11 RS232C_2_SG O R NC ---
12 RS232C_2_TX O R TX NC ---
13 RS232C_2_CTS I/O R NC ---
14 (NC) — —
WA380-5L 10-2993
AMP040-8P [CN-L58]
Harness not
Flash writing data
1 RS232C_0_TXD O S --- connected in
(sending)
machine
Harness not
2 FLASH_SW I S Flash writing switch --- connected in
machine
Harness not
Flash writing data
3 RS232C_0_TXD O S --- connected in
(sending)
machine
Harness not
4 (NC) — — (NC) --- connected in
machine
Harness not
Flash writing data
5 RS232C_0_RXD I S --- connected in
(receiving)
machine
Harness not
6 (NC) — — (NC) --- connected in
machine
Harness not
Flash writing data
7 RS232C_0_RXD I S --- connected in
(receiving)
machine
Harness not
8 GND O — GND --- connected in
machine
Setting switches (on board)
1 16 Posi rotary SW1 I — Model selection Model selection
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 engine Common rail engine
1 26 Posi dip SW1 I —
controller selection controller selection
Work equipment Work equipment
2 26 Posi dip SW2 I —
5 controller selection controller selection
3 26 Posi dip SW3 I — (Spare) ---

6
10-3003 WA380-5L
MEMORANDUM
WA380-5L 10-3013
TRANSMISSION CONTROL SYSTEM MAINTENANCE STANDARD
TRANSMISSION CONTROL SYSTEM
System Diagram
10-3023 WA380-5L
MAINTENANCE STANDARD TRANSMISSION CONTROL SYSTEM
Control Function
1. Gear Speed Change Function
A. Electronic Modulation Function

In order to reduce shocks at gear speed changes (at engagement of the clutch), this function controls the clutch oil
pressure to the level suitable to oil-pressure circuit depending on engine speed, oil temperature of the transmission,
travel speed and gear speed change pattern. This control is performed through the whole range of gear speeds
(including lock-up clutch) according to data in the transmission modulation data table stored in the transmission
controller memory.
The clutch to be turned off is also included in the target of the modulation control in order to reduce running out of the
torque. A learning function is also provided so that an abnormal time lag in the gear speed change may be
automatically modulation controlled.
B. Automatic Gear Speed Change

This function is consisted of the auto-shift and manual shift. The former decides gear speed automatically according
the travel speed and the latter selects the gear speed according to the gear speed specified by the gear shift lever.
In the auto-shift, the travel speed mode is switched between the auto-shift up and down depending on the state of the
engine-power mode and torque converter lockup control.
Shift mode change in case of the overseas spec.

In case of the overseas spec., depending on the status of the shift mode (NORMAL/H/M/L) changeover switch, the
status of the torque converter lock up (OFF/ON) switch and the status of the power mode (POWER/NORMAL)
changeover switch, automatic shift up or shift down is made to become the following shift modes.
Power mode switch position Lockup switch position Shift mode switch position
Manual H M L
POWER Manual H-mode M-mode L-mode
OFF
NORMAL Manual M-mode M-mode L-mode
POWER Manual H-mode M-mode L-mode
ON
NORMAL Manual L-mode L-mode L-mode
When the engine speed is 1000 rpm or above, switching between the auto-shift up and down in the auto-shift mode is
implemented according to a travel speed mode selected from the "Table - Auto Shift Point List" stored in the
transmission controller’s memory. Here, selection of a shift mode is done by referencing the signals from the
forward-reverse lever, shift lever and travel speed sensor.
i. 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.
ii. Forward-reverse lever at “N” position

When the forward-reverse lever is at the neutral position, the number of speed of the transmission is fixed to the
gear speed being set before the lever was shifted to “N”.
As long as the forward-reverse lever is at “N” position, operating the gearshift lever does not change the gear
speed.
iii. Forward-reverse lever at “F” position

As the forward-reverse lever is shifted from N F, the transmission sends the modulation instruction to the F-
clutch and 2nd speed clutch’s ECMV (auto 2nd speed start).
WA380-5L 10-3033
a) Shift up (Gearshift lever at 4th speed and the auto-shift mode “H” is on)
If you increase travel speed up to 10.2km/h by increasing the engine speed from the accelerator pedal, the
gear speed will be shifted to the 3rd speed. If the travel speed is increased to 18.0km/h, the gear speed is
shifted to the 4th speed.
b) Shift down (Gearshift lever at 4th speed and auto-shift mode “H” is on)
If you reduce the travel speed to 16.0km/h or less when 1,000 rpm or above engine speed is turned on (when
travelling up hills, for instance), the gear speed is shifted is to the 3rd speed.
If the travel speed is further reduced to 10.7km/h or less, it will be shifted to the 2nd speed.
c) Skip shift down (Gearshift lever at 3rd or 4th speed) speed)
If you reduce the engine speed to less than 1,000 rpm by releasing the accelerator pedal while the machine is
traveling, the 3rd or 4th speed will be maintained until the travel speed reaches 1km/h. As the travel speed
reaches 1km/h, the gear speed will be shifted to the 2nd speed.
If you run the accelerator pedal again when the travel speed is reduced to 5km/h or less and the gearshift
lever is positioned at 3rd or 4th speed, the gear speed will be shifted to the 2nd speed as the engine speed
reaches 1,000 rpm or above.
iv. Forward-reverse lever at “R” position

In this case, just like when the forward-reverse lever is at “F” position, travel speed is changed according to the
position of the gearshift lever, auto-shift mode selected and given travel speed as specified in the “Auto-Shift
Point List”.
v. Gear speed change disabling time

It is a specified duration of time in which a selected gear speed is maintained in order to prevent hunting after
changing the speed. Duration of this time depends on the gear change pattern (see the Auto-Shift Point List).
C. Shift Hold Function

This function is used to hold the gear speed being selected at when the hold switch is depressed.
Increasing a traveling speed does not cause the shift up as long as this function is turned on. Likewise, slowing down
the traveling speed does not result in the shift down.
You can cancel the shift hold function by hitting the hold switch again.
This function is automatically cancelled if you operate the forward-reverse lever, gearshift lever or kick down switch.
This function does not hold ON status of the lockup.
D. Kick-Down Function
i. Kick down in the manual shift mode

The kick-down switch is operable only when the forward 2nd speed (F2) is selected. It is inoperable at any other
speeds.
You can cancel the kick-down by shifting the forward-reverse lever to any position other than F or by shifting the
gearshift lever to any position other than F2.
You can select the 2nd speed by shifting the forward-reverse lever to R after selecting F1 from the kick-down
switch. If you move the gearshift lever to any speed other than the 2nd speed, the speed will be changed to the
one where the lever is positioned.
ii. Kick-down in the auto-shift mode

The kick-down switch is enabled irrespective of the position of the forward-reverse lever and gearshift lever.
Following gear speed changes are available from the kick-down switch at respective travel speeds.
Gear speed change from the kick-down switch is implemented after the predetermined gear speed change
disabling time is expired. When it is done from the forward-reverse lever, the gear speed change is executed
according to the Auto-Shift Point List.
10-3043 WA380-5L
Gear speed change

Gear speed before change Travel speed Gear speed after change
disabling time
2nd speed Through entire speed ranges 1st speed 5 seconds
3rd speed Less than 12.5 km/h 1st speed 5 seconds
3rd speed 12.5 km/h to less than 25 km/h 2nd speed 4 seconds
3rd speed More than 25 km/h Gear speed change is not avail- ---
able (remains in 3rd speed)
4th speed Less than 12.5 km/h 1st speed 5 seconds
4th speed 12.5 to less than 35 km/h 3rd speed 4 seconds
4th speed More than 35 km/h Gear speed change is not ---
available (remains in 4th speed)
3rd speed Less than 12.5 km/h 1st speed 5 seconds
(when lockup is ON)
3rd speed More than 12.5 km/h 3rd speed 1
(when lockup is ON) (after lockup is canceled)
4th speed Less than 12.5 km/h 1st speed 5 seconds
(when lockup is ON)
4th speed More than 12.5 km/h 4th speed 1
(when lockup is ON) (after lockup is 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 increases from less than lockup ON speed to above ON speed (both indicated in the Auto-Shift Point List).
E. 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.
i. When the auto-shift is turned on

Zone I: F-R shift is enabled and the 2nd speed is selected (normal zone).
Zone II: F-R shift is enabled and the 2nd speed is selected, but alarm is warned.
Zone III: F-R shift is enabled though accompanied by alarm. Gear speed of the speed clutch is selected from
the Auto-Shift Point List and then the shift down to the 2nd speed maximum results depending on the
travel speed.
ii. When the manual shift mode (3rd/4th speed) is turned on

(speed of the speed clutch is not changed because of the
manual shift)
Zone I: F-R shift alone is enabled (normal alarm).
Zone II: F-R shift is enabled but accompanied by alarm.
Zone III: F-R shift is enabled but accompanied by alarm.
WA380-5L 10-3053
F. Travel Speed Alarm Function

Alarm buzzer is sounded for travel speeds beyond 38 km/h (24 mph) as over speeds. The alarm is turned off as the
travel speed is reduced to 36 km/h (22 mph) or below.
Auto-Shift Point List

Forward (F) Reverse (R) Gear speed change
disabling time after
Shift lever position Solenoid signal
Speed Speed the preceding
km/h (mph) km/h (mph) change (sec)
1T/C2T/C(L&M) 4.7 (2.9) 4.7 (2.9) 2
2, 3 or 4
1T/C2T/C(H) 5.3 (3.3) 5.3 (3.3) 2
2T/C3T/C(H) 10.2 (6.3 10.2 (6.3 2
3 or 4 2T/C3T/C(M) 9.0 (5.6) 9.0 (5.6) 2
2T/C3T/C(L) 7.0 (4.4) 7.0 (4.4) 2
3T/C3L/U(M&H) 13.9 (8.6) 16.0 (9.9) 0
Engine speed (1,000 rpm or above)
3
3T/C3L/U(L) 11.0 (6.8) 16.0 (9.9) 0
3T/C4T/C(H) 18.0 (11.2) 18.0 (11.2) 1
3T/C4T/C(M) 16.5 (10.3) 16.5 (10.3) 1
3T/C4T/C(L) 15.0 (9.3) 15.0 (9.3) 1
4
4T/C4L/U(H) 23.7 (14.7) 25.2 (15.7) 0
4T/C4L/U(M) 22.2 (13.8) 23.6 (14.7) 0
4T/C4L/U(L) 20.7 (12.9) 22.0 (13.7) 0
4L/U4T/C(L&M&H) 40.0 (24.9) 40.0 (24.9) 5
4L/U4T/C(L&M&H) 19.1 (11.9) 20.3 (12.6) 1
4 4T/C3T/C(H) 16.0 (9.9) 16.0 (9.9) 1
4T/C3T/C(M) 14.5 (9.0) 14.5 (9.0) 1
4T/C3T/C(L) 13.0 (8.1) 13.0 (8.1) 1
3T/C2T/C(H) 10.7 (6.7) 10.7 (6.7) 2
3 or 4 3T/C2T/C(M) 9.5 (5.9) 9.5 (5.9) 2
3T/C2T/C(L) 6.5 (4.0) 6.5 (4.0) 2
1,000 rpm)
4T/C2T/C(L&M&H) 1.0 (0.6) 1.0 (0.6) 0

(less than
4
Engine
speed
3T/C2T/C(L&M&H) 1.0 (0.6) 1.0 (0.6) 0

3 or 4
Engine speed (Less than 1,000 4T/C2T/C(L&M&H) 5.0 (3.1) 5.0 (3.1) 2
rpm Above 1,000 rpm) 3T/C2T/C(L&M&H) 5.0 (3.1) 5.0 (3.1) 2
2T/C1T/C(L&M&H) Through all speed Through all speed 5
ranges ranges
3T/C1T/C(L&M&H) Less than 12.5 (7.8) Less than 12.5 (7.8) 5
3L/U3T/C(L&M&H) Through all speed Through all speed 0
Kick-down mode (When kick-down ranges ranges
switch OFF ON) 4T/C1T/C(L&M&H) Less than 12.5 (7.8) Less than 12.5 (7.8) 5
4L/U4T/C(L&M&H) Through all speed Through all speed 0
ranges ranges
4T/C3T/C(L&M&H) 12.5-35.0 (7.8-21.8) 12.5-35.0 (7.8-21.8) 4
3T/C2T/C(L&M&H) 12.5-35.0 (7.8-21.8) 12.5-35.0 (7.8-21.8) 4
10-3063 WA380-5L
Gear speed
Forward (F) Reverse (R)
change disabling
Shift lever position Solenoid signal time after the
Speed Speed preceding
km/h (mph) km/h (mph) change (sec)
4L/U2T/C(L&M&H) Zone I & II Zone I & II 2
4T/C2T/C(L&M&H) Zone I & II Zone I & II 2
2, 3 or 4 3L/U2T/C(L&M&H) Zone I & II Zone I & II 2
3T/C2T/C(L&M&H) Zone I & II Zone I & II 2
1T/C2T/C(L&M&H) Through all speed ranges Through all speed ranges 2
4L/U4T/C(H) Zone III & 18.0 (11.2) & up Zone III & 18.0 (11.2) & up 2
(R) NF
4L/U4T/C(M) Zone III & 16.5 (10.3) & up Zone III & 16.5 (10.3) & up 2
4L/U4T/C(L) Zone III & 15.0 (9.3) & up Zone III & 15.0 (9.3) & up 2
Zone III & 13.0-18.0 Zone III & 13.0-18.0
4L/U3T/C(H) 2
When direction switch is shifted (1) (F) NR
(8.1-11.2) (8.1-11.2)
Zone III & 13.0-16.5 Zone III & 13.0-16.5
4L/U3T/C(M) 2
(8.1-10.3) (8.1-10.3)
Zone III & 13.0-15.0 Zone III & 13.0-15.0
4L/U3T/C(L) 2
(8.1-9.3) (8.1-9.3)
Zone III & 13.0-18.0 Zone III & 13.0-18.0
4 4T/C3T/C(H) 2
(8.1-11.2) (8.1-11.2)
Zone III & 13.0-16.5 Zone III & 13.0-16.5
4T/C3T/C(M) 2
(8.1-10.3) (8.1-10.3)
Zone III & 13.0-15.0 Zone III & 13.0-15.0
4T/C3T/C(L) 2
(8.1-9.3) (8.1-9.3)
3T/C3T/C(H) Zone III & 13.0-18.0 Zone III & 13.0-18.0
2
No gear speed change (8.1-11.2) (8.1-11.2)
3T/C3T/C(M) Zone III & 13.0-16.5 Zone III & 13.0-16.5
2
3T/C3T/C(L) Zone III & 13.0-15.0 Zone III & 13.0-15.0
2
3L/U3T/C(L&M&H) Zone III Zone III 2
3 3T/C3T/C(L&M&H)
Zone III Zone III 2
No gear speed change
4L/U(H) 23.7 (14.7) and up 25.2 (15.7) and up ---
4L/U(M) 22.2 (13.8) and up 23.6 (14.7) and up ---
When direction switch is shifted (2) FNR RNF
4L/U(L) 20.7 (12.9) and up 22.0 (13.7) and up ---

4T/C(H) 18.0-23.7 (11.2-14.7) 18.0-25.4 (11.2-15.8) 0
4 4T/C(M) 16.5-22.2 (10.3-14.7) 16.5-23.9 (10.3-14.9) 0
4T/C(L) 15.0-20.7 (9.3-12.9) 15.0-22.4 (9.3-13.9) 0
3T/C(H) 10.2-18.0 (6.3-11.2) 10.2-18.0 (6.3-11.2) 0
3T/C(M) 9.0-16.5 (5.6-10.3) 9.0-16.5 (5.6-10.3) 0
3T/C(L) 7.0-15.0 (4.4-9.3) 7.0-15.0 (4.4-9.3) 0
3L/U(M&H) 13.9 (8.6) and up 16.0 (9.9) and up ---
3L/U(L) 11.0 (6.8) and up 16.0 (9.9) and up ---
3 3T/C(H) 10.2-13.9 (6.3-8.6) 10.2-16.0 (6.3-9.9) 0
3T/C(M) 9.0-13.9 (5.6-8.6) 9.0-16.0 (5.6-9.9) 0
3T/C(L) 7.0-11.0 (4.4-6.8) 7.0-16.0 (4.4-9.9) 0
2T/C(H) up to 10.2 (6.3) up to 10.2 (6.3) 0
3 or 4 2T/C(M) up to 9.0 (5.6) up to 9.0 (5.6) 0
2T/C(L) up to 7.0 (4.4) up to 7.0 (4.4) 0
2 2T/C(L&M&H) Through all speed ranges Through all speed ranges ---
WA380-5L 10-3073
2. Torque Converter Lockup Control Function (Option)
A. The torque converter lockup switch operation (ON/OFF) enables to implement the lockup automatically.
When the lockup switch is turned on, the torque converter lockup can be automatically turned on or off in the manual
shift mode, too.
Following table shows the lockup specification-based gear speeds
Lockup specification-based gear speeds Lockup: Å
Travel mode F1 F2 F3 F4 R1 R2 R3 R4
Manual shift
Auto-shift (L, M, H)
: In the auto-shift mode, the lockup is not available only at the 3rd gear speed (gearshift lever position).
B. Lockup travel speed

For the travel speed that turns ON/OFF the lockup, refer to the [Auto-Shift Point List].
In the manual shift mode, too, the lockup is turned on or off at the same travel as in the auto-shift mode.
The lockup is cancelled as the travel speed reaches 40 km/h (25 mph) or above. This arrangement is prepared to
ensure the driver safety. After the cancellation, if the travel speed is increased from below 38km/h (24 mph) to
38km/h (24 mph) or above, the lockup is applied again.
C. Lockup protection function

The lockup is turned on only when the machine traveling direction matches the lever position.
Judgement of machine travel direction
i. When the travel speed is ≥ 10 km/h (6 mph), the lever position decides the machine travel direction.
ii. As long as the travel speed ≥ 10km/h (6 mph) is kept, judgement of B above is maintained.
iii. When the travel speed < 10km/h (6 mph) is detected continuously for one second or more, the protection
function judges that no speed data is available.
iv. When data on FR travel direction is not stored in the memory or when the travel direction does not match the
lever position, the lockup function is not turned on.
3. Transmission Cutoff Function
A. Function
If you step on the left brake pedal, this function causes the transmission to the neutral detecting oil pressure in the
brake circuit by use of the pressure sensor.
This function enables the cutoff at any position by storing position of the stepped-on brake where the transmission is
caused to the neutral as the brake circuit pressure.
B. Input and output
10-3083 WA380-5L
C. Description of the control

This function causes the Transmission to neutral as a pressure greater than the pre-
(1) Transmission cutoff control determined level is signaled by the left brake pressure sensor (when Transmission
cutoff switch is ON).
Enable condition Transmission cutoff switch ON (Transmission cutoff is enabled)
Step on the left brake pedal until it comes to the position desired as the cutoff point.
Push and release the Transmission cutoff set switch.
The pressure at the time when the switch is released is temporarily stored. The setup
complete buzzer is sounded twice (beep).
Setup procedure
At the same time, the indicator built in the Transmission cutoff switch flashes for 2.5
seconds.
After flashing for 2.5 seconds, the brake position is stored on memory (your setting is
(2) Set up cutoff point
held after the key is turned off).
Push and release the Transmission cutoff set switch.
The indicator built in the Transmission cutoff switch will flash for 2.5 seconds.
While the flashing continued, push and release the Transmission cutoff set switch
Reset procedure again.
As the flashing ends, the cutoff point is set as the default left brake pressure. The
setup cancel buzzer is sounded.
The default value is stored in memory (the set value is held after turning the key off).
D. Output conditions for the buzzer, indicator (main monitor) and indicator built in the Transmission cutoff switch
Output condition Indicator built in Transmission Buzzer sound Cutoff point
cutoff switch
When Transmission cutoff switch Comes on Not available Control is based on the value
is ON stored in previous operation
While Transmission cutoff point Flashes Setup complete buzzer is Pressure at your releasing the
is set sounded as the set switch is set switch is stored
released
When Transmission cutoff switch Goes off Not available No control is provided.
is ON but error is present on Stored value is not changed.
sensor
When Transmission cutoff switch Goes off Not available Control is based on the value
is ON but error is present on set stored in previous operation.
switch Stored value is not changed.
When Transmission is OFF Goes off Not available No control is provided
E. Transmission cutoff point settable range

Settable range Note: If you specify a value less than 0.49MPa (5kg/cm²) {71 psi}, it will be set as 0.49MPa
(5kg/cm²) {71 psi}.
0.49~4.41MPa {5~45kg/cm²} Note: When a value larger than 4.41MPa (45kg/cm²) {640 psi}, it will be set as 4.41MPa
(71~640 psi) (45kg/cm²) {640 psi}. The default value is 1.47MPa (15kg/cm²) {213 psi}.
A separation of 0.20MPa (2kg/cm²) is provided between the cutoff IN pressure (causing Transmission to neutral) and
OUT (reset) pressure.
Example: When 0.98MPa (10kg/cm²) is set on the pressure sensor
Cutoff IN pressure = 0.98MPa (10kg/cm²)
Cutoff OUT pressure = 0.78MPa (8kg/cm²)
WA380-5L 10-3093
4. Right FNR Switch Selecting Function (If equipped)

The right FNR switch on the side of the work equipment lever can select forward/reverse travel without operating
forward-reverse lever on the steering column.
★ Right FNR switch is installed only for overseas specification.
System Diagram
10-3103 WA380-5L
A. Turning on the right FNR switch functions

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

switch lever
Normal position N N
When switched from steering to
Even resulting from abnormal position Error is warned Error is warned
right F-N-R
Correcting approach Set to N Set to N
Normal position N N
When switched from right F-N-R to
Even resulting from abnormal position Error is warned Error is warned
steering
Correcting approach Set to N Set to N
B. Switching between forward and reverse from the right FNR

If the forward-reverse lever on the steering column is positioned at the neutral in the state of step A above, switching
between forward and reverse becomes available from the right FNR.
When forward-reverse lever on the steering column is positioned at F or R, precedence is given to the lever operation
irrespective of the right FNR switch position.
C. Gear speed change from the right FNR switch

The same gear speed change functions as those from the steering column become available.
Operable switches when the right FNR switch function is installed
Operation on work
Operation on steering column
equipment
Switching between
Gearshift lever
Switch selection auto-shift and Right FNR switch Forward-reverse lever
position
manual shift
When the lever is positioned at N, Gear speed

Switching between change becomes
operation from the work equipment is
forward and reverse is available by
Manual shift enabled. When the lever is at F or R,
available from the changing the lever
precedence is given to the lever position.
switch
When right FNR is though an error is warned.
selected When the lever is positioned at N,
Switching between
operation from the work equipment is
forward and reverse is Maximum gear
Auto-shift (L,M,H) enabled. When the lever is at F or R,
available from the speed (limiter)
precedence is given to the lever
switch
though an error is warned.
Normal operation is Switching between forward and Gear speed

available when fixed to change becomes
Manual shift reverse becomes available from the
N. Error is warned at any available from the
position other than N. lever. lever.
When steering
column is selected
Normal operation is Switching between forward and
available when fixed to Maximum gear
Auto-shift (L,M,H) reverse becomes available from the
N. Error is warned at any speed (limiter)
position other than N. lever.
D. Safety function to be turned on at startup of engine

If the right FNR switch on the work equipment is not positioned at N, output of the neutral signal from transmission
controller is disabled, and thus you can’t start the engine. In this case, too, the neutral caution is warned.
WA380-5L 10-3113
5. Gear Speed Change Function available from Joystick Steering (If equipped)
Forward-reverse travel of the travel system as well as gear speed change operation is available from the transmission
controller-controlled joystick function.
As long as the joystick function is turned on, travel at the 4th speed is prohibited in order to ensure driver safety.
Steering on both sides is done from the joystick work equipment controller.
System Diagram
10-3123 WA380-5L
A. Turning on the joystick function

If you turn on Joystick FNR switch after turning on Joystick spring switch by shifting the armrest for the joystick to
the lock position, the joystick function enable signal is entered to the transmission controller.
When you switch the function between the joystick and steering, both the forward-reverse lever on the steering
column and Joystick FNR switch on the joystick must be positioned at neutral (N). It is so required from the safety
standpoint.
Joystick FNR switch Forward-reverse lever Gearshift lever

Normal position N N 1st to 3rd speeds
Even resulting from
When switching is done Error is warned Error is warned Error is warned
abnormal position
from steering to joystick
Position at one of 1st to
Correcting approach Position at N Position at N
3rd speeds
Normal position N N Any position
When switching is done Even resulting from
Error is warned Error is warned ---
from joystick to steering abnormal position
Correcting approach Position at N Position at N ---
B. Switching between forward and reverse from joystick

If the forward-reverse level on the joystick is at the neutral position in the state of 1) above, switching between
forward and reverse becomes available from Joystick FNR switch.
When the forward-reverse level is positioned at F or R, precedence is given to the lever irrespective of the Joystick
FNR switch position.
WA380-5L 10-3133
C. Switching of gear speed from joystick

● When the manual shift is selected
You can switch the gear speed from the shift up/down switches provided at the head of the joystick. In this case,
however, the gearshift lever on the steering column must be positioned at the maximum gear speed (in the gear
speed change range).
Example: When the gearshift lever is at the 3rd speed, switching from the shift up/down switches is available in
the range of the 1st and 3rd speeds. Pushing the shift up/down switches from the 3rd speed does not turn on the
4th speed.
● When the auto-shift (L, M, H) is selected
The gearshift lever on the steering column is positioned at the maximum gear speed (gear speed change range),
thereby enabling the gear speed change. In this case, the shift up/down switches provided at the head of the joy-
stick is disabled for the speed change.
● Gear speed change from the hold switch or the kick down switch
The same function as that from the steering column becomes available.
Operable Switches (Levers) when Joystick Function is Installed
Operations on joystick Operations on steering column
Joystick
Switching of Shift up Shift down Gearshift lever
switching Joystick FNR switch Forward-reverse lever
auto-shift switch switch position
function
When fixed at N, When the lever is
switching is available positioned at the
Switching between
from the joystick. maximum gear
forward and reverse is
Manual shift Shift up Shift down At any other positions, speed (limiter),
available from the
precedence is given to selection is available
switch.
the lever, accompanied only in the range of
Joystick by an error warning. 1st to 3rd speeds.
selected When fixed at N, When the lever is
switching is available positioned at the
Switching between
from the joystick. maximum gear
Auto-shift forward and reverse is
Disabled Disabled At any other positions, speed (limiter),
(L,M,H) available from the
precedence is given to selection is available
switch.
the lever, accompanied only in the range of
by an error warning. 1st to 3rd speeds.
Normal operation is
Switching between
available when fixed Switching between
forward and reverse
Manual shift to N. An error is Disabled Disabled forward and reverse is
is available from the
indicated at any available from the lever.
Steering lever.
position other than N.
column
selected Normal operation is
available when fixed Switching between
Auto-shift Maximum gear
to N. An error is Disabled Disabled forward and reverse is
(L,M,H) speed (limiter)
indicated at any available from the lever.
position other than N.
D. Safety function to be turned on at start of engine

If the joystick is selected and Joystick FNR switch is not at N position at startup of the engine, output of the neutral
signal from the transmission controller is disabled and thus the engine can’t be started.
When the joystick lever is operated (located at any position other than N), output of the neutral signal is disabled by
the network signal from the work equipment controller. Thus, the engine can’t be started.
The neutral caution will be warned for both of above cases.
10-3143 WA380-5L
6. Travel Damper Function

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 control of vertical motion of the work equipment.
Following table shows the operating conditions of the travel damper.

Travel damper switch Gear speed Travel speed Travel damper output Operational status
Through all gear Not activated
OFF 0 ~ MAX OFF
speeds (in the process of charging)
Not activated
1st speed 0 ~ MAX OFF
(in the process of charging)
ON Not activated
Condition A OFF
2nd ~ 4th speeds (in the process of charging)
Condition B ON Activated
WA380-5L 10-3153
7. Electric Emergency Steering Function (If equipped)
A. Operation of electric emergency steering function

The transmission controller constantly monitors state of the steering oil pressure switch of the steering circuit. If oil
pressure of the steering goes low, thereby increasing the travel speed above the emergency steering activation level,
the transmission controller outputs the emergency steering ON signal to the relay to turn on the emergency steering.
This function can also be turned on from the emergency steering switch independent of the travel speed or steering oil
pressure.
10-3163 WA380-5L
B. Self-check operation of emergency steering

3 seconds after the starting switch is turned on (after the monitor check is completed), the transmission controller
implements the self-check in which the controller checks operation of the emergency steering automatically.
In the following cases, however, the self-check is not implemented.
i. When the engine starter is turned on from the starting switch.
ii. When the engine is already started (when engine speed of 500 rpm or above is detected).
iii. When the steering pressure is already present.
iv. When the automatic engine pre-heating function is turned on.
v. When a emergency steering-related error is detected in the monitor check.
vi. When the engine has not been operated more than 10 seconds from the last self-check (when the engine has not
been operated at 500 rpm for 10 seconds or more).
The emergency steering ON signal at the self-check is output for 3 seconds maximum. If the monitor 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 signal, the transmission controller ends
the self-check of the emergency steering. If the above signal is not sent within 3 seconds, the controller warns an
error.
WA380-5L 10-3173
8. Cooling Fan Control Function
A. Fan control
This system reduces loss of horsepower and noise at low temperature by employing the hydraulic drive for the
cooling fan and controlling the swash plate of the hydraulic pump swash.
Engine coolant temperature, operating oil temperature and oil temperature of the torque converter detected by the
machine monitor are sent to the transmission controller via the network. Upon receiving above information, the
transmission controller turns on a fan revolution suitable to the temperature and engine speed by controlling the
swash plate of the hydraulic pump by use of electric current.
10-3183 WA380-5L
B. Control of reverse fan rotation

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

Reverse fan Output from
rotation SOL (before Engine speed reverse rotation Monitor indicator
rotation switch fan pump EPC
switch operation) SOL
OFF OFFON ON MIN rotation OFFON
OFF ONOFF Stopped OFF Normal BlinkingOFF
ON OFFON (less than 500 rpm) ON MIN rotation BlinkingON
ON ONOFF OFF Normal ONOFF
OFF OFFON OFF Normal OFFBlinking
OFF ONOFF OFF Normal BlinkingOFF
Started
ON OFFON (500 rpm 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
WA380-5L 10-3193
9. Switch Pump Cutoff Function

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

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

Targeted Condition A Condition B Condition C Condition D Condition E Condition F
downshift TM output speed TM output speed Engine speed TM output speed TM output speed Engine speed
gear speed
3rd speed None 2,658 rpm 2,100 rpm None Less than Less than
or above or above 2,436 rpm 1,900 rpm
2nd speed 2,658 rpm 1,846 rpm 2,100 rpm Less than Less than Less than
or above or above or above 2,436 rpm 1698 rpm 1,900 rpm
1st speed 1,846 rpm 1,107 rpm 2,100 rpm Less than Less than Less than
or above or above or above 1,698 rpm 997 rpm 1,900 rpm
10-3203 WA380-5L
C. Protect alarm cancel condition: In any of the following cases, output of the protect alarm is stopped and normal
control is restored.
i. When matching is established between the input instruction and output instruction from the gearshift lever (shift
switch).
ii. When a shift above the one specified with the output instruction is selected from the gearshift lever (shift switch).
D. Operations restricted while the downshift protect is turned on: As long as the protect is turned on, hold and kick down
operations are disabled.
Transmission output shaft speed and travel speed Protection travel speed (km/h)
WA380-5L (small diameter tire) WA380-5L (large diameter tire)
Transmission output shaft 2,658 30.3 33.2
speed converted to travel 1,846 21.1 23.0
speed (rpm)
1,107 12.6 13.8
11. Troubleshooting
The transmission controller self diagnoses the system by monitoring the input/output signals constantly.
If any errors are found in the self-diagnosis, the controller sends error information to the machine monitor via the network.
The machine monitor allows you to check the errors.
WA380-5L 10-3213
12. Gear shift function by multi function mono lever

If FNR switch, kick-down switch and holding switch are attached on the top of the multi function mono lever (working
equipment operation lever), directional control and gear shift can be performed by other than the directional lever and gear
shift lever on the steering column.
10-3223 WA380-5L
A. Operation of the FNR switch on the multi function mono lever

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

mono lever
Normal position N N
When switching directional
operation from the steering Symptoms in other than Generation of error warning Generation of error warning
column to the multi function normal position
mono lever
Correcting method Place in the N position. Place in the N position.
Normal position N N
When switching directional
operation from the multi function Symptoms in other than Generation of error warning Generation of error warning
mono lever to the steering normal position
column
Correcting method Place in the N position. Place in the N position.
B. Directional operation on the multi function mono lever

When the directional lever installed on the steering column is in neutral position (in step A condition), directional
operation can be performed by the FNR switch on the multi function mono lever.
When the FNR lever on the steering column is set in the F or R position, regardless of the position of the FNR switch
on the multi function mono lever, priority is given to the lever operation.
C. When the FNR switch on the multi function mono lever is operated, the same function as gearshift using the ordinary
steering column is performed.
Operable switch (lever) when multi function mono lever is equipped.
Operation on the multi Operation on the steering column

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

is in other than N position. range (Limiter)
D. Safety function when starting the engine

When the FNR switch on multi function mono lever is selected at the time of starting the engine, a neutral signal from
the transmission controller is not output and the engine is not started if the FNR switch on the multi function mono
lever is not in the N position. In this case, neutral caution is given.
WA380-5L 10-3233
E. Kickdown function
i. Kickdown during manual shift

The kickdown switch can be operated only at the forward 2nd-speed (F2). Operation of the kickdown 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.
ii. 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.
Time that speed

Speed range Travel speed Speed range after shifting cannot be shifted
2nd-speed Whole range 1st-speed 5 seconds
Less than 12.5 km/h 1st-speed 5 seconds
3rd-speed Less than 12.5 - 25 km/h 2nd-speed 4 seconds
25 km/h or higher No shifting (3-speed) —
4th-speed Less than 12.5 - 35 km/h 3rd-speed 4 seconds
35 km/h or higher No shifting (4-speed) —

3rd-speed (at lockup)
12.5 km/h or higher 3rd-speed (lockup released) *1

4th-speed (at lockup)
12.5 km/h or higher 4th-speed (lockup released) *1
*1: When the lockup is released by kickdown switch operation, lockup must not be applied again until the following
conditions occur:
● Change the torque converter lockup switch from OFF to ON temporarily.
● The travel speed less than that with the lockup ON in the list of the auto shift points changes to the speed exceeding it.
F. Shift hold function

The speed at the time when the hold switch was pressed is held and it will not be upshifted even when the travel speed
increases or it will not be downshifted even when the travel speed decreases.
When the directional lever, gear shift lever, FNR switch, or kickdown switch is operated, the shift hold function is
automatically released.
The condition of lockup ON/OFF will not be held.
10-3243 WA380-5L
13. Torque Converter Charging Pump Bypass Function (If equipped)

At a low temperature, the oil viscosity is high and the pump load torque increases against the engine starting torque and
the engine start ability becomes poor. As for the corrective action, when starting the engine at a low temperature, bypass
oil inside the pump to reduce load to the pump, so that the engine start ability will improve.
The bypass solenoid operation signal outputting conditions are shown in the table below. When Conditions 1 to 4 are all
satisfied, the bypass solenoid operation signal is output.
Condition 1 Starting Signal C is switched on or 10 seconds after the signal is switched on to off.
Condition 2 Engine coolant temperature: Less than -15°C (5°F).
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")
WA380-5L 10-3253
Electric Circuit Diagram (Standard)
★ Mark * indicates optional parts.
10-3263 WA380-5L
WA380-5L 10-3273
Electric Circuit Diagram (If Equipped)
10-3283 WA380-5L
WA380-5L 10-3293
TRANSMISSION CONTROLLER MAINTENANCE STANDARD
TRANSMISSION CONTROLLER
10-3303 WA380-5L
MAINTENANCE STANDARD TRANSMISSION CONTROLLER
Input and Output Signals
DEUTSCH-24P [CN-L61]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 NC Input 13 NC Input
2 Shift mode H Input 14 Shift mode L Input
4 Signal GND — 16 Sensor supply source output (+24V) Output
5 Transmission cutoff set switch Input 17 Steering pressure switch (NC) Input
6 Engine power mode switch Input 18 Lockup selector switch Input
7 Reverse fan rotation switch Input 19 Left brake pressure sensor Input
8 Shift mode M Input 20 Rear brake oil temperature sensor Input
9 Transmission oil temperature sensor Input 21 Analog GND —
10 Signal GND — 22 Potentiometer power (+5V) Output
11 Transmission cutoff switch Input 23 Steering pressure switch (NO) Input
12 Kick down switch Input 24 E.C.S.S. switch Input
DEUTSCH-40P(1) [CN-L62]
1 NC Output 21 S_NET Input/Output
2 ECMV fill switch lock-up Input 22 CAN0_L Input/Output
3 ECMV fill switch 4th Input 23 CAN1_L Input/Output
4 232C_RxD Input 24 Write-to-flash-memory enable signal Input
5 Right FNR (Joystick) forward-reverse R Input 25 Right FNR (Joystick) forward-reverse Input
6 Neutralizer (Parking Brake) signal Input 26 Forward-reverse lever N Input
7 ECMV fill switch 2nd Input 27 ECMV fill switch R Input
8 NC Output 28 NC Input
9 Engine speed pulse unlatched output Output 29 Pulse GND —
10 Engine speed signal (+) Input 30 NC Input
11 NC Output 31 S_NET GND —
12 CAN shield — 32 CAN0_H Input/Output
13 ECMV fill switch 3rd Input 33 CAN1_H Input/Output
14 232_TxD Output 34 RS232C GND —
15 Right FNR (Joystick) forward-reverse N Input 35 Right FNR (Joystick) switch Input
16 Forward-reverse lever R Input 36 Forward-reverse lever F Input
17 ECMV fill switch 1st Input 37 ECMV fill switch F Input
18 NC Output 38 Shift hold switch Input
19 Travel speed pulse unlatched output Output 39 Pulse GND —
20 Travel speed signal (+) Input 40 NC Input
1 VB (controller power) Input 21 GND (controller ground) Input
2 VIS (solenoid power) Input 22 VIS (solenoid power) Input
3 SOL_COM (common solenoid ground) Input 23 SOL_COM (common solenoid ground) Input
4 Back lamp relay Output 24 Key switch signal Input
5 ECMV F Output 25 ECMV 1st Output
6 ECMV 2nd Output 26 ECMV 4th Output
7 Electric emergency steering relay Output 27 Switch pump cutoff relay Output
8 Indicator built in Transmission cutoff Output 28 Reverse fan pump rotation solenoid Output
9 Joystick shift up switch Input 29 Electric emergency steering operation Input
10 Gearshift lever 1st speed Input 30 Gearshift lever 3rd speed Input
12 VIS (solenoid power) Input 32 GND (controller ground) Input
13 SOL_COM (common solenoid ground) Input 33 GND (controller ground) Input
14 Key switch signal Input 34 NC —
15 ECMV R Output 35 ECMV lock-up Output
16 ECMV 3rd Output 36 Fan pump EPC Output
17 E.C.S.S. Output 37 Neutral output Output
18 Low temperature by-pass relay Output 38 Fan pump neutral solenoid Output
19 Joystick shift down switch Input 39 Starter switch C-terminal Input
20 Gearshift lever 2nd speed Input 40 Gearshift lever 4th speed Input
WA380-5L 10-3313
WORK EQUIPMENT CONTROL SYSTEM MAINTENANCE STANDARD
WORK EQUIPMENT CONTROL SYSTEM
System Diagram
10-3323 WA380-5L
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL SYSTEM
1. Work equipment control
A. Electric lever control

● Lift arm controlling function
This function controls the EPC valve according to how much the lift arm lever was moved to allow control valve
of the work equipment to operate, which in turn allows the lift arm RAISE/LOWER function to be performed.
● Bucket controlling function
This function controls the EPC valve according to how much the bucket lever was moved to allow the control
valve of the work equipment to operate, which, in turn allows the bucket TILT/DUMP function to be performed.
● 3rd Lever controlling function
This function controls the EPC valve according to how much the 3rd lever was moved to allow the control valve
of the work equipment to operate, which, in turn allows the 3rd valve cylinder EXTEND/RETRACT function to
be performed.
WA380-5L 10-3333
● Work equipment neutral cut

When the work equipment lock lever for blocking the passage on the work equipment lever circuit is in the
LOCK position, the work equipment neutral cut solenoid is excited to unload the pilot pressure on the work
equipment valve. This mechanism prevents the work equipment from being accidently operated by operation of
the work equipment lever.
Function Table
Operator’s action Controller input Controller output Movement at machine
Work equipment Neutral lock

Work equipment lever Work equipment lever switch Hydraulic power
valve
Raise (FREE) ON (CLOSE) OFF (OPEN) Active
Lower (LOCK) OFF (OPEN) ON (24V) Inactive
10-3343 WA380-5L
B. Detent control
● Boom kick-out control
Operating the lift arm lever to reach the RAISE detent range allows a detent-on signal to be output from the work
equipment controller.
This enables the lift arm lever to be maintained in the RAISE state even when the lever is released.
When lift arm is raised and an input signal of lift arm angle sensor approaches the top angle, detent is cancelled
and the lift arm stops rising. At this same time, the work equipment controller gradually slows down the lift arm
RAISE EPC (referred to as modulation control) to prevent 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.
● Lift arm releasing function

Lowering the lift arm lever to allow it to reach the detent range, a detent-on signal is output from the work
equipment controller to cause the lift arm lever to be maintained in the LOWER state. At this time, the lift
cylinder is released to allow the lift arm to be raised or lowered by external force.
Therefore, it this function starts when the lift arm is up in the air, it goes down due to its own weight.
WA380-5L 10-3353
● Bucket leveling function

If the bucket is below the horizontal position, operating the bucket lever to allow it to approach the TILT detent
range causes a detent-on signal to be output from the work equipment controller, which, in turn allows the bucket
lever to be maintained in the TILT state.
When the bucket is tilted and approaches the horizontal position, the bucket proximity switch detects it,
cancelling detent to stop the TILT operation.
At this time, the work equipment controller gradually slows down the bucket TILT EPC (referred to as
modulation control) to prevent excessive impact from arising upon stoppage of the bucket motion.
If the bucket is tilted above the horizontal position, detent does not work even when the lever is operated to
approach the detent position.
10-3363 WA380-5L
2. Remote positioner control

The remote positioner enables the operator to set lift arm stop position as desired, smoothing lift arm starting and stopping
motions.
This enables safety and operability of backward digging operations as well as machine body operations for approaching
DUMP.
Functions
The remote positioner stops after slowing down at the lift arm RAISE/LOWER position.
The work equipment controller constantly detects the lift arm angle (position) based upon the direction in which the lever
is operated and data from the arm angle potentiometer.
★ To stop the lift arm RAISE operation (when the RAISE selection switch is turned on) Operating the lift arm lever to
enter RAISE detent and allowing the lift arm to be raised before the set position cancels lift arm RAISE detent, which
starts modulation control for stopping the lift arm.
The lift arm can be manually raised in all cases except for the RAISE detent position.
If RAISE is not selected (when the selection switch is turned off), only kick-out is enabled.
★ To stop lift arm LOWER operation (when the LOWER selection switch is turned on).
Place the lift arm lever at the "FLOAT detent" position. The lift arm starts slowing down at 10 degrees before the set
position, and FLOAT detent is canceled 4 degrees before the set position to perform modulation control for stopping
the lift arm.
Retain the lift arm lever at that position to restart lowering it.
If LOWER is not selected (when the LOWER selection switch is turned off), only FLOAT detent is enabled.
If the lift arm angle is above the horizontal position when the lever is placed in the detent position, only FLOAT
detent is enabled.
Remote positioner mode selection and stop angle setting
Selection mode RAISE and
RAISE stop LOWER stop
Selection switch LOWER stop
RAISE selection switch ON (●) OFF ( ) ON (●)
LOWER selection switch OFF ( ) ON (●) ON (●)

Indicator output
Lamp on (Switch ON) : ●
Lamp off (Switch OFF) :
Applicable setting range for remote positioner stop position

Stop position
For RAISE For LOWER
Model
WA380-5L 0° - +45.8° 0° - -40.8°

0°: Horizontal lift arm position
WA380-5L 10-3373
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 setting position where the switch was released is within the applicable
range, the angle attained when the switch was released is tentatively
saved, and the setting completion buzzer beeps twice.
Setting procedure
Otherwise, the setting cancellation buzzer beeps.
Setting of remote
4) The RAISE indicator blinks (for 2.5 seconds).
2 positioner RAISE
5) The setting is saved after the indicator blinks for 2.5 seconds (the setting
stop angle point
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 maintained
even after the equipment is keyed off.)
10-3383 WA380-5L
LOWER position setting

1 Remote positioner LOWER stop control LOWER lift arm stop (selection switch = ON)
LOWER selection switch = ON (remote positioner LOWER stop enabled)

Enabled if:
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 setting position where the switch was released is within the applicable
range, the angle attained when the switch was released is tentatively
saved, and the setting completion buzzer beeps twice.
Setting procedure
Otherwise, the setting cancellation buzzer beeps.
Setting of remote
4) The LOWER indicator blinks (for 2.5 seconds).
2 positioner LOWER
5) The setting is saved after the indicator blinks for 2.5 seconds (the setting
stop angle point
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 LOWER
indicator is blinking), press the remote positioner LOWER position setting
switch again, and release it.
Resetting procedure 2) As the indicator stops blinking, set the LOWER stop position point to "0°"
(horizontal). The setting cancellation buzzer beeps.
3) The set value is saved (as the default value). (The set status is maintained
even after the equipment is keyed off.)
Output conditions for buzzers and indicator lamps

The same output conditions apply for both RAISE and LOWER operations.
Output condition Indicator lamp Buzzer output Stop position
Remote positioner selection switch = ON Comes on None Controlled with the value saved previously
Remote positioner selection switch = ON; Setting completion buzzer Controlled with the value saved previously.
Blinks (for 2.5
Position setting switch = ON. seconds or beeps upon releasing setting Value attained when setting switch was
Output for 2.5 seconds or until reset (When
the sensor is operating normally) until reset) switch released is saved.
Remote positioner selection switch = ON; Setting cancellation buzzer Controlled with the value saved previously.
Position setting switch = ON; Comes on beeps upon releasing setting The value stored is not altered.
Lift arm angle = Outside the setting range. switch.
Remote positioner selection switch = ON; Not controlled.

Goes off None
When sensor is not operating normally. The value stored is not altered.
Remote positioner selection switch = ON; Controlled with the value saved previously.
When sensor is not operating normally. Comes on None
The value stored is not altered.
Remote positioner selection switch = ON; Controlled with the value saved previously.
Setting cancellation buzzer The default value is saved.
Position setting switch = ON.
Comes on beeps upon releasing setting
Reset during 2.5-second blinking
switch.
(Position setting switch = ON again)
Not controlled.
Remote positioner selection switch = OFF Goes off None
RAISE/FLOAT detent is controlled.
WA380-5L 10-3393
3. Semi-auto digging control

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

● Turn the auto-digging selection switch on (in the soft or hard mode).
● Set the lift arm angle of the work equipment to -35° or below (so that the bucket contacts the ground).
● Operate the kickdown switch to shift down to the 1st speed gear with the transmission kept in the forward mode.
● The engine speed increases and the travel speed drops (travel speed in km/h < 3.5 multiplied by engine speed in
rpm divided by 2,000).
● Semi-auto digging starts with lift arm RAISE operation.
10-3403 WA380-5L
B. Starting semi-auto digging
i. When the lift arm lever was replaced to the neutral position after semi-auto digging had started:
● Auto TILT starts on the bucket.
● The lift arm starts auto-lift after a travel speed of 1 km/h or below is maintained for 1 second.
● If lift arm RAISE is started at this time, AUTO-TILT stops during lift arm RAISE operation.
ii. When the lift arm lever was placed in the detent position after semi-auto digging had started:
● AUTO-TILT does not start if the lift arm RAISE speed does not drop due to failure of loading into the
bucket (after the lift arm continued to be raised at 1 deg/sec for 0.5 seconds).
● AUTO-TILT starts when the bucket stops being raised (after being raised at 1 deg/sec for 0.5 seconds).
C. Termination of semi-auto digging

Semi-auto digging is terminated if one of the following conditions is satisfied:
● The shift lever is placed in a position other than forward.
● The lift arm is placed above the horizontal position.
● TILT operation reaches the stroke end.
● AUTO-TILT has been performed six times in the hard mode.
D. Semi-auto digging mode

● Soft mode
AUTO-TILT is continuously performed.
NOTE, however, TILT may temporarily stop due to manual interference
● Hard mode
AUTO-TILT operates intermittently in a cycle of 1 or 2 seconds.
The semi-auto digging mode is terminated when TILT has been performed six times in the hard mode.
WA380-5L 10-3413
4. Joystick steering control

Joystick steering control enables steering of the machine to be performed simply with the joystick, without operating the
steering wheel.
The steering wheel can be operated even during operation of the joystick. However, operation is articulated by either the
joystick or steering wheel, depending upon which is more powerful (in terms of steering force) if the operating direction
differs between the two.
The work equipment controller controls the steering system of the joystick.
The traveling system (forward/backward travel and gear shift) is controlled by the transmission controller.
10-3423 WA380-5L
A. 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.
B. Modulation control
Steering with the joystick applies modulation control in order to reduce impact that may be experienced 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.
WA380-5L 10-3433
5. Calibration function
A. EPC calibration
This is an adjusting function to reduce variances of the starting points of the lift arm, bucket and joystick due to
cumulative errors with the electric lever, EPC valve and main valve.
B. Sensor adjustment
This function provides offset adjustment for errors due to installation of the joystick lever angle potentiometer to
enable the position data of the work equipment to be correctly detected.
C. Calibrating method
Calibration is performed in the service mode on the monitor panel. See the "Equipment Monitoring" section for
details.
6. Troubleshooting
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 information via the equipment-monitoring net-
work. In case of faulty occurrences, you can check the status with the equipment-monitoring function.
10-3443 WA380-5L
MEMORANDUM
WA380-5L 10-3453
Electric Circuit Diagram
10-3463 WA380-5L
WA380-5L 10-3473
WORK EQUIPMENT CONTROLLER MAINTENANCE STANDARD
WORK EQUIPMENT CONTROLLER
10-3483 WA380-5L
MAINTENANCE STANDARD WORK EQUIPMENT CONTROLLER
Input and output signals

DEUTSCH-24P [CN-L71]
1 Bucket lever potentiometer B Input 13 Lift arm lever potentiometer B Input
2 NC Input 14 Third EPC lever B Input
3 Joystick lever potentiometer B Input 15 NC Input
4 Signal GND — 16 Sensor power Output
5 NC Input 17 Lever prohibiting equipment operation sw Input
7 Bucket lever potentiometer A Input 19 Lift arm lever potentiometer A Input
8 Lift arm angle sensor Input 20 Third EPC lever A Input
9 Joystick lever potentiometer A Input 21 Analog GND —
10 Signal GND — 22 Potentiometer power Output
11 NC Input 23 Joystick ON/OFF SW Input
1 NC Output 21 S_NET Input/Output
2 22 CAN0_L Input/Output
3 23 CAN1_L Input/Output
4 232C_RxD Input 24 Flash memory write enable signal Input
8 NC Output 28 NC Input
9 NC Output 29 Pulse GND —
10 Engine rev. signal Input 30 NC Input
11 NC Output 31 S_NET GND —
12 CAN shield — 32 CAN0_H Input/Output
13 Remote positioner lifting set switch Input 33 CAN1_H Input/Output
14 232_TxD Output 34 RS232C GND —
18 NC Output 38 Remote positioner lowering select switch Input
19 NC Output 39 Pulse GND —
20 Vehicle speed signal Input 40 NC Input
1 Controller power Input 21 GND (controller ground) Input
2 Solenoid power Input 22 Solenoid power Input
3 SOL_COM (common solenoid) ground) Input 23 SOL_COM (common solenoid ground) Input
4 NC Output 24 KEY_SIG Input
5 Bucket tilting EPC Output 25 Third EXT EPC Output
6 Lift arm lifting EPC Output 26 Right EPC Output
7 Joystick EPC cut-off relay Output 27 Lift arm lever manual detention of float Output
8 Remote positioner lifting indicator Output 28 Bucket and lift arm neutral lock solenoid Output
9 Semi-auto loading hard mode switch Input 29 NC Input
10 Joystick speed select switch Input 30 Bucket cylinder tilt switch Input
12 VIS (solenoid power) Input 32 GND (controller ground) Input
13 SOL_COM (common solenoid) ground) Input 33 GND (controller ground) Input
14 KEY_SIG Input 34 Reserve —
15 Bucket dumping EPC Output 35 Third RET EPC Output
16 Lift arm lowering EPC Output 36 Joystick left EPC Output
17 Lift arm lever auto detection of lifting Output 37 Magnetic detention of bucket lever tilt pos Output
18 Remote positioner lowering indicator Output 38 NC Output
19 Semi-auto loading soft mode switch Input 39 NC Input
20 Bucket cylinder horizontal switch Input 40 NC Input
WA380-5L 10-3493
ELECTRIC TRANSMISSION CONTROL MAINTENANCE STANDARD
ELECTRIC TRANSMISSION CONTROL
10-3503 WA380-5L
MAINTENANCE STANDARD ELECTRIC TRANSMISSION CONTROL
1. Brake valve (left) 8. Gearshift lever

2. Transmission cutoff switch 9. Forward-reverse lever
3. Transmission cutoff set switch 10. Speed sensor
4. Relay box 11. Transmission control valve
5. Fuse box 12. Kick down switch
6. Transmission controller 13. Hold switch
7. Parking brake switch 14. Left brake pressure sensor
Functions
1 Selection of forward, reverse or N (neutral) It is performed from the forward-reverse lever
2 Selection of gear speed It is done from the gearshift lever
3 Kick down switch 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 the auto-shift
mode is selected, shift down is carried out according to the gear speed
and travel speed being selected prior to operation of this is operated.
4 Hold switch When the auto-shift is selected, this switch maintains the gear speed of
the time when the switch is depressed without allowing shift up accom-
panying increased travel speed.
5 Transmission cutoff function You can cause the transmission to neutral by turning on the transmis-
sion cutoff switch and depressing the left brake pedal.
6 Transmission cutoff position adjusting function You can specify any pedal depression depth for turning on the trans-
mission cutoff function.
7 Transmission cutoff switching function It allows you to enable or disable the transmission cutoff function.
When the function is disabled, the left brake pedal offers the same
braking function as that of the right brake pedal.
8 Neutralizer It shifts the transmission to neutral as long as the parking brake is in
operation. It prevents seizure of the parking brake that can result from
travelling while the parking brake is in operation.
9 Neutral safety function This function disables startup of the engine from the starter switch
when the forward-reverse lever is not at N (neutral). This function is
provided to prevent accidents due to unexpected starting of the
machine.
10 Alarm function As the reverse travel is started, this function turns on the back lamp
and back horn buzzer to alert nearby people.
WA380-5L 10-3513
ELECTRIC TRANSMISSION CONTROL MAINTENANCE STANDARD
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 combination 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 simultaneously turn ON blinking of right and left turn signals.
9 Emergency blinking pilot lamp It starts blinking with emergency blinking lamp.
10 Parking brake switch Used to turn ON (activate) or OFF (deactivate) the parking brake.
10-3523 WA380-5L
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.
● Setting the forward-reverse lever (1) at F position, the magnet
comes right above Hall IC (4) of the control switch at F position.
Thus, magnetism of magnet (3) is irradiated to the Hall IC (4)
through the clearance and case (6).
● Because the Hall IC (4) is inside the magnetism detection circuit,
the circuit detects magnetism from the magnet (3) and then sends
the F position signal to the current amplifier circuit. Receiving this
signal, the current amplifier circuit outputs the signal to operate the
transmission.
WA380-5L 10-3533
KICK DOWN, HOLD SWITCH MAINTENANCE STANDARD
KICK DOWN, HOLD SWITCH
1. Switch A (white harness)

2. Spring
3. Harness
4. Switch B (yellow harness)
Functions
● 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.
● The contact of both switches A and B resets automatically. Normally, the contacts close only when the switches are
depressed.
10-3543 WA380-5L
MAINTENANCE STANDARD ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT
Function
Adoption of the neutral safety circuit assured safety when starting the engine.
● The engine cannot start except when the forward-reverse lever is in the N (neutral) position.
● When the right FNR selector switch (If equipped) is in the ON position, the engine cannot start except when the right FNR
switch (If equipped) is in the N (neutral) position.
● When the Joystick steering (If equipped) is in the ON position, the engine cannot start except when the FNR switch of the
Joystick lever is in the N (neutral) position and also the Joystick lever is in the N (neutral) position.
WA380-5L 10-3553
ENGINE STARTING CIRCUIT MAINTENANCE STANDARD
Operation
1. When the starting switch is in the [ON] position
● If you place the starting switch in the [ON] position, the terminals B and BR of starting switch close. Current flows
from the battery, and goes through the starting switch and battery relay coil to grounding, closing the battery relay
contacts. By this operation, every circuit of the machine is powered.
At this time, the current from ACC terminal of starting switch flows to timer relay, then contacts close for 3 seconds,
then current flows to the pull side coil of fuel cut solenoid. The current from ACC terminal of starting switch also
flows to hold side coil of fuel cut solenoid. So, by hold side coil after pull side coil is magnetized, fuel can be supplied
to engine. Provision of the starting engine is completed.
2. Neutral safety circuit

● If you place the forward-reverse lever at the N (neutral) position, then current flows from the N contact of forward-
reverse lever and goes through the exchange relay to the neutral safety relay coil. As a result, the current is carried
between the terminals 3 and 5 of neutral safety relay.
● When the right FNR switch (If equipped) is used (when the right FNR selector switch is in the ON position), current
flows from the right FNR selector switch to the exchange relay coil to operate the relay. If the right FNR switch is in
the N (neutral) position at that time, the Transmission controller outputs current to the exchange relay. It flows from
the Transmission controller to the exchange relay and finally it reaches the neutral safety relay coil. As a result, the
current is carried between the terminals 3 and 5 of neutral safety relay.
● When the Joystick steering (If equipped) is used, lower the Joystick arm rest and place the Joystick selector switch in
the ON position. Then, current flows from the Joystick selector switch to the exchange relay coil to operate the relay.
If the FNR switch of the Joystick lever is in N (neutral) position and the Joystick lever is in the N (neutral) position,
the Transmission controller outputs current to the exchange relay. It goes through the exchanger relay to neutral
safety relay coil, consequently making the current flow between the terminals 3 and 5 of the neutral safety relay.
(When the Joystick steering is mounted, the Joystick flip switch and Joystick selector switch are mounted instead of
the right FNR selector switch in the figure above, and the Joystick lever FNR switch is mounted instead of right FNR
switch.)
3. When the starting switch is in the [Start] position

● If you place the starting switch in the [Start] position, and then, current goes from the terminal B of starting switch,
terminal C, terminal 3 of neutral safety relay, and terminal 5 to the starter, starting the engine.
● Except when the forward-reverse lever is in the N (neutral) position, the right FNR switch is the N (neutral) position
(when the right FNR switch is used), or the Joystick lever FNR switch is in the N (neutral) position and also the
Joystick lever is in the N (neutral) position, the neutral safety relay, not allowing the engine to start.
10-3563 WA380-5L
MAINTENANCE STANDARD ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT
OPERATION
● The current from ACC terminal of starting switch to hold side coil of fuel cut solenoid is cut off 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, power generation of the alternator stops to
shut off voltage supply from terminal R of the alternator. In addition, the current from terminal BR of starting switch is
shut off. Consequently, the battery relay contact opens to shut down the power supplied to every circuit of the machine.
WA380-5L 10-3573
PREHEATING CIRCUIT MAINTENANCE STANDARD
PREHEATING CIRCUIT
Outline
● The automatic preheating system improves the engine starting capability in cold weather areas. Turning the starting
switch, this system decreases the preheating time and, at the same time, it automatically sets the preheating time, matching
the coolant temperature.
● When the starting switch is turned ON, the preheating pilot lamp on the machine monitor lights and the electric intake air
heater starts preheating the intake air.
As for the preheating time, the coolant temperature sensor senses the coolant temperature. The controller, which is built
into the machine monitor, actuates the preheat 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 cancelled.
Operation
● When the starting switch is turned ON, the machine monitor is
started up. At this time, if the coolant temperature is 0° C (32° F) or
less, the machine monitor completes the preheating relay circuit to
ground. The electric intake air heater now preheats the incoming
air.
● The operating time of the preheating process is shown at right.
10-3583 WA380-5L
MAINTENANCE STANDARD ENGINE POWER MODE SELECTOR CIRCUIT
ENGINE POWER MODE SELECTOR CIRCUIT
Function
● When the power mode selector switch is set to "POWER", the stroke restriction of the accelerator pedal will be released
and the engine power will be controlled. Also, when the switch is set to "NORMAL", the stroke of the accelerator pedal
will be limited and the work fuel consumption will be reduced.
● Switching signals are input into the transmission controller, and gear speed and travel speed suitable for the power mode
are selected at the time of automatic shifting.
Operation
● When the power mode selector switch is set to "POWER", current flows from the fuse to the engine power mode relay to
the power mode selector switch and to ground. The relay coil is now energized.
● The current from the fuse flows to the accelerator pedal hi-idle stopper motor terminals A~B, to the engine power mode
relay terminals 5~3 and to the motor to rotate the motor (the cable will expand).
● When the motor rotates, the terminal D will rotate at the same time. When the non-continue portion of the Terminal D
comes to Terminal B, the circuit from Terminal A to Terminal B will open and the current from the fuse to the motor will
be interrupted. Alhough the motor tries to continue rotating by inertia, both poles of the motor will short-circuited to
ground. The motor will stop rotating when the continue portion of the Terminal D touches Terminal B. The accelerator
pedal hi-idle stopper motor cable extends completely under the state, and the stopper limiting the stroke of the accelerator
pedal is released. The power mode is selected.
● When the power mode selector switch is set to "NORMAL," the relay coil will be demagnetized.
● The current from the fuse flows to the accelerator pedal hi-idle stopper motor terminals A~C, to the engine power mode
relay terminals 4~3 and to the motor to rotate the motor (the cable will contract).
● When the motor rotates, Terminal D will rotate at the same time. When the non-continue portion of Terminal D comes to
Terminal C, the circuit from Terminal A to Terminal C will open. The current from the fuse to the motor is interrupted.
Although the motor tries to continue rotating by inertia, both poles of the motor will be short-circuited to ground. The
motor will stop rotating when the continue portion of Terminal D touches Terminal C.
The accelerator pedal hi-idle stopper motor cable contracts completely under the state, and the stopper limits the stroke of
the accelerator pedal.
WA380-5L 10-3593
PARKING BRAKE CIRCUIT MAINTENANCE STANDARD
PARKING BRAKE CIRCUIT
Operation
1. When the starting switch is in the OFF position.

● Placing the starting switch in the OFF position opens the battery relay contacts, preventing current flow to the parking
brake circuit. For this reason, if the starting switch is in the OFF position, the current does not flow to the parking
brake solenoid regardless of whether the parking brake switch is in the ON or OFF position, operating the parking
brake.
10-3603 WA380-5L
MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
2. When the starting switch is in the ON position
A. When the parking brake switch is in the ON (operation) position before placing the starting switch in the ON position
● Because the parking brake selector switch is in the ON (operate) position, current goes through the battery relay,
contact 1 of parking brake selector switch, contact 3, and parking brake safety relay coil to the ground.
Consequently, terminals 3 and 5 of the parking brake safety relay close. The current from the battery relay
continues to flow to the parking brake safety relay coil and opens the battery relay contact which is held open
until the current stops flowing to the parking brake circuit.
● At that time, the current does not flow to the parking brake solenoid and the parking brake remains in operation.
● In addition, this signal is input to the Transmission controller to prevent dragging of the parking brake by placing
the transmission in the neutral position during the operation of the parking brake.
● Placing the parking brake selector switch in the OFF (open) position causes current to flows through the battery
relay, parking brake safety relay, and contact 3 of the parking brake selector switch, contact 2, emergency brake
switch, and parking brake solenoid to ground. The parking brake is now released.
WA380-5L 10-3613
PARKING BRAKE CIRCUIT MAINTENANCE STANDARD
B. When the parking brake is in the OFF (release) position before placing the starting switch in the ON position.
● Since current does not flow to the parking brake safety relay when the starting switch is in the OFF position, the
relay contact is open. Even if the starting switch is placed in the ON position, the current does not flow to the
parking brake solenoid. Therefore, the parking brake will not be automatically released.
10-3623 WA380-5L
MAINTENANCE STANDARD PARKING BRAKE CIRCUIT
3. When main brake oil pressure lowers (the emergency brake operates).
● When the main brake oil pressure lowers, the contact of the emergency brake switch mounted to the accumulator
opens. This shuts off current to the parking brake solenoid, consequently draining the oil pressure out of the parking
brake cylinder to operate the parking brake.
In this case, however, the parking brake release signal is sent to the Transmission controller. Therefore, the
transmission is not switched to the N position.
By using this design and the engine brake when the emergency brake functions, braking distance is decreased. Even if
the emergency brake should function, it is possible to move the machine.
WA380-5L 10-3633
SENSORS MAINTENANCE STANDARD
SENSORS
Engine Speed Sensor
1. Coil 4. Housing
2. Magnet 5. Connector
3. Terminal
FUNCTION
● The engine speed sensor mounts to the ring gear of the flywheel housing. The sensor generates pulse voltage, depending
on the rotation of the gear teeth. The voltage signal is sent to the Transmission controller.
● The speed sensor is mounted to the transmission output gear. The sensor generates pulse voltage, depending on the rota-
tion of the gear teeth. The voltage signal is sent to the Transmission controller.
The signal converted from the pulse to machine speed in the Transmission controller is sent to the machine monitor for
display through the network.
10-3643 WA380-5L
MAINTENANCE STANDARD SENSORS
Engine Oil Pressure Sensor
1. Plug 2. Contact ring 3. Contact 4. Diaphragm 5. Spring 6. Terminal
Function
This sensor mounts to the engine block. The diaphragm detects oil pressure, and when it falls below the specified value, the
switch turns ON.
Engine Oil Level Sensor
1. Connector 2. Bracket 3. Float 4. Switch
Function
This sensor is mounted to the side surface of the oil pan. The float lowers when the oil level reaches below the specified level,
turning OFF the switch.
WA380-5L 10-3653
Temperature Sensor
Coolant Temperature - For Monitor
Torque Converter Oil Temperature
Hydraulic Oil Temperature
Transmission Oil Temperature
Brake Oil Temperature
1. Connector 2. Plug 3. Thermistor
Coolant Temperature - Preheating
1. Connector 2. Plug 3. Thermistor
Function
● The engine water temperature sensor is mounted to the engine cylinder block. The torque converter oil temperature sensor
is mounted to the transmission case. The hydraulic oil temperature sensor is mounted to the hydraulic piping.
The thermistor, inside the temperature sensor, varies its resistance according to the temperature. A voltage is sent to the
machine monitor, which displays the temperature.
In addition, the temperature signal is sent to the Transmission controller through the network and is used for cooling fan
control.
● The transmission oil temperature sensor is mounted to the transmission case. The thermistor, inside the temperature
sensor, varies its resistance according to the temperature. A voltage signal from the sensor is sent to the Transmission
controller.
The Transmission controller is used for changing over temperature tables for the electronic modulation to use a gear shift
pattern appropriate to the oil temperature.
● The brake oil temperature sensor is mounted to the rear axle. The thermistor, inside the temperature sensor, varies its
resistance according to the temperature. The sensor sends a signal to the Transmission controller. The Transmission
controller sends a signal to the machine monitor. When the pre-set value is reached, the lamp lights and buzzer sounds as
a warning.
10-3663 WA380-5L
Transmission Cut-off Pressure Sensor
1. Sensor
2. Lead
3. Connector
Function
This sensor is mounted to the brake line block under the floor. The sensor detects brake operating pressure to use it for position
setting and operation of the variable transmission cut-off function.
Relationship between pressure and voltage.
WA380-5L 10-3673
Coolant Level Sensor
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
This sensor is mounted to the sub-tank in the bulkhead. The float lowers to turn off the switch when the coolant level reaches
below the specified level.
10-3683 WA380-5L
Fuel Level Sensor
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
● This sensor is mounted to the side surface of the fuel tank. The float moves vertically depending on the remaining quantity
of the fuel inside the tank. The movement of the float operates the variable resistor through the arm and sends a signal to
the machine monitor to indicate the remaining quantity of the fuel.
WA380-5L 10-3693
Lift Arm Angle Sensor (If Equipped)
1. Shaft 4. Rotor
2. Housing 5. Connector
3. Bearing
Function
● This sensor is mounted to the front frame. When the lift arm angle changes, a link on the lift arm that connects to the shaft
(1) causes the shaft (1) to rotate, which varies the sensor’s electrical resistance. Mount the sensor when mounting a load
meter or electric work equipment control lever.
10-3703 WA380-5L
Air Cleaner Clogging Sensor
1. Indicator 3. Adapter
2. Spring 4. Connector
Function
● This sensor is mounted to the air cleaner outlet. A clogged air cleaner increases pressure on the clean side (inner side) of
the air filter. The warning lamp on the machine monitor lights up.
Load Meter Pressure Sensor (If Equipped)
1. Sensor 3. Connector
2. Lead
Function
● This sensor is mounted to the bottom of the lift arm cylinder and the both ends of the rod. This sensor measures cylinder
pressure and uses it for load weight calculation.
WA380-5L 10-3713
Battery Electrolyte Level Sensor(If Equipped)
1. Body 4. Packing
2. Connector 5. Pin
3. Filter
Function
● This sensor is mounted to the battery. The sensor sends a signal to the machine monitor to indicate voltage change that
occurs when the sensor tip is not covered by the battery electrolyte.
10-3723 WA380-5L
Relay
1. Case 2. Plug
WA380-5L 10-3733
MEMORANDUM
10-3743 WA380-5L
20 STANDARD VALUE TABLES
STANDARD SERVICE VALUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2

Standard Service Value Table For Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Standard Value Table For Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
WA380-5L 20-1 3
STANDARD VALUE TABLES STANDARD SERVICE VALUE TABLE
12
STANDARD SERVICE VALUE TABLE
Standard Service Value Table For Engine
Machine Model WA380-5L
Engine SAA6D114E-2
Item Measurement Conditions Unit Standard Value For Service Limit Value
New Machine
High idle (N mode) 1,900 ± 50 1,900 ± 50
High idle (P mode) 2,210 ± 50 2,210 ± 50
Low idle (N mode) 900 +50

0 900 +50
0
Engine speed rpm
Low idle (P mode) 900 +50
0 900 +50
0
Rated speed (N mode) 1,730 1,730
Rated speed (P mode) 2,000 2,000
Turbocharger exhaust At rated output Atmospheric
temperature temperatures: 20 °C (68°F) °C (°F) Max. 550 (1,022) Max. 600 (1,112)
Exhaust gas color At sudden acceleration Bosch index Max. 4.5 6.5
At high idling Max. 1.0
Max. 106.4
Intake air pressure (Boost At rated output kPa 113.1 ~ 126.4 (Max. 15.43)
pressure) (psi) (16.40 ~ 18.33) Min. 133.3
(Min. 19.33)
Exhaust temperature
(Turbocharger inlet Whole speed range °C (°F) Max. 650 (1202) 700 (1292)
Ambient temperature 20°C (68°F)
temperature)
Intake valve 0.33 (0.013) —
Valve clearance Exhaust valve mm (in) 0.56 (0.022) —
Oil temperature: 40 ~ 60 °C MPa (psi) Min. 2.4 (348.1) Min. 2.0 (290.1)
Difference between
Compression pressure (104~140°F) cylinders: Max. 0.7
(SAE oil)
(Engine speed) (rpm) 250 rpm (102.0)
(250 rpm)
At rated output
Crankecase pressure
(SAE oil) (Operating range coolant kPa (psi) Max. 0.98 (0.14) 1.96 (0.28)
temperature) (SAE 30 oil)
(Operating range coolant
temperature)
0.36 ~ 0.61 0.21
At high idle (15W-40) {3.5 ~ 6.0} {2.1}
Oil pressure At low idle (15W-40) kPa Min. 0.15 0.07

(psi) {1.5} {0.7}
0.30 - 0.56 0.18
At high idle (SAE10W)
{3.0 - 5.5} {1.8}
Min. 0.10 0.07
At low idle (SAE10W) {1.0} {0.7}
Oil temperature At all speed ranges (Inside oil pan) °C (°F) 90 ~ 120 (194 ~ Min. 120 (248)
248)
Before compression top dead
Fuel injection timing °(deg.) 8.5 ± 1 8.5 ± 1
center
Deflection
made by finger Above 10
Idler pulley - 8
pressure of Crank pulley (0.5) or
about about 6 below 6
kg (13.2lbs) mm
Belt tension
Deflection (in)
made by finger Air conditioner
pressure of - crankshaft 16 ~ 20 16 ~ 20
(0.6 ~ 0.8) (0.6 ~ 0.8)
about about 10 pulley
kg (22.0 lbs)
20-2 3 WA380-5L
Standard Value Table For Chassis

The * mark shows the value before the detent.
Standard Value For
Category Item Measurement Conditions Unit Service Limit Value
New Machine
N - FORWARD, kg 5.9 0.6 Max. 16.7
Operating effort
Directional REVERSE • Engine Stopped (oz) (35.2) (21.2) (60069.0)
lever • Measure at center of lever knob
N - FORWARD, mm 35 ± 10 35 ± 20
Travel
REVERSE (in) (1.4 ± 0.4) (1.4 ± 0.8)
5.9 0.6
1st ~ 2nd Max. 16.7 (36.8)
(35.2) (21.2)
kg 5.9 0.6
Operating effort 2nd ~ 3rd Max. 16.7 (36.8)
(oz) (35.2) (21.2)
• Engine stopped 5.9 0.6
Speed lever 3rd ~ 4th • Measure at center of lever knob Max. 16.7 (36.8)
(35.2) (21.2)
1st ~ 2nd 35 ± 10 (1.4 ± 0.4) 35 ± 20 (1.4 ± 0.8)
mm
Travel 2nd ~ 3rd 35 ± 10 (1.4 ± 0.4) 35 ± 20 (1.4 ± 0.8)
(in)
3rd ~ 4th 35 ± 10 (1.4 ± 0.4) 35 ± 20 (1.4 ± 0.8)
HOLD RAISE Max. 1.3 (3.0) * Max. 2.0 (4.4) *
RAISE HOLD Max. 1.5 (3.3) Max. 2.3 (5.1)
HOLD Max. 1.3 (3.0) * Max. 2.0 (4.4) *

LOWER
Boom
LOWER — —
HOLD • Engine speed: Low idling
Operating • Hydraulic oil temperature: kg
effort LOWER 45 ~ 55 °C (lbf) Max. 1.6 (4.0) Max. 2.4 (5.3)
FLOAT
(113 ~ 131 °F)
FLOAT Max. 1.5 (3.3) Max. 2.3 (5.1)
HOLD
Working
equipment HOLD DUMP Max. 1.8 (4.0) Max. 2.7 (6.0)
control lever
Bucket HOLD TILT Max. 1.3 (3.0) * Max. 2.0 (4.4) *
TILT HOLD Max. 1.5 (3.3) Max. 2.3 (5.1)
43 ± 18 (1.5 ± 0.7)
HOLD RAISE 43 ± 9 (1.5 ± 0.4) *
*
Boom 43 ± 18 (1.5 ± 0.7)
HOLD RAISE • Engine speed: Low idling 43 ± 9 (1.5 ± 0.4) *
*
• Hydraulic oil temperature: mm
Travel
HOLD RAISE 45 ~ 55 °C (in) 50 ± 9 (2.0 ± 0.4) 50 ± 18 (2.0 ± 0.7)
(113 ~ 131 °F)
HOLD RAISE 50 ± 9 (2.0 ± 0.4) 50 ± 18 (2.0 ± 0.7)
Bucket 43 ± 18 (1.5 ± 0.7)
HOLD RAISE 43 ± 9 (1.5 ± 0.4) * *
• Engine stopped mm
Play • Machine facing straight to front Max. 20 (0.1) Max. 50 (2.0)
(in)
• Flat, horizontal, straight, dry

paved road surface kg 6.9 ~ 12.6
Operating effort • Engine speed: Low idling Max. 19.6 (43.2)
(lbs) (15.2 ~ 28.0)
(Bucket empty)
Steering • Engine speed: High idling

wheel Turning speed (Not including play) Turn 4.0 ± 0.4 4.0 ± 0.4
• Left lock - right lock s
Low idling • Engine speed: 4.5 ± 0.4 Max. 7.0

Low idling
Operating • Hydraulic oil P mode 3.6 ± 0.3 Max. 5.3
temp: Sec.
time
High idling 45 ~ 55°C
(113 ~ 131°F) N mode 3.7 ± 0.3 Max. 5.7
• Engine speed: 1,200 rpm"

• Hydraulic oil temperature: 45 - 55°C
Clearance between front frame and (113 ~ 131°F) 25 ± 2
Frame mm —
rear frame • Flat, level, straight, dry, and paved (1.1 ± 0.1)
road
At max. steering angle
WA380-5L 20-3 3

Standard Value For Service Limit
Category Item Measurement Condition Unit New Machine Value
• Measure while engine is running.
• Measure at 150 mm from fulcrum of kg 6.2 ~ 8.2 (14.0 ~ Max. 12.0
Pressing effort (lbs) 18.1) (26.4)
pedal.
Neutral (α1) • Measure while engine is stopped. 48 —

Accelerator
pedal Pressing deg. 33 ± 1 —
angle P-mode
Neutral (α2)
37 ± 1 —
N-mode
Height of stopper (L) mm 60 ± 5 (2.4 ± 0.2) —
(in)
• Engine speed: Low idling kg
Operating effort (lbs) 30 ± 3 (66.1 ± 7.0) Max. 43 (95.1)
• Hydraulic oil temperature: 45 ~ 55°C
Neutral (α1) (113 ~ 131°F) 45 —
Operating deg.
angle Neutral (α2) 15 +1
—
0
Brake pedal
Play mm 5 ± 0.5 (0.2 ± 0.01) —

(in)
Fitting of wheel lock A • Tire inflation pressure: Specified Max. 2.5 (0.1) —
ring B pressure Max. 4.0 (0.2) —
Tire mm
(in)
Clearance of wheel
lock ring C 2 ~ 10 (0.01 ~ 0.4) —
20-4 3 WA380-5L

Standard Value For
Category Item Measurement Conditions Unit Service Limit Value
New Machine
• Engine coolant N mode 1,830 ± 50 1,830 ± 100
temperature:
Torque converter
Operating range
P mode 2,120 ± 50 2,120 ± 100
• Torque converter oil
temperature:
60 ~ 80°C N mode 1,810 ± 100 1,810 ± 200
Engine speed Hydraulic stall (140 ~ 176°F) rpm
• Hydraulic oil temp.: P mode 2,120 ± 100 2.120 ± 200
45 ~ 55°C
(113 ~ 131°F)
N mode 1,715 ± 100 1,715 ± 200
Torque converter stall +
hydraulic stall
P mode 1,715 ± 100 1,715 ± 200
Low idling • Torque converter oil temp.: 27.9 ± 2 27.9 ± 2

Main relief 60 ~ 80°C (140 ~ 176°F) (397.1 ± 28.4) (397.1 ± 28.4)
valve Rated • Engine: Rated speed 29.2 ± 2.0 29.2 ± 2.0
speed (415.3 ± 28.4) (415.3 ± 28.4)
Torque converter relief
Max. 9.0 (128.1) Max. 9.0 (128.1)
(Inlet port) pressure
Transmission,
Torque converter outlet port kg/cm2 4.5 ± 0.5 4.5 ± 0.5
torque con- oil pressure (psi) (64.1 ± 7.1) (64.1 ± 7.1)
verter
1st, 2nd, • Torque converter oil temp.: 21.5 ± 1.5 21.5 ± 1.5
3rd, 4th 60 ~ 80°C (140 ~ 176°F) (306.1 ± 21.3) (306.1 ± 21.3)
ECMV output • Engine: Rated speed 19.5 ± 1.5 19.5 ± 1.5
(Clutch) oil F-R
pressure • Manual switch ON (277.4 ± 21.3) (277.4 ± 21.3)
17.5 ± 1.5 17.5 ± 1.5
Lock-up (249.1 ± 21.3) (249.1 ± 21.3)
• Hydraulic oil temperature:
kg/cm2 160 ± 5 150 - 165
Steering Steering relief pressure 45 ~ 55°C (113 ~ 131°F)
(psi) (2276.1 ± 71.1) (2133.5 - 2346.8)
• Engine speed: High idling
• Engine speed: • Point where brake

Low idling
• Hydraulic oil oil pressure 60 - 65 55 - 70
Charge cut-in pressure temperature:
warning lamp (853.4 to 924.5) (782.3 to 995.6)
45 ~ 55°C
(113 ~ 131°F) goes out
kg/cm2
Accumulator (psi)
• Point where oil
pressure is going 100 t- 110 95 - 115
Charge cut-out pressure up and then starts (1422.3 to 1564.6) (1351.2 to 1635.7)
to go down
WA380-5L 20-5 3

Standard Value For New
Category Item Measurement Conditions Unit Machine Service Limit Value
1st 6.8 (4.2) 6.8 (4.2)
2nd 12.3 (8.1) 12.3 (8.1)

P mode
3rd 21.4 ± 1 (13.3 ± 0.6) 21.4 ± 1 (13.3 ± 0.6)
4th 34.0 ± 2 (21.1 ± 1.2) 34.0 ± 2 (21.1 ± 1.2)

FORWARD
1st 5.3 (3.3) 5.3 (3.3)
2nd 9.3 (6.1) 9.3 (6.1)

N mode
3rd 16.7 (10.4) 16.7 (10.4)
4th 27.0 ± 1 (17.1 ± 0.6) 27.0 ± 2 (17.1 ± 0.6)

Power Travel speed km/h
train (Bucket empty) 1st (mph) 7.3 (5.1) 7.3 (5.1)
2nd 12.8 ± 1 (8.1 ± 0.6) 12.8 ± 1 (8.1 ± 0.6)

P mode
3rd 22.6 ± 1 (14.1 ± 0.6) 22.6 ± 2 (14.1 ± 0.6)
4th 35.0 ± 2 (22.1 ± 1.2) 35.0 ± 3 (22.1 ± 1.2)

REVERSE
1st 5.7 (4.1) 5.7 (4.1)
2nd 9.9 (6.2) 9.9 (6.2)

N mode
3rd 17.7 ± 1 (11.1 ± 0.6) 17.7 ± 1 (11.1 ± 0.6)
4th 27.9 ± 1 (17.3 ± 0.6) 27.9 ± 2 (17.3 ± 0.6)
Brake oil pres- • Hydraulic oil temperature:

5.1 ± 0.49 (52 ± 5) 5.1 ± 0.98 (52 ± 10)
sure 45 ~ 55 °C (113 ~ 131°F)
• Engine stopped kg/

• Keep brake pedal depressed cm2
(psi)
Drop in brake at 50 kg/cm2 (171.2 psi) and Max. 1.0 (14.2) Max. 1.0 (14.2)
pressure
measure drop in oil pressure
after 5 min.
• Tire inflation pressure:

Specified pressure
• Flat, horizontal, straight, dry
Wheel paved road surface
brake • Speed when applying brake:
20 km/h, (12.4mph) braking
Performance m (in) Max. 5 (71.1) Max. 5 (71.1)
delay: Within 0.1 sec.
• Brake pedal operating effort:
Specified operating effort 34.0
± 3.4kg
(75.1 ± 7.1)
• Measure braking distance
• Oil pressure: 50 kg/cm2 (171.2 Shaft protrusion reaches

Disc wear psi) mm Shaft protrusion 0 wear limit position 2.4 mm
(in)
• Pedal depressed fully (0.1 in)
20-6 3 WA380-5L

Standard Value Service Limit
Category Item Measurement Conditions Unit
For New Machine Value
• Torque converter oil temperature: 60 ~
Parking brake inlet 80°C (140 ~ 176°F) kg/cm2
Min. 23.1 (329.1) Min. 23.1 (329.1)
pressure (psi)
• Engine speed: Low idling
• Tire inflation pressure: Specified pres-

sure
• Flat paved road with 1/5 (11× 20’) grade
• Dry, paved road surface
• Machine at operating condition
Parking
brake input
pressure Performance — Holds in position Holds in position
3.2 ±0.08
Disc thickness mm (in) (0.13 ±0.001) 2.97 (114.2)
• Hydraulic oil temperature:

PPC valve basic pressure 45 ~ 55°C (113 ~ 131°F) 38 ±2 (540.4 ±2) 38 (540.4 ±2)
kg/cm2
PPC Lift arn RAISE, • Hydraulic oil temperature:
PPC FLOAT; Bucket
(psi) 38 ±2 (540.4 ±2) 38 (540.4 ±2)
valve DUMP, TILT 45 ~ 55°C (113 ~ 131°F)
output
pres- • Engine speed: High idling
Lift arm 2.2 ±0.25 2.2 ±0.39
sure LOWER • Control lever operated fully {22.5 ±2.5} {22.5 ±4}
WA380-5L 20-7 3

Standard Value
Service Limit
Category Item Measurement Conditions Unit For New
Value
Machine
• Hydraulic oil temperature: 45 ~ 55°C (113 ~ 131°F) kg/cm2 210 ± 5 197 - 215
Work equipment relief pressure • Run engine at high idling. (psi) (2987 ± 71.1) (2802 - 3058)
• Hydraulic oil temperature: 45 ~ 55°C

(113 ~ 131°F) N mode 6.2 ± 0.5 Max. 8.0
• Run engine at high idling.
Lift arm RAISE • Apply no load.
P mode 5.3 ± 0.5 Max. 7.0
N mode 2.8 ± 0.5 Max. 4.0
Lift arm LOWER

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

(113 ~ 131°F) N mode 1.6 ± 0.3 Max. 2.3
Forward • Engine speed: High idling
• No load
P mode 1.4 ± 0.3 Max. 2.0
Work equipment
Bucket full
stroke
N mode 2.2 ± 0.3 Max. 3.0
Backward
P mode 1.9 ± 0.3 Max. 2.6
N mode 1.4 ± 0.3 Max. 2.0

Moving
bucket from Backward
level position
P mode 1.2 ± 0.3 Max. 1.8
Retraction of lift • Hydraulic oil temperature: 45 ~ 55°C (113 ~ 131°F) Max. 14 Max. 17
cylinder rod • Stop engine and leave for 5 minutes, then measure (1.0) (1.1)
for 15 minutes.
• Apply no load to bucket and set lift arm and bucket
in level position.l
Hydraulic drift
mm (in)
Retraction of bucket Max. 36 Max. 43
cylinder rod (1.4) (2.1)
20-8 3 WA380-5L

Standard Value For
Category Item Measurement Conditions Unit New Machine Service Limit Value

• Engine water temperature: Min.
95°C (203°F)
Max. fan speed • Hydraulic oil temperature: Min. 1,400 ± 100 1,400 ± 200
95°C (203°F)
• Torque converter oil temperature:
Min. 105°C (221°F)
Oil pressure drive
rpm
fan • Engine speed: Low idling
• Engine water temperature: Max.
40°C (104°F)
Min. fan speed • Hydraulic oil temperature: Max. 240 ± 50 240 ± 100
40°C (104°F)
• Torque converter oil temperature:
Max. 40°C (104°F)
WA380-5L 20-9 3
MEMORANDUM
20-10 3 WA380-5L
30 TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING . . . . . . . . . . . . . . . . 30-4

Special Tool Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Determining a Defective Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Determining Cylinder Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Isolating the Defective Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Measuring Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
Measuring Exhaust Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
Measuring Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
Adjusting Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
Measuring Compression Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
Measuring Blow-by Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
Measuring Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
Measuring Intake Air Pressure (Boost Pressure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
Testing And Adjusting Fuel Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
Adjusting Engine Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21
Bleeding Air From Fuel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
Adjusting Engine Stop Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
ADJUSTING ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
Adjusting the Power Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
Adjusting the Normal Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-25
ADJUSTING TRANSMISSION SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
POWER TRAIN OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
FLUSHING TORQUE CONVERTER, TRANSMISSION AND HYDRAULIC CIRCUIT 30-31
TRANSMISSION VALVE FAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
MOVING MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
STEERING CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34
STEERING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
TESTING HYDRAULIC FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-37
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
Measuring Brake Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
Testing Wear of Wheel Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
Bleeding Air from Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
Testing Wear of Parking Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
Manual Release Method for Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-43
ACCUMULATOR CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
PPC OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
WORK EQUIPMENT HYDRAULIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49
BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
WA380-5L 30-13
BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52

PROXIMITY SWITCH ACTUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
ADJUSTING MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54
LOAD METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61
Fan Motor Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61
Work Equipment PPC Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-61
RELEASING REMAINING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
In Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-62
E.C.S.S. Damper Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-63
PM-CLINIC INSPECTION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-64
30-23 WA380-5L
MEMORANDUM
WA380-5L 30-33
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND
12
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Check or Symbol Part No. Part Name Qty Remarks
measurement item
Intake air pressure _

(Boost pressure) A 799-201-2202 Boost gauge kit 1 101 - 200 kPa (_760 - 1,500 mmHg)
Coolant temperature, Digital

oil temperature, B 799-101-1502 1 _
thermometer 99.9 - 1,299 °C
exhaust temperature
Oil pressure kit Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 1 {25, 60, 400, 600 kg/cm2}
(Analog)
1
790-261-1204 Oil pressure kit
1 Pressure gauge: 58.8 MPa {600 kg/cm2}
(Digital)
Oil pressure C
Oil pressure
2 799-401-2320 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
gauge
3 799-401-3300 Nipple 1
4 790T-301-1750 T-piece 1 Male, female: R1/8
Compression
Compression 1 795-790-3610 1
D gauge
pressure
2 795-790-3710 Adapter 1
Blow-by
1 799-201-1504 1
Blow-by pressure E checker
2 799-201-1590 Gauge 1 0-0.981 MPa {0-1,000 mmH2O}
795-799-1950 Lock pin 1

Valve clearance F Commercially
Filler gauge 1
available
Fuel injection timing F 1 795-799-1950 Pin 1
Handy smoke
1 799-201-9001 1
meter
Exhaust gas color G Bosch index: 0 - 9
Commercially
2 Smoke meter 1
available
1 793-605-1001 Brake test kit 1
2 790-101-1430 Coupler 1
3 790-101-1102 Pump 1
Brake oil pressure H 4 799-301-1720 Adapter 1 M20 X 1.5: Rc1/8
5 799-101-5160 Nipple 1
6 799-401-2220 Hose 1 L=5m
7 790-261-1130 Coupling 1
Check of hydraulic
J 799-205-1100 Multi-tachometer 1 Digital indication: 6 - 99999.9 rpm
drive fan
Moving of machine
when transmission K 794-423-1190 Plug 1 20 X 1.5 mm
valve has failure
30-43 WA380-5L
Check or Symbol Part No. Part Name Qty Remarks

measurement item
Check of parking Commercially

M Slide calipers 1 MITSUTOYO (Equivalent to N10)
brake disc for wear available
Operating effort, 79A-264-0021 Push-pull scale 1 0 - 294 N {0 - 30 kg}

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

R Stopwatch 1
speed available
Commercially
Voltage, resistance S Tester 1
available
T-adapter
799-601-7400 1
assembly
1 799-601-7330 Adapter 1 For S-16 (White)
799-601-7350 Adapter 1 For S-12 (White)

Check of sensors and
T 799-601-7360 Adapter 1 For relay (5 pin type)
wiring harness
T-adapter
2 799-601-9000 1 Fot DT type connector
assembly
T-adapter Fot DT type connector

3 799-601-9300 1
assembly (For 24, 40 pin types)
WA380-5L 30-53
Special Tool Drawing

Note) We will not liable for any result caused by a special tool made according to this drawing.
Tool C4
30-63 WA380-5L
TESTING AND ADJUSTING ENGINE COMPONENTS
12
ENGINE COMPONENTS
Determining a Defective Cylinder

★ The purpose of performing a cylinder cut-out test is to determine which cylinder or cylinders are contributing the least to
the performance of the engine. This is achieved by monitoring the fuel rate change of each cylinder on the monitor. The
cylinder that makes the least change in fuel rate is most likely a defective cylinder.
★ It is important not to rely on the RPM change due to the compensation function of the electronic governor. RPM readings
can be deceptive. Always rely on fuel rate change and engine sounds.
WARNING! To prevent the machine from moving, lower the bucket to the ground, set the parking
brake and put blocks under the tires. Perform these tests on a flat level surface.
Procedures
1. Interview the operator and determine at what temperature or engine RPM the performance complaint was registered.
2. Refer to the special functions of the monitor for cylinder cut-out. See “CYLINDER CUT-OUT FUNCTION”.
3. Eliminate all parasitic loads on the engine, i.e., hydraulic fan, air conditioner, etc.
Determining Cylinder Group

★ First determine which group of cylinders has the highest rate of
change.
★ With engine at an idle, disable three companion cylinders (1, 3, 5)
or (2, 4, 6) and observe the fuel rate change.
• Keep in mind the cylinder group with the highest fuel rate
change is most likely to be the defective group.
• Record this information on a sheet of paper.
Isolating the Defective Cylinder

★ After determining which group of cylinders has the highest fuel rate change, (1, 3, 5) or (2, 4, 6), restore cylinder cut-out
function and disable the opposite companion group to determine which cylinder in the high rate group is defective.
★ With the opposite group of cylinders disabled, cut each individual
cylinder out in the running set for several moments and observe the
fuel rate change. Before moving to the next cylinder in the running
set, restore the last cylinder that was cut-out back to operating
condition. (see example on the right).
• Allow enough time for engine RPM and cylinder function to
restore before moving to the next cylinder.
• It is also important to listen for any engine changes during
cylinder cancellation.
• The cylinder found with the highest fuel rate change is most
likely to be the defective cylinder of the total group.
WA380-5L 30-73
Measuring Engine Speed
WARNING! Put blocks under the tires.
WARNING! Before starting measurement, check that there is no one in the surrounding area.
★ Measure the engine speed under the following conditions.

• Coolant temperature: Within operating range
• Hydraulic temperature: 45 ~ 55 °C (113 ~ 131 °F)
• Torque converter oil temperature: 60 ~ 80 °C (140 ~ 176 °F)
1. Measuring engine speed (low idling and high idling)
A. Switch to monitoring function of Service Mode 1 and display

the engine speed. For details, see SPECIAL FUNCTIONS OF
MACHINE MONITOR in TROUBLESHOOTING section.
• Monitoring item: ENG SPEED
B. Start engine, set to the measurement conditions, and measure

the engine speed.
2. Measuring torque converter stall speed.
A. Switch to the monitoring function of Service Mode 1 and use

the 2-item simultaneous monitoring function to display the
following 2 items. For details, see SPECIAL FUNCTIONS OF
MACHINE MONITOR in the TROUBLESHOOTING
section.
★ Monitoring items
c Code No. 01001: Engine speed
d Code No. 40100: Torque converter oil temperature
B. Start the engine.
C. Turn the transmission cut-off selector switch OFF and depress

the left brake securely.
D. Place the directional lever at F4 or R4.

★ Operate the shift mode switch to MANUAL and place the speed lever at F4 or R4.
E. Release the parking brake.
F. Depress the accelerator pedal gradually to raise the engine speed to full throttle, and measure the engine speed when
the torque converter stalls.
★ Measure the stall speed 2 or 3 times.
★ Do not keep the stall condition for more than 20 seconds. Make sure that the torque converter oil temperature
does not exceed 120 °C. (248 °F)
30-83 WA380-5L
3. Measuring hydraulic stall speed:
Switch to the monitoring function of Service Mode 1 and use the
2-item simultaneous monitoring function to display the following 2
items. For details, see SPECIAL FUNCTIONS OF MACHINE
MONITOR in the TROUBLESHOOTING section.
★ Monitoring items
c Code No. 01001: Engine speed
d Code No. 40100: Torque converter oil temperature
A. Start the engine and run at high idle.
B. Measure the engine speed when the boom cylinder or bucket

cylinder is extended and the circuit is relieved.
4. Measuring torque converter stall + hydraulic stall (full stall) speed:
A. Setting of the machine monitor is the same as step 2-A)

Measuring torque converter stall speed.
B. Start the engine.
C. Turn the transmission cut-off selector switch (2) OFF and depress the left brake securely.
D. Place the directional lever at F4 or R4.
E. Release the parking brake.
F. Run the engine at high idle, stall the torque converter, extend the boom cylinder or bucket cylinder at the same time to
relieve the circuit, and measure the engine speed.
★ Do not keep the stall condition for more than 20 seconds. Make sure that the torque converter oil temperature
does not exceed 120 °C. (248 °F)
WA380-5L 30-93
Measuring Exhaust Temperature

Special tools required
Symbol Part Number Part Name Qty. Remarks
B 799-101-1502 Digital temperature gauge 1 -99.9 - 1,299° C (-1,768 - 2,370° F)
WARNING! Wait for the temperature of the exhaust pipe to go down before installing or removing the
measuring equipment.
1. Remove the adiabatic cover, then remove exhaust temperature

measurement plug (1) (R 1/8).
2. Install sensor (2) and connect to digital temperature gauge B.

★ Be careful not to let the wiring harness of the temperature
gauge touch the high temperature portion.
3. When measuring the exhaust temperature at torque converter stall,
do as follows.
★ To prevent overheating the torque converter, stabilize the
exhaust temperature at full stall (torque converter stall +
hydraulic stall), then stall the torque converter only and
measure the temperature.
A. Start the engine and raise the coolant temperature to operating
range.
B. Turn the transmission cut-off selector switch OFF and depress
the left brake securely.
C. Place the directional lever at F4 or R4.
★ Turn the transmission manual switch ON and place speed
lever at F4 and R4.
D. Release the parking brake.
E. Depress the accelerator pedal gradually to raise engine speed to
full throttle, stall the torque converter, and extend the boom
cylinder or bucket cylinder at the same time to relieve circuit.
★ Continue until the exhaust temperature is around standard
value of 650° C (1,202° F)
WARNING! Do not keep the stall condition for

more than 20 seconds. Make sure that
the torque converter oil temperature
does not exceed 120° C (248° F).
30-103 WA380-5L
F. When the temperature becomes stable around the target temperature, cancel the hydraulic relief, perform only torque
converter stall, and measure the exhaust temperature.
★ The exhaust temperature at full stall will start to go down, so measure the temperature when it becomes stable.
★ If the exhaust temperature does not go down and continues to go up, make the temperature setting at full stall
higher.
4. When measuring maximum value for exhaust gas temperature, carry out actual work and measure the maximum value
when operating.
★ Use the PEAK mode function (the maximum value can be recorded) of the temperature gauge.
★ The exhaust temperature differs greatly according to the ambient temperature (engine intake temperature), so if an
abnormal value is recorded, compensate for the temperature.
★ Compensation temperature value = measured value + 2 x (converted ambient temperature - ambient temperature).
• The converted ambient temperature is taken as 20° C (68° F).
WA380-5L 30-113
Measuring Exhaust Smoke
1 799-201-9001 Handy Smoke Checker 1

G Bosch index: 0 - 9
2 Commercially available Smoke meter 1
WARNING! When installing or removing the measuring equipment, be careful not to touch any high-
temperature parts.
★ When measuring in the field where there is no air or power supply, use Handy Smoke Checker G1; when recording
official data, use Smoke meter G2.
1. Measuring with Handy Smoke Checker G1

A. Fit filter paper in tool G1.
B. Insert the exhaust gas intake port into the exhaust pipe.
C. Start the engine and raise the engine coolant temperature to the
operating range.
D. Accelerate the engine suddenly run it at high idle, and at the
same time operate the handle of Handy Smoke Checker G1 to
catch the exhaust gas on the filter paper.
E. Remove the filter paper and compare it with the scale provided
to judge the condition.
2. Measuring with Smoke Meter G2

A. Insert probe [1] of smoke meter G2 into the outlet port of the
exhaust pipe, then secure it to the exhaust pipe with the clip.
B. Connect the probe hose, accelerator switch plug, and air hose
to smoke meter G2.
★ The pressure of the air supply should be less than 1.5 MPa
{15 kg/cm2} (218 psi).
C. Connect the power cord to the AC 100 V outlet.
★ Before connecting the cord, check that the power switch of
the smoke meter is OFF.
D. Loosen the cap nut of the suction pump, then fit the filter paper.
★ Fit the filter paper securely so that the exhaust gas does
not leak.
E. Turn the power switch of smoke meter G2 ON.
F. Accelerate the engine suddenly, and at the same time, depress
the accelerator pedal and operate the relief valve to catch the
exhaust gas color on the filter paper.
G. Lay the filter paper used to catch the exhaust gas color on top
of unused filter papers (10 sheets or more) inside the filter
paper holder, and read the indicated value.
30-123 WA380-5L
Adjusting Valve Clearance

1 795-799-1950 Pin 1
F ___
2 Commercially available Feeler gauge 1
1. Open the engine side cover.
2. Remove cover (1) and intake hose (2).
3. Disconnect blow-by tube (3) from the head cover.
4. Disconnect clamps (4) (2 places).
5. Disconnect turbocharger waste gate tube (5) from the turbocharger.
6. Remove head cover mounting bolts (6) and head cover (7).
7. Apply bar ➀ to bolt at the crank pulley end and revolve it forward
to bring yellow paint a of the damper to the top. Push in timing pin
(8) and set No. 1 cylinder piston to the compression top dead center
(Insert timing pin in the gear hole).
WA380-5L 30-133
★ Pushing depth of timing pin (8): 8 mm (0.315 in.)
★ When the No. 1 cylinder piston is at the compression top dead
center, the No. 1 cylinder rocker arm can be moved with the
hand by the valve clearance. If the rocker arm does not move,
the piston is not at the compression top dead center. In this
case, revolve the crankshaft 1 more turn.
★ After setting the No. 1 cylinder piston to the compression top
dead center, make a match mark on the damper and install
pointer ➁ to the front cover with a wire.
★ If it is difficult to check with the timing pin installed to the
engine, metallic pin assembly F1 may be used.
★ After setting to the compression top dead center, be sure to pull
out the timing pin.
8. While No. 1 cylinder piston is at the compression top dead center,

adjust the clearances of valves marked z in the valve arrangement
table. Then, revolve the crankshaft forward by 360 degrees and
adjust the clearances of the valves marked with .
9. Insert filler gauge F2 in clearance b between rocker lever (9) and

valve stem (10) and adjust the clearance with adjustment screw
(11).
★ Turn the adjustment screw so that the inserted filler gauge will
move lightly.
10. Secure adjustment screw (11) and tighten locknut (12).

★ After tightening the locknut, check the valve clearance again.
Locknut : 24 ± 4.0 Nm {2.45 ± 0.41 kgm} (18 ± 3 lbf ft)
30-143 WA380-5L
Measuring Compression Pressure

1 795-790-3610 Compression gauge 1

D
2 795-790-3710 Adapter 1
WARNING! When measuring the compression pressure, take care not to get burned with a hot part or
caught in a rotary part.
★ Measure the compression pressure after the engine is warmed up.

• Engine oil temperature: 40 - 60° C {104 - 140° F}.
1. Adjust the valve clearance. For details, see Adjusting valve clearance.
2. Remove engine hood assembly (1), exhaust muffler assembly (2),

air intake muffler assembly (3), and air intake manifold (4). For
details, see DISASSEMBLY AND ASSEMBLY, Removal and
installation of nozzle holder assembly.
3. Remove injection tube (5) of the cylinder to be measured and

disconnect spill tube (6).
4. Remove holder (7) and pull out nozzle assembly (8).

★ Take care that foreign matter does not enter the nozzle and
cylinder.
5. Install adapter D2 to the nozzle holder mounting part of cylinder to

be measured and tighten it to the specified torque.
Holder mounting bolt: 23.5 ± 3.9 Nm {2.4 ± 0.4 kgm}
(17 ± 3 lbf ft)
6. Connect compression gauge D1 to the adapter.
WA380-5L 30-153
7. Disconnect connector (10) (CN-E34) of fuel cut solenoid (9) to
prevent injection, then revolve engine with the starting motor and
read the pressure after pressure gauge pointer stops.
★ Apply some oil to the adapter mounting part so that air will not
leak.
★ When measuring the compression pressure, check that the
engine speed is in the measuring range.
★ After measuring the compression pressure, install the nozzle
holder assembly.
30-163 WA380-5L
Measuring Blow-by Pressure

E 799-201-1504 Blow-by checker 1 0 - 4.9 kPa {0 - 500 H2O
1. Install nozzle 1 and hose 2 to blow-by hose (1), and connect to

blow-by checker E .
2. Run the engine and raise the coolant temperature to the operating
range.
3. Turn the transmission cut-off selector switch OFF and depress the
left brake securely.
4. Place the speed lever at F4 and R4.

★ Turn the transmission manual switch ON and place the speed
lever at F4 and R4.
5. Release the parking brake.
6. Depress the accelerator pedal gradually to raise the engine speed to full throttle, and measure the blow-by pressure when
the torque converter stalls.
WARNING! Do not keep the stall condition for more than 20 seconds. Make sure that the torque
converter oil temperature does not exceed 120° C {248 ° F}.
★ Precautions when measuring blow-by

Blow-by varies greatly according to engine condition.
Therefore, if the blow-by value is considered abnormal, check
for problems connected with defective blow-by, such as
excessive oil consumption, defective exhaust gas color, and
prematurely dirty or deteriorated oil.
WA380-5L 30-173
Measuring Engine Oil Pressure

Pressure gauge: 0.98 MPa {10 kg/cm2}

C2 799-401-2320 Oil pressure gauge 1
(Use hose in C1 tool kit).
1. Open the engine right side cover.
2. Remove engine oil pressure switch (1) (width across flats: 26mm).
3. Install nipple ➀ and hose ➁, and connect oil pressure gauge C2.
4. Run the engine and raise the coolant temperature to the operating
range.
5. Measure the oil pressure with the engine at low idle and high idle.
6. After completing the measurement, remove measuring equipment

and return to the original condition.
30-183 WA380-5L
Measuring Intake Air Pressure (Boost Pressure)

_
A 799-201-2202 Boost gauge kit 1 101 - 200 kPa (_760 - 1,500 mmHg)
WARNING! When installing and removing the measuring devices, take care not to touch a hot part.
1. Remove intake air pressure pickup plug (1) (NPTF 1/4) and install
adapter (4) of oil pressure gauge kit C1.
★ Remove mounting bolt (2) of the fuel tube clamp and loosen
the mounting bolt of stay (3) and slide the stay backward.
2. Connect oil pressure measurement nipple (5) and hose (6) to

adapter (4) and pressure gauge A.
3. Start the engine.
4. Turn OFF the transmission cut-off selector switch and press the left
brake securely.
5. Set the gear shift lever to F4 or R4.

★ Turn on the transmission manual switch and set the gear shift
lever to F4 or R4.
6. Release the parking brake.
7. Press the accelerator pedal gradually to full throttle, then stall the torque converter and measure the intake air pressure at
that time.
WA380-5L 30-193
Testing And Adjusting Fuel Injection Timing

F 1 795-799-1950 Pin 1
1. Testing.
A. Apply bar ➀ to the bolt at the crank pulley end and revolve it
forward to bring yellow paint a of the damper to the top. Push
in timing pin (1) and set the No. 1 cylinder piston to the com-
pression top dead center (Insert the timing pin in the gear hole).
★ Pushing depth of timing pin (1): 8 mm (0.315 in.)

★ If checking with the timing pin installed to the engine is
difficult, metallic pin assembly F1 may be used.
B. Remove plug (2) and reverse timing pin (3) and check that tim-
ing pointer (4) on the injection pump side is meshed with pin
(3).
2. Adjusting
• When the timing pin is not meshed.
A. Remove the injection pump. For details, see DISASSEMBLY

AND ASSEMBLY, Removal of fuel injection pump assembly.
B. Revolve the camshaft of the injection pump and mesh timing

pin (3) with timing pointer (4).
C. Install the injection pump. For details, see DISASSEMBLY

AND ASSEMBLY, Removal of fuel injection pump assembly.
30-203 WA380-5L
Adjusting Engine Speed Sensor

★ Adjust engine speed sensor (CN-E27) according to the following
procedure.
1. Open the engine right side cover.
2. Screw in until the tip of sensor (1) contacts the tip of the tooth of
flywheel ring gear (2).
★ Check that there are no scratches or metal particles stuck to the
tip of the sensor.
Thread portion: Hydraulic sealant
3. Turn sensor (1) back 1/2 - 2/3 turns from that position.
★ Adjust clearance a between so that the tip of the sensor and the
tip of the gear tooth is 0.75 - 1.00 mm {0.030 - 0.039 in.}.
4. Secure sensor (1) with nut (3).
Nut: 69 - 74 Nm {7.0 - 7.5 kgm} (51 - 55 lbf ft)
WA380-5L 30-213
Bleeding Air From Fuel Circuit

★ If the fuel runs out or if any fuel circuit device is removed and installed, bleed air according to the following procedure.
1. Remove fuel filter (1) and fill it with fuel and install it again.
★ When filling, use clean fuel and be careful not to let dirt get in.
★ Add fuel through inlet port portion a (8 places) of the filter.
Portion b is the outlet port (clean side) after the fuel has been
filtered, so never add fuel from here.
★ If clean fuel is not available, do not remove the filter. Operate
the priming pump to fill the filter with fuel.
2. Remove air bleed plug (2) of the fuel filter and operate priming
pump (3).
★ Continue operating the priming pump until fuel flows from the
plug hole. When fuel comes out, install the plug.
Air bleed plug:

7.8 - 9.8 Nm {0.8 - 1.0 kgm} (69 - 87 lbf in)
3. Crank the engine (for 15 - 20 seconds) with the starting motor 2 - 3

times.
30-223 WA380-5L
Adjusting Engine Stop Solenoid
★ If the fuel injection pump or engine stop solenoid is replaced, adjust the engine stop solenoid according to the following
procedure.
1. Install solenoid (1) to bracket (2).
2. Install ball joint (3) to stop lever (4).
3. Install bracket (2) to the cylinder block.
4. Turn the starting switch to the ON position to turn on (hold) the solenoid.
5. Pull (Retract) rod (5) of solenoid (1) with the hand to the stroke end.
6. Check that stop lever (4) touches the stopper on the RUN side.
7. Install the solenoid so that its rod will be pulled to the stroke end without fail.
★ Stroke of solenoid: 25.4 mm (1 in)
8. Check that the engine "starts" and "stops" normally and the solenoid is not heated abnormally.
WA380-5L 30-233
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL
ADJUSTING ACCELERATOR PEDAL
Adjusting the Power Mode
1. Adjust the installed length of accelerator cable (3) so that inclination X of pedal (2) will be 48° when lever (1) is pressed
against the low idling stopper of the engine.
• Installed length of cable
Pedal side y: 150 mm (6 in)
Lever side z: 277 mm (11 in)
★ Screw in the cable and joint more than 6 mm (0.2 in).
2. Press the accelerator pedal to the end in the power mode and insert a steel sheet 0.2 mm (0.01 in) thick to W between
stopper (4) on the engine side and lever (1).
3. Under the above condition, adjust the bolt length so that pedal (2) will touch stopper bolt (5) when a force of 3 - 5 kg
(7 - 11 lbs) is applied to the end of pedal.
• Height of stopper bolt (Standard) h: 60 mm (2.4 in)
30-243 WA380-5L
TESTING AND ADJUSTING ADJUSTING ACCELERATOR PEDAL
Adjusting the Normal Mode
1. Operate the mode selector switch to select the normal mode. [Motor cable (1) is shortened.]
• Installed length x: 140 mm (5.5 in)
• Check the clearance between stopper (2) and lever (3).
Clearance b: 1.0 mm (0.039 in)
2. Projection a of stopper bolt (4): 20 mm (0.79 in) (Temporary tightening.)
3. Operate the mode selector switch and check that the cable moves smoothly.
• Position of stopper bolt
➀: Power mode
➁: Normal mode
4. Start the engine and adjust stopper bolt (4) so that the high idling speed in the normal mode will be 1900 ± 50 rpm, then
tighten locknut (5).
WA380-5L 30-253
TESTING AND ADJUSTING ADJUSTING TRANSMISSION SPEED SEN-
ADJUSTING TRANSMISSION SPEED SENSOR

• Adjust speed sensor (1) (CN-REV OUT) as follows.
1. Remove the cover at the left side of the rear frame.
2. Screw in until the tip of sensor (1) contacts the tip of the tooth of
gear (2).
★ Check that there are no scratches or metal particles stuck to the
tip of the sensor
Thread portion: Gasket sealant (LG-5)
3. Turn sensor (1) back 1/2 - 1 turn from that position.

★ Adjust clearance a between the tip of the sensor and the tip of
the gear tooth to approximately 1.5 mm (0.059 in).
4. Secure sensor (1) with nut (3)
Nut: 74 Nm {7.0 - 7.5 kgf m} (55 lbf ft)
30-263 WA380-5L
TESTING AND ADJUSTING POWER TRAIN OIL PRESSURE
POWER TRAIN OIL PRESSURE

Sym-
bol Part No. Part Name Qty Remarks
Analog Pressure gauge: 25,

799-101-5002 hydraulic 1 Set 60, 400, 600 kg/cm2
tester (353, 5689, 8534 psi)
C1
Digital Pressure gauge:
790-261-1203 hydraulic 1 Set 600 kg/cm2
tester (853 psi)
Hydraulic Pressure gauge:

C2 799-401-2320 1 10 kg/cm2
gauge (142 psi)
Male/Female R 1/8
C4 790T-301-1750 T-piece 1 See attached drawing.
WARNING! Put block under the tires.
WARNING! Wait for the temperature of the oil to go

down before installing or removing the
measuring equipment.
★ Measure the power train oil pressure under the following

conditions.
• Coolant temperature: Within operating range
• Power train oil temperature: 60 ~ 80° C (140 ~ 176° F)
• Remove the cover at the left side of the rear frame.
★ Turn the transmission cut-off selector switch OFF and use the left brake.
Oil pressure measuring position and measuring gauges
Gauge
No. Measuring Oil Pressure MPa (psi)
1 Main relief pressure 5.9 (856)
2 Torque converter relief pressure 5.9 (856)
3 Torque converter outlet pressure 0.98 (142)
4 Transmission F clutch pressure 5.9 (856)
5 Transmission R clutch pressure 5.9 (856)
6 Torque converter lock-up clutch pressure 5.9 (856)
7 Transmission 4th clutch pressure 5.9 (856)
8 Transmission 1st clutch pressure 5.9 (856)
9 Transmission 3rd clutch pressure 5.9 (856)
10 Transmission 2nd clutch pressure 5.9 (856)
11 Parking brake pressure 5.9 (856)
WA380-5L 30-273
1. Measuring main relief pressure
A. Install hose ➀ to oil pressure measurement nipple (1).
B. Connect oil pressure gauge C1.
C. Start the engine, keep the gearshift lever at the N position, and
measure the oil pressure with the engine at low idling and rated
speed.
D. After completing the measurement, remove the measuring

equipment and return to the original condition.
2. Adjusting the main relief valve
WARNING! Adjust the main relief valve with the

engine stopped.
• If the main relief pressure is not within the standard value,

adjust as follows.
A. Remove plug (12).
B. Remove inner spring (13) and outer spring (14).
C. Adjust by changing the thickness of shim (15).

★ Standard shim thickness: 0.5 mm (0.02 in)
★ Amount of adjustment for one shim: 0.04 mm (0.002 in)
3. Measuring torque converter relief pressure (inlet)
A. Install hose ➀ to oil pressure measurement nipple (2).
measure the oil pressure with the engine at rated speed.

30-283 WA380-5L
4. Measuring torque converter outlet pressure
A. Remove oil pressure measurement plug and install nipple (3)

and install tee C4, nipple ➀ and hose ➁.
measure the oil pressure with the engine at rated speed.

5. Measuring transmission clutch pressure

• Remove measurement plug A of the ECMV valve, install the
nipple and the hose, then connect oil pressure gauge C1.
A. 1st, 2nd, 3rd, 4th clutch

• Plug 7: 4th clutch pressure
• Plug 8: 1st clutch pressure
• Plug 9: 3rd clutch pressure
• Plug 10: 2nd clutch pressure
i. Depress the brake.
ii. Start the engine and turn the parking brake switch OFF.
iii. Run the engine at low idling, set the directional lever at N, switch the shift mode selector switch to the
MANUAL position, then place the speed lever in the speed range to be measured.
iv. With the engine at low idling, keep the brake depressed, place the directional lever on F or R, then return the
directional lever to N.
★ The above operation is carried out because when the directional lever is at N, even if the speed lever is
operated, the speed range is not shifted.
WARNING! The machine will move, so check carefully that the surrounding area is safe.
v. Measure the oil pressure of the measurement clutch oil with the engine at rated speed.
vi. After completing the measurement, remove the measuring equipment and return to the original condition.
WA380-5L 30-293
B. F, R clutch (measurement plug: 4, 5)
ii. Start the engine and turn the parking brake switch OFF.
iii. Place the gearshift mode selector switch at MANUAL.
iv. With the engine at low idling, keep the directional lever at N, and operate the speed lever to 4th speed.
v. With the engine at low idling, keep the brake depressed, place the directional lever in F or R, then return the
directional lever to N.
WARNING! The machine will move, so check carefully that the surrounding area is safe.
vi. Run the engine at rated speed and measure the F and R clutch oil pressure.
vii. After completing the measurement, remove the measuring equipment and return to the original condition.
C. Torque converter lock-up clutch (measurement plug: 6)
WARNING! The measurement is made with the machine travelling, so check carefully that the
surrounding area is safe.
ii. Place the gearshift mode selector switch at AUTO.
iii. Turn the parking brake switch OFF.
iv. Place the speed lever at 3rd.
v. Place the directional lever at F and drive the machine.
vi. Travel with the engine running at rated speed and measure the oil pressure at the point where the lock-up pilot
lamp lights up in F3.
vii. After completing the measurement, remove the measuring equipment and return to the original condition.
D. Measuring parking brake pressure (measurement plug: 11)
i. Turn the parking brake switch OFF.
ii. Start the engine and measure the pressure with the engine at low idling.
30-303 WA380-5L
TESTING AND ADJUSTING FLUSHING TORQUE CONVERTER, TRANS-
FLUSHING TORQUE CONVERTER, TRANSMISSION AND

HYDRAULIC CIRCUIT
★ Metal particles and other dirt in the torque converter and transmission hydraulic circuit will reduce the life of the torque
converter and transmission, and will cause internal damage. To prevent this, carry out flushing to remove the dirt in the
hydraulic circuit.
1. Flush the circuit if the following conditions apply.
A. If there has been any breakage of the torque converter, transmission, or hydraulic equipment, and metal particles are
circulating in the hydraulic circuit.
B. When the torque converter and transmission have been overhauled or repaired.
2. Install a new filter cartridge.
A. Drain the oil from the filter piping.
B. Remove the transmission oil filter cartridge, then install the cartridge.
3. Fill the transmission case with oil.

• Add fresh oil through oil filter port to the specified level, and run the engine to circulate oil through the system. Then
re-check the level again.
Transmission case: 54 liter (14.2 gal)
4. Carry out flushing as follows.
A. After starting the engine, run engine for approximately 20 minutes at low idle without operating the speed lever or
directional lever.
★ From time to time, raise the engine speed to approximately 1500 rpm.
★ If the ambient temperature is low and the engine coolant temperature gauge does not enter the white range,
continue the warming-up operation longer.
B. Travel or carry out actual operations for 20 minutes.

★ Use all the speed ranges (FORWARD, REVERSE, and 1st - 4th).Repeat the procedure in step 4-1) and run the
engine at low idling for approximately 20 minutes.
5. Replace the filter cartridge.
A. Using the procedure in Step 2, replace the cartridge used for flushing with a new cartridge.
WARNING! If the cartridge used for flushing is used for a long time, there will be premature clogging,
so always replace the flushing element with the standard element.
B. Add oil and check the level again.
WA380-5L 30-313
TESTING AND ADJUSTING TRANSMISSION VALVE FAILS
TRANSMISSION VALVE FAILS
MOVING MACHINE
Special tool required
Symbol Part No. Part Name Qty Remarks

K 794-423-1190 Plug 1 M20 x 1.5
ECMV allocation diagram

★ If the machine cannot be moved because of a failure in any parts of
the transmission valve system (electrical system, solenoid valves,
spools, etc.), it is possible to move the machine by installing plug
K.
WARNING! Plug K is only for emergency use when

the machine cannot be moved in any
speed range because of a failure in the
transmission control valve. Install plug K
to the ECMV only when there has been a
failure and it is necessary to move the
machine from a dangerous working area
to a safe place for repairs.
WARNING! When carrying out this operation, keep

strictly to the procedure and pay careful
attention to safety when moving the
machine.
WARNING! To prevent the machine from moving,

lower the work equipment completely to
the ground, apply the parking brake, and
put blocks under the tires.
WARNING! Carry out the operation with the engine

stopped.
WARNING! Be careful not to burn yourself if the oil is

hot.
1. Remove cover (1) at the left side of the rear frame.

★ Wash the area around the ECMV clean and remove all dirt and
mud.
30-323 WA380-5L
TESTING AND ADJUSTING TRANSMISSION VALVE FAILS
2. Disconnect wiring connector (2) of each ECMV. (12 places).
3. Depending on the direction for moving the machine (forward or

reverse), remove 2 ECMV solenoids (3) and install plug K.
• FORWARD: F solenoid and 2nd solenoid
• REVERSE: R solenoid and 2nd solenoid
★ If there is any mistake in the selection of the solenoid to
remove, there is danger that the transmission may be
damaged.
★ Install plug K with the protruding surface 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 inside the
removed solenoid or valve.
4. Depress the brake pedal securely.
5. Start the engine, release the parking brake, then release the brake pedal gradually to allow the machine to start, and move
the machine.
★ If a failure in the electrical system makes it impossible to release the parking brake, manually release the parking
brake. For details, see MANUAL RELEASE METHOD FOR PARKING BRAKE.
WARNING! Remove the blocks from under the tires.
WARNING! When the engine is started, the transmission is also engaged to start the machine. To
ensure safety when starting the engine, check carefully that the direction of travel and
area around the machine are safe, and always keep the brake pedal depressed.
WARNING! After moving the machine, stop the engine, apply the parking brake, and put blocks under
the tires.
WA380-5L 30-333
TESTING AND ADJUSTING STEERING CONTROL
STEERING CONTROL
★ Measurement conditions
• Hydraulic oil temperature: 45 ~ 55° C (113 ~ 131° F)
• Engine speed: 1,200 rpm
• Road surface: Flat, horizontal, dry paved surface
• Tire inflation pressure: Standard pressure
Testing
1. Start the engine, operate the steering wheel, and set the front and
rear frames straight.
2. Check the looseness of locknut (2), or stopper bolt (1).
3. Start the engine and measure clearance between the front frame and
rear frame stopper 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.
Adjusting
1. Adjust the stopper bolt.
A. Screw in stopper bolt (1) to make it the minimum length.
B. Run engine at low idle and slowly operate the steering to contact the frame stopper.
C. Turn the stopper bolt until the head of stopper bolt (1) contacts the end face of the
spool of the stop valve (3).
D. Set the machine facing straight, and stop the engine.
E. Loosen stopper bolt (1) 8.5 turns, then lock it in position with locknut (2).
F. Carry out steps A thru E for both the left and right sides.
2. Start the engine and measure clearance (a) between the front frame and rear frame stopper 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.
30-343 WA380-5L
TESTING AND ADJUSTING STEERING OIL PRESSURE
STEERING OIL PRESSURE


Pressure gauge:2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Analog type hydraulic tester 1 Set
C1 (363.0, 856.0, 5685.4, 8528.2 psi)
790-261-1203 Digital type hydraulic tester 1 Set Pressure gauge:58.8 MPa (8528.2 psi)
• Hydraulic oil temperature: 45 ~ 55 °C (113 ~ 131 °F)

Measuring
WARNING! Loosen the oil filler cap slowly to release

pressure inside the hydraulic tank, and
operate the steering wheel 2 or 3 times to
release remaining pressure in the
hydraulic piping.
1. Fit safety bar (1) to the frame.
2. Install oil pressure gauge C1 [39.2 MPa] (5685 psi) to nipple (2) for
measuring the left turn steering circuit.
3. Run engine at high idle, then turn the steering wheel to the left and
measure pressure when the relief valve is actuated.
★ If the plug for the right turn steering circuit was removed, turn
the steering wheel to the right and measure the pressure.
WA380-5L 30-353
TESTING AND ADJUSTING STEERING OIL PRESSURE
Adjusting
WARNING! Always stop the engine before adjusting

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

★ Turn the adjustment screw to adjust the pressure as follows.
• To INCREASE pressure, turn CLOCKWISE
• To DECREASE pressure, turn COUNTERCLOCKWISE
★ Pressure adjustment for one turn of adjustment screw: 14.8
MPa (2147.1 psi)
★ If the relief pressure cannot be measured correctly, do not try to
adjust it.
30-363 WA380-5L
TESTING AND ADJUSTING TESTING HYDRAULIC FAN
TESTING HYDRAULIC FAN

Tool List

Measurement range:
J 799-203-8001 Multi-tachometer 1 L: 60 ~ 1,999rpm
H: 60 ~ 19,999rpm
1. Open the radiator grill and remove covers (1), (2), and (3).
2. Install stand ➀, probe ➁, and reflector tape ➂ of multi-tachometer

J.
3. Connect probe ➁ to multi-tachometer ➄ by cable ④.
4. Run the engine and measure the fan speed at the high idling and
low idling engine speeds.
WA380-5L 30-373
TESTING AND ADJUSTING BRAKE SYSTEM
BRAKE SYSTEM
Measuring Brake Oil Pressure

1 Brake test
793-605-1001 1 ---
kit
2 790-101-1430 Coupler 1 ---
3 790-101-1102 Pump 1 ---
H 4 M20 x 1.5
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 ---
WARNING! Apply parking brake and place blocks under the tires.
★ Use the same procedure to measure the front brakes (left and right)
and rear brakes (left and right)
1. Stop the engine.
2. Remove brake tube (1) on the side to be measured.
3. Remove union (2), install adapter H4 and nipple H5, then assemble
brake test kit H1.
★ Use the O-ring assembled to the union.
4. Loosen bleeder screw (3) and bleed the air.

★ Operate pump H3 to bleed the air
30-383 WA380-5L
5. Tighten bleeder screw (3), operate pump H3, raise the pressure to
4.9 MPa (711 psi), then tighten stop valve (1).
6. After applying the pressure, leave for 5 minutes and measure the
drop in the pressure.
★ If the hose is moved while measuring the pressure, the pressure
will change, so do not move the hose.
★ When removing brake test kit H1 after testing, operate pump
H3 to lower the pressure of brake test kit H1, then remove it.
★ After completing the operation, install the brake tube, then
bleed the air from the brake circuit.
Brake test tool
WA380-5L 30-393
Testing Wear of Wheel Brake Disc
WARNING! Stop the machine on horizontal ground and put blocks under the tires.
★ Brake oil pressure: 4.9 ± 0.49 MPa (711 ± 71 psi)
1. Remove cap (1).
2. Depress the brake pedal fully.
3. Push in shaft (2), then check protrusion x (amount of wear) from

guide (3).
★ Keep the pedal depressed while measuring.
★ If the groove of shaft (2) is protruding from the end face of
guide (3), replace the disc.
• Amount of wear: x
• Wear limit: y [2.4 mm] (0.09 in)
4. After completing the measurement, return to the original condition.
Cap (1): 29.4 - 39.2 Nm {3.0 - 4.0 kgf m}

(22 - 29 lb-ft)
30-403 WA380-5L
Bleeding Air from Brake Circuit
WARNING! Stop the machine on horizontal ground and put block under the tires.
★ If equipment in the brake circuit has been removed and installed, bleed the air from the brake circuit as follows.
★ Use the same procedure for both the front brake circuit and rear brake circuit (2 places each).
1. Remove front frame cover (1).
2. Connect air bleed hose ➀ to bleeder screw (2), then insert the other
end in a container.
3. Start the engine and run at low idling.
4. Depress the brake pedal, and keep the brake pedal depressed.
5. Loosen bleeder screw (2) approximately 1/2 turn, and drain the air
and oil.
6. When no more bubbles come out with the oil from the hose, tighten
bleeder screw (2).
Bleeder screw: 10 - 20 Nm {1 - 2 kgf m} (7 - 15 lb-ft)
7. After completing the air bleeding, run the engine at low idling, check the oil level in the hydraulic tank, and more oil if
necessary.
WA380-5L 30-413
Testing Wear of Parking Brake Disc


M Commercially available Calipers 1 (Mitsutoyo N10 or equivalent)
★ If the parking brake effect becomes weak, measure the piston stroke
as follows.
WARNING! To prevent the machine from moving,

lower the bucket to the ground and put
blocks under the tires.
WARNING! Always stop the engine before carrying

out this procedure.
1. Drain the oil from the transmission case.
Transmission case:54 liter (14.3 gal)
2. Remove 1 plug (1) (remove 1 of the 2 plugs)
3. Measure depth a with calipers M from the end face of cage (2) to
piston (3).
• Standard depth a: Max. 42.3 mm (1.7 in)
4. When the depth a is more than the standard value, remove parking
brake disc (4), and measure disc width W. For details, see
DISASSEMBLY AND ASSEMBLY, Removal of parking brake
disc.
• Judgement standard width W: 2.97 mm (0.12 in)
• When the depth of the parking brake disc is less than the
standard value replace the disc.
30-423 WA380-5L
Manual Release Method for Parking Brake

★ The parking brake is controlled by hydraulic pressure, so if there should be any failure in the transmission or the
emergency release solenoid and it becomes impossible to release the parking brake, it is possible to release it manually to
move the machine.
WARNING! The manual release of the parking brake is designed only to move the machine from a
dangerous working area to a safe place where repairs can be carried out. This method
must not be used except in an emergency.
WARNING! To prevent the machine from moving, lower the bucket to the ground and put blocks
under the tires.
WARNING! Always stop the engine before carrying out this procedure.
1. Remove 2 plugs (1). (left and right)

★ Approximately 20 liters (5.28 gal) of oil will come out from
the plug mount, so prepare a container to catch it.
★ After releasing the parking brake, coat the plug with gasket
sealant (LG-5) and tighten it.
2. Remove 2 gauge mounting bolts (2), and tighten to plug mounting

portion in turn.
★ Remove 2 bolts on opposite sides.
★ When bolts (2) are screwed in, piston (3) is pulled and the
parking brake is released.
★ Tighten the 2 bolts uniformly a little at a time. (Tighten approx-
imately 4.5 turns after the bolts contacts the seat.)
• Refilling with oil (transmission case)

After carrying out the manual release method for the parking brake,
add oil through the oil filler to the specified level. Run the engine to
circulate the oil through the system, then check the oil again.
WA380-5L 30-433
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
ACCUMULATOR CHARGE PRESSURE


Pressure gauge:
1
799-101-5002 Analog type hydraulic tester 2.5, 5.9, 39.2, 58.8 MPa
Set
1 (363.0, 856.0, 5685.4, 8528.2 psi)
1 Pressure gauge:
C 790-261-1203 Digital type hydraulic tester Set 58.8 MPa (8528.2 psi)
Both male and female:
799-401-2930 Nipple —
3 11/16-16UN (Rc1/8)
02896-11009 O-ring —
Measuring
• Hydraulic oil temperature: 45 ~ 50 °C (113 ~ 131 °F)
WARNING! Put blocks under the tires.
WARNING! Stop the engine, then depress the brake

pedal at least 100 times to release the
pressure inside the accumulator circuit.
1. Open the main control valve cover and disconnect accumulator

inlet port hose (1).
2. Install tool C3 to nipple ➀ at charge valve end, then assemble hose

➁ again.
3. Fit nipple ➀ and hose ➁ for measuring oil pressure to tool C3, then
install oil pressure gauge C1 [39.2 MPa] (5,686 psi).
4. Measure the accumulator charge cut-in pressure.

Start the engine, run at low idling, and measure the oil pressure
when the brake oil pressure warning pilot lamp on the maintenance
monitor goes out.
5. Measure the accumulator charge cut-out pressure.

After the accumulator charge cut-in, the pressure rises. Measure the oil pressure at the point where the oil pressure gauge
indicator suddenly drops after rising.
30-443 WA380-5L
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
Adjusting
★ When the accumulator charge cut-out pressure 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 (811 psi)
Locknut: 9.8 - 11.8 Nm {1.0 - 1.2 kgf m} (87 - 104 lbf in)
★ After completion of the adjustment, repeat the above procedure

for testing to check the accumulator charge cut-in pressure and
cut-out pressure again.
WA380-5L 30-453
TESTING AND ADJUSTING PPC OIL PRESSURE
PPC OIL PRESSURE


Pressure gauge:
799-101-5002 Analog type hydraulic tester 1 Set 2.5, 5.9, 39.2, 58.8 MPa
C1 (363.0, 856.0, 5685.4, 8528.2 psi)
Pressure gauge:
790-261-1203 Digital type hydraulic tester 1 Set 58.8 MPa(8528.2 psi)
• Hydraulic oil temperature: 45 ~ 55° C (113 ~ 131° F)

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

the pressure inside the hydraulic tank.
WARNING! Operate the control levers several times to

release pressure in the PPC accumulator
circuit.
Measuring
1. PPC pump basic pressure
A. Remove oil pressure measuring plug (1) (M10 x 1.25) which

is installed to left side rear frame of the machine.
B. Install nipple ➀ and hose ➁ and connect pressure gauge C1

5.9 MPa {60 kg/cm2} (856 psi).
C. Start the engine, operate the work equipment control lever

at high idling and measure the oil pressure.
30-463 WA380-5L
2. Measuring PPC valve output pressure
A. Raise the lift arm and install a support to it and remove front frame
inspection cover (1).
B. Remove oil pressure measurement plug (PT 1/8) of the circuit

to be measured, then fit nipple ➀ and hose ➁ and install oil
pressure gauge C1 [5.9 MPa] {60 kg/cm2} (856 psi).
★ Plug A: Lift arm LOWER, FLOAT

Plug B: Lift arm RAISE
Plug C: Bucket DUMP
Plug D: Bucket TILT
3. Start engine, run at high idle, then operate the work equipment
control lever, and measure the oil pressure.
WA380-5L 30-473
Adjusting
1. Adjusting PPC relief valve

Loosen locknut (3) of PPC valve (5), then turn adjustment screw (4)
to adjust.
★ Turn the adjustment screw to adjust as follows.
• To DECREASE the pressure, turn
COUNTERCLOCKWISE.
★ Amount of adjustment for one turn of adjustment screw:
1.79 MPa {18.3 kg/cm2} (260 psi).
Locknut : 9.8 - 11.8 Nm {1.0 - 1.2 kgf m} (87 - 104 lbf in)
★ After completion of the adjustment, check the accumulator

charge cut-in pressure and cut-out pressure again. For details,
see TESTING AND ADJUSTING ACCUMULATOR
CHARGE PRESSURE.
30-483 WA380-5L
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRES-
WORK EQUIPMENT HYDRAULIC PRESSURE


Pressure gauge:
799-101-5002 Analog type hydraulic tester 1 Set 2.5, 5.9, 39.2, 58.8 MPa
C1 (363.0, 856.0, 5685.4, 8528.2 psi)
Pressure gauge:
790-261-1230 Digital type hydraulic tester 1 Set 58.8 MPa (8528.2 psi)
★ Hydraulic oil temperature: 45 ~ 55 °C (113 ~ 131 °F)
1. Measuring work equipment relief pressure
A. Raise bucket portion a approximately 30 ~ 50 mm

(1.2 ~ 2.1 in) and set portion b in contact with the ground.
B. Stop the engine, then operate the work equipment control lever
and check that the bottom surface of the bucket (both portion a
and portion b is in contact with the ground.
★ After lowering bucket to the ground, operate the work
equipment control lever several times to release remaining
pressure in the piping.
C. Remove the oil pressure measurement plug, then fit nipple and
hose ➀, then install oil pressure gauge C1 [39.2 MPa] (5686
psi).
D. Start engine, raise the lift arm approximately 400 mm (16 in),
run the engine at high idle, tilt the bucket back, then measure
oil pressure when the relief valve is actuated.
WARNING! After measuring, repeat the procedure

used when installing the oil pressure
gauge to release the pressure inside
the circuit, then remove the oil pressure
gauge.
WA380-5L 30-493
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRES-
Adjusting
1. Adjusting work equipment relief valve
WARNING! When adjusting the oil pressure, be

sure to stop the engine.
A. Raise the lift arm and install a support to it and remove

front frame inspection cover (1).
B. Remove cap nut (2) of the relief valve.
C. Loosen locknut (3) and adjust with adjustment screw (4).

★ As the adjustment screw is
• To DECREASE the pressure, turn COUNTER
CLOCKWISE.
2. Quantity of adjustment per turn of adjustment screw: 3.5 MPa

{35.7 kg/cm2} (508 psi)
Locknut: 28 - 34 Nm (2.8 - 3.5 kgm} (21 - 25 lbf ft)
★ After completion of the adjustment, repeat the above procedure

to measure the work equipment relief pressure again.
30-503 WA380-5L
TESTING AND ADJUSTING BUCKET POSITIONER
BUCKET POSITIONER
★ Engine water temperature: Within white range on engine water temperature gauge
★ Hydraulic oil temperature: 45 ~ 55 °C (113 ~ 131°F)
Testing
1. With the engine stopped, check that clearance a between proximity

switch (1) and detector bar (2) is the standard value.
2. Start the engine, run at a midrange speed (1500 rpm), and check the
actuation point. (Check three times and take the average.)
Adjusting
1. Lower bucket to the ground, set bucket to the desired digging angle,
return lever to the HOLD position, and stop the engine.
2. Adjust nut (4) of the switch so clearance b between tip of switch

protector (3) and sensing surface of the switch is in the standard
value, then secure in position.
★ Standard clearance b: 0.5 ~ 1.0 mm (0.020 ~ 0.039 in)
Mounting nut: 14.7 - 19.6 Nm {1.5 - 2.0 kgm

(11 - 15 lbf ft)
3. Adjust with shims and the proximity switch bracket mounting bolts,
and secure in position so that the clearance a between the sensing
surface of proximity switch (1) and detector bar (2) is the standard
value.
★ Clearance a: 3 ~ 5 mm (0.12 ~ 0.20 in)
★ Adjust so that the clearance a is within the standard value for
the whole stroke of detector bar (2).
4. Adjusting installing position (stopping position).
A. Lower the bucket to the ground and set it to a desired digging

angle, then return the lever to the holding position and stop the
engine.
B. Secure switch protector (3) to the bucket cylinder so that sensing bar (2) will be at the center of the sensitive surface
of proximity switch (1).
★ The installing position may be checked by checking the operation of the pilot lamp of the proximity switch with
the starting switch at the ON position. (When the pilot lamp goes off, the bucket stops.)
★ After adjusting, start the engine and operate the bucket control lever to check that the bucket positioner operates
at the desired position.
WA380-5L 30-513
TESTING AND ADJUSTING BOOM KICK-OUT
BOOM KICK-OUT
★ Hydraulic oil temperature: 45 ~ 55 °C (113 ~ 131°F)
Testing
1. Start the engine, operate the lift arm lever to actuate proximity
switch (1), then stop the engine.
WARNING! Always be sure to apply the safety lock

to the work equipment control lever.
2. After stopping the engine, measure dimension a between the center

of proximity switch (1) and the top of plate (2).
★ Standard dimension a: 0 ~ 5 mm (0 ~ 0.20 in)
3. Measure clearance b between the proximity switch sensing surface

and the plate.
★ Standard dimension b: 3 ~ 5 mm (0.1 ~ 0.2 in)
Adjusting
1. If dimension a is not within the standard value, move the plate to

adjust.
2. If dimension b is not within the standard value, adjust proximity

switch mounting nut (3).
Mounting nut: 14.7 - 19.6 Nm {1.5 - 2.0 kgm

(11 - 15 lbf ft)
★ After adjusting, operate the lift arm lever and check that the
proximity switch is actuated normally.
30-523 WA380-5L
TESTING AND ADJUSTING PROXIMITY SWITCH ACTUATION
PROXIMITY SWITCH ACTUATION

The proximity switch is equipped with a pilot lamp which shows when
it is being actuated, so use this when adjusting.
Proximity
Switch
Lights Up Goes Out
Actuation
Pilot Lamp
Director When dector is positioned at detection surface of When detector has moved away from dection
Position proximity switch. surface of proximity switch.
Bucket
Positioner
Boom
Kick-out
WA380-5L 30-533
TESTING AND ADJUSTING ADJUSTING MACHINE MONITOR
ADJUSTING MACHINE MONITOR

Machine monitor rotary switches (SW1, SW2, SW3) and dip switches (SW5, SW6)
In the following cases, check the settings of the rotary switches and dip switches at the rear face of the machine monitor, and
change the settings as necessary.
• When the machine monitor has been removed and installed again.
• When the tire size has been changed (travel speed compensation setting).
• When an optional device has been installed or removed.
• When the parts of the machine monitor have been replaced with new parts (service meter, odometer).
★ When carrying out these settings, it is necessary to use the special operation of the character display and mode
switch. For details, see STRUCTURE AND FUNCTION, SPECIAL FUNCTIONS OF MACHINE MONITOR.
• The status of each switch can be checked with the special function of the machine monitor (monitoring function).
★ All setting operations are carried out with the starting switch OFF and the monitor panel removed.
★ Always set each switch as instructed.
★ Be careful not to touch anything inside the grommet except for the switch.
★ When turning the rotary switch, use a precision cross-head screwdriver and turn slowly.
★ The protruding triangular part of the rotary switch is the setting arrow.
★ When changing the dipswitch, use a precision flat-headed screwdriver and turn slowly.
Setting function of switches
Switch Position Content Of Setting Position When Monitor Is Shipped

SW1 0~F Model selection 2
SW2 0~F Not used (Always set to 0) 0
SW3 0~F Speed/tachometer & tire size selection 0
30-543 WA380-5L
OFF Common rail engine controller: Not installed

1 ON
ON Common rail engine controller: Installed
OFF Work equipment controller: For J/S (opt.) Not installed
2 OFF
ON Work equipment controller: For J/S (opt.) Installed
SW5
OFF
3 Not used (Always set to OFF) OFF
ON
OFF
ON
OFF
ON
OFF
ON
SW6
OFF
ON
OFF
ON
1. Setting rotary switch SW1

The machine monitor is designed to handle many models, so it must be set for the model on which it is actually installed.
When the machine monitor is replaced, use rotary switch SW1 to select the correct model.
Model SW1 Remarks

WA380-5L 0 —
2. Setting rotary switch SW2

Rotary switch SW2 is set as follows. The setting must not be changed.
• Set position of SW2: 0
3. Setting the rotary switch SW3

The machine monitor is set to calculate the travel speed for machines using standard tires. If the tire size has been
changed, adjust with rotary switch SW3 to compensate the speed display.
The settings for the tire sizes are as follows.
Meter Display SW3 WA380-5L
KM/H display 0 20.5-25

MP/H display 1 (Small Tire)
KM/H display 3 23.5-25

MP/H display 4 (Standard Tire)
WA380-5L 30-553
When the meter display is changed, the content of the speedometer display in the center of the monitor changes.
• As an optional setting, it is possible to change from the speedometer display to the tachometer display.
• The units for the odometer on the character displayed as set above.
★ If the tire size has been changed, adjust with rotary switch SW3 to compensate the speed display.
• If unlisted tires are used or if the tires become worn and the speed display does not match the actual speed, use on optional
setting to compensate for the tires.
4. Setting dipswitch SW5-1

The setting when the common rail engine controller is installed is as follows. The setting must not be changed.
• Set position of dipswitch SW5-1: OFF

When the joystick controller has been installed or removed, set as follows.
• Controller removed
• Controller installed
• Set position of dipswitch SW5-2: ON

Dipswitch SW5-3 is set as follows. The setting must not be changed.





30-563 WA380-5L
TESTING AND ADJUSTING LOAD METER
LOAD METER
• Since the load meter is a simple measuring instrument, test it periodically (at any intervals) according to the following
procedure. Test it, too, when a bucket which is not standard is installed, when the pressure sensors for the monitor and
load meter or the boom angle sensor is replaced, or when the load meter is used for the first time.
Testing
Test the load meter according to the following procedure.

1. Measure the weight without applying any load on the bucket.
2. Put weights of about the normal load and about 1/2 of the normal load, the weight of which is known accurately, on the
bucket and measure their weight.
3. Check that the error of the displayed weight is below the standard value.
Standard value: Error of measured value =< 1.5%
Model Normal Load Error at precision of 1.5% Allowable error of displayed load
WA380-5L 5.1 t ± 0.077 t ± 0.1 t
• When calculating accuracy, note that the indicated weight is rounded off to two decimal places (Unit: 10 kg {22 lbs}).
Adjusting
If the measurement accuracy of the load meter is out of the standard range, adjust load meter according to the following
procedure.
1. Adjust the boom angle for the load meter (at both upper limit and lower limit) in the monitor service mode.
★ See STRUCTURE, FUNCTION AND MAINTENANCE STANDARD, Machine Monitor.
2. Calibrate the load meter for no load in the operator mode.

★ See OPERATION AND MAINTENANCE MANUAL, Handling Load Meter.
• Calibrate the load meter for no load according to Performing Calibration for No Load (Zero Point Adjustment) shown
below.
Performing Calibration for No Load (Zero Point Adjustment)
(Supplemental Explanations)
When carrying out calibration for no load, use the following procedure to improve accuracy:
• Hydraulic oil temperature: The hydraulic oil temperature should be in approx 60 - 85° C (140 - 185° F):
Perform calibration at around the center of the white range on the hydraulic oil temperature gauge.
(It is possible to compensate error of pressure sensor due to the temperature, to perform calibration appropriate for the
machine.)
• Engine speed: When carrying out calibration, keep revolutions constant at the normal engine speed (about the rated
speed).
(The maximum effect of correction for the engine speed can be achieved. When actually taking readings, accurate
measurements can be obtained even if the engine speed varies.)
• Bucket posture: Perform calibration with the bucket in the fully tilted position. When taking readings of weight, the
bucket should also be placed in the fully tilted position. In other than the fully tilted position, the center of gravity
changes, which could result in inaccurate measurement.
• Speed of work equipment: When performing calibration, run the work equipment at a slow speed.
(Approx. 10 seconds from the travel postures to the uppermost position of the lift arm.
(This operation is carried out to increase measurement data when performing calibration.)
A. Check that normal display of the service meter and clock

appears on the character display.
WA380-5L 30-573
B. Press ( ) on monitor panel mode selector switch 1 to display
LOAD METER.
C. Press ( ) on monitor panel mode selector switch 1, and then

press (>) or (<) on monitor panel mode selector switch 2 to
select CALIBRATION.
3. After calibrating the load meter for no load, perform TESTING

again to check the measurement accuracy of the load meter.
4. If the measurement accuracy of the load meter does not satisfy the
standard, calibrate the load meter for load in the operator mode.
★ Calibrate the load meter for load with weights of the normal load and 1/2 of the normal load. In the calibration for
load, the load meter automatically judges the data of the normal load or the data of 1/2 of the normal load and changes
the standard data according to the numeral data input when calibration is started.
★ When using the vehicle with loads heavier than the normal load, do not calibrate with the normal load but calibrate
with the maximum hauling capacity for higher accuracy. Note that a load larger than twice the normal load is not
calculated.
Model Set range of calibration of normal load data Set range of calibration of 1/2 of normal load data
WA380-5L 5.0 t - 5.6 t 2.3 t - 2.8 t
Performing Calibration for Load (Zero Point Adjustment)

(Supplementary Explanations)
A. Check that the service meter and clock appears normally on the
character display.
B. Press ( ) on monitor panel mode selector switch 1 to display

load meter.
C. Press ( ) on monitor panel mode selector switch 1, and then

press (>) or (<) on monitor panel mode selector switch 2 to
select CALIBRATION.
D. Press ( ) on monitor panel mode selector switch 1. EMPTY

BUCKET appears on the lower line.
30-583 WA380-5L
E. Press (>) on the monitor panel mode selector switch 2 to
change the message on the lower line to LOAD BUCKET and
then press ( ) on monitor panel mode selector switch 1.
F. Press ( ) on monitor panel mode selector switch 1. Display

changes to STEP 1. The display on the lower line changes
between FULLY ROLL BACK and Set to AT CARRY POSI
every three seconds.
G. Load the bucket with a load of which the weight is known, tilt
the bucket at the way back by following the prompts, and
lower the lift arm to bring it to travel posture.
H. When the lift arm is lowered, the display changes to STEP 2

RAISE TO TOP. It is ready to perform calibration for load.
I. Raise the lift arm to its uppermost position by following the

prompts. When raising the lift arm, perform operation as close
as to that of actual work.
J. When the calibration for load setting has been successfully

completed, two short beeps are sounded and the screen for
entering the target weight appears.
K. When calibration for load has not been successfully completed,

a beep sounds, and the display goes back to CALIBRATION
on the upper line and LOAD BUCKET on the lower line.
L. Repeat the steps from 6.
M. Input the weight value on the screen for entering targets. The
weight calculated from the last data appears on the screen. The
cursor is now on 10 tons. When chaging the last target weight
7.1t to 7.5t (loaded weight at step 7) of this time, input
procedure is as folows.
N. Since the "10 ton" value is "0," leave it as it is. Press ( ) on

monitor panel mode selector switch 1 once.
Following confirmation of "0," the cursor moves to 1 ton.
O. It is not necessary to change the "1 ton" value because it is the same "7" as the display, so press ( ) on monitor panel
mode selector switch 1. Following confirmation of "7," the cursor moves to "0.1 ton."
WA380-5L 30-593
P. For display of the "0.1 ton" value as "1," select 5 by pressing
(>) or (<) on monitor panel mode selector switch 2 and press
( ) on monitor panel mode selector switch 1 once. Now "5"
has been confirmed and the target weight is set at 7.5 tons.
Q. Press ( ) on monitor panel mode selector switch 1. When the

monitor accepts the entry, two short beeps are sounded and
calibration for load setting is completed. The display is
restored to a normal view of a service meter and clock.
30-603 WA380-5L
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
Fan Motor Circuit

1. Bleeding air from fan motor circuit
A. Open the radiator grill, then remove covers (1) and (2).
B. Connect air bleed hose ➀ to nipple (3) at the inlet port of the
motor.
C. Start the engine, and when oil comes out from the air bleed
hose, stop the engine and remove bleed hose ➀.
Work Equipment PPC Circuit

1. Bleeding air from work equipment PPC circuit
A. Operate each work equipment lever and hold it in position to relieve the circuit for approximately 1 minute. Perform
this operation once for each work equipment lever.
Cylinders
1. Bleeding air from cylinders
A. Start the engine and run at idling for approximately 5 minutes.
B. Run the engine at low idling, then raise and lower the lift arm 4 ~ 5 times in succession.
★ Operate the piston rod to a point approximately 100 mm (3.94 in) before the end of its stroke. Do not relieve the
circuit under any circumstances.
C. Run the engine at full throttle and repeat Step B. After that, run the engine at low idling, and operate the piston rod to
the end of its stroke to relieve the circuit.
D. Repeat Steps B and C to bleed the air from the bucket and steering cylinders.
★ When the cylinder has been replaced, bleed the air before connecting the piston rod.
WA380-5L 30-613
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE
RELEASING REMAINING PRESSURE
In Hydraulic Circuit
1. Releasing remaining pressure between each hydraulic cylinder and control valve.
★ If piping between the hydraulic cylinder and control valve is to be disconnected, release the remaining pressure from
the circuit as follows.
A. Stop the engine.
B. Slowly loosen the oil filler cap to release pressure inside the hydraulic tank.
C. Operate the control levers.

★ When the levers are operated 2 ~ 3 times, the pressure stored in the PPC accumulator is removed. Start the engine
again, run at low idle for approximately 5 minutes to charge the accumulator, then stop the engine and operate
the control levers.
★ Repeat the above operation 2 ~ 3 times to release all remaining pressure.
2. Releasing remaining pressure in brake accumulator circuit.

★ If the piping between the brake accumulator and parking brake manual valve, between the accumulator and the accu-
mulator check valve, or between the accumulator and brake valve is to be disconnected, release the remaining pres-
sure from the circuit as follows.
A. Stop the engine.
B. Depress the brake pedal at least 100 times to release the pressure inside the brake accumulator circuit.
3. Releasing remaining pressure in PPC accumulator circuit.

★ If the piping between the PPC accumulator and PPC valve is to be disconnected, release the remaining pressure from
the circuit as follows.
l Operate the control lever 2 ~ 3 times to release the remaining pressure in the circuit.
30-623 WA380-5L
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE
E.C.S.S. Damper Circuit

★ When removing piping of the travel damper circuit and travel damper valve, release pressure in the accumulator as
follows.
1. Loosen locknut (2) of travel damper valve (1).
2. Loosen adjustment screw (3) 1/2 ~ 1 turn and release pressure from
the accumulator.
• Locknut (2) and adjustment screw (3) are painted red.
3. After releasing the remaining pressure, return adjustment screw (3)

to its original position and tighten locknut (2) securely.
Locknut: 12.7 ±0.6 Nm {1.3 ±0.06 kgm} (112 ±5 lbf in)
WA380-5L 30-633
TESTING AND ADJUSTING PM-CLINIC INSPECTION TABLE
PM-CLINIC INSPECTION TABLE

Machine serial No. #
- HOUR INSPECTION
Engine serial No. #
Work Instruction No. Date Of Service Service Meter Inspector
Interview With Operator And Walk-around Inspection
Problems before inspection:
1 Outside
temp.
2
3 Max:
4
Min:
What is the maximum level of coolant What is the maximum level of torque converter and transmission oil
temperature (During operation) temperature (During operation)
High:
White Green Green Green Green Red Red Green Green Green Green Green Red Red
1 2 3 4 5 6 7 1 2 3 4 5 6 7
★ If machine is cold, warm it up. Working mode: P-mode
Standard value for Measurement Good Poor

Item Condition Unit Service limit value
new machine results ✔ ✔
Engine at LOW idle 825 - 875 825 - 875
Engine at HIGH idle 2,180 - 2,280 2,180 - 2,280

Engine at HIGH idle
2,080 - 2,180 2,030 - 2,230
Engine Speed Torque converter stalled RPM
Hydraulic equipment stalled 2,120 - 2,320 2,020 - 2,420

Torque converter stalled + work
1,995 - 2,195 1,895 - 2,295
equipment relieved
Engine at full throttle and torque kPa Max. 0.98 Max. 1.96
Engine
Blow-by pressure
converter stalled (psi) (Max. 0.14) (Max. 0.28)
Min. 3.0 Min. 2.5
SAE10W30DH Full throttle
Engine lubricating kg/cm2 (Min. 43) (Min. 36)
SAE15W40DH
oil pressure (psi) Min. 1.0 Min. 0.7
SAE30DH Low idle
(Min. 14) (Min. 10)
Engine at full pressure and torque kPa Min. 140 Min. 113
Boost pressure
converter stalled (psi) (Min. 20) (Min. 16)
Engine at full pressure and torque
o
C Max. 550 (1,022) Max. 600 (1,112)
Exhaust temp. converter stalled
(oF)
Outside temperature ⎯ ⎯
25.9 - 29.9 25.9 - 29.9
Main Low idle
(368 - 425) (368 - 425)
Transmission valve
relief
Rated • Torque converter 27.5 - 31.5 27.5 - 31.5
press.
speed oil temperature (391 - 448) (391 - 448)
kg/cm2
60 - 80oC (140 - 176oF)
Torque converter (psi) Max. 9.0 Max. 9.0
inlet oil pressure • Engine at rated speed (Max. 128) (Max. 128)
Torque converter 3.5 - 6.0 3.5 - 6.0
outlet oil pressure (50 - 85) (50 - 85)
30-643 WA380-5L
Transmission valve 1st. 2nd. • Torque converter

3rd. oil temperature 22.0 - 25.0 22.0 - 25.0
ECMV 4th. 60 - 80oC (140 - 176oF) (313 - 356) (313 - 356)
output kg/cm2
(Clutch) F-R (psi)
oil press • Engine at rated speed
• Manual switch: ON 16 - 19 16 - 19
Lockup
(228 - 270) (228 - 270)
★ Secure frame with safety lever

Steering
Steering relief Hyd. oil temp. 45 - 55oC kg/cm2 237.5 - 262.5 225 - 262.5
pressure (113 - 131) Engine at HIGH idle (psi) (3,890 - 3,734) (3,200 - 3,734)
Hyd. oil temp. 45 - 55oC

Parking brake inlet kg/cm2 Min. 24.5 Min. 24.5
pressure (113 - 131oF) Engine at low idle (psi) (Min. 348) (Min. 348)
Parking brake released
• Tire pressure: specified
press.
Parking brake
• Test on flat level straight and ⎯ Stopped Stopped
performance
paved road
• Machine in operating state
Parking brake disc mm 3.12 - 3.28
• Measure with vernier caliper 2.97 (0.12)
thickness (in) (0.123 - 0.13)
Measure when
Charge cut-in Hyd. oil temp. brake oil pres- 60 - 65 55 - 70
pressure sure warning (853 - 925) (782 - 996)
45 - 55oC lamp goes off
(113 - 131oF)
Measure when
Engine at low
Charge cut-out brake oil pres- 100 - 110 95 - 115
pressure idle sure starts lower- (1,422 - 1,565) (1,351 - 1,636)
kg/cm2
ing after rising
Brakes
(psi)
Hyd. oil temp. 45 - 55oC 42.8 - 51 Min. 40.7
Brake oil pressure
(113 - 131oF) Engine at low idle (609 - 725) (Min. 579)
Engine stopped
Lowering of brake oil Max. 1.0 Max. 1.0
pressure Measure pressure from 50 kg/cm2 (Max. 14) (Max. 14)
(711 psi) in 5 minutes.
• Tire pressure: specified
press.
• Test on flat level straight and
paved road
• Braking initial speed: 20 km/
h (12 mph) m
Performance Max. 5 (16) Max. 5 (16)
• Max. 0.1 sec. (ft)
• Brake pedal pressing force:
normal 294 ± 29 Nm
(217 ± 21 ft/lbs)
• Measure braking
distance
mm Max. 2.4
Wear of disc Measure with disc wear indicator 0
(in) (Max. 0.09)
Work equipment
Bucket circuit 304 - 336 280 - 336
valve relief
relieved kg/cm2 (4,324 - 4,779) (3,983 - 4,779)
press.
(psi)
Engine at full Control lever 13 - 17 11 - 19
LS diff. press.
throttle moved half way (185 - 242) (156 - 270)
In P-mode
Work equipment
Raising time 5.4-6.4 Max. 4.4

Lift arm speed Hyd. oil temp. 45
- 55oC Lowering time 2.8-3.8 Max.5.0
(113 - 131oF) Bucket full stroke sec.
2.0 - 2.6 Max. 3.0
Bucket tilt back time
speed Bucket at level
1.3 - 1.9 Max. 3.0
time
mm/15
Bucket cyl. Max. 17 Max.20
Hydraulic drift of min.
Engine stopped
work equipment (in/
Lift cyl. 15min) Max. 20 Max. 24
Front axle There must not be excessive

Axle
Visual check of differential drain plug ---

Rear axle metal powder
WA380-5L 30-653
MEMORANDUM
30-663 WA380-5L
40 TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 40-15

SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-17
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 40-18
Precautions When Handling Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-18
Handling Electronic Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22
When Troubleshooting Electrical Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-24
ELECTRIC WIRE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-25
Classification by Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-25
Classification by Color and Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-25
How to Read Electric Wire Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-26
Points to Remember When Handling Hydraulic Equipment . . . . . . . . . . . . . . . . . . . . . . 40-28
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30
SPECIAL FUNCTIONS OF MACHINE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-31
Flow of Modes and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-32
Failure Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40
Monitoring Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . 40-65
T-ADAPTER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-88
CONNECTOR TYPES AND LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-91
CONNECTOR LAYOUT DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-98
TRANSMISSION CONTROL SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-104
TRANSMISSION CONTROL SYSTEM (TM MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-107
Failure Code [1500L1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-107
Double Engagement Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-107
Failure Code [15SAL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-108
Short Circuit in F_ECM Fill Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-108
Failure Code [15SALH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110
F_ECM Fill Switch System Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110
Failure Code [15SBL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-112
Short Circuit in R_ECM Fill Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-112
Failure Code [15SBLH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-114
R_ECM Fill Switch System Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-114
Failure Code [15SEL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-116
Short Circuit in 1st_ECM Fill Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-116
Failure Code [15SELH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-118
1st_ECM Fill Switch System Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-118
Failure Code [15SFL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120
Short Circuit in 2nd_ECM Fill Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120
Failure Code [15SFLH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-122
2nd_ECM Fill Switch System Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-122
WA380-5L 40-1 3
TROUBLESHOOTING
Failure Code [15SGL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-124

Short Circuit in 3rd_ECM Fill Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-124
Failure Code [15SGLH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-126
3rd_ECM Fill Switch System Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-126
Failure Code [15SHL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-128
Short Circuit in 4th_ECM Fill Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-128
Failure Code [15SHLH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130
4th_ECM Fill Switch System Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130
Failure Code [15SJL1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-132
Short Circuit in Lock-up_ECM Fill Switch System . . . . . . . . . . . . . . . . . . . . . . . . 40-132
Failure Code [15SJLH] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-133
Lock-up_ECM Fill Switch System Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . 40-133
Failure Code [989F00] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-134
Transmission Protection Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-134
Failure Code [B@C7NS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-135
Rear Brake Cooling Oil Overheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-135
Failure Code [D150KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-136
Emergency Steering Relay Output System Disconnected . . . . . . . . . . . . . . . . . . . . 40-136
Failure Code [D150KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-137
Short Circuit in Emergency Steering Relay Output System . . . . . . . . . . . . . . . . . . 40-137
Failure Code [D160KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-138
Back-up Alarm Relay Output System Disconnected . . . . . . . . . . . . . . . . . . . . . . . . 40-138
Failure Code [D160KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-139
Short Circuit in Back-up Alarm Relay Output System . . . . . . . . . . . . . . . . . . . . . . 40-139
Failure Code [D191KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140
Neutral Safety Relay Output System Disconnected . . . . . . . . . . . . . . . . . . . . . . . . 40-140
Failure Code [D191KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-142
Short Circuit in Neutral Safety Relay Output System . . . . . . . . . . . . . . . . . . . . . . . 40-142
Failure Code [D192KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-144
E.C.S.S. Relay Output System Disconnected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-144
Failure Code [D192KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-145
Short Circuit in E.C.S.S. Relay Output System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-145
Failure Code [D198KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-146
Ground Fault in the Low Temperature By-pass Relay System . . . . . . . . . . . . . . . . 40-146
Failure Code [D198KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-148
Hot-short in the Low-temperature By-pass Relay System . . . . . . . . . . . . . . . . . . . 40-148
Failure Code [DAQ0KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150
Controller Power Supply Voltage Lowered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150
Failure Code [DAQ2KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-152
Defective Solenoid Power Supply System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-152
Failure Code [DAQ9KQ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-154
Model Selection Signal Mismatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-154
Failure Code [DDK3KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-156
No Right FNR Switch Signal Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-156
Failure Code [DDK3KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-158
Multiple Right FNR Switch Signal Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-158
No Input Signal to Joystick Forward/Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . 40-160
40-2 3 WA380-5L
TROUBLESHOOTING
Multiple Joystick Forward/Reverse Switch Signals are Input . . . . . . . . . . . . . . . . . 40-162

Failure Code [DDK5LD] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-164
Hot Short in Joystick Shift_Up/Shift_Down Switch . . . . . . . . . . . . . . . . . . . . . . . . 40-164
No Input Signal from Forward-Reverse Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-166
Multiple Forward-Reverse Lever Signal Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-168
Failure Code [DDS5KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170
Steering Pressure Switch Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170
Failure Code [DDS5KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-172
Steering Pressure Switch Grounded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-172
Failure Code [DDT0L4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-174
Manual/Auto-Shift Selector Switch Selection Failure . . . . . . . . . . . . . . . . . . . . . . . 40-174
Failure Code [DDT4LD] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-176
Ground Fault in Transmission Cut-off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-176
Failure Code [DDW9LD] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-178
Short in Kickdown Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-178
Failure Code [DDWLLD] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180
Ground Fault in Hold Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180
Failure Code [DF10KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-182
No Input Signal in Gear Shift Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-182
Failure Code [DF10KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-184
Multiple Gear Shift Lever Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-184
Failure Code [DGF1KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-186
Transmission Oil Temperature Sensor System Failure . . . . . . . . . . . . . . . . . . . . . . 40-186
Failure Code [DGR2KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-188
Rear Brake Oil Temperature Sensor System Open . . . . . . . . . . . . . . . . . . . . . . . . . 40-188
Failure Code [DGR2KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190
Ground Fault In Rear Brake Oil Temperature Sensor System . . . . . . . . . . . . . . . . 40-190
Failure Code [DHT1KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-192
Transmission Cut-off (Left Brake Pressure Sensor) Signal Open . . . . . . . . . . . . . . 40-192
Failure Code [DLE2KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-194
Engine Speed Sensor Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-194
Failure Code [DLE2LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-195
Engine Speed Sensor Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-195
Failure Code [DLT3KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-196
Speed Sensor System Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-196
Failure Code [DT20KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-197
Ground Fault In Indicator Lamp System (Transmission Cut-off Switch) . . . . . . . . 40-197
Failure Code [DW7BKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-198
Fan Pump Reverse Solenoid System Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-198
Failure Code [DW7BKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-199
Fan Reverse Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-199
Failure Code [DW7CKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200
Switch Pump Cut-off Relay Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200
Failure Code [DW7CKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-201
Switch Pump Cut-off Relay Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-201
Failure Code [DX16KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-202
Fan Pump EPC Solenoid System Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-202
WA380-5L 40-3 3
TROUBLESHOOTING
Failure Code [DX16KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-203

Fan Pump EPC Solenoid System Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-203
Failure Code [DXH1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-204
Lock-up Clutch_ECMV Solenoid System Open . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-204
Failure Code [DXH1KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-205
Lock-up Clutch ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . 40-205
1st_ECMV Solenoid System Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-206
1st_ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-207
2nd_ECMV Solenoid System Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-208
2nd_ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-209
3rd_ECMV Solenoid System Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210
3rd_ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-211
R_ECMV Solenoid System Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-212
R_ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-213
F_ECMV Solenoid System Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-214
F_ECMV Solenoid System Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-215
Failure Code [DXHHKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-216
4th_ECMV Solenoid System Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-216
Failure Code [DXHHKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-217
4th_ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-217
Failure Code [DY30MA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-218
Motor-Driven Emergency Steering Pump Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 40-218
Failure Code [DY30MC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220
Motor-Driven Emergency Steering Pump Failure . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220
Failure Code [TM-1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-222
Open or Short in Kickdown Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-222
Failure Code [TM-2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-224
Hold Switch System Open Or Short . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-224
Failure Code [TM-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-226
Torque Converter Lock-up Switch System Failure . . . . . . . . . . . . . . . . . . . . . . . . . 40-226
Failure Code [TM-4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-228
Neutral Signal System Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-228
Failure Code [TM-5] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-230
Emergency Steering Switch Signal System Failure . . . . . . . . . . . . . . . . . . . . . . . . 40-230
Failure Code [TM-6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-232
Transmission Cut-off Switch System Open or Shorted . . . . . . . . . . . . . . . . . . . . . . 40-232
Failure Code [TM-7] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-234
Transmission Cut-off Setting Switch System Open or Shorted . . . . . . . . . . . . . . . 40-234
Failure Code [TM-8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-236
40-4 3 WA380-5L
TROUBLESHOOTING
Transmission Cut-off (Left Brake Sensor) Signal Shorted . . . . . . . . . . . . . . . . . . . 40-236

Failure Code [TM-9A] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-238
Joystick Shift Up/shift Down Switch System Failure . . . . . . . . . . . . . . . . . . . . . . . 40-238
Failure Code [TM-9B] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-240
Joystick Shift Up/shift Down Switch System Failure . . . . . . . . . . . . . . . . . . . . . . . 40-240
Failure Code [TM-10] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-242
FNR Switch Mode Change Over Switch System Failure . . . . . . . . . . . . . . . . . . . . 40-242
Failure Code [TM-11] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-244
Starting Switch "C" (IGN_C) Signal System Failure . . . . . . . . . . . . . . . . . . . . . . . 40-244
Failure Code [TM-12] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-248
Engine Power Mode Switch Open or Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-248
Failure Code [TM-13] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-250
Open or Short in Travel Damper ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . 40-250
Failure Code [TM-14] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-252
Open or Short in Hydraulic Fan Reverse Signal System . . . . . . . . . . . . . . . . . . . . . 40-252
Failure Code [TM-15] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-254
Short in Motor Driven Emergency Steering Relay System . . . . . . . . . . . . . . . . . . . 40-254
Failure Code [TM-16] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-255
Short in Travel Damper Relay System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-255
Failure Code [TM-17] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-256
Switch Pump Cut-off Relay System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-256
Failure Code [TM-18] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-257
Back Lamp Relay System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-257
Failure Code [TM-19] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-258
Neutral System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-258
Failure Code [TM-20] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-259
F_ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-259
Failure Code [TM-21] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-260
R_ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-260
Failure Code [TM-22] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-261
1st_ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-261
Failure Code [TM-23] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-262
2nd_ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-262
Failure Code [TM-24] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-263
3rd_ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-263
Failure Code [TM-25] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-264
4th_ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-264
Failure Code [TM-26] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-265
Lock-Up ECMV Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-265
Failure Code [TM-27] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-266
Fan Pump EPC Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-266
Failure Code [TM-28] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-267
Fan Reverse Solenoid System Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-267
Failure Code [TM-29] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-268
Speed Sensor System Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-268
Failure Code [TM-30] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-270
E.C.S.S. Solenoid System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-270
WORK EQUIPMENT CONTROL SYSTEM (WRK MODE) . . . . . . . . . . . . . . . . . . . . . . 40-272
Connector Types And Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-272
WA380-5L 40-5 3
TROUBLESHOOTING
Connector Layout Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-280

Work Equipment Control System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-286
Failure Code [D193KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-290
Defective Joystick Steering Relay System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-290
Failure Code [D193KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-292
The Joystick Solenoid Relay Output System Shorted . . . . . . . . . . . . . . . . . . . . . . . 40-292
Failure Code [DB90KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-294
Lowering Work Equipment Controller Power Supply Fault . . . . . . . . . . . . . . . . . . 40-294
Failure Code [DB92KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-296
Defective Solenoid Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-296
Failure Code [DB95KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-298
Open in 5 V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-298
Failure Code [DD1ALD] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-300
Defective Remote Positioner UP Set Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-300
Failure Code [DD1BLD] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-302
Defective Remote Positioner DOWN Set Switch . . . . . . . . . . . . . . . . . . . . . . . . . . 40-302
Failure Code [DFAOKM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-304
Defective Neutral Caution for Joystick Work Equipment . . . . . . . . . . . . . . . . . . . . 40-304
Failure Code [DK59KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-306
Defective Lift Arm EPC Lever Potentiometer System
(Main Circuit Discontinuity or Ground Fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-306
Failure Code [DK59KY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-308
Defective Lift Arm EPC Lever Potentiometer System (Main Short Circuit) . . . . . 40-308
Failure Code [DK59L8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-310
Defective Lift Arm EPC Potentiometer System
(Displacement of Main and Sub Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-310
Failure Code [DK5AKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-312
Defective Lift Arm EPC Lever Potentiometer System (Disconnection of Main) . . 40-312
Failure Code [DK5AKY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-314
Defective Lift Arm EPC Lever Potentiometer System (Short Sub Circuit) . . . . . . 40-314
Failure Code [DK5BKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-315
Defective Bucket EPC Lever Potentiometer System (Disconnection of Main) . . . 40-315
Failure Code [DK5BKY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-316
Defective Bucket EPC Lever Potentiometer System (Main Short Circuit) . . . . . . . 40-316
Failure Code [DK5BL8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-318
Defective Bucket EPC Potentiometer System
Failure Code [DK5CKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-320
Defective Bucket EPC Lever Potentiometer System (Disconnection of Main) . . . 40-320
Failure Code [DK5CKY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-321
Defective Bucket EPC Lever Potentiometer System (Short Sub Circuit) . . . . . . . . 40-321
Failure Code [DK5DKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-322
Defective 3rd Valve Lever Potentiometer System (Main Circuit Discontinuity or Ground Fault)
40-322
Failure Code [DK5DKY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-324
Defective Lift Arm EPC Lever Potentiometer System (Main Circuit Short Circuit) 40-324
Failure Code [DK5DL8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-326
Defective 3rd Valve EPC Potentiometer System
40-6 3 WA380-5L
TROUBLESHOOTING
Failure Code [DK5EKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-328

Defective 3rd Valve Lever EPC Potentiometer System
(Sub Circuit Discontinuity or Ground Fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-328
Failure Code [DK5EKY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-329
Defective Lift Arm EPC Lever Potentiometer System (Short Sub Circuit) . . . . . . 40-329
Failure Code [DK5FKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-330
Defective Joystick Steering EPC System (Main Circuit Open or Shorted) . . . . . . . 40-330
Failure Code [DK5FKY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-331
Defective Joystick Steering EPC Potentiometer System (Main Circuit Shorted) . . 40-331
Failure Code [DK5FKM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-332
Joystick Steering EPC Lever Neutral System Caution . . . . . . . . . . . . . . . . . . . . . . 40-332
Failure Code [DK5FL8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-334
Defective Joystick Steering EPC Lever Potentiometer Input Signal . . . . . . . . . . . . 40-334
Failure Code [DK5GKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-336
Defective Joystick Steering EPC Potentiometer System
(Open or Short in Sub Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-336
Failure Code [DK5GKY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-337
Defective Joystick Steering EPC Potentiometer System (Sub Circuit Short) . . . . . 40-337
Failure Code [DKAOKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-338
Defective Lift Arm Angle Sensor System (Open or Short) . . . . . . . . . . . . . . . . . . . 40-338
Failure Code [DKAOKY] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-340
Defective Lift Arm Angle Sensor (System Shorted) . . . . . . . . . . . . . . . . . . . . . . . . 40-340
Failure Code [DLE2LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-342
Defective Engine Speed Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-342
Failure Code [DLT3LC] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-343
Defective Transmission Output AXIS Speed Sensor System (Open) . . . . . . . . . . . 40-343
Failure Code: [DUM1KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-344
Remote Positioner RAISE Lamp System Ground Fault . . . . . . . . . . . . . . . . . . . . . 40-344
Failure Code: [DUM2KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-345
Remote Positioner LOWER Lamp System Ground Fault . . . . . . . . . . . . . . . . . . . . 40-345
Failure Code: [DW4PKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-346
Disconnected Lift Arm RAISE EPC Solenoid System . . . . . . . . . . . . . . . . . . . . . . 40-346
Failure Code: [DW4PKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-347
Lift Arm RAISE EPC Solenoid System Ground Fault . . . . . . . . . . . . . . . . . . . . . . 40-347
Failure Code: [DW4QKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-348
Disconnected Lift Arm LOWER EPC Solenoid System . . . . . . . . . . . . . . . . . . . . . 40-348
Failure Code: [DW4QKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-349
Lift Arm LOWER EPC Solenoid System Ground Fault . . . . . . . . . . . . . . . . . . . . . 40-349
Failure Code: [DW4RKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-350
Disconnected Bucket TILT EPC Solenoid System . . . . . . . . . . . . . . . . . . . . . . . . . 40-350
Failure Code: [DW4RKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-351
Bucket TILT EPC Solenoid System Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . . 40-351
Failure Code: [DW4SKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-352
Disconnected Bucket DUMP EPC Solenoid System . . . . . . . . . . . . . . . . . . . . . . . 40-352
Failure Code: [DW4SKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-353
Bucket DUMP EPC Solenoid System Ground Fault . . . . . . . . . . . . . . . . . . . . . . . . 40-353
Failure Code: [DWM1KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-354
Work Equipment Neutral Lock Solenoid System Disconnection . . . . . . . . . . . . . . 40-354
Failure Code: [DWM1KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-355
WA380-5L 40-7 3
TROUBLESHOOTING
Work Equipment Neutral Lock Solenoid System Ground Fault . . . . . . . . . . . . . . . 40-355

Failure Code: [DWN6KA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-356
Lift Arm RAISE Magnet Detent System Disconnection . . . . . . . . . . . . . . . . . . . . . 40-356
Failure Code: [DWN6KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-358
Lift Arm RAISE Magnet Detent System Ground Fault . . . . . . . . . . . . . . . . . . . . . 40-358
Lift Arm FLOAT Magnet Detent System Disconnection . . . . . . . . . . . . . . . . . . . . 40-360
Lift Arm FLOAT Magnet Detent System Ground Fault . . . . . . . . . . . . . . . . . . . . . 40-362
Lift Arm TILT Magnet Detent System Disconnection . . . . . . . . . . . . . . . . . . . . . . 40-364
Lift Arm TILT Magnet Detent System Ground Fault . . . . . . . . . . . . . . . . . . . . . . . 40-365
Failure Code: [DXHJKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-366
3rd Valve Extension EPC Solenoid System Disconnection . . . . . . . . . . . . . . . . . . 40-366
Failure Code: [DXHJKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-367
3rd Valve Extension EPC Solenoid System Ground Fault . . . . . . . . . . . . . . . . . . . 40-367
Failure Code: [DXHKKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-368
3rd Valve Retraction EPC Solenoid System Disconnection . . . . . . . . . . . . . . . . . . 40-368
Failure Code: [DXHKKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-369
3rd Valve Retraction EPC Solenoid System Ground Fault . . . . . . . . . . . . . . . . . . . 40-369
Failure Code: [DXHLKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-370
Open in Joystick Steering Right-Hand EPC Solenoid System . . . . . . . . . . . . . . . . 40-370
Failure Code: [DXHLKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-372
Joystick Steering Right-Hand EPC Solenoid System Ground Fault . . . . . . . . . . . . 40-372
Failure Code: [DXHMKA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-374
Joystick Steering Left-Hand EPC Solenoid System Open . . . . . . . . . . . . . . . . . . . 40-374
Failure Code: [DXHMKB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-376
Joystick Steering Left-Hand EPC Solenoid System Ground Fault . . . . . . . . . . . . . . . . 40-376
Failure Code: [WRK-1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-378
Defective Lift Arm Lock Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-378
Failure Code: [WRK-2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-380
Defective Remote Positioner RAISE Setting Switch System . . . . . . . . . . . . . . . . . 40-380
Failure Code: [WRK-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-382
Defective Remote Positioner LOWER Setting Switch System . . . . . . . . . . . . . . . . 40-382
Failure Code: [WRK-4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-384
Defective Remote Positioner RAISE Selection Switch System . . . . . . . . . . . . . . . 40-384
Failure Code: [WRK-5] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-386
Defective Remote Positioner LOWER ON/OFF Switch System . . . . . . . . . . . . . . 40-386
Failure Code: [WRK-6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-388
Defective Bucket Cylinder Proximity Switch System . . . . . . . . . . . . . . . . . . . . . . . 40-388
Failure Code: [WRK-7] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-390
Defective Bucket Cylinder Full Stroke Detection Switch System . . . . . . . . . . . . . 40-390
Failure Code: [WRK-8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-392
Defective Semi-Automatic Digging HARD Selection Switch System . . . . . . . . . . 40-392
Failure Code: [WRK-9] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-394
Defective Semi-Automatic Digging SOFT Selection Switch System . . . . . . . . . . . 40-394
Failure Code: [WRK-10] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-396
Defective Joystick ON/OFF Switch System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-396
40-8 3 WA380-5L
TROUBLESHOOTING
Failure Code: [WRK-11] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-398

Defective Joystick Steering Speed HI/LO Switch System . . . . . . . . . . . . . . . . . . . 40-398
Failure Code: [WRK-12] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-400
Defective Joystick Solenoid Cut Relay Output System . . . . . . . . . . . . . . . . . . . . . . 40-400
Failure Code: [WRK-13] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-401
Hot Short-Circuited Lift Arm RAISE Magnet Detent Output System . . . . . . . . . . 40-401
Failure Code: [WRK-14] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-402
Hot Short-Circuited Lift Arm FLOAT Magnet Detent Output System . . . . . . . . . . 40-402
Failure Code: [WRK-15] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-403
Hot Short-Circuited Bucket TILT Magnet Detent Output System . . . . . . . . . . . . . 40-403
Failure Code: [WRK-16] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-404
Hot Short-Circuited Work Equipment Neutral Lock Solenoid Output System . . . . 40-404
Failure Code: [WRK-17] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-405
Hot Short-Circuited Lift Arm RAISE EPC Solenoid System . . . . . . . . . . . . . . . . . 40-405
Failure Code: [WRK-18] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-406
Hot Short- Circuited Lift Arm LOWER EPC Solenoid System . . . . . . . . . . . . . . . 40-406
Failure Code: [WRK-19] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-407
Hot Short- Circuited Bucket TILT EPC Solenoid System . . . . . . . . . . . . . . . . . . . 40-407
Failure Code: [WRK-20] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-408
Hot Short- Circuited Bucket DUMP EPC Solenoid System . . . . . . . . . . . . . . . . . . 40-408
Failure Code: [WRK-21] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-409
Hot Short- Circuited 3 Valves Extension EPC Solenoid System . . . . . . . . . . . . . . 40-409
Failure Code: [WRK-22] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-410
Hot Short- Circuited 3 Valves Retraction EPC Solenoid System . . . . . . . . . . . . . . 40-410
Failure Code: [WRK-23] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-411
Short in Joystick Steering Right EPC Solenoid System . . . . . . . . . . . . . . . . . . . . . 40-411
Failure Code: [WRK-24] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-412
Short in Joystick Steering Left EPC Solenoid System . . . . . . . . . . . . . . . . . . . . . . 40-412
Failure Code: [WRK-25] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-414
Failure Code: [WRK-26] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-416
Defective Boom Kick-Out Function and Cancellation . . . . . . . . . . . . . . . . . . . . . . 40-416
Failure Code: [WRK-27] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-419
Defective Bucket Leveler Function and Cancellation . . . . . . . . . . . . . . . . . . . . . . . 40-419
Failure Code: [WRK-28] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-422
Defective Lift Arm FLOAT Holding and Cancellation . . . . . . . . . . . . . . . . . . . . . . 40-422
MONITOR SYSTEM (MON MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-424
Connector Types and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-424
Monitor System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-437
Failure Code [2F00KM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-441
Dragging Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-441
Failure Code [2G42ZG] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-444
Accumulator Oil Pressure (Front Brake Circuit) Low . . . . . . . . . . . . . . . . . . . . . . . 40-444
Failure Code [2G43ZG] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-446
Accumulator Oil Pressure (Rear Brake Circuit) Low . . . . . . . . . . . . . . . . . . . . . . . 40-446
Failure Code [AA1ANX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-448
Air Cleaner 1 Clogged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-448
Failure Code [AB00L6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-450
Defective Battery Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-450
WA380-5L 40-9 3
TROUBLESHOOTING
Failure Code [AB00MA] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-452

The Battery Charging Circuit is Out of Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-452
Failure Code [B@BAZG] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-454
Engine Oil Pressure Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-454
Failure Code [B@BAZK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-455
Engine Oil Level Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-455
Failure Code [B@BCNS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-456
Engine Coolant Temperature Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-456
Failure Code [B@BCZK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-458
Alarm Indicating Low Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-458
Failure Code [B@HANS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-459
Hydraulic Oil Temperature Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-459
Failure Code [B@CENS] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-460
Torque Converter Oil Temperature Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-460
Failure Code [D182KZ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-462
The Preheater Relay Coil is Open or Shorted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-462
Failure Code [D5ZHL6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-464
Start Switch C (IGN "C") Input Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-464
Failure Code [DA80L4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-466
Auto Grease Input is Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-466
Failure Code [DAF3KK] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-468
When the SW Power Supply (for Operation) is ON, the NSW Power Supply
(for Memory) is OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-468
Failure Code [DAF5KP] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-470
5-V Power Supply Output Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-470
Failure Code [DAF6KP] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-472
24-V Power Supply Output Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-472
Failure Code [DAFBKM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-474
Incorrect Information on Model Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-474
Failure Code [DAFSKQ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-475
Incorrect Information on Meter Indication Selection . . . . . . . . . . . . . . . . . . . . . . . 40-475
Failure Code [DAQSKR] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-476
S-NET Communication Failure (Between Monitor Panel and
Transmission Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-476
Failure Code [DBQSKR] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-478
Work Equipment Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-478
Failure Code [DB9SKR] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-480
Work Equipment Controller) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-480
Failure Code [DD15LD] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-482
Monitor Panel Mode Selector Switch 1 [■] (Panel SW1) Input Error . . . . . . . . . . 40-482
Monitor Panel Mode Selector Switch 1 [◊] (Panel SW2) Input Error . . . . . . . . . . . 40-484
Monitor Panel Mode Selector Switch 2 [<] (Panel SW3) Input Error . . . . . . . . . . . 40-486
Monitor Panel Mode Selector Switch 2 [>] (Panel SW4) Input Error . . . . . . . . . . . 40-488
Failure Code [DD1CLD] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-490
40-10 3 WA380-5L
TROUBLESHOOTING
Sub-Total Switch Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-490

Failure Code [DDK3KM] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-492
CAUTION: Right FNR Switch is in "N" (Neutral) . . . . . . . . . . . . . . . . . . . . . . . . . 40-492
CAUTION: Joystick FNR Switch is in "N" (Neutral) . . . . . . . . . . . . . . . . . . . . . . . 40-493
CAUTION: FNR (Forward- Reverse) Lever Switch is in "N" (Neutral) . . . . . . . . 40-494
Failure Code [DDS5L6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-496
Decreased Steering Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-496
Failure Code [DDY0LD] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-498
Cancel Switch Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-498
Failure Code [DGE2KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-500
Engine Coolant Temperature (High Temperature) Sensor System Failure . . . . . . . 40-500
Failure Code [DGE3L6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-502
Abnormal Connection of Engine Coolant Temperature (Low Temperature)
Sensor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-502
Failure Code [DGH2KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-504
Hydraulic Oil Temperature Sensor System Failure . . . . . . . . . . . . . . . . . . . . . . . . . 40-504
Failure Code [DGT1KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-505
Torque Converter Oil Temperature Sensor System Failure . . . . . . . . . . . . . . . . . . 40-505
Failure Code [DHE4L6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-506
Engine Oil Pressure Sensor System Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-506
Failure Code [DHPCKX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-508
Bottom Pressure Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-508
Failure Code [DHPDKX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-510
Head Pressure Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-510
Failure Code [DKA0KX] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-512
Lift Arm Angle Sensor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-512
Failure Code [DV00KB] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-514
Shorted Alarm Buzzer Output System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-514
Failure Code [DY30ME] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-516
The Emergency Steering Remains Actuated For More Than One Minute . . . . . . . 40-516
Troubleshooting Code [MON-1] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-520
The Parking Brake Indicator Lamp Does Not Light Up When the
Parking Brake Switch is Turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-520
Circuit Diagnostic Procedures for Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-522
The Brake Oil Pressure Caution Lamp Does Not Light Up When the
Emergency Brake is Applied (Rear Circuit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-524
The Air Cleaner Clogging Indicator Lamp Does Not Light . . . . . . . . . . . . . . . . . . 40-526
The Engine Oil Pressure Caution Lamp Does Not Light . . . . . . . . . . . . . . . . . . . . 40-528
The Engine Oil Level Caution Lamp Does Not Light . . . . . . . . . . . . . . . . . . . . . . . 40-529
The Engine Coolant Temperature Caution Lamp Does Not Light . . . . . . . . . . . . . 40-530
WA380-5L 40-11 3
TROUBLESHOOTING
The Coolant Level Caution Lamp Does Not Light . . . . . . . . . . . . . . . . . . . . . . . . . 40-531

The Hydraulic Oil Temperature Caution Lamp Does Not Light . . . . . . . . . . . . . . . 40-532
Troubleshooting Code [MON-10] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-533
The Torque Converter Oil Temperature Caution Lamp Does Not Light . . . . . . . . 40-533
The Steering Hydraulic Caution Lamp Does Not Light . . . . . . . . . . . . . . . . . . . . . 40-534
Input Fault in Monitor Panel Mode Switch 1 [■] (Panel SW1) . . . . . . . . . . . . . . . 40-536
Input Fault in Monitor Panel Mode Switch 1 [◊] (Panel SW2) . . . . . . . . . . . . . . . 40-538
Input Fault in Monitor Panel Mode Switch 2 [<] (Panel SW3) . . . . . . . . . . . . . . . . 40-540
Input Fault in Monitor Panel Mode Switch 2 [>] (Panel SW4) . . . . . . . . . . . . . . . . 40-542
Defective Subtotal Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-544
Defective Cancel Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-546
Defective Bottom Pressure Sensor (Short Fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-548
Defective Head Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-550
The Alarm Buzzer Does Not Sound or Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-552
HYDRAULIC AND MECHINCAL SYSTEMS (H MODE) . . . . . . . . . . . . . . . . . . . . . . . 40-554
H-1 - The Machine Does Not Move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-554
H-2 - The Lock-up Clutch is Not Released (The Engine Stops)
(When the Lock-up Clutch is Provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-556
H-3A - The Travel Speed is Slow, Thrusting Force is Weak,
Uphill Traveling Power is Weak, and the Gear is Not Shifted . . . . . . . . . . . . . . . . . . 40-557
H-3B - The Torque Converter Lock-up Clutch is Not Let in
(When Lock-up Clutch is Provided) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-559
H-4 - Shocks are Large at the Times of Starting and Shifting Gear . . . . . . . . . . . . . . . 40-560
H-5 - Time Lag is Large at the Times of Starting and Shifting Gear . . . . . . . . . . . . . . 40-562
H-6 - Torque Converter Oil Temperature is High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-564
H-7 - Steering Wheel Does Not Turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-565
H-8 - Steering Does Not Turn [Machine With Joystick] . . . . . . . . . . . . . . . . . . . . . . . . 40-566
H-9 - Turning, Response of Steering is Poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-567
H-10 - Steering is Heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-568
H-11 - Steering Wheel Shakes or Jerks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-569
H-12 - The Brake Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-570
H-13 - The Brake is Not Released or is Draging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-571
H-14 - The Parking Brake is Not Released or Draging . . . . . . . . . . . . . . . . . . . . . . . . . 40-572
H-15 - The Boom Does Not Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-573
H-16 - The Boom Moves Slowly or the Boom Rising Force is Insufficient . . . . . . . . . 40-574
H-17 - When Rising, the Boom Comes to Move Slowly at Specific Height . . . . . . . . 40-575
H-18 - The Boom Cylinder Cannot Hold Down the Bucket
(the Bucket Rises in the Air) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-575
40-12 3 WA380-5L
TROUBLESHOOTING
H-19 - Hydraulic Drifts of the Boom Occur Often . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-575

H-20 - The Boom Wobbles During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-576
H-21 - When the Control Lever is Switched From “Hold” to “Raise,”
the Boom Falls Temporarily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-576
H-22 - The Bucket Does Not Tilt Back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-577
H-23 - The Bucket Moves Slowly or the Tilting Back Force is Insufficient . . . . . . . . . 40-578
H-24 - The Bucket Comes to Operate Slowly in the Midst of Tilting-back . . . . . . . . . 40-579
H-25 - The Bucket Cylinder Cannot Hold Down the Bucket . . . . . . . . . . . . . . . . . . . . 40-579
H-26 - Hydraulic Drifts of the Bucket Occur Often . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-579
H-27 - The Bucket Wobbles During Travel with Cargo
(The Work Equipment Valve is Set to “Hold”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-580
H-28 - When the Control Lever is Switched From “Hold” to “Tilt,”
The Bucket Falls Temporarily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-580
H-29 - The Control Levers of Boom and Bucket Do Not Move Smoothly and Heavy 40-581
H-30 - E.C.S.S. Does Not Work and There is Pitching and Bouncing . . . . . . . . . . . . . 40-582
ELECTRICAL SYSTEM (E MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-583
Connector Types and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-583
Electrical System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-596
Action Code: [E-1-a] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-597
The Engine Does Not Crank (Ignition System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-597
Action Code: [E-1-b] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-602
The Engine Does Not Start. (Engine Stop Solenoid System) . . . . . . . . . . . . . . . . . 40-602
Action Code: [E-2] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-606
The Engine Does Not Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-606
Action Code: [E-3] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-608
Preheating Inoperable or Remains ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-608
Action Code: [E-4] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-612
The Engine Power Mode Inoperable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-612
Action Code: [E-5] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-616
The Front Wiper Does Not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-616
Action Code: [E-6] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-620
The Rear Wiper Does Not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-620
Action Code: [E-7] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-624
The Side Wiper Does Not Function (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . 40-624
Action Code: [E-8] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-628
The Window Washer Does Not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-628
Action Code: [E-9] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-632
The Headlamp (Lo Beam) Does Not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-632
Action Code: [E-10] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-636
The Headlamp (Hi Beam) Does Not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-636
Action Code: [E-11] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-640
Clearance Lamps Do Not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-640
Action Code: [E-12] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-644
Turn Signal Does Not Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-644
Action Code: [E-13] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-648
Horn Does Not Sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-648
Action Code: [E-14] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-650
Air Conditioner Does Not Work or Does Not Shut Down . . . . . . . . . . . . . . . . . . . 40-650
WA380-5L 40-13 3
TROUBLESHOOTING
ENGINE SYSTEM (S-MODE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-654

Method Of Using Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-654
(S-1) Engine Starting Performance Is Poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-658
(S-2) Engine Does Not Crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-659
Engine Cranks But No Exhaust Smoke Comes Out Of Stack . . . . . . . . . . . . . . . . . 40-660
Smoke Comes Out Of Stack But Engine Does Not Start . . . . . . . . . . . . . . . . . . . . 40-661
(S-3) Engine Does Not Run Smoothly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-662
(S-4) Engine Stops During Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-663
(S-5) Engine Speed Hunts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-664
(S-6) Engine Lacks Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-665
(S-7) Exhaust Smoke Is Black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-667
(S-8) Oil Consumption Is Excessive Or Exhaust Smoke Is Blue . . . . . . . . . . . . . . . . . 40-668
(S-9) Oil Becomes Contaminated Quickly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-669
(S-10) Fuel Consumption Is Excessive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-670
(S-11) Oil Found In Coolant, Or Coolant Spurts From Radiator . . . . . . . . . . . . . . . . . 40-671
(S-12) Oil Pressure Caution Lamp Lights Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-672
(S-13) Oil Level Rises (Coolant Or Fuel Found In Oil) . . . . . . . . . . . . . . . . . . . . . . . . 40-673
(S-14) Coolant Temperature Too High (Overheating) . . . . . . . . . . . . . . . . . . . . . . . . . 40-674
(S-15) Abnormal Noise Is Heard When Engine Is Running . . . . . . . . . . . . . . . . . . . . . 40-675
(S-16) Excessive Vibration When Engine Is Running . . . . . . . . . . . . . . . . . . . . . . . . . 40-676
40-14 3 WA380-5L
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
POINTS TO REMEMBER WHEN TROUBLESHOOTING
WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking
brake are securely fitted.
WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and
cause burns, so wait for the engine to cool down before starting troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect negative (-) terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, coolant,
or air, always release the internal pressure first. When installing measuring equipment,
be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure.
When carrying out troubleshooting, 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.
1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of
the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator.
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the failure occurred?
C. Did the failure occur suddenly, or were there problems with the machine condition before this?
D. Under what conditions did the failure occur?
E. Had any repairs been carried out before the failure? When were these repairs carried out?
F. Has the same kind of failure occurred before?
WA380-5L 40-15 3
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLE-
3. Check before troubleshooting.
A. Check the oil level.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
C. Check the travel of the control levers.
D. Check the stroke of the control valve spool.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4. Confirming the failure.
A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.
5. Troubleshooting
A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.
B. The basic procedure for troubleshooting is as follows.
i. Start from the simple points.
ii. Start from the most likely points.
iii. Investigate other related parts or information.
6. Measures to remove root cause of failure.
A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.
B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
40-16 3 WA380-5L
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLE-
SEQUENCE OF EVENTS IN TROUBLESHOOTING
WA380-5L 40-17 3
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT
12
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).
Precautions When Handling Electrical Equipment

1. Handling High Voltage Circuits
A. If the machine is equipped with an electronically controlled

engine, high voltage is used to control fuel injection,
(110 - 130 V) for the fuel injector drive. Never handle the
engine wiring harness while the engine is running, tamper with
or modify this circuit, sever injury may result due to the high
voltage and amps in the circuit. Always use caution when
working around this circuit.
2. Handling Wiring Harnesses And Connectors
A. Wiring harnesses consist of wiring connecting one component

to another component, connectors used for connecting and
disconnecting one wire from another wire, and protector or
tubes used for protecting the wiring. Compared with other
electrical components fitted in boxes or cases, wiring harnesses
are more likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during inspection and
repair operations they are frequently removed and installed
again, so they are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely careful when
handling wiring harnesses.
3. Main Failures Occurring In Wiring Harness
A. Faulty contact of connectors:

(faulty contact between male and female). Problems with
faulty contact are likely to occur because the male connector is
not properly inserted into the female connector, or because one
or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidation of
the contact surfaces.
40-18 3 WA380-5L
B. Defective compression or soldering of connectors:
The pins of the male and female connectors are in contact at
the compressed terminal or soldered portion, but there is
excessive force on the wiring, and the plating peels to cause
improper connection or breakage.
C. Disconnections in wiring:
If the wiring is held and tugged and the connectors are pulled
apart, or components are lifted with a crane with the wiring
still connected, or a heavy object hits the wiring, the crimping
compression of the connectors to the wire may be loosened, or
the soldering may be damaged, or the wiring may be broken.
D. High pressure water entering a connector:

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

If oil or grease are stuck to the connector and an oil film is
formed on the mating surface between the male and female
pins, the oil will not let the electricity pass, and this will cause
a defective contact.If there is oil or grease or dirt stuck to the
connector, wipe it off with a dry cloth or blow dry with air, and
spray it with a contact restorer.
★ When wiping the mating portion of the connector, be
careful not to use excessive force or deform the pins.
★ If there is water or oil present, it will increase the
contamination of the points, so clean with air until all
water and oil has been removed.
WA380-5L 40-19 3
4. Removing, Installing, And Drying Connectors And Wiring
Harnesses.
A. Disconnecting connectors:
i. Hold the connectors when disconnecting.

When disconnecting the connectors, hold the connectors
and not the wires. For connectors held by a screw, loosen
the screw fully, then hold the male and female connectors
in each hand and pull apart. For connectors which have a
lock stopper, press down the stopper with your thumb and
pull the connectors apart.
★ Never try to pull apart with one hand
ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted to the left and right or up
and down, the housing may break.
iii. When disconnecting male and female connectors, release

the lock and pull in parallel with both hands.
★ Never try to pull apart with one hand.
iv. Action to take after removing connectors.

After removing any connector, cover it with a vinyl bag to
prevent any dust, dirt, oil, or water from getting in the
connector portion.
40-20 3 WA380-5L
B. Connecting connectors:
i. Check the connector visually.

l Check that there is no oil, dirt, or water stuck to the
connector pins (mating portion).
l Check that there is no deformation, faulty contact,
corrosion, or damage to the connector pins.
l Check that there is no damage or breakage to the
outside of the connector.
★ If there is any oil, water, or dirt stuck to the connector,
wipe it off with a dry cloth. If any water has gotten
inside the connector, warm the inside of the wiring
with a dryer, but be careful not to make it too hot as
this will cause short circuits.
★ If there is any damage or breakage, replace the
connector.
ii. Assemble the connector securely.

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

of the wiring harness.
For connectors fitted with boots, correct any protrusion or
the boot. In addition, if the wiring harness is misaligned,
or the clamp is out of position, adjust it to its correct
position.
★ When blowing with dry air, there is danger that the oil
in the air may cause improper contact, so clean with
properly filtered air.
iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and
check that there is no looseness of the clamp.
C. Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type connectors have two
latches respectively, push them in until they click 2 times.
• Male connector (1), Female connector (2).
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
WA380-5L 40-21 3
D. Drying wiring harness:
If there is any oil or dirt on the wiring harness, wipe it off with
a dry cloth. Avoid washing it in water or using steam. If the
connector must be washed in water, do not use high pressure
water or steam directly on the wiring harness. If water gets
directly on the connector, do as follows:
i. Disconnect the connector and wipe off the water with a

dry cloth.
★ If the connector is blown dry with air, there is the risk
that oil in the air may cause a faulty contact, so avoid
blowing with air.
ii. Dry the inside of the connector with a dryer.

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

After drying, leave the wiring harness disconnected and
carry out a continuity test to check for any short circuits
between pins caused by water.
★ After completely drying the connector, spray it with
contact restorer and reassemble.
Handling Electronic Control Unit

1. The electronic control unit contains a microcomputer and electronic
circuits.
★ This controls all of the electronic circuits on the machine, so be
extremely careful when handling the control unit.
2. Do not open the cover of the control box unless necessary.
40-22 3 WA380-5L
3. Do not place objects on top of the control unit.
4. Cover the control connectors with tape or a vinyl bag.
5. Do not leave the control unit in a place where it is exposed to rain.
6. Do not place the control unit on oil, water, or soil, or in any hot
place, even for a short time.
★ Place it on a suitable dry stand.
7. Precautions when carrying out arc welding.

★ When carrying out arc welding on the body, disconnect all
wiring harness connectors connected to the control unit. Attach
the arc welding ground close to the welding point as possible.
WA380-5L 40-23 3
12
When Troubleshooting Electrical Circuits
1. Always turn power OFF before disconnecting or connecting connectors.
2. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
★ Disconnect and connect the related connectors several times to check.
★ Check each individual wire on the connector suspected of the problem by performing a pull test on the wire insert.
3. Always connect any disconnected connectors before going on to the next step.
★ If power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity or current), move the related
wiring and connectors several times and check that there is no charge in the reading of the tester.
★ If there is any charge, there is probably defective contact in that circuit.
5. When checking a single diode circuit:

★ Isolate the diode from the circuit.
★ Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
★ Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.
6. When checking a dual diode circuit:

★ Isolate the diode from the circuit.
★ Using a digital volt ohm meter, in the Ohms mode, check the
polarity of the diode as shown in the illustration. Reversing the
meter leads, you should have a reading in one direction only.
★ Electrical flow should be negative (-) to positive (+) only, red
lead positive and black lead negative.
7. Always be aware of what you are measuring. Voltage, Ohms or

Amps. Always use caution when measuring a circuit.
★ When measuring voltage, be sure the meter is set in the voltage
range, AC or DC and above the voltage value you are
measuring.
★ When measuring ohms, be sure the circuit is dead and has (no
voltage) in it before you take any readings. Be sure the meter is
set in the proper ohms range.
★ When measuring Amps, be sure your meter is rated for the
amount of amps you will be measuring. Failure to follow these
procedures may damage your equipment or possibly cause
injury. Always study the operators manuel for the meter you
will be using.
40-24 3 WA380-5L
TROUBLESHOOTING ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
Classification by Thickness
Copper wire
Nominal Cable O.D. Current
Number of Dia. Of strand Cross Applicable circuit
number (mm) rating (A)
strands (mm) section (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Classification by Color and Code

Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Primary
Code W B B R Y G L
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 Black & Yellow & Green &
Color White & Red — Red & White Blue & White
White Red White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow &
Color — Red & Black Green & Red Blue & Red
Black low Black
Code WL — BR RY YG GY LY
Auxiliary
4 Red & Yel- Yellow & Green & Yel- Blue & Yel-
Color White & Blue — Black & Red
low Green low low
Code WG — — RG YL GB LB
5 White & Yellow & Green &
Color — — Red & Green Blue & Black
Green Blue Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
WA380-5L 40-25 3
12
How to Read Electric Wire Code
★ The information about the wires unique to each machine model is described in Troubleshooting section, Relational infor-
mation of troubleshooting.
★ In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The elec-
tric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal
No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness
and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Type Symbol Material temperature Example of use
range (°C)
Low-voltage Annealed copper for electric
Conductor General wiring
wire for auto- AV appliance
(Nominal No. 5 and above)
mobile Insulator Soft polyvinyl chloride
Thin-cover Annealed copper for electric –30 to +60
Conductor
low-voltage appliance General wiring
AVS
wire for auto- (Nominal No. 3 and below)
mobile Insulator Soft polyvinyl chloride
Heat-resistant Annealed copper for electric

Conductor
low-voltage appliance General wiring in extremely cold dis-
AEX –50 to +110
wire for auto- Heat-resistant crosslinked poly- trict, wiring at high-temperature place
Insulator
mobile ethylene
40-26 3 WA380-5L
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 –
Cov-
AV Standard – – – – – – – 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard – – – – – – – – –
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
“f” of nominal No. denotes flexible”.
WA380-5L 40-27 3
12
Points to Remember When Handling Hydraulic Equipment
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material)
in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary
to be particularly careful.
1. Be careful of the operating environment.

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

If disassembly or maintenance work is carried out on hydraulic
equipment in the field, there is danger of dust entering the
equipment. It is also difficult to confirm the performance after
repairs, so it is desirable to use unit exchange. Disassembly and
maintenance of hydraulic equipment should be carried out in a
specially prepared dust proof workshop, and the performance
should be confirmed with special test equipment.
3. Seal or cover all openings of disconnected piping.

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 environmental regulation for any disposal of oil.
4. Do not let any dirt, or dust get in during refilling operations.

Be careful not to let any dirt or dust get in when refilling with
hydraulic oil. Always keep the oil filler and the area around it clean,
and also use clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt that has collected
during storage, so this is an even more effective method.
40-28 3 WA380-5L
5. Change hydraulic oil when the temperature is high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the
circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible
of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; but drain the oil from the filter
and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6. Flushing operations.
After disassembling and assembling the equipment, 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 specified hydraulic oil.
7. Cleaning operations.
After repairing the hydraulic equipment (pump, control valve, etc.)
or when running the machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil circuit.The oil cleaning
equipment is used to remove the ultra fine (about 3µ) particles that
the filter built into the hydraulic equipment cannot remove, so it is
an extremely effective device.
WA380-5L 40-29 3
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Value Action
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
3. Check hydraulic oil level — Add oil
Lubricating oil, coolant
4. Check hydraulic strainer — Clean, drain

5. Check swing machinery oil level — Add oil
6. Check engine oil level — Add oil
7. Check coolant level — Add coolant
8. Check dust indicator for clogging — Clean or replace
9. Check hydraulic filter — Replace
10. Check final drive oil level — Add oil
11. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
equipment
Electrical
12. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
13. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
14. Check operation of instruments — Repair or replace
15. Check for abnormal noise, smell — Repair
mechanical
Hydraulic,
equipment
16. Check for oil leakage — Repair

17. Carry out air bleeding
— Bleed air
18. Check battery voltage (Engine stopped) 24 - 26 V Replace

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

22. Check for water leaking on wiring (Pay particular attention to water leaking on con- Disconnect
—
nectors or terminals) connector and dry
23. Check for blown, corroded fuses — Replace
After running for
24. Check alternator voltage (Engine running at 1/2 throttle or above) several minutes: Replace
27.5 ~ 29.5 V
25. Sound of actuation of battery relay (When starting switch is turned ON, OFF) — Replace
40-30 3 WA380-5L
TROUBLESHOOTING SPECIAL FUNCTIONS OF MACHINE MONI-
SPECIAL FUNCTIONS OF MACHINE MONITOR

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

Functions for which the content is normally displayed or which can be used displayed and operated by the operator
operating the switches.
2. Special functions 1: Service Mode 1

Functions which the serviceman can display and operate with the special switches to carry out inspection, maintenance,
and troubleshooting.
3. Special functions 2: Service Mode 2

Special operations performed by the serviceman or at the factory.
Operator mode ⇔ Service mode 1 ⇔ Service mode 2

Service meter, time display Electrical system trouble data Service meter setting
1 11 20
(Load meter specification) display function function
2 Load meter function 12 Mechanical system trouble 21 Odometer setting function

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

function
Filter, oil replacement time
6 Language selection function 16 setting function
Monitor brightness
7 17 Option selection function
adjustment function
8 Time adjustment function 18 Serial No. setting function
9 Action code display function 19 Initialize function
10 Failure code display function
WA380-5L 40-31 3
12
Flow of Modes and Functions
40-32 3 WA380-5L
12
WA380-5L 40-33 3
12
40-34 3 WA380-5L
Operator Mode
★ No. 2 ~ No. 8 give an endless display according to the operation of the switch.
★ When a failure occurs, the screen changes automatically to No. 9, regardless of the display 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 operated 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.
Service Mode 2
★ No. 20 and 21 switch according to the operation of the switch.
The character display consists of a top line and bottom line with 16
characters each. A combination of the following characters (alphabet
and numerals) and symbols is displayed according to the content.
A. Numerals: 1 2 3 . . .
B. Small letters: a b c . . .
C. Capital letters: A B C . . .
D. Katakana: Japanese display only
E. Symbols: @ Y= $ . . .
F. Special characters
Control switches
Control of the machine monitor display is all carried out with machine
monitor mode selector switches (1) and (2). The following functions are
provided for the buttons of each switch.
A. ◊: Select, Run
B. ■: Cancel, Release, Select (YES/NO screen only)
C. >: Right, Next, Continue
D. <: Left, Previous, Return
WA380-5L 40-35 3
Operation and displays for operator mode
1. Service meter, time display function

When the starting switch is turned ON, the top line shows the
service meter and the bottom line shows the time.
• The time display function is only on the load meter
specification machine.
2. Load meter function (opt.)
★ For details, see the OPERATION AND MAINTENANCE MANUAL, Machine Monitor and Other Functions.
40-36 3 WA380-5L
3. Distance traveled in reverse display function. From the normal
service meter display, press the [◊] switch to display the odometer.
• On machines without a load meter, this display is shown first.
★ For details, see the OPERATION AND MAINTENANCE
MANUAL, Machine Monitor and Other Functions.
4. Filter, oil replacement interval display function
A. Filter, oil replacement time display (automatic display) When

the replacement interval for the filters or oil approaches, this
information is automatically displayed on the machine monitor
to recommend the operator to carry out maintenance.
B. Resetting replacement time (selection menu). When the

maintenance operation for the filters and oil replacement has
completed, the switches on the machine monitor can be used to
reset the interval.
★ The replacement interval can be set using Service Mode 1.
5. Telephone number input function. The telephone number set inside

the machine monitor can be input, corrected, or cancelled by
operating the switches.
★ When action code [E03] is displayed, the telephone number is
displayed at the same time as [CALL].
6. Language selection function. The language used for the machine

monitor display can be selected by operating the switches.
★ The functions of Service Mode 1 and Service Mode 2 are not
included in the functions for display selection, so they are
always displayed in English.
WA380-5L 40-37 3
7. Monitor brightness adjustment function. The brightness of the
machine monitor can be adjusted by the switch to 7 levels.
8. Time adjustment function (load meter specification). The setting of

the date and time on the machine monitor can be selected by the
switch.
MANUAL, Handling Load Meter.
9. Action code display function. If any abnormality occurs on the

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

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

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

Reduce when engine speed and machine speed while continuing operations.
E02 Not displayed
• When overheat related display is shown:
Stop machine and keep engine running at mid-range speed under no load.
E03 Displayed • Stop engine and machine immediately and contact serviceman.
40-38 3 WA380-5L
10. Failure code display function. While the action code is being
displayed on the machine monitor, press the [>] button once to
display the failure codes for the existing failures.
★ The failure codes detected in the past are divided into failures
of the electrical system and the mechanical system and are
recorded as trouble data. (For details, see 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. 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.
★ With the service code display function, the following data are
displayed.
i. Failure code (location code + problem code)
ii. Controller codes

MON: Machine monitor
ENG: Engine controller
TM : Transmission controller
WRK: Work equipment controller
iii. System with problem

★ For details of the displayed failure codes, see FAILURE
CODE TABLE.
★ If no switch is operated on the failure code display screen for more than 30 seconds, the display automatically returns
to the action code display screen.
WA380-5L 40-39 3
12
Failure Code Table
Failure Code Location of Failure Nature of Failure Controller Action

(Location, component with failure) (Problem, nature of failure) Code
1500L0 Transmission clutch See separate table (L0) TM E03
15B0NX Transmission filter Clogged (NX) MON E01
15SAL1 Fill switch for F clutch See separate table (L1) TM E03
15SALH Fill switch for F clutch See separate table (LH) TM E01
15SBL1 Fill switch for R clutch See separate table (L1) TM E03
15SBLH Fill switch for R clutch See separate table (LH) TM E01
15SEL1 Fill switch for 1st clutch See separate table (L1) TM E03
15SELH Fill switch for 1st clutch See separate table (LH) TM E01
15SFL1 Fill switch for 2nd clutch See separate table (L1) TM E03
15SFLH Fill switch for 2nd clutch See separate table (LH) TM E01
15SGL1 Fill switch for 3rd clutch See separate table (L1) TM E03
15SGLH Fill switch for 3rd clutch See separate table (LH) TM E01
15SHL1 Fill switch for 4th clutch See separate table (L1) TM E03
15SHLH Fill switch for 4th clutch See separate table (LH) TM E01
15SJL1 Fill switch for lock-up clutch See separate table (L1) TM E03
15SJLH Fill switch for lock-up clutch See separate table (LH) TM E01
(2F00KM) Parking Brake Mistaken operation or mistaken setting (KM) MON E00
(2F00MR) Parking Brake Brake failure (MR) MON E00
2G42ZG Accumulator (Front) Drop in oil pressure (ZG) MON E03
2G43ZG Accumulator (Rear) Drop in oil pressure (ZG) MON E03
(989F00) Transmission overrun prevention command signal Actuated (00) TM E00
(989G00) Neutral position confirmation signal Actuated (00) TM E00
A000N1 Engine Overrun (N1) ENG E02
AA1ANX Engine air cleaner 1 Clogged (NX) MON E01
AA1BNX Engine air cleaner 2 Clogged (NX) MON E01
AB00L6 Alternator See separate table (L6) MON E03
AB00MA Alternator Function impossible (MA) MON E03
AD00L2 Common rail See separate table (L2) ENG E03
AD00MA Common rail Function impossible (MA) ENG E03
AD10L3 Fuel supply pump See separate table (L3) ENG E03
AD10MA Common rail Function impossible (MA) ENG E03
AD10MB Fuel supply pump Drop in function (MB) ENG E03
AD11KA Fuel supply pump solenoid valve 1 Disconnection (KA) ENG E03
AD11KB Fuel supply pump solenoid valve 1 Short circuit (KB) ENG E03
AD51KA Fuel supply pump solenoid valve 2 Disconnection (KA) ENG E03
AD51KB Fuel supply pump solenoid valve 2 Short circuit (KB) ENG E03
ADA1KA No. 1 injector solenoid valve Disconnection (KA) ENG E03
ADAZKB No. 1, 2, 3 injector solenoid valve Short circuit (KB) ENG E03
ADB1KA No. 2 injector solenoid valve Disconnection (KA) ENG E03
ADC1KA No. 3 injector solenoid valve Disconnection (KA) ENG E03
ADD1KA No. 4 injector solenoid valve Disconnection (KA) ENG E03
ADDZKB No. 4, 5, 6 injector solenoid valve Short circuit (KB) ENG E03
ADE1KA No. 5 injector solenoid valve Disconnection (KA) ENG E03
ADF1KA No. 6 injector solenoid valve Disconnection (KA) ENG E03
B@BAZG Engine oil pressure Drop in oil pressure (ZG) MON E03
40-40 3 WA380-5L
Location of Failure Nature of Failure Action

Failure Code Controller
B@BAZK Engine oil Drop in level (ZK) MON E01
B@BCNS Engine Overheat (NS) MON E02
B@BCZK Radiator water level Drop in level (ZK) MON E01
B@C6ZK Brake oil (Front) Drop in level (ZK) MON E01
B@C7NS Brake oil temperature sensor Overheat (NS) TM E02
B@C7ZK Brake oil (Rear) Drop in level (ZK) MON E01
B@CENS Torque converter Overheat (NS) MON E02
B@GAZK Battery 1 Drop in level (ZK) MON E01
B@GBZK Battery 2 Drop in level (ZK) MON E01
B@HANS Hydraulic tank Overheat (NS) MON E02
D150KA Emergency steering relay Disconnection (KA) TM E03
D150KB Emergency steering relay Short Circuit (KB) TM E03
D160KA Back-up lamp relay Disconnection (KA) TM E01
D160KB Back-up lamp relay Short Circuit (KB) TM E01
D182KZ Preheating relay Disconnection or short circuit (KZ) ENG E03
D191KA Neutral output relay Disconnection (KA) TM E03
D191KB Neutral output relay Short circuit (KB) TM E01
D192KA Travel damper relay Disconnection (KA) TM E01
D192KB Travel damper relay Short circuit (KB) TM E01
D193KA Joystick lever solenoid relay Disconnection (KA) WRK E03
D193KB Joystick lever solenoid relay Short circuit (KB) WRK E03
D1D0KB Engine controller load power source relay Short circuit (KB) ENG E01
D5ZHL6 Monitor panel See separate table (L6) MON E01
DAF0KK Monitor panel Drop in power source voltage, input (KK) MON E03
DAF0KT Monitor panel Abnormality inside controller (KT) MON E03
DAF3KK Monitor panel Drop in power source voltage, input (KK) MON E03
DAF5KP Load meter Drop in output voltage (KP) MON E01
DAF6KP Load meter Drop in output voltage (KP) MON E01
DAFAKM Monitor panel Mistaken operation or mistaken setting (KM) MON E03
DAFBKM Monitor panel Mistaken operation or mistaken setting (KM) MON E03
DAFSKQ Monitor panel Non match in model selection signal (KQ) MON E01
DAQ0KK Drop in power source voltage Drop in power source voltage, input (KK) TM —
DAQ2KK Solenoid power source circuit Drop in power source voltage, input (KK) TM —
DAQ9KQ Transmission Non match in model selection signal (KQ) TM E03
DAQSKR Monitor panel Defective communication, abnormality in MON E03

applicable component system (KR)
DB20KK Engine controller Drop in power source voltage, input (KK) ENG E03
DB20KT Engine controller Abnormality inside controller (KT) ENG E03
DB22KK Engine controller load power source relay Drop in power source voltage, input (KK) ENG E03
DB29KQ Engine controller connecting wiring harness Non match in model selection signal (KQ) ENG E03
DB2AMA Engine controller fuel injection quantity control Function impossible (MA) ENG E01
switch
Defective communication, abnormality in
DB2SKR Monitor panel MON E03
applicable component system (KR)
DB90KK Work equipment controller power source circuit Drop in power source voltage, input (KK) WRK E03
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
Defective communication, abnormality in
DB9SKR Monitor panel applicable component system (KR) MON E03
WA380-5L 40-41 3

DD11KB Starting switch Short circuit (KB) ENG E03
DD15LD Monitor panel See separate table (LD) MON E01
DD1ALD Remote positioner lamp See separate table (LD) WRK E03
DD1BLD Remote positioner lamp See separate table (LD) WRK E03
DD1CLD Load meter See separate table (LD) MON E01
DDA1MA Engine controller Lo idling switch Function impossible (MA) ENG E01
DDA7LD Throttle lock switch See separate table (LD) ENG E01
DDE2L6 Engine oil pressure switch See separate table (L6) ENG E03
DDK3KA Shift switch Disconnection (KA) TM E03
DDK3KB Shift switch Disconnection (KB) TM E03
(DDK3KM) Shift switch neutral position confirmation Mistaken operation or mistaken setting (KM) MON E00
DDK4KA Joystick Disconnection (KA) TM E03
DDK4KB Joystick Short circuit (KB) TM E03
(DDK4KM) Joystick lever neutral position confirmation Mistaken operation or mistaken setting (KM) MON E00
DDK5LD Joystick See separate table (LD) TM E03
DDK6KA Shift lever Disconnection (KA) TM E03
DDK6KB Shift lever Short circuit (KB) TM E03
(DDK6KM) Shift switch neutral position confirmation Mistaken operation or mistaken setting (KM) MON E00
DDS5KA Steering circuit oil pressure Disconnection (KA) TM E03
DDS5KB Steering circuit oil pressure Short circuit (KB) TM E03
DDS5L6 Steering oil pressure Drop in oil pressure (ZG) MON E03
DDT0L4 Shift mode switch See separate table (L4) TM —
DDT4LD Transmission cut-off switch See separate table (LD) TM E01
DDW9LD Kick-down switch See separate table (LD) TM E01
DDWLLD Hold switch See separate table (LD) TM E01
DDY0LD Load meter See separate table (LD) MON E01
DF10KA Shift lever Disconnection (KA) TM E01
DF10KB Shift lever Short circuit (KB) TM E01
(DF10KM) Joystick shift lever Mistaken operation or mistaken setting (KM) TM E00
Work equipment lever neutral position confirmation
(DFA0KM) signal Mistaken operation or mistaken setting (KM) WRK E00
DGE2KX Water temperature sensor (High temperature) Input signal outside range (KX) MON E01
DGE3L6 Water temperature sensor See separate table (L6) ENG E01
DGE3L6 Water temperature sensor (Low temperature) See separate table (L6) MON E01
DGE4KX Fuel temperature sensor Input signal outside range (KX) ENG E01
DGF1KX Transmission oil temperature sensor Input signal outside range (KX) TM —
DGH2KX Hydraulic tank Input signal outside range (KX) MON E01
DGR2KA Rear brake oil temperature sensor Disconnection (KA) TM E01
DGR2KB Rear brake oil temperature sensor Short circuit (KB) TM E01
DGT1KX Torque converter Input signal outside range (KX) MON E01
DH30KX Boost pressure sensor Input signal outside range (KX) ENG E01
DH40KX Common rail pressure sensor Input signal outside range (KX) ENG E01
DHA4KA Engine air cleaner 1 Disconnection (KA) MON E01
DHA5KA Engine air cleaner 2 Disconnection (KA) MON E01
DHE4L6 Engine oil pressure sensor See separate table (L6) MON E01
40-42 3 WA380-5L

DHPCKX Cylinder bottom pressure sensor Input signal outside range (KX) MON E01
DHPDKX Cylinder rod pressure sensor Input signal outside range (KX) MON E01
DHT1KX Brake pressure sensor Input signal outside range (KX) TM E01
DHT2L6 Transmission filter See separate table (L6) MON E01
DJB1KX Battery electrolyte level 1 Input signal outside range (KX) MON E01
DJB3KX Battery electrolyte level 2 Input signal outside range (KX) MON E01
DK10KX Accelerator sensor Input signal outside range (KX) ENG E03
DK5FKA Joystick lever EPC potentiometer Disconnection (KA) WRK E03
(DK5FKM) Joystick lever neutral position confirmation signal Mistaken operation or mistaken setting (KM) WRK E03
DK5FKY Joystick lever EPC potentiometer Short circuit in power supply line (KY) WRK E03
DK5FL8 Joystick lever EPC potentiometer See separate table (L8) WRK E03
DK5GKA Joystick lever EPC potentiometer Disconnection (KA) WRK E03
DK5GKY Joystick lever EPC potentiometer Short circuit in power supply line (KY) WRK E03
DKA0KA Lift arm angle sensor Short circuit in power supply line (KY) WRK E01
DKA0KX Lift arm angle sensor Input signal outside range (KX) MON E01
DKA0KY Lift arm angle sensor Short circuit in power supply line (KY) WRK E01
DLE2KA Engine speed sensor Disconnection (KA) TM E03
DLE2LC Engine speed sensor See separate table (LC) TM E03
DLE2LC Engine speed sensor See separate table (LC) WRK E01
DLE3LC Engine Ne speed sensor See separate table (LC) ENG E03
DLH1LC Engine G speed sensor See separate table (LC) ENG E03
DLT3KA Speed sensor Disconnection (KA) TM E03
DLT3LC Speed sensor See separate table (LC) WRK E01
DT20KB Transmission cut-off indicator Short circuit (KB) TM —
DV00KB Alarm buzzer Short circuit (KB) MON E01
DW7BKA Reverse rotation solenoid valve for fan pump Disconnection (KA) TM E01
DW7BKB Reverse rotation solenoid valve for fan pump Short circuit (KB) TM E01
DW7CKA Switch pump solenoid Disconnection (KA) TM E01
DW7CKB Switch pump solenoid Short circuit (KB) TM E01
DW7DKA EPC solenoid valve for fan pump Disconnection (KA) TM E01
DW7DKB EPC solenoid valve for fan pump Short circuit (KB) TM E01
DWM1KA Work equipment solenoid Disconnection (KA) WRK E01
DWM1KB Work equipment solenoid Short circuit (KB) WRK E01
DWN6KA Boom RAISE magnet detent Disconnection (KA) WRK E01
DWN6KB Boom RAISE magnet detent Short circuit (KB) WRK E01
DWN7KA Lift arm FLOAT magnet detent Disconnection (KA) WRK E01
DWN7KB Lift arm FLOAT magnet detent Short circuit (KB) WRK E01
DWN8KA Bucket TILT magnet detent Disconnection (KA) WRK E01
DWN8KB Bucket TILT magnet detent Short circuit (KB) WRK E01
DX16KA EPC valve for fan pump Disconnection (KA) TM E01
DX16KB EPC valve for fan pump Short circuit (KB) TM E01
DXH1KA ECMV for lock-up clutch Disconnection (KA) TM E01
DXH1KB ECMV for lock-up clutch Short circuit (KB) TM E01
DXH4KA ECMV for 1st clutch Disconnection (KA) TM E03
DXH4KB ECMV for 1st clutch Short circuit (KB) TM E03
DXH5KA ECMV for 2nd clutch Disconnection (KA) TM E03
DXH5KB ECMV for 2nd clutch Short circuit (KB) TM E03
WA380-5L 40-43 3

DXH6KA ECMV for 3rd clutch Disconnection (KA) TM E03
DXH6KB ECMV for 3rd clutch Short circuit (KB) TM E03
DXH7KA ECMV for R clutch Disconnection (KA) TM E03
DXH7KB ECMV for R clutch Short circuit (KB) TM E03
DXH8KA ECMV for F clutch Disconnection (KA) TM E03
DXH8KB ECMV for F clutch Short circuit (KB) TM E03
DXHHKA ECMV for 4th clutch Disconnection (KA) TM E03
DXHHKB ECMV for 4th clutch Short circuit (KB) TM E03
DXHLKA Joystick lever right EPC solenoid Disconnection (KA) WRK E03
DXHLKB Joystick lever right EPC solenoid Short circuit (KB) WRK E03
DXHMKA Joystick lever left EPC solenoid Disconnection (KA) WRK E03
DXHMKB Joystick lever left EPC solenoid Short circuit (KB) WRK E03
DY30MA Emergency steering pump Function impossible (MA) TM E03
DY30MC Emergency steering pump Operation impossible (MC) TM E03
(DY30ME) Emergency steering Cancel impossible (ME) MON E02
Separate table: Detailed phenomena of problem codes (L*)
Problem Code Nature

L0 Fill signals on 2 or more channels for clutches not forming a set are input at same time
L1 Fill signal is ON when command current to ECMV is OFF
L2 Fuel pressure is higher than maximum set pressure
L3 Corresponding component cannot be controlled
L4 ON/OFF signals for 2 systems do not match
L5 Potentiometer signal and switch signal do not match
Engine speed signal, terminal C signal, signals for oil pressure switch, water temperature switch, etc.
L6
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
★ Failure codes with ( )
These failure codes are not recorded as trouble data for either the electrical system or the mechanical system.
★ Controller codes and troubleshooting mode names. The controller code name shown in the Controller column and the
troubleshooting mode name in the troubleshooting section are linked, so check the controller code for the failure code
displayed, then go to the applicable troubleshooting mode.
• ENG: Troubleshooting of engine control system (ENG MODE)
• TM: Troubleshooting of transmission control system (TM MODE)
• MON: Troubleshooting of machine monitor system (MON MODE)
• WRK: Troubleshooting of joy stick control system (WRK MODE)
40-44 3 WA380-5L
Procedure for switching to Service Mode 1 and screen display
★ When using Service Mode 1, carry out the following special operation to switch the screen display.
A. Checking screen display. With the machine monitor in the operator mode, check that the screen is one of the
following displays: Service meter, action code, or failure code.
B. Initial screen display for ID input. Press the following 2

buttons at the same time for at least 5 seconds to display the
initial screen display for the ID input.
• [■] button and [<] button.
★ Check that screen gives no display, then release buttons. If
the buttons are held pressed for at least 5 seconds, the
whole screen will give no display, so check that the screen
gives no display, then release the buttons.
C. 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 confirmed.
• [■] 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.
D. Displaying menu initial screen. After all four digits of the ID

are confirmed, the menu initial screen of Service Mode 1 is
displayed.
★ Once the ID has been input and confirmed, it remains
effective until the starting switch is turned OFF.
WA380-5L 40-45 3
E. Menu selection in Service Mode 1. Press the [>] or [<] buttons
on the menu screen and the menus of Service Mode 1 are
displayed endlessly in the following order.
★ The menu is displayed in the places marked with [*].
• [>] button: Go on to the next menu
• [<] button: Go back to previous menu
• ELECTRICAL FAULT: Trouble data display function for
electrical system
• MACHINE FAULT: Trouble data display function for
mechanical system
• REAL-TIME MONITOR: Machine data monitoring
function
• CYLINDER CUT-OUT: Reduced cylinder mode
• TUNING: Adjustment function
• MAINTENANCE MONITOR: Filter, oil replacement interval setting function
• OPTION SELECT: Option installation selection function
• MACHINE No. SET: Serial No. setting function
• INITIALIZE: Initialize function (exclusive function for factory)
F. Completion of mode, function. When operating at any point in any function, it is possible to finish the mode or
function by using any of the following methods.
• When continuing operations in another mode or function: Press the [■] button and return to the mode screen to
be used or menu screen to be used.
★ Note that if the [■] button is pressed on the YES/NO screen, the function will be executed.
★ If you return to the normal screen (operator mode) by mistake, repeat the procedure from Step A above (there is
no need to input the ID again).
• When completing all operations: Turn the starting switch OFF.
40-46 3 WA380-5L
1. Electrical system trouble data display function (ELECTRIC
FAULT). The monitor retains the data for problems that occurred in
the electrical system in the past as failure codes. They can be
displayed as follows.
A. 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 displayed in the [**] portion. (Recorded up to a
maximum of 20 items)
B. Trouble data display. With the menu selected, press the [◊]
button and display the trouble data recorded in memory.
• [◊] button: Run menu
2. Displayed trouble data. With the display function for trouble data of
the electrical system, the following data can be displayed.
A. Record number
B. Failure code (4-digit location code + 2 digit problem code
C. Number of occurrences (number of occurrences of same code

in past)
D. Elapsed time 1 (time elapsed on service meter since first

occurrence)
E. Elapsed time 2 (time elapsed on service meter since last

occurrence)
★ Failure codes for problems that are still existing are shown on a flashing display.
★ For details of the failure codes displayed, see FAILURE CODE TABLE in the explanation for the failure code
display function.
★ Note that with the trouble data display function and failure code display function for the electrical system, the
displayed data are partially different.
★ If no trouble data are recorded, [-] is displayed on the display portion.
WA380-5L 40-47 3
3. Switching trouble data display. If the [>] button or [<] button is pressed during the display of trouble data, the display
switches to the other recorded trouble data.
• [>] button: Go on to data for next record number.
• [<] button: Go back to data for last record number.
4. Deleting individual trouble data

• Display the trouble data to be deleted, then press the [◊] button
once to display the individual item CLEAR screen (Fig. 4).
• [◊] button: Display CLEAR screen
• Operate the buttons according to the explanation on the screen
(Fig. 4).
• [<] button: Select YES
• [>] button: Select NO
• [■] button: Run
★ The data for an existing problem (flashing display) cannot
be deleted.
5. Deleting all trouble data

• Display the trouble data, then press the [>] button or [<] button
to display the ALL CLEAR menu (Fig. 5).
• Press the [◊] button once to display the ALL CLEAR screen
(Fig. 6).
• [◊] button: Run ALL CLEAR menu
• Operate the buttons according to the explanation on the screen
(Fig. 6).
• [<] button: Select YES
• [>] button: Select NO
• [■] button: Run
★ The data for an existing problem (flashing display) cannot

be deleted.
40-48 3 WA380-5L
6. Mechanical system trouble data display function (MACHINE
FAULT). The machine monitor retains the data for problems that
occurred in the mechanical system in the past as failure codes. They
can be displayed as follows.
A. Menu selection. Select the display function for MACHINE

FAULT trouble data on the menu screen of Service Mode 1
(Fig. 1).
★ The total number of trouble data items recorded in
memory is displayed in the [**] portion.
B. Trouble data display. With the menu selected, press the [◊]
button and display the trouble data recorded in memory
(Fig. 2: example).
7. Display trouble data. With the display function for trouble data of
the mechanical system, the following data can be displayed (Fig. 3).
A. Record number
B. Failure code (4-digit location code + 2-digit problem code)
C. Number of occurrences (number of occurrences of same code

in past)
D. Elapsed time 1 (time elapsed on service meter since first

occurrence)
E. Elapsed time 2 (time elapsed on service meter since last

occurrence)
★ Failure codes for problems that are still existing are shown
on a flashing display.
★ For details of the failure code displayed, see FAILURE
CODE TALBLE in the explanation for the failure code
display function.
★ Note that with the trouble data display function and failure
code display function for the mechanical system, the
displayed data are partially different.
★ If no trouble data are recorded, [-] is displayed on the
display portion.
8. Switching trouble data display

If the [>] button or [<] button is pressed during the display of
trouble data, the display switches to the other recorded trouble data.
• [>] button: Go on to data for the next record number
• [<] button: Go back to data for last record number
9. Deleting trouble data (not permitted)

★ The trouble data for the mechanical system cannot be deleted.
WA380-5L 40-49 3
10. Machine data monitoring function (REAL-TIME MONITOR). The
machine monitor can monitor the condition of the machine in real
time through the signals from the sensors installed to various parts
of the machine. In the machine data monitoring function, the
following 2 types of display can be shown.
• 1st item independent display (for each controller)
• 2nd item simultaneous display (code input)
A. Menu selection
Select the machine data monitoring function on the menu
screen of the Service Mode 1 (Fig. 1).
B. Display sub menu. With the sub menu selected, press the [◊]
button and display the initial screen of the sub menu (Fig. 2).
C. Select sub menu

If the [>] button or [<] button is pressed on the sub menu
screen, the sub menu displays endlessly in the following order
(Fig. 3).
★ The sub menu is displayed in the [*]
position.
• [>] button: Go on to next menu
• [<] button: Go back to last menu
i. MONITOR PANEL: Machine monitor system
ii. TRANSMISSION: Transmission controller system
iii. ENGINE: Engine controller system
iv. BOOM: Work equipment controller system
v. 2 ITEM: 2-item display
40-50 3 WA380-5L
D. Setting 1st item individual monitoring
i. Select the controller system for monitoring on the sub

menu screen (Fig. 4: Example).
ii. With the sub menu selected, press the [◊] button and siplay
the monitoring data initial screen.
• [◊] button: Run sub menu
iii. Press the [>] button or [<] button to select the item for
monitoring (Fig. 5: Example).
• [>] button: Go on to next item
• [<] button: Go back to last item
★ Scroll the monitoring items to display in the internally
set order.
★ If the button is kept pressed, the items will scroll at
high speed.
★ To hold or cancel monitoring data:
If the [◊] button is pressed during monitoring, the monitor
data is held and the [◊] mark flashes. If the [◊] button is
pressed again, it becomes active again.
E. Display data for 1st item individual monitoring. On the 1st

item individual monitoring screen, the following data are
displayed (Fig. 6).
i. Item display
ii. Monitoring data (5-digit)
iii. Monitoring data (including unit)

★ For details, see MONITORING CODE TABLE.
WA380-5L 40-51 3
F. Setting 2nd item simultaneous monitoring
i. Select the 2nd item display on the sub menu screen.
ii. With the sub menu selected, press the [◊] button and dis-
play the monitoring code input screen.
• [◊] button: Run sub menu
iii. Operate each button and input the monitoring code for the
2nd monitoring item directly.
• [>] button: Number at cursor goes up
• [<] button: Number at cursor goes down
• [◊] button: Number at cursor is
confirmed
• [■] button: Returns to code input screen
iv. When both of the monitoring codes have been confirmed,

the screen switches to the 2nd item display screen.
★ To hold or cancel monitoring data: If the [◊] button is
pressed during monitoring, the monitor data are held and
the [◊] mark flashes. If the [◊] button is pressed again, it
becomes active again.
G. Display data for 2nd item simultaneous monitoring. On the 2nd

item simultaneous monitoring screen, the following data are
displayed.
i. Monitoring code 1
ii. Monitoring data 1 (including unit)
iii. Monitoring code 2
iv. Monitoring data 2 (including unit)

★ For details, see MONITORING CODE TABLE.
40-52 3 WA380-5L
12
Monitoring Code Table
MONITOR PANEL [Machine monitor system]
Monitoring
No. Monitoring Item Item Display Code Data Display Range Unit
1 Monitor ROM part No. MONTORING ROM 20202 Arabic Numerals Status display
2 Engine speed ENG SPEED 01001 0 ~ 3000 rpm
3 Travel speed SPEED 40000 0 ~ 50 (0 ~ 31) km/h (mph)
4 Fuel level FUEL SENSOR 04202 0 ~ 100 %
5 Hydraulic oil temperature HYD TEMP 04401 24 ~ 131 (75 ~ 268) °C (°F)
6 Engine water temperature COOLANT TEMP 04103 24 ~ 131 (75 ~ 268) °C (°F)
7 Engine water temperature (Low temperature) COOLANT Lo 04104 -31 ~ 91 (-23.8 ~ 196) °C (°F)
8 Torque converter oil temperature TC OIL TEMP 40100 24 ~ 131 (75 ~ 268) °C (°F)
9 Battery charge ALTERNATOR R 04302 0.00 ~ 30.00 V
10 Side lamp voltage SMALL LAMP 40200 0.00 ~ 30.00 V
11 Battery electrolyte A BATTERY A2V 40300 0.00 ~ 30.00 V
12 Battery electrolyte B BATTERY B2V 40301 0.00 ~ 30.00 V
13 Lift arm angle BOOM ANG 06001 -41 ~ 46 deg.
14 Lift arm bottom pressure BTM PRESS 40400 0 ~ 50 (0 ~ 7252) MPa (psi)
15 Lift arm rod pressure ROD PRESS 40500 0 ~ 50 (0 ~ 7252) MPa (psi)
16 Load meter calibration pressure CAL PRESS 40600 0 ~ 50 (0 ~ 7252) MPa (psi)
17 Load meter calculation pressure MES PRESS 40700 0 ~ 50 (0 ~ 7252) MPa (psi)
18 Load meter calculation load MES LOAD 40800 0 ~ 50 (0 ~ 7252) MPa (psi)
19 Setting status of rotary switch SW1, SW2, SW3 30802 0 ~ F, 0 ~ F, 0 ~ F Status display
20 Setting status of dipswitch SW5-1, SW5-2 30904 ON/OFF, ON/OFF Status display
24 Input signal D_IN_0-7 D-IN--0------7 40900 See separate table Status display
★ Note: The following monitoring items display data for 2 or 3 systems at the same time.
• No. 19: Setting status of rotary switch (displays 3 items at same time)
• No. 20: Setting status of dipswitch (displays 2 items at same time)
WA380-5L 40-53 3
12
TRANSMISSION [Transmission controller system]
No. Monitoring Item Item Display Monitoring Data Display Range Unit
Code
1 Transmission controller ROM part No. TRANSM ROM 20201 Arabic Numerals Status display
2 Fan pump speed FAN PUMP 41000 0 ~ 3000 rpm
3 Transmission cut-off pressure LH BRAKE 41200 0 ~ 50 (0 ~ 7252) MPa
4 Left brake pressure CUT OFF 41100 0 ~ 50 (0 ~ 7252) MPa
5 No. of times of kick down K/D TIMES 41300 — —
6 Average cycle time CYCLE TIME 41400 — sec.
7 F clutch solenoid circuit ECMV F 31608 0 ~ 1000 mA
8 R clutch solenoid circuit ECMV R 31608 0 ~ 1000 mA
9 1st clutch solenoid circuit ECMV 1 31602 0 ~ 1000 mA
10 2nd clutch solenoid circuit ECMV 2 31603 0 ~ 1000 mA
11 3rd clutch solenoid circuit ECMV 3 31604 0 ~ 1000 mA
12 4th clutch solenoid circuit ECMV 4 31605 0 ~ 1000 mA
13 Lock-up clutch solenoid current ECMV LU 31609 0 ~ 1000 mA
14 Fan pump solenoid valve current FAN EPC 41400 0 ~ 1000 mA
15 Torque converter oil temperature ECMV OIL TEMP 41500 24 ~ 131 °C
16 Engine mode selection ENGINE MODE 41600 P/N —
17 Shift mode selection SHIFT MODE 41700 H/M/L —
18 F clutch fill time FILL TIME F 41808 0 ~ 2550 msec
19 R clutch fill time FILL TIME R 41806 0 ~ 2550 msec
20 1st clutch fill time FILL TIME 1 41802 0 ~ 2550 msec
21 2nd clutch fill time FILL TIME 2 41803 0 ~ 2550 msec
22 3rd clutch fill time FILL TIME 3 41804 0 ~ 2550 msec
23 4th clutch fill time FILL TIME 4 41805 0 ~ 2550 msec
24 F clutch fill display FILL SW(F) 31508 0~1 Status display
25 R clutch fill display FILL SW(R) 31506 0~1 Status display
26 1st clutch fill display FILL SW(1) 31502 0~1 Status display
27 2nd clutch fill display FILL SW(2) 31503 0~1 Status display
28 3rd clutch fill display FILL SW(3) 31504 0~1 Status display
29 4th clutch fill display FILL SW(4) 31505 0~1 Status display
34 Output signal D_OUT_0-6 D-OUT-0------6 40915 See separate table Status display
35 Output signal SOL/0_0-5 SOL/O-0------5 40914 See separate table Status display
36 Rear brake oil temperature R BRAKE OIL 30202 24 ~ 131 (75 ~ 268) °C (°F)
★ Content of display for monitoring items No. 24 ~ 29
0: Normal; 1: Delayed
40-54 3 WA380-5L
12
WORK [Work equipment controller system]
No. Monitoring Item Item Display Monitoring Data Display Range Unit
Code
1 Work equipment controller ROM part No. BOOM ROM 20202 — —
2 Joystick steering right solenoid valve current RH J/S EPC 41904 0 ~ 1000 mA
3 Joystick steering left solenoid current LH J/S EPC 41905 0 ~ 1000 mA
4 Lever potentiometer voltage joystick steering 1 J/S POT1 42004 0.00 ~ 5.00 V
5 Lever potentiometer voltage joystick steering 2 J/S POT2 42005 0.00 ~ 5.00 V
6 Lift arm angle BOOM ANG 06002 -41 ~ 46 deg.
7 Lift arm bottom pressure BTM PRESS 40401 0 ~ 50 (0 ~ 7252) MPa (psi)
9 Travel speed SPEED 40001 0 ~ 50 (0 ~ 31 km/h (mph)
14 Output signal D_OUT_0-6 D-OUT-0------6 40917 See separate table Status display
15 Output signal SOL/0_0-5 SOL/O-0------5 40916 See separate table Status display
ENGINE [Engine controller system]

Monitoring
No. Monitoring Item Item Display Data Display Range Unit
Code
1 Engine controller part No. ENGINE ROM 20203 Arabic numerals Status display
2 Accelerator pedal voltage THROTTLE POS 31702 0.00 ~ 5.00 V
3 Accelerator pedal angle THROTTLE POS 31701 0 ~ 100 %
4 Operating mode ENG STATUS 36600 0~3 —
6 Target common rail pressure RAIL PRESS(C) 36200 0 ~ 150 (0 ~ 21756) MPa (psi)
7 Common rail pressure RAIL PRESS(A) 36400 0 ~ 150 (0 ~ 21756) MPa (psi)
8 Boost pressure BOOST PRESS 36500 0 ~ 300 (0 ~ 44.1) kPa (psi)
9 Target fuel injection amount FUEL DELIVERY 31600 0 ~ 500 (0 ~ 20) mm (in)
10 Target injection timing INJECT TIMING 36300 -30 ~ 31 degree
11 Torque ratio TORQUE RATIO 36700 0 ~ 100 %
12 Selection status of fuel injection quantity control switch Q ADJUST SW 36800 0 ~ F, 0 ~ F Status display
COOLANT TEMP
13 Engine water temperature (For high temperature) H 04102 0 ~ 150 (0 ~ 302) °C (°F)
14 Engine water temperature (For low temperature) COOLANT TEMP L 04101 -30 ~ 100 (-22 ~ 212) °C (°F)
15 Fuel temperature FUEL TEMP 04203 -30 ~ 100 (-22 ~ 212) °C (°F)
★ Content of display for monitoring item No. 4
0: Control stopped
1: Split injection
2: Fixed injection
3: Normal injection
★ Content of setting for monitoring item No. 12
Switch 1: F; Switch 2: F
WA380-5L 40-55 3
★ ON/OFF switch signals input to controller
A. Method of reading input signal to controller

• Input status display 0: No input (OFF)
• Input status display 1: Input (ON)
i. Monitoring code
ii. Input status

Starting from the left, the status is displayed in turn from
D-IN-0 to D-IN-7.
B. Method of reading output signal D-OUT-0.....7

• Output status display 0: No output (OFF)
• Output status display 1: Output (ON)
i. Monitoring code
ii. Output status

Starting from the left, the status is displayed in turn from D-OUT-0 to
D-OUT-7.
Monitor Panel
Input/
No. Monitoring Output Display Item Content of ON/OFF Switch
Code
Signal
D-IN-0 Head lamp Head lamp lights up ON=(24V)/OFF(OPEN)
1 40900
D-IN-2 Starting switch output Starting motor started = 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 Breaker oil pressure (Front) Oil pressure normal = ON(GND)/(OPEN)
3 40902 D-IN-17 Breaker 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)
40-56 3 WA380-5L
Transmission Controller
Monitoring Input/Out-
No. Display Item Content of ON/OFF Switch
Code put Signal
D-IN-0 Steering pressure switch (N.O.) Pressure normal ON=(OPEN)/OFF(GND)
D-IN-1 Steering pressure switch (N.C.) Pressure normal ON=(OPEN)/OFF(GND)
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) /Economy mode(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(GND)/OFF(OPEN)
D-IN-17 Right seesaw switch & joystick FORWARD FORWARD = ON(24V)/OFF(OPEN)
D-IN-18 Right seesaw switch & joystick Neutral NEUTRAL = ON(24V)/OFF(OPEN)
D-IN-19 Right seesaw switch & joystick REVERSE REVERSE = ON(24V)/OFF(OPEN)
3 40907
D-IN-20 Direction lever FORWARD FORWARD = ON(24V)/OFF(OPEN)
D-IN-21 Direction lever Neutral NEUTRAL = ON(24V)/OFF(OPEN)
D-IN-22 Direction lever REVERSE REVERSE = ON(24V)/OFF(OPEN)
D-IN-23 Neutralizer (Parking brake) signal Parking switch ON = ON(24V)/OFF(OPEN)
D-IN-24 F clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-25 R clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-26 1st clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-27 2nd clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
4 40908
D-IN-28 3rd clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-29 4th clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-30 Lock-up clutch fill switch Fill switch ON = ON(GND)/OFF(OPEN)
D-IN-31 Shift hold switch Switch pressed = ON(GND)/OFF(OPEN)
D-OUT-0 Backup lamp relay Output ON (24V)/OFF(GND)
5 40915
D-OUT-1 Transmission cut-off indicator Output ON (24V)/OFF(GND)
SOL/O-0 Electric emergency steering relay Output ON (24V)/OFF(GND)
SOL/O-1 E.C.S.S. relay Output ON (24V)/OFF(GND)
SOL/O-2 Switch pump cut-off Output ON (24V)/OFF(GND)
6 40914
SOL/O-3 Neutral output Output ON (24V)/OFF(GND)
SOL/O-4 Fan pump reverse rotation solenoid Output ON (24V)/OFF(GND)
SOL/O-5 Fan pump neutral solenoid Output ON (24V)/OFF(GND)
WA380-5L 40-57 3
Work Equipment and Joystick Controller

Monitoring Input/Out-
No. Display Item Content of ON/OFF Switch
Code put Signal
1 40910 D-IN-0 Joystick ON/OFF selector switch Joystick (right FNR) selected = ON(24V)/(OPEN)
2 40911 D-IN-8 Joystick speed Hi/Lo selector switch Joystick Hi speed selected = ON(GND)/OFF(OPEN)
3 40916 SOL/O-0 Joystick EPC cut relay Output ON (24V)/OFF(GND)
40-58 3 WA380-5L
1. Reduced cylinder mode (CYLINDER CUT-OUT). As one method
of troubleshooting for the engine, the machine monitor has a
reduced cylinder function that can set the desired cylinder to the
NO INJECTION condition.
A. Starting engine
★ With this function, it is possible to use the engine speed in
the reduced cylinder mode to judge if there is a problem
with any cylinder, so run the engine during the operation.
B. Menu selection
i. Select the reduced cylinder mode on the menu screen of

Service Mode 1.
ii. With the menu selected, press the [◊] button and display
the cylinder selections screen.
★ The cylinder No. and engine speed are displayed at the
same time.
C. Setting cut-out cylinder. Operate each button and select the

cylinder to be cut out.
• [>] button: Selector cursor moves to right
• [<] button: Selector cursor moves to left
• [◊] button: Cylinder is confirmed (canceled)
• [■] button: Returns to menu screen
★ When the [◊] button is used to confirm the cut-out
cylinder, communications is carried out between the
machine monitor and engine controller. During this time,
the cylinder No. flashes. After completion of the
communication, the segment under the cylinder No.
becomes black to show that the cylinder has been cut out.
★ Single cylinders or multiple cylinders can be cut out.
D. Cancelling cylinder cut out

★ Cancel the cylinder cut out in the same way as when
setting the cut out.
WA380-5L 40-59 3
2. Adjustment function (default setting)
★ The machine monitor is used to carry out the default setting when the transmission has been overhauled or replaced,
or the sensors, EPC valve, controller have been replaced or added, or when adjusting or compensating for tolerance in
installation or individual differences in manufacture.
★ For details, see STRUCTURE AND FUNCTION, Settings needed when installing optional equipment.
40-60 3 WA380-5L
3. Filter, oil replacement interval setting function. The machine
monitor can set the maintenance interval for filters and oil. This
forms the base for the filter and oil replacement interval and
display.
★ For details, see STRUCTURE AND FUNCTION,
Maintenance monitor items.
Table of filter and oil replacement interval set items [when shipping]
No. Item Code Display Replacement Interval
1 Engine oil 01 ENG OIL 500
2 Engine oil filter 02 ENG OIL FILTER 500
3 Fuel filter 03 FUEL FILTER 500
4 Corrosion resistor 06 CORR RESISTOR 1000
5 Transmission oil 12 TM OIL 1000
6 Transmission oil filter 13 TM OIL FILTER 1000
7 Hydraulic filter 04 HYD OIL FILTER 2000
8 Hydraulic tank breather element 05 BREATHER ELE 2000
9 Axle oil 15 AXLE OIL 2000
10 Hydraulic oil 10 HYD OIL 2000
WA380-5L 40-61 3
4. Option selection function
• When adding or removing optional equipment, change the setting on the machine monitor.
• When the machine monitor has been replaced, set the status of optional equipment installed on the machine.
Option set items

Item No. Real-time Monitor Items English Display Remarks
Monitor Panel Controller
1 Battery electrolyte level drop sensor BAT LIQUID
2 Transmission clogging sensor TRANSM CLOG
3 Printer PRINTER
4 Lift arm Hi lift specification HI LIFT
5 Speedometer/tachometer display switch ENGINE RPM Use ADD screen to display engine speed
6 Short ton switch SHORT TON Can be switched only when MPH is displayed
Transmission Control
1 Travel damper E.C.S.S.
2 Torque converter lock-up LOCK UP
3 Emergency steering EMER STRG
4 Tire size TIRE SIZE Tire compensation for non-specified tires
5 Automatic reverse fan AUTO RE FAN
6 Right FNR switch RH FNR SW
Work Equipment Controller
1 Joystick JOY STICK
40-62 3 WA380-5L
5. Serial No. setting function. This is used to set the serial number of the machine.
6. Initialize function
★ This function is a special function used only at the factory, so it
cannot be used when servicing the machine.
WA380-5L 40-63 3
Service Mode 2
The following functions are provided for use when replacing the machine monitor.
1. Setting service monitor. This sets the service meter values recorded in the machine monitor
★ It is possible to set only a value that is higher than the present value.
2. Setting odometer. This sets the odometer value recorded in the machine monitor.
★ It is possible to set only a value that is higher than the present value.
40-64 3 WA380-5L
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion
of the housing.
★ Deutsch connector has marks of pin numbers on the wiring harness side.
Number X Type Connector
of Pins Male (Female housing) Female (Male housing) T-adapter
1 Part number: 08055-00181 Part number: 08055-00191 799-601-7010
2 799-601-7020
Part number: 08055-00282 Part number: 08055-00292
3 799-601-7030
4 799-601-7040

Terminal part number: 79A-222-3370 Terminal part number: 79A-222-3390
• Wire size: 0.85 • Wire size: 0.85
— —
• Quantity: 20 pieces • Quantity: 20 pieces
• Grommet: black • Grommet: black
Terminal part number: 79A-222-3380 Terminal part number: 79A-222-3410
— • Quantity: 20 pieces • Quantity: 20 pieces —
• Grommet: red • Grommet: red
WA380-5L 40-65 3
Number of SWP Type Connector

Pins Male (Female housing) Female (Male housing) T-adapter
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
40-66 3 WA380-5L
Number of SWP Type Connector

Pins Male (Female housing) Female (Male housing) T-adapter r
16 799-601-7320

Terminal part number: Terminal part number:
— —
• Grommet: black • Grommet: black
Terminal part number: Terminal part number:
— —
• Grommet: red • Grommet: red
Number of M Type Connector

1 Part number: 08056-00171 Part number: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
WA380-5L 40-67 3
4 799-601-7120
6 799-601-7130
8 799-601-7340
Number of S Type Connector

8 799-601-7140
40-68 3 WA380-5L
10 (white) 799-601-7150
12 (white) 799-601-7350
16 (white) 799-601-7330
Number of S Type Connector

10 (blue) —
— —
WA380-5L 40-69 3
12 (blue) 799-601-7160
16 (blue) 799-601-7170

★ Terminal part number: 79A-222-3470 (for all numbers of pins)
Number of MIC Type Connector

7 Body part number: 79A-222-2640 Body part number: 79A-222-2630 —

(Quantity: 5 pieces) (Quantity: 5 pieces)
Body part number: 79A-222-2680 Body part number: 79A-222-2670
11 —
5 799-601-2710

40-70 3 WA380-5L
9 799-601-2950

13 799-601-2720

17 799-601-2730

21 799-601-2740

— —
WA380-5L 40-71 3
8 799-601-7180
Housing part number: 79A-222-3430

— (Quantity: 5 pieces)
12 799-601-7190
— Housing part number: 79A-222-3440

(Quantity: 5 pieces)
16 799-601-7210
Housing part number: 79A-222-3450

— (Quantity: 5 pieces)
20 799-601-7220
— Housing part number: 79A-222-3460

(Quantity: 5 pieces)
40-72 3 WA380-5L
Number of AMP070 Type Connector

10 799-601-7510
— Part number: 08195-10210
12 799-601-7520
— Part number: 08195-12210
14 799-601-7530
— Part number: 08195-14210
18 799-601-7540
— Part number: 08195-18210
WA380-5L 40-73 3
20 799-601-7550
— Part number: 08195-20210
L Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
2 —
— —
PA Type Connector
Number of
Pins Male (Female housing) Female (Male housing) T-adapter Part
Number
9 —
— —
40-74 3 WA380-5L
Number of BENDIX (MS) Type Connector

10 799-601-3460
— —
WA380-5L 40-75 3
Number of KES1 Automobile Type Connector

2 —
Part number: 08027-10210 (Natural color) Part number: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
40-76 3 WA380-5L
Number of KES1 Automobile Type Connector

8 —
08027-10820 (Black) 08027-10870 (Black)
WA380-5L 40-77 3
Number of Connector for relay (Socket)

5 799-601-7360
— —
6 799-601-7370
— —
Type F Type Connector

(shell size
code) Pin (Male terminal) Body (Female terminal) T-adapter
4 —
— —
40-78 3 WA380-5L
★ The pin No. is also marked on the connector (electric wire insertion end)
Type HD30 Series connector
(shell size
code) Body (plug) Body (receptacle) T-adapter
Pin (male terminal) Pin (female terminal)
799-601-9210
Part number: 08191-11201, 08191-11202 Part number: 08191-14101, 08191-14102

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (female terminal) Pin (male terminal)
799-601-9210

08191-11205, 08191-12206 08191-13105, 08191-13106
799-601-9220

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220

08191-22205, 08191-22206 08191-23105, 08191-23106
WA380-5L 40-79 3
(shell size
799-601-9230
18-20 Part number: 08191-31201, 08191-31202 Part number: 08191-34101, 08191-34102

799-601-9230

799-601-9240

799-601-9240
40-80 3 WA380-5L
(shell size
799-601-9250

799-601-9250

799-601-9260

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260

08191-62205, 08191-62206 08191-63105, 08191-63106
WA380-5L 40-81 3
(shell size
799-601-9270

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part number: 08191-81201, 08191-81202, Part number: 08191-84101, 08191-84102,

08191-81203, 08191-81204, 08191-84103, 18191-84104,
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part number: 08191-82201, 08191-82202, Part number: 08191-83101, 08191-83102,

08191-82203, 08191-82204, 08191-83103, 18191-83104,
08191-82205, 08191-82206 08191-83105, 08191-83106
40-82 3 WA380-5L
(shell size
799-601-9290

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290

08191-92205, 08191-92206 08191-93105, 08191-93106
WA380-5L 40-83 3
Number DT Series connector

of Pins Body (plug) Body (receptacle) T-adapter
2 799-601-9020
Part number: 08192-12200 (normal type) Part number: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
40-84 3 WA380-5L
Number DT Series connector

8GR: 799-601-9060
8B: 799-601-9070
8 8G: 799-601-9080
8BR: 799-601-9080
Part number: 08192-1820 T (normal type) Part number: 08192-1810 T (normal type)
08192-2820 T (fine wire type) 08192-2810 T (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
10 12G: 799-601-9130
12BR: 799-601-9140
Part number: 08192-1920 T (normal type) Part number: 08192-1910 T (normal type)
08192-2920 T (fine wire type) 08192-2910 T (fine wire type)
WA380-5L 40-85 3
Number of DTM Series connector

Pins Body (plug) Body (receptacle) T-adapter
2 799-601-9010
Number DTHD Series connector

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)
40-86 3 WA380-5L
12
No. of DRC26 Series connector

pins T-adapter
24 Body (plug) Body (receptacle)
799-601-9360
40 ⎯ Part No.:7821-93-3110
(A)
799-601-9350
40 ⎯ Part No.:7821-93-3120
(A)
799-601-9350
50 ⎯ Part No.:7821-93-3130
799-601-4210
⎯ ⎯
WA380-5L 40-87 3
TROUBLESHOOTING T-ADAPTER TABLE
12
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.
799-601-2500
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.
799-601-2600 For measuring box Econo-21P O O O O O O

799-601-3100 For measuring box MS-37P O
799-601-3200 For measuring box MS-37P O
799-601-3300 For measuring box Econo-24P O
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P O O
799-601-3420 BENDIX(MS) 24P O O
799-601-3430 BENDIX(MS) 17P O O
799-601-3440 BENDIX(MS) 17P O O
799-601-3450 BENDIX(MS) 5P O O
799-601-3460 BENDIX(MS) 10P O O
799-601-3510 BENDIX(MS) 5P O O
799-601-3520 BENDIX(MS) 14P O O
799-601-3530 BENDIX(MS) 19P O O
799-601-2910 BENDIX(MS) 14P O O
799-601-3470 CASE O
799-601-2710 MIC 5P O O O O
799-601-2720 MIC 13P O O O O
799-601-2730 MIC 17P O O O O O O O
799-601-2740 MIC 21P O O O O O O O
799-601-2950 MIC 9P O O O O
799-601-2750 ECONO 2P O O
799-601-2760 ECONO 3P O O
799-601-2770 ECONO 4P O O
799-601-2780 ECONO 8P O O
799-601-2790 ECONO 12P O O
799-601-2810 DLI 8P O O
799-601-2820 DLI 12P O O
799-601-2830 DLI 16P O O
799-601-2840 Extension cable O O O
799-601-2850 CASE O
799-601-7010 X 1P O O
799-601-7020 X 2P O O O O
799-601-7030 X 3P O O O O
799-601-7040 X 4P O O O O
799-601-7050 SWP 6P O O O
799-601-7060 SWP 8P O O O
799-601-7310 SWP 12P O
40-88 3 WA380-5L
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-7070 SWP 14P O O

799-601-7320 SWP 16P O
799-601-7080 M 1P O O
799-601-7090 M 2P O O O O
799-601-7110 M 3P O O O O
799-601-7120 M 4P O O O O
799-601-7130 M 6P O O O O
799-601-7340 M 8P O
799-601-7140 S 8P O O O O
799-601-7150 S 10P-White O O O O
799-601-7160 S 12P-Blue O O O
799-601-7170 S 16P-Blue O O O O
799-601-7330 S 16P-White O
799-601-7350 S 12P-White O
799-601-7180 AMP040 8P O
799-601-7190 AMP040 12P O O
799-601-7210 AMP040 16P O O O O
799-601-7220 AMP040 20P O O O O
799-601-7230 Short connector X-2 O O O O
799-601-7240 Case O O
799-601-7270 Case O
799-601-7510 070 10P O
799-601-7520 070 12P O
799-601-7530 070 14P O
799-601-7540 070 18P O
799-601-7550 070 20P O
799-601-7360 Relay connector 5P O
799-601-7370 Relay connector 6P O
799-601-7380 JFC connector 2P O
799-601-9010 DTM 2P O O
799-601-9020 DT 2P O O
799-601-9030 DT 3P O O
799-601-9040 DT 4P O O
799-601-9050 DT 6P O O
799-601-9060 DT 8P-Gray O O
799-601-9070 DT 8P-Black O O
799-601-9080 DT 8P-Green O O
799-601-9090 DT 8P-Blown O O
799-601-9110 DT 12P-Gray O O
799-601-9120 DT 12P-Black O O
799-601-9130 DT 12P-Green O O
799-601-9140 DT 12P-Blown O O
799-601-9210 HD30 18-8 O O
799-601-9220 HD30 18-14 O O
WA380-5L 40-89 3
KIT No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9230 HD30 18-20 O O

799-601-9240 HD30 18-21 O O
799-601-9250 HD24 24-9 O O
799-601-9260 HD30 2-16 O O
799-601-9270 HD30 24-21 O O
799-601-9280 HD30 24-23 O O
799-601-9290 HD30 24-31 O O
799-601-9310 Plate For HD30 O O O
799-601-9320 For measuring box For DT, HD O O O
799-601-9330 Case O
799-601-9340 Case O
799-601-9350 DEUTSCH 40P O
799-601-9360 DEUTSCH 24P O
799-601-9410 For NE, G sensor 2P O
799-601-9420 For boost pressure, 3P O

fuel
799-601-9430 PVC socket 2P O
40-90 3 WA380-5L
TROUBLESHOOTING CONNECTOR TYPES AND LOCATIONS
CONNECTOR TYPES AND LOCATIONS

★ The address column of the table indicates each address of a connector placement diagram (diagram in three dimensions)
and an electrical circuit system diagram.
★ Symbols of the circuit diagram address column of the table:
TM: Transmission control system,WRK: Work equipment control system, MON: Monitoring system, E: Electrical
system.
★ The item enclosed by parentheses in the connector type column indicates the color of the connector body.
(B: Black, Br: Brown, G: Green, Gr: Gray, L: Blue, W: White.
Number Address
Connector No. Connector Type of Installation Name System
Pins Layout Drawing
Drawing
1.PS DT-T 2 Transmission 1st clutch solenoid J-4 TM

1.SW DT 2 Transmission 1st clutch fill switch J-4 TM
2.PS DT-T 2 Transmission 2nd clutch solenoid J-3 TM
2.SW DT 2 Transmission 2nd clutch fill switch J-3 TM
3.PS DT-T 2 Transmission 3rd clutch solenoid J-4 TM
3.SW DT 2 Transmission 3rd clutch fill switch J-4 TM
4.PS DT-T 2 Transmission 4th clutch solenoid J-5 TM
4.SW DT 2 Transmission 4th clutch fill switch J-5 TM
A1 M 6 Air conditioner blower motor and resistor U-2 —
A2 SWP 6 Air conditioner air mixing servomotor U-2 —
A3 M 2 Air conditioner thermistor U-2 —
A4 X 2 Air conditioner air servomotor T-9 —
A5 X 2 Air conditioner condenser switch T-1 —
A6 Yazaki 2 Air conditioner Hi-Lo switch T-1 —
A7 Yazaki 4 Air conditioner blower relay (Main) W-6 —
A8 Yazaki 4 Air conditioner blower relay (Hi) W-6 —
A9 Yazaki 4 Air conditioner blower relay (M2) W-6 —
A11 Yazaki 4 Air conditioner condenser relay W-5 —
A12 Yazaki 4 Air conditioner condenser Hi (1) relay W-5 —
A14 Yazaki 4 Air conditioner MAG clutch relay W-4 —
A20 Terminal 1 Ground (Floor) T-2 —
AL1 M 6 Intermediate connector (Air conditioner relay) U-2 —
AL2 S (W) 12 Intermediate connector (Air conditioner relay) V-3 —
B01 DT-T 3 Air conditioner condenser motor A-7 —
B02 DT-T 3 Air conditioner condenser motor B-7 —
BR1 DT-T 2 Intermediate connector (Air conditioner condenser motor) J-2 W-6
C01 Yazaki 2 AM/FM radio C-9 —
C02 KES0 2 Speaker (Right) F-9 —
C03 KES0 2 Speaker (Left) G-9 —
C04 M 2 Front working lamp (Right) C-8 E-8
C05 M 2 Front working lamp (Left) B-8 E-8
C07 KES1 2 Room lamp C-8 —
C08 M 1 Door switch (Right) (Room Lamp) C-8 —
C09 M 1 Door switch (Left) (Room lamp) B-8 —
C10 — 2 Cigarette lighter A-7 —
WA380-5L 40-91 3
Number Address
Pins Layout Drawing
Drawing
C12 M 6 Front wiper motor A-7 —

C15 M 4 Rear wiper motor F-9 —
C17 Kyoritsu ES 4 Warning lamp switch D-9 —
C18 Plug 1 Warning lamp (Beacon) C-8 —
C19 DT-T 6 Glass heater switch D-9 —
C29 M 1 Glass heater ON E-9 —
C33 H 1 Rear glass heater E-9 —
C35 H 1 Rear glass heater G-9 —
C38 M 1 Connector (Electric power take-off) — —
C39 Terminal 1 Ground (Radio) C-9 E-7
C40 Terminal 1 Ground (Cab) C-8 —
C41 M 1 Warning lamp F-9 —
C43 Yazaki 6 Side wiper switch E-9 —
C44 M 4 Right side wiper motor A-7 —
C45 M 4 Left side wiper motor A-7 —
C46 M 1 Intermediate connector (Power source) D-9 —
C47 Terminal 1 Ground (Cab) F-9 —
C47 AMP172021-2 16 A/C control AMP P-1 —
C49 SWP 8 Left Servomotor R-1 —
C50 SWP 8 Right Servomotor M-3 —
CAN1 DT-T 3 Resistor O-1 B-2
CAN2 DT-T 3 Resistor R-9 B-2
CL1 S 8 Intermediate connector A-4 E-7
CL2 S (L) 12 Intermediate connector (Wiper motor) A-4 —
CL6 DT-T (G) 12 Intermediate connector (Monitor panel controller) W-6 C-4
CL7 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-2 C-5
CL9 DT-T (Gr) 8 Intermediate connector (Monitor panel controller) O-1 C-6
CN55 DT-T 2 Intermediate connector (Backup buzzer) K-9 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) E-6 TM
E01 DT-T 2 Intermediate connector (Starting motor) B-1 W-4
E02 Terminal 1 Alternator R D-3 X-5
E03 Terminal 1 Alternator B D-3 X-5
E04 Terminal 1 Alternator E D-3 X-5
E05 Terminal 1 Engine heater relay C-9 Q-9
E06 Terminal 1 Engine heater relay A-9 Q-9
E08 DT-T 2 Engine water temperature sensor (Monitor) C-1 O-8
E09 DT-T 2 Engine water temperature sensor (Preheater) D-2 O-8
E10 DT-T 2 Air conditioner compressor magnet clutch D-2 —
E11 DT-T 2 Diode (Air conditioner compressor) D-4 —
E14 Terminal 1 Ground (Rear frame) A-5 X-5
40-92 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing
E26 DT-T 2 Engine oil level sensor A-5 P-8

E27 DT-T 2 Engine speed sensor C-6 TM
E28 DT 2 Diode (Engine heater relay) C-9 O-8
E29 Terminal 1 Engine oil pressure switch B-5 P-8
E30 Terminal 1 Starting motor B B-1 X-4
E31 DT-T 2 Diode — E
E32 DT-T 2 Diode (Fuel cut solenoid) C-6 E
E33 DT-T 2 Dust indicator B-9 O-8
E34 DT-T 3 Fuel cut solenoid C-7 —
ER1 DT-T (G) 8 Intermediate connector (Engine) Z-2 P-5
ER3 DT-T (Gr) 8 Intermediate connector (Engine) A-1 O-5
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-3
F03 Terminal 1 Horn (303 Hz) A-1 W-1
F05 Terminal 1 Horn (303 Hz) C-1 W-1
F06 Terminal 1 Horn (303 Hz) B-1 W-1
F07 DT-T 2 Switching pump cut-off solenoid C-1 TM
F09 DT-T 3 Bucket positioner proximity switch A-3 WRK

F10 DT-T 3 Bucket positioner proximity switch (STD) A-3 WRK
F13 DT-T 2 Lift arm damper solenoid C-1 TM
F14 DT-T 2 Diode (Damper solenoid) D-1 TM
F15 DT-T 3 Lift arm angle signal (For load meter) A-2 M-8
F16 DT-T 3 Lift arm bottom signal (For load meter) B-1 M-8
F17 DT-T 3 Lift arm rod signal (For load meter) B-1 M-8
F30 Terminal 1 Ground (Front frame) C-1 U-1
FF1 S 10 Intermediate connector (Front lamp) E-1 N-3
FF2 DT-T (Gr) 8 Intermediate connector (Work equipment sensor) D-1 E
FL1 S 12 Intermediate connector (Front lamp) — K-3
FL2 DT-T (Gr) 8 Intermediate connector (Work equipment sensor) — E
FL3 DT-T 6 Intermediate connector (Load meter) — K-5
FL7 DT-T (Br) 12 Intermediate connector (Work equipment solenoid) F-1 WRK
FL8 DT-T (G) 8 Intermediate connector (Work equipment solenoid) F-2 WRK
FL9 DT-T 6 Intermediate connector (3rd lever solenoid) F-2 WRK
FS1 L 2 Intermediate connector (Fuse box) W-7 E
FS2 L 2 Intermediate connector (Fuse box) V-7 E
FS3 S (W) 16 Intermediate connector (Fuse box) V-8 E
FS5 M 6 Intermediate connector (Fuse box) V-7 E
FS6 Plug 1 Intermediate connector (Fuse box) V-8 —
FS7 Plug 1 Intermediate connector (Fuse box) W-7 —
F.PS DT-T 2 Transmission F clutch solenoid J-6 TM
F.SW DT 2 Transmission F clutch fill switch J-6 TM
G01 Terminal 1 Backup buzzer J-9 TM
G04 M 2 Rear working lamp (Left) K-9 V-8
WA380-5L 40-93 3
Number Address
Pins Layout Drawing
Drawing
G05 M 2 Rear working lamp (Right) J-9 U-8

GR1 DT-T 4 Intermediate connector (Fan reverse solenoid, rear working lamp) L-7 U-6
GR2 DT-T 2 Fan reverse solenoid L-8 TM
HEAD M 3 Head lamp (Right) A-6 W-3
HEAD M 3 Head lamp (Left) — W-2
JT1 DT-T (B) 8 Centralized connector (Ground) E-5 Q-8
JT2 DT-T (B) 8 Centralized connector (Shield) E-4 TM
JT3 DT-T 6 Centralized connector E-4 TM
L01 SWP 6 Parking brake switch M-6 TM
L02 SWP 6 Dimmer switch, light switch M-5 B-1
L03 SWP 6 Turn signal and hazard switch M-6 B-1
L04 SWP 14 Shift switch M-3 TM
L05 DT-T 2 Horn switch M-5 E-8
L07 DT-T 6 Machine monitor switch (Mode/Cancel selector switch) Q-1 B-8
L08 DT-T 6 Machine monitor switch (Screen selector switch) Q-1 A-8
L09 DT-T 2 Stop lamp switch Q-1 D-8
L10 DT-T 3 Left brake pressure sensor R-1 TM
L11 DT-T 2 Air suspension seat S-1 —
L12 DT-T 4 R direction switch O-7 —
L13 DT-T 2 Lift arm N lock switch O-7 —
L14 DT-T 4 Kicking and hold switch P-7 —
L15 DT-T 4 Load meter cancel and sub-total switch O-7 D-8
L16 M 2 Intermediate connector (DC converter) V-2 —
L17 M 4 DC24V/DC12V converter W-5 —
L18 Yazaki 2 DC12V socket W-3 —
L19 M 4 Flasher unit U-8 H-8
L20 M 2 Alarm buzzer U-8 I-7
L21 S 10 Front and rear wiper switch N-1 —
L25S DT-T 2 Work equipment lever electrical detent N-7 WRK
L31 M 6 Intermittent wiper timer W-7 —
L34 DT-T 4 Joystick level positioner W-7 WRK
L35 DT-T 2 Joystick EPC solenoid P-1 WRK
L37 DTM 12 Joystick lever switch M-6 K-8
L38 DT-T 3 Joystick N lock switch W-7 K-1
L39 DT-T 6 Joystick ON/OFF switch T-1 K-2
L40 DT-T 6 Steering speed mode switch S-1 K-1
L41 Relay 6 Joystick cutoff relay N-6 WRK
L42 Plug 1 Connector (Spare power supply) A-5 —
L44 M 6 Intermediate connector (Printer) V-3 I-7
L45 D-sub 25 Printer (Load meter) — I-8
L46 G 4 Printer (Load meter) — H-9
L51 AMP070 20 Monitor panel controller M-5 B-6
40-94 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing

L58 AMP040 8 Monitor panel controller M-2 —
L61 DRC 24 Transmission and fan pump motor controller P-8 TM, F-8
L62 DRC 40 Transmission and fan pump motor controller Q-8 TM, F-8
L71 DRC 24 Lift arm bucket and joystick controller Q-9 WRK
L72 DRC 40 Lift arm bucket and joystick controller Q-9 WRK, K-8
L73 DRC 40 Lift arm bucket and joystick controller R-9 WRK, K-8
L88 DT-T (Gr) 8 Engine mode selector motor P-1 OTH
L91 DT-T 6 Timer P-8 —
L100 Terminal 1 Ground (Floor) R-1 J-1
L101 S (W) 16 Intermediate connector (Relay sub-unit) T-9 I-7
L102 S (L) 16 Intermediate connector (Relay sub-unit) T-9 J-7
L103 S (W) 16 Intermediate connector (Relay sub-unit) S-9 J-7
L104 S (W) 16 Intermediate connector (Relay sub-unit) T-9 —
L106 S (W) 16 Intermediate connector (Relay sub-unit) T-9 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 J-9
L114 — 5 Automatic preheater relay V-8 J-9
L115 — 5 Engine controller power supply relay V-9 —
L116 — 4 Neutral safety relay W-7 J-9
L117 — 4 Backup lamp relay W-7 K-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 —
L123 — 5 Lift arm detent relay (STD) X-9 —
L124 — 5 Bucket detent relay (STD) X-9 —
L125 — 5 Lift arm damper relay V-9 —
L126 — 4 Emergency steering relay X-8 —
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 —
LC.PS DT-T 2 Torque converter lockup solenoid (OPT) J-5 TM
LC.SW DT 2 Torque converter lockup fill switch (OPT) J-5 TM
LL5 DT 3 Intermediate connector (Vehicle with joystick) Q-1 WRK
LL6 DT-T (Gr) 12 Intermediate connector (Vehicle with joystick) Q-1 WRK
LL7 DT-T (G) 12 Intermediate connector (Vehicle with joystick) Q-1 K-5
LL8 DT-T (Gr) 8 Intermediate connector (Joystick switch) R-1 WRK
WA380-5L 40-95 3
Number Address
Pins Layout Drawing
Drawing
LR1 DTHD#12 1 Intermediate connector (Slow-blow fuse) — E

LR2 DT-T (G) 12 Intermediate connector (Engine) — K-4
LR4 L 2 Intermediate connector (Slow-blow fuse) — TM
LR6 L 2 Intermediate connector (Ground) — K-1
LR8 DTHD#8 1 Intermediate connector (Ground) — K-2
LR9 DT-T (G) 12 Intermediate connector (Steering and brake oil pressure switch) — K-2
LR10 DT-T (Gr) 12 Intermediate connector — K-3
LT1 HD-24 31 Intermediate connector (Transmission) E-3 K-4
PB.PS DT-T 2 Parking brake solenoid I-2 TM
PB.SW DT-T 2 Parking brake indicate switch I-2 P-8
R.PS DT-T 2 Transmission R clutch solenoid J-6 TM
R.SW DT 2 Transmission R clutch fill switch J-6 TM
R01 Terminal 1 Battery relay J-2 X-6
R02 Terminal 1 Slow-blow fuse L-2 E
R04 Terminal 1 Battery relay L-1 X-6
R05 Terminal 1 Slow-blow fuse K-2 X-7
R06 Terminal 1 Slow-blow fuse K-2 E
R15 Terminal 1 Emergency steering relay J-1 TM
R22 Terminal 1 Battery G-9 T-9
R24 DT-T 2 Diode (Battery relay) I-1 P-1
R26 DT-T 2 Diode (Starting motor) H-1 P-1
R27 DT-T 2 Diode (Starting motor) J-2 P-1
R29 DT-T 2 Fan pump EPC A-6 TM
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 V-8
R37 DT-T 3 Emergency steering pressure switch D-1 W-8
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 —
R47 DT-T 2 Hydraulic oil temperature sensor A-6 W-1
R50 Terminal 1 Ground (Rear frame) I-9 T-1
40-96 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing
R51 DT-T 2 Emergency brake switch 1 F-1 TM

R53 DT-T 2 Front brake accumulator low pressure switch F-1 W-8
R54 DT-T 2 Rear brake accumulator low pressure switch F-1 W-8
R55 DT-T 2 Intermediate connector (Rear brake oil temperature) J-2 —
R56 DT-T 2 Rear brake oil temperature sensor H-1 —
R63 Terminal 1 Slow-blow fuse L-2 —
R64 Terminal 1 Ground (Rear frame) L-5 —
R65 DT-T 6 Cooler automatic tilt motor switch (OPT) L-4 —
R66 DT-T 2 Cooler automatic tilt motor H-9 —
R68 Terminal 1 Fuel solenoid relay I-9 —
R72 DT-T 2 Fuel solenoid relay K-9 —
REV OUT DT-T 2 Speed sensor E-3 TM
S01 DT-T 6 Front working lamp switch O-1 C-8
S02 DT-T 6 Rear working lamp switch O-1 C-8
S03 DT-T 6 Transmission cut-off ON/OFF switch M-4 —
S04 DT-T 6 Right FNR selector switch — TM
S05 DT-T 6 Transmission cut-off set switch M-9 TM
S06 DT-T 6 Torque converter lockup ON/OFF switch O-8 TM
S07 DT-T 6 Lift arm damper ON/OFF switch O-1 TM
S12 DT-T 6 Remote positioner set switch (Vehicle with joystick) N-7 WRK
S13 DT-T 6 Upper remote positioner ON/OFF switch (Vehicle with joystick) N-9 WRK
S14 DT-T 6 Lower remote positioner ON/OFF switch (Vehicle with joystick) N-8 WRK
S16 DT-T 6 Hydraulic fan reverse switch M-9 TM
S19 DT-T 6 Emergency steering check switch N-9 TM
S21 DT-T 4 Engine power mode switch M-9 TM
S22 DT-T 4 Auto shift mode switch N-7 TM
S31 DT 4 Starting switch N-7 L-7
T20 Terminal 1 Ground H-2 TM
TC.T DT-T 2 Torque converter oil temperature sensor G-7 TM
TEL DT-T (Gr) 12 Intermediate connector (KOMTRAX) Q-1 K-1
TM.T DT-T 2 Transmission oil temperature sensor I-3 Q-8
WA380-5L 40-97 3
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
CONNECTOR LAYOUT DRAWING
40-98 3 WA380-5L
WA380-5L 40-99 3
40-100 3 WA380-5L
WA380-5L 40-101 3
40-102 3 WA380-5L
WA380-5L 40-103 3
TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM DIA-
TRANSMISSION CONTROL SYSTEM DIAGRAM
40-104 3 WA380-5L
WA380-5L 40-105 3
40-106 3 WA380-5L
TROUBLESHOOTING TRANSMISSION CONTROL SYSTEM (TM
TRANSMISSION CONTROL SYSTEM (TM MODE)
Failure Code [1500L1]

Double Engagement Detected
Controller
Action code Failure code
code Trouble Double engagement detected
E03 1500L1 TM
Description of
• A fill signal is input when double engagement is detected
trouble
Controller
• No reaction.
reaction
Effect on
machine
Related
information
Possible Cause Standard value in normal state/Remarks on troubleshooting

Causes and
Standard ★ Refer to Failure Codes 15SAL1, 15 SBL1, 15SEL1, 15SFL1, 15SGL1 and 15SHL1.
Values
Related Circuit Diagram
★ Refer to Failure Codes 15SAL1, 15 SBL1, 15SEL1, 15SFL1, 15SGL1 and 15SHL1.
WA380-5L 40-107 3
Failure Code [15SAL1]

Short Circuit in F_ECM Fill Switch System
Troubleshooting Controller
Failure code
code code Trouble Short circuit in F_ECM fill switch system.
E03 15SAL1 TM
Description of
• An F_ECMV fill switch signal is input when F_ECMV is OFF.
trouble
Controller
• Assumes that the F_ECMV fill switch signal is ON and turns output to “N”.
reaction
Effect on
• No travel.
machine
Related
• Can be checked with the monitoring function (Code: 40908, D-IN-24).
information
Cause Standard value in normal state/Remarks on troubleshooting
1) Turn starting switch OFF.

2) Disconnect connector F.SW.
3) Connect T-adapter.
4) Start engine.
5) Turn transmission cut-off switch OFF.
6) Turn parking brake switch OFF.
Defective F_ECMV fill 7) Do not apply parking brake while traveling.
1
switch
Forward-reverse lever (or 1 Ω and
Resistance
switch) = F below
Between F.SW
(Male) (1) and body
1 MΩ and
Other than above Resistance
above
Possible 1) Turn starting switch OFF.

2) Disconnect connectors L62 and F.SW.
Causes and
Wiring harness ground 3) Connect T-adapter.
Standard Values 2
fault
Between L62 (Female) (37) F.SW (Female) (1) - 1 MΩ and
body Resistance
above

2) Disconnect connector L62.
3) Insert T-adapter.
4) Connect connector.
5) Start engine.
Defective transmission 6) Turn transmission cut-off switch OFF.
3 and fan pump motor 7) Turn parking brake switch OFF.
controller 8) Do not apply parking brake while traveling.
Forward-reverse lever (or 1 V and

switch) = F Voltage
Between L62 (37) below
body
Other than above Voltage 20 - 30 V
40-108 3 WA380-5L
Related circuit diagram
WA380-5L 40-109 3
Failure Code [15SALH]

F_ECM Fill Switch System Disconnected
Failure code
code code Trouble F_ECM fill switch system disconnected.
E01 15SALH TM
Description of
• An F_ECMV fill switch signal is input when F_ECMV is OFF.
trouble
Controller
• Assumes that the F_ECMV fill switch signal is OFF and uses fill-less modulation data.
reaction
Effect on
• No travel.
machine
Related
information

4) Start engine.
Defective F_ECMV fill 7) Do not apply parking brake while traveling.
1
switch
Resistance
switch) = F below
Between F.SW (Male)
(1) and body
1 MΩ and
above

Wiring harness, Wiring 2) Disconnect connectors L62 and F.SW.
Causes and
harness discontinuity 3) Connect T-adapter.
Standard Values 2
(Disconnection or
defective contact) Wiring harness between L62 (Female) (37) F.SW 1 MΩ and
(Female) (1). Resistance
above

5) Start engine.
Defective transmission 6) Turn transmission cut-off switch OFF.
3 and fan pump motor 7) Turn parking brake switch OFF.
controller 8) Do not apply parking brake while traveling.

switch) = F Voltage
body
40-110 3 WA380-5L
WA380-5L 40-111 3
Failure Code [15SBL1]

Short Circuit in R_ECM Fill Switch System
Failure code
code code Trouble Short circuit in R_ECM fill switch system.
E03 15SBL1 TM
Description of
• An R_ECMV fill switch signal is input when R_ECMV is OFF.
trouble
Controller
• Assumes that the R_ECMV fill switch signal is ON and turns output to “N”.
reaction
Effect on
• No travel.
machine
Related
information

4) Start engine.
Defective R_ECMV fill 7) Do not apply parking brake while traveling.
1
switch
Resistance
switch) = R below
Between R.SW
(Male) (1) and body
1 MΩ and
above
Causes and 2) Disconnect connectors L62 and R.SW.
Standard Values Wiring harness ground 3) Connect T-adapter.
2
fault
Between L62 (Female) (27) R.SW (Female) (1) - 1 MΩ and
body Resistance
above

4) Start engine.
Defective transmission 6) Turn parking brake switch OFF.
3 and fan pump motor 7) Do not apply parking brake while traveling.
controller
switch) = R Voltage
body
40-112 3 WA380-5L
WA380-5L 40-113 3
Failure Code [15SBLH]

R_ECM Fill Switch System Disconnected
Failure code
code code Trouble R_ECM fill switch system disconnected.
E01 15SBLH TM
Description of
• An R_ECMV fill switch signal is input when R_ECMV is ON.
trouble
Controller
• Assumes that the R_ECMV fill switch signal is OFF and uses fill-less modulation data.
reaction
Effect on
• No travel.
machine
Related
information

4) Start engine.
Defective R_ECMV fill 7) Do not apply parking brake while traveling.
1
switch
Resistance
switch) = R below
Between R.SW
(Male) (1) and body
1 MΩ and
above
Causes and Wiring harness, Wiring 2) Disconnect connectors L62 and R.SW.
Standard Values harness discontinuity 3) Connect T-adapter.
2
(Disconnection or
defective contact) Wiring harness between L62 (Female) (27) R.SW 1 MΩ and
(Female) (1). Resistance
above

4) Start engine.
controller
switch) = R Voltage
body
40-114 3 WA380-5L
WA380-5L 40-115 3
Failure Code [15SEL1]

Short Circuit in 1st_ECM Fill Switch System
Failure code
code code Trouble Short circuit in 1st_ECM fill switch system.
E03 15SEL1 TM
Description of
• An 1st_ECMV fill switch signal is input when 1st_ECMV is ON.
trouble
Controller
• Assumes that the 1st_ECMV fill switch signal is ON and turns speed clutch output OFF.
reaction
Effect on
• No travel.
machine
Related
information

2) Disconnect connector 1.SW.
4) Start engine.
Defective 1st_ECMV 7) Do not apply parking brake while traveling.
1
fill switch
Gear shift lever = 1st 1 Ω and
Resistance
speed below
Between 1.SW
(Male) (1) - body
1 MΩ and
above
Causes and 2) Disconnect connectors L62 and 1.SW.
Standard Values Wiring harness ground 3) Connect T-adapter.
2
fault
Wiring harness between L62 (Female) (17) - 1.SW 1 MΩ and
(Female) (1) - body. Resistance
above

4) Start engine.
controller
Gear shift lever = 1st 1 V and
Voltage
Between L62 (17) - speed below
body
40-116 3 WA380-5L
WA380-5L 40-117 3
Failure Code [15SELH]

1st_ECM Fill Switch System Disconnected
Failure code
code code Trouble 1st_ECM fill switch system disconnected.
E01 15SELH TM
Description of
• An 1st_ECMV fill switch signal is input when 1st_ECMV is ON.
trouble
Controller
• Assumes that the 1st_ECMV fill switch signal is OFF and uses fill-less modulation data.
reaction
Effect on • May not travel at 1st speed.

machine • Gear shifting shock or time lag may occur on 1st-speed-travel switch over.
Related
information

4) Start engine.
Defective 1st_ECMV 7) Do not apply parking brake while traveling.
1
fill switch
Gear shift lever = 1st 1 Ω and
speed Resistance
below
Between 1.SW
(Male) (1) - body
1 MΩ and
above
Causes and Wiring harness, Wiring 2) Disconnect connectors L62 and 1.SW.
Standard Values harness discontinuity 3) Connect T-adapter.
2
(Disconnection or
defective contact) Wiring harness between L62 (Female) (17) - 1.SW 1 MΩ and
Resistance
(Female) (1). above

4) Start engine.
controller
Gear shift lever = 1st 1 V and
Voltage
body
40-118 3 WA380-5L
WA380-5L 40-119 3
Failure Code [15SFL1]

Short Circuit in 2nd_ECM Fill Switch System
Failure code
code code Trouble Short circuit in 2nd_ECM fill switch system.
E03 15SFL1 TM
Description of
• An 2nd_ECMV fill switch signal is input when 2nd_ECMV is ON.
trouble
Controller
• Assumes that the 2nd_ECMV fill switch signal is ON and turns speed clutch output OFF.
reaction
Effect on
• No travel.
machine
Related
information

4) Start engine.
Defective 2nd_ECMV 7) Do not apply parking brake while traveling.
1
fill switch
Gear shift lever = 2nd 1 Ω and
Resistance
speed below
Between 2.SW
(Male) (1) - body
1 MΩ and
above

Possible 2) Disconnect connectors L62 and 2.SW.
Causes and Wiring harness ground 3) Connect T-adapter.
2
Standard Values fault
above

4) Start engine.
Defective transmission 7) Do not apply parking brake while traveling.
3 and fan pump motor 8) Turn manual/auto shift selector switch to "Manual".
controller 9) Turn forward-reverse lever (Or switch) to "F" or "R".
Gear shift lever = 2nd 1 V and

Voltage
body
40-120 3 WA380-5L
WA380-5L 40-121 3
Failure Code [15SFLH]

2nd_ECM Fill Switch System Disconnected
Failure code
code code Trouble 2nd_ECM fill switch system disconnected.
E01 15SFLH TM
Description of
• An 2nd_ECMV fill switch signal is input when 2nd_ECMV is ON.
trouble
Controller
• Assumes that the 2nd_ECMV fill switch signal is OFF and uses fill-less modulation data.
reaction
Effect on • May not travel at 2nd speed.

machine • Gear shifting shock or time lag may occur on 2nd-speed-travel switch over.
Related
information

4) Start engine.
Defective 2nd_ECMV 7) Do not apply parking brake while traveling.
1
fill switch
Gear shift lever = 2nd 1 Ω and
speed Resistance
below
Between 2.SW
(Male) (1) - body
1 MΩ and
above

Possible Wiring harness, Wiring 2) Disconnect connectors L62 and 2.SW.
Causes and harness discontinuity 3) Connect T-adapter.
2
Standard Values (Disconnection or
Resistance
(Female) (1). above

4) Start engine.
Gear shift lever = 2nd 1 V and

Voltage
body
40-122 3 WA380-5L
WA380-5L 40-123 3
Failure Code [15SGL1]

Short Circuit in 3rd_ECM Fill Switch System
Failure code
code code Trouble Short circuit in 3rd_ECM fill switch system.
E03 15SGL1 TM
Description of
• An 3rd_ECMV fill switch signal is input when 3rd_ECMV is ON.
trouble
Controller
• Assumes that the 3rd_ECMV fill switch signal is ON and turns speed clutch output OFF.
reaction
Effect on
• No travel.
machine
Related
information

4) Start engine.
Defective 3rd_ECMV 7) Do not apply parking brake while traveling.
1
fill switch
Gear shift lever = 3rd 1 Ω and
Resistance
speed below
Between 3.SW
(Male) (1) - body
1 MΩ and
above

2
above

4) Start engine.
Gear shift lever = 3rd 1 V and

Voltage
body
40-124 3 WA380-5L
WA380-5L 40-125 3
Failure Code [15SGLH]

3rd_ECM Fill Switch System Disconnected
Failure code
code code Trouble 3rd_ECM fill switch system disconnected.
E01 15SGLH TM
Description of
• An 3rd_ECMV fill switch signal is input when 3rd_ECMV is ON.
trouble
Controller
• Assumes that the 3rd_ECMV fill switch signal is OFF and uses fill-less modulation data.
reaction
Effect on • May not travel at 3rd speed.

machine • Gear shifting shock or time lag may occur on 3rd-speed-travel switch over.
Related
information

4) Start engine.
Defective 3rd_ECMV 7) Do not apply parking brake while traveling.
1
fill switch
Gear shift lever = 3rd 1 Ω and
speed Resistance
below
Between 3.SW
(Male) (1) - body
1 MΩ and
above

2
Resistance
(Female) (1). above

4) Start engine.
Gear shift lever = 3rd 1 V and

Voltage
body
40-126 3 WA380-5L
WA380-5L 40-127 3
Failure Code [15SHL1]

Short Circuit in 4th_ECM Fill Switch System
Failure code
code code Trouble Short circuit in 4th_ECM fill switch system.
E03 15SHL1 TM
Description of
• An 4th_ECMV fill switch signal is input when 4th_ECMV is ON.
trouble
Controller
• Assumes that the 4th_ECMV fill switch signal is ON and turns speed clutch output OFF.
reaction
Effect on
• No travel.
machine
Related
information

4) Start engine.
Defective 4th_ECMV 7) Do not apply parking brake while traveling.
1
fill switch
Gear shift lever = 4th 1 Ω and
Resistance
speed below
Between 4.SW
(Male) (1) - body
1 MΩ and
above

2
above

4) Start engine.
Gear shift lever = 4th 1 V and

Voltage
body
40-128 3 WA380-5L
WA380-5L 40-129 3
Failure Code [15SHLH]

4th_ECM Fill Switch System Disconnected
Failure code
code code Trouble 4th_ECM fill switch system disconnected.
E01 15SGLH TM
Description of
• An 4th_ECMV fill switch signal is input when 4th_ECMV is ON.
trouble
Controller
• Assumes that the 4th_ECMV fill switch signal is OFF and uses fill-less modulation data.
reaction
Effect on • May not travel at 4th speed.

machine • Gear shifting shock or time lag may occur on 4th-speed-travel switch over.
Related
information

4) Start engine.
Defective 4th_ECMV 7) Do not apply parking brake while traveling.
1
fill switch
Gear shift lever = 4th 1 Ω and
speed Resistance
below
Between 4.SW
(Male) (1) - body
1 MΩ and
above

2
Resistance
(Female) (1). above

4) Start engine.
Gear shift lever = 4th 1 V and

Voltage
body
40-130 3 WA380-5L
WA380-5L 40-131 3
Failure Code [15SJL1]

Short Circuit in Lock-up_ECM Fill Switch System
Failure code
code code Trouble Short circuit in Lock-up_ECM fill switch system.
E03 15SJL1 TM
Description of
• A Lock-up_ECMV fill switch signal is input when Lock-up_ECMV is ON.
trouble
Controller
• Assumes that the Lock-up_ECMV fill switch signal is ON and turns speed clutch output OFF.
reaction
Effect on
• No travel.
machine
Related
information

2) Disconnect connectors L62 and LC.SW.
Wiring harness ground 3) Connect T-adapter.
1
fault
Between L62 (Female) (2) - LC.SW (Female) (1) - 1 MΩ and
body. Resistance
Possible above
Causes and
Standard Values 2) Disconnect connector L62.
Defective transmission
4) Start engine.
and fan pump motor
2
controller or 1 V and
lockup_ECMV fill switch Lock-up = ON Voltage
Between L62 below
(Female) (2) - body.
40-132 3 WA380-5L
Failure Code [15SJLH]

Lock-up_ECM Fill Switch System Disconnected
Failure code
code code Trouble Lock-up_ECM fill switch system disconnected.
E03 15SJL1 TM
Description of
• A Lock-up_ECMV fill switch signal is input when Lock-up_ECMV is ON.
trouble
Controller
• Assumes that the Lock-up_ECMV fill switch signal is OFF and uses fill-less modulation data.
reaction
Effect on • May not be locked up.

machine • Gear shifting shock or time lag may occur on lock-up switch over.
Related
information

Wiring harness, Wiring 2) Disconnect connectors L62 and LC.SW.
harness discontinuity 3) Connect T-adapter.
1
(Disconnection or
defective contact) 1 MΩ and
Between L62 (Female) (2) - LC.SW (Female) (1). Resistance
Possible below
Causes and
Defective transmission
4) Start engine.
and fan pump motor
2
controller or 1 V and
lockup_ECMV fill switch Lock-up = ON Voltage
Between L62 below
(Female) (2) - body.
WA380-5L 40-133 3
Failure Code [989F00]

Transmission Protection Caution
Action Code FAILURE CODE Controller Code
Trouble Transmission protection caution
E00 989F00 TM
• Not considered to be a failure.
Description of • The travel speed exceeds the allowable speed of the transmission on down shifting.
Trouble • The allowable speed of the transmission is exceeded on FR gear shifting.
• The travel speed exceeds 38km/h {24 mph).
Controller Reaction • Issues a warning to attract operator's attention on FR gear shifting in auto shift mode.
• May be started at 2nd speed during FR gear shifting in auto shift mode.
Effect on Machine
• Down shifting may not be possible when the accelerator is fully pushed down.
• Refer to "Structure and Operation" (Transmission protection, travel speed warning, and engine over-
Related Information
run functions)
Related circuit diagram (None)
40-134 3 WA380-5L
Failure Code [B@C7NS]

Rear Brake Cooling Oil Overheat
Failure code
code code Trouble Rear brake cooling oil overheat
E02 B@C7NS TM
Description of
• Rear brake overheat.
trouble
Controller
• No reaction.
reaction
Effect on • Brake may be broken.

machine • A rear brake overheat warning is displayed.
Related
• Can be checked with the monitoring function (Code: 30202 R BRAKE OIL).
information

2) Disconnect connector R56.
Defective rear brake oil
1 At normal temperature
temperature sensor Resistance 35 - 50 K Ω
Between R56 (25° C) {77° F}
Possible (Male) (1) - (2)
Causes and At 100° C {212° F} Resistance 3.1 - 4.5 K Ω
Standard Values
Defective transmission 1) Turn starting switch OFF.
and fan pump motor 2) Disconnect connector L61.
controller 3) Connect T-adapter.
2
Between L61 At normal temperature
(Female) (20) Resistance 35 - 50 KΩ
(25° C) {77° F}
- (31)
At 100° C {212° F} Resistance 3.1 - 4.5 K Ω
WA380-5L 40-135 3
Failure Code [D150KA]

Emergency Steering Relay Output System Disconnected
Failure code
code code Trouble Emergency steering relay output system disconnected
E03 D150KA TM
Description of
• No signal is output to the emergency steering relay due to disconnection.
trouble
Controller
• No reaction.
reaction
Effect on
• The electric emergency steering motor does not rotate.
machine
Related
—
information
1) Turn starting switch OFF 10 or more seconds after starting engine.

2) Replace relay.
3) Turn starting switch ON (at self-check).
This Failure code (D150KA) issued Relay L126 is not defective

Defective emergency
1 This Failure code (D150KA) not issued Relay L126 is defective
steering realy (L126)
Possible Between L105 (Male) (9) - (10) Resistance 200 - 400 Ω
Causes and
Standard Values 1) Turn starting switch OFF.
2) Disconnect connectors L63 and L105.
Wiring harness
2 discontinuity
(Disconnection or
Wiring harness between L63 (Female)
Resistance 1 Ω and below
(7) - L105 (Female) (9)
defective contact)
Wiring harness between L105
(Female) (10) - body

Defective transmission 2) Disconnect connector L63.
3 and fan pump motor 3) Connect T-adapter.
controller
Between L63 (Female) (7) - body Resistance 200 - 400 Ω
40-136 3 WA380-5L
Failure Code [D150KB]

Short Circuit in Emergency Steering Relay Output System
Failure code
code code Trouble Short circuit in Emergency steering relay output system.
E03 D150KB TM
Description of
• No signal is output to the emergency steering relay due to disconnection.
trouble
Controller
• No reaction.
reaction
Effect on
machine
Related
—
information
1) Turn starting switch OFF 10 or more seconds after starting engine.

2) Replace relay.
3) Turn starting switch ON (at self-check).
This Failure code (D150KB) issued Relay L126 is not defective

Defective emergency
1 This Failure code (D150KB) not issued Relay L126 is defective
steering realy (L126)
Possible 3) Connect T-adapter.
Causes and
Between L105 (Male) (9) - (10) Resistance 200 - 400 Ω
Standard Values
Wiring harness 2) Disconnect connectors L63 and L105.
discontinuity 3) Connect T-adapter.
2 (Disconnection or
defective contact) Wiring harness between L63 (Female)
Resistance 1 MΩ and above
(7) - L105 (Female) (9)

controller
WA380-5L 40-137 3

Back-up Alarm Relay Output System Disconnected
Failure code
code code Trouble Back-up alarm relay output system disconnected
E03 D160KA TM
Description of
• Back-up alarm relay output system disconnected.
trouble
Controller
• No reaction.
reaction
Effect on
machine
Related
• No back-up buzzer sounds or the back-up lamp does not come on (Traveling is possible).
information
1) Turn starting switch OFF

2) Replace relay.
3) Turn starting switch ON.
4) Turn forward-reverse lever to “R”.

Defective back-up
1
lamp realy (L117) This Failure code (D160KA) not issued Relay L117 is defective

Possible
Causes and Between L103 (Male) (1) - (2) Resistance 200 - 400 Ω
Standard Values
Wiring harness
discontinuity Wiring harness between L63 (Female)
2 (Disconnection or Resistance 1 Ω and below
(4) - L103 (Male) (1)
defective contact)
Wiring harness between L103 (Male)
(2) - body

controller
40-138 3 WA380-5L

Short Circuit in Back-up Alarm Relay Output System
Failure code
code code Trouble Short circuit in Back-up alarm relay output system
E03 D160KB TM
Description of
• No signal is output to the Back-up alarm relay output due to short circuit.
trouble
Controller
• Turns output to the back-up lamp relay OFF.
reaction
Effect on
• No back-up buzzer sounds or the back-up lamp does not come on (Traveling is possible).
machine
Related
—
information

2) Replace relay.
4) Turn forward-reverse lever to “R”.

Defective back-up
1
lamp realy (L117) This Failure code (D160KB) not issued Relay L117 is defective

Causes and
Standard Values Between L103 (Male) (1) - (2) Resistance 200 - 400 Ω

2 Wiring
fault.
harness ground
(4) - L103 (Male) (1) - body

controller
WA380-5L 40-139 3

Neutral Safety Relay Output System Disconnected
Failure code
code code Trouble Neutral safety relay output system disconnected.
E03 D191KA TM
Description of
• No signal is output to the neutral safety relay due to disconnection.
trouble
Controller
• Turns neutral output OFF.
reaction
Effect on • The engine cannot be started when the right FNR switch or joystick mode is on (Can be started in
machine steering wheel mode).
Related
—
information

2) Replace relay.
Defective exchange 4) Turn right or joystick F
1 5) Turn FNR selector switch ON.
relay (L115)
This Failure code (D191KA) not issued Relay L113 is defective

2) Replace relay.
4) Turn right or joystick FNR switch.
2 Defective neutral
safety relay (L116) 5) Turn FNR selector switch ON.
Possible This Failure code (D191KA) issued Relay L116 is not defective
Causes and
Standard Values This Failure code (D191KA) not issued Relay L116 is defective

2) Disconnect connectors L62, L63, L101 and L102.
Wiring harness between L63 (Female) (37) -

L101 (Female) (14).

Wiring harness Resistance 1 Ω and below
discontinuity L102 (Female) (11).
3 (Disconnection or
defective contact) Wiring harness between L62 (Female) (35) -
L101 (Female) (11).

body.

body.
40-140 3 WA380-5L

5) Turn forward-reverse lever to “N”.
When right FNR switch mounted (Right FNR switch = ON)
Between L63 (37) - Right FNR switch = N Voltage 17 - 30 V

Possible Defective body
transmission and Other than above Voltage 1 V and below
Causes and 4
fan pump motor
Standard Values controller When joystick mounted (arm rest lock and joystick switch = ON)
Joystick FNR switch =

"N" and joystick lever = Voltage 17 - 30 V
Neutral
Between L63 (37) -
body Voltage 1 V and below
N
Joystick lever being

Voltage 1 V and below
operated
WA380-5L 40-141 3
12
Short Circuit in Neutral Safety Relay Output System
Failure code
code code Trouble Short circuit in neutral safety relay output system.
E01 D191KA TM
Description of
• No signal is output to the neutral safety relay due to grounding.
trouble
Controller
reaction • Turns output to the neutral safety relay OFF when it is grounded.
Effect on • The engine cannot be started when the right FNR switch or joystick mode is on (Can be started in
machine steering wheel mode).
Related
—
information

2) Replace relay.
Defective exchange 4) Turn right or joystick FN
1 5) Turn FNR selector switch ON.
relay (L115)
This Failure code (D191KB) not issued Relay L113 is defective

2) Replace relay.
Possible 3) Turn starting switch ON.
Causes and 4) Turn right or joystick FNR switch.
Standard Values Defective neutral
2 safety relay (L116) 5) Turn FNR selector switch ON.
This Failure code (D191KB) not issued Relay L116 is defective

2) Disconnect connectors L63, L101 and L102.
Wiring harness Wiring harness between L63 (Female) (37) -
3 ground fault Resistance 1 MΩ and above
L101 (Female) (14) - body.

L102 (Female) (11) - body.
40-142 3 WA380-5L

5) Turn forward-reverse lever to “N”.
When right FNR switch mounted (Right FNR switch = ON)
Between L63 (37) - Right FNR switch = N Voltage 17 - 30 V

Possible Defective body
Causes and 4
fan pump motor
Standard Values controller When joystick mounted (arm rest lock and joystick switch = ON)

"N" and joystick lever = Voltage 17 - 30 V
Neutral
Between L63 (37) -
N
Joystick lever being

operated
WA380-5L 40-143 3

E.C.S.S. Relay Output System Disconnected
Failure code
code code Trouble E.C.S.S. relay output system disconnected.
E01 D192KA TM
Description of
• No signal is output to the E.C.S.S. relay due to disconnection.
trouble
Controller
• Turns output OFF.
reaction
Effect on
• The boom damper does not operate.
machine
• 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
Related
correctly.
information
• Check that the E.C.S.S. switch is turned ON. Referring to TROUBLESHOOTING, Special functions of
machine monitor, check that the optional selection of the E.C.S.S. is effective.

Defective boom damper relay 3) Connect T-adapter.
1
(L125)
Between L104 (Female) (11) - (12) Resistance 200 - 400 Ω

Causes and Wiring harness discontinuity
2 (Disconnection or defective Wiring harness between L63 (Female)
Standard Values Resistance 1 Ω and below
contact) (17) - L104 (Female) (11)

(12) - body

Defective transmission and
3 3) Connect T-adapter.
fan pump motor controller
40-144 3 WA380-5L

Short Circuit in E.C.S.S. Relay Output System
Failure code
code code Trouble Short circuit in E.C.S.S. relay output system.
E01 D192KB TM
Description of
• No signal is output to the E.C.S.S. relay due to grounding.
trouble
Controller
• Turns output to the boom damper OFF.
reaction
Effect on
• The boom damper does not operate.
machine
Related
correctly.
information
• Check that the E.C.S.S. switch is turned ON. Referring to TROUBLESHOOTING, Special functions of

Defective boom damper relay 3) Connect T-adapter.
1
(L125).

Possible
Causes and
2 Wiring harness ground fault. 3) Connect T-adapter.
Standard Values
(17) - L104 (Female) (11) - body

3 Defective transmission and
fan pump motor controller. 3) Connect T-adapter.
Between L63 (Female) (17) - body Resistance 200 - 400Ω
WA380-5L 40-145 3

Ground Fault in the Low Temperature By-pass Relay System
Failure code
code code Trouble Ground fault in the low temperature by-pass relay system.
E03 D198KB TM
Description of • Ground fault in wiring harness or relay between the transmission controller and the low temperature
trouble bypass relay
Controller
• Triggers an alarm.
reaction
Effect on
• Function to improve starting ability at low temperature (at -20° C (68° F) or lower) does not work.
machine
Related
• This function works when the kit (If equipped) for improving low temperature starting is installed.
information
1) Turn the starting switch off.

2) Disconnect the L63 and L93 connectors.
3) Connect the T-adapter.
1 Ground fault in wiring harness
Between L63 (female)(18), L93
Resistance 1 Ω or less
(female) (1) and machine body
1) Turn the starting switch off.

2) Disconnect the connector L93.
Possible
3) Connect the t-adapter.
Causes and
Standard Values Between L93 (female) (1) and (2). Resistance 200 - 400 Ω
Defective low temperature 1) Turn the starting switch off. 2) Disconnect the L93 connector.
2 3) Replace the low-temperature bypass relay (L93) with another one.
by-pass relay
4) Turn the starting switch on.
Defective low-temperature
Actuates normally.
bypass relay (L93).
Does not actuate normally (the error Normal temperature bypass

display stays on). relay (L93)
40-146 3 WA380-5L
WA380-5L 40-147 3
Failure Code [D198KY]

Hot-short in the Low-temperature By-pass Relay System
Failure code
code code Trouble Hot-short in the low-temperature by-pass relay system.
E03 D198KY TM
Description of
• Hot-short in the wiring harness or relay between the TM controller and the low-temperature bypass relay
trouble
Controller
reaction
Effect on
• The torque converter pump does not operate (inability to travel).
machine
Related
• This function works when the kit (If equipped) for improving low-temperature starting is installed.
information
Possible 1) Turn the starting switch off.

2) Disconnect the L63 connector.
Causes and
3) Connect the T-adapter.
Standard Values 1 Hot short in wiring harness
Between L63 (female)(18) and
Voltage 1 V or less
chassis
40-148 3 WA380-5L
WA380-5L 40-149 3
Failure Code [DAQ0KK]

Controller Power Supply Voltage Lowered
Failure code
code code
Trouble Controller power supply voltage lowered.
— DAQ0KK TM
Description of
• The controller power supply voltage is lowered.
trouble
Controller
• Cannot detect input signals properly.
reaction
Effect on
• Normal operation is disabled.
machine
Related
—
information

2) Disconnect connectors L63 and FS3.
Wiring harness discontinuity
contact) (1)/ (11) - FS3 (Female) (3)
Between L63 (Female) (21)/ (31)/ (32)/

(33) - body.
Possible
Causes and 1) Turn starting switch OFF.
2) Disconnect connector L63 and FS3.
Standard Values 3) Connect T-adapter.
2 Wiring harness ground fault
Between L63 (Female) 1/A/FS3
(Female) 3 - body Resistance 1 MΩ and above

Defective transmission and 4) Turn starting switch ON.
3
Between L63 1/A - Constant (NSW)
Voltage 20 - 30 V
body power supply
40-150 3 WA380-5L
WA380-5L 40-151 3
Failure Code [DAQ2KK]

Defective Solenoid Power Supply System
Failure code
code code Trouble Defective solenoid power supply system.
— DAQ2KK TM
Description of
• The solenoid power supply system voltage is lowered.
trouble
Controller
• Disables solenoid output.
reaction
Effect on
• Normal operation is disabled.
machine
Related
—
information

contact) (2)/ (12)/ (22) - FS4 (Female) (2).
Between L63 (Female) (21)/ (31)/ (32)/

(33) - body
Possible
2) Disconnect connector L63 and FS4.
Between L63 (Female) (2)/ (12)/ (22) -
body

Defective transmission and 4) Turn starting switch ON.
3
Between L63 (2)/ Constant (NSW)
Voltage 20 - 30 V
(12)/ (22) - body power supply
40-152 3 WA380-5L
WA380-5L 40-153 3
Failure Code [DAQ9KQ]

Model Selection Signal Mismatch
Action Code FAILURE CODE Controller Code
Trouble Model selection signal mismatch
E03 DAQ9KQ TM
Description of • The controller is recognized as another model.
Trouble
• Operates assuming the model operated before the FAILURE CODE was issued (Basically WA480) or
Controller Reaction
default model (WA470).
Effect on Machine • Gear shifting shock may occur.
Related Information • Set the model using the rotary switch (Refer to "Testing and Adjusting")
Possible Causes Causes Standard Values in Normal State and Remarks on Troubleshooting
and Standard Values 1 Controller model selection error —
40-154 3 WA380-5L
MEMORANDUM
WA380-5L 40-155 3
Failure Code [DDK3KA]

No Right FNR Switch Signal Input
Failure code
code code
Trouble No Right FNR switch signal input.
E03 DDK3KA TM
Description of
• No signal is input due to disconnected or grounded right FNR switch input signal system.
trouble
Controller
• Cannot judge the faulty line input signal.
reaction
Effect on
• Traveling is possible in steering wheel mode after the machine is stopped.
machine
Related
• Can be checked with the monitoring function (Code: 40907, D-IN-17, D-IN-18 or D-IN-19).
information

2) Disconnect connectors FS4 and L12.
Wiring harness between FS4 (Female) (2) - L12

(Female) (1)

Wiring harness 2) Disconnect connectors FS4 and L12.
discontinuity
1 (Disconnection or 3) Connect T-adapter.
defective contact)
Wiring harness between L62 (Female) (25) - L12
(Female) (2)

(Female) (3)

(Female) (4)
Possible Causes
and Standard
Values
Wiring harness
2 Between L62 (Female) (25) - L12 (Female) (2) - body Resistance 1 MΩ and above
ground fault
Between L62 (Female) (15) - L12 (Female) (3) - body Resistance 1 MΩ and above
Between L62 (Female) (5) - L12 (Female) (4) - body Resistance 1 MΩ and above

Right FNR switch = F Resistance 1 Ω and below

Between L12 (Male) (2) -
(1) Other than above Resistance 1 MΩ and above
Defective right
3
FNR switch Right FNR switch = N Resistance 1 Ω and below
Right FNR switch = R Resistance 1 Ω and below

40-156 3 WA380-5L

When right FNR switch mounted (Right FNR switch = On)
Possible Causes Defective Right FNR switch = F Voltage 20 - 30 V

transmission and Between L62 (25) and body
and Standard 4
fan pump motor Other than above Voltage 1 V and below
Values controller
Right FNR switch = N Voltage 20 - 30 V
Between L62 (15) and body
Other than above Voltage 1 V and below
Right FNR switch = R Voltage 20 - 30 V

Between L62 (5) and body
WA380-5L 40-157 3
Failure Code [DDK3KB]

Multiple Right FNR Switch Signal Input
Failure code
code code Trouble Multiple right FNR switch signal input
E03 DDK3KB TM
Description of
• Multiple signals are input due to short-circuit in joystick forward/reverse input signal system.
trouble
Controller
• Cannot judge input signal of joystick forward/reverse switch.
reaction
Effect on
machine
Related
information

Hot short in
wiring harness Between L62 (Female) (25)/ L12 (Female) (2) -
1 (Contact with Voltage 1 V and below
body
24V wiring
harness) Between L62 (Female) (15)/ L12 (Female) (3) -
body
Between L62 (Female) (5)/ L12 (Female) (4) -

body

Between L12 (Male) (2) Right FNR switch = F Resistance 1 Ω and below
- (1) Other than above Resistance 1 MΩ and above
Possible Defective right
2
Causes and FNR switch Right FNR switch = N Resistance 1 Ω and below
Between L12 (Male) (3)
Standard
Values
Between L12 (Male) (4) Right FNR switch = R Resistance 1 Ω and below

Defective Right FNR switch = F Voltage 20 - 30 V

transmission Between L62 (25) and
3 body
and fan pump Other than above Voltage 1 V and below
motor controller
Right FNR switch = N Voltage 20 - 30 V
Between L62 (15) and
body

Between L62 (5) and
body
40-158 3 WA380-5L
When multi function mono lever mounted
WA380-5L 40-159 3

No Input Signal to Joystick Forward/Reverse Switch
Failure code
code code Trouble No input signal to joystick forward/reverse switch.
E03 DDK4KA TM
Description of • Signal is not input because of disconnection or short circuit with chassis ground in joystick forward/
trouble reverse input signal system.
Controller
• Cannot judge input signal in corresponding line.
reaction
Effect on
machine
Related
information


(Female) (1)

Disconnection 2) Disconnect connectors L6237nd L12.
(or defective
contact) in wiring
harness
(Female) (2)
Possible
Causes and Wiring harness between L62 (Female) (15) - L37
Standard (Female) (3)
Values
(Female) (4)

Wiring harness between L62 (Female) (25) - L37 1 MΩ and

Short circuit with Resistance
2 chassis ground (Female) (2) above
in wiring harness
Resistance
(Female) (3) above

Resistance
(Female) (4) above
40-160 3 WA380-5L

When joystick forward/reverse

switch is at "F"
Between L12
(Male) (2) - (1) When joystick forward/reverse 1 MΩ and
switch is not at "F" Resistance
above
Defective
3 joystick forward/ When joystick forward/reverse Resistance 1 Ω and below
reverse switch switch is at "N"
Between L12
switch is not at "N" Resistance
above
When joystick forward/reverse

switch is at "R"
Between L12
switch is not at "R" Resistance
above
Possible
Causes and
Standard
Values
5) Turn joystick switch ON
When joystick switch FNR switch is

Voltage 20 - 30 V
at "F"
Between L62
Defective (25) and body
transmission When joystick switch FNR switch is
4 Voltage 1 V and below
and fan pump not at "F"
motor controller
Voltage 20 - 30 V
at "N"
Between L62
(15) and body
not at "N"

Voltage 20 - 30 V
at "R"
Between L62
(5) and body
not at "R"
Related electrical circuit diagram
WA380-5L 40-161 3

Multiple Joystick Forward/Reverse Switch Signals are Input
Failure code
code code
Trouble Multiple joystick forward/reverse switch signals are input.
E03 DDK4KB TM
Description of
• Multiple signals are input due to short-circuited right FNR switch input signal system.
trouble
Controller
• Cannot judge the FNR switch input signal.
reaction
Effect on
machine
Related
information

Hot short in 3) Connect T-adapter.
wiring
harness 4) Turn starting switch ON.
1 (Contact
with Between L62 (Female) (25)/ L12 (Female) (2) - chassis ground Voltage 1 V and below
24V wiring
harness) Between L62 (Female) (15)/ L12 (Female) (3) - chassis ground Voltage 1 V and below
Between L62 (Female) (5)/ L12 (Female) (4) - chassis ground Voltage 1 V and below

Between L12 When joystick forward/reverse switch is at "F" Resistance 1 Ω and below
Defective
(Male) (2) - (1)
joystick When joystick forward/reverse switch is not at "F" Resistance 1 MΩ and above
2 forward/
Possible reverse Between L12 When joystick forward/reverse switch is at "N" Resistance 1 Ω and below
Causes and switch (Male) (3) - (1)
When joystick forward/reverse switch is not at "N" Resistance 1 MΩ and above
Standard
Values
Between L12 When joystick forward/reverse switch is at "R" Resistance 1 Ω and below
(Male) (4) - (1)
When joystick forward/reverse switch is not at "R" Resistance 1 MΩ and above


Defective
transmissio Between L62 When joystick switch FNR switch is at "F" Voltage 20 - 30 V
n and fan (25) - chassis
3 pump ground When joystick switch FNR switch is not at "F" Voltage 1 V and below
motor
controller
Between L62 When joystick switch FNR switch is at "N" Voltage 20 - 30 V
(15) - chassis
ground When joystick switch FNR switch is not at "N" Voltage 1 V and below
Between L62 When joystick switch FNR switch is at "R" Voltage 20 - 30 V

(5) - chassis
ground When joystick switch FNR switch is not at "R" Voltage 1 V and below
40-162 3 WA380-5L
WA380-5L 40-163 3
Failure Code [DDK5LD]

Hot Short in Joystick Shift_Up/Shift_Down Switch
Failure code
code code Trouble Hot short in joystick SHIFT_UP/SHIFT_DOWN switch
E03 DDK5LD TM
Description of
• Joystick SHIFT_UP/SHIFT_DOWN switch signal is input for 30 seconds continuously.
trouble
Controller
• Ignores input signal.
reaction
• Gear is shifted up or down once, then it cannot be shifted up or down with the joystick SHIFT_UP or
Effect on
SHIFT_DOWN switch.
machine
• Operate can shift gear in auto shift mode or steering wheel mode.
Related
• This failure can be checked with monitoring function (Code: 40906, D-IN-12, DIN-13).
information

2) Disconnect L63 and L37.
Hot short in 4) Turn starting switch ON.
wiring harness
1 (Contact with
Between L63 (female) (9), L37 (female) (8) - Voltage 1 V and below
24V wiring chassis ground
harness)
Between L63 (female) (19), L37 (female) (6) - Voltage 1 V and below
chassis ground

When switch is at
Defective Between L37 (Male) (8) SHIFT_UP
joystick
2 SHIFT_UP/ - (1)
Possible When switch is not at
SHIFT_DOWN above position Resistance 1 MΩ and above
Causes and switch
Standard When switch is at
Values Resistance 1 Ω and below
Between L37 (Male) (6) SHIFT_DOWN
- (1)
When switch is not at
above position

When switch is at
Defective Voltage 20 - 30 V
Between L63 (9) - SHIFT_UP
transmission
3 chassis ground
and fan pump When switch is not at
motor controller Voltage 1 V and below
above position
When switch is at
Voltage 20 - 30 V
Between L63 (19) - SHIFT_DOWN
chassis ground
When switch is not at
above position
40-164 3 WA380-5L
WA380-5L 40-165 3

No Input Signal from Forward-Reverse Lever
Failure code
code code Trouble No input signal from Forward-reverse lever.
E03 DDK6KA TM
Description of
• No signal is input due to disconnected or grounded forward-reverse input signal system.
trouble
Controller
• Cannot judge the faulty line (F, N or R) input signal.
reaction
Effect on • Traveling is impossible with the lever positioned where an Error alarm is caused (Forward or reverse).
machine • Traveling is possible in right FNRSW mode when right FNRSW is mounted.
Related
information
Forward-reverse
1 lever positioned Make sure that the lever is not positioned neutral.
incorrectly

Wiring harness Wiring harness between L62 (Female) (36) - L04

discontinuity Resistance 1 Ω and below
(Female) (2).
2 (Disconnection
or defective Wiring harness between L62 (Female) (26) - L04
contact) Resistance 1 Ω and below
(Female) (3).

(Female) (4).

Possible
Causes and Between L62 (Female) (36)/L04 (Female) (2) -
Standard Wiring harness body.
3
Values ground fault
Between L62 (Female) (26)/L04 (Female) (3) -
body.

body.

Right FNR switch = F Voltage 20 - 30 V

Defective - body
4 forward-reverse
lever Right FNR switch = N Voltage 20 - 30 V
- body

- body
40-166 3 WA380-5L


Possible Between L62 (36) -
Defective body
Causes and transmission Other than above Voltage 1 V and below
5
Standard and fan pump
Values motor controller Right FNR switch = N Voltage 20 - 30 V
Between L62 (26) -
body

Between L62 (16) -
body
WA380-5L 40-167 3

Multiple Forward-Reverse Lever Signal Input
Failure code
code code
Trouble Multiple Forward-reverse lever signal input.
E03 DDK6KB TM
Description of
• Multiple signals are input due to short-circuited forward-reverse lever input signal system.
trouble
Controller
• Stops traveling (Neutral state).
reaction
Effect on • Traveling is impossible with the lever positioned where an Error alarm is caused (Forward or reverse).
machine • Traveling is possible in right FNRSW mode when right FNRSW is mounted.
Related
information

Wiring harness
hot-shorted 4) Turn starting switch ON.
1 incorrectly
(Coming in Between L62 (Female) (36)/L04 (Female) (2) - body. Voltage 1 V and below
contact with 24 V
wiring harness) Between L62 (Female) (26)/L04 (Female) (3) - body. Voltage 1 V and below
Between L62 (Female) (16)/L04 (Female) (4) - body. Voltage 1 V and below

Forward-reverse lever =
Voltage 20 - 30 V
Between L04 (Male) (2) - F
body
Defective
2 forward-reverse Other than above Voltage 1 V and below
Possible Causes lever
and Standard Forward-reverse lever =
Voltage 20 - 30 V
Values Between L04 (Male) (3) - N
body
Forward-reverse lever =
Voltage 20 - 30 V
Between L04 (Male) (4) - R
body


Defective Between L62 (36) - body
3
fan pump motor
controller Right FNR switch = N Voltage 20 - 30 V
Between L62 (26) - body

40-168 3 WA380-5L
WA380-5L 40-169 3
Failure Code [DDS5KA]

Steering Pressure Switch Open
Failure code
code code Trouble Steering pressure switch disconnected.
E03 DDS5KA TM
Description of
• Both N.C and N.O signals of the steering pressure switch are open simultaneously.
trouble
Controller
• Turns electric emergency motor relay output OFF.
reaction
• The auto emergency steering does not operate (However, the emergency steering can be operated
Effect on
manually).
machine
• Self-check of the emergency steering does not work.
Related • Operate the emergency steering manually if the steering pressure is zero.
information • Can be checked with the monitoring function (Code: 40905, D-IN-0 or D-IN-1).

Engine stopped Resistance 1 Ω and below
Between R36 (Male) (C) Open to atmosphere

Defective - (A) (Reference)
1 steering
pressure switch Engine started Resistance 1 MΩ and above
Engine stopped Resistance 1 MΩ and above
Between R36 (Male) (B) Open to atmosphere

- (A) (Reference)
Engine started Resistance 1 Ω and below

Causes and 2) Disconnect connectors L61 and R36.
Standard 3) Connect T-adapter.
Values Wiring harness
discontinuity Wiring harness between L61 (Female) (17) - R36
2 (Disconnection Resistance 1 Ω and below
(Female) (C)
or defective
contact) Wiring harness between L61 (Female) (23) - R36
(Female) (B)
Wiring harness between - R36 (Female) (A) - body Resistance 1 Ω and below

Defective
transmission Engine stopped Voltage 1 V and below
3 Between L61 (17) -
and fan pump
motor controller body Engine started Voltage 20 - 30 V
Between L61 (23) - Engine stopped Voltage 20 - 30 V

body Engine started Voltage 1 V and below
40-170 3 WA380-5L
WA380-5L 40-171 3
Failure Code [DDS5KB]

Steering Pressure Switch Grounded
Failure code
code code Trouble Steering pressure switch grounded.
E03 DDS5KB TM
Description of
• Both N.C and N.O signals of the steering pressure switch are closed simultaneously.
trouble
Controller
• Turns electric emergency motor relay output OFF.
reaction
Effect on • Auto emergency steering does not operate (However, emergency steering can be operated manually).
machine • Self-check of the emergency steering does not work.
Related • Operate emergency steering manually if the steering pressure is zero.

information • Can be checked with the monitoring function (Code: 40905, D-IN-0 or D-IN-1).

Engine stopped Resistance 1 Ω and below
Between R36 (Male) (C) Open to atmosphere

Defective - (A) (Reference)
1 steering
pressure switch Engine started Resistance 1 MΩ and above
Engine stopped Resistance 1 MΩ and above
Between R36 (Male) (B) Open to atmosphere

- (A) (Reference)
Engine started Resistance 1 Ω and below

Possible
Standard 2) Disconnect connectors L61 and R36.
Values 3) Connect T-adapter.
Wiring harness
2 Between L61 (Female) (17)/R36 (Female) (C) -
ground fault Resistance 1 MΩ and above
body
Between L61 (Female) (23)/R36 (Female) (B) -

body

Defective
3 transmission Engine stopped Voltage 1 V and below
and fan pump Between L61 (17) -
motor controller body Engine started Voltage 20 - 30 V
Between L61 (23) - Engine stopped Voltage 20 - 30 V

body Engine started Voltage 1 V and below
40-172 3 WA380-5L
WA380-5L 40-173 3
Failure Code [DDT0L4]

Manual/Auto-Shift Selector Switch Selection Failure
Failure code
code code
Trouble Manual/auto-shift selector switch selection failure
— DDT0L4 TM
Description of
• Signals of an incorrect combination were input from the manual/auto-shift selector switch.
trouble
Controller
• Switches to the manual shift mode.
reaction
Effect on
• The position of the manual/auto-shift selector switch does not match the shift mode.
machine
Related • The current shift mode selection can be checked with the monitoring function (Code: 41700) and the auto-shift
information indicator.

2) Disconnect connectors L61 and S22.
Wiring harness between L61 (Female) (14) - S22

discontinuity (Female) (2)
1
(Disconnection or
defective contact) Wiring harness between L61 (Female) (8) - S22
(Female) (3)

(Female) (4)

2 Wiring harness
ground fault
Between L61 (Female) (14)/S22 (Female) (2) - body Resistance 1 MΩ and above
Possible Causes 1) Turn starting switch OFF.

and Standard 2) Disconnect connector S22.
Values
Manual shift Resistance 1 MΩ and above
Between S22 (Male) (1) - Auto-shift L Resistance 1 Ω and below

(2)
Auto-shift M Resistance 1 MΩ and above
Auto-shift H Resistance 1 MΩ and above
Defective Manual shift Resistance 1 MΩ and above

3 manual/auto-shift
selector switch
(Overseas) Between S22 (Male) (1) - Auto-shift L Resistance 1 MΩ and above
(3)
Auto-shift M Resistance 1 Ω and below
Auto-shift H Resistance 1 MΩ and above
Manual shift Resistance 1 MΩ and above
Between S22 (Male) (1) - Auto-shift L Resistance 1 MΩ and above

(4)
Auto-shift M Resistance 1 MΩ and above
Auto-shift H Resistance 1 Ω and below
40-174 3 WA380-5L

Manual shift Resistance 1 V or above
Auto-shift L Resistance 1 V or below

Between L61 (Female)
(14) - body Auto-shift M Resistance 1 V or above
Auto-shift H Resistance 1 V or above

Possible Causes Defective
transmission and Manual shift Resistance 1 V or above
and Standard 4 fan pump motor
Values controller Auto-shift L Resistance 1 V or above
(8) - body Auto-shift M Resistance 1 V or below
Auto-shift H Resistance 1 V or above
Manual shift Resistance 1 V or above
Auto-shift L Resistance 1 V or above

(2) - body Auto-shift M Resistance 1 V or above
Auto-shift H Resistance 1 V or below
WA380-5L 40-175 3
Failure Code [DDT4LD]

Ground Fault in Transmission Cut-off Switch
Failure code
code code Trouble Ground fault of transmission cut-off setting switch.
E01 DDT4LD TM
Description of • Due to ground fault of the transmission cut-off setting switch system, a cut-off setting signal remains as
trouble input.
Controller
—
reaction
Effect on
• The transmission cut-off point cannot be reset.
machine
Related
information

2) Disconnect connector S05.
Defective
transmission
1 Cutoff setting switch =
and fan pump Resistance 1 Ω and below
motor controller Between S05 (Male) ON
(4) - (3) Cutoff setting switch =
OFF
Causes and 2) Disconnect connector L61 and S05.
Standard 2 Wiring harness
ground fault 3) Connect T-adapter.
Values

2) Disconnect connector L61 and S05.
Defective 4) Turn starting switch ON.
transmission
3 Cutoff setting switch =
and fan pump Voltage 1 V and below
motor controller ON
Between L61 (5) -
body Cutoff setting switch =
Voltage 20 - 30 V
OFF
40-176 3 WA380-5L
WA380-5L 40-177 3
Failure Code [DDW9LD]

Short in Kickdown Switch System
Failure code
code code Trouble Ground fault of kickdown switch system.
E01 DDW9LD TM
Description of
• Due to ground fault of the kickdown switch system, kickdown cannot be turned OFF.
trouble
Controller
• Cannot perform kickdown control after performing it once at ground fault.
reaction
Effect on
• Cannot perform kickdown control after performing it once at ground fault.
machine
Related
information

Defective 3) Connect T-adapter.
1
kickdown switch
Between L14 (Male) Kickdown switch = ON Resistance 1 Ω and below
(1) - (2) Kickdown switch = OFF Resistance 1 MΩ and above

Causes and 2) Disconnect connector L61 and L14.
ground fault
Values
body

2) Disconnect connector L61 and 14.
transmission 4) Turn starting switch ON.
3
and fan pump
motor controller Kickdown switch = ON Voltage 1 V and below
Between L61 (12) -
body Kickdown switch = OFF Voltage 20 - 30 V
40-178 3 WA380-5L
Related electrical circuit diagram (Standard)
Related electrical circuit diagram (When mulit function mono lever is mounted)
WA380-5L 40-179 3
Failure Code [DDWLLD]

Ground Fault in Hold Switch System
Failure code
code code Trouble Ground fault of hold switch system.
E01 DDWLLD TM
Description of
• Due to ground fault of the hold switch system, the hold cannot be changed over.
trouble
Controller
• Cannot perform hold control after performing it once at ground fault.
reaction
Effect on
• Cannot perform hold control after performing it once at ground fault.
machine
Related
information

Defective hold 3) Connect T-adapter.
1
switch
Between L14 (Male) Hold switch = ON Resistance 1 Ω and below
(3) - (4) Hold switch = OFF Resistance 1 MΩ and above

Causes and 2) Disconnect connector L14.
ground fault
Values
body

2) Disconnect connector L62 and 14.
3
and fan pump
motor controller Hold switch = ON Voltage 1 V and below
Between L62 (38) -
body Hold switch = OFF Voltage 20 - 30 V
40-180 3 WA380-5L
Related electrical circuit diagram (Standard)
Related electrical circuit diagram (When mulit function mono lever is mounted)
WA380-5L 40-181 3
Failure Code [DF10KA]

No Input Signal in Gear Shift Lever
Failure code
code code Trouble No input signal of gear shift lever.
E01 DF10KA TM
Description of
• Due to disconnection of or ground fault of the gear shift lever system, no signal is input.
trouble
Controller • Cannot determine the input signal in the relevant shift range. The shift range is fixed to that before
reaction disconnection occurred.
Effect on
• The relevant gear speed cannot be achieved.
machine
Related
• Can be checked with the monitoring function (Code: 40906, D-IN-8, D-IN-9, D-IN-10, D-IN-11).
information


(Female) (1)

Wiring harness 3) Connect T-adapter.
discontinuity
1 (Disconnection
or defective Resistance 1 Ω and below
contact) (Female) (5)

(Female) (6)
Possible
Causes and Wiring harness between L63 (Female) (30) - L04
Standard (Female) (7)
Values
(Female) (8)

Between L63 (Female) (10) - L04 (Female) (5) -

body
Wiring harness
2 ground fault Between L63 (Female) (20) - L04 (Female) (6) -
body

body

body
40-182 3 WA380-5L

Shift range = 1 Voltage 20 - 30 V

Defective gear Shift range = 2 Voltage 20 - 30 V

3 Between L04 (6) - body
shift switch


Possible Between L04 (8) - body
Causes and Other than above Voltage 1 V and below
Standard 1) Turn starting switch OFF.
Values 2) Disconnect connector L63.
4) Turnstarting switch ON.

Between L63 (10) -
body
Defective
transmission Shift range = 2 Voltage 20 - 30 V
4 Between L63 (20) -
and fan pump body
motor controller Other than above Voltage 1 V and below

Between L63 (30) -
body

Between L63 (40) -
body
WA380-5L 40-183 3
Failure Code [DF10KB]

Multiple Gear Shift Lever Signals
Failure code Input of multiple gear shift lever signals
code code Trouble
No input of gear shift lever signal
E01 DF10KB TM
Description of
• Due to disconnection of or ground fault of the gear shift lever system, no signal is input.
trouble
Controller • Cannot determine the input signal in the relevant shift range. The shift range is fixed to that before
reaction disconnection occurred.
Effect on
• The relevant gear speed cannot be achieved.
machine
Related
• Can be checked with the monitoring function (Code: 40906, D-IN-8, D-IN-9, D-IN-10, D-IN-11).
information


Wiring harness Voltage 1 V and below
body
hot short-
1 circuiting
(Contacting 24-V Between L63 (Female) (20) - L04 (Female) (6) -
wiring harness) body

body

Possible body
Causes and
Standard 1) Turn starting switch OFF.
Values 2) Disconnect connectors L63 and L04.

Defective gear Shift range = 2 Voltage 20 - 30 V
2
shift switch Between L04 (6) - body


40-184 3 WA380-5L

4) Turnstarting switch ON.

Between L63 (10) -
body
Possible Other than above Voltage 1 V and below
Causes and Defective
transmission Shift range = 2 Voltage 20 - 30 V
Standard 3 Between L63 (20) -
and fan pump body
Values motor controller Other than above Voltage 1 V and below

Between L63 (30) -
body

Between L63 (40) -
body
WA380-5L 40-185 3
Failure Code [DGF1KX]

Transmission Oil Temperature Sensor System Failure
Failure code
code code Trouble Transmission oil temperature sensor system failure.
— DGF1KX TM
Description of • Due to Error of the transmission oil temperature sensor system, no transmission oil temperature signal
trouble can be input.
Controller
• Cannot determine the transmission oil temperature correctly.
reaction
Effect on
• Gear shift shock occurs.
machine
Related
• Can be checked with the monitoring function (Code: 41500, ECMV OIL TEMP).
information

2) Disconnect connector TM.T.
transmission oil
1
temperature At normal temperature
sensor Between TM.T. (male) Resistance 35 - 50 kΩ
25° C (77° F)
(1) - (2)
At 100° C (212° F) Resistance 3.1 - 4.5 kΩ

2) Disconnect connectors L61 and TM.T.
2
Possible ground fault
Between L61 (Female) (9)/TM.T (Female) (1) -
Causes and Resistance 1 MΩ and above
body
Standard
Values Wiring harness 1) Turn starting switch OFF.
discontinuity 2) Disconnect connector L61 and TM.T.
(Disconnection 3) Connect T-adapter.
3 or defective
contact)
Wiring harness between L61 (Female) (9) - TM.T
Resistance 1 Ω or below
(Female) (1).

4 transmission
and fan pump At normal temperature
motor controller Between L61 (female) Resistance 35 - 50 kΩ
25° C (77° F)
(9) - body
40-186 3 WA380-5L
WA380-5L 40-187 3
Failure Code [DGR2KA]

Rear Brake Oil Temperature Sensor System Open
Failure code
code code Trouble Rear brake oil temperature sensor system disconnection.
E01 DGR2KA TM
Description of • Due to disconnection of the rear brake oil temperature sensor system, no rear brake oil temperature
trouble signal can be input.
Controller
• Assumes that the rear brake oil temperature is low.
reaction
Effect on
• Does not issue a brake oil temperature alarm.
machine
Related
• Can be checked with the monitoring function (Code: 30202, R BRAKE OIL).
information

Defective rear 3) Connect T-adapter.
brake oil
1
sensor Between R56. (male) Resistance 35 - 50 kΩ
25° C (77° F)
(1) - (2)

2) Disconnect connectors L61, L63, and R56.
Wiring harness
discontinuity Wiring harness between L61 (Female) (20) - R56
2 (Disconnection (Female) (1). Resistance 1 MΩ and above
Possible or defective
Causes and contact) Wiring harness between R56 (Female) (2) - L63
(Female) (21) (31). Resistance 1 MΩ and above
Standard
Values
Wiring harness between R56 (Female) (2) - body. Resistance 1 MΩ and above
Wiring harness 1) Turn starting switch OFF.

discontinuity 2) Disconnect connector L61 and R56.
3 or defective
contact)
Wiring harness between L61 (Female) (20) - R56 Resistance 1 Ω or below
(Female) (1).

4 transmission
and fan pump At normal temperature
25° C (77° F)
(20) - body
40-188 3 WA380-5L
WA380-5L 40-189 3
Failure Code [DGR2KB]

Ground Fault In Rear Brake Oil Temperature Sensor System
Failure code
code code Trouble Ground fault of rear brake oil temperature sensor system.
E01 DGR2KB TM
Description of • Due to ground fault of the rear brake oil temperature sensor system, no rear brake oil temperature signal
trouble can be input.
Controller
• Assumes that the rear brake oil temperature is high.
reaction
Effect on
• Continue to issue a brake oil temperature alarm.
machine
Related
• Can be checked with the monitoring function (Code: 30202, R BRAKE OIL).
information

Defective rear 3) Connect T-adapter.
brake oil
1
sensor Between R56. (male) Resistance 35 - 50 kΩ
25° C (77° F)
(1) - (2)

Causes and 2) Disconnect connectors L61and R56.
ground fault
Values
Between L61 (Female) (20)/R56 (Female) (1) -
body. Resistance 1 MΩ or above

transmission
3 and fan pump At normal temperature
25° C (77° F)
(20) - body
40-190 3 WA380-5L
WA380-5L 40-191 3
Failure Code [DHT1KX]

Transmission Cut-off (Left Brake Pressure Sensor) Signal Open
Failure code
code code Transmission cut-off (Left brake pressure sensor) signal
Trouble discontinuity.
E01 DHT1KX TM
Description of • Due to discontinuity of the left brake pressure sensor signal system, no oil pressure sensor signal for the
trouble left brake oil pressure can be input.
Controller
• Cancels the transmission cut-off function.
reaction
Effect on • Does not perform transmission cut-off when the left brake is stepped on while the transmission cut-off
machine function is on.
Related • Left brake oil pressure can be checked with the monitoring function (Code: 41100, L.H. BRAKE).
information • Can be checked by stepping on the left brake while the transmission cut-off function is on.

4) Start engine.
5) Step on the left brake.
1 Defective brake
pressure sensor Between (2) - (1) (Power supply) Voltage 20 - 30 V
Between (3) - (1) (Signal) Voltage 0.7 - 5.3 V

L10
Between (3) - (1) (Note: when open to
Voltage 0.5 - 1.5 V
atmosphere)

Possible 2) Disconnect connectors L61 and L10.
Causes and 3) Connect T-adapter.
Standard Wiring harness
Values discontinuity Wiring harness between L61 (Female) (19) - L10
2 (Disconnection Resistance 1Ω or below
(Female) (3).
or defective
contact) Wiring harness between L61 (Female) (16) - L10
Resistance 1Ω or below
(Female) (2).
Wiring harness between L10 (Female) (1) - body. Resistance 1Ω or below

Defective
3 5) Step on the left brake.
and fan pump
motor controller
Between (16) - body (Power supply) Voltage 20 - 30 V
L61
Between (19) - body (Signal) Voltage 0.7 - 5.3 V
40-192 3 WA380-5L
WA380-5L 40-193 3
Failure Code [DLE2KA]

Engine Speed Sensor Open
Failure code
code code Trouble Engine revolution sensor system discontinuity.
E03 DLE2KA TM
Description of
• Due to discontinuity of the engine revolution sensor system, no engine speed signal can be input.
trouble
Controller
• Cannot detect engine speed. (Assumes that engine speed is 2,100 rpm.)
reaction
Effect on
• Gear shift shock may occur.
machine
Related —
information

2) Disconnect connectors L62 and E27.
discontinuity
1 (Disconnection Wiring harness between L62 (Female) (10) - E27
or defective (Female) (1).
contact)
Wiring harness between L62 (Female) (39) - E27
Possible (Female) (2).
Causes and
Standard Defective engine 2) Disconnect connectors E27.
Values 2 revolution 3) Connect T-adapter.
sensor
Between E27 (Male) (1) - (2). Resistance 500 - 1,000 Ω

2) Disconnect connectors L62.
3 and fan pump
motor controller
Voltage (Measured in
Between L62 (10) - (39) Voltage 0.5 V or above
AC range)
40-194 3 WA380-5L
Failure Code [DLE2LC]

Engine Speed Sensor Shorted
Failure code
code code Trouble Engine revolution sensor failure.
E03 DLE2LC TM
Description of
• Due to ground fault of the engine revolution sensor system, no engine speed signal can be input.
trouble
Controller
• Cannot detect engine speed. (Assumes that engine speed is 2,100 rpm.)
reaction
Effect on
• Gear shift shock may occur.
machine
Related —
information

1 ground fault or
short-circuiting Between L62 (Female) (10) - E27 (Female) (1) -
Resistance 1MΩ or above
body.
Causes and Defective engine 2) Disconnect connector E27.
Standard 2 revolution 3) Connect T-adapter.
Values sensor
Between E27 (Male) (1) - (2). Resistance 500 - 1,000 Ω

3
and fan pump
motor controller
Voltage (Measured in
Between L62 (10) - (39) Voltage 0.5 V or above
AS range)
WA380-5L 40-195 3
Failure Code [DLT3KA]

Speed Sensor System Open
Failure code
code code Speed sensor transmission output shaft revolution system
Trouble discontinuity
E03 DLT3KA TM
Description of • Due to discontinuity of the speed sensor transmission output shaft revolution system, no speed sensor
trouble signal is input.
Controller
• Cannot recognize the travelling speed.
reaction
Effect on • Indication of the vehicle speed stays at 0 km/h.

machine • Shift up cannot be performed in the auto-shift mode.
Related —
information

2) Disconnect connectors L62 and REV.OUT.
discontinuity
1 (Disconnection Wiring harness between L62 (Female) (20) -
or defective REV.OUT (Female) (1).
contact)
Possible Wiring harness between L62 (Female) (29) -
Causes and REV.OUT (Female) (2).
Standard
Values 2) Disconnect connector REV.OUT.
Defective speed
sensor
Between REV.OUT (Male) (1) - (2). Resistance 500 - 1,000 Ω

Defective 2) Disconnect connectors L62.
transmission 3) Connect T-adapter.
3
and fan pump
motor controller
Between L62 (Female) (20) - (29) Resistance 500 - 1,000 Ω
40-196 3 WA380-5L
Failure Code [DT20KB]

Ground Fault In Indicator Lamp System (Transmission Cut-off Switch)
Failure code
code code Ground fault of built-in indicator lamp system of transmission cut-
Trouble off switch
— DT20KB TM
Description of • Due to ground fault of the built-in indicator lamp system of transmission cut-off switch, no output goes to
trouble the indicator lamp.
Controller
• No action.
reaction
Effect on
• The indicator lamp built in the transmission cut-off switch does not come on.
machine
Related
—
information

1
ground fault
Between L63 (Female) (8)/S03 (Female) (5) - body Resistance 1Ω or above

Defective built in 3) Connect T-adapter.
Possible
Causes and 2 indicator lamp of
transmission
4) Turn on starting switch.
Standard cut-off switch Cutoff switch = ON Voltage 17 - 30 V
Values Between S03 (5) - (6)
Cutoff switch = OFF Voltage 1 V or below

3
and fan pump
motor controller Cutoff switch = ON Voltage 17 - 30 V
Cutoff switch = OFF Voltage 1 V or below
WA380-5L 40-197 3
Failure Code [DW7BKA]

Fan Pump Reverse Solenoid System Open
Failure code
code code Trouble Fan pump reverse solenoid system discontinuity.
E01 DW7BKA TM
Description of • Due to disconnection or hot short-circuiting of the fan pump reverse solenoid system, no output goes to
trouble the fan reverse solenoid.
Controller
• Turns OFF output to the fan reverse solenoid.
reaction
Effect on
• Cannot reverse rotation of the fan.
machine
Related
—
information

2) Disconnect connector GR2.
Defective fan 3) Connect T-adapter
1
reverse solenoid
Between GR2 (Male) (1) - (2) Resistance 35 - 45 Ω
Causes and Wiring harness 2) Disconnect connectors L63 and GR2.
Standard 2 (Disconnection
Values or defective Wiring harness between L63 (Female) (28) - GR2
contact) Resistance 1Ω or below
(Female) (1)

Defective 2) Disconnect connector L63.
3
and fan pump
motor controller
40-198 3 WA380-5L
Failure Code [DW7BKB]

Fan Reverse Solenoid System Shorted
Failure code
code code Trouble Fan pump reverse solenoid system short-circuiting.
E01 DW7BKA TM
Description of • Due to short-circuiting of the fan pump reverse solenoid system, no output goes to the fan reverse
trouble solenoid.
Controller
reaction
Effect on
machine
Related
—
information

2) Disconnect connector GR2.
Defective fan 3) Connect T-adapter
1
reverse solenoid
Between GR2 (Male) (1) - (2) Resistance 35 - 45 Ω
Causes and 2) Disconnect connectors L63 and GR2.
Standard Wiring harness 3) Connect T-adapter.
2
Values ground fault
Wiring harness between L63 (Female) (28) - GR2
(Female) (1)

3
and fan pump
motor controller
WA380-5L 40-199 3
Failure Code [DW7CKA]

Switch Pump Cut-off Relay Open
Failure code
code code Trouble Switch pump cut-off relay discontinuity
E01 DW7CKA TM
Description of • Due to discontinuity of the transmission pump cut-off relay system, no output goes to the transmission
trouble pump cut-off relay.
Controller
reaction
Effect on
machine
Related
—
information

Defective transmission pump 2) Disconnect connector L106.
cut-off relay (L130)

Standard Values 2 (Disconnection or defective Wiring harness between L63 (Female)
(27) - L106 (Male) (13).
Wiring harness between L106 (Male)

(14) and body

fan pump motor controller 3) Connect T-adapter.
Between L63 (Female) (27) - body. Resistance 200 - 400 Ω
40-200 3 WA380-5L
Failure Code [DW7CKB]

Switch Pump Cut-off Relay Ground Fault
Failure code
code code Trouble Switch pump cut-off relay ground fault.
E01 DW7CKB TM
Description of • Due to ground fault of the switch pump cut-off relay system, no output goes to the switch pump cut-off
trouble relay.
Controller
• Turns output to the transmission pump cut-off relay OFF.
reaction
Effect on
• Cannot turn transmission pump cut-off relay ON.
machine
Related
—
information

1 pump cut-off relay 3) Connect T-adapter.
(L106)

Causes and
Standard Values 2 Wiring
fault
harness ground 3) Connect T-adapter.
Between L63 (Female) (27)/L106 (Male) (13)

Resistance 1 MΩ or above
- body.

controller
Between L63 (Female) (27) - body. Resistance 200 - 400 Ω
WA380-5L 40-201 3
Failure Code [DX16KA]

Fan Pump EPC Solenoid System Open
Failure code
code code Trouble Fan pump EPC solenoid system discontinuity.
E01 DX16KA TM
Description of
• Due to discontinuity of the fan pump EPC solenoid system, no output goes to the fan pump EPC solenoid.
trouble
Controller
• No action.
reaction
Effect on
• Fan revolution reaches the limit.
machine
Related
—
information

Defective fan pump EPC 2) Disconnect connector R29.
solenoid system
Between R29 (Male) (1) - (2) Resistance 5 - 10 Ω

2) Disconnect connectors L63 and R29.
(36) - R29 (Female) (1).

(23) - R29 (Female) (2)

Between L63 (Female) (36) - (23). Resistance 5 - 10 Ω
40-202 3 WA380-5L
12
Failure Code [DX16KB]
Fan Pump EPC Solenoid System Ground Fault
Failure code
code code Trouble Fan pump EPC solenoid system ground fault.
E01 DX16KB TM
Description of
• Due to ground fault of the fan pump EPC solenoid system, no output goes to the fan pump EPC solenoid.
trouble
Controller
• Turns output to the fan pump EPC solenoid OFF.
reaction
Effect on
• Fan revolution reaches the limit.
machine
Related
—
information

Defective fan pump 2) Disconnect connector R29.
EPC solenoid
Between R29 (Male) (1) - (2) Resistance 5 - 10 Ω

Possible 2) Disconnect connectors L63 and R29.
Causes and
fault
Between L63 (Female) (36)/R29 (Female)

(1) - body.

controller
WA380-5L 40-203 3
Failure Code [DXH1KA]

Lock-up Clutch_ECMV Solenoid System Open
Failure code
code code Trouble Lock-up clutch _ECMV solenoid system discontinuity.
E01 DXH1KA TM
Description of • Due to discontinuity of the lock-up clutch ECMV solenoid system, no output goes to the lock-up
trouble clutch _ECMV.
Controller
• No action
reaction
Effect on
• The lock-up clutch cannot be engaged.
machine
Related
—
information

2) Disconnect connector LC.PS.
1 Defective lock-up 3) Connect T-adapter.
clutch _ECMV
Between LC.PS (Male) (1) - (2) Resistance 5 - 10 Ω

2) Disconnect connectors L63 and LC.PS.
(35) - LC.PS (Female) (1).

(23) - LC.PS (Female) (2)

40-204 3 WA380-5L
12
Failure Code [DXH1KB]
Lock-up Clutch ECMV Solenoid System Shorted
Failure code
code code Trouble Lock-up clutch _ECMV solenoid system short-circuiting.
E01 DXH1KB TM
Description of • Due to short-circuiting of the lock-up clutch ECMV solenoid system, no output goes to the lock-up
trouble clutch _ECMV.
Controller
• No action
reaction
Effect on
• The lock-up clutch cannot be engaged.
machine
Related
—
information

2) Disconnect connector LC.PS.
1 Defective lock-up 3) Connect T-adapter.
clutch _ECMV
Between LC.PS (Male) (1) - (2) Resistance 5 - 10 Ω

Possible 2) Disconnect connectors L63 and LC.PS.
Causes and
fault

LC.PS (Female) (1) - body.

controller
WA380-5L 40-205 3

1st_ECMV Solenoid System Open
Failure code
code code Trouble 1st_ECMV solenoid system discontinuity.
E03 DXH4KA TM
Description of
• Due to discontinuity of the 1st_ECMV solenoid system, no output goes to the 1s _ECMV.
trouble
Controller
• No action
reaction
Effect on
• "1st" cannot be engaged (Traveling in other speeds is possible).
machine
Related
—
information

2) Disconnect connector 1.PS.
1 Defective 1st_ECMV 3) Connect T-adapter.
Between 1.PS (Male) (1) - (2) Resistance 5 - 10 Ω

2) Disconnect connectors L63 and 1.PS.
(25) - 1.PS (Female) (1).

(13) - 1.PS (Female) (2)

40-206 3 WA380-5L
12
1st_ECMV Solenoid System Shorted
Failure code
code code Trouble 1st_ECMV solenoid system short-circuiting.
E03 DXH4KB TM
Description of
• Due to ground fault of the 1st_ECMV solenoid system, no output goes to the 1st_ECMV.
trouble
Controller
• No action
reaction
Effect on
• "1st" cannot be engaged (Traveling in other speeds is possible).
machine
Related
—
information

1 Defective 1st_ECMV 3) Connect T-adapter.

Possible 2) Disconnect connectors L63 and 1.PS.
Causes and
fault
Wiring harness between L63 (Female) (25)/

1.PS (Female) (1) - body.

controller
WA380-5L 40-207 3

2nd_ECMV Solenoid System Open
Failure code
code code Trouble 2nd_ECMV solenoid system discontinuity.
E03 DXH5KA TM
Description of
• Due to discontinuity of the 2nd_ECMV solenoid system, no output goes to the 2nd_ECMV.
trouble
Controller
• No action
reaction
Effect on
• "2nd" cannot be engaged (Traveling in other speeds is possible).
machine
Related
—
information

1 Defective 2nd_ECMV 3) Connect T-adapter.

(6) - 2.PS (Female) (1).

(3) - 2.PS (Female) (2)

40-208 3 WA380-5L

2nd_ECMV Solenoid System Shorted
Failure code
code code Trouble 2nd_ECMV solenoid system short-circuiting.
E03 DXH5KB TM
Description of
• Due to ground fault of the 2nd_ECMV solenoid system, no output goes to the 2nd_ECMV.
trouble
Controller
• No action
reaction
Effect on
• "2nd" cannot be engaged (Traveling in other speeds is possible).
machine
Related
—
information

1 Defective 2nd_ECMV 3) Connect T-adapter.

Causes and
fault


controller
WA380-5L 40-209 3

3rd_ECMV Solenoid System Open
Failure code
code code Trouble 3rd_ECMV solenoid system discontinuity.
E03 DXH6KA TM
Description of
• Due to discontinuity of the 3rd_ECMV solenoid system, no output goes to the 3rd_ECMV.
trouble
Controller
• No action
reaction
Effect on
• "3rd" cannot be engaged (Traveling in other speeds is possible).
machine
Related
—
information

1 Defective 3rd_ECMV 3) Connect T-adapter.

(16) - 3.PS (Female) (1).

(3) - 3.PS (Female) (2)

40-210 3 WA380-5L
3rd_ECMV Solenoid System Shorted

Failure code
code code Trouble 3rd_ECMV solenoid system short-circuiting.
E03 DXH6KB TM
Description of
• Due to ground fault of the 3rd_ECMV solenoid system, no output goes to the 3rd_ECMV.
trouble
Controller
• No action
reaction
Effect on
• "3rd" cannot be engaged (Traveling in other speeds is possible).
machine
Related
—
information

1 Defective 3rd_ECMV 3) Connect T-adapter.

Causes and
fault


controller
WA380-5L 40-211 3

R_ECMV Solenoid System Open
Failure code
code code Trouble R_ECMV solenoid system discontinuity.
E03 DXH7KA TM
Description of
• Due to discontinuity of the R_ECMV solenoid system, no output goes to the R_ECMV.
trouble
Controller
• No action
reaction
Effect on
• "R" cannot be engaged (Traveling in "F" is possible).
machine
Related
—
information

2) Disconnect connector R.PS.
1 Defective R_ECMV 3) Connect T-adapter.
Between R.PS (Male) (1) - (2) Resistance 5 - 10 Ω

2) Disconnect connectors L63 and R.PS.
(15) - R.PS (Female) (1).

(13) - R.PS (Female) (2)

40-212 3 WA380-5L
R_ECMV Solenoid System Shorted

Failure code
code code Trouble R_ECMV solenoid system short-circuiting.
E03 DXH7KB TM
Description of
• Due to ground fault of the R_ECMV solenoid system, no output goes to the R_ECMV.
trouble
Controller
• Turns output to the R_ECMV solenoid OFF.
reaction
Effect on
• "R" cannot be engaged (Traveling in "F" is possible).
machine
Related
—
information

2) Disconnect connector R.PS.
1 Defective R_ECMV 3) Connect T-adapter.
Between R.PS (Male) (1) - (2) Resistance 5 - 10 Ω

Possible 2) Disconnect connectors L63 and R.PS.
Causes and
fault

R.PS (Female) (1) - body.

controller
WA380-5L 40-213 3

F_ECMV Solenoid System Open
Failure code
code code Trouble F_ECMV solenoid system discontinuity.
E03 DXH8KA TM
Description of
• Due to discontinuity of the F_ECMV solenoid system, no output goes to the F_ECMV.
trouble
Controller
• No action
reaction
Effect on
• "F" cannot be engaged (Traveling in "R" is possible).
machine
Related
—
information

2) Disconnect connector F.PS.
1 Defective F_ECMV 3) Connect T-adapter.
Between F.PS (Male) (1) - (2) Resistance 5 - 10 Ω

2) Disconnect connectors L63 and F.PS.
(5) - F.PS (Female) (1).

(3) - F.PS (Female) (2)

40-214 3 WA380-5L
12
F_ECMV Solenoid System Ground Fault
Failure code
code code Trouble F_ECMV solenoid system ground fault.
E03 DXH7KB TM
Description of
• Due to ground fault of the F_ECMV solenoid system, no output goes to the F_ECMV.
trouble
Controller
• Turns output to the F_ECMV solenoid OFF.
reaction
Effect on
• "F" cannot be engaged (Traveling in "R" is possible).
machine
Related
—
information

2) Disconnect connector F.PS.
1 Defective F_ECMV 3) Connect T-adapter.
Between F.PS (Male) (1) - (2) Resistance 5 - 10 Ω

Possible 2) Disconnect connectors L63 and F.PS.
Causes and
fault

F.PS (Female) (1) - body.

controller
WA380-5L 40-215 3
Failure Code [DXHHKA]

4th_ECMV Solenoid System Open
Failure code
code code Trouble 4th_ECMV solenoid system discontinuity.
E03 DXHHKA TM
Description of
• Due to discontinuity of the 1st_ECMV solenoid system, no output goes to the 4th_ECMV.
trouble
Controller
• No action
reaction
Effect on
• "4th" cannot be engaged (Traveling in other speeds is possible).
machine
Related
—
information

1 Defective 4th_ECMV 3) Connect T-adapter.

(26) - 1.PS (Female) (1).

(13) - 4.PS (Female) (2)

40-216 3 WA380-5L
12
Failure Code [DXHHKB]
4th_ECMV Solenoid System Shorted

Failure code
code code Trouble 4th_ECMV solenoid system short-circuiting.
E03 DXHHKB TM
Description of
• Due to ground fault of the 4th_ECMV solenoid system, no output goes to the 4th_ECMV.
trouble
Controller
• Turns output to the 4th_ECMV solenoid OFF.
reaction
Effect on
• "4th" cannot be engaged (Traveling in other speeds is possible).
machine
Related
—
information

1 Defective 4th_ECMV 3) Connect T-adapter.
Between 4PS (Male) (1) - (2) Resistance 5 - 10 Ω

Causes and
fault


controller
WA380-5L 40-217 3
Failure Code [DY30MA]

Motor-Driven Emergency Steering Pump Failure
Failure code Motor-driven emergency steering pump failure (malfunction in
code code Trouble
manual mode )
E03 DY30MA TM
Description of • An activation signal for the motor-driven emergency steering motor (pump) (S-NET) is issued although
trouble motor driven emergency steering output is turned OFF.
Controller
• Turns motor-driven emergency steering output OFF.
reaction
• The motor-driven emergency steering motor (pump) operates although the motor-driven emergency
Effect on
steering switch is not operated.
machine
• The emergency steering operation indicator comes on.
• Check operation of the emergency steering motor with the monitoring function (Code: 40903 D-IN-30).
Related
• Check steering pressure drop with the monitoring function (Code: 40905 D-IN-0, D-IN-1).
information
• Failure code documentation "DY30ME" related to monitoring.

3) Connect T-adapter (Single-unit check).
Defective
emergency Between L105 (Male)
Relay = OFF Resistance 1 MΩ or above
steering relay (11) - (12).
1
(L126) (Power
and signal lines 1) Turn starting switch OFF.
short-circuited) 2) Disconnect connector L105.
3) Connect T-adapter (Single-unit check).
Defective 1) Turn starting switch OFF.

emergency 2) Disconnect two harnesses at 100B at both ends of emergency steering motor.
steering relay 3) Connect T-adapter.
(For driving
2 emergency
steering motor)
(Power and Between disconnected relay terminals Resistance 1 MΩ or above
Possible
Causes and signal lines
Standard Values short-circuited)

2) Disconnect connectors L63, L105 and R15, and line 396 (between emergency
steering
relay and emergency steering motor).
Short-circuiting
3 between Between L63 (Female) (7)/L105 (Female) (9) -
harnesses Voltage 1 V or below
body
Between L105 (Female) (12), R15 terminal, - body Voltage 1 V or below
Between line 396 (Emergency steering relay,

Voltage 1 V or below
emergency steering motor, and body)

Wiring harness 2) Disconnect connectors L54 and R37.
discontinuity
4 (Disconnection 3) Connect T-adapter.
or defective
contact) Wiring harness between L54 (Female) (3) - R37
(Female) (C).
40-218 3 WA380-5L

Emergency steering =
Defective Stopped
emergency
5
steering At open to atmosphere
pressure switch Between R37 (Male) Resistance 1 Ω or below
Possible (for reference)
(C) - (A)
Causes and
Standard Values Emergency steering =
Operating (Hi pressure) Resistance 1 Ω or below
(Operate in manual
mode.)

transmission 2) Disconnect connector L63.
6 and fan pump 3) Connect T-adapter.
motor controller
WA380-5L 40-219 3
Failure Code [DY30MC]

Motor-Driven Emergency Steering Pump Failure
Failure code Motor-driven emergency steering pump failure (Malfunction in
code code Trouble
manual mode).
E03 DY30MC TM
Description of • An activation signal for the motor-driven emergency steering motor (pump) (S-NET) is issued although
trouble motor driven emergency steering output is turned ON.
Controller
• Turns motor-driven emergency steering output OFF.
reaction
Effect on • The motor-driven emergency steering motor (pump) operates although the motor-driven emergency
machine steering switch is operated.
• Check operation of the emergency steering motor with the monitoring function (Code: 40903 D-IN-30).
Related
• Check steering pressure drop with the monitoring function (Code: 40905 D-IN-0, D-IN-1).
information
• See failure code documentation "DY30ME" related to monitoring.
1) Keep engine on for 10 seconds or longer and turn starting switch OFF.
2) Replace L126 relay with another relay of the same type.
3) Turn starting switch ON (for self-check).
Defective
emergency Issues this Failure code (DY30MC). Relay (L126) = Normal
steering relay
1 (L126) (Internal Does not issue this Failure code (DY30MC). Relay (L126) = Defective
discontinuity or
defective 1) Turn starting switch OFF.
contact) 2) Disconnect connector L105.
Between L105 (Male) 9 - 0 Resistance 200 - 400 Ω

2) Disconnect connectors L105, R15, R16, line 396 (between emergency steering relay
Possible and terminals at both ends of emergency steering motor), and line 030 (battery relay
and emergency steering relay).
Standard Values
Wiring harness Wiring harness between L105 (Female) (12) - R15
discontinuity Resistance 1 Ω or below
terminal
2 (Disconnection
or defective Wiring harness between R16 terminal - body Resistance 1 Ω or below
contact)
Line R01 (Battery relay and emergency steering
relay)
Line 396 (Emergency steering relay and

emergency steering motor)

Wiring harness 3) Connect Tadapter.
3
ground fault
Between L54 (Female) (3)/R37 (Female) (C) -
body
40-220 3 WA380-5L

Defective Stopped
emergency
4
steering At open to atmosphere
pressure switch Between R37 (Male) Resistance 1 Ω or below
(for reference)
(C) - (A)
Operating (Hi pressure) Resistance 1 MΩ or above
(Operate in manual
Possible mode.)
Causes and
Standard Values 1) Turn starting switch ON.
Between emergency Emergency steering =

Defective motor (+) terminal and Voltage 1 V or below
5 emergency Stopped
body
steering motor
Operating (Operate in Voltage 20 - 30 V
manual mode.)

transmission 2) Disconnect connector L63.
6 and fan pump 3) Connect T-adapter.
motor controller
WA380-5L 40-221 3
Failure Code [TM-1]

Open or Short in Kickdown Switch System
Failure code
code code Trouble Discontinuity or hot short-circuiting of kickdown switch system.
TM-1 — TM
Description of
• Due to discontinuity or hot short-circuiting of the kickdown switch system, kickdown cannot be performed.
trouble
Controller
• No action.
reaction
Effect on
• Cannot perform kickdown control by turning the kickdown switch ON.
machine
Related
information

1 Defective
kickdown switch
Between L14 (Male) Kickdown switch = ON Resistance 1 Ω or below
(1) - (2). Kickdown switch = OFF Resistance 1 MΩ or above

discontinuity 2) Disconnect connectors L61 and L14.
or defective
2 contact)
Possible (Female) (1).
Causes and Between L14 (Female) (2) - body Resistance 1 Ω or below
Standard Values
short-circuiting 2) Disconnect connectors L61 and L14.
★ In this case,
3 fuse A-2 burns 4) Turn starting switch ON.
out when the
switch is Between L61 (Female) (12)/L14 (Female) (1) -
operated. Voltage 1 V or below
body

transmission
4 and fan pump
Kickdown switch = ON Voltage 1 V or below
motor controller Between L61 (12) -
body
Kickdown switch = OFF Voltage 20 - 30 V
40-222 3 WA380-5L
Related electrical circuit diagram (For standard)
Related electrical circuit diagram (When multi function momo lever mounted)
WA380-5L 40-223 3
Failure Code [TM-2]

Hold Switch System Open Or Short
Failure code Hold switch system discontinuity or hot short-circuiting
code code Trouble
(No hold control performed by pressing hold switch)
TM-2 — TM
Description of • Due to discontinuity or hot short-circuiting of the hold switch system, the hold switch cannot be changed
trouble over.
Controller
• No reaction.
reaction
Effect on
• Hold control cannot be performed by pressing the hold switch.
machine
Related
information

1 Defective
kickdown switch
Between L14 (Male) Hold switch = ON Resistance 1 Ω or below
(3) - (4). Hold switch = OFF Resistance 1 MΩ or above

discontinuity
2 (Disconnection
or defective Resistance 1 Ω or below
Possible contact) (Female) (3).
Causes and Between L14 (Female) (4) - body Resistance 1 Ω or below
Standard Values
short-circuiting 2) Disconnect connectors L62 and L14.
★ In this case,
3 fuse A-2 burns 4) Turn starting switch ON.
out when the
switch is Between L61 (Female) (38)/L14 (Female) (3) -
operated. Voltage 1 V or below
body

transmission
4 and fan pump
Hold switch = ON Voltage 1 V or below
motor controller
Hold switch = OFF Voltage 20 - 30 V
40-224 3 WA380-5L
Related electrical circuit diagram (For standard)
Related electrical circuit diagram (When multi function momo lever mounted)
WA380-5L 40-225 3
Failure Code [TM-3]

Torque Converter Lock-up Switch System Failure
Failure code
code code Torque converter lock-up switch system failure (No lockup
Trouble performed or no lock-up cancellation performed)
TM-3 — TM
• Due to failure of the torque converter lock-up switch system, lock-up cannot be performed (Failure
Description of
associated with discontinuity) or lock-up cannot be cancelled normally (Failure associated with ground
trouble
fault).
Controller
• No reaction.
reaction
Effect on
• Lock-up or lock-up cancellation cannot be performed.
machine
• Torque converter lock-up switch input signal can be checked with the monitoring function (Code: 40905,
Related
D-IN-5).
information
• The service mode of the monitor can be used to check if the lock-up option is implemented or not..

Defective torque
1 converter
Torque converter lock-up
lock-up switch switch = ON Resistance 1 Ω or below
Between S06 (Male)
(4) - (3)
Other than above Resistance 1 MΩ or above

discontinuity
2 (Disconnection Wiring harness between L61 (Female) (18) - S06
Between S06 (Female) (3) - body Resistance 1 Ω or below

Possible short-circuiting 2) Disconnect connectors L61 and S06.
Causes and (Contacting 24V 3) Connect T-adapter.
Standard Values 4) Turn starting switch ON.
harness
3
★ In this case,
fuse A-2 burns Between L61 (Female) (18)/S06 (Female) (4) -
out when the Voltage 1 V or below
switch is body
operated.

Wiring harness 2) Disconnect connectors L61 and S06.
ground fault
Between L61 (Female) (18)/S06 (Female) 4 - body Resistance 1 MΩ or above

transmission
5 and fan pump
motor controller Torque converter lock-up
Between L61 (18) - switch = ON
body
40-226 3 WA380-5L
WA380-5L 40-227 3
Failure Code [TM-4]

Neutral Signal System Failure
Failure code
code code Trouble Neutralizer signal (Parking brake switch signal) system failure
TM-4 — TM
• Due to failure of the neutralizer signal (Parking brake switch signal) system, always the neutral state is
Description of
ON (Failure associated with hot short-circuiting) or FR operation is performed while the parking brake is
trouble
operated and traveling occurs with the brake engaged (Failure associated with discontinuity).
Controller
• No reaction.
reaction
Effect on
• The neutralizer cannot be controlled, or it is always operating.
machine
Related
• Parking brake input switch signal can be checked with the monitoring function (Code: 40907, D-IN-23).
information

Parking brake switch = ON Resistance 1 Ω or below

Between L01
Defective (Male) (1) - (3)
Parking brake switch = OFF Resistance 1 MΩ or above
1 parking brake
switch
Parking brake switch = ON Resistance 1 MΩ or above
Between L01
(Male) (2) - (3)
Parking brake switch = OFF Resistance 1 Ω or below
Between L01
Always Resistance 1 MΩ or above
(Male) (1) - (2)

2) Disconnect connectors PB and PS.
Causes and Defective
Standard Values 2 parking brake Between PB.PS (Male) 1 - 2 Resistance 10 - 40 Ω
solenoid
Between PB.PS (Female) 2 - body Resistance 1 Ω or below
Between PB.PS (Male) 1/2 - body Resistance 1 Ω or below

Wiring harness 2) Disconnect connectors L62 and L01.
3 (Disconnection
or defective Wiring harness between L62 (Female) (6) - L01
contact) Resistance 1 Ω or below
(Female) (2)

Wiring harness 2) Disconnect connectors L61, L01, and PB.PS.
short-circuiting 4) Turn starting switch ON.
4
(Contacting 24V
harness Between L62 (Female) (6)/L01 (Female) (2)
{PB.PS (Female) (1)} - body
40-228 3 WA380-5L

2) Disconnect connector DIODE.
To be measured from 2 side in Continuity Positive

Wiring harness diode range.
5 Between DIODE
ground fault
(Male) 2 - 1
To be measured from 1 side in
diode range. Continuity None
★ Replacing DIODE can also correct this failure.

ground fault - In 2) Disconnect connectors L62, L01 and PB.PS.
this case, the fuse 3) Connect T-adapter.
6 blows out when
the switch is Between L62 (Female) (6)/L01 (Female) (2) {PB.PS
operated. Resistance 1 MΩ or above
(Female) (1)} - body
Possible
When parking brake switch is

switched from OFF to ON Voltage 1 V or below
(Not released)
Defective
transmission and Parking brake switch = OFF
7 (Retained OFF) (Not Voltage 1 V or below
fan pump motor
controller released)
Between L62 (6) -
body
switched from ON to OFF Voltage 20 - 30 V
(Released)
Parking brake switch = ON

(Retained on) (Not Voltage 1 V or below
released)
WA380-5L 40-229 3
Failure Code [TM-5]

Emergency Steering Switch Signal System Failure
Failure code Emergency steering switch (motor-driven emergency steering
code code Trouble
operation switch) signal system failure
TM-5 — TM
Description of • Due to failure of the emergency steering switch (motor-driven emergency steering operation switch)
trouble signal system, emergency steering does not function. Or, emergency steering always functions.
Controller
• No reaction.
reaction
Effect on
• Emergency steering does not function. Or, emergency steering always functions.
machine
Related • Emergency steering switch input signal can be checked with the monitoring function (Code: 40906,
information DN-IN-14).

emergency
1
steering manual Emergency steering switch = ON Resistance 1 Ω or below
switch Between S19
(Male) (4) - (3) Emergency steering switch =
OFF

emergency 3) Connect T-adapter.
2 steering relay
(L126) Between L126 (Female) (3)/L126 (Female) (5) -
body

emergency 2) Disconnect connectors R15, R16 and both power lines (100sq).
Possible 3
steering
Causes and operation relay Between relay contacts. Resistance 1 MΩ or above
Standard Values
4 (Disconnection
or defective Wiring harness between L63 (Female) (29) - S19
(Female) (1)
Hot short- 1) Turn starting switch OFF.

circuiting 2) Disconnect connectors L63 and S19.
between 3) Connect T-adapter.
5
harnesses
(Contacting Between L63 (Female) (29)/S19 (Female) (1) -
24-V harness) body

2) Disconnect connectors L63, L105, L126 and S19.
6 Wiring harness
Between L63 (Female) S/S19 (Female) 1 - body Resistance 1 MΩ or above
40-230 3 WA380-5L

2) Disconnect connectors L63, L126 and S19.
Between L63 (Female) (29)/L126 (Female) (1)/

Wiring harness Resistance 1 MΩ or above
7 S19 (Female) (4) - body
short-circuiting
Causes and 4) Turn starting switch ON.
Standard Values
Between L126 (5)/R15 - body Resistance 1 MΩ or above

8
and fan pump
motor controller Between L63 Emergency steering switch = ON Voltage 20 - 30 V
(29) -body
Other than above Voltage 1 V or below
WA380-5L 40-231 3
Failure Code [TM-6]

Transmission Cut-off Switch System Open or Shorted
Failure code
code code Transmission cut-off switch system discontinuity or
Trouble ground fault
TM-6 — TM
• Due to discontinuity or ground fault of the transmission cut-off switch system, the transmission cut-off
Description of
mode cannot be enabled (Failure associated with discontinuity).
trouble
• Or the transmission cut-off mode cannot be cancelled (Failure associated with ground fault).
Controller
• No reaction.
reaction
Effect on
• The transmission cut-off mode cannot be enabled or cancelled.
machine
Related
information

1 transmission
cut-off switch Transmission cut-off switch = ON Resistance 1 Ω or below
Between S03
(Male) (4) - (3)
Transmission cut-off switch = OFF Resistance 1 MΩ or above

2 (Disconnection
(Female) (4)
contact)
Between S03 (Female) 3 - body Resistance 1 Ω or below
Hot short- 1) Turn starting switch OFF.

circuiting 2) Disconnect connectors L61 and S03.
between 3) Connect T-adapter.
Possible harnesses 4) Turn starting switch ON.
(Contacting 24-V
Causes and
harness)
Standard Values 3 ★ In this case,
fuse A-2
blows out Between L61 (Female) (11)/S03 (Female) (4) - body Voltage 1 V or below
when the
switch is
operated.

Wiring harness
ground fault
Between L61 (Female) (11)/S03 (Female) (4) - body Resistance 1 MΩ or above

5 transmission 4) Turn starting switch ON.
and fan pump
motor controller Transmission cut-off switch = ON Voltage 1 V or below
Between L61
(11) - body Transmission cut-off switch = OFF Voltage 20 - 30 V
40-232 3 WA380-5L
WA380-5L 40-233 3
Failure Code [TM-7]

Transmission Cut-off Setting Switch System Open or Shorted
Failure code
code code Transmission cut-off setting switch system discontinuity or hot
Trouble short-circuiting.
TM-7 — TM
Description of • Due to discontinuity or hot short-circuiting of the transmission cut-off setting switch system, the cut-off
trouble setting signal is left as input.
Controller
• No reaction.
reaction
Effect on
• The transmission cut-off point cannot be reset.
machine
Related
information

1 transmission
cut-off setting
Transmission cut-off switch = ON Resistance 1 Ω or below
switch Between S05
(Male) (4) - (3)
Transmission cut-off switch = OFF Resistance 1 MΩ or above

discontinuity 2) Disconnect connectors L61 and S05.
2 (Disconnection
or defective Wiring harness between L61 (Female) (5) - S05
Possible Resistance 1 MΩ or above
Causes and
Hot short- 2) Disconnect connectors L61 and S03.
circuiting
3 between 3) Connect T-adapter.
harnesses
Between L61 (Female) (5)/S03 (Female) (4) - body Voltage 1 V or below

2) Disconnect connector L61 and S05.
4
and fan pump
motor controller Transmission cut-off switch = ON Voltage 1 V or below
Between L61
(5) - body Transmission cut-off switch = OFF Voltage 20 - 30 V
40-234 3 WA380-5L
WA380-5L 40-235 3
Failure Code [TM-8]

Transmission Cut-off (Left Brake Sensor) Signal Shorted
Failure code
code code Trouble Transmission cut-off (left brake sensor) signal short-circuiting
TM-8 — TM
Description of • Due to short-circuiting of the left brake pressure sensor signal system, no signal for the left brake oil
trouble pressure sensor can be input.
Controller
• No reaction.
reaction
Effect on • Even when the left brake is not stepped ON, traveling in the neutral mode is not possible when
machine transmission cutoff is ON (When the transmission cut-off function is used).
Related • Left brake oil pressure can be checked with the monitoring function (Code: 41100, L.H. BRAKE).
information • Can be checked by stepping ON the left brake while the transmission cut-off function is ON.

4) Start engine.
Defective left 5) Step ON the left brake.
1 brake pressure
sensor Between L10 (2) - (1) (Power supply) Voltage 20 - 30 V
Between L10 (3) - (1) (Signal) Voltage 0.7 - 5.3 V
Between L10 (3) - (1) (Note: when open to atmosphere) Voltage 0.5 - 1.5 V
Possible
Standard Values Wiring harness 2) Disconnect connectors L61 and L10.
short-circuiting
Between L61 (Female) (19)/L10 (Female) (3) - body Voltage 1 V or below

Defective
transmission 4) Start engine.
3 5) Step ON the left brake.
and fan pump
motor controller
Between L61 (16) - body (Power supply) Voltage 20 - 30 V
Between L61 (19) - body (Signal) Voltage 0.7 - 5.3 V
40-236 3 WA380-5L
WA380-5L 40-237 3
Failure Code [TM-9A]

Joystick Shift Up/shift Down Switch System Failure
Failure code
code code Joystick SHIFT_UP/SHIFT_DOWN siwtch system failure
Trouble (discontinuity or ground fault)
TM-9A — TM
Description of • When operating the joystick, SHIFT_UP or SHIFT_DOWN action cannot be enabled (due to discontinuity
trouble or ground fault).
Controller
• No reaction.
reaction
• When operating the joystick, SHIFT_UP or SHIFT_DOWN action cannot be enabled (due to discontinuity
Effect on
or ground fault).
machine
• The gear can be shifted in the auto-shift or handle mode.
Related • Can be check with the monitoring function (Code: 40906, D-IN-12, D-IN-13).
information Note: The up/down switch (SHIFT_UP/SHIFT_DOWN) cannot be used in the auto-shift mode.

Wiring harness Wiring harness between L63 (Female) (9) - L37

discontinuity Resistance 1 Ω or below
(Female ) (8)
1 (Disconnetion or
defective
(Female ) (6)
Wiring harness between fuse A-(2) - L37 (Female )

(1) (In this case, FNR does not work either.)

ground fault 2) Disconnect connectors L63 and L37.
★ In this case, 3) Connect T-adapter.
fuse A-2
2 Between L63 (Female) (9)/L37 (Female) (8) - body Resistance 1 MΩ or above
blows out
when the
switch is Between L63 (Female) (19)/L37 (Female) (6) - body Resistance 1 MΩ or above
Possible operated
Causes and
Defective
joystick SHIFT_UP Resistance 1 Ω or below
3 SHIFT_UP/ Between L37 (Male) (1) - (2)
SHIFT_DOWN Other than above Resistance 1 MΩ or above
switch
SHIFT_DOWN Resistance 1 Ω or below
Between L37 (Male) (6) - (1)

Defective
transmission SHIFT_UP Voltage 20 - 30 V
4
and fan pump Between L63 (9) - body
motor controller Other than above Voltage 1 V or below
SHIFT_DOWN Voltage 20 - 30 V
40-238 3 WA380-5L
WA380-5L 40-239 3
Failure Code [TM-9B]

Joystick Shift Up/shift Down Switch System Failure
Failure code
code code Trouble Joystick ON/OFF change over switch system failure
TM-9B — TM
• Due to failure of the joystick ON/OFF change over switch system, the joystick cannot be switched ON/
Description of
OFF.
trouble
• The FNR mode cannot be enabled (Due to ground fault), or in the handle mode (Due to discontinuity).
Controller
• No reaction.
reaction
• The joystick mode cannot be enabled or cancelled.

Effect on
• The FNR switch mode cannot be enabled.
machine
• The handle mode cannot be enabled.
• The joystick ON/OFF switch input signal can be checked with the monitoring funtion (Code: 40907,
Related
D-IN-16).
information
• The service mode of the monitor can be used to check if the joystick (If equipped) is implemented or not.

1 joystick ON/OFF
switch
Between L39 Joystick ON/OFF switch = ON Resistance 1 Ω or below
(Female) (4) - (3) Other than above Resistance 1 MΩ or above

2 joystick N lock
switch
Between L38 Left arm rest = Locked Resistance 1 Ω or below
(Female) (A) - (B) Other than above Resistance 1 MΩ or above

Causes and
Standard Values Wiring harness between L62 (Female) (35) - L39 Resistance 1 Ω or below
(Female) (3)

discontinuity 2) Disconnect connectors L38 and L39.
or defective
contact) Wiring harness between L38 (Female) (A) - L39
(Female) (4)

Between L38 (Female) (C) - body Voltage 20 - 30 V

hot short- 2) Disconnect connectors L62 and S04.
circuiting 3) Connect T-adapter.
4 (Contacting 24 V 4) Turn starting switch ON.
harness)
Between L62 (Female) (35)/S04 (Female) (4) - body Voltage 1 V or below
40-240 3 WA380-5L

ground fault 2) Disconnect connectors L62,S04, L71, L39, and L40.
★ In this case, 3) Connect T-adapter.
fuse A-2
5
blows out
when the Between L62 (Female) (35)/S04 (Female) (4) - body Resistance 1 MΩ or above
switch is
Possible
operated.
Causes and
6
and fan pump
motor controller Joystick ON/OFF switch = ON Voltage 20 - 30 V
Between L62 (35) -
body
WA380-5L 40-241 3
Failure Code [TM-10]

FNR Switch Mode Change Over Switch System Failure
Failure code
code code Trouble FNR switch mode change over switch system failure
TM-10 — TM
• Due to failure of the FNR switch mode change over switch system, the FNR switch mode cannot be
Description of changed over.
trouble • The FNR switch mode cannot be enabled (Due to ground fault). Or the handle mode cannot be enabled
(Due to discontinuity).
Controller
• No reaction.
reaction
Effect on
• The FNR switch mode cannot be enabled or cancelled.
machine
• The FNR switch mode change over signal can be checked with the monitoring function (Code: 40907,
Related
D-IN-16).
information
• The service mode of the monitor can be used to check if the right FNR switch is installed or not.

Defective FNR 3) Connect T-adapter.
1 switch mode change
FNR switch mode change over
over switch
Between S04 Resistance 1 Ω or below
switch = ON
(Male) (4) - (3)

Wiring harness Wiring harness between L62 (Female) (35) - S04

discontinuity (Female) (4)
2 (Disconnection or
Possible defective contact) 1) Turn starting switch OFF.
Causes and 2) Disconnect connectors L62 and S04.
Between S04 (Female) 3 - body Voltage 20 - 30 V

Wiring harness hot 3) Connect T-adapter.
short-circuiting 4) Turn starting switch ON.
3
(Contacting 24-V
harness)
Between L62 (Female) (35)/S04 (Female) (4) -
body

ground fault 2) Disconnect connectors L62, S04, and L101.
★ In this case, fuse 3) Connect T-adapter.
4
A-2 blows out
when the switch Between L62 (Female) (35)/S04 (Female) (4) -
is operated. body
40-242 3 WA380-5L

Possible Defective
transmission and fan 4) Turn starting switch ON.
Causes and 5
pump motor
Standard Values controller FNR switch mode change over
Voltage 20 - 30 V
Between L62 switch = ON
(35) - body
WA380-5L 40-243 3

Starting Switch "C" (IGN_C) Signal System Failure
Failure code
code code Trouble Starting switch "C" (IGN_C) signal system failure.
TM-11 — TM
Description of • After the engine started, discontinuity or ground fault occurred in the "C" terminal signal input circuit of the
trouble starting switch.
Controller
• No reaction.
reaction
Effect on • The engine cannot be started. (Ground fault causes fuse B-1 to blow out, resulting in disabling the starting
machine switch.)
Related • Terminal input signal (0/1) of the starting switch "C" (IGN "C") can be checked with the monitoring function
information (Code: 40906,D-IN-15).

Defective starting
1 (Ignition key) switch Starting switch = "C" (at
starting) Resistance 1 Ω or below
Between S31
(Male) (1) - (3)

2 Defective diode R26 Between R26 (Male) (1) - (2)

★ To be measured from (2) side in diode Continuity Positive
range.
Possible ★ Replacing R26 can also correct this failure.

Causes and
3 Defective diode R27 Between R27 (Male) (1) - (2)

★ To be measured from (2) side in diode Continuity Positive
range.
★ Replacing R27 can also correct this failure.

Defective neutral 3) Connect T-adapter.
4
safety relay (L116
Relay = ON Resistance 1 Ω or below
Between L116
(Male) (3) - (5)
Relay = OFF Resistance 1 MΩ or above
Defective starting
5 ★ Perform separate inspection.
motor
40-244 3 WA380-5L

6 discontinuity
(Disconnection or Wiring harness between L63 (Female) (39) -
defective contact) L102 (Female) (14)
Between L102 (Female) (13) - S31 (Female) (3) Resistance 1 Ω or below

Wiring harness hot
short-circuiting
7 Between L63 (Female) (39)/L102 (Female) (14) -
(Contacting 24-V Voltage 1 V or below
body
harness)
body
Possible
Standard Values Wiring harness 2) Disconnect connectors L63, S31, E01, L81 and L52.
8
★ In this case, fuse Between L63 (Female) (39)/L102 (Female) (14) -
A-2 blows out Resistance 1 MΩ or above
body
when the switch
is operated. Between L102 (Female) (13)/S31 (Female) (3) -
body

Defective
9
pump motor
controller Starting switch = "C" (at
Voltage 20 - 30 V
Between L63 starting)
(39) - body
WA380-5L 40-245 3
40-246 3 WA380-5L
MEMORANDUM
WA380-5L 40-247 3

Engine Power Mode Switch Open or Shorted
Failure code
code code Trouble Engine power mode switch discontinuity or ground fault
TM-12 — TM
• Due to discontinuity or ground fault of the engine power mode switch, the engine power mode cannot be
Description of changed over.
trouble • Power mode selection is disabled (Due to discontinuity), or the economy mode cannot be selected (Due
to ground fault).
Controller
• No reaction.
reaction
Effect on
• As the engine mode cannot be changed over, the engine is fixed either to the power or economy mode.
machine
Related
• Can be checked with the monitoring function (Code: 41600 ENGINE MODE).
information

Defective engine 3) Connect T-adapter.
1 mode selection
switch Engine = Power mode Resistance 1 Ω or below
Between S21
(Male) (4) - (1)
Engine = Economy mode Resistance 1 MΩ or above

2 discontinuity
(Disconnection or Wiring harness between L61 (Female) (6) - S21
defective contact) (Female) (4)
Between S21 (Female) (1) - body Resistance 1 Ω or below
Wiring harness hot 1) Turn starting switch OFF.

Possible short-circuiting 2) Disconnect connectors L61 and S21.
Causes and (Contacting 24-V 3) Connect T-adapter.
harness) 4) Turn starting switch ON.
Standard Values 3 ★ In this case, fuse
A-2 blows out Between L61 (Female) (6)/S21 (Female) (4) -
when the switch Voltage 1 V or below
body
is operated.

4
ground fault
body

5
pump motor
controller Engine = Power mode Voltage 1 V or below
Between L61
(6) -body
Engine = Economy mode Voltage 20 - 30 V
40-248 3 WA380-5L
WA380-5L 40-249 3

Open or Short in Travel Damper ON/OFF Switch
Failure code
code code Trouble E.C.S.S. ON/OFF switch discontinuity or ground fault
TM-13 — TM
Description of • Due to discontinuity or ground fault of the E.C.S.S. ON/OFF switch, the E.C.S.S. function cannot be
trouble enabled (Due to discontinuity) or cancelled (Due to ground fault).
Controller
• No reaction.
reaction
Effect on • The E.C.S.S. function cannot be enabled.

machine • The E.C.S.S. function cannot be cancelled.
Related correctly.
information • Check that the E.C.S.S. switch is turned ON. Referring to TROUBLESHOOTING, Special functions of

Defective E.C.S.S.
1 Boom damper ON/OFF switch
ON/OFF switch Resistance 1 Ω or below
= ON
Between S07
(Male) (4) - (3)
Boom damper ON/OFF switch
= OFF

2 discontinuity
(Disconnection or Wiring harness between L61 (Female) (24) - S07
Possible defective contact) (Female) (4) Resistance 1 Ω or below
Causes and
Standard Values Between S07 (Female) (3) - body Resistance 1 Ω or below
Wiring harness hot 1) Turn starting switch OFF.

short-circuiting 2) Disconnect connectors L61 and S07.
(Contacting 24-V 3) Connect T-adapter.
3 ★ In this case, fuse
body
is operated.

4 ground fault
body
40-250 3 WA380-5L

Possible Defective 4) Turn starting switch ON.
transmission and fan
Causes and 5
pump motor Boom damper ON/OFF switch
Standard Values Voltage 1 V or below
controller = ON
Between L61
(24) -body
Boom damper ON/OFF switch
Voltage 20 - 30 V
= OFF
WA380-5L 40-251 3

Open or Short in Hydraulic Fan Reverse Signal System
Failure code
code code Hydraulic fan reverse switch signal system hot short-circuiting or
Trouble discontinuity
TM-14 — —
Description of • Due to ground fault or discontinuity of the fan reverse switch signal system, the fan reverse switch cannot
trouble be turned OFF (Due to hot short circuiting) or ON (Due to discontinuity).
Controller
• No reaction.
reaction
Effect on
• The reverse fan switch cannot be turned ON or OFF.
machine
Related
—
information

1 Defective E.C.S.S.
ON/OFF switch
Fan reverse switch = ON Resistance 1 Ω or below
Between S16
(Male) (4) - (3)
Fan reverse switch = OFF Resistance 1 MΩ or above


Wiring harness Resistance 1 Ω or below
(Female) (4)
discontinuity
2 (Disconnection or 1) Turn starting switch OFF.
defective contact) 2) Disconnect connectors L61 and S16.
Between S16 (Female) (3) - body Voltage 20 - 30 V

Possible
Causes and Wiring harness hot 1) Turn starting switch OFF.
Standard Values short-circuiting 2) Disconnect connectors L61 and S16.
(Contacting 24-V 3) Connect T-adapter.
3 ★ In this case, fuse
body
is operated.

4
ground fault
body

5
pump motor
controller Fan reverse switch = ON Voltage 20 - 30 V
Between L61
(7) -body
Fan reverse switch = OFF Voltage 1 V or below
40-252 3 WA380-5L
WA380-5L 40-253 3

Short in Motor Driven Emergency Steering Relay System
Failure code
code code Motor-driven emergency steering relay output system hot
Trouble short-circuiting
TM-15 — —
Description of • Due to hot short-circuiting of the motor-driven emergency steering relay output system, the emergency
trouble steering motor keeps operating.
Controller
• No reaction.
reaction
Effect on
• The emergency steering motor keeps operating.
machine
Related
—
information

1 Wiring harness hot 4) Turn starting switch ON.
short-circuiting
Possible
Causes and Voltage 1 V or below
body
Standard Values
transmission and fan 3) Connect T-adapter.
2 4) Turn starting switch ON.
pump motor
controller
40-254 3 WA380-5L

Short in Travel Damper Relay System
Failure code
code code
Trouble E.C.S.S. relay output system hot short-circuiting
TM-16 — —
Description of
• Due to hot short-circuiting of the E.C.S.S. relay output system, the E.C.S.S. keeps operating.
trouble
Controller
• No reaction.
reaction
Effect on
• The E.C.S.S. keeps operating.
machine
• Referring to TESTING AND ADJUSTING, Adjusting machine monitor, check that the rotary switches (SW1,
Related SW2, and SW3) and DIP switches (SW5 and SW6) on the back side of the monitor panel are set correctly.
information • Check that the E.C.S.S. switch is turned ON. Referring to TROUBLESHOOTING, Special functions of machine
monitor, check that the optional selection of the E.C.S.S. is effective.


Wiring harness hot body
1 short-circuiting
Possible Causes
and Standard Val- 1) Turn starting switch OFF.
2) Disconnect connectors F13 and L125.
ues 3) Connect T-adapter.
Between F13 (Female) (1)/L125 (Female) (5) - body Voltage Max. 1 V

2 transmission and fan 3) Connect T-adapter.
pump motor controller
WA380-5L 40-255 3

Switch Pump Cut-off Relay System Shorted
Failure code
code code Trouble Switch pump cut-off relay output system hot short-circuiting
TM-17 — —
Description of • Due to hot short-circuiting of the switch pump cut-off relay output system, the switch pump cut-off relay is
trouble always ON.
Controller
• No reaction.
reaction
Effect on
• The switch pump cut-off relay is always ON.
machine
Related
—
information

Possible short-circuiting
Standard Values body

2
pump motor
controller
40-256 3 WA380-5L

Back Lamp Relay System Shorted
Failure code
code code Trouble Switch pump cut-off relay output system hot short-circuiting
TM-18 — —
Description of
• Due to hot short-circuiting of the back lamp relay output system, the back lamp buzzer keeps beeping.
trouble
Controller
• No reaction.
reaction
Effect on
• The back lamp buzzer keeps beeping.
machine
Related
—
information


2
pump motor
controller
WA380-5L 40-257 3

Neutral System Shorted
Failure code
code code Trouble Neutral output system hot short-circuiting
TM-19 — —
Description of • Due to hot short-circuiting of the output system, engine can be started when the FNR lever or FNR switch
trouble is not in the "N" position in the Joystick mode.
Controller
• No reaction.
reaction
Effect on • The engine can be started when the FNR lever or FNR switch is not in the "N" position in the Joystick
machine mode.
Related
—
information


2
pump motor
controller
40-258 3 WA380-5L

F_ECMV Solenoid System Shorted
Failure code
code code Trouble FECMV solenoid system hot short-circuiting
TM-20 — —
Description of • Due to hot short-circuiting of the FECMV solenoid system, FECMV is turned ON without direction lever
trouble turned to "F".
Controller
• No reaction.
reaction
Effect on • The transmission may be damaged.

machine • Traveling may be disabled.
Related
—
information

2) Disconnect connectors L63 and F.PS.
Causes and Between L63 (Female) (5)/F.PS (Female) (1) -

2 pump motor
controller
WA380-5L 40-259 3

R_ECMV Solenoid System Shorted
Failure code
code code Trouble RECMV solenoid system hot short-circuiting
TM-21 — —
Description of • Due to hot short-circuiting of the RECMV solenoid system, RECMV is turned ON without direction lever
trouble turned to "R".
Controller
• No reaction.
reaction

Related
—
information

2) Disconnect connectors L63 and R.PS.
Causes and Between L63 (Female) (15)/R.PS (Female) (1) -

2 pump motor
controller
40-260 3 WA380-5L

1st_ECMV Solenoid System Shorted
Failure code
code code Trouble 1st ECMV solenoid system hot short-circuiting
TM-22 — —
Description of • Due to hot short-circuiting of the 1st ECMV solenoid system, 1st ECMV is turned ON without shifting the
trouble gear to "1st".
Controller
• No reaction.
reaction

Related
—
information

Causes and Between L63 (Female) (25)/1.PS (Female) (1) -

2 pump motor
controller
WA380-5L 40-261 3

2nd_ECMV Solenoid System Shorted
Failure code
code code Trouble 2nd ECMV solenoid system hot short-circuiting
TM-23 — —
Description of • Due to hot short-circuiting of the 2nd ECMV solenoid system, 2nd ECMV is turned ON without shifting the
trouble gear to "2nd".
Controller
• No reaction.
reaction

Related
—
information


2 pump motor
controller
40-262 3 WA380-5L

3rd_ECMV Solenoid System Shorted
Failure code
code code Trouble 3rd ECMV solenoid system hot short-circuiting
TM-24 — —
Description of • Due to hot short-circuiting of the 3rd ECMV solenoid system, 3rd ECMV is turned ON without shifting the
trouble gear to "3rd".
Controller
• No reaction.
reaction

Related
—
information


2 pump motor
controller
WA380-5L 40-263 3

4th_ECMV Solenoid System Shorted
Failure code
code code Trouble 4th ECMV solenoid system hot short-circuiting
TM-25 — —
Description of • Due to hot short-circuiting of the 4th ECMV solenoid system, 4th ECMV is turned ON without shifting the
trouble gear to "4th".
Controller
• No reaction.
reaction

Related
—
information


2 pump motor
controller
40-264 3 WA380-5L

Lock-Up ECMV Solenoid System Shorted
Failure code
code code Trouble Lock-up ECMV solenoid system hot short-circuiting
TM-26 — —
Description of
• Due to hot short-circuiting of the Lock-up ECMV solenoid system, Lock-up suddenly turns ON.
trouble
Controller
• No reaction.
reaction
Effect on
• Lock-up suddenly turns ON.
machine
Related
—
information

2) Disconnect connectors L63 and LC.PS.
Causes and Between L63 (Female) (35)/LC.PS (Female) (1)
Standard Values - body

2
pump motor
controller
WA380-5L 40-265 3

Fan Pump EPC Solenoid System Shorted
Failure code
code code Trouble Fan pump EPC solenoid system hot short-circuiting
TM-27 — —
Description of • Due to hot short-circuiting of the fan pump EPC solenoid system, the fan operates with minimum
trouble revolution.
Controller
• No reaction.
reaction
Effect on
• The fan operates with minimum revolution.
machine
Related
—
information

Causes and Between L63 (Female) (36)/R29 (Female) (1) -

2
pump motor
controller
40-266 3 WA380-5L

Fan Reverse Solenoid System Shorted
Failure code
code code Trouble Fan reverse solenoid system hot short-circuiting
TM-28 — —
Description of • Due to hot short-circuiting of the fan reverse solenoid system, the fan keeps operating in reverse
trouble revolution.
Controller
• No reaction.
reaction
Effect on
• The fan keeps operating in reverse revolution.
machine
Related
—
information

2) Disconnect connectors L63 and GR2.
Causes and Between L63 (Female) (28)/GR2 (Female) (1) -

2
pump motor
controller
WA380-5L 40-267 3

Speed Sensor System Failure
Failure code
code code Speed sensor (transmission output shaft revolution) system
Trouble failure
TM-29 — —
Description of
• Due to ground fault of the speed sensor system, speed sensor signal cannot be input.
trouble
Controller
• No reaction.
reaction
• Gear shift shock occurs.

Effect on
• Shift up cannot be performed in the auto-shift mode. (Traveling in the manual mode is possible.)
machine
• Engine overrun may occur.
Related
—
information
Defective installation of speed Check the clearance between the sensor and the gear.
1
sensor ★ See the checking/adjusting manual.
2) Disconnect connector REV.OUT.
2 Defective speed sensor 3) Connect T-adapter.
Between REV.OUT (Male) (1) - (2) Resistance 500 - 1000 Ω

Causes and 2) Disconnect connectors L62 and REV.OUT.
Standard Values
3 Wiring harness ground fault Between L62 (Female) (20)/REV.OUT
(Female) (1) - body
Between L62 (Female) (29)/REV.OUT

(Female) (2) - body

Defective transmission and 3) Connect T-adapter.
4
40-268 3 WA380-5L
MEMORANDUM
WA380-5L 40-269 3

E.C.S.S. Solenoid System
Failure code
code code Trouble E.C.S.S. solenoid system discontinuity or ground fault
TM-30 — —
Description of • Since the E.C.S.S. solenoid is defective or its circuit is discontinued or has a ground fault, the E.C.S.S.
trouble system does not operate.
Controller
• No reaction.
reaction
Effect on
• The E.C.S.S. system does not operate.
machine
Check the following items in advance.

Related correctly.
information • Check that the E.C.S.S. switch is turned ON.
• Referring to TROUBLESHOOTING, Special functions of machine monitor, check that the optional
selection of the E.C.S.S. is effective.
• Check that failure codes [D192KA] and [D192KB] are not displayed.

Between L125 (female) (3) - body Voltage 20 - 30 V

2) Disconnect connector F13.
Possible 1 (Disconnection or defective
Causes and contact)
5) Turn E.C.S.S. switch ON.
Standard Values
Between F13 (female) (1) - body Voltage 20 - 30 V

Between F13 (female) (2) - body Resistance Max. 1Ω

2 Defective E.C.S.S. solenoid
Between F13 (male) (1) - (2) Resistance 21 - 24Ω
40-270 3 WA380-5L
WA380-5L 40-271 3
TROUBLESHOOTING WORK EQUIPMENT CONTROL SYSTEM
WORK EQUIPMENT CONTROL SYSTEM (WRK MODE)
Connector Types And Locations

system.
★ The item enclosed by parentheses in the connector type column indicates the color of the connector body. (B: Black, Br:
Brown, G: Green, Gr: Gray, L: Blue, W: White.
Number Address
Pins Layout Drawing
Drawing

A21 Yazaki 2 Water temperature sensor (Vehicle with automatic air conditioner) W-3 —
A22 Yazaki 2 Inside temperature sensor (Vehicle with automatic air conditioner) U-2 —
A23 Yazaki 2 Outside temperature sensor (Vehicle with automatic air conditioner) W-4 —
A24 DT-T 2 Diode (Vehicle with automatic air conditioner) W-3 —
A25 DT-T 2 Diode (Vehicle with automatic air conditioner) V-3 —
A26 DT-T 2 Intermediate connector (Vehicle with automatic air conditioner) W-3 —
40-272 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing

C47 AMP040 20 A/C control AMP (Vehicle with automatic air conditioner) D-9 —
C48 AMP040 16 A/C control AMP (Vehicle with automatic air conditioner) D-9 —
C51 Yazaki 2 Diode (Vehicle with automatic air conditioner) M-3 —
CL5 S (W) 16 Intermediate connector (Vehicle with automatic air conditioner) M-2 —
CL6 M 6 Intermediate connector (Vehicle with automatic air conditioner) M-2 —
WA380-5L 40-273 3
Number Address
Pins Layout Drawing
Drawing

DL DT-T (Gr) 12 Connector (S-NET) U-8 K-5
ER-1 DT-T (G) 8 Intermediate connector (Engine) Z-2 P-5
ER-3 DT-T (Gr) 8 Intermediate connector (Engine) A-1 O-5

F18 DT-T 3 Lift arm angle sensor (For boom EPC) A-5 WRK
F19 DT-T 3 Bucket positioner proximity switch (For bucket EPC) A-3 WRK
F20 DT-T 2 Lift arm RAISE EPC A-2 WRK
F21 DT-T 2 Lift arm LOWER EPC A-1 WRK
F22 DT-T 2 Bucket CURL EPC A-1 WRK
F23 DT-T 2 Bucket DUMP EPC A-1 WRK
F24 DT-T 2 ATT. EXT. EPC (OPT) A-3 WRK
40-274 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing
F25 DT-T 2 ATT. RET. EPC (OPT) A-2 WRK

F26 DT-T 2 Lift arm EPC cut-off solenoid B-1 WRK
F27 DT-T 2 Diode (For boom EPC cut-off solenoid) A-4 WRK
WA380-5L 40-275 3
Number Address
Pins Layout Drawing
Drawing

L25E DT-T 2 Lift arm and bucket EPC lever M-6 WRK
L26E DT-T 2 Lift arm and bucket EPC lever P-8 WRK
L27 DT-T 2 Lift arm and bucket EPC lever N-6 WRK
L28 DT-T 4 Lift arm and bucket EPC lever P-8 WRK
L29 DT-T 4 Lift arm and bucket EPC lever O-7 WRK
L30 DT-T 4 3rd EPC lever P-8 WRK
40-276 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing

LR5 DT-T 6 Intermediate connector (Auto grease controller) — K-1
WA380-5L 40-277 3
Number Address
Pins Layout Drawing
Drawing

R38 DT-T 6 Auto grease controller — N-1
40-278 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing

S15 DT-T 6 Automatic digging switch (Vehicle with joystick) N-9 WRK
S17 DT-T 6 Auto grease switch O-8 A-8
WA380-5L 40-279 3
Connector Layout Drawing
40-280 3 WA380-5L
12
WA380-5L 40-281 3
12
40-282 3 WA380-5L
12
WA380-5L 40-283 3
12
40-284 3 WA380-5L
12
WA380-5L 40-285 3
Work Equipment Control System Diagram
40-286 3 WA380-5L
12
WA380-5L 40-287 3
12
40-288 3 WA380-5L
MEMORANDUM
WA380-5L 40-289 3
Defective Joystick Steering Relay System

Failure code
code code Defective joystick steering cut relay system (Main circuit
Trouble
disconnected.)
E03 D193KA WRK
Description of
• The joystick steering solenoid cut relay output system is disconnected (Defective).
trouble
Controller • Stops the joystick steering solenoid cut relay output and joystick steering EPC solenoid output (Both left
reaction and right).
Effect on
• The joystick steering cannot be operated.
machine
Related
information
—

1 Defective relay (L41) 3) Connect T-adapter.

Possible
Wiring harness discontinuity 2) Disconnect connectors L73 and L41.
Causes and
2 (Disconnection or defective 3) Connect T-adapter.
Standard Values
contact) Wiring harness between L73
(Female) (7)/L41 (Female) (5)

3 Defective
controller
work equipment
40-290 3 WA380-5L
Related Circuit Diagram
WA380-5L 40-291 3
The Joystick Solenoid Relay Output System Shorted

Failure code
code code Trouble The joystick solenoid cut relay output system is grounded.
E03 D193KB WRK
Description of
• The joystick solenoid cut relay output system is grounded.
trouble
Controller
• Stops the joystick solenoid cut relay output and joystick solenoid output.
reaction
Effect on
• The joystick steering cannot be operated.
machine
Related
information
—

1 Defective relay (L41) 3) Connect T-adapter.

Possible
Wiring harness discontinuity 2) Disconnect connectors L73 and L41.
Causes and
2 (Disconnection or defective 3) Connect T-adapter.
Standard Values
contact) Wiring harness between L73
(Female) (7)/L41 (Female) (5)

3 Defective
controller
work equipment
40-292 3 WA380-5L
WA380-5L 40-293 3
Failure Code [DB90KK]
Lowering Work Equipment Controller Power Supply Fault

Failure code
code code Trouble Lowering work equipment controller power supply.
E03 DB90KK WRK
Description of
• Controller power supply voltage is lowered.
trouble
Controller
• The input signal cannot be detected normally.
reaction
Effect on
• Normal operation is impossible.
machine
Related
information
—

discontinuity
1 (Disconnection or Wiring harness between L73 (Female) (1)/(11) -
defective connector FS3 (Female) (3)
contact)
Between L73 (Female) (21)/(31)/(32)/(33) -
body

Causes and Wiring harness 2) Disconnect connectors L73 and FS4.
Standard Values 2 ★ In this case,
FS4 is broken. Between L73 (Female) (1)/(11)/FS4 (Female)
(5) - body

Defective work 4) Turn starting switch ON.
3
equipment controller
Between L73 (1)/(11) - Constant (NSW)
electric power Voltage 20 - 30 V
body supply
40-294 3 WA380-5L
WA380-5L 40-295 3
Failure Code [DB92KK]
Defective Solenoid Power Supply

Failure code
code code Trouble Defective solenoid electric power supply system
E03 DB92KK WRK
Description of
• The solenoid power supply voltage is lowered.
trouble
Controller
• No output to solenoid (Stops all the electric power supply voltage at 18 V and below).
reaction
Effect on
• The work equipment cannot be operated.
machine
Related
information
—

discontinuity
1 (Disconnection or Wiring harness between L73 (Female) (2)/(12)/
defective connector (22) - FS4 (Female) (5)
contact)
Between L73 (Female) (21)/(31)/(32)/(33) -
body

Possible
Wiring harness 2) Disconnect connectors FS2 and battery relay M terminal.
Causes and ground fault
Standard Values ★ In this case,
FS4 is broken. Between L73 (Female) (2)/(12)/(22)/FS4
(Female) (5) - body

Defective work 2) Connect connector L73.
3
equipment controller 4) Turn starting switch ON.
Between L73 (2)/(12)/ (SUL) electric power Voltage 20 - 30 V

(22) - body supply
40-296 3 WA380-5L
WA380-5L 40-297 3
Failure Code [DB95KX]
Open in 5 V Power Supply

Failure code
code code Trouble Defective 5 V electric power supply system
E03 DB95KX WRK
Description of
• 5 V sensor electric power supply system is grounded improperly.
trouble
Controller
• Turns off the output to all EPC.
reaction
Effect on
• The work equipment and the joystick cannot be operated.
machine
Related
information
—

2) Disconnect connectors L71, L28, L29, L30, L34, L30, and F18.
1 Wiring harness ground fault 3) Connect T-adapter.
Between L71 (Female) (22) - body Resistance 1 MΩ and above

2 Defective boom EPC lever
potentiometer
Between L28 (Male) (4) - (1) Resistance 2.5 - 3.9 Ω
Between L28 (Male) (4) - body Resistance 1 MΩ and above

Defective bucket EPC lever 3) Connect T-adapter.
3
potentiometer
Possible Between L29 (Male) (4) - body Resistance 1 MΩ and above

Causes and
4 Defective joystick steering
EPC lever potentiometer

5 Defective 3rd EPC lever
potentiometer

6 Defective boom EPC lever
potentiometer
Between F18 (Male) (3) - (1) Resistance 2.5 - 3.9 Ω
Between F18 (Male) (3) - body Resistance 1 MΩ and above
40-298 3 WA380-5L

Possible 2) Disconnect connector L71.
Defective work equipment 3) Connect T-adapter.
Causes and 7
controller 4) Turn starting switch ON.
Standard Values
Between L71 (22) - (21) Voltage 4.75 - 5.25 V
WA380-5L 40-299 3
Failure Code [DD1ALD]
Defective Remote Positioner UP Set Switch

Failure code
code code Trouble Defective remote positioner UP set switch (Ground fault).
E03 DD1ALD WRK
Description of
• Cannot be set to up because the remote positioner UP set switch system is grounded improperly.
trouble
• Cancels the UP set position setting and the remote UP stop setting.
Controller
• The UP set indicator is switched off the light.
reaction
• UP set indicator goes out.
Effect on
• The UP set position cannot be set.
machine
Related
• Can be checked with the monitoring function (Code: 40917).
information

1
ground fault
body

Possible 2 Defective remote
Remote positioner set switch
Causes and
positioner set switch Resistance 1 Ω and below
Between S12 = Up
Standard Values
(Male) (1) - (2) Remote positioner set switch
= Other than above

Defective work
3
equipment controller Remote positioner set switch
Between L72 Voltage 1 V and below
= Up
(Male) (13) -
body Remote positioner set switch
Voltage 17 - 30 V
= Other than above
40-300 3 WA380-5L
WA380-5L 40-301 3
Failure Code [DD1BLD]
Defective Remote Positioner DOWN Set Switch

Failure code
code code Trouble Defective remote positioner DOWN set switch (Ground fault).
E03 DD1BLD WRK
Description of
• Cannot be set to up because the remote positioner DOWN set switch system is grounded improperly.
trouble
• Cancels the DOWN set position setting and the remote UP stop setting.
Controller
• The DOWN set indicator is switched off the light.
reaction
• DOWN set indicator goes out.
Effect on
• The DOWN set position cannot be set.
machine
Related
information

1
ground fault
body

Possible 2 Defective remote
Remote positioner set switch
Causes and
positioner set switch Resistance 1 Ω and below
Between S12 = Up
Standard Values
(Male) (3) - (2) Remote positioner set switch
= Other than above

Defective work
3
equipment controller Remote positioner set switch
= Up
(Male) (3) -
body Remote positioner set switch
Voltage 17 - 30 V
= Other than above
40-302 3 WA380-5L
WA380-5L 40-303 3
Failure Code [DFAOKM]
Defective Neutral Caution for Joystick Work Equipment

Failure code
code code Trouble Defective neutral caution for joystick work equipmentnt lever
E00 DFAOKM WRK
Description of
• The neutral system for joystick work equipment lever is mistakenly operated.
trouble
Controller • Stops the joystick EPC solenoid output (Process after resetting from error: Return the lever to neutral
reaction position once).
Effect on
• The work equipment cannot be operated.
machine
Related
information

Defective lift arm neutral lock
switch
5) Set lock lever to lock position.
Between L71 (17) - body Voltage 1 V and below

Defective lift arm EPC lever 3) Connect T-adapter.
potentiometer
5) Set lock lever to neutral position.
Possible
Causes and Between L71(19) - (21) Voltage 2.4 - 3.9 V
Standard Values
3 Defective bucket EPC lever
potentiometer 4) Turn starting switch ON.
Between L71(7) - (21) Voltage 2.4 - 3.9 V

Defective 3rd EPC lever
position
Between L71(20) - (21) Voltage 2.4 - 3.9 V
40-304 3 WA380-5L
WA380-5L 40-305 3
Failure Code [DK59KA]
Defective Lift Arm EPC Lever Potentiometer System (Main Circuit Discontinuity or
Ground Fault)
Failure code Defective lift arm EPC lever potentiometer system
code code Trouble
(Main circuit discontinuity or ground fault)
E03 DK59KA WRK
Description of • The lift arm EPC lever potentiometer signal system is disconnected (Main circuit discontinuity or ground
trouble fault).
Controller
• Stops the lift arm EPC solenoid output and the lift arm lever magnet detent output.
reaction
Effect on
• The lift arm cannot be operated.
machine
Related
information

Wiring harness discontinuity 2) Disconnect connector L71 and L28.
1 (Disconnection or defective
contact) Wiring harness between L71 (Female)
(19) - L28 (Female) (3)

2) Disconnect connector L71 and L28.

Possible
3 Defective potentiometer 4) Turn starting switch ON.

Defective work equipment
controller
Between L71 (19) - (21) (Set lever to
Voltage 2.4 - 2.6 V
neutral position)
40-306 3 WA380-5L
WA380-5L 40-307 3
Failure Code [DK59KY]
Defective Lift Arm EPC Lever Potentiometer System (Main Short Circuit)
code code Trouble
(Main short circuit)
E03 DK59KY WRK
Description of
• The electrical power supply is contacted to the lift arm EPC lever potentiometer signal system.
trouble
Controller
• Stops the lift arm EPC solenoid output and the lift arm EPC lever magnet detent output.
reaction
Effect on
machine
Related
information

Harness shorted to electric 3) Connect T-adapter.
power supply (Contacted to
1
electric power supply Between L71 (Female) (19)/L28
(Female) (3) - body Voltage 1 V and below
Possible harness)
Causes and Between L71 (19) - (21) Voltage 1 V and below
Standard Values
controller
40-308 3 WA380-5L
WA380-5L 40-309 3
Failure Code [DK59L8]
Defective Lift Arm EPC Potentiometer System (Displacement of Main and Sub Circuit)
Failure code Defective lift arm EPC potentiometer system
code code Trouble
(Displacement of main and sub circuit)
E03 DK59L8 WRK
Description of
• The input signal for the lift arm EPC lever potentiometer system (Main and sub circuit) is not coincided.
trouble
Controller
• Stops the lift arm EPC solenoid output and the lift arm EPC lever magnet detent output.
reaction
Effect on
machine
Related
• Can be checked with the monitoring function (Code: 42000 and 42001).
information

Lever = Neutral Voltage 2.4 - 2.6 V
Lever = Full stroke at the

Between L28 Voltage 3.9 - 4.4 V
raised side
(3) - (1)
Defective
potentiometer Lever = Full stroke at the
Voltage 0.6 - 1.1 V
1 ★ Defective lowered side
installation
(Loose and play) Lever = Neutral Voltage 2.4 - 2.6 V
Possible
Causes and Lever = Full stroke at the
Standard Values raised side
(2) - (1)
Voltage 3.9 - 4.4 V
lowered side
Between L28
(4) - (1)

discontinuity
2 Wiring harness between L71 (Female) (19) - L28 Resistance 1 Ω and below
(Disconnection or (Female) (3)
defective contact)
Wiring harness between L71 (Female) (13) - L28 Resistance 1 Ω and below
(Female) (2)
40-310 3 WA380-5L


(19) - (21) raised side
Possible
Defective work
Causes and 3 Lever = Full stroke at the
equipment controller Voltage 0.6 - 1.1 V
Standard Values lowered side

(13) - (21) raised side

Voltage 3.9 - 4.4 V
lowered side
WA380-5L 40-311 3
Failure Code [DK5AKA]
Defective Lift Arm EPC Lever Potentiometer System (Disconnection of Main)

Failure code
code code Defective lift arm EPC lever potentiometer system
Trouble
(Disconnection of main) (Disconnection, ground of sub)
E03 DK5AKA WRK
Description of • Defective lift arm EPC lever potentiometer system (Main circuit discontinuity) (Sub circuit discontinuity or
trouble ground fault).
Controller
• Stops the lift arm EPC solenoid output.
reaction
Effect on
machine
Related
information

(13) - L28 (Female) (2)

Between L71 (Female) (13)/L28
(Female) (2) - body
Possible
5) Set lever to neutral position.

controller
40-312 3 WA380-5L
WA380-5L 40-313 3
Failure Code [DK5AKY]
Defective Lift Arm EPC Lever Potentiometer System (Short Sub Circuit)
code code Trouble
(Short sub circuit)
E03 DK5AKY WRK
Description of • The electric power supply harness is contacted to the lift arm EPC lever potentiometer sub circuit signal
trouble system harness.
Controller
• Stops the lift arm EPC solenoid output.
reaction
Effect on
machine
Related
information

Defective harness hot short 3) Connect T-adapter.
1 (Contacted to electric power
supply harness)
Possible (Female) (2) - body Voltage 1 V and below
Causes and
controller
40-314 3 WA380-5L
Failure Code [DK5BKA]
Defective Bucket EPC Lever Potentiometer System (Disconnection of Main)

Failure code
code code Defective bucket EPC lever potentiometer system
Trouble
E03 DK5BKA WRK
Description of • The bucket EPC lever potentiometer signal system is disconnected (Main circuit discontinuity or ground
trouble fault).
Controller
• Turns off the bucket EPC solenoid output and the bucket magnet detent output.
reaction
Effect on
• The bucket cannot be operated.
machine
Related
information

(7) - L29 (Female) (3)


Possible

4 Defective work equipment
WA380-5L 40-315 3
Failure Code [DK5BKY]
Defective Bucket EPC Lever Potentiometer System (Main Short Circuit)

Failure code Defective bucket EPC lever potentiometer system
code code Trouble
(Main short circuit)
E03 DK5BKY WRK
Description of
• The electric power supply harness is contacted to the bucket EPC lever potentiometer signal system.
trouble
Controller
reaction
Effect on
machine
Related
information

Possible
Causes and
Between L71 (Female) (7) - (21) Voltage 1 V and below
Standard Values
controller
40-316 3 WA380-5L
WA380-5L 40-317 3
Failure Code [DK5BL8]
Defective Bucket EPC Potentiometer System (Displacement of Main and Sub Circuit)
Failure code Defective bucket EPC potentiometer system
code code Trouble
(Displacement of main and sub circuit)
E03 DK5BL8 WRK
Description of
• The input signal for the bucket EPC lever potentiometer system (Main and sub circuit) is not coincided.
trouble
Controller
reaction
Effect on
machine
Related
information

Lever = Full stroke at the tilt

side
Defective (3) - (1)
potentiometer
1 ★ Defective Voltage 0.6 - 1.1 V
dump side
installation
Possible
Causes and
Standard Values Between L29 Voltage 0.6 - 1.1 V
side
(2) - (1)
Voltage 3.9 - 4.4 V
dump side

discontinuity
defective contact)
(Female) (2)
40-318 3 WA380-5L


(7) - (21) side
Possible
Defective work
Standard Values dump side

(1) - (21) side

Voltage 3.9 - 4.4 V
dump side
WA380-5L 40-319 3
Failure Code [DK5CKA]
Defective Bucket EPC Lever Potentiometer System (Disconnection of Main)

Failure code
code code Defective bucket EPC lever potentiometer system
Trouble
(Sub circuit discontinuity or ground fault).
E03 DK5CKA WRK
Description of • The bucket EPC lever potentiometer signal system is disconnected (Sub circuit discontinuity or ground
trouble fault).
Controller
• Turns off the bucket EPC solenoid output.
reaction
Effect on
machine
Related
information

(1) - L29 (Female) (2)


Possible

40-320 3 WA380-5L
Failure Code [DK5CKY]
Defective Bucket EPC Lever Potentiometer System (Short Sub Circuit)

Failure code Defective bucket EPC lever potentiometer system
code code Trouble
(Short sub circuit)
E03 DK5CKY WRK
Description of
• The electric power supply harness is contacted to the bucket EPC lever potentiometer signal system.
trouble
Controller
• Turns off the bucket EPC solenoid output .
reaction
Effect on
machine
Related
information

Electric power supply shorted
to harness.
Possible Between L71 (Female) (1)/L29
Causes and
Standard Values
controller
Between L71 (1) - (21) (Lever neutral) Voltage 2.4 - 2.6 V
WA380-5L 40-321 3
Failure Code [DK5DKA]
Defective 3rd Valve Lever Potentiometer System (Main Circuit Discontinuity or Ground
Fault)
Failure code Defective 3rd valve lever potentiometer system
code code Trouble
E03 DK5DKA WRK
Description of • The 3rd valve lever potentiometer signal system is disconnected (Main circuit discontinuity or ground
trouble fault).
Controller
• Turns off the 3rd EPC solenoid output.
reaction
Effect on
• The 3rd valve cannot be operated.
machine
Related
information

(20) - L30 (Female) (3)


Possible

Defective work equipment 4) Turn starting switch ON.
4
controller 5) Set lever to neutral position.
Between L71 (20) - (21) (Lever

Voltage 2.4 - 2.6 V
neutral)
40-322 3 WA380-5L
WA380-5L 40-323 3
Failure Code [DK5DKY]
Defective Lift Arm EPC Lever Potentiometer System (Main Circuit Short Circuit)
code code Trouble
(Main circuit short circuit)
E03 DK5DKY WRK
Description of
• The electric power supply harness is contacted to the 3rd valve lever potentiometer signal system.
trouble
Controller
reaction
Effect on
machine
Related
information

supply harness)
Causes and
controller
40-324 3 WA380-5L
WA380-5L 40-325 3
Failure Code [DK5DL8]
Defective 3rd Valve EPC Potentiometer System (Displacement of Main and Sub Circuit)
Failure code Defective 3rd valve EPC lever potentiometer system input signal
code code Trouble
(Displacement of main and sub circuit).
E03 DK5DL8 WRK
Description of
• The input signal for the 3rd EPC lever potentiometer 2 systems (Main and sub circuit) is not coincided.
trouble
Controller
• Turns off the 3rd valve EPC solenoid output and the 3rd valve magnet detent output.
reaction
Effect on
machine
Related
information


extension side
Defective (3) - (1)
potentiometer
1 ★ Defective Voltage 0.6 - 1.1 V
retraction side
installation
Possible
Causes and
Standard Values Between L30 Voltage 0.6 - 1.1 V
extension side
(2) - (1)
Voltage 3.9 - 4.4 V
retraction side

discontinuity
defective contact)
(Female) (2)
40-326 3 WA380-5L


(20) - (21) extension side
Possible
Defective work
Standard Values retraction side

(14) - (21) extension side

Voltage 3.9 - 4.4 V
retraction side
WA380-5L 40-327 3
Failure Code [DK5EKA]
Defective 3rd Valve Lever EPC Potentiometer System (Sub Circuit Discontinuity or
Ground Fault)
Failure code Defective 3rd valve EPC lever potentiometer system
code code Trouble
(Sub circuit discontinuity or ground fault)
E03 DK5EKA WRK
Description of • The 3rd valve lever potentiometer signal system is disconnected (Sub circuit discontinuity or ground
trouble fault).
Controller
reaction
Effect on
machine
Related
information

(14) - L30 (Female) (2)


Possible

controller
40-328 3 WA380-5L
Failure Code [DK5EKY]
Defective Lift Arm EPC Lever Potentiometer System (Short Sub Circuit)
code code Trouble
(Short sub circuit)
E03 DK5EKY WRK
Description of
• The electric power supply harness is contacted to the 3rd valve EPC lever potentiometer signal system.
trouble
Controller
reaction
Effect on
machine
Related
information

supply harness)
Causes and
controller
WA380-5L 40-329 3
Failure Code [DK5FKA]
Defective Joystick Steering EPC System (Main Circuit Open or Shorted)

Failure code
code code Defective joystick steering EPC lever potentiometer system
Trouble
(Main circuit discontinuity or ground fault).
E03 DK5FKA WRK
Description of • The joystick steering EPC lever potentiometer signal system is disconnected (Main circuit discontinuity or
trouble ground fault).
Controller • Turns off the joystick steering EPC solenoid output.

reaction • Stops the joystick steering EPC lever magnet detent output.
Effect on
• The joystick lever steering cannot be operated.
machine
Related
information

(9) - L34 (Female) (3)

2 Wiring harness round fault
Between L71 (Female) (9), L34
(Female) (3) - body Resistance 1 MΩ and above
Possible
Causes and

40-330 3 WA380-5L
Failure Code [DK5FKY]
Defective Joystick Steering EPC Potentiometer System (Main Circuit Shorted)

Failure code
Trouble
(Main circuit shorted)
E03 DK5FKY WRK
Description of
• The electric power supply harness is contacted to the joystick steering EPC lever magnet detent output.
trouble
Controller • Turns off the joystick steering EPC solenoid output and the joystick steering EPC lever magnet detent
reaction output.
Effect on
• The steering cannot be operated by the joystick lever.
machine
Related
information

Wiring harness discontinuity 3) Connect T-adapter.
contact)
(9) - L34 (Female) (3)

Possible Wiring harness hot short 3) Connect T-adapter.
Causes and 2 circuit (Electric power supply 4) Turn starting switch ON.
Standard Values harness is contacted)
(9)/L34 (Female) (3) - body

controller
WA380-5L 40-331 3
12
Failure Code [DK5FKM]
Joystick Steering EPC Lever Neutral System Caution

Failure code
code code Trouble Joystick steering EPC lever neutral system caution
E00 DK5FKM WRK
Description of
• The joystick steering EPC lever neutral operation is abnormal.
trouble
Controller
• Turns off the joystick steering EPC solenoid output.
reaction
Effect on
• The steering cannot be operated by the joystick lever.
machine
Related
information
• —
40-332 3 WA380-5L
MEMORANDUM
WA380-5L 40-333 3
Failure Code [DK5FL8]
Defective Joystick Steering EPC Lever Potentiometer Input Signal

Troubleshooting Controller Defective joystick steering EPC lever potentiometer system
Failure code
code code Trouble input signal (Deviation of positional signals of main and sub
E03 DK5FL8 WRK circuits)
Description of • Input signals of the joystick steering EPC lever potentiometer 2 systems (Main and sub circuits) are not
trouble identical.
Controller
• Stops joystick steering EPC solenoid output.
reaction
Effect on • The steering cannot be operated by joystick.

machine • It is operable by using the handle in the handle mode.
Related
information


Defective
potentiometer Between L34
Lever = left Full stroke Voltage 1.1 - 1.5 V
★ Defective (3) - (1)
1 installation Lever = right Full stroke Voltage 3.5 - 4.0 V
(Loose and
Possible play) Lever = Neutral Voltage 2.4 - 2.6 V
Causes and Between L34
Lever = left Full stroke Voltage 3.5 - 4.0 V
Standard Values (2) - (1)
Lever = right Full stroke Voltage 1.1 - 1.5 V

discontinuity
defective contact)
(Female) (2)


Possible Between L71
Defective work (9) - (21) Lever = left Full stroke Voltage 1.1 - 1.5 V
Causes and 3
Standard Values Lever = right Full stroke Voltage 3.5 - 4.0 V

Between L71
(3) - (21) Lever = left Full stroke Voltage 3.5 - 4.0 V
Lever = right Full stroke Voltage 1.1 - 1.5 V
40-334 3 WA380-5L
WA380-5L 40-335 3
Failure Code [DK5GKA]
Defective Joystick Steering EPC Potentiometer System (Open or Short in Sub Circuit)
Failure code
Trouble
(Disconnection or ground fault of sub circuit).
E03 DK5GKA WRK
Description of • The joystick steering EPC lever potentiometer (Sub) signal system is disconnected (Disconnection or
trouble ground fault of sub circuit).
Controller
• Stops joystick steering EPC solenoid output.
reaction
Effect on
• Steering cannot be operated by using the joystick.
machine
Related
information

contact) Between L71 (Female) (3) - L34
(Female) (2) - body

Between L71 (Female) (3) - L34
Possible (Female) (2) - body
Causes and

controller
40-336 3 WA380-5L
Failure Code [DK5GKY]
Defective Joystick Steering EPC Potentiometer System (Sub Circuit Short)

Failure code
Trouble
(Sub circuit short circuit)
E03 DK5GKY WRK
Description of • The power supply line is contacting the joystick steering EPC lever potentiometer signal (Sub), which
trouble prevents output to the joystick EPC solenoid.
Controller
• Stops joystick steering EPC solenoid output until leverís neutral position will be detected.
reaction
Effect on • The steering cannot be operated by using the joystick. It is operable by using the handle in the handle
machine mode.
Related
• Can be checked with the monitoring function (Code 42005).
information

(3) - L34 (Female) (2) - body

Causes and 2 Wiring harness hot-short 4) Turn starting switch ON.
Standard Values
(Female) (3)/L34 (Female) (2) - body

3 Defective
controller
work equipment
WA380-5L 40-337 3
Failure Code [DKAOKA]
Defective Lift Arm Angle Sensor System (Open or Short)

Failure code
code code Defective lift arm angle sensor system
Trouble
(Disconnection or ground fault)
E01 DKAOKA WRK
Description of
• Disconnection or ground fault of lift arm angle signal system and power supply system disconnection.
trouble
• Controls the voltage value of the lift arm EPC potentiometer signal as input voltage.
Controller
• Cancels the remote positioner function.
reaction
• Cancels semi-auto excavation function.
Effect on
• The remote positioner and the semi-auto excavation function cannot operate.
machine
Related
information

2) Disconnect connectors L71 and F18.
Wiring harness
1 discontinuity Wiring harness between L71 (Female) (8) - F18
(Disconnection or Resistance 1 Ω and below
defective contact) (Female) (B)
Wiring harness between L71 (Female) (22) - F18

(Female) (C)

2 Wiring harness
ground fault
Wiring harness between L71 (Female) (8) - F18
(Female) (B) - body
Possible
Causes and Wiring harness between L71 (Female) (22) - F18
Standard Values (Female) (C) - body

Between F18 (C) - (A) Voltage 4.75 - 5.25 V
At the time of boom RAISE

Defective boom Voltage 3.5 - 4.0 V
3 Between F18 stroke end
angle sensor
(B) - (A) At the time of boom LOWER
Voltage 1.0 - 2.0 V
stroke end

Between F18 (C) - (A) Resistance 4 - 6 kΩ
40-338 3 WA380-5L

Possible Defective work Between L71
Causes and 4 equipment The whole range Voltage 4.75 - 5.25 V
(22) - body
Standard Values controller
At the time of the boom
Voltage 3.5 - 4.0 V
maximum raising
Between L71
(8) - body
Voltage 1.0 - 2.0 V
maximum lowering
WA380-5L 40-339 3
Failure Code [DKAOKY]
Defective Lift Arm Angle Sensor (System Shorted)

Failure code
code code Trouble Defective lift arm angle sensor system (Short circuit)
E01 DKAOKY WRK
Description of
• Short circuit of the lift arm angle signal system and the GND system disconnection.
trouble
• Controls the voltage value of the lift arm EPC potentiometer signal as input voltage.
Controller
• Cancels the remote positioner function.
reaction
• Cancels semi-auto excavation function.
Effect on
• The remote positioner and the semi-auto excavation function cannot operate.
machine
Related
information

Defective wiring 2) Disconnect connectors L71 and F18.
harness short 3) Connect T-adapter.
circuit (The signal
harness contacts
the power supply
harness) Wiring harness between L71 (Female) (8) - F18
(Female) (B)

Wiring harness 2) Disconnect connectors L71 and F18.
discontinuity
2 (Disconnection or 3) Connect T-adapter.
defective contact)
Wiring harness between F18 (Female) (A) - body Resistance 1 Ω and below


Possible
Causes and At the time of boom RAISE
Defectivelift arm Voltage 3.5 - 4.0 V
Standard Values 3 Between F18 stroke end
angle sensor
(B) - (A) At the time of boom LOWER
Voltage 1.0 - 2.0 V
stroke end

Between F18 (C) - (A) Resistance 4 - 6 kΩ

Defective work Between L71
4 equipment The whole range Voltage 4.75 - 5.25 V
(22) - body
controller
Voltage 3.5 - 4.0 V
maximum raising
Between L71
(8) - body
Voltage 1.0 - 2.0 V
maximum lowering
40-340 3 WA380-5L
WA380-5L 40-341 3
12
Failure Code [DLE2LC]
Defective Engine Speed Sensor System

Failure code
code code Trouble Defective engine speed sensor system
E01 DLE2LC WRK
Description of
• The engine speed sensor system ground fault prevents the engine speed signal input.
trouble
Controller
• Cannot detect engine speed (Recognizes engine speed as 2000 rpm).
reaction
Effect on
• Work equipment feeling decreases.
machine
Related
information

1 (Disconnection or defective Wiring harness between L72
contact) (Female) (10) - L62 (Female) (9)
★ When the transmission controller does not detect "Defective engine

speed sensor" (Failure code: DLE2KA and DLE2LC)
40-342 3 WA380-5L
12
Failure Code [DLT3LC]
Defective Transmission Output AXIS Speed Sensor System (Open)

Failure code Defective transmission output axis speed sensor system
code code Trouble
(Disconnected)
E03 DLT3LC WRK
Description of
• Speed sensor system disconnection prevents the speed sensor signal from being input.
trouble
Controller
• Cannot detect travel speed (Recognizes the speed is low).
reaction
Effect on • The semi-auto excavator cannot be used.

machine • Feeling of the joystick steering decreases.
Related
information

1 (Disconnection or defective Wiring harness between L72
contact) (Female) (20) - L62 (Female) (19)
★ When the transmission controller does not detect "Defective engine

speed sensor" (Failure code: DLT3KA)
WA380-5L 40-343 3
Failure Code: [DUM1KB]
Remote Positioner RAISE Lamp System Ground Fault

Failure code
code code Trouble Remote positioner RAISE lamp system ground fault
E03 DUM1KB WRK
Description of
• The remote positioner RAISE lamp system ground fault prevents output to the indicator lamp.
trouble
Controller
• No reaction.
reaction
Effect on
• The remote positioner RAISE indicator lamp cannot be turned on.
machine
Related
information

Defective remote 2) Disconnect connector S13.
1 positioner RAISE 3) Connect T-adapter.
indicator lamp
Between S13 (Male) (5) - (6) Resistance Approx. 20 Ω

Possible 2 Wiring harness

ground fault
Causes and Wiring harness between L73 (Female) (8), S13

Standard Values (Female) (5) - body

Defective work
3
equipment controller When the remote positioner
Voltage 17 - 30 V
Between L73 RAISE lamp is ON.
(8) - body
When the remote positioner
RAISE lamp is OFF.
40-344 3 WA380-5L
Failure Code: [DUM2KB]
Remote Positioner LOWER Lamp System Ground Fault

Failure code
code code Trouble Remote positioner LOWER lamp system ground fault
E03 DUM2KB WRK
Description of
• The remote positioner LOWER lamp system ground fault prevents output to the indicator lamp.
trouble
Controller
• No reaction.
reaction
Effect on
• The remote positioner LOWERE indicator lamp cannot be turned on.
machine
Related
information

Defective remote 2) Disconnect connector S14.
1 positioner RAISE 3) Connect T-adapter.
indicator lamp
Between S14 (Male) (5) - (6) Resistance Approx. 20 Ω

Possible 2 Wiring harness

ground fault
Causes and Wiring harness between L73 (Female) (18),

Standard Values S14 (Female) (5) - body

Defective work
3
equipment controller When the remote positioner
Voltage 17 - 30 V
Between L73 RAISE lamp is ON.
(18) - body
When the remote positioner
RAISE lamp is OFF.
WA380-5L 40-345 3
Failure Code: [DW4PKA]
Disconnected Lift Arm RAISE EPC Solenoid System

Failure code
code code Trouble Disconnected lift arm RAISE EPC solenoid system
E03 DW4PKA WRK
Description of • The lift arm RAISE EPC solenoid system disconnection prevents output to the lift arm RAISE EPC
trouble solenoid.
Controller • Stops the output to the lift arm RAISE EPC solenoid.
reaction • Stops the output to the lift arm RAISE detent.
Effect on
• The lift arm cannot raise.
machine
Related
information

Defective lift arm 3) Connect T-adapter.
1
RAISE EPC solenoid
Between F20 (Male) (1) - (2) Resistance 9 - 10.2 Ω

Possible
Causes and Wiring harness
Standard Values discontinuity
2 (Disconnection or
Wiring harness between L73 (Female) (6), F20
defective contact) (Female) (1) - body

(Female) (2) - body

Defective work 3) Connect T-adapter.
3
Between L73 (6) - (3) Resistance 9 - 10.2 Ω
40-346 3 WA380-5L
Failure Code: [DW4PKB]
Lift Arm RAISE EPC Solenoid System Ground Fault

Failure code
code code Trouble Lift arm RAISE EPC solenoid system ground fault
E03 DW4PKB WRK
Description of
• The lift arm RAISE EPC solenoid system ground fault prevents output to the lift arm RAISE EPC solenoid.
trouble
Controller • Stops the output to the lift arm RAISE EPC solenoid.
reaction • Stops the output to the lift arm RAISE detent.
Effect on
• The lift arm cannot raise.
machine
Related
information

Defective lift arm
1 RAISE EPC solenoid 3) Connect T-adapter.

Possible Wiring harness 2) Disconnect connectors L73 and F20.
Causes and ground fault 3) Connect T-adapter.
2 (Disconnection or
Standard Values
body

3
WA380-5L 40-347 3
Failure Code: [DW4QKA]
Disconnected Lift Arm LOWER EPC Solenoid System

Failure code
code code Trouble Disconnected lift arm LOWER EPC solenoid system
E03 DW4QKA WRK
Description of • The lift arm LOWER EPC solenoid system disconnection prevents output to the lift arm LOWER EPC
trouble solenoid.
Controller • Stops the output to the lift arm LOWER EPC solenoid.
reaction • Stops the output to the lift arm LOWER detent.
Effect on
• The lift arm cannot lower.
machine
Related
information

1 LOWER EPC
solenoid Between F21 (Male) (1) - (2) Resistance 9 - 10.2 Ω

Possible
2 (Disconnection or
Wiring harness between L73 (Female) (16),
defective contact) F21 (Female) (1) - body

(Female) (2) - body

3
40-348 3 WA380-5L
Failure Code: [DW4QKB]
Lift Arm LOWER EPC Solenoid System Ground Fault

Failure code
code code Trouble Lift arm LOWER EPC solenoid system ground fault
E03 DW4QKB WRK
Description of • The lift arm LOWER EPC solenoid system ground fault prevents output to the lift arm LOWER EPC
trouble solenoid.
Controller • Stops the output to the lift arm LOWER EPC solenoid.
reaction • Stops the output to the lift arm LOWER detent.
Effect on
• The lift arm cannot lower.
machine
Related
information

Defective lift arm 2) Disconnect connector F21.
1 LOWER EPC 3) Connect T-adapter.
solenoid

2 (Disconnection or
Standard Values
body

3
WA380-5L 40-349 3
Failure Code: [DW4RKA]
Disconnected Bucket TILT EPC Solenoid System

Failure code
code code Trouble Disconnected bucket TILT EPC solenoid system
E03 DW4RKA WRK
Description of
• The bucket TILT EPC solenoid system disconnection prevents output to the bucket TILT EPC solenoid.
trouble
Controller • Stops the output to the bucket TILT EPC solenoid.

reaction • Stops the output to the lbucket TILT detent.
Effect on
• The bucket cannot tilt.
machine
Related
information

Defective bucket 3) Connect T-adapter.
1
TILT EPC solenoid

Possible
2 (Disconnection or
defective contact) (Female) (1) - body

(Female) (2) - body

3
Between L73 (Female) (5) - (3) Resistance 9 - 10.2 Ω
40-350 3 WA380-5L
Failure Code: [DW4RKB]
Bucket TILT EPC Solenoid System Ground Fault

Failure code
code code Trouble Bucket TILT EPC solenoid system ground fault
E03 DW4RKB WRK
Description of
• The bucket TILT EPC solenoid system ground fault prevents output to the bucket TILT EPC solenoid.
trouble
Controller • Stops the output to the bucket TILT EPC solenoid.

reaction • Stops the output to the bucket TILT detent.
Effect on
• The bucket cannot tilt.
machine
Related
information

Defective bucket
1 TILT EPC solenoid 3) Connect T-adapter.

2 (Disconnection or
Standard Values
body

3
WA380-5L 40-351 3
Failure Code: [DW4SKA]
Disconnected Bucket DUMP EPC Solenoid System

Failure code
code code Trouble Disconnected bucket DUMP EPC solenoid system
E03 DW4SKA WRK
Description of • The bucket DUMP EPC solenoid system disconnection prevents output to the bucket DUMP EPC
trouble solenoid.
Controller
• Stops the output to the bucket DUMP EPC solenoid.
reaction
Effect on
• The bucket cannot dump.
machine
Related
information

Defective bucket 3) Connect T-adapter.
1
DUMP EPC solenoid

Possible
Causes and Wiring harness Wiring harness between L73 (Female) (15),
Standard Values discontinuity F23 (Female) (1) - body
2 (Disconnection or
body

(Female) (2) - body

3
40-352 3 WA380-5L
Failure Code: [DW4SKB]
Bucket DUMP EPC Solenoid System Ground Fault

Failure code
code code Trouble Bucket DUMP EPC solenoid system ground fault
E03 DW4SKB WRK
Description of
• The bucket DUMP EPC solenoid system ground fault prevents output to the bucket DUMP EPC solenoid.
trouble
Controller
• Stops the output to the bucket DUMP EPC solenoid.
reaction
Effect on
• The bucket cannot dump.
machine
Related
information

Defective bucket
DUMP EPC solenoid

2 (Disconnection or
Standard Values
body

3
WA380-5L 40-353 3
Failure Code: [DWM1KA]
Work Equipment Neutral Lock Solenoid System Disconnection

Failure code
code code Trouble Work equipment neutral lock solenoid system disconnection
E01 DWM1KA WRK
Description of
• Work equipment neutral lock solenoid power supply system is disconnected.
trouble
Controller
• No reaction.
reaction
Effect on
• Normal operation is possible (Does not affect the lock lever).
machine
Related
• —
information

Defective neutral
lock solenoid
Between F26 (Male) (1) - (2) Resistance 35 - 45 Ω

Wiring harness
Causes and 2 discontinuity Wiring harness between L73 (Female) (28),
Standard Values (Disconnection or Resistance 1 Ω and below
defective contact) F26 (Female) (1)
Wiring harness between F26 (Female) (2) -

body

3
40-354 3 WA380-5L
Failure Code: [DWM1KB]
Work Equipment Neutral Lock Solenoid System Ground Fault

Failure code
code code Trouble Work equipment neutral lock solenoid system ground fault.
E01 DWM1KB WRK
Description of
• Work equipment neutral lock solenoid power supply system ground fault.
trouble
Controller
• Stops the output to the neutral lock solenoid.
reaction
Effect on
• Normal operation is possible (Does not affect the lock lever).
machine
Related
• —
information

Defective neutral 3) Connect T-adapter.
1 lock solenoid
(ground fault) Between F26 (Male) (1) - (2) Resistance 35 - 45 Ω

Causes and Wiring harness 2) Disconnect connectors L73 and F26.
Standard Values ground fault 3) Connect T-adapter.
2 (Disconnection or
defective contact) Wiring harness between L73 (Female) (28),
F26 (Female) (1) - body

3
WA380-5L 40-355 3
Failure Code: [DWN6KA]
Lift Arm RAISE Magnet Detent System Disconnection

Failure code
code code Trouble Lift arm RAISE magnet detent system disconnection.
E01 DWN6KA WRK
Description of
• The detent cannot be controlled due to the lift arm RAISE magnet detent system disconnection.
trouble
• Stops output to the magnet detent solenoid.

Controller
• Stops the remote RAISE function.
reaction
• Stops the output of the remote positioner RAISE lamp.
Effect on
• The detent does not work but normal operation is possible.
machine
Related
information

2) Disconnect connector L26E.
1 RAISE magnet
detent Between L26E (Male) (1) - (2) Resistance 35 - 45 Ω
Between L26E - body Resistance 1 MΩ and above

Wiring harness 2) Disconnect connectors L73 and L26E.
2 (Disconnection or
Possible Resistance 1 Ω and below
L26E (Female) (1)
Causes and
Between L73 (Female) (17) - L26E (Female)

(1)
Defective work
3 1) Turn starting switch OFF.
Between L73 Lever neutral Voltage 1 V and below

(17) - body Lever maximum raise position Voltage 17 - 30 V
40-356 3 WA380-5L
WA380-5L 40-357 3
Failure Code: [DWN6KB]
Lift Arm RAISE Magnet Detent System Ground Fault

Failure code
code code Trouble Lift arm RAISE magnet detent system ground fault
E01 DWN6KB WRK
Description of
• The detent cannot be controlled due to the lift arm RAISE magnet detent system ground fault.
trouble

Controller
• Stops the remote RAISE function.
reaction
• Stops the output of the remote positioner RAISE lamp.
Effect on
machine
Related
information

Defective lift arm
1
RAISE EPC solenoid Between L26E (Male) (1) - (2) Resistance 35 - 45 Ω
Wiring harness between L26E (Male) (1) -

body
Causes and 2) Disconnect connectors L73 and L26E.
Wiring harness
2 (Disconnection or
L26E (Female) (1) - body

3
40-358 3 WA380-5L
WA380-5L 40-359 3
Lift Arm FLOATING Magnet Detent System Disconnection

Failure code
code code Trouble Lift arm FLOATING magnet detent system disconnection.
E01 DWN7KA WRK
Description of
• The detent cannot be controlled due to the lift arm FLOATING magnet detent system disconnection.
trouble

Controller
• Stops the remote FLOATING function.
reaction
• Stops the output of the remote positioner FLOATING lamp.
Effect on
machine
Related
information

1 FLOATING magnet
detent Between L27 (Male) (1) - (2) Resistance 35 - 45 Ω

Possible Wiring harness 2) Disconnect connectors L73 and L27.
Causes and discontinuity 3) Connect T-adapter.
2 (Disconnection or
Standard Values
L27 (Female) (1)

3
(27) - body Lever FLOATING position Voltage 17 - 30 V
40-360 3 WA380-5L
WA380-5L 40-361 3
Lift Arm FLOATING Magnet Detent System Ground Fault

Failure code
code code Trouble Lift arm FLOATING magnet detent system ground fault
E01 DWN7KB WRK
Description of
• The detent cannot be controlled due to the lift arm FLOATING magnet detent system ground fault.
trouble

Controller
• Stops the remote FLOATING function.
reaction
• Stops the output of the remote positioner FLOATING lamp.
Effect on
machine
Related
information

1 FLOATING magnet
detent Between L27 (Male) (1) - (2) Resistance 35 - 45 Ω
Wiring harness between L27 (Male) (1) - body Resistance 1 MΩ and above

Causes and Wiring harness 2) Disconnect connectors L73 and L27.
2 (Disconnection or
L27 (Female) (1) - body

3
40-362 3 WA380-5L
WA380-5L 40-363 3
Lift Arm TILT Magnet Detent System Disconnection

Failure code
code code Trouble Lift arm TILT magnet detent system disconnection.
E01 DWN8KA WRK
Description of
• The detent cannot be controlled due to the lift arm TILT magnet detent system disconnection.
trouble

Controller
• Stops the remote TILT function.
reaction
• Stops the output of the remote positioner TILT lamp.
Effect on
machine
Related
information

1
TILT magnet detent
Between L25E (Male) (1) - (2) Resistance 35 - 45 Ω
Between L25E (Male) - body Resistance 1 MΩ and above

Possible Wiring harness 2) Disconnect connectors L73 and L25E.
Causes and discontinuity 3) Connect T-adapter.
2 (Disconnection or
Standard Values
L25E (Female) (1)

3
(37) - body Lever TILT position Voltage 17 - 30 V
40-364 3 WA380-5L
Lift Arm TILT Magnet Detent System Ground Fault

Failure code
code code Trouble Lift arm TILT magnet detent system ground fault
E01 DWN8KB WRK
Description of • The detent cannot be controlled due to the ground fault of the power supply system of the bucket TILT
trouble magnet detent system.

Controller
• Stops the remote TILT function.
reaction
• Stops the output of the remote positioner TILT lamp.
Effect on
machine
Related
information

Defective lift arm
1 FLOATING magnet
detent Between L25E (Male) (1) - (2) Resistance 35 - 45 Ω
Wiring harness between L25E (Male) (1) -

body
Causes and 2) Disconnect connectors L73 and L25E.
Wiring harness
Standard Values discontinuity 3) Connect T-adapter.
2 (Disconnection or
L25E (Female) (1) - body

3
WA380-5L 40-365 3
Failure Code: [DXHJKA]
3rd Valve Extension EPC Solenoid System Disconnection

Failure code
code code Trouble 3rd valve extension EPC solenoid system disconnection
E03 DXHJKA WRK
Description of
• 3rd valve extension EPC solenoid system disconnection prevents output to the 3rd valve EPC solenoid.
trouble
Controller
• Stops output to the 3rd valve extension EPC solenoid.
reaction
Effect on
• The 3rd valve cannot extend.
machine
Related
information

Defective 3rd valve 3) Connect T-adapter.
1 extension EPC
Between F24 (Male) - body Resistance 1 MΩ and above

Possible 2) Disconnect connectors L73 and F24.
Wiring harness
Standard Values
2 ground fault Wiring harness between L73 (Female) (25),

F24 (Female) (2)

Defective work 2) Disconnect connector L73.
40-366 3 WA380-5L
Failure Code: [DXHJKB]
3rd Valve Extension EPC Solenoid System Ground Fault

Failure code
code code Trouble 3rd valve extension EPC solenoid system ground fault.
E01 DXHJKB WRK
Description of
• 3rd valve extension EPC solenoid system ground fault prevents output to the 3rd valve EPC solenoid.
trouble
Controller
reaction
Effect on
machine
Related
information

Defective 3rd valve 2) Disconnect connector F24.
1 extension EPC 3) Connect T-adapter.
solenoid

Wiring harness
Causes and 2 ground fault and 3) Connect T-adapter.
Standard Values defective short circuit
body

3
WA380-5L 40-367 3
Failure Code: [DXHKKA]
3rd Valve Retraction EPC Solenoid System Disconnection

Failure code
code code Trouble 3rd valve retraction EPC solenoid system disconnection
E03 DXHKKA WRK
Description of
• 3rd valve retraction EPC solenoid system disconnection prevents output to the 3rd valve EPC solenoid.
trouble
Controller
reaction
Effect on
machine
Related
information

Defective 3rd valve 3) Connect T-adapter.
1 extension EPC
Between F25 (Male) - body Resistance 1 MΩ and above

Wiring harness
Standard Values
2 ground fault Wiring harness between L73 (Female) (35),

F25 (Female) (2)

Defective work 2) Disconnect connector L73.
40-368 3 WA380-5L
Failure Code: [DXHKKB]
3rd Valve Retraction EPC Solenoid System Ground Fault

Failure code
code code Trouble 3rd valve retraction EPC solenoid system ground fault.
E01 DXHKKB WRK
Description of
• 3rd valve retraction EPC solenoid system ground fault prevents output to the 3rd valve EPC solenoid.
trouble
Controller
• Stops output to the 3rd valve retraction EPC solenoid.
reaction
Effect on
machine
Related
information

Defective 3rd valve 2) Disconnect connector F25.
1 extension EPC 3) Connect T-adapter.
solenoid

Wiring harness
Causes and 2 ground fault and 3) Connect T-adapter.
Standard Values defective short circuit
body

3
WA380-5L 40-369 3
Failure Code: [DXHLKA]
Open in Joystick Steering Right-Hand EPC Solenoid System

Failure code
code code Trouble Joystick steering right-hand EPC solenoid system disconnection
E03 DXHLKA WRK
Description of • Joystick steering right-hand EPC solenoid system disconnection prevents output to the joystick steering
trouble right-hand EPC solenoid.
Controller • Stops output to the joystick steering right-hand EPC solenoid (Both sides).
reaction • Stops output to the joystick solenoid cutoff relay.
Effect on
• Cannot operate the steering with the joystick steering lever.
machine
Related
• —
information

Defective joystick steering 3) Connect T-adapter.
1
right-hand EPC solenoid


Possible
(26) - L36 (Female) (1) Resistance 1 Ω and below
contact)
(Female) (2) - body

(Female) (23) - L41 (Female) (2)

3
controller
Resistance 10 - 15 Ω
(Female) (1)
40-370 3 WA380-5L
WA380-5L 40-371 3
Failure Code: [DXHLKB]
Joystick Steering Right-Hand EPC Solenoid System Ground Fault

Failure code
code code Trouble Joystick steering right-hand EPC solenoid system ground fault
E03 DXHLKB WRK
Description of • Joystick steering right-hand EPC solenoid system ground fault prevents output to the joystick steering
trouble right-hand EPC solenoid.
Controller • Stops output to the joystick steering right-hand EPC solenoid (Both sides).
Effect on
machine
Related
• —
information

Defective joystick steering
1 right-hand EPC solenoid 3) Connect T-adapter.

Causes and 2 Wiring harness ground fault 3) Connect T-adapter.
Standard Values
(26), L36 (Female) (1) - body

3
controller
(Female) (1)
40-372 3 WA380-5L
WA380-5L 40-373 3
Failure Code: [DXHMKA]
Joystick Steering Left-Hand EPC Solenoid System Open

Failure code
code code Trouble Joystick steering left-hand EPC solenoid system disconnection
E03 DXHMKA WRK
Description of • Joystick steering left-hand EPC solenoid system disconnection prevents output to the joystick steering
trouble left-hand EPC solenoid.
Controller • Stops output to the joystick steering left-hand EPC solenoid (Both sides).
Effect on
machine
Related
• —
information

Defective joystick steering 3) Connect T-adapter.
1
right-hand EPC solenoid


Possible
contact)
(Female) (2) - body

(Female) (23) - L41 (Female) (4)

3
controller
(Female) (3)
40-374 3 WA380-5L
WA380-5L 40-375 3
Failure Code: [DXHMKB]
Joystick Steering Left-Hand EPC Solenoid System Ground Fault

Failure code
code code Trouble Joystick steering left-hand EPC solenoid system ground fault
E03 DXHMKB WRK
Description of • Joystick steering left-hand EPC solenoid system ground fault prevents output to the joystick steering left-
trouble hand EPC solenoid.
Controller • Stops output to the joystick steering left-hand EPC solenoid (Both sides).
Effect on
machine
Related
• —
information

Defective joystick steering left-
1 hand EPC solenoid 3) Connect T-adapter.

Causes and 2 Wiring harness ground fault 3) Connect T-adapter.
Standard Values
(36), L35 (Female) (1) - body

3
controller
(Female) (3)
40-376 3 WA380-5L
WA380-5L 40-377 3
Failure Code: [WRK-1]
Defective Lift Arm Lock Switch System

Failure code
code code Trouble Defective lift arm lock switch system
WRK-1 — (WRK)
Description of • The work equipment (Lift arm and bucket) does not operate due to disconnected, short-circuited, or
trouble grounded lift arm lock (Work equipment lock lever) switch system or cannot be locked.
Controller
• No reaction.
reaction
Effect on
• The work equipment (Lift arm and bucket) does not operate or cannot be locked.
machine
Related
• Can be checked with the monitoring function (Code: 40917_D_IN_1).
information

Defective lift arm lock 3) Connect T-adapter.
1
switch
Between L13 Boom lock switch = ON Resistance 1 Ω and below
(Male) (1) - (2) Boom lock switch = OFF Resistance 1 MΩ and above

2) Disconnect connectors L71, L13, and FS4.
2 discontinuity
(Disconnection or Between FS4 (Female) (5) - L13 (Male) (2) Resistance 1 Ω and below
defective contact)
(Female) (17) Resistance 1 Ω and below

Possible Wiring harness 2) Disconnect connectors L71 and L13.
Causes and grounded or short- 3) Connect T-adapter.
Standard Values 3 circuited incorrectly 4) Turn starting switch ON.
★ Fuse A-5 blows
in this case Between L13 (Female) (1), L71 (Female) (17)
- body

Wiring harness
4 hotshorted 3) Connect T-adapter.
incorrectly
Between L13 (Female) (1), L71 (Female) (17)
- body

5
Between L71 Boom lock switch = ON Voltage 1 V and below
(17) - body Boom lock switch = OFF Voltage 20 - 30 V
40-378 3 WA380-5L
WA380-5L 40-379 3
Defective Remote Positioner RAISE Setting Switch System

Failure code
code code Trouble Defective remote positioner RAISE setting switch system
WRK-2 — (WRK)
Description of • The RAISE stopping position of the remote positioner cannot be set due to disconnected remote
trouble positioner RAISE setting switch system and hot-short.
Controller
• No reaction.
reaction
Effect on
• The stopping position of the remote positioner RAISE setting cannot be set.
machine
Related
information

Defective remote
1 positioner RAISE Remote positioner setting
setting switch Resistance 1 Ω and below
Between S12 switch = RAISE
(Male) (1) - (2) Remote positioner setting
switch = other than above

2 (Disconnection or
S12 (Female) (1) Resistance 1 Ω and below
Possible
Causes and
3 ground fault or hot 4) Turn starting switch ON.
shorted
Between L72 (Female) (13), S12 (Female) (1)
- body

Defective work
4
equipment controller Remote positioner setting
Between L72 switch = RAISE Voltage 1 V and below
(Male) (13) -
body Remote positioner setting
switch = other than above Voltage 20 - 30 V
40-380 3 WA380-5L
WA380-5L 40-381 3
Defective Remote Positioner LOWER Setting Switch System

Failure code
code code Trouble Defective remote positioner LOWER setting switch system
WRK-3 — (WRK)
Description of • The LOWER stopping position of the remote positioner cannot be set due to disconnected remote
trouble positioner LOWER setting switch system and hot-short.
Controller
• No reaction.
reaction
Effect on
• The stopping position of the remote positioner LOWER setting cannot be set.
machine
Related
information

Defective remote
1 positioner LOWER Remote positioner setting
setting switch Resistance 1 Ω and below
Between S12 switch = LOWER
(Male) (2) - (3) Remote positioner setting
switch = other than above

2 (Disconnection or
S12 (Female) (3) Resistance 1 Ω and below
Possible
Causes and
Hot-shorted wiring
harness
Between L72 (Female) (3), S12 (Female) (3) -
body

Defective work
4
equipment controller Remote positioner setting
Between L72 switch = LOWER Voltage 1 V and below
(Male) (3) -
body Remote positioner setting
switch = other than above Voltage 20 - 30 V
40-382 3 WA380-5L
WA380-5L 40-383 3
Defective Remote Positioner RAISE Selection Switch System

Failure code
code code Trouble Defective remote positioner RAISE selection switch system
WRK-4 — (WRK)
Description of • The remote positioner cannot select RAISE or cancel RAISE selection due to disconnected, grounded, or
trouble hot-shorted remote positioner RAISE selection switch system.
Controller
• No reaction.
reaction
Effect on
• The remote positioner cannot select RAISE or cancel RAISE selection.
machine
Related
information

Defective remote
1 positioner RAISE Remote positioner RAISE
selection switch Resistance 1 Ω and below
selection switch = ON
Between S13
(Male) (4) - (3)
Remote positioner RAISE
selection switch = OFF

2) Disconnect connectors L72, S13, S12, and FS3.
Wiring harness
2 discontinuity Wiring harness between L72 (Female) (2), S13
(Disconnection or
(Female) (4) - S12 (Female) (6) Resistance 1 Ω and below
defective contact)
Wiring harness between FS3 (Female) (11) -
S12 (Female) (5)

Causes and 2) Disconnect connectors L72, S13, and S12.
Standard Values Wiring harness 4) Turn starting switch ON.
3
ground fault
Between L72 (Female) (2), S13 (Female) (4),
S12 (Female) (6) - body

2) Disconnect connectors L72, S13, and S12.
Hot-shorted wiring 4) Turn starting switch ON.
4
harness

Defective work
5
equipment controller Remote positioner RAISE
selection switch = ON
(Female) (2)
body Remote positioner RAISE Voltage 20 - 30 V
selection switch = OFF
40-384 3 WA380-5L
WA380-5L 40-385 3
Defective Remote Positioner LOWER ON/OFF Switch System

Failure code
code code Trouble Defective remote positioner LOWER ON/OFF switch system
WRK-5 — (WRK)
Description of • The remote positioner cannot select LOWER or cancel LOWER selection due to disconnected, grounded,
trouble or hot-shorted remote positioner LOWER ON/OFF switch system.
Controller
• No reaction.
reaction
Effect on
• The remote positioner cannot select LOWER or cancel LOWER selection.
machine
Related
information

Defective remote
1 positioner LOWER Remote positioner ON/OFF
ON/OFF switch Resistance 1 Ω and below
switch = ON
Between S14
(Male) (4) - (3)
Remote positioner ON/OFF
switch = OFF

2) Disconnect connectors L72, S14, S12, and FS3.
Wiring harness
2 discontinuity Wiring harness between L72 (Female) (38),
(Disconnection or
S14 (Female) (4) - S12 (Female) (4) Resistance 1 Ω and below
defective contact)
S12 (Female) (5)

Causes and 2) Disconnect connectors L72, S14, and S12.
Standard Values Wiring harness 4) Turn starting switch ON.
3
ground fault

2) Disconnect connectors L72, S14, and S12.
Hot-shorted wiring 4) Turn starting switch ON.
4
harness

Defective work
5
equipment controller Remote positioner ON/OFF
switch = ON
(Female) (38)
body Remote positioner ON/OFF Voltage 20 - 30 V
switch = OFF
40-386 3 WA380-5L
WA380-5L 40-387 3
Defective Bucket Cylinder Proximity Switch System

Failure code
code code Trouble Defective bucket cylinder proximity switch system
WRK-6 — (WRK)
Description of • The bucket leveler does not function due to disconnected, grounded, or short-circuited bucket cylinder
trouble proximity switch system.
Controller
• No reaction.
reaction
Effect on
• The bucket leveler does not function.
machine
Related
information

2) Disconnect connectors L73, F09, and L104.

discontinuity F09 (Female) (A)
1
(Disconnection or
F09 (Female) (B)
Wiring harness between F09 (Female) (C) -

body

Wiring harness Between L73 (Female) (20), F09 (Female) (B),
Possible 2 Resistance 1 MΩ and above
ground fault L104 (7) - body
Causes and
Standard Values FS4 (Female) (5), F09 (Female) (A) - body
★ Fuse A-(5) blows in this case
Hot-shorted wiring 3) Connect T-adapter.
harness
Between L73 (Female) (20), F09 (Female) (B),
L104 (7) - body

Defective bucket
4 cylinder proximity 4) Turn starting switch ON.
switch
Bucket under level Voltage 1 V and below
Between F09
(B) - (C)
Bucket above level Voltage 20 - 30 V
40-388 3 WA380-5L

Possible 3) Insert T-adapter.
Causes and 5 Defective work 4) Turn starting switch ON.
Standard Values
Between L73 Bucket under level Voltage 1 V and below
(20) - body Bucket above level Voltage 20 - 30 V
WA380-5L 40-389 3
Defective Bucket Cylinder Full Stroke Detection Switch System

Failure code
code code Trouble Defective bucket cylinder full stroke detection switch system
WRK-7 — (WRK)
Description of • The semi-automatic digging mode is not available or cannot be cancelled due to disconnected, grounded
trouble or short-circuited bucket cylinder full stroke detection switch system.
Controller
• No reaction.
reaction
Effect on
• Semi-automatic general operation mode is not available or cannot be cancelled
machine
Related
information

Wiring harness Wiring harness between FS4 (Female) (5) - Resistance 1 Ω and below
discontinuity F19 (Female) (A)
1
(Disconnection or
F19 (Female) (B)
Wiring harness between F19 (Female) (C) -

body

Wiring harness Between L73 (Female) (30), F19 (Female) (B)
Possible 2 Resistance 1 MΩ and above
ground fault - body
Causes and
Standard Values FS4 (Female) (5), F09 (Female) (A) - body
★ Fuse A-(5) blows in this case
Hot-shorted wiring
harness
Between L73 (Female) (30), F19 (Female) (B)
- body Voltage 1 V and below

Defective bucket
4 cylinder full stroke 4) Turn starting switch ON.
detection switch
Bucket under level Voltage 1 V and below
Between F19
(B) - (C)
Bucket above level Voltage 20 - 30 V

Possible 3) Insert T-adapter.
Causes and 5
Standard Values
Between L73 Bucket under level Voltage 1 V and below
(30) - body Bucket above level Voltage 20 - 30 V
40-390 3 WA380-5L
WA380-5L 40-391 3
Defective Semi-Automatic Digging HARD Selection Switch System

Failure code
code code Defective Semi-Automatic Digging HARD Selection switch
Trouble
system
WRK-8 — (WRK)
• The semi-automatic digging HARD control is not available or the semi-automatic digging HARD mode
Description of
cannot be cancelled due to disconnected, grounded or short-circuited semi-automatic digging HARD
trouble
selection switch system.
Controller
• No reaction.
reaction
Effect on • Semi-automatic digging HARD control is not available or the semi-automatic digging HARD mode cannot
machine be cancelled.
Related
information

Wiring harness
discontinuity Wiring harness between L73 (Female) (9) -
1 Resistance 1 Ω and below
(Disconnection or
defective contact) S15 (Female) (1)
Wiring harness between S15 (Female) (2) -

body

Wiring harness Between L73 (Female) (9), S15 (Female) (1) -
2 Resistance 1 MΩ and above
ground fault body
Possible FS3 (Female) (11), S15 (Female) (5) - body

Causes and ★ Fuse A-(5) blows in this case
Standard Values
Hot-shorted wiring
harness
Between L73 (Female) (9), S15 (Female) (1) -

Defective
4 semi-automatic Semi-automatic digging
digging (HARD) Voltage 1 V and below
switch (HARD) = ON
Between S15
(1) - (2) Semi-automatic digging
switch (HARD) = other than Voltage 20 - 30 V
ON
40-392 3 WA380-5L

Possible
Defective work
Causes and 5 Semi-automatic digging
equipment controller Voltage 1 V and below
Standard Values switch (HARD) = ON
Between L73
(9) - body Semi-automatic digging
switch (HARD) = other than Voltage 20 - 30 V
ON
WA380-5L 40-393 3
Defective Semi-Automatic Digging SOFT Selection Switch System

Failure code
code code Defective Semi-Automatic Digging SOFT Selection switch
Trouble
system
WRK-9 — (WRK)
• The semi-automatic digging SOFT control is not available or the semi-automatic digging SOFT mode
Description of
cannot be cancelled due to disconnected, grounded or short-circuited semi-automatic digging SOFT
trouble
selection switch system.
Controller
• No reaction.
reaction
Effect on • Semi-automatic digging SOFT control is not available or the semi-automatic digging SOFT mode cannot
machine be cancelled.
Related
information

Wiring harness
(Disconnection or
defective contact) S15 (Female) (3)
Wiring harness between S15 (Female) (2) -

body

Wiring harness Between L73 (Female) (19), S15 (Female) (2)
ground fault - body
Possible FS3 (Female) (11), S15 (Female) (5) - body

Causes and ★ Fuse A-(5) blows in this case
Standard Values
Hot-shorted wiring
harness
Between L73 (Female) (19), S15 (Female) (3)
- body Voltage 1 V and below

Defective
4 semi-automatic Semi-automatic digging
digging (SOFT) Voltage 1 V and below
switch (SOFT) = ON
Between S15
(3) - (2) Semi-automatic digging
switch (SOFT) = other than Voltage 20 - 30 V
ON
40-394 3 WA380-5L

Possible
Defective work
Causes and 5 Semi-automatic digging
equipment controller Voltage 1 V and below
Standard Values switch (SOFT) = ON
Between L73
(19) - body Semi-automatic digging
switch (SOFT) = other than Voltage 20 - 30 V
ON
WA380-5L 40-395 3
Defective Joystick ON/OFF Switch System

Failure code
code code Trouble Defective joystick ON/OFF switch system
WRK-10 — (WRK)
Description of
• The joystick mode cannot be used or be cancelled due to defective joystick ON/OFF switch system.
trouble
Controller
• No reaction.
reaction
Effect on
• The joystick mode cannot be used or cancelled.
machine
Related
information

Defective joystick
1
ON/OFF switch Joystick ON/OFF switch Resistance 1 Ω and below
Between L39 = ON
(Female) (4) - (3)
Other than above = OFF Resistance 1 MΩ and above

2 Defective joystick N
lock switch
Between L38 Left arm rest = Lock Resistance 1 Ω and below
(Female) (1) - (3) Other than above = OFF Resistance 1 MΩ and above

2) Disconnect connectors L71, L39, and L38.
Causes and
Standard Values Wiring harness between L71 (Female) (23) -
L39 (Female) (4)
Wiring harness
(Disconnection or L39 (Female) (3)
defective contact)
Between L38 (Female) (1) - body Voltage 20 - 30 V

Hot-shorted wiring 3) Connect T-adapter.
4 harness (Contacting 4) Turn starting switch ON.
24 V harness)
- body
40-396 3 WA380-5L

2) Disconnect connectors L71, S04, L71, L39, and L40.
Wiring harness Between L71 (Female) (23), L40 (Female) (4)
5
ground fault - body
★ Fuse A-(2) blows at switch operation in
Possible this case
Defective work
6 equipment controller
Joystick ON/OFF switch
Voltage 20 - 30 V
Between L71 (23) = ON
- body
Other than above = OFF Voltage 1 V and below
WA380-5L 40-397 3
Defective Joystick Steering Speed HI/LO Switch System

Failure code
code code Trouble Defective joystick steering speed HI/LO switch system
WRK-11 — (WRK)
Description of • The joystick steering speed slows or accelerates (Cannot be switched between HI/LO) due to defective
trouble joystick steering speed HI/LO switch system.
Controller
• No reaction.
reaction
Effect on
• The joystick steering speed slows or accelerates (Cannot be switched between HI/LO).
machine
Related
information

Defective joystick
1
H!/LO switch Joystick ON/OFF switch Resistance 1 Ω and below
Between L40 = ON
(Female) (4) - (3)
Other than above = OFF Resistance 1 MΩ and above

discontinuity
2 Wiring harness between L73 (10) - L40
defective contact) (Female) (4)
Between L40 (Female) (3) - body Resistance 1 Ω and below

Causes and Hot-shorted wiring 3) Connect T-adapter.
Standard Values 3 harness (Contacting 4) Turn starting switch ON.
24 V harness)
- body

2) Disconnect connectors L73, FS4, L71, L39, and L40.
Wiring harness Between L73 (Female) (10), L40 (Female) (4)
5
ground fault - body
★ Fuse A-(2) blows at switch operation in
this case

Defective work
6
Joystick ON/OFF switch
Voltage 20 - 30 V
Between L73 (10) = ON
- body
40-398 3 WA380-5L
WA380-5L 40-399 3
Defective Joystick Solenoid Cut Relay Output System

Failure code
code code Trouble Defective joystick solenoid cut relay output system
WRK-12 — (WRK)
Description of
• The joystick mode cannot be used or be cancelled due to defective joystick ON/OFF switch system.
trouble
Controller
• No reaction.
reaction
Effect on
• The joystick steering solenoid cannot be turned OFF.
machine
Related
• —
information

Hot-shorted wiring harness 3) Connect T-adapter.
Possible (Contacting 24 V harness)
Causes and Between L73 (Female) (7), L41
Standard Values Voltage 1 V and below
(Female) (5) - body

2 Defective
controller
work equipment 3) Connect T-adapter.
40-400 3 WA380-5L
Hot Short-Circuited Lift Arm RAISE Magnet Detent Output System

Failure code
code code Trouble Hot short-circuited lift arm RAISE magnet detent output system
WRK-13 — (WRK)
Description of
• RAISE detent cannot be cancelled due to hot short-circuited lift arm RAISE magnet detent output system.
trouble
Controller
• No reaction.
reaction
Effect on • RAISE detent left turned ON.

machine • Normal operation is possible excluding automatic cancel of detent.
Related
• —
information

2) Disconnect connectors L73 and L26E.
1 Short-circuited wiring harness 4) Turn starting switch ON.
Possible
Causes and Between L73 (Female) (17), L26E
(Female) (1) - body

2 Defective
controller
WA380-5L 40-401 3
Hot Short-Circuited Lift Arm FLOAT Magnet Detent Output System

Failure code
code code Trouble Hot short-circuited lift arm FLOAT magnet detent output system
WRK-14 — (WRK)
Description of • FLOAT detent cannot be cancelled due to hot short-circuited lift arm FLOAT magnet detent output
trouble system.
Controller
• No reaction.
reaction
Effect on • FLOAT detent left turned ON.

Related
• —
information

Possible
(Female) (1) - body

2 Defective
controller
40-402 3 WA380-5L
Hot Short-Circuited Bucket TILT Magnet Detent Output System

Failure code
code code Trouble Hot short-circuited bucket TILT magnet detent output system
WRK-15 — (WRK)
Description of
• TILT detent cannot be cancelled due to hot short-circuited bucket TILT magnet detent output system.
trouble
Controller
• No reaction.
reaction
Effect on • TILT detent left turned ON.

Related
• —
information

2) Disconnect connectors L73 and L25E.
Possible
Causes and Between L73 (Female) (37), L25E
(Female) (1) - body

2 Defective
controller
WA380-5L 40-403 3
Hot Short-Circuited Work Equipment Neutral Lock Solenoid Output System

Failure code
code code Hot short-circuited work equipment neutral lock solenoid output
Trouble
system
WRK-16 — (WRK)
Description of • Neutral lock solenoid cannot be turned OFF due to hot short-circuited work equipment neutral lock
trouble solenoid output system.
Controller
• No reaction.
reaction
Effect on
• Working equipment locked even when the lock lever is free.
machine
Related
• —
information

Possible
Causes and Between L73 (Female) (28), F26
(Female) (1) - body

2 Defective
controller
40-404 3 WA380-5L
Hot Short-Circuited Lift Arm RAISE EPC Solenoid System

Failure code
code code Trouble Hot short-circuited lift arm RAISE EPC solenoid system
WRK-17 — (WRK)
Description of • Lift arm RAISE EPC solenoid gets turned on due to hot short-circuited lift arm RAISE EPC solenoid
trouble system.
Controller
• No reaction.
reaction
Effect on
• Lift arm raises at full speed.
machine
Related
• —
information

Possible
(Female) (1) - body

2 Defective
controller
Between L73 (Female) (6) - body Resistance 9 - 10.2 Ω
WA380-5L 40-405 3
Hot Short- Circuited Lift Arm LOWER EPC Solenoid System

Failure code
code code Trouble Hot short-circuited lift arm LOWER EPC solenoid system
WRK-18 — (WRK)
Description of • Lift arm LOWER EPC solenoid gets turned on due to hot short-circuited lift arm LOWER EPC solenoid
trouble system.
Controller
• No reaction.
reaction
Effect on
• Lift arm lowers at full speed.
machine
Related
• —
information

Possible
(Female) (1) - body

2 Defective
controller
40-406 3 WA380-5L
Hot Short- Circuited Bucket TILT EPC Solenoid System

Failure code
code code Trouble Hot short-circuited bucket TILT EPC solenoid system
WRK-19 — (WRK)
Description of
• Bucket TILT EPC solenoid gets turned on due to hot short-circuited bucket TILT EPC solenoid system.
trouble
Controller
• No reaction.
reaction
Effect on
• Bucket tilts at full speed.
machine
Related
• —
information

Possible
(Female) (1) - body

2 Defective
controller
WA380-5L 40-407 3
Hot Short- Circuited Bucket DUMP EPC Solenoid System

Failure code
code code Trouble Hot short-circuited bucket DUMP EPC solenoid system
WRK-20 — (WRK)
Description of • Bucket DUMP EPC solenoid gets turned on due to hot short-circuited bucket DUMP EPC solenoid
trouble system.
Controller
• No reaction.
reaction
Effect on
• Bucket dumps at full speed.
machine
Related
• —
information

Possible
(Female) (1) - body

2 Defective
controller
40-408 3 WA380-5L
Hot Short- Circuited 3 Valves Extension EPC Solenoid System

Failure code
code code Trouble Hot short-circuited 3 valves extension EPC solenoid system
WRK-21 — (WRK)
Description of • 3 valves extension EPC solenoid gets turned on due to hot short-circuited 3 valves extension EPC
trouble solenoid system.
Controller
• No reaction.
reaction
Effect on
• 3 valves extends at full speed.
machine
Related
• —
information

Possible
(Female) (1) - body

2 Defective
controller
WA380-5L 40-409 3
Hot Short- Circuited 3 Valves Retraction EPC Solenoid System

Failure code
code code Trouble Hot short-circuited 3 valves retraction EPC solenoid system
WRK-22 — (WRK)
Description of • 3 valves retraction EPC solenoid gets turned on due to hot short-circuited 3 valves retraction EPC
trouble solenoid system.
Controller
• No reaction.
reaction
Effect on
• 3 valves retracts at full speed.
machine
Related
• —
information

Possible
(Female) (1) - body

2 Defective
controller
40-410 3 WA380-5L
Short in Joystick Steering Right EPC Solenoid System

Failure code
code code Trouble Hot short-circuited joystick steering right EPC solenoid system
WRK-23 — (WRK)
Description of • The joystick steering right EPC solenoid gets turned on due to hot short-circuited joystick steering speed
trouble right EPC solenoid system.
Controller
• No reaction.
reaction
Effect on
• Steering all the way to the right is possible.
machine
Related
• —
information

Possible
(Female) (1) - body

2 Defective
controller
WA380-5L 40-411 3
Short in Joystick Steering Left EPC Solenoid System

Failure code
code code Trouble Hot short-circuited joystick steering left EPC solenoid system
WRK-24 — (WRK)
Description of • The joystick steering left EPC solenoid gets turned on due to hot short-circuited joystick steering speed
trouble left EPC solenoid system.
Controller
• No reaction.
reaction
Effect on
• Steering all the way to the left is possible.
machine
Related
• —
information

Possible
(Female) (1) - body

2 Defective
controller
40-412 3 WA380-5L
WA380-5L 40-413 3

Defective Bucket Positioner, Boom Kick-Out and FLOAT Holding Function
Failure code
code code Defective bucket positioner, boom kick-out and FLOAT holding
Trouble
function
WRK-25 — —
Description of • Bucket positioner, boom kick-out and lift arm FLOAT holding functions do not function due to proximity
trouble switch and PPC detent circuit power supply system ground fault.
Controller
• No reaction.
reaction
Effect on
• Bucket positioner, boom kick-out and FLOAT holding do not function.
machine
Related
• —
information
Wiring harness ground 1) Turn starting switch OFF.

fault 2) Disconnect connector FS4, L104, L27S, (LL5), F9 and F10.
★ Fuse A-5 blows in this
case Between FS4 (Female) (5) - body Resistance 1 MΩ and above

3) Disconnect relays L123, L124.
4) Connect T-adapter
Between L104 (Male) (1) - (2), (7), (12) -

Relay sub-wiring harness body
ground fault
2 Between L104 (Male) (3) - (2), (7), (12) -
★ Fuse A-5 blows in this Resistance 1 MΩ and above
body
case
Possible Between L104 (Male) (6) - (2), (7), (12) -

Causes and body
Standard Values
Between L104 (Male) (8) - (2), (7), (12) -
body

Relay ground fault 3) Connect T-adapter.
3 ★ Fuse A-5 blows in this ★ In case 2 items are normal
case
Between L104 (Male) (1) - (2) - body Resistance 1 MΩ and above
Between L104 (Male) (6) - (7) - body Resistance 1 MΩ and above

Proximity switch ground 2) Disconnect connectors F9 and F10.
fault 3) Connect T-adapter.
4
★ Fuse A-5 blows in this Between F09 (Male) (A) - (B), (C) - body Resistance 1 MΩ and above
case
Between F10 (Male) (A) - (B), (C) - body Resistance 1 MΩ and above
40-414 3 WA380-5L
WA380-5L 40-415 3
Defective Boom Kick-Out Function and Cancellation

Failure code
code code
Trouble Defective boom kick-out function and cancellation
WRK-26 — —
Description of • Boom kick-out does not function or cannot be cancelled due to defective boom kick-out proximity switch
trouble system, lift arm PPC detent system and lift arm detent relay system.
Controller
reaction
• —
Effect on
• Boom kick-out does not function or cannot be cancelled.
machine
Related
information
• —


Defective lift arm detent 2) Disconnect connector L123.
1
relay 3) Replace boom detent relay (L123) with other relay.
4) Boom kick-out operation.
Boom detent relay (L123) is

Boom kick-out functions
abnormal

Possible Boom kick-out does not function
abnormal
Causes and
Defective lift arm PPC 2) Disconnect connector L26S.
2 3) Connect Tadapter.
detent
Between L26S (Male) (1) - (2) Resistance 30 - 50 Ω

3) Replace boom positioner proximity switch (F10) with bucket leveler
proximity switch (F9).
Defective lift arm 4) Boom kick-out operation.
3
positioner proximity switch
Boom kick-out proximity switch
Boom kick-out functions
(F10) is abnormal
Boom kick-out proximity switch

Boom kick-out does not function
(F10) is normal
40-416 3 WA380-5L

2) Disconnect connectors FS4, L104, L26S, and F10.
Wiring harness between FS4 (Female)

(5) - F10 (Female) (A)

(2) - F10 (Female) (B)
Wiring harness
4 Wiring harness between F10 (Female)
discontinuity
(C) - body

(5) - L26S (Female) (1)
Wiring harness between L26S (Female)

(2) - body
★ Boom kick-out does not function in all items.

2) Disconnect connectors L104, F10, and FS4.
Between L104 (Female) (2), F10

(Female) (B) - body
★ Boom kick-out detent function is not Resistance 1 MΩ and above
effective in this case (Lever returns to
Possible
Wiring harness ground neutral)
Causes and 5
Between L104 (Female) (5), L26S
(Female) (1) - body
★ Fuse A-2 blows and all detents will not
function (Lever returns to neutral)
Between FS4 (Female) (5), F10 (Female)

(A) - body
★ Fuse A-2 blows and all detents will not Resistance 1 MΩ and above


(Female) (B) - body
★ Fuse of hot-shorted circuit blows in this Voltage 1 V and below
case
6 Hot-shorted wiring harness
2) Disconnect connectors L104 and L26S.

(Female) (1) - body
★ Boom kick-out does not function in this
case (Lever does not return to neutral).
WA380-5L 40-417 3
40-418 3 WA380-5L
Defective Bucket Leveler Function and Cancellation

Failure code
code code
Trouble Defective bucket leveler function and cancellation
WRK-27 — —
Description of • Bucket kick-out does not function or cannot be cancelled due to defective bucket leveler proximity switch
trouble system, bucket PPC detent system and bucket detent relay system.
Controller
reaction
• —
Effect on
• Bucket leveler does not function or cannot be cancelled.
machine
Related
information
• —


Defective bucket detent 2) Disconnect connector L124.
1
relay 3) Replace bucket detent relay (L124) with other relay.
4) Bucket leveler operation.

Bucket leveler functions
abnormal

Possible Bucket leveler does not function
abnormal
Causes and
Defective bucket PPC 2) Disconnect connector L25S.
2 3) Connect Tadapter.
detent

3) Replace bucket leveler proximity switch (F09) with boom kick-out
proximity switch (F10).
Defective bucket leveler 4) Boom kick-out operation.
3
positioner proximity switch
Bucket leveler proximity switch
Bucket leveler functions
(F09) is abnormal
Bucket leveler proximity switch

Bucket leveler does not function
(F09) is normal
WA380-5L 40-419 3

2) Disconnect connectors FS4, L104, L25S, and F09.
Wiring harness between FS4 (Female)

(5) - F09 (Female) (A)

(7) - F09 (Female) (B)
Wiring harness
4 Wiring harness between F09 (Female)
discontinuity
(C) - body

(9) - L25S (Female) (1)
Wiring harness between L25S (Female)

(2) - body
★ Bucket positioner does not function in all items.

2) Disconnect connectors L104, F09, and FS4.

(Female) (B) - body
★ Buckrt leveler detent function is not Resistance 1 MΩ and above
effective in this case (Lever returns to
Possible
Wiring harness ground neutral)
Causes and 5
Between L104 (Female (9), L25S
(Female) (1) - body
★ Fuse A-2 blows and all detents will not
Between FS4 (Female) (5), F09 (Female)

(A) - body
★ Fuse A-2 blows and all detents will not Resistance 1 MΩ and above


(Female) (B) - body
★ Fuse of hot-shorted circuit blows in this Voltage 1 V and below
case
6 Hot-shorted wiring harness
2) Disconnect connectors L104 and L25S.

(Female) (1) - body
★ Bucket leveler does not function in this
case (Lever does not return to neutral).
40-420 3 WA380-5L
WA380-5L 40-421 3
Defective Lift Arm FLOAT Holding and Cancellation

Failure code
code code
Trouble Defective lift arm FLOAT holding and cancellation
WRK-28 — —
Description of • Lift arm FLOAT holding does not function or cannot be cancelled due to defective lift arm FLOAT PPC
trouble detent system.
Controller
• No reaction.
reaction
Effect on
• Lift arm FLOAT holding does not function or cannot be cancelled.
machine
Related
information
• —

2) Disconnect connector L27S.
1 Defective bucket PPC detent 3) Connect T-adapter.

Possible
Standard Values 2) Disconnect connectors FS4 and L27S.
2 (Disconnection or defective Wiring harness between FS4
contact) (Female) (5) and L27S (Female) (1)
Wiring harness between L27S

(Female) (2) and body
40-422 3 WA380-5L
WA380-5L 40-423 3
TROUBLESHOOTING MONITOR SYSTEM (MON MODE)
MONITOR SYSTEM (MON MODE)
Connector Types and Locations

system.
Number Address
Pins Layout Drawing
Drawing

40-424 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing

C29 M 1 Glass heater "ON" E-9 —
WA380-5L 40-425 3
Number Address
Pins Layout Drawing
Drawing


40-426 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing

WA380-5L 40-427 3
Number Address
Pins Layout Drawing
Drawing

40-428 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing
WA380-5L 40-429 3
Number Address
Pins Layout Drawing
Drawing

40-430 3 WA380-5L
WA380-5L 40-431 3
40-432 3 WA380-5L
WA380-5L 40-433 3
40-434 3 WA380-5L
WA380-5L 40-435 3
40-436 3 WA380-5L
Monitor System Diagram
WA380-5L 40-437 3
40-438 3 WA380-5L
WA380-5L 40-439 3
40-440 3 WA380-5L
Failure Code [2F00KM]

Dragging Parking Brake
Failure code
code code Trouble Defective parking brake system
E00 2F00KM MON
Description of • The parking brake operating detection circuit is opened when the F or R clutch is operating
trouble (the neutralization function does not work).
Controller
reaction
Effect on
• Dragging of parking brake (The parking brake remains operating).
machine
• The monitoring function (code: 40903, D-IN-26) allows the input state (ON/OFF) of the parking brake
pressure switch to be checked.
Related • The transmission gear shift lever input signal can be checked with the monitoring function (code: 40907,
information D-IN-20, 21 or 22).
• The monitoring function (code: 40907, D-IN-23) allows the input state (ON/OFF) of the parking brake
switch to be checked.

2) Disconnect connector PB.SW.
3) Connect t-adapter.
Defective parking Parking brake oil pressure =

1 brake indicator 0.6 MPa (6.1 kg/cm2) {5 lbf in} Resistance 1 Ω and below
switch Between and above
PB.SW (Male)
(1) - (2) Parking brake oil pressure =
0.34 MPa (3.5 kg/cm2) {3 lbf in} Resistance 1 MΩ and above
and above

Possible discontinuity 2) Disconnect connectors L54 and PB.SW.
Causes and (Disconnection or 3) Connect t-adapter.
2 defective contact
Standard Values
PB.SW (Female) (1)

4) Start engine.
Defective monitor Parking brake oil pressure =
3
panel 0.6 MPa (6.1 kg/cm2) {5 lbf in} Voltage 1 V and below
Between L54 and above
(Female) (1) -
body Parking brake oil pressure =
0.34 MPa (3.5 kg/cm2) {3 lbf in} Voltage 20 - 30 V
and above
WA380-5L 40-441 3

Parking brake switch = ON Resistance 1 Ω and below

Between L01
Defective parking (Male) (1) - (3)
4 Parking brake switch = OFF Resistance 1 MΩ and above
brake switch
Parking brake switch = ON Resistance 1 MΩ and above
Between L01
(Male) (2) - (3)
Parking brake switch = OFF Resistance 1 Ω and below
Between L01
At any time Resistance 1 MΩ and above
(Male) (1) - (2)

2) Disconnect connector PB.PS.
Defective parking
5
brake solenoid Between PB.PS (Male) (1) - (2) Resistance 10 - 40 Ω
Between PB.PS (Female) (2) - body Resistance 1 Ω and below
Between PB.PS (Male) (1)/(2) - body Resistance 1 MΩ and above

Possible
Causes and Parking brake oil pressure =
Standard Values 4.41 MPa (45 kg/cm2) Resistance 1 Ω and below
{39 lbf in} and above
Between R51
(Male) (1) -(2)
Parking brake oil pressure =
4.41 MPa (45 kg/cm2) Resistance 1 MΩ and above
Defective {39 lbf in} and below
6 emergency brake
pressure switch 1) Turn starting switch OFF.

4.41 MPa (45 kg/cm2) Resistance 1 Ω and below
{39 lbf in} and above
Between R52
(Male) (1) - (2)
4.41 MPa (45 kg/cm2) Resistance 1 Ω and below
{39 lbf in} and below

2) Disconnect connectors L01 ,L62 and PB.SW.
Wiring harness 3) Connect t-adapter.
discontinuity Dis
7 Wiring harness between L01 (Female) (2) and
connection or Resistance 1 Ω and below
PB.PS (Female) (1)
defective contact)
Wiring harness between L01 (Female) (2) and
L62 (Female) (6)
40-442 3 WA380-5L
WA380-5L 40-443 3
Failure Code [2G42ZG]

Accumulator Oil Pressure (Front Brake Circuit) Low
Failure code
code code Trouble Accumulator oil pressure (Front brake circuit) low
E03 2G42ZG MON
Description of
• The accumulator pressure sensor (Front) circuit is opened 50 seconds after the engine started.
trouble
Controller
reaction
• The accumulator oil pressure (Front brake circuit) is low.

Effect on
★ The front brake may be disabled.
machine
★ The parking brake may remain ON.
Related
• Can be checked with the monitoring function (Code: 40902_D-IN-16).
information
Low accumulator
1 oil pressure (Front —
brake circuit)

4) Start engine.
Defective brake oil
pressure sensor Front brake oil pressure = 5.88
2 (Front brake MPa (60 kg/cm2) {52 lbf in} and Resistance 1 Ω and below
circuit) above
Between R53
(Male) (1) - (2) Front brake oil pressure = 5.88
MPa (60 kg/cm2) {52 lbf in} and Resistance 1 MΩ and above
Possible below
Causes and
discontinuity 3) Connect t-adapter.
3
(Disconnection or
defective contact) Wiring harness between L53 (Female) (1) and
R53 (Female) (1)

Front brake oil pressure = 5.88

Defective monitor 1 Ω and below
4 MPa (60 kg/cm2) {52 lbf in} and Resistance
panel Between L53 above
(Female) (1) -
body Front brake oil pressure = 5.88
below
40-444 3 WA380-5L
WA380-5L 40-445 3
Failure Code [2G43ZG]

Accumulator Oil Pressure (Rear Brake Circuit) Low
Failure code
code code Trouble Accumulator oil pressure (Rear brake circuit) low
E03 2G43ZG MON
Description of
• The accumulator pressure sensor (Rear) circuit is opened 50 seconds after the engine started.
trouble
Controller
reaction
• The accumulator oil pressure (Rear brake circuit) is low.

Effect on
★ The rear brake may be disabled.
machine
★ The parking brake may remain ON.
Related
• Can be checked with the monitoring function (Code: 40902_D-IN-17).
information
Low accumulator
1 oil pressure (Front —
brake circuit)

4) Start engine.
Defective brake oil
pressure sensor Front brake oil pressure = 5.88
2 (Rear brake MPa (60 kg/cm2) {52 lbf in} and Resistance 1 Ω and below
circuit) above
Between R54
(Male) (1) - (2) Front brake oil pressure = 5.88
Possible below
Causes and
discontinuity 3) Connect t-adapter.
3
(Disconnection or
defective contact) Wiring harness between L53 (Female) (7) and
R54 (Female) (1)

Front brake oil pressure = 5.88

Defective monitor 1 Ω and below
4 MPa (60 kg/cm2) {52 lbf in} and Resistance
panel Between L53 above
(Female) (7) -
body Front brake oil pressure = 5.88
below
40-446 3 WA380-5L
WA380-5L 40-447 3
Failure Code [AA1ANX]

Air Cleaner 1 Clogged
Failure code
code code Trouble Air cleaner 1 clogged
E01 AA1ANX MON
Description of
• The clogging sensor circuit for air cleaner is opened.
trouble
Controller
reaction
Effect on
• Air cleaner 1 is clogged (The engine may be damaged).
machine
Related
information
Clogged air
1 —
cleaner

2) Disconnect connector E33.
This failure code (AA1ANX)

2 Defective
indicator 1
dust
Short-circuit issued
Dust indicator is not defective.
between E33
(Female) (1) -
(2) This failure code (AA1ANX) Dust indicator is defective
not issued (Air cleaner clogged).


Defective dust
Possible 3 2) Replace relay.
indicator relay
Causes and 3) Start engine.
Standard Values
Dust indicator relay 1 is not
This failure code (AA1ANX) issued
defective.
Dust indicator relay 1 is

This failure code (AA1ANX) not issued
defective.

Wiring harness
(Disconnection or
defective contact) body

(Female) (4)

Wiring harness 2) Disconnect connectors L112 and E33.
5 3) Connect t-adapter.
ground fault
Between L112 (Female) 2/E33 (Female) 1 - body Resistance 1 MΩ and above
40-448 3 WA380-5L

6 hot-shorted 4) Turn starting switch ON.
incorrectly
body
Possible
Causes and
Standard Values 3) Insert t-adapter.
4) Start engine.
7 Defective monitor
panel Dust indicator is not defective
Voltage 20 - 30 V
Between L53 (Air cleaner not clogged)
(Female) (3) -
body Dust indicator is defective (Air
cleaner clogged)
WA380-5L 40-449 3
Failure Code [AB00L6]

Defective Battery Charging Circuit
Failure code Defective battery charging circuit (Alternator terminal R signal
code code Trouble
detected when engine stopped)
E03 AB00L6 MON
Description of
• The alternator terminal R input voltage is 12 V or higher before the engine started.
trouble
Controller
reaction
Effect on • The engine cannot be started.

machine • The service meter increases simply by key-on.
Related
information
Between Engine started (Throttle 1/2 or

Voltage 27.5 - 29.5 V
Defective alternator more)
1
alternator terminal R
(E02) - body Engine stopped Voltage 1 V or below

2) Disconnect connectors L52, ER1 and alternator terminal R.
2 hot-shorted
incorrectly Wiring harness between connector L52 (Female)
(18) ER1 (Female) (3) - alternator terminal R Voltage 1 V or below
(E02)
Possible
Causes and 2) Disconnect connector L52.
Standard Values 3) Insert t-adapter.
Defective monitor
3 Engine started (Throttle 1/2 or
panel Voltage 27.5 - 29.5 V
Between L52 more)
(18) - body
Engine stopped Voltage 1 V or below

Defective diode 4) Turn starting switch ON.
4 R24
Wiring harness between connector L52 (Female)
(18), ER1 (Female) (3) - alternator terminal R Voltage 1 V or below
(E02)
40-450 3 WA380-5L
WA380-5L 40-451 3
Failure Code [AB00MA]

The Battery Charging Circuit is Out of Order
Failure code Defective battery charging circuit is out of order (No signal from
code code Trouble
alternator R terminal, Abnormal detection)
E03 AB00MA MON
Description of
• During engine operation, the input voltage to the alternator R terminal is below 5V.
trouble
Controller
• Alarm sounds.
reaction
Effect on
• The battery is deteriorated, the engine does not start and the service meter does not work.
machine
Related
information
Battery
1 —
deterioration
Between Engine started (Throttle 1/2 or

Voltage 27.5 - 29.5 V
Defective alternator more)
2
alternator terminal R
(E02) - body Engine stopped Voltage 1 V or below

Disconnection of 2) Disconnect connectors L52, ER1 and alternator terminal R.
harness 3) Connect t-adapter.
3 (disconnection,
Possible defective contact) Harnesses among Connectors L52 (female) (18),
Causes and ER1 (female) (3) and alternator R terminal (E02).
Standard Values
Ground fault of 3) Connect t-adapter.
4
harness
Connectors L52 (female) (18), ER1 (female) (3)
and alternator R terminal (E02) and body.

3) Insert t-adapter.
Defective monitor
5 Engine started (Throttle 1/2 or
panel Voltage 27.5 - 29.5 V
Between L52 more)
(18) - body
Engine stopped Voltage 1 V or below
40-452 3 WA380-5L
WA380-5L 40-453 3
Failure Code [B@BAZG]

Engine Oil Pressure Low
Failure code
code code Trouble Engine oil pressure low
E03 B@BAZG MON
Description of • The engine oil pressure sensor circuit is closed 15 minutes after the engine started and when the engine
trouble speed is 1,500 rpm or higher.
Controller
reaction
Effect on
• The engine oil pressure is low (The engine may be damaged).
machine
Related
information
Low engine oil

1 —
pressure

Defective engine
2 oil pressure Between oil Engine stopped Resistance 1 Ω and below
sensor pressure
switch terminal
(E29) and Engine rotating Resistance 1 MΩ and above
Possible body
Causes and
3 ground fault
Between L54 (Female) (2)/E29 - body Resistance 1 MΩ and above

Defective monitor 3) Connect t-adapter.
4
panel Between L54 Engine stopped Voltage 1 V and below
(Female) (2) -
body Engine rotating Voltage 20 - 30 V
40-454 3 WA380-5L
Failure Code [B@BAZK]

Engine Oil Level Low
Failure code
code code Trouble Engine oil level low
E01 B@BAZK MON
Description of
• The engine oil level sensor circuit is opened.
trouble
Controller
reaction
Effect on
• The engine oil level is low (The engine may be damaged).
machine
Related
information
Low engine oil

1 —
pressure

2 Defective engine
oil level sensor
Between E26 Oil level is normal Resistance 1 Ω and below
(Male) (1) -
body Oil level is low Resistance 1 MΩ and above
Possible
Standard Values 2) Disconnect connectors L54 and E26.
3
ground fault
Between L54 (Female) (11) - E26 (Female (1) Resistance 1 MΩ and above

Defective monitor 3) Connect t-adapter.
4
panel Between L54 Oil level is normal Resistance 1 Ω and below
(Female) (11) -
body Oil level is low Resistance 1 MΩ and above
WA380-5L 40-455 3
Failure Code [B@BCNS]

Engine Coolant Temperature Overheating
Failure code
code code Trouble Engine coolant temperature overheating
E02 B@BCNS MON
Description of
• The engine coolant temperature is above 105°C (221°F).
trouble
Controller • Triggers an alarm (Turns the engine coolant temperature caution lamp ON at 102°C (215°F) or above and
reaction issues this failure code at 105°C (221°F) or above).
Effect on • The engine coolant temperature overheat alarm is issued (The engine may be damaged if operation
machine continues).
Related
information
Overheating
1 engine coolant —
temperature

Defective engine 3) Connect t-adapter.
2 coolant
temperature Normal temperature (25°C)
sensor Resistance 35 - 50 Ω
Between E08 {77°F}
(Male) (1) - (2)
Possible 100°C (212°F) Resistance 3.1 - 4.5 Ω
3
ground fault
Wiring harness between L55 (Female) (8)/E08
(Female (1) - body

Defective monitor
4
panel Normal temperature (25°C)
Between L55 Resistance 35 - 50 Ω
(Female) (8) - {77°F}
body 100°C (212°F) Resistance 3.1 - 4.5 Ω
40-456 3 WA380-5L
WA380-5L 40-457 3
Failure Code [B@BCZK]

Alarm Indicating Low Coolant Level
Failure code
code code Trouble Alarm Indicating Low Coolant Level
E01 B@BCZK MON
Description of
• The coolant level sensor circuit is opened.
trouble
Controller
reaction
Effect on
• The coolant level is low (The engine may be damaged).
machine
Related
information
1 Low coolant level —

2 Defective coolant
level sensor Reserve tank low level and
Between R32 below (abnormal)
(Male) (1) - (2)
Reserve tank low level and
above (normal)
Possible
Standard Values Wiring harness 3) Connect t-adapter.
3
ground fault
Wiring harness between L54 (Female) (10) - R32
(Female) (1)

Defective monitor
4 Reserve tank low level and
panel Between L54 Resistance 1 MΩ and above
below (abnormal)
(Female) (10) -
body Reserve tank low level and
above (normal)
40-458 3 WA380-5L
Failure Code [B@HANS]

Hydraulic Oil Temperature Overheating
Failure code
code code Trouble Hydraulic oil temperature overheating
E02 B@BCNS MON
Description of
• The hydraulic oil temperature is above 110°C (230°F).
trouble
Controller
reaction
Effect on • The hydraulic oil temperature overheat alarm is issued (The pump/cylinder sealing may be damaged if
machine operation continues)
Related
information
Overheating
1 hydraulic oil —
temperature

Defective 3) Connect t-adapter.
2 hydraulic oil
Between R47 {77°F}
(Male) (1) - (2)
Possible 100°C (212°F) Resistance 3.1 - 4.5 Ω
Standard Values 2) Disconnect connectors L55 and R47.
3
ground fault
Wiring harness between L55 (Female) (7)/R47
(Female) (1) - body

Defective monitor
4
(Female) (7) - {77°F}
WA380-5L 40-459 3
Failure Code [B@CENS]

Torque Converter Oil Temperature Overheating
Failure code
code code Trouble Torque converter oil temperature overheating
E02 B@BCNS MON
Description of
• The torque converter oil temperature is above 130°C (266°F).
trouble
Controller • Triggers an alarm (Turns the torque converter oil temperature caution lamp ON at 120°C (248°F) or
reaction above and issues this failure code at 130°C (266°F) or above).
Effect on • The hydraulic oil temperature overheat alarm is issued (The pump/cylinder sealing may be damaged if
machine operation continues)
Related
information
Overheating
1 —
torque converter

2) Disconnect connector TC.T.
2 torque converter
Between TC.T {77°F}
(Male) (1) - (2)
100°C (212°F) Resistance 3.1 - 4.5 Ω
Possible
Standard Values 2) Disconnect connectors L55 and TC.T.
3
ground fault
Wiring harness between L55 (Female) (2)/TC.T
(Female) (1) - body

Defective monitor
4
(Female) (2) - {77°F}
40-460 3 WA380-5L
WA380-5L 40-461 3
Failure Code [D182KZ]

The Preheater Relay Coil is Open or Shorted
Failure code
code code Trouble The preheater relay coil is disconnected or short-circuited.
E01 D182KZ MON
Description of
• The preheater relay drive circuit was disconnected or short-circuited with ground.
trouble
Controller
• The preheater relay can not be set to ON.
reaction
Effect on
• The machine does not start smoothly at the time of low temperature.
machine
Related
• —
information
1) Starting switch OFF.

2) Replace the relay with another relay of the same kind.
3) Starting switch ON.
4) Set the forward-reverse lever to "R."
The failure code "D182KZ" is

The relay (L114) is normal.
displayed.
1 Defective preheater relay
(L114) The failure code "D182KZ" is not
The relay (L114) is abnormal.
displayed.

2) Disconnect the connectors L51 and L114.
3) Connect a T-adaptor.
Between L114(male) (1) and (2) Resistance 100 - 500 Ω
Possible 1) Starting switch OFF.

Causes and 3) Connect a T-adapter.
Standard Values Disconnection of harness
2 (Disconnection, defective Harness between the fuse B. (10) and
contact) L102 (female) (1).
Harness between L51 (female) (12)

and L102 (female) (2).

3 Wiring harness ground fault 3) Connect a T-adapter.
Machine body between L51 (female)

(12) and L102 (female) (2).

Defective monitor 3) Insert a T-adaptor.
4
panel 4) Starting switch ON.
Between L51 (12) - body. Voltage 20 - 30 V
40-462 3 WA380-5L
WA380-5L 40-463 3
Failure Code [D5ZHL6]

Start Switch C (IGN "C") Input Failure
Failure code
code code Trouble The starting switch "C" (IGN "C") is not set normally.
E01 D5ZHL6 MON
Description of • After the engine starts, no signal is input to the terminal of the starting switch "C" (IGN "C"). (The input cir-
trouble cuit is disconnected or short-circuited with the ground.)
Controller
• Alarm sounds.
reaction
Effect on • The engine cannot start.(In case of ground fault, the fuse (B-1) is blown, and the starting switch is not set
machine to "ON."
Related • The monitoring function (Code 40900, D-IN2)) can check input signals to the terminal of the starting
information switch "C" (IGN "C").

2) Disconnect the starting switch terminal.
Defective starting
1 switch When the starting switch is set
Starting switch
to "START." Resistance 1 Ω and below
terminals B
and C Other than the above Resistance 1 MΩ and above
1) Starting switch OFF

Disconnection of 2) Disconnect the starting switch C terminal and the connectors L116
harness 3) Connect a T-adaptor.
2 (disconnection,
defective contact) Harness between the starting switch C terminal
Possible (harness) and L116 (female) (3).
Causes and
Ground fault of 1) Starting switch OFF
Standard Values
harness 2) Disconnect the starting switch C terminal and the connectors L116..
★ When this 3) Insert a T-adaptor.
3 phenomenon
occurs, the Among the starting switch C terminal (harness),
fuse (B-1) will Resistance 1 MΩ and above
L116 (Female) (3) - body
be blown off.

3) Insert a T-adaptor.
Defective monitor 4) Starting switch ON.
4
panel
When the starting switch is set Voltage 20 - 30 V
Between L52 to "START."
(2) - body
Other than the above Voltage 1 V or less
40-464 3 WA380-5L
WA380-5L 40-465 3
Failure Code [DA80L4]

Auto Grease Input is Abnormal
Failure code
code code Trouble Auto grease input is abnormal.
E01 DA80L4 MON
Description of
• The auto grease sensor input circuits A and B "open" or "close" at the same time.
trouble
Controller
• Alarm sounds.
reaction
Effect on
• Auto greasing state, abnormal state and tank empty state cannot be checked.
machine
Related
• The monitoring function (Code 40900, D-IN-45) can check the auto grease input signals (2 systems, O/1).
information

2) Disconnect the connectors L52 and R38
Disconnection of
1 harness Harnesses between L52 (female) (3) and R38
(disconnection, Voltage 1 V or less
(female) (2).
defective contact)
Harnesses between L52 (female) (12) and R38
Voltage 1 V or less
(female) (3).

2) Disconnect the connectors L52 and R38
2 Hot short of
harness
Among L52 (female) (3) and R38 (female) (2) -
Voltage 1 V or less
body.
Possible Among L52 (female) (12) and R38 (female) (3) -

Voltage 1 V or less
Causes and body.
Standard Values
2) Disconnect the connectors L52 and R38.
4) Disconnect the connector.
When the auto grease operates. Voltage 1 V or less

Between R38
Defective auto (2) - body. When the auto grease does not
3 Voltage 20 - 30 V
grease controller operate (the tank is empty).
When the auto grease operates. Voltage 20 - 30 V

Between R38
(3) - body When the auto grease does not
Voltage 1 V or less
operate (the tank is empty).
★ When the above is normal, refer to the Auto Grease System Troubleshooting for
the check.
40-466 3 WA380-5L

2) Disconnect the connectors L52 and R38.
4) Disconnect the connector.
When the auto grease operates. Voltage 1 V or less

Possible Between L52
Defective monitor (3) - body. When the auto grease does not
Causes and 4 Voltage 20 - 30 V
panel operate (the tank is empty).
Standard Values
When the auto grease operates. Voltage 20 - 30 V
Between L52
(12) - body When the auto grease does not
Voltage 1 V or less
operate (the tank is empty).
★ When the above is normal, refer to the Auto Grease System Troubleshooting for
the check.
WA380-5L 40-467 3
12
Failure Code [DAF3KK]
When the SW Power Supply (for Operation) is ON, the NSW Power Supply (for Memory)
is OFF
Failure code
code code When the SW power supply (for operation) is ON, the NSW
Trouble
power supply (for memory) is OFF.
E03 DAF3KK MON
Description of • When the SW power supply (for operation) voltage is over 17V, the NSW power supply (& the memory
trouble power supply) voltage is less than 17V.
Controller
• Alarm sounds.
reaction
Effect on • Service meter time is not accurate, the odometer value (accumulated travel distance value) does not
machine advance and trouble record data is not stored.
Related
information
• —
1 Defective fuse B-3 The fuse shall be normal.

2) Disconnect the battery relay B terminal and the connectors FS1 and
L51.
Harness between the battery relay B

Disconnection of harness Resistance 1 Ω and below
2 (disconnection, defective terminal and FS1 (female) (1)
contact) Harness among FS1 (female) (1), L51
(female) (4) and (5)
Possible
Causes and Harness among L51 (female) (9),
Standard Values (10), (17), (18), (19), (20) and Resistance 1 Ω and below
machine body
2) Disconnect the battery relay B terminal, the connectors FS1, L51,

L63, L80 (L72).
Among the battery relay B terminal,

FS1 (female) (1) and machine body
3 Ground fault of harness Among FS1 (female) (1), L51
(female) (4) and (5) and machine Resistance 1 MΩ and above
body
★ When this system is short-circuited with the ground, the fuse B-3 is
blown.
40-468 3 WA380-5L

Among L51 (4), (5) and machine

Voltage 20 - 30 V
body.
Among L51 (4), (5)-(9), (10), (17),

Voltage 20 - 30 V
Possible (18), (19) and (20)
Causes and 4 Defective monitor panel 1) Starting switch OFF.
Standard Values 2) Disconnect the connector L51.
Among L51 (4), (5) and machine

Voltage 20 - 30 V
body.
Among L51 (6), (7)-(9), (10), (17),

Voltage 20 - 30 V
(18), (19) and (20)
WA380-5L 40-469 3
Failure Code [DAF5KP]

5-V Power Supply Output Failure
Failure code
code code Trouble The 5V power supply abnormal output.
E01 DAF5KP MON
Description of
• The 5V sensor power supply output line is short-circuited with the ground.
trouble
Controller • The 5V power supply output stops until the starting switch is set to OFF.
reaction • No load is displayed.
Effect on
• Load detection is impossible. (No load is displayed.)
machine
Related
• —
information

2) Disconnect the connectors F15.
Between F15 (male) (C) and (A) Resistance 4-6Ω

Defective lift arm 3) Connect a T-adaptor.
1 4) Starting switch ON.
angle sensor
When the lift arm is raised

Voltage 3.5 - 4.0 V
Between F15 maximum.
(B) - (A) When the lift arm is lowered
Voltage 1.0 - 2.0 V
maximum.

Possible 2) Disconnect the connectors L52 and F15.
Causes and Ground fault of 3) Connect a T-adaptor.
2
Standard Values harness
Among L51 (female) (16), F15 (female) (C) -
body.

2) Disconnect the connector L51 and L55.
Between L51 (male) (16) - body Resistance 4-6Ω

2) Disconnect the connector L51 and L55.
Defective monitor 3) Insert a T-adaptor.
3
panel 4) Starting switch ON.
Between L51 (16) - body Voltage 4.75 - 5.25 V
When the lift arm is raised

Voltage 3.5 - 4.0 V
Between L55 maximum.
(10) - body When the lift arm is lowered
Voltage 1.0 - 2.0 V
maximum.
40-470 3 WA380-5L
WA380-5L 40-471 3
Failure Code [DAF6KP]

24-V Power Supply Output Failure
Failure code
code code Trouble The 24V power supply abnormal output.
E01 DAF6KP MON
Description of
• The 24V sensor power supply output line is short-circuited with the ground.
trouble
Controller • The 24V power supply output stops until the starting switch is set to OFF.
reaction • No load is displayed.
Effect on
• Load detection is impossible. (No load is displayed.)
machine
Related
• —
information

Defective lift arm 4) Starting switch ON
1 pressure sensor
(on bottom side) Between F16 (B) - (A) Voltage 20 - 30 V
Between F16 When it operates Voltage 0.7 - 5.3 V

(C) - (A) When atmosphere is released Voltage 0.7 - 5.3 V

Defective lift arm 4) Starting switch ON
2 pressure sensor
(on head side) Between F17 (B) - (A) Voltage 20 - 30 V
Between F17 When it operates Voltage 0.7 - 5.3 V

Possible (C) - (A) When atmosphere is released Voltage 0.7 - 5.3 V
Causes and
Standard Values 1) Starting switch OFF.
2) Disconnect the connectors L51 and F16., and F17
Ground fault of 3) Connect a T-adaptor.
3
harness
Among L51 (female) (15), F16 (female) (B), F17
(female) (B) - body.

2) Disconnect the connectors L51, F16 and F17.
Between L51 (15) - body Voltage 20 - 30 V

Defective monitor
4 Between L55
panel When it operates Voltage 0.7 - 5.3 V
(4) - body
Between L55
When it operates Voltage 0.7 - 5.3 V
(9) - body
Between L55
When atmosphere is released Voltage 0.5 - 1.5 V
(4), (9) - body
40-472 3 WA380-5L
WA380-5L 40-473 3
Failure Code [DAFBKM]

Incorrect Information on Model Selection
Failure code
code code Trouble Incorrect information on model selection.
E03 DAFBKM MON
Description of
• The model selection SW (SW1) is set to (A) - (F).
trouble
Controller
• It operates as "WA380".
reaction
• Travel speed/engine speed indications and odometer indication do not agree with actual ones.
Effect on
• The gear shift shock is large.
machine
• The load meter weight is different from the actual weight.
Related
information
• —
Possible At the normal time Positions (0) - (9)

SW1 setting (on rear side of
Causes and 1 Incorrect model setting
monitor) At abnormal time Positions (A) - (F)
Standard Values
2 Defective monitor panel —
40-474 3 WA380-5L
Failure Code [DAFSKQ]

Incorrect Information on Meter Indication Selection
Failure code
code code Trouble Incorrect information on meter indication selection.
E01 DAFSKQ MON
Description of
• The meter indication selection SW (SW3) is set to (9) ~ (F)
trouble
Controller
• It operates as indication in km/h.
reaction
Effect on • Since machine speeds are calculated with STD tires, machine speed and odometer indications may not
machine be normal.
Related • The monitoring function (Code: 30802, SW3) can check meter indication selection information (SW3)
information signals (0) ~ (F)
Possible At the normal time Positions (0) - (8)

SW3 setting (on rear side of
Causes and 1 Incorrect model setting
monitor) At abnormal time Positions (9) - (F)
Standard Values
2 Defective monitor panel —
WA380-5L 40-475 3
Failure Code [DAQSKR]

S-NET Communication Failure (Between Monitor Panel and Transmission Controller)
Failure code Abnormal S-NET Communication (between monitor panel and
code code Trouble
transmission controller).
E03 DAQSKR MON
Description of • The S-NET (+) signal line between the monitor panel and the transmission controller is disconnected,
trouble short-circuited with the ground or hot short-circuited.
Controller
• Alarm sounds.
reaction
Effect on
• The monitor does not display normally. (The shift indicator, travel speed/engine speed are not displayed.)
machine
Related
• —
information

Disconnection of harness 2) Disconnect the connectors L56 and L62.
1 (disconnection, defective
contact) Harness between L56 (female) (1) -
L62 (female) (21).

2 Ground fault of harness
Among L56 (female) (1) - L62
(female) (21) - body.
Possible
Causes and 1) Starting switch OFF.
Standard Values 2) Disconnect L56, L62 (L72), L80 and L07.
3 Hot short-circuit of harness 4) Starting switch ON.


4 Defective monitor panel 4) Starting switch ON.
Among L56 (1), (2) - body. Voltage 4-8V
Among L56 (1), (2) - (4), (5) Voltage 4-8V
40-476 3 WA380-5L
WA380-5L 40-477 3
Failure Code [DBQSKR]

S-NET Communication Failure (Between Monitor Panel and Work Equipment Controller)
code code Trouble
work equipment controller).
E03 DBQSKR MON
Description of • Disconnection, ground fault, or hot-short has occurred in the S-NET (+) signal line between the monitor
trouble panel and the engine controller.
Controller
• Activates an alarm.
reaction
Effect on • The joystick indicator pilot lamp does not turn ON.
machine • The work equipment controller functions with WA380-5. (A faulty joystick feeling.)
Related
information
• —

1 Wiring harness discontinuity
Harness between L56 (female) (1) -
L72 (female) (21).

2) Disconnect the connectors L56, L62, L72, L80, L82, and L107.
Possible
Standard Values 2) Disconnect connectors L56 and L72.
Wiring harness hot 3) Connect a T-adaptor.
short-circuit

Among L56 (1), (2) - (4), (5) Voltage 4-8V
40-478 3 WA380-5L
WA380-5L 40-479 3
Failure Code [DB9SKR]

S-NET Communication Failure (Between Monitor Panel and Work Equipment Controller)
code code Trouble
work equipment controller).
E03 DB9SKR MON
Description of • Disconnection, ground fault, or hot-short has occurred in the S-NET (+) signal line between the monitor
trouble panel and the work equipment controller.
Controller
reaction
Effect on • The joystick indicator pilot lamp does not turn ON.
machine • The work equipment controller functions with WA380-5. (A faulty joystick feeling.)
Related
information
• —

1 Wiring harness discontinuity
Harness between L56 (female) (1) -
L72 (female) (21).

2) Disconnect the connectors L56, L62, L72, L80, L82, and L107.
Possible
Standard Values 2) Disconnect connectors L56 and L72.
Wiring harness hot 3) Connect a T-adaptor.
short-circuit

Among L56 (1), (2) - (4), (5) Voltage 4-8V
40-480 3 WA380-5L
WA380-5L 40-481 3
Failure Code [DD15LD]

Monitor Panel Mode Selector Switch 1 [■] (Panel SW1) Input Error
Failure code
code code Trouble Monitor panel mode selector switch 1 [■] (Panel SW1) input error
E01 DD15LD MON
Description of • The monitor panel mode selector switch 1 [■] (Panel SW1) input circuit remains closed for more than one
trouble minute.
Controller
reaction
Effect on
• The monitor does not work (Service mode cannot be activated).
machine
• The input signal (0 or 1)of the monitor panel mode selector switch 1 ¦ (Panel SW1) can be verified with the
Related
monitoring function (Code: 40901, D-IN-15).
information
• Since switch is faulty, the monitoring function may not be activated.

Faulty monitor 3) Connect T-adapter.
panel mode
1 When monitor panel mode
selector switch 1
[■] Between L07 selector switch 1 [■] is turned Resistance 1 Ω and below
(Female) (2) - ON
(3)
Other than above Resistance 1 MΩ and above

Possible
Causes and 2 Wiring harness
hot-short 4) Turn starting switch ON.
Standard Values
Voltage 1 V or less
body

Defective monitor
3
panel When monitor panel mode
Between L52 selector switch 1 [■] is turned Voltage 20 - 30 V
(Female) (17) - ON
body
40-482 3 WA380-5L
WA380-5L 40-483 3

Monitor Panel Mode Selector Switch 1 [◊] (Panel SW2) Input Error
Failure code
code code Trouble Monitor panel mode selector switch 1 [◊] (Panel SW2) input error
E01 DD16LD MON
Description of • The monitor panel mode selector switch 1 [◊] (Panel SW2) input circuit remains closed for more than one
trouble minute.
Controller
reaction
Effect on
machine
• The input signal (0 or 1)of the monitor panel mode selector switch 1 [◊] (Panel SW2) can be verified with
Related
the monitoring function (Code: 40901, D-IN-14).
information
• Since [◊] switch is faulty, the monitoring function may not be activated.

panel mode
selector switch 1
[◊] Between L07 selector switch 1 [◊] is turned Resistance 1 Ω and below
(Female) (2) - ON
(1)

Possible
Standard Values
Voltage 1 V or less
body

Defective monitor
3
Between L52 selector switch 1 [◊] is turned Voltage 20 - 30 V
(Female) (8) - ON
body
40-484 3 WA380-5L
WA380-5L 40-485 3

Monitor Panel Mode Selector Switch 2 [<] (Panel SW3) Input Error
Failure code
code code Trouble Monitor panel mode selector switch 2 [<] (Panel SW3) input error
E01 DD17LD MON
Description of • The monitor panel mode selector switch 2 [<] (Panel SW3) input circuit remains closed for more than one
trouble minute.
Controller
reaction
Effect on
machine
• The input signal (0 or 1)of the monitor panel mode selector switch 2 [<] (Panel SW3) can be verified with
Related
information
• Since [<] switch is faulty, the monitoring function may not be activated.

panel mode
selector switch 2
[<] Between L08 selector switch 2 [<] is turned Resistance 1 Ω and below
(Female) (3) - ON
(2)

Possible
Standard Values
body

Defective monitor
3
Between L54 selector switch 2 [<] is turned Voltage 1 V or less
(Female) (7) - ON
body
40-486 3 WA380-5L
WA380-5L 40-487 3

Monitor Panel Mode Selector Switch 2 [>] (Panel SW4) Input Error
Failure code
code code Trouble Monitor panel mode selector switch 2 [>] (Panel SW4) input error
E01 DD18LD MON
Description of • The monitor panel mode selector switch 2 [>] (Panel SW4) input circuit remains closed for more than one
trouble minute.
Controller
reaction
Effect on
machine
• The input signal (0 or 1)of the monitor panel mode selector switch 2 [>] (Panel SW4) can be verified with
Related
information
• Since [>] switch is faulty, the monitoring function may not be activated.

panel mode
selector switch 2
[>] Between L08 selector switch 2 [>] is turned Resistance 1 Ω and below
(Female) (1) - ON
(2)

Possible
Standard Values
body

Defective monitor
3
Between L54 selector switch 2 [>] is turned Voltage 1 V or less
(Female) (15) - ON
body
40-488 3 WA380-5L
WA380-5L 40-489 3
Failure Code [DD1CLD]

Sub-Total Switch Failure
Failure code
code code Trouble Sub-total switch 2 failure.
E01 DD1CLD MON
Description of
• The sub-total switch input circuit remains closed for more than one minute.
trouble
Controller
reaction
Effect on
• The sub-total operation on the load meter does not work.
machine
• This code is applied to the load meter specification.

Related
• The input signal (0 or 1)of the sub-total switch can be verified with the monitoring function (Code: 40904,
information
D-IN-32).

Faulty sub-total 3) Connect T-adapter.
switch (BUCKET
1
LEVER FOR OPT When the sub-total switch
LDM) Between L15 Resistance 1 Ω and below
is turned ON
(Female) (3) - (4)

Possible
Standard Values
body

Defective monitor 4) Turn starting switch ON.
3
panel
Between L54 When the sub-total switch
Voltage 1 V or less
is turned ON
(Female) (4) -
body Other than above Voltage 20 - 30 V
40-490 3 WA380-5L
WA380-5L 40-491 3
Failure Code [DDK3KM]

CAUTION: Right FNR Switch is in "N" (Neutral)
Action Code Failure Code Controller Code
Trouble Caution: Right FNR switch is in N (Neutral)
E00 DDK3KM MON
Description of • The switch is set to F or R when the right FNR switch is selected and during engine stop.
Trouble
Controller Reaction • Activates an alarm.
Effect on Machine • The right FNR switch is held in the neutral position (N) until it is returned to that position.
Related Information • Can be verified with the monitoring function (Code: 40907, D-IN-17, 18, 19)
Causes Standard Value in Normal State and Remarks on Troubleshooting
Possible Causes
and Standard Values 1 Faulty right FNR switch position (Other than N) Return right FNR switch to the neutral position (N)
2 See DAQSKR (S-NET failure) or transmission controller failure code DDK4KA (N signal failure)
40-492 3 WA380-5L

CAUTION: Joystick FNR Switch is in "N" (Neutral)
Trouble Caution: Joystick FNR switch is in N (Neutral)
E00 DDK4KM MON
Description of • The lever is set to F or R when the joystick steering mode is selected and during engine stop.
Trouble
Effect on Machine • The joystick FNR switch is held in the neutral position (N) until it is returned to that position.
Possible Causes 1 Faulty joystick FNR switch position (Other than N) Return joystick FNR switch to the neutral position
and Standard Values (N)
2 See DAQSKR (S-NET failure) or transmission controller failure code DDK4KA (N signal failure)
WA380-5L 40-493 3

CAUTION: FNR (Forward- Reverse) Lever Switch is in "N" (Neutral)
Trouble Caution: FNR (Forward-reverse) lever switch is in N (Neutral)
E00 DDK6KM MON
Description of Trouble • The FNR (Forward-reverse) lever is set to F or R when the lever is selected and during engine stop.
Effect on Machine • The FNR (Forward-reverse) lever is held in the neutral position (N) until it is returned to that position.
Possible Causes and
1 Faulty forward-reverse lever position (Other than N) Return forward-reverse lever to the neutral position (N)
Standard Values
2 See DAQSKR or DB9QSKR (S-NET failure) or DDK6KA (N signal failure)
40-494 3 WA380-5L
MEMORANDUM
WA380-5L 40-495 3
Failure Code [DDS5L6]

Decreased Steering Oil Pressure
Failure code
code code Trouble Decreased steering oil pressure
E03 DDS5L6 MON
Description of
• The steering sensor circuit remains CLOSED when the engine speed is over 500 rpm.
trouble
Controller
reaction
Effect on • Due to detection of decreased steering oil pressure, the emergency steering pump (Motor) may cause
machine steering control to be selected when the speed is over 1 km/h.
Related
• Can be verified with the monitoring function (Code: 40904, D-IN-39).
information
Decreased
1 steering oil —
pressure

Faulty steering oil With engine stopped Resistance 1 Ω and below

2
pressure sensor
Between R36 With pressure released to air
(Male) (3) - (1) (For reference purpose)
Engine started Resistance 1 MΩ and above

Possible
Standard Values 2) Disconnect connectors L54, R36 and L61.
3 Wiring harness 3) Connect T-adapter.
ground fault
Between L54 (Female) (16)/R36 (Female) (3) -
body

Defective monitor Normal temperature (25°C)

4 panel Resistance 35 - 50 kΩ
Between L54 {77°F}
(Female) (16) -
100°C {212°F} Resistance 3.1 - 4.5 kΩ
body
40-496 3 WA380-5L
WA380-5L 40-497 3
Failure Code [DDY0LD]

Cancel Switch Failure
Failure code
code code Trouble Cancel switch failure
E01 DDY0LD MON
Description of
• The cancel switch input circuit remains closed for more than one minute.
trouble
Controller
reaction
Effect on
• The cancellation of weight on the load meter is disabled.
machine
Related • This code is applied to the load meter specification.

information • The cancel switch input signal can be verified with the monitoring function (Code: 40904, D-IN-33).

Faulty cancel 3) Connect T-adapter.
switch (BUCKET
1
LEVER FOR OPT When the cancel switch is
LDM) Between L15 turned ON Resistance 1 Ω and below
(Female) (1) -
(2)

ground fault
Standard Values
body

Defective monitor 4) Turn starting switch ON.
3
panel
When the cancel switch is
Between L54 Voltage 1 V or less
turned ON
(13) - body
40-498 3 WA380-5L
WA380-5L 40-499 3
Failure Code [DGE2KX]

Engine Coolant Temperature (High Temperature) Sensor System Failure
Failure code
code code Engine coolant temperature (high temperature) sensor system
Trouble failure
E01 DGE2KX MON
Description of • The engine coolant temperature is more than 150°C {302°F} (The engine coolant temperature sensor
trouble input voltage is less than 0.98 V)
Controller • Activates the engine coolant temperature overheat alarm. The failure is stored in the electrical system
reaction failure history only; not in the machine system failure history.
Effect on
• The engine coolant temperature gauge is in the MAX position.
machine
Related
• Can be verified with the monitoring function (Code: 04103).
information

Faulty engine 3) Connect T-adapter.
coolant
1 temperature
sensor (for Normal temperature (25°C)
Between E08 Resistance 35 - 50 kΩ
monitor) {77°F}
(Female) (1) - (2)
100°C {212°F} Resistance 3.1 - 4.5 kΩ

Causes and 2) Disconnect connectors L55 and E08.
Standard Values 2 Wiring harness
Between L55 (Female) (8)/E08 (Female) (1) - body Resistance 1 MΩ and above

Defective
3
monitor panel Between Normal temperature (25°C)
Resistance 35 - 50 kΩ
L55(Female) (8) {77°F}
- body 100°C {212°F} Resistance 3.1 - 4.5 kΩ
40-500 3 WA380-5L
WA380-5L 40-501 3
Failure Code [DGE3L6]

Abnormal Connection of Engine Coolant Temperature (Low Temperature) Sensor
System
Failure code
code code Abnormal connection of engine coolant temperature (low
Trouble
temperature) sensor system.
E01 DGE3L6 MON
Description of
• Engine coolant temperature (low temperature) sensor signals are not input.
trouble
Controller
• It operates for normal control.
reaction
Effect on
• The machine does not start smoothly at low temperature.
machine
Related
• The monitoring function (Code : 04104) is useful for check.
information

Defective engine
coolant temperature 3) Connect T-adapter.
1
(low temperature)
sensor Between E09 (Female) (1) - 25°C {50°F} Resistance 9 kΩ approx.
(2) 100°C {212°F} Resistance 0.3 kΩ approx.

Disconnection of
2 harness Between L55 (Female) (3)/E09 (Female) (A) -
(disconnection, Resistance 1 Ω and below
Possible defective contact) body
Causes and Between L55 (Female) (6)/E09 (Female) (B) -
body

2) Disconnect L82 and TWL.
3 Wiring harness
ground fault
Among L55 (female) (3), E09 (female) (A) and

machine body.

4
monitor panel
Between L55(Female) (3) - 25°C {50°F} Resistance 9 kΩ approx.
(6) 100°C {212°F} Resistance 0.3 kΩ approx.
40-502 3 WA380-5L
WA380-5L 40-503 3
Failure Code [DGH2KX]

Hydraulic Oil Temperature Sensor System Failure
Failure code
code code Trouble Hydraulic oil temperature sensor system failure
E01 DGH2KX MON
Description of
• The hydraulic oil temperature sensor input voltage is less than 0.98 V.
trouble
Controller • Activates the hydraulic oil temperature overheat alarm. The failure is stored in the electrical system failure
reaction history only; not in the machine system failure history.
Effect on
• The hydraulic oil temperature gauge is in the MAX position.
machine
Related
information

Faulty hydraulic
1 oil temperature
sensor) Normal temperature (25°C)
Between R47 Resistance 35 - 50 kΩ
{77°F}
(Female) (1) - (2)
100°C {212°F} Resistance 3.1 - 4.5 kΩ

Between L55 (Female) (7)/R47 (Female) (1) - body Resistance 1 MΩ and above

Defective
3
L55(Female) (1) {77°F}
40-504 3 WA380-5L
Failure Code [DGT1KX]

Torque Converter Oil Temperature Sensor System Failure
Failure code
code code Trouble Torque converter oil temperature sensor system failure
E01 DGT1KX MON
Description of
• The torque converter oil temperature sensor input voltage is less than 0.98 V.
trouble
Controller • Activates the torque converter oil temperature overheat alarm. The failure is stored in the electrical
reaction system failure history only; not in the machine system failure history.
Effect on
• The torque converter oil temperature gauge is in the MAX position.
machine
Related
information

2) Disconnect connectorTC.T.
Faulty torque 3) Connect T-adapter.
converter oil
1
sensor) Between TC.T Resistance 35 - 50 kΩ
{77°F}
(Female) (1) - (2)
100°C {212°F} Resistance 3.1 - 4.5 kΩ

Possible
2) Disconnect connectors L55 and TC.T.
Causes and
ground fault
Between L55 (Female) (2)/TC.T (Female) (1) -

body

Defective
3
L55(Female) (2) {77°F}
WA380-5L 40-505 3
Failure Code [DHE4L6]

Engine Oil Pressure Sensor System Failure
Failure code
code code Trouble Engine oil pressure sensor system failure
E01 DHE4L6 MON
Description of
• The engine oil pressure sensor circuit remains open when the engine is not running.
trouble
Controller
reaction
• The decreased engine oil pressure alarm is disabled.

Effect on
• After engine start has failed (Once the key is put ON the terminal C position), an erroneous alarm may be
machine
issued.
Related
information
Decreased engine
1 —
oil pressure

Faulty engine oil
2
pressure sensor
Between L54 When engine is NOT running Resistance 1 Ω and below
(Female) (2) -
E29. When engine is running Resistance 1 MΩ and above
Possible
3 Wiring harness
ground fault
Between L54 (Female) (2) - E29. Resistance 1 Ω and below

Defective 4) Connect L54.
4
monitor panel
Between L54 When engine is NOT running Voltage 1 V or less
(Female) (2) -
body When engine is running Voltage 20 - 30 V
40-506 3 WA380-5L
WA380-5L 40-507 3
Failure Code [DHPCKX]

Bottom Pressure Sensor Failure
Failure code
code code Trouble Bottom pressure sensor failure
E01 DHPCKX MON
Description of
• The bottom pressure sensor input voltage is less than 0.5 V.
trouble
Controller
• Activates an alarm and disables load display.
reaction
Effect on
machine

Related
• The bottom pressure signal (0.01 MPa {1.5 psi}) can be verified with the monitoring function
information
(Code: 40400).

Faulty lift arm
1 pressure sensor Between F16 (B) - (A) Voltage 20 - 30 V
(Bottom side)
When machine is in operation Voltage 0.7 - 5.3 V
Between F16
(C) - (A) When pressure is released to
Voltage 0.5 - 1.5 V
air

Wiring harness 2) Disconnect connectors L51, L55 and F16.
2 (Broken wires or
loose Between L55 (Female) (9) - F16 (Female) (C) Resistance 1 Ω and below
Possible connections)
Causes and Between L51 (Female) (15) - F16 (Female) (B) Resistance 1 Ω and below
Standard Values
2) Disconnect connectors L55, F16, F17.
3
ground fault
Between L55 (Female) (9), F16 (Female) (C)
and body

2) Disconnect connectors L51, F16 and F17.
Defective
4 Between L51 (15) - body Voltage 20 - 30 V
monitor panel
Between L55
(9) - body When pressure is released to
Voltage 0.5 - 1.5 V
air
40-508 3 WA380-5L
WA380-5L 40-509 3
Failure Code [DHPDKX]

Head Pressure Sensor Failure
Failure code
code code Trouble Head pressure sensor failure
E01 DHPDKX MON
Description of
• The head pressure sensor input voltage is less than 0.5 V.
trouble
Controller
reaction
Effect on
machine

information • The head pressure signal (0.01 MPa {1.5 psi}) can be verified with the monitoring function (Code: 40400).

Faulty lift arm
1 pressure sensor Between F17 (B) - (A) Voltage 20 - 30 V
(Head side)
Between F17
(C) - (A) When pressure is released to
Voltage 0.5 - 1.5 V
air

Wiring harness 2) Disconnect connectors L51, L55, F16, and F17.
2 (Broken wires or
loose Between L55 (Female) (4) - F17 (Female) (C) Resistance 1 Ω and below
Possible connections)
Causes and Between L51 (Female) (15) - F17 (Female) (B) Resistance 1 Ω and below
Standard Values
2) Disconnect connectors L55, F16, F17.
3
ground fault
Between L55 (Female) (4), F17 (Female) (C)
and body

Defective
4 Between L51 (15) - body Voltage 20 - 30 V
monitor panel
Between L55
(4) - body When pressure is released to
Voltage 0.5 - 1.5 V
air
40-510 3 WA380-5L
WA380-5L 40-511 3
Failure Code [DKA0KX]

Lift Arm Angle Sensor Failure
Failure code
code code Trouble Lift arm angle sensor failure
E01 DKA0KX MON
Description of
• The lift arm angle sensor input voltage is less than 1 V or more than 4 V.
trouble
Controller
reaction
Effect on
machine

information • The lift arm angle signal (° ) can be verified with the monitoring function (Code: 06001).

Between F15 (Male) (C) - (A) Resistance 4 - 6 kΩ

1 Faulty boom angle 2) Disconnect connector F15.
sensor 3) Insert T-adapter.
Between F15 With lift arm fully raised Voltage 3.5 - 4.0 V
(B) - (A) With lift arm fully lowered Voltage 1.0 - 2.0 V

Wiring harness 2) Disconnect connectors L51, L55 and F15.
Possible discontinuity 3) Connect T-adapter.
Causes and 2 (Broken wires or
Standard Values loose Between L51 (Female) (16) - F15 (Female) (C) Resistance 1 Ω and below
connections)
Between L55 (Female) (10) - F15 (Female) (B) Resistance 1 Ω and below

2) Disconnect connectors L51, L71 and F15.
3
ground fault
Between L55 (Female) (10) L71 (Female) (8),
F15 (Female) (B) - body

4
monitor panel
Between L51 (16) - body Voltage 4.75 - 5.25 V
Between L55 With lift arm fully raised Voltage 3.5 - 4.0 V
(10) - body With lift arm fully lowered Voltage 1.0 - 2.0 V
40-512 3 WA380-5L
WA380-5L 40-513 3
Failure Code [DV00KB]

Shorted Alarm Buzzer Output System
Failure code
code code Trouble Short-circuited alarm buzzer output system
E01 DV00KB MON
Description of
• Hot-short has occurred in the alarm buzzer output circuit.
trouble
Controller
• The alarm buzzer output is stopped until the starting switch is turned OFF.
reaction
Effect on
• The alarm buzzer does not sound until the starting switch is turned OFF.
machine
Related
• —
information

Faulty alarm 4) Turn starting switch ON and wait until 5 seconds have elapsed.
1
buzzer
With L20 (2) Alarm buzzer sounds. Alarm buzzer is normal.
grounded to
machine body Alarm buzzer does not sound. Alarm buzzer is faulty.

2 Wiring harness
hot-short
Possible Between L51 (Female) (14), L20 (Female) (2) -
Voltage 1 V or less
Causes and body
Standard Values
When starting switch is turned

Voltage 20 - 30 V
ON.
Defective
3 2 seconds after starting switch
monitor panel
Between L51 is turned ON (Alarm buzzer Voltage 1 V or less
(14) - body does not sound).
3 seconds after 2 seconds has

elapsed when starting switch Voltage 17 - 30 V
was turned ON (Alarm buzzer
sounds).
40-514 3 WA380-5L
WA380-5L 40-515 3
Failure Code [DY30ME]

The Emergency Steering Remains Actuated For More Than One Minute
Failure code The emergency steering remains actuated for more than one
code code Trouble
minute
E02 DY30ME MON
Description of
• The emergency steering detector circuit remains open for more than one minute.
trouble
Controller
reaction
• An alarm is issued if the emergency steering remains actuated for more than one minute (the emergency
Effect on steering motor may be defective or burn out).
machine • Even though the emergency steering motor is not in operation, the indicator lights up.
• The emergency steering always actuates.
Related
information
Actuation of
emergency
1 —
steering for more
than one minute

When emergency steering is

Faulty emergency Resistance 1 Ω and below
not turned ON
2 steering pressure
switch When pressure is released to
Between R37 Resistance 1 Ω and below
air (For reference purpose)
(Male) (C) - (A)
When emergency steering is
Possible turned ON (Under high Resistance 1 MΩ and above
Causes and pressure)
Standard
Values Wiring harness 2) Disconnect connectors L54 and R37.
3 (Broken wires or
loose Between L54 (Female) (3) - R37 (Female) (C) Resistance 1 Ω and below
connections)
Between R37 (Female) (A) - body Resistance 1 Ω and below

Defective monitor
4 When emergency steering is
panel Voltage 1 V or less
not turned ON
Between L54
(3) - body When emergency steering is
turned ON (Under Voltage 20 - 30 V
high pressure)
40-516 3 WA380-5L

When engine is not running Resistance 1 Ω and below
Between R36 When pressure is released to

Faulty steering (Male) (C) - (A) air (For reference purpose)
5
pressure switch
When engine is starting Resistance 1 MΩ and above
When engine is not running Resistance 1 MΩ and above
Between R36 When pressure is released to

(Male) (B) - (A) air (For reference purpose)
When engine is starting Resistance 1 Ω and below

4) Apply left brake after engine starts.
Wiring harness
6 ground fault Between L61 (Female) (17) /R36 (Female) (C) -
body
Between L61 (Female) (23) /R36 (Female) (B) -

body

Possible 2) Disconnect connector S19.
Causes and
Faulty emergency
Standard When emergency steering
7 steering manual Resistance 1 Ω and below
Values switch is turned ON
switch Between S19
(Male) (4) - (3)
When emergency steering
switch is turned OFF

2) Disconnect connectors L63, L126 and S19.
Wiring harness 3) Insert T-adapter.
short circuit fault
Between L63 (Female) (29)/L126 (Female) (1)/

Wiring harness 3) Insert T-adapter.
short circuit fault
Between L126 (5)/R15 - body Resistance 1 MΩ and above

Faulty emergency 3) Insert T-adapter.
10 steering relay 4) Turn starting switch ON.
(L126)
body
Faulty emergency 1) Turn starting switch OFF.

2) Disconnect connectors R15 and R16 and two power supply wires (100B).
11 steering actuating
relay Between relay contacts Resistance 1 MΩ and above
WA380-5L 40-517 3
40-518 3 WA380-5L
MEMORANDUM
WA380-5L 40-519 3
Troubleshooting Code [MON-1]

The Parking Brake Indicator Lamp Does Not Light Up When the Parking Brake Switch is
Turned ON
Troubleshooting Controller The parking brake indicator lamp does not light up when the
Failure code
code code Trouble parking brake switch is turned ON (The parking brake indicator
MON-1 — (MON) switch circuit suffers a ground fault).
Description of
• The parking brake detector circuit remains CLOSED when the parking brake switch is operated.
trouble
Controller
• No reaction.
reaction
Effect on • When the parking brake switch is turned ON (parking), neither the parking brake indicator lamp light up
machine nor the 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).
Faulty parking
1 —
brake
Turn starting switch OFF.

2) Disconnect PB.SW connectors.
Faulty parking When parking brake oil

2 brake indicator pressure is above 0.6 MPa Resistance 1 Ω and below
switch Between {6.1 kg/cm2} (87 psi)
PB.SW (Male)
(1) - (2) When parking brake oil
pressure is below 0.34 MPa Resistance 1 MΩ and above
{3.5 kg/cm2} (49 psi)
Causes and 2) Disconnect connector L54 and PB.SW.
Standard Values
3 Wiring harness
ground fault
Between L54 (Female) (1), PB.SW (Female) (1)

- body

4) Start engine.
Defective monitor When parking brake oil
4
panel pressure is above 0.6 MPa Voltage 1 V or less
Between L54 {6.1 kg/cm2} (87 psi)
(Female) (1) -
body When parking brake oil
pressure is below 0.34 MPa Voltage 20 - 30 V
{3.5 kg/cm2} (49 psi)
40-520 3 WA380-5L


Between L01 turned ON
(Male) (1) - (3) When parking brake switch is
Faulty parking Resistance 1 MΩ and above
5 turned OFF
brake switch
Between L01 turned ON
(Male) (2) - (3) When parking brake switch is
turned OFF
Possible
Between L01
Causes and At all times. Resistance 1 MΩ and above
(Male) (1) - (2)
Standard Values
2) Disconnect PB.PS connectors.
Faulty parking
6
brake solenoid Between PB.PS connectors (Male) (1) - (2) Resistance 10 - 40 Ω
Between PB.PS connectors (Female) (2) - body Resistance 1 Ω and below
Between PB.PS connectors (Male) (1) / (2) - body Resistance 1 MΩ and above

2) Disconnect connector L01 and PB.PS.
short circuit fault
Between PB.PS connectors (Female) (1) - (2) Voltage 1 V or less
WA380-5L 40-521 3

Circuit Diagnostic Procedures for Error Code
Failure code The brake oil pressure caution lamp does not light up when the
code code Trouble
emergency brake is applied (Front circuit)
MON-2 — (MON)
Description of • The accumulator pressure sensor (Front) circuit remains CLOSED (i.e. front brake oil pressure is normal)
trouble when the emergency brake is actuated.
Controller
• No reaction.
reaction
Effect on • The brake oil pressure caution lamp does not light up when the emergency brake is actuated and when
machine the brake oil pressure is decreased.
Related
• Can be verified with the monitoring function (Code: 40902_D-IN-16).
information

4) Start engine.
Faulty brake oil
pressure sensor When front brake oil pressure
1 (Front brake is above 5.88 MPa {60 kg/cm2} Resistance 1 Ω and below
circuit) (853 psi)
Between R53
(Male) (1) - (2)
When front brake oil pressure
is below 5.88 MPa {60 kg/cm2} Resistance 1 MΩ and above
(853 psi)

ground fault
Between L53 (Female) (1)/R53 (Female) (1)

- body

Defective When front brake oil pressure

3 monitor panel is above 5.88 MPa {60 kg/cm2} Resistance 1 Ω and below
Between L53 (853 psi)
(Female) (1) -
body When front brake oil pressure
(853 psi)
40-522 3 WA380-5L
WA380-5L 40-523 3

The Brake Oil Pressure Caution Lamp Does Not Light Up When the Emergency Brake is
Applied (Rear Circuit)
Failure code The brake oil pressure caution lamp does not light up when the
code code Trouble
emergency brake is applied (Rear circuit)
MON-3 — (MON)
Description of • The accumulator pressure sensor (Rear) circuit remains CLOSED (i.e. rear brake oil pressure is normal)
trouble when the emergency brake is actuated.
Controller
• No reaction.
reaction
Effect on • The brake oil pressure caution lamp does not light up when the emergency brake is actuated and when
machine the brake oil pressure is decreased.
Related
• Can be verified with the monitoring function (Code: 40902_D-IN-16).
information

4) Start engine.
Faulty brake oil
pressure sensor When front brake oil pressure
1 1 Ω and below
(Rear brake is above 5.88 MPa {60 kg/cm2} Resistance
circuit) (853 psi)
Between R54
(Male) (1) - (2)
When front brake oil pressure
(853 psi)

ground fault
Between L53 (Female) (7)/R54 (Female) (1)

- body

Defective When front brake oil pressure

3
monitor panel is above 5.88 MPa {60 kg/cm2} Resistance 1 Ω and below
Between L53 (853 psi)
(Female) (7) -
body When front brake oil pressure
(853 psi)
40-524 3 WA380-5L
WA380-5L 40-525 3

The Air Cleaner Clogging Indicator Lamp Does Not Light
Failure code
code code Trouble The air cleaner clogging indicator lamp does not light ON
MON-4 — (MON)
Description of
• When the air cleaner is clogged, the sensor circuit is in the CLOSE (Not clogged) state.
trouble
Controller
• No reaction.
reaction
Effect on
• The air cleaner caution lamp does not go OFF.
machine
Related
information
Faulty dust
1 —
indicator 1

Defective dust
2 indicator relay 1 3) Connect T-adapter.
Between L112 (Male) (1) -(2) Resistance 200 - 400 Ω

2) Disconnect connector L51, L112 and E33.
Harness 3) Connect T-adapter.
disconnection
(Disconnection
3 or defective Between L51 (Female) (6) - L112 (Female) (1) Resistance 1 Ω and below
Possible connector
Causes and contact) Between L112 (Female) (2) - E33 (Female) (1) Resistance 1 Ω and below
Standard Values
Between E33 (Female) (2) - body Resistance 1 Ω and below

4
ground fault
Between L53 (Female) (3), L112 (Female) (4) -
body

Harness hot 3) Connect T-adapter.
short fault
body
40-526 3 WA380-5L

4) Start the engine.
Dust indicator normal (Air

Voltage 20 - 30 V
Possible Between L53 cleaner not clogged)
Causes and 6 Defective
monitor panel (3) - body Dust indicator normal (Air
Standard Values Voltage 1 V or below
cleaner clogged)

Between L51 (Male) (6) - body Resistance 200 - 400 Ω
WA380-5L 40-527 3

The Engine Oil Pressure Caution Lamp Does Not Light
Failure code
code code Trouble The engine oil pressure caution lamp does not light ON
MON-5 — (MON)
Description of • When the starting switch is ON (the engine stops), the engine oil pressure sensor circuit is in the OPEN
trouble state.
Controller
• No reaction.
reaction
Effect on
• The engine oil pressure caution lamp does not light ON.
machine
Related
information

Defective engine 3) Connect t-adapter.
1 oil pressure
sensor
Between oil pressure When the engine stops Resistance 1 Ω and below
switch pin (E29) - body When the engine runs Resistance 1 MΩ and above

Standard Values 2 Harness
disconnection 3) Connect t-adapter.
Between L54 (Female) (2) - E29 Resistance 1 MΩ and above

3
monitor panel
Between L54 (Female) When the engine stops Resistance 1 Ω and below
(2) - body When the engine runs Resistance 1 MΩ and above
40-528 3 WA380-5L

The Engine Oil Level Caution Lamp Does Not Light
Failure code
code code Trouble The engine oil level caution lamp does not light ON
MON-6 — (MON)
Description of
• The engine oil level sensor circuit is in the CLOSE state.
trouble
Controller
• No reaction.
reaction
Effect on
• The engine oil level caution lamp does not light ON.
machine
Related
information

Defective engine
1 oil level sensor Oil level normal Resistance 1 Ω and below
Between oil pressure
switch pin (E26) - body Oil level insufficient
(Reduces)

Possible
Causes and
fault
ground 3) Connect t-adapter.
Between L54 (Female) (11), E26 (Female) (1) -

body

Defective
3
monitor panel Oil level normal Resistance 1 Ω and below
(11) - body Oil level insufficient Resistance 1 MΩ and above
(Reduces)
WA380-5L 40-529 3

The Engine Coolant Temperature Caution Lamp Does Not Light
Troubleshooting Controller The engine coolant temperature caution lamp does not light ON.
Failure code
code code Trouble After the engine starts, the engine coolant temperature gauge
MON-7 — (MON) does not rise.
Description of
• The engine coolant temperature sensor circuit is always in the OPEN state.
trouble
Controller
• No reaction.
reaction
Effect on • The engine coolant temperature caution lamp does not light ON.
machine • After the engine starts, the engine coolant temperature gauge does not rise.
Related
information

engine coolant
1
sensor Between E08 (Male) Resistance 35 - 50 kΩ
{77°F}
(1) - (2)
100°C {212°F} Resistance 3.1 - 4.5 kΩ

fault
ground
Between L55 (Female) (8), E08 (Female) (1) - body Resistance 1 MΩ and above

Defective
3
monitor panel Normal temperature (25°C)
Between L55 Resistance 35 - 50 kΩ
{77°F}
(Female) (8) - body
100°C {212°F} Resistance 3.1 - 4.5 kΩ
40-530 3 WA380-5L

The Coolant Level Caution Lamp Does Not Light
Failure code
code code Trouble The engine coolant level caution lamp does not light ON
MON-8 — (MON)
Description of
• The engine coolant level sensor circuit is always in the CLOSE state.
trouble
Controller
• No reaction.
reaction
Effect on • When the coolant level is insufficient, the coolant level caution lamp does not light ON. (The engine may
machine be damaged.)
Related
information

1 Defective coolant
Subtank low level or
level sensor
less (Abnormal) Resistance 1 Ω and below
Between R32 (Male)
(1) - (2) Subtank low level or
more (Normal) Resistance 1 MΩ and above

Possible
Causes and
fault
ground 3) Connect t-adapter.
Between L54 (Female) (10), R32 (Female) (1) -

body

Defective
3 Subtank low level or
monitor panel Resistance 1 Ω and below
Between L54 (Female) less (Abnormal)
(10) - body Subtank low level or
more (Normal)
WA380-5L 40-531 3

The Hydraulic Oil Temperature Caution Lamp Does Not Light
Troubleshooting Controller The hydraulic oil temperature caution lamp does not light ON
Failure code
code code Trouble After the engine starts, the hydraulic oil temperature gauge does
MON-9 — (MON) not rise.
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
information

hydraulic oil
1
sensor Between R47 (Male) Resistance 35 - 50 kΩ
{77°F}
(1) - (2)
100°C {212°F} Resistance 3.1 - 4.5 kΩ
Possible Harness 1) Turn starting switch OFF.

Causes and disconnection 2) Disconnect connectors L55 and R47.
Standard Values 2 (Disconnection 3) Connect t-adapter.
or defective
contact) Between L55 (Female) (7), R47 (Female) (1) Resistance 1 MΩ and above

Defective
3
monitor panel Normal temperature (25°C)
{77°F}
(Female) (7) - body
100°C {212°F} Resistance 3.1 - 4.5 kΩ
40-532 3 WA380-5L

The Torque Converter Oil Temperature Caution Lamp Does Not Light
Troubleshooting Controller The torque converter oil temperature caution lamp does not light
Failure code
code code ON.
Trouble
After the engine starts, the torque converter oil temperature
MON-10 — (MON) gauge does not rise.
Description of
• The torque converter oil temperature sensor circuit is always in the OPEN state.
trouble
Controller
• No reaction.
reaction
Effect on • The torque converter oil temperature caution lamp does not light ON.
machine • After the engine starts, the torque converter oil temperature gauge does not rise.
Related
information

2) Disconnect connector TC.T.
torque
1 converter oil
Between TC.T Resistance 35 - 50 kΩ
sensor {77°F}
(Male) (1) - (2)
100°C {212°F} Resistance 3.1 - 4.5 kΩ
Possible Harness 1) Turn starting switch OFF.

Causes and disconnection 2) Disconnect connectors L55 and TC.T.
Standard Values 2 (Disconnection 3) Connect t-adapter.
or defective
contact) Between L55 (Female) (2), TC.T (Female) (1) Resistance 1 MΩ and above

Defective
3 monitor panel Normal temperature (25°C)
{77°F}
(Female) (2) - body
100°C {212°F} Resistance 3.1 - 4.5 kΩ
WA380-5L 40-533 3

The Steering Hydraulic Caution Lamp Does Not Light
Failure code
code code Trouble The steering hydraulic caution lamp does not light ON
MON-11 — (MON)
Description of
• The steering hydraulic sensor circuit is always in the OPEN state.
trouble
Controller
• No reaction.
reaction
Effect on • At emergency steering self-check, the steering hydraulic caution lamp does not light ON.
machine • The emergency steering self-check may not be performed.
Related
information

Defective steering The engine stops Resistance 1 Ω and below
1
hydraulic sensor
Between R36
Atmosphere open (Reference) Resistance 1 Ω and below
(Male) (C) - (A)

Harness 2) Disconnect connectors L54, R36, and L61.
disconnection 3) Connect T-adapter.
2 (Disconnection 4) Turn starting switch ON.
or defective
Possible contact) Between L54 (Female) (16), R36 (Female) (C) -
Causes and Resistance 1 Ω and below
body
Standard Values
Harness hot 3) Connect T-adapter.
3
short fault
Between L54 (Female) (16), R36 (Female) (C) -
body

Defective
4 The engine stops Resistance 1 Ω and below
monitor panel Between L54
(Female) (16) - Atmosphere open (Reference) Resistance 1 Ω and below
body
40-534 3 WA380-5L
WA380-5L 40-535 3

Input Fault in Monitor Panel Mode Switch 1 [■] (Panel SW1)
Failure code
code code Trouble Input fault in monitor panel mode switch 1 [■] (Panel SW1).
MON-12 — (MON)
Description of
• The input circuit of monitor panel mode switch 1 [■] (Panel SW1) is in the OPEN state.
trouble
Controller
• No reaction.
reaction
Effect on
• The monitor operation is impossible. (Not placed into the service mode.)
machine
• The input signal (0/1) of monitor panel mode switch 1 [■] (Panel SW1) can be checked with monitoring
Related
function (Code: 40901, D-IN-15).
information
• Since [■] switch is abnormal, the monitoring function may not be implemented.

monitor panel
1
mode switch 1 When monitor panel
[■] Between L07 Resistance 1 Ω and below
mode switch 1 [■] is ON
(Female) (2) - (3)
Others Resistance 1 MΩ and above

Harness 2) Disconnect connectors L51, L52, and L07.
2 (Disconnection
or defective Between L52 (Female) (17) - L07 (Female) (3) Resistance 1 Ω and below
contact)
Between L51 (Female) (4), (5), L07 (Female) (2) Resistance 1 Ω and below
Possible
Causes and Harness ground 1) Turn starting switch OFF.
Standard Values fault 2) Disconnect connectors L51, L52, and L07.
(At occurrence of a 3) Connect T-adapter.
ground fault, the
3 fuse blows during Between L52 (Female) (17) - L07 (Female) (3) -
switch operation, body
and the subse-
quence operation is Between L51 (Female) (4), (5), L07 (Female) (2)
impossible. - body

4
monitor panel
When monitor panel
Between L52 (17) - Voltage 20 - 30 V
mode switch 1 [■] is ON
body
Others Voltage 1 V and below
40-536 3 WA380-5L
WA380-5L 40-537 3

Input Fault in Monitor Panel Mode Switch 1 [◊] (Panel SW2)
Failure code
code code Trouble Input fault in monitor panel mode switch 1 [◊] (Panel SW2).
MON-13 — (MON)
Description of
• The input circuit of monitor panel mode switch 1 [◊] (Panel SW2) is in the OPEN state.
trouble
Controller
• No reaction.
reaction
Effect on
machine
• The input signal (0/1) of monitor panel mode switch 1 [◊] (Panel SW2) can be checked with monitoring
Related
information
• Since [◊] switch is abnormal, the monitoring function may not be implemented.

monitor panel
1
[◊] Between L07 Resistance 1 Ω and below
mode switch 1 [◊] is ON
(Female) (2) - (3)

Harness 2) Disconnect connectors L51, L52, and L07.
2 (Disconnection
or defective Between L52 (Female) (8) - L07 (Female) (1) Resistance 1 Ω and below
contact)
Between L51 (Female) (4), (5), L07 (Female) (2) Resistance 1 Ω and below
Possible
Causes and Harness ground 1) Turn starting switch OFF.
Standard Values fault 2) Disconnect connectors L51, L52, and L07.
(At occurrence of a 3) Connect T-adapter.
ground fault, the
3 fuse blows during Between L52 (Female) (8) - L07 (Female) (1) -
switch operation, body
and the subse-
quence operation is Between L51 (Female) (4), (5), L07 (Female) (2)
impossible. - body

4
monitor panel
When monitor panel
Between L52 (8) - Voltage 20 - 30 V
mode switch 1 [◊] is ON
body
40-538 3 WA380-5L
WA380-5L 40-539 3

Input Fault in Monitor Panel Mode Switch 2 [<] (Panel SW3)
Failure code
code code Trouble Input fault in monitor panel mode switch 1 [<] (Panel SW3).
MON-14 — (MON)
Description of
• The Input circuit of monitor panel mode switch 1 [<] (Panel SW3) is in the OPEN state.
trouble
Controller
• No reaction.
reaction
Effect on
machine
• The input signal (0/1) of monitor panel mode switch 1 [<] (Panel SW3) can be checked with monitoring
Related
information
• Since [<] switch is abnormal, the monitoring function may not be implemented.

monitor panel
1
[<] Between L08 Resistance 1 Ω and below
mode switch 1 [<] is ON
(Female) (3) - (2)
Harness 1) Turn starting switch OFF.

disconnection 2) Disconnect connectors L54 and L08.
or defective
Possible contact) Between L54 (Female) (7) - L08 (Female) (3) Resistance 1 Ω and below
Causes and
Harness hot short 3) Connect T-adapter.
3
fault
body

4
monitor panel
When monitor panel Voltage 20 - 30 V
Between L54 (7) - mode switch 1 [<] is ON
body
40-540 3 WA380-5L
WA380-5L 40-541 3

Input Fault in Monitor Panel Mode Switch 2 [>] (Panel SW4)
Failure code
code code Trouble Input fault in monitor panel mode switch 1 [>] (Panel SW4).
MON-15 — (MON)
Description of
• The Input circuit of monitor panel mode switch 1 [>] (Panel SW4) is in the OPEN state.
trouble
Controller
• No reaction.
reaction
Effect on
machine
• The input signal (0/1) of monitor panel mode switch 1 [>] (Panel SW4) can be checked with monitoring
Related
information
• Since [>] switch is abnormal, the monitoring function may not be implemented.

monitor panel
1
[<] Between L08 Resistance 1 Ω and below
mode switch 1 [<] is ON
(Female) (1) - (2)

or defective
Causes and
3
fault
body

4
monitor panel
When monitor panel Voltage 20 - 30 V
Between L54 (15) - mode switch 1 [<] is ON
body
40-542 3 WA380-5L
WA380-5L 40-543 3

Defective Subtotal Switch
Failure code
code code Trouble Defective subtotal switch.
MON-16 — (MON)
Description of
• The subtotal switch input circuit is in the OPEN state.
trouble
Controller
• No reaction.
reaction
Effect on
• The load meter subtotal operation is impossible.
machine

Related
• The subtotal switch input signal (0/1) can be checked with the monitoring function
information
(Code: 40904, D-IN-32).

Defective
subtotal switch 3) Connect T-adapter.
1
(BUCKET LEVER
FOR OPTLDM) Between L15 Subtotal switch = ON Resistance 1 Ω and below
(Female) (3) - (4) Others Resistance 1 MΩ and above

or defective
Causes and
3
fault
body

4
monitor panel
Between L54 (4) - Subtotal switch = ON Voltage 20 - 30 V
body Others Voltage 1 V and below
40-544 3 WA380-5L
WA380-5L 40-545 3

Defective Cancel Switch
Failure code
code code Trouble Defective cancel switch.
MON-17 — (MON)
Description of
• The cancel switch input circuit is in the OPEN state.
trouble
Controller
• No reaction.
reaction
Effect on
• The load meter cancel operation is impossible.
machine

Related
• The subtotal switch input signal (0/1) can be checked with the monitoring function
information
(Code: 40904, D-IN-33).

Defective
cancel switch 3) Connect T-adapter.
1
(BUCKET LEVER
FOR OPTLDM) Between L15 Cancel switch = ON Resistance 1 Ω and below
(Female) (1) - (2) Others Resistance 1 MΩ and above

or defective
Causes and
3
fault
body

4
monitor panel
Between L54 (13) - Cancel switch = ON Voltage 20 - 30 V
body Others Voltage 1 V and below
40-546 3 WA380-5L
WA380-5L 40-547 3

Defective Bottom Pressure Sensor (Short Fault)
Failure code
code code Trouble Defective bottom pressure sensor (short fault).
MON-18 — (MON)
Description of
• The input voltage from the bottom pressure sensor is 5.3 V and above.
trouble
Controller
• No reaction.
reaction
Effect on
• The alarm does not function and the load is not displayed.
machine

information • The bottom pressure signal (0.01 MPa) can be checked with the monitoring function (Code: 40400).

Defective lift arm 4) Turn starting switch ON.
1 pressure sensor
(Bottom side) Between F16 (B) - (A) Voltage 20 - 30 V
At running Voltage 0.7 - 5.3 V

Between F16 (C) - (A)
At atmosphere Voltage 0.5 - 1.5 V
Harness hot 1) Turn starting switch OFF.

Possible
short fault 2) Disconnect connector F16.
Causes and
2 (Contact with 3) Connect T-adapter.
Standard Values
power supply Between L55 (Female) (9) - F16 (Female) (C) -
harness) Voltage 1 V and below
body

2) Disconnect connectors L51, F16, and F17.
Defective
3
monitor panel Between L51 (15) - body Voltage 20 - 30 V

40-548 3 WA380-5L
WA380-5L 40-549 3

Defective Head Sensor
Failure code
code code Trouble Defective head sensor.
MON-19 — (MON)
Description of
• The input voltage from the head pressure sensor is 5.3V and above.
trouble
Controller
• No reaction.
reaction
Effect on
• The alarm does not function and the load is not displayed.
machine

information • The bottom pressure signal (0.01 MPa) can be checked with the monitoring function (Code: 40500).

Defective lift arm 4) Turn starting switch ON.
1 pressure sensor
(Head side) Between F17 (B) - (A) Voltage 20 - 30 V

Between F17 (C) - (A)
Harness hot 1) Turn starting switch OFF.

Possible
short fault 2) Disconnect connector F17
Causes and
2 (Contact with 3) Connect T-adapter.
Standard Values
power supply Between L55 (Female) (4) - F17 (Female) (C) -
harness) Voltage 1 V and below
body

Defective
3
monitor panel Between L51 (15) - body Voltage 20 - 30 V

40-550 3 WA380-5L
WA380-5L 40-551 3

The Alarm Buzzer Does Not Sound or Stop
Failure code The alarm buzzer does not sound or stop.
code code Trouble
(Disconnection in alarm buzzer output system, or ground fault)
MON-20 — (MON)
Description of
• A disconnection or ground fault occurs in the alarm buzzer output circuit.
trouble
Controller
• No reaction.
reaction
Effect on
• The alarm buzzer does not sound or stop.
machine
Related
• —
information

2) Disconnect connectorL20.
4) Connect connector L20.
Defective alarm 5) 5 sec. lapsed after the starting switch was turned ON.
1
buzzer
The alarm buzzer sounds Alarm buzzer normal
L20 (2) to body
ground The alarm buzzer does not
Alarm buzzer abnormal
sound.

Possible Harness
Causes and disconnection
2 Harness between L51 (Female) (14) - L20
Standard Values (Disconnection Resistance 1 Ω and below
or contact fault) (Female) (2)
Harness between FS3 (Female) (9) - L20

(Female) (1)

2) Disconnect connectors L51, FS3, and L20.

3 Harness
fault
ground body
Between FS3 (Female) (9) and L51 (Female) (6),

(7), L20 (Female) (1) and body
★ In this case, fuse B-9 blows, and monitor
does not start.
40-552 3 WA380-5L

Turn starting switch ON. Voltage 20 - 30 V

Possible For 2 sec. after the starting
Defective
Causes and 4 switch was turned ON. (The Voltage 1 V and below
monitor panel
Standard Values Between L51 alarm buzzer sounds.)
(14) -body
For 1 sec. after 2 sec. lapsed
after the starting switch was
Voltage 17 - 30 V
turned ON. (The alarm buzzer
does not sound.)
WA380-5L 40-553 3
TROUBLESHOOTING HYDRAULIC AND MECHINCAL SYSTEMS (H
HYDRAULIC AND MECHINCAL SYSTEMS (H MODE)
H-1 - The Machine Does Not Move

Ask the operator about the following: Cause
• Has the machine suddenly stopped? Torque Converter Torque Main Relief Parking
ECMV Transmission
→Seizure of clutch, breakage of parts Charging Pump Converter Valve Brake
Did the machine cause any abnormal noise at the time and
a b c d e f g h i j k l m n o
where?
Defective operation of parking brake solenoid valve

Defective operation of torque converter relief valve
Inspection before diagnosis
The relevant clutch piston seal is defective

• Does the machine monitor function normally?
The parking brake piston seal is defective

The relevant clutch shaft seal is defective
Defective operation of relevant ECMV
Set pressure drop of main relief valve
Internal breakage of torque converter
• Has the machine monitor displayed any failure code of the
Wear or seizure of relevant clutch

Internal breakage of transmission
The charging pump is defective
Clogging of last chance filter

electrical system?
Air intake on suction side

The PTO is defective
• Did you smell deteriorated or burnt transmission oil?
Clogging of strainer
• Have the transmission filter and strainer been clogged?
• Can you find any damage or oil leak from the appearance?
• Has the drive shaft been broken?
• Have the wheel brake and the parking brake been locked?
Remedy Δ Δ Δ Δ Δ Δ Δ
No. X X X X X
Diagnosis X C X X X X X
1 The machine does not move at all gear speeds
2 The machine does not move at specific gear speeds
When the transmission oil temperature is low, the
3 charging pump or the transmission filter causes
abnormal noise(s)
When the transmission oil temperature rises, the
4
machine does not move
Metal (Aluminum, copper, iron, etc.) powders are
5 adhered to the transmission filter or the strainer
6 The speed is higher at all

When the stall speed of the gear speeds
torque converter is
measured The speed is higher at
7
specific gear speeds
The oil pressure is low at
8 all gear speeds
9 When the ECMV output The oil pressure is low at

(Clutch) oil pressure is specific gear speeds
measured
The oil pressure does not
10 become stable as the
gauge touches the oil
When the torque converter relief (Inlet) oil pressure is
11
measured, the oil pressure is low
Proceed to the paragraph of "Defective clutch and ECMV Specifying Method (Check by Failure Code)."
40-554 3 WA380-5L
12
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.”
Transmission ECMV
★ When replacing the ECMV for diagnosis, remove mud and dust around the ECMV completely
and clean it, and then tighten the mounting bolt with the specified torque.
★ For the following diagnoses, start the engine and select the manual mode: a b c d e f g h i j k l
Table of Applicable Clutches Clutch

F R 1st 2nd 3rd 4th
Wear or seizure of 2nd clutch disk or wear of piston seal

Wear or seizure of 3rd clutch disk or wear of piston seal
Wear or seizure of 4th clutch disk or wear of piston seal
Wear or seizure of 1st clutch disk or wear of piston seal
Defective operation of 2nd clutch ECMV (Fill switch)

Wear or seizure of R clutch disk or wear of piston seal
Wear or seizure of F clutch disk or wear of piston seal
Defective operation of 3rd clutch ECMV (Fill switch)

Defective operation of 4th clutch ECMV (Fill switch)
Defective operation of 1st clutch ECMV (Fill switch)
●
Defective operation of R clutch ECMV (Fill switch)

Defective operation of F clutch ECMV (Fill switch)
In the Automatic Mode
N
In the Manual Mode
F1 ● ●
F2 ● ●
Gear Speed
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
★ When the gear speed is N in the manual mode, the clutch of the gear speed (Marked with O),
to which the gear shift lever is set, is ON.
• Even if the gear shift lever is used when the gear speed is N, the clutch position cannot be
changed.
Remedy Failure
No. Code X X X X X X X X X X X X
Diagnosis
B The code is not displayed at R1~R4 but is displayed at F1~F4 15SAL1
When the failure code is 15SAL1 after the diagnosis in B, the failure code comes
1
C not to be displayed when the F fill switch connector (CN-F.SW) is disconnected. 15SALH
When the failure code is 15SALH, the failure code comes not to be displayed when
the ECMV is replaced with any one other than F clutch ECMV
B The code is not displayed at F1~F4 but is displayed at R1~R4 15SBL1
When the failure code is 15SBL1 after the diagnosis in B, the failure code comes not
2 to be displayed when the R fill switch connector (CN-R.SW) is disconnected.
C 15SBLH
When the failure code is 15SBLH, the failure code comes not to be displayed when
the ECMV is replaced with any one other than R clutch ECMV
B The code is not displayed at F2, F3, and F4 but is displayed at F1 15SEL1
When the failure code is 15SEL1 after the diagnosis in B, the failure code comes not
3 to be displayed when the 1st fill switch connector (CN-1.SW) is disconnected.
C When the failure code is 15SELH, the failure code comes not to be displayed when 15SELH
the ECMV is replaced with any one other than the 1st clutch ECMV
B The code is not displayed at F1, F3, and F4 but is displayed at F2 15SFL1
When the failure code is 15SFL1 after the diagnosis in B, the failure code comes not
4
C to be displayed when the 2nd fill switch connector (CN-2.SW) is disconnected. 15SFLH
When the failure code is 15SFLH, the failure code comes not to be displayed when
the ECMV is replaced with any one other than the 2nd clutch ECMV
B The code is not displayed at F1, F2, and F4 but is displayed at F3 15SGL1
When the failure code is 15SGL1 after the diagnosis in B, the failure code comes
5 not to be displayed when the 3rd fill switch connector (CN-3.SW) is disconnected.
C 15SGLH
When the failure code is 15SGLH, the failure code comes not to be displayed when
the ECMV is replaced with any one other than the 3rd clutch ECMV
B The code is not displayed at F1, F2, and F3 but is displayed at F4 15SHL1
When the failure code is 15SHL1 after the diagnosis in B, the failure code comes
6 not to be displayed when the 4th fill switch connector (CN-4.SW) is disconnected.
C When the failure code is 15SHLH, the failure code comes not to be displayed when 15SHLH
the ECMV is replaced with any one other than the 4th clutch ECMV
WA380-5L 40-555 3
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
Defective operation of lock-up ECMV
Seizure of lock-up clutch

No. Remedy X X
Diagnosis
1 The lock-up oil pressure does not come to 0
2 The clutch is not released even when the lock-up oil pressure is 0
40-556 3 WA380-5L
12
H-3A - The Travel Speed is Slow, Thrusting Force is Weak, Uphill Traveling
Power is Weak, and the Gear is Not Shifted

• Has an abnormality occurred suddenly? Torque
→ Breakage of related equipment Converter
Torque
Torque Main Relief Parking
Converter Oil ECMV Transmission Others
Did any abnormal noise occur at the time and where? Charging Cooler Converter Valve Brake
• Have any abnormal signs come to occur gradually? Pump
→ Wear of related equipment, defective seal a b c d e f g h i j k l m n o p q r
Defective seal of work equipment and steering system hydraulic pump

Check of abnormality
Breakage of oil cooler and pipe (After torque converter outlet)

Clogging of oil cooler and pipe (After torque converter outlet)
• Execute digging and measure traveling speeds on a level
Defective operation of torque converter relief valve
shaft (Mixing of hydraulic oil in transmission case)

ground and on a slope to check whether the abnormality
actually occurs or is a matter of operator's sense
Defective seal of relevant clutch piston

Defective operation of relevant ECMV
Defective seal of parking brake piston

Defective seal of relevant clutch shaft
Drop of main relief valve set pressure

Air intake on pump suction side
Oil leak inside torque converter


• Is any failure code of the electrical system displayed on
Clogging of breather
Engine degradation
the machine monitor?
• Are the transmission oil level and the oil type appropriate?
• Is any external oil leak found on the mating faces of pipes
and valves around the torque converter and transmission?
• Has the wheel brake or the parking brake being 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 Δ Δ Δ Δ Δ Δ Δ C Δ
No. X X X X X Note
Diagnosis X X X X X X X X X X
1 Any abnormality occurs at all gear speeds
2 Any abnormality occurs at specific gear speeds
When the transmission oil temperature is low, the
3 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.) powders adhere
6 to the transmission filter or the strainer
The engine low idling and high idling speeds are
7
measured to be abnormal
8 When the stall speed of the The speed is high
torque converter is mea-
9 sured The speed is low
The oil pressure drops as
10
the temperature rises
11 The oil pressure is low at

When the ECMV output all gear speeds
(Clutch) oil pressure is The oil pressure is low at
12 measured specific gear speeds
13 become stable as the
gauge touches the oil
When the torque converter relief (Inlet) oil pressure is
14 measured, the oil pressure is low. (Nos. 11~13 are —
normal.)
15 When the oil pressure at the torque converter outlet is
measured, the oil pressure is low. (No. 14 is normal.)
Proceed to the paragraph of "Defective clutch and ECMV Specifying Method (Check by Failure Code)."
WA380-5L 40-557 3
Defective Clutch and ECMV Specifying Method (Check by Failure Code)
Machine Monitor.”
★ When replacing the ECMV for diagnosis, remove mud and dust around the ECMV completely Transmission ECMV
and clean it, and then tighten the mounting bolt with the
specified torque.

F R 1st 2nd 3rd 4th



●

In the Automatic Mode
N
In the Manual Mode
F1 ● ●
F2 ● ●
Gear Speed
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
changed.
Remedy Failure
Diagnosis
1 not to be displayed when the F fill switch connector (CN-F.SW) is disconnected.
C When the failure code is 15SALH, the failure code comes not to be displayed when 15SALH
2
C to be displayed when the R fill switch connector (CN-R.SW) is disconnected. 15SBLH
C 15SELH
When the failure code is 15SELH, the failure code comes not to be displayed when
4 to be displayed when the 2nd fill switch connector (CN-2.SW) is disconnected.
C When the failure code is 15SFLH, the failure code comes not to be displayed when 15SFLH
5
C not to be displayed when the 3rd fill switch connector (CN-3.SW) is disconnected. 15SGLH
C 15SHLH
When the failure code is 15SHLH, the failure code comes not to be displayed when
40-558 3 WA380-5L
H-3B - The Torque Converter Lock-up Clutch is Not Let in (When Lock-up
Clutch is Provided)
• Has the torque converter lock-up clutch come not to be let in suddenly?
a b c d e f g
→ Internal seizure or breakage
• Did any abnormal noise occur at the time? → Breakage of parts
Wear of lock-up clutch piston seal ring

Defective operation of lock-up ECMV
Clogging of last change filter

Crack on lock-up clutch case
Wear of input shaft seal ring

Wear of lock-up clutch disk
• Is the transmission oil level appropriate?
• Is oil leaking outside?
• Oil pressure of main relief valve
• Oil pressure of lock-up clutch
• Traveling speed
Remedy Δ
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
4 Letting the lock-up clutch in takes a 15SJLH

long time
WA380-5L 40-559 3
12
H-4 - Shocks are Large at the Times of Starting and Shifting Gear

• Did shocks become large suddenly?
→ Breakage of related equipment Torque
Converter Main Relief ECMV Transmission Parking
Did any abnormal noise occur at the time and where? Valve Brake
Charging Pump
• Did shocks become large gradually?
→ Wear of related equipment, defective seal a b c d e f g h i j k
Defective return (Release) of relevant clutch piston

• Did any of the following abnormal phenomena occur at the same time: The
Defective operation of relevant ECMV★
Defect of transmission controller system

Defective operation of main relief valve

traveling speed is slow, the braking is weak, the uphill travelling power is

weak, the gear is not shifted.
Clogging of last change filter

→ Execute H-3
• Is any failure code of the electrical system displayed on the machine
monitor?
• Is any external oil leak found on the mating faces of pipes and valves around
the torque converter and the transmission?
• Is the engine speed high at the time of low idling?
• Is play of each drive shaft large?
Remedy C Δ Δ
No. X X X X
Diagnosis X X X
1 Shocks are large at all gear speeds
2 Shocks are large at specific gear speeds
The oil pressure is low at all gear
3 speeds
4 When the ECMV output (Clutch) The oil pressure is low at specific
oil pressure is measured gear speeds
The oil pressure is high at all gear
5
speeds
★ Defective operation of relevant ECMV or defective operations of fill switch and solenoid due to bolting wastes of
pressure control valve spool.
Proceed to the paragraph of "Defective Clutch and ECMV Specifying Method (Check by Failure Code)."
Proceed to the paragraph of "Troubleshooting of Transmission Controller System (TM Mode)."
40-560 3 WA380-5L

Machine Monitor.”
Transmission ECMV

F R 1st 2nd 3rd 4th



In the Automatic Mode ●
N
In the Manual Mode
F1 ● ●
F2 ● ●
Gear Speed
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
changed.
Remedy Failure
Diagnosis
1
C 15SBLH
4
C 15SGLH
WA380-5L 40-561 3
H-5 - Time Lag is Large at the Times of Starting and Shifting Gear
• Did the time lag become large suddenly? Torque
→ Breakage of related equipment Converter Main Relief ECMV Transmission Parking
Did any abnormal noise occur at the time and where? Valve Brake
Charging Pump
• Has the time lag become large gradually?
→ Wear of related equipment, defective seal a b c d e f g h i
• Did any of the following abnormal phenomena occur at the same time: The
traveling speed is slow, the braking is weak, the uphill travelling power is
Defective operation of relevant ECMV★

weak, the gear is not shifted → Execute H-3

• Is any failure code of the electrical system displayed on the machine
monitor?
• Is any external oil leak found on the mating faces of pipes and valves
around the torque converter and the transmission?
Remedy C Δ Δ
No. X X X X
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, abnormal noise occurs
3 from the charging pump or the transmission filter
4 The torque converter oil temperature is abnormally high
The oil pressure is low at all gear
5
When the ECMV output (Clutch) speeds
oil pressure is measured
6 The oil pressure is low 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.
Proceed to the paragraph of “Defective Clutch and ECMV Specifying Method (Check by Failure Code).”
40-562 3 WA380-5L

Machine Monitor.”
Transmission ECMV

F R 1st 2nd 3rd 4th



In the Automatic Mode ●
N
In the Manual Mode
F1 ● ●
F2 ● ●
Gear Speed
F3 ● ●
F4 ● ●
R1 ● ●
R2 ● ●
R3 ● ●
R4 ● ●
changed.
Remedy Failure
Diagnosis
1
C 15SBLH
4
C 15SGLH
WA380-5L 40-563 3
H-6 - Torque Converter Oil Temperature is High

• Does the oil temperature rise when the torque converter stalls and
does the temperature fall at the time of no load? → Selection of Torque Torque Main
Converter Torque
improper gear speed Charging Converter Converter Relief Transmission Others
Did any abnormal noise occur at the time and where? Oil Cooler Valve
Pump
• Does the oil temperature rise only at the time of lifting?
→ Improvement of operating method
a b c d e f g h i j k l
Defective seal of work equipment and steering system hydraulic pump

Breakage of oil cooler and pipe (After torque converter outlet)
Clogging of oil cooler and pipe (After torque converter outlet)
• Measure the torque converter oil temperature to find if the oil
shaft (Mixing of hydraulic oil in transmission case)

temperature is really high. → The torque converter oil temperature
gauge is defective


Oil leak inside torque converter

Clogging of breather
Engine degradation
• Are the water level in the radiator and the belt tension appropriate?
• Are the oil level in the transmission and the oil type appropriate?
Note: When the inspection result was “Engine Degradation,” proceed to

Engine System Troubleshooting (S Mode).
Remedy C Δ Δ Δ Δ Δ Δ C Δ
No. X X Note
Diagnosis X X X X X X X X X
1 When the transmission oil temperature is low, the charging

pump or the transmission filter causes any abnormal noise
Traveling speed, braking force and uphill travelling power do
2
not occur at all gear speeds
Traveling speed, braking force and uphill travelling power do
3 not occur at specific gear speeds
4 The transmission oil level rises and falls
Metal powders (Aluminum, copper, iron, etc.) are adhered to the
5 transmission filter and the strainer
6 The engine low idling and high idling speeds are measured to be
abnormal
When the stall speed of the torque converter is measured, the
7
speed is high
The oil pressure drops as the
8 oil temperature rises
The oil pressure is low at all
9 gear speeds
When the ECMV output
10 (Clutch) oil pressure is measured The oil pressure is low at
specific gear speeds
11 become stable as the gauge
vibrates
When the torque converter relief (Inlet) oil pressure is measured,
12
the oil pressure is low. (Nos. 9~11 are normal.)
When the oil pressure at the torque converter outlet is measured,
13 the oil pressure is low. (No. 12 is normal.)
40-564 3 WA380-5L
H-7 - Steering Wheel Does Not Turn

Ask the operator about the following questions. Cause
• Did the problem suddenly start? Hydraulic Charge Orbit- Stop Steering Cylin-
Yes = Related equipment broken Pump Valve roll valve valve der
• Was there any abnormal noise when this happened? a b c d e f g h i
Where did the noise come from?
Defective actuation of demand spool
Defective actuation of steering spool

Defective steering and switch pump
Checks before troubleshooting
Defective safety-suction valve

• Is the oil level in the hydraulic tank correct?
Defective PPC pump
Defective piston seal

Defective stop valve
Defective stop valve

Is the type of oil correct?
Defective Orbit-roll
• Is the steering shaft broken?
• Is the stop valve stopper properly adjusted?
• Has the safety bar been removed from the frame?
Remedy Δ Δ Δ Δ Δ Δ
No. X X X
Diagnosis X X X X X X
1 Steering wheel does not turn in both directions (left and right)
2 Steering wheel turns only in one direction (left or right)
3 Steering wheel is heavy in both directions (left and right)
4 Work equipment moves
5 Work equipment does not move
6 Abnormal noise comes from around PTO
7 Abnormal noise comes from around PPC pump or hydraulic tank
8 Oil pressure is low or there is no pressure in

When steering relief pressure both directions (left or right)
is measured Oil pressure is low or there is no pressure in one
9
direction (left or right)
When Orbit-roll output pressure is measured, oil pressure is found to be low or
10 there is no oil pressure
11 When PPC valve (Orbit-roll) Oil pressure is low
12 basic pressure is measured There is no oil pressure
Since the steering circuit is closely related to the work equipment circuit, check how the work equipment operates when
the steering is felt abnormal
WA380-5L 40-565 3
H-8 - Steering Does Not Turn [Machine With Joystick]

• Did the problem suddenly start? Cylin-

Hydraulic Charge Orbit- Joystick Stop Steering Valve der
Yes = Related equipment broken Pump Valve roll valve valve
• Was there any abnormal noise when this happened? a b c d e f g h i j k l m

Defective actuation of joystick solenoid valve

Air sucked in at suction end of pump

Defective actuation of stop valve
Defective 2-way restrictor valve

Defective charge valve

Defective PPC pump

• Is the steering shaft broken?
Defective PTO
• Is the stop valve stopper properly adjusted?
Clogged filter
• Has the safety bar been removed from the frame?
• Is the operation of the steering and the steering mode switch correct?
Remedy Δ Δ Δ C Δ Δ Δ Δ
No. Δ X X X X
Diagnosis X X X X X X X X
1 Steering does not move (steering wheel mode

only
When steering mode
2 switch is switched Steering does not move (joystick mode only)
3 Steering does not move in either mode
4 Steering wheel does not turn in both directions (left and right)
5 Steering wheel turns only in one direction (left or right)
6 Steering wheel is heavy in both directions (left and right)
7 Steering wheel is heavy in one direction (left or right)
11 Abnormal noise comes from around PPC pump or hydraulic tank
12 Oil pressure is low, or there is no pressure in

When steering relief both directions (left or right)
pressure is measured Oil pressure is low, or there is no pressure in
13
one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure is found to be
14 low or there is no oil pressure
15 When joystick solenoid valve output pressure is measured, oil pressure

is found to be low or there is no oil pressure
16 When PPC valve (Orbit- Oil pressure is low
roll) basic pressure is
17 measured There is no oil pressure
40-566 3 WA380-5L
12
H-9 - Turning, Response of Steering is Poor
• Did the problem suddenly start? Hydraulic Charge Orbit- Stop Steering Cylin-
Yes = Related equipment broken Pump Valve roll valve valve der
• Was there any abnormal noise when this happened? a b c d e f g h i j k l m
• Where did the noise come from?
• Did the problem gradually appear?
Yes = Wear of related parts, defective
seal
Air sucked in at suction end of pump


Defective main relief valve

Defective steering pump
Defective switch pump

Defective PPC pump

Defective PTO
Remedy Δ Δ Δ Δ Δ Δ Δ Δ
No. Δ X X X X
Diagnosis X X X X X X X X
Turning, response of steering is poor in both directions (left and
1
right)
2 Turning, response of steering is poor in one direction (left or right)
3 Steering wheel is heavy in both directions
4 Steering wheel is heavy in one direction (left or right)
Abnormal noise comes from around steering pump or hydraulic
8 tank
9 Abnormal noise comes from around switch pump or hydraulic tank
Oil pressure is low or there is no

10 pressure in both directions (left
When steering relief pressure is and right)
measured Oil pressure is low or there is no
11 pressure in one directions (left or
right)
When Orbit-roll output pressure is measured, oil pressure is found
12
to be low
When PPC valve (Orbit-roll) basic pressure is measured, oil pres-
13 sure is found to be low
★ There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the
steering, check the operation of the work equipment also.
WA380-5L 40-567 3
12
H-10 - Steering is Heavy
Checking for abnormalities Cause
• Is the steering difficult to turn? Orbit- Stop
S/V Others
Yes = Go to H-8 or H-9 roll valve
• Measure the operating effort and turning speed, and check the STANDARD VALUE TABLE to see if they a b c d
are abnormal.

Ask the operator the following questions.
Interference of steering wheel

• Did the problem suddenly start?
Yes = Related equipment broken
or steering shaft
• Was there there previously any symptom, such as heavy steering?
Yes = Wear of related equipment, defective seal

• Is the tire inflation pressure correct?
Remedy Δ Δ Δ Δ
No.
Problems X X X X
1 Steering is heavy when turned in both directions (left and right)
2 Steering is heavy when turned in one directions (left or right)
3 Steering is heavy even when joint between steering shaft and Orbit-roll is disconnected
4 Oil pressure is low in both directions (left and right)
When steering relief pressure is mea-
5 sured Oil pressure is low in one directions (left and right)
6 When Orbit-roll output pressure is measured, pressure is found to be low
40-568 3 WA380-5L
12
H-11 - Steering Wheel Shakes or Jerks
Checking for abnormalities Causes
Charge Orbit- Stop
• Is the steering difficult to turn? valve roll valve Steering valve Cylinder
Yes = Go to H-8 a b c d e f g h
• Is there any abnormal noise from around the steering equipment

• Is the steering wheel play correct?
• Is there any abnormality in the connection between the steering shaft and the Orbit-roll?

• Is the tire inflation pressure correct?

Defective main relief valve

Remedy Δ Δ Δ Δ Δ Δ Δ Δ
No.
Problems X X X X X X X
1 Steering wheel shakes or jerks in both directions (left and right)
2 Steering wheel shakes or jerks in one direction (left or right)
During operations or when traveling (when steering), steering wheel shakes or
3 jerks in both directions (left and right)
4 During operations or when traveling (when steering), steering wheel shakes or

jerks in one directions (left and right)
Steering wheel jerks or there is excessive shock when steering is operated to end of
5
its stroke
6 Work equipment also jerks
Oil pressure is unstable in both directions
7
When steering relief pressure is mea- (left and right)
sured Oil pressure is unstable in one direction
8 (left or right)
9 Oil pressure is unstable in both directions

When Orbit-roll output pressure is mea- (left and right)
sured Oil pressure is unstable in one direction
10
(left or right)
When PPC value (Orbit-roll) basic pressure is measured, oil pressure is found to
11 be unstable
WA380-5L 40-569 3
12
H-12 - The Brake Does Not Work
• Has the brake failed suddenly?
→ Breakage of brake
• Has the brake failed gradually?
a b c d e f g h i j
→ Wear of seals, lining, disk
Defective seal of accumulator piston, insufficient gas pressure

Metal contact due to complete wear of brake lining in axle
Insufficient scuffing of pilot pump (For charge)

• Is the hydraulic oil level appropriate?
Wear or abnormality of brake lining in axle

Defective operation of brake piston in axle
Defective seal of brake piston in axle
• Is the play of brake pedal appropriate?
Defective operation of charge valve

• Oil leak from brake tube and connector, deformation of tube
The brake in axle is defective
Mixing of air in brake circuit
Defect inside brake valve

• Tire air pressure and state of tire tread
Check of Abnormality
• Measure the braking force and check referring to the standard value table if the brake
does not work practically.
Remedy Δ Δ Δ Δ Δ Δ Δ Δ Δ Δ
No.
1 When the brake pedal is stepped on, only a little resistance is felt
2 When the brake pedal is stepped on, a strong resistance is felt
3 To get the specified braking force, an abnormal leg-power is required
4 When the brake works, an abnormal noise occurs from the axle brake
5 The machine does not travel well. (Insufficient drawbar pull)
When the four wheels are jacked up, the axle is placed on a table and the brake is
6 applied at the first forward speed, only a specific wheel rotates
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 A lot of metal powders are mixed in the axle oil
10 The brake pedal leg-power and stroke are normal, but the brake does 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
40-570 3 WA380-5L
12
H-13 - The Brake is Not Released or is Draging
• Has the brake pedal returned completely?
• Is the parking brake released completely? a b c
Defect inside brake valve (Sticking of piston)
Defective operation of brake piston in axle

Abnormal lining of brake in axle

• Abnormal heat of brake
• Does the machine travel smoothly by inertia on a level ground?
Remedy Δ Δ Δ
No.
Diagnosis X X X
1 The brake pedal is released, but the brake is still applied
When the brake pedal is released, oil is drained from the air bleeder, the circuit pressure drops and the brake is
2
released
The four wheels are jacked up, the axle is placed on a table, the engine is stopped, the parking brake is released
3
and the tires are rotated by hand but a specific tire hardly rotates
WA380-5L 40-571 3
12
H-14 - The Parking Brake is Not Released or Draging
• Check if the emergency parking brake release valve is closed. (When this valve is open, the parking brake is
always released.)
• Check if the parking brake is automatically applied when the engine stops. a b c d e
Being pinched due to peeling of parking brake disk lining

Insufficient oil level due to defect of transmission valve
Broken harness of parking brake switch line
Defective operation of parking brake piston

Defect inside parking brake solenoid valve
• Abnormal heat of brake
• Does the machine travel smoothly by inertia on a level ground?
Remedy Δ Δ Δ Δ
No. Δ
Diagnosis X X X X
1 When the parking brake switch is off, the parking brake is not released
2 When the parking brake switch is off, the brake is not applied even if 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
40-572 3 WA380-5L
12
H-15 - The Boom Does Not Rise
• Has the boom failed suddenly → Seizure or breakage of each equipment Work
Tank Pump Steering PPC Equipment Cylinder
• Did any abnormal noise occur at the time (And where)? Valve Valve
• Was there the phenomenon that the boom worked slowly? Valve
→ Wear of parts or deformation of spring a b c d e f g h i j
Clogging of pump suction port or mixing of much air in oil
The hydraulic pump and the switch pump are defective

Breakage inside valve body (Boom spool)

• Is the oil level in the hydraulic tank appropriate?
Damage of boom cylinder piston seal

Defective operation of demand spool
Defective operation of relief valve

• Is the stroke of the boom control lever appropriate?
The pump PTO does not drive
Defective operation of spool

The PPC pump is defective
Remedy C Δ Δ Δ Δ Δ Δ
No.
Diagnosis Δ X X X X X X X X X
1 The bucket cannot operate and the boom cannot rise
The boom can lift the machine but cannot rise, or the bucket operates but the
2 boom cannot rise
3 The boom can rise without load but cannot rise when loaded
4 The hydraulic pump causes an abnormal noise
5 Large hydraulic drift of boom cylinder
6 When the engine is at full throttle, the steering operation is light and too fast
7 When the engine is at full throttle, the steering operation is heavy and slow
WA380-5L 40-573 3
12
H-16 - The Boom Moves Slowly or the Boom Rising Force is Insufficient
• Is the stroke of the boom control lever appropriate? Work
Tank Steering PPC Equipment Cylinder Cutoff
Pump Valve Valve Valve
Valve
Check of Abnormality a b c d e f g h i
Defective operation or improper adjustment of main relief valve

• Rising force and speed problem are closely related, and this problem occurs as
Defective operation or improper adjustment of cutoff valve

insufficient rising speed at first. Measure the boom rising speed when the boom

is loaded and make sure referring to the criterion table that the speed is abnormal.
Wear or breakage inside valve body (Boom spool)
Damage of boom cylinder piston seal


Remedy C Δ Δ Δ Δ A Δ Δ
No.
The bucket tilting force and speed are abnormal, and the boom rising
1
speed is slow
The bucket tilting force and speed are normal, and the boom rising speed
2 is slow
3 When the oil temperature rises in No. 1, the boom speed becomes very
slow
4 The hydraulic pump is causing an abnormal noise
5 When the engine is at full throttle, the steering operation is light and too
fast
7 Large hydraulic drift of cylinder
The relief oil pressure from the relief valve of the work equipment valves
8 is low
9 The relief oil pressure from the relief valve of the work equipment valves
is too high
40-574 3 WA380-5L
12
H-17 - When Rising, the Boom Comes to Move Slowly at Specific Height
• Deformation of boom cylinder in appearance
Cause
• Expansion of boom cylinder tube or damage inside
★ For other abnormal phenomena during boom rise, see “H-16. The boom moves slowly or the boom rising force is insufficient.”
H-18 - The Boom Cylinder Cannot Hold Down the Bucket (the Bucket Rises
in the Air)
See “H-16. The boom moves slowly or the boom rising force is insufficient.”

• Is the stroke of the boom control lever appropriate?
Cause
• Defective seat of suction valve on the boom cylinder rod side of work equipment valve
• Oil leak from boom cylinder piston seal
H-19 - Hydraulic Drifts of the Boom Occur Often

Ask the operator about the following:
• Have hydraulic drifts come to occur often suddenly? → Wastes pinched in valve or damage of parts
• Have hydraulic drifts come to occur often gradually? → Wear of parts

• Is the boom spool at the neutral position? → The spool detent is defective
Diagnosis and Cause

• Does any leaking noise occur inside the boom cylinder when hydraulic drift is measured? → The cylinder packing is defective
WA380-5L 40-575 3
12
H-20 - The Boom Wobbles During Operation
The bucket and the boom moves up and down as the topography goes in digging or leveling with the boom control lever in the “HOLD” position.
Diagnosis and Cause

Check at first the hydraulic drift and if the boom cylinder can lift the machine
• When the hydraulic drift is more than the standard value, see “H-19. Hydraulic drifts of the boom occur often.”
• When the boom cylinder cannot lift the machine, see “H-18. The boom cylinder cannot hold down the bucket.”
• When the boom cylinder comes to enable to lift the machine after the boom is operated several times with the normal hydraulic drift and after the boom
cylinder operates to full stroke → The cause is vacuum generated inside the cylinder
★ Frequent hydraulic drifts → The suction valve on the boom cylinder rod side is defective
H-21 - When the Control Lever is Switched From “Hold” to “Raise,” the
Boom Falls Temporarily
Check of Phenomenon
• When the control lever is switched from “HOLD” to “RAISE” gradually at low idling of the engine, the boom falls temporarily due to its own weight.
When the control lever is completely set to “RAISE,” the boom returns to normal.
Cause
• Improper adhesion of boom spool check valve of the work equipment valve
40-576 3 WA380-5L
12
H-22 - The Bucket Does Not Tilt Back
• Has the bucket failed suddenly → Seizure or breakage of each equipment Work
Tank Pump Steering PPC Equipment Cylinder
• Did any abnormal noise occur at the time (And where)? Valve Valve
• Was there the phenomenon that the bucket worked slowly? Valve
→ Wear of parts or deformation of spring a b c d e f g h i j

Breakage inside valve body (Bucket spool)

• Is the stroke of the bucket control lever appropriate?
Damage of bucket cylinder piston seal

The pump PTO does not drive
The relief valve is defective

The PPC pump is defective
The spool is defective

Remedy C Δ Δ Δ Δ Δ Α X X
No. Diagnosis
Δ X X X X X X X
1 The boom cannot operate and the bucket cannot tilt back
The bucket can lift the machine but cannot tilt back, or the boom operates but
2
the bucket cannot tilt back
3 The bucket can tilt back without load but cannot in digging or scooping up
4 The hydraulic pump causes an abnormal noise
5 Large hydraulic drift of bucket cylinder
WA380-5L 40-577 3
12
H-23 - The Bucket Moves Slowly or the Tilting Back Force is Insufficient
• Is the stroke of the bucket control lever appropriate? Work
Tank Steering PPC Equipment Cylinder Cutoff
• Seizure of work equipment linkage bushing (Does any abnormal noise occur?) Pump Valve Valve Valve
Valve
a b c d e f g h i j
Defective operation of safety valve (With suction valve) on bucket cylinder bottom side
• Make sure in an actual operation that the tilting-back force is insufficient.
• Measure the operating speed of the bucket, and make sure referring to the criterion
Defective operation or improper adjustment of main relief valve

value table that the speed is abnormal
Defective operation or improper adjustment of cutoff valve

Wear or breakage inside valve body (Bucket spool)
Damage of bucket cylinder piston seal


Remedy C Δ Δ Δ Δ ΔΑ Δ Δ
No.
Diagnosis Δ X X X X X X X X X
The boom rising force and speed are abnormal, and the bucket tilting force and
1
speed are abnormal
The boom rising force and speed are normal, and the bucket tilting force and
2 speed are abnormal
3 When the oil temperature rises in No. 1, the bucket speed becomes worse
4 The hydraulic pump is causing an abnormal noise
7 Large hydraulic drift of bucket cylinder
The relief oil pressure from the relief valve of the work equipment valves is
8
low
The relief oil pressure from the relief valve of the work equipment valves is
9 too high
40-578 3 WA380-5L
12
H-24 - The Bucket Comes to Operate Slowly in the Midst of Tilting-back
• Deformation of bucket cylinder in appearance
Cause
• Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see “H-23. The bucket moves slowly or the tilting-back force is insufficient.”
H-25 - The Bucket Cylinder Cannot Hold Down the Bucket

See “H-23. The bucket moves slowly or the tilting-back force is insufficient.”

• Is the stroke of the bucket control lever appropriate?
Cause
• Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
• Oil leak from bucket cylinder piston seal
H-26 - Hydraulic Drifts of the Bucket Occur Often

Ask the operator about the following:
• Have hydraulic drifts come to occur often suddenly? → Wastes pinched in valve or damage of parts
• Have hydraulic drifts come to occur often gradually? → Wear of parts

• Is the bucket spool at the neutral position? → Seizure of link bushing or the spool detent is defective
• Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically
Cause
• Oil leak in bucket cylinder
• Improper adhesion of safety valve (With suction valve) on the bottom side
WA380-5L 40-579 3
12
H-27 - The Bucket Wobbles During Travel with Cargo (The Work Equipment
Valve is Set to “Hold”)
• Pin of work equipment linkage and “play of bushing” (Is any abnormal noise heard?)
Cause
• Defective seal of bucket cylinder piston
• Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal phenomena, refer to diagnoses for relevant
abnormal phenomena.
H-28 - When the Control Lever is Switched From “Hold” to “Tilt,” The Bucket
Falls Temporarily
Check of Phenomenon
• When the control lever is switched from “HOLD” to “RAISE” gradually at low idling of the engine, the bucket falls temporarily due to its own weight.
When the control lever is completely set to “TILT,” the bucket returns to normal.
Cause
• Improper adhesion of bucket spool check valve of the work equipment valve
40-580 3 WA380-5L
12
H-29 - The Control Levers of Boom and Bucket Do Not Move Smoothly and
Heavy
Check of Abnormality Cause
• Refer to the criterion value table and check if the lever operating efforts are large. PPC Valve Work Equipment Valve
a b c d e f g h i j
Strain of valve body due to uneven tightening of valve mounting bolt
Improper roundness between work equipment valve body and spool

Improper clearance between work equipment valve body and spool
Defective operation of work equipment valve spool detent
Improper roundness between PPC valve body and spool
Improper clearance between PPC valve body and spool
Foreign matter pinched in work equipment valve spool

Foreign matter pinched in PPC valve spool
The work equipment valve spool is bent

The PPC valve spool is bent
Remedy Δ Δ C
No.
Diagnosis X X X Δ
1 When the machine is loaded and the oil pressure rises, the levers do not to move
smoothly
2 The levers do not to move smoothly as the oil pressure rises
3 The levers partly do not to move smoothly during operation irrespective of oil
pressure and oil temperature
The levers totally do not to move smoothly during operation irrespective of oil pres-
4
sure and oil temperature
WA380-5L 40-581 3
H-30 - E.C.S.S. Does Not Work and There is Pitching and Bouncing
E.C.S.S.: Electronically controlled suspension system Cause
Solenoid valve
Ask the operator the following questions.
Accumulator
Controller
• Did the problem suddenly start?
Sensor
Yes = Related equipment broken
a b c d
Improper roundness between PPC valve body and spool

Improper clearance between PPC valve body and spool
• Was there any abnormal noise when this happened?
Foreign matter pinched in PPC valve spool

• Did the problem gradually appear?
Yes = Wear of related parts, defective seal
The PPC valve spool is bent

• Is operation of E.C.S.S. switch correct?
• Are the DIP switches and rotary switches on the back side of the main monitor set correctly?
(See TESTING AND ADJUSTING, Adjusting machine monitor.)
• Are failure codes [D191KA] and [D191KB] displayed?
(For details, see Troubleshooting for transmission system (TM mode).)
Remedy
No. X X X X
Diagnosis
1 Speed (3 km/h) {2 mph} for start of actuation of E.C.S.S. is greatly out of adjustment
2 E.C.S.S. does not work when traveling loaded
3 E.C.S.S. does not work when traveling unloaded
4 When E.C.S.S. is actuated when traveling loaded, boom drops greatly

(more than 30 cm {11.8 in})
5 E.C.S.S. does not work at all
40-582 3 WA380-5L
TROUBLESHOOTING ELECTRICAL SYSTEM (E MODE)
ELECTRICAL SYSTEM (E MODE)
Connector Types and Locations

system.
Number Address
Pins Layout Drawing
Drawing

WA380-5L 40-583 3
Number Address
Pins Layout Drawing
Drawing

40-584 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing


WA380-5L 40-585 3
Number Address
Pins Layout Drawing
Drawing

40-586 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing

WA380-5L 40-587 3
Number Address
Pins Layout Drawing
Drawing
40-588 3 WA380-5L
Number Address
Pins Layout Drawing
Drawing

WA380-5L 40-589 3
40-590 3 WA380-5L
WA380-5L 40-591 3
40-592 3 WA380-5L
WA380-5L 40-593 3
40-594 3 WA380-5L
WA380-5L 40-595 3
Electrical System Diagram
40-596 3 WA380-5L
Action Code: [E-1-a]

The Engine Does Not Crank (Ignition System)
Failure code
code code
Trouble The Engine Does Not Crank (Ignition System)
E-1-a — —
Description of
• The starting motor system is defective, and the engine does not start.
trouble
Controller
reaction
• —
Effect on
• The starting motor system is defective, and the engine does not start.
machine
Related • Check that the fuses A-2 and B-2 are not blown. (If they are blown, check if the related harness is
information short-circuited with the ground.).
Specific
1.26 and above
1 Defective battery gravity
Voltage 25 V and above
Among battery relay terminals R13, R01,

Voltage 20 - 30 V
R04 and machine body.

2) Disconnect the connector S31 and the terminal R13.
3) Insert a T-adapter.
Harness among S31 (female) (2), battery

Disconnection between relay and the terminal R13.
Continuity Yes
2 battery relay body and ★ Measure continuity from S31 (female) (2)
related harness in the diode range.

Possible
Causes and Between battery (+) terminal and (-) terminal. Voltage 20 - 30 V
Standard
Values
2) Disconnect the (-) terminal of the battery relay.
Harness between battery relay (-) terminal

and machine body.

2) Disconnect the connector E01.
4) Starting switch "Start."
Disconnection between
3 starting motor and Between E01 (1) and machine body. Voltage 20 - 30 V
related harness
Between starting motor B terminal and

Voltage 20 - 30 V
machine body

Defective alternator 3) Insert a T-adapter.
(regulator)
Between E01 (2) and machine body Voltage 1 V and below
WA380-5L 40-597 3

Among S31 (1), (2), (3) and machine body

(Starting switch "Start" between (3) and Voltage 20 - 30 V
machine body)

2) Disconnect the starting switch terminals B, BR and C.
Disconnection between
5 starting switch and Between starting switch terminal B and BR Resistance 1 Ω and below
related harness
Between starting switch terminal B and C Resistance 1 Ω and below

2) Disconnect the connectors S31, FS3 and L116.
3) Connect a T-adapter.
Harness between S31 (female) (1) and FS3

(female) (1)
Harness between S31 (female) (1) and L116

(female) (3)

2) Disconnect the connector TEL.
Harness between TEL (female) (7) and TEL

Disconnection between (female) (8)
Possible
Causes and 6 short connector (TEL)
and related harness 1) Starting switch OFF.
Standard 2) Disconnect the connectors TEL and L116.
Values 3) Connect a T-adapter.
Harness between TEL (male) (8) and L116

(female) (3) Resistance 1 Ω and below

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
Between L113 (1) and machine body. Voltage 1 V and below

Disconnection between 1) Starting switch OFF.
7 relay (L113) and 2) Disconnect the relays L113 and L116.
related harness 3) Connect a T-adapter.
Harness between L113 (female) (3) and L116 Resistance 1 Ω and below
(female) (1).
Between the relays L113 (male)( )1 and (2). Resistance 200 - 400 Ω

Harness between L113 (female) (4) and L04

(female) (1).
40-598 3 WA380-5L

Disconnection between 2) Disconnect the connectors L101 and L102.
relay (L113) and 3) Connect a T-adapter.
7
related harness
Harness between L101 (female) (12) and
L102 (female) (12).

2) Disconnect the connectors L102 and E01.

E01 (female) (1).
Disconnection between Continuity Yes
★ Measure the continuity from L102 (14)
8 relay (L116) and related
harness side in the diode range.

2) Disconnect the relay L116.
3) Connect a Tadapter.
Between the relays L116 (male) (1) and (2). Resistance 200 - 400 Ω

4) Starting switch "ON."
Disconnection between Among L04 (1), (3) and machine body. Voltage 20 - 30 V
9 shift switch and related
harness 1) Starting switch OFF.
2) Disconnect the connectors L04 and FS4.
Possible Harness between L04 (female) (1) and FS4

Causes and (female) (2).
Standard
Values 1) Starting switch OFF.
2) Disconnect the connector R26.
Between R26 (male) (2) and (1).
★ Measure the continuity from the (2) side

Continuity Yes
in the diode range.

Continuity No
in the diode range.
★ The diode R26 can be replaced.

Disconnection among 3) Connect a T-adapter.
10 diodes R26, R27 and
related harness
Between R27 (male) (2) and (1).

Continuity Yes
in the diode range.

Continuity No
in the diode range.
★ The diode R27 can be replaced.

2) Disconnect the connectors L102, R26 and R27.

R26 (female) (2)
WA380-5L 40-599 3
Harness between L102 (female) (14) and Resistance 1 Ω and below

R27 (female) (2)

2) Disconnect the connectors E01, R26 and R27.
Disconnection among
10 diodes R26, R27 and 3) Connect a T-adapter.
related harness
Harness between E01 (female) (1) and R26
(female) (1).
Harness between E01 (female) (1) and R27

(female) (1).

2) Disconnect the connectors FS2 and FS4.
Between FS3 (1) and machine body. Voltage 20 - 30 V
Among FS1 (1), (2) and machine body. Voltage 20 - 30 V

2) Disconnect the connectors LR1 and LR4.
Between LR1 (1) and machine body. Voltage 20 - 30 V

Possible
Causes and Among LR4 (1), (2) and machine body. Voltage 20 - 30 V
Standard
Values 2) Disconnect the connectors FS1, FS2, LR1 and LR4.
Harness between FS1 (female) (1) and LR1

Disconnection between Resistance 1 Ω and below
(male) (1).
11 fuse and related
harness
Harness between FS1 (female) (2) and LR4
(male) (1).
Harness between LR4 (male) (2) and FS2

(female) (1).

2) Slow blow fuse (firm power supply).
Among terminal R02, R03 and machine

body.

2) Disconnect the slow blow fuse (firm power supply) terminal R02 and battery
relay terminal R01.
Harness between the slow blow fuse (firm

power supply) terminal R02 and the battery Resistance 1 Ω and below
relay terminal R01

2) Disconnect the slow blow fuse (firm power supply) terminal R05 and battery
relay terminal R04.
Harness between the slow blow fuse (firm

power supply) terminal R05 and the battery Resistance 1 Ω and below
relay terminal R04
40-600 3 WA380-5L

Possible 2) Disconnect the connector S04.
Causes and Defective FNR switch 3) Insert a T-adapter.
12
Standard mode selector switch 4) Starting switch ON.
Values
Between S04 (4) and machine body. Voltage 1 V and below
WA380-5L 40-601 3
Action Code: [E-1-b]

The Engine Does Not Start. (Engine Stop Solenoid System)
Failure code
code code
Trouble The Engine Does Not Start. (Engine Stop Solenoid System)
E-1-b — —
Description of
• The engine stop solenoid system is out of order, and the engine does not start.
trouble
Controller
reaction
• —
Effect on • The engine stop solenoid system is out of order, and the engine does not start. (The starting motor
machine rotates, but the engine does not start.)
Related
• —
information

Defective fuel cut 2) Disconnect the connector R72.
1 3) Connect a T-adapter.
solenoid relay
Between R72 (male) (1) and (2). Resistance 50 - 90 Ω

Defective fuel cut
2
solenoid. Between E34 (male) (A) and (C). Resistance 0.6 - 1.0 Ω
Between E34 (male) (B) and (C). Resistance 37 - 46 Ω

3) Insert a Tadapter.
4) Connect the connector.
Between L91 Starting switch "ON." Voltage 24 V and above

3 Defective timer (1) and (2)
Possible Starting switch "Start." Voltage 16 V and above
Causes and
Standard Values For 2 to 4 sec. from Starting
Between L91 Voltage 16 V and above
Switch "ON."
(5) and (6)
Other than the above Voltage 1 V and below

2) Disconnect the connectors E34, L91, S31, R12, R68, R72 and L102.
Harness between R12 and R68. Resistance 1 Ω and below
Harness between R69 and E34 (female) (A). Resistance 1 Ω and below
Disconnection of
harness Harness between S31 (female) (4) and L91 Resistance 1 Ω and below
4 (female) (1).
(Disconnection,
defective contact)
Harness between S31 (female) (4) and E34 Resistance 1 Ω and below
(female) (B).
Harness between L91 (female) (5) and R72 Resistance 1 Ω and below
(female) (1).
Harness between L91 (female) (6) and R72 Resistance 1 Ω and below
(female) (2).
40-602 3 WA380-5L
Harness between L91 (female) (4) and L102 Resistance 1 Ω and below
Disconnection of (female) (14).
harness
4
(Disconnection, Between L91 (female) (2) and machine body. Resistance 1 Ω and below
defective contact)
Between E34 (female) (C) and machine body. Resistance 1 Ω and below

2) Disconnect the connectors E34, L91, S31, R12, R68, R72 and L102.
Among R12, R68 and machine body. Resistance 1 MΩ and above

Possible
Causes and Among R69, E34 (female) (A) and machine body. Resistance 1 MΩ and above
Standard Values
★ In the above two cases, the flow blow fuse is blown.
Ground fault of
5
harness Among S31 (female) (4), L91 (female) (1), E34
(female) (B) and machine body.
L91 (female) (5), R72 (female) (1) and machine

body.
Harness between L91 (female) (1) and E34

(female) (B).
★ In the above three cases, the fuse B-1 is blown.
WA380-5L 40-603 3
40-604 3 WA380-5L
MEMORANDUM
WA380-5L 40-605 3
Action Code: [E-2]

The Engine Does Not Shut Down
Failure code
code code
Trouble The engine does not shut down.
E-2 — —
Description of
• The engine stop solenoid system is out of order, and the engine does not stop.
trouble
Controller
reaction
• —
Effect on
• Even if the starting switch (ignition key switch) is set to "OFF," the engine does not stop.
machine
Related
• —
information

Defective fuel cut 3) Connect a T-adapter.
1
solenoid relay
Between R72 (male) (1) and (2). Resistance 50 - 90 Ω

2 Defective fuel cut
solenoid
Between E34 (male) (A) and (C). Resistance 0.6 - 1.0 Ω
Between E34 (male) (B) and (C). Resistance 37 - 46 Ω

4) Connect the connector.
Possible
Causes and Between L91 Starting switch "ON." Voltage 24 V and above
Standard Values (1) and (2)
3 Defective timer Starting switch "Start." Voltage 16 V and above
Between L91 For 2 to 4 sec. from Starting Voltage 16 V and above

(5) and (6) Switch "ON." Voltage 1 V and below
★ Unless the engine stops when the connector L91 is disconnected, the timer
needs not be inspected.

Hot short-circuit of Between E34 (male) (A) and machine body. Voltage 1 V and below
4
harness
Between E34 (male) (B) and machine body. Voltage 1 V and below
★ Unless the engine stops when the connector E34 is disconnected, the cause is
the solenoid or the fuel circuit system (mechanical system).
40-606 3 WA380-5L
WA380-5L 40-607 3
Action Code: [E-3]

Preheating Inoperable or Remains ON
Failure code
code code
Trouble Preheating is impossible or constant.
E-3 — —
Description of
• The preheating system is out of order, and preheating is impossible or constant.
trouble
Controller
reaction
• —
Effect on
• Preheating is impossible or constant.
machine
Related • When any failure code appears, diagnose the machine referring to the failure code "D182KZ" related to
information the monitor. The monitoring function (Code : 04104) enables to check engine coolant temperature.

2) Disconnect the connectors E05, E06 and E07.
★ Solid part check
Defective intake
1
air heater relay Between E05 and machine body. Resistance 19 - 25 Ω
Between E06 When the relay is ON Resistance 1 Ω and below

and E07 When the relay is OFF Resistance 1 MΩ and above

Defective intake 2) Disconnect the heater terminal.
2
air heater
Between heater terminal and ground Resistance

2) Disconnect the connectors L102, E05, E06, E07, R11 and heater terminal.
Disconnection of 3) Connect a T-adapter.
harness
(Disconnection, Harness between L102 (female) 4 and E05. Resistance 1 Ω and below
Possible 3
defective contact)
Causes and (Intake air heater
system) Harness between R11 and E06. Resistance 1 Ω and below
Standard
Values Harness between E07 and heater terminal. Resistance 1 Ω and below

2) Disconnect the connectors L102, E05, E06, E07, R11 and heater terminal.
Among L102 (female) (4), E05 and machine body Resistance 1 MΩ and above
Ground fault of
4 harness (Intake air ★ In cases other than the above, the fuse B-0 will be blown.
heater system)
Among R11, E06 and machine body Resistance 1 MΩ and above
Among E07, heater terminal and machine body Resistance 1 MΩ and above
In case other than the above two paragraphs, the slow blow fuse will be blown.

Defective engine 3) Connect aT-adapter.
coolant
5
temperature
Between E09 At the time of 10°C (50°F) Resistance 7 - 11 Ω
sensor
(male) (1) and
(2) At the time of 100°C (212°F) Resistance 0.1 - 0.5 Ω
40-608 3 WA380-5L
Ground fault of 1) Starting switch OFF.

harness 2) Disconnect the connectors L55 and TWH.
6 (Engine coolant
temperature Among L55 (female) (3), E09 (A) and machine
sensor system) Resistance 1 MΩ and above
body

3) Connect aT-adapter.
Defective monitor
7
panel Between L55 At the time of 10°C (50°F) Resistance 7 - 11 Ω
(female) (3)
and machine
body At the time of 100°C (212°F) Resistance 0.1 - 0.5 Ω

Between L114 (male) (1) and (2) Resistance 200 - 400 Ω

Possible 1) Starting switch OFF.
Causes and Defective 2) Disconnect the connector L114.
8
Standard preheater relay 3) Replace the preheater relay (114) with another relay.
Values 4) Starting switch ON.
The preheater relay (L114) is

The machine operates normally. out of order.
The preheater relay (L114) is

The machine does not operate normally. normal.
Disconnection of 1) Starting switch OFF.

harness 2) Disconnect the connectors L151 and L114.
(Disconnection, 3) Connect a T-adapter.
9
defective contact)
(Preheater relay Resistance 1 Ω and below
(female) (12)
system)
Disconnection of 1) Starting switch OFF.

harness 2) Disconnect the connectors L52 and S32.
(Disconnection, 3) Connect a T-adapter.
10
defective contact)
(Starting switch Harness between L52 (female) (11) and S32 Resistance 1 Ω and below
(female) (1)
R1 system)
WA380-5L 40-609 3
40-610 3 WA380-5L
MEMORANDUM
WA380-5L 40-611 3
Action Code: [E-4]

The Engine Power Mode Inoperable
Failure code
code code
Trouble The engine power modes cannot be selected.
E-4 — —
Description of
• The engine power mode system is out of order, and the power modes cannot be selected.
trouble
Controller
reaction
• —
Effect on
• The engine power modes cannot be selected.
machine
Related
• —
information

2) Disconnect the connector S21.
Defective power
1 mode selector ★ Solid part check
switch
Between S01 (male) In the economy mode Resistance 1 MΩ and above
(1) and (4) In the power mode Resistance 1 Ω and below

2) Replace L115 with any other relay.
3) Starting switch "ON."
Defective power
2 mode selector The power mode selector relay
relay It returned to normal.
is out of order.
The power mode selector relay

It does not return to normal.
is normal.
Possible
Standard Values 2) Disconnect the connectors S21, L102, L88, L61 and FS33.
Harness between S21 (female) (4), L61 (female) Resistance 1 Ω and below
(6) and L102 (female) (7)
Harness between S21 (female) (1) and machine Resistance 1 Ω and below
body
Disconnection of Harness between L102 (female) (9) and L88

harness (female) (5)
★ In the above three cases, the power mode cannot be selected.

Harness between FS3 (female) (5) and L88
(female) (4), L102 (female) (6)

(female) (10)
★ In the above two cases, the economy mode cannot be selected.
40-612 3 WA380-5L
Harness between L88 (female) (8) and machine

body
Disconnection of Harness between L88 (female) (7) and L102

harness (female) (8)
★ In the above two cases, the economy mode cannot be changed to the power
mode, and the power mode cannot be changed to the economy mode.

2) Disconnect the connectors S21, L102 and L61.
Among S21 (female) (4), L61 (female) (6), L102

Amng L88 (female) (3), L102 (female) (10) and

machine body
Ground fault of ★ In the above two cases, the economy mode cannot be selected.
4
harness
Possible Among FS3 (female) (5), L88 (female) (4), L102
(female) (6) and machine body Resistance 1 MΩ and above
Causes and
Standard Values ★ In the above case, the fuse B-6 will be blown.
Among L88 (female) (7), L102 (female) (8) and
machine body
★ In the above two cases, the economy mode cannot be changed to the power
mode, and the power mode cannot be changed to the economy mode.

2) Disconnect the connectors S21, L102 and L61.
Among S21 (female) (4), L61 (female) (6), L102

Hot short-circuit of
5
harness ★ In the above case, the fuse B-6 will be blown when the power mode is selected.
Among L88 (female) (7), L102 (female) (8) and
machine body
★ In the above case, the economy mode is changed to the power mode, and the
power mode is changed to the economy mode automatically without operation.
WA380-5L 40-613 3
40-614 3 WA380-5L
MEMORANDUM
WA380-5L 40-615 3
Action Code: [E-5]

The Front Wiper Does Not Function
Failure code
code code Trouble The front wiper does not function
E-5 — —
Description of
• Since a fault occurs in the front wiper, switch timer, or harness, the front wiper does not function
trouble
Controller
• —
reaction
Effect on
• The front wiper does not function
machine
Related
• —
information

2) Disconnect connector C12.
Between C12 (2) - body (Wiper switch

Voltage 20 - 30 V
Lo)
1 Front wiper motor fault
Voltage 20 - 30 V
Hi)
Between C12 (6) - body Voltage 20 - 30 V
When the wiper switch is turned OFF during wiper operation, voltage is
applied between C12 (5) - body until the wiper motor stops.

Possible
Causes and Between L31 (3) - body Voltage 20 - 30 V
Standard Values
2 Wiper timer (relay) fault Between L31 (4) - body (Wiper switch
Voltage 20 - 30 V
INT)
Between L31 (2) - body (Wiper switch

Voltage 20 - 30 V
washer side)
Between L31 (5) - body (The voltage is output intermittently by wiper

switch INT) 20 to 30 V ➞ 0 V ➞ 20 to 30 V ➞ 0 V repeated


3 Front wiper switch fault 1) Turn starting switch OFF.
Between L21 (Male) (7) - (5) (Wiper

switch Lo)
40-616 3 WA380-5L

switch Hi)

3 Front wiper switch fault switch INT)

switch INT)

2) Disconnect connectors L21, L31, and C12.
Harness between L21 (Female) (2) -

L31 (Female) (4)

(Female) (4) - body

L31 (Female) (5)

Harness disconnection or (Female) (5) - body
Possible
Causes and ground fault
4 ★ Fuse A-(7) blows in Harness between L21 (Female) (5) -
ground fault case. C12 (Female) (2)
Between L21 (Female) (5), C12

(Female) (2) - body

C12 (Female) (1)

(Female) (1) - body

C12 (Female) (5)

(Female) (5)- body

2) Disconnect connectors FS4, L21, C12, C15, C43, C44, and C45.
Harness disconnection or 3) Connect T-adapter
ground fault
5 Harness between L21 (Female) (7) -
★ Fuse A-(7) blows in Resistance 1 Ω and below
FS4 (Female) (7)
ground fault case.
Between L21 (Female) (7), FS4
(Female) (7) - body
WA380-5L 40-617 3
40-618 3 WA380-5L
MEMORANDUM
WA380-5L 40-619 3
Action Code: [E-6]

The Rear Wiper Does Not Function
Failure code
code code Trouble The rear wiper does not function
E-6 — —
Description of
• Since a fault occurs in the rear wiper, switch, or harness, the rear wiper does not function
trouble
Controller
• —
reaction
Effect on
• The rear wiper does not function
machine
Related
• —
information

1 Rear wiper motor fault Between C15 (2) - body (Wiper switch
Voltage 20 - 30 V
Lo)
Between C15 (1) - body Voltage 20 - 30 V
When the wiper switch is turned OFF during wiper operation, voltage is
applied between C15 (3) - body until the wiper motor stops.


Possible
Causes and
2 Rear wiper switch fault 2) Disconnect connector L21.
Standard Values

switch Lo)

switch OFF)

2) Disconnect connectors L21 and C15.
Harness disconnection or Harness between L21 (Female) (8) -

ground fault Resistance 1 Ω and below
3 C15 (Female) (3)
★ Fuse A-(7) blows in
ground fault case. Between L21 (Female) (8), C15
(Female) (3) - body

C15 (Female) (2)
40-620 3 WA380-5L
Between L21 (Female) (9), 15

(Female) (2) - body

Possible Harness disconnection or 2) Disconnect connectors FS4, L21, C12, C15, C43, C44, and C45.
Causes and 3 ★ Fuse A-(7) blows in
Standard Values ground fault case. Harness between L21 (Female) (7) -
FS4 (Female) (7)

(Female) (7) - body
WA380-5L 40-621 3
40-622 3 WA380-5L
MEMORANDUM
WA380-5L 40-623 3
Action Code: [E-7]

The Side Wiper Does Not Function (If Equipped)
Failure code
code code
Trouble The side wiper does not function (If equipped)
E-7 — —
Description of
• Since a fault occurs in the side wiper, switch, or harness, the side wiper does not function.
trouble
Controller
reaction
• —
Effect on
• The side wiper does not function.
machine
Related
• —
information

2) Disconnect connectors C44 and C45.
4) Turn starting switch ON
• Right side wiper

Voltage 20 - 30 V
Lo)
When the wiper switch is turned OFF during running of the wiper, the
1 Side wiper fault voltage is applied between the C44 (2) - body until the wiper motor stops
Between C44 (4) - body (Power) Voltage 20 - 30 V
• Left side wiper

Voltage 20 - 30 V
Lo)
Possible
Causes and When the wiper switch is turned OFF during running of the wiper, the
Standard Values voltage is applied between the C45 (2) - body until the wiper motor stops


2 Side wiper switch fault 2) Disconnect connector C43.
Between C43 (Female) (3) - (2)

(Wiper switch Lo)
Between C43 (Female) (2) - (1)

(Wiper switch OFF)
40-624 3 WA380-5L

2) Disconnect connectors C43, C44, and C45.
Harness between C43 (Female) (2) -

C44 (Female) (1) C45 (Female) (1)
Between C43 (Female) (2) - C44

(Female) (1) (C45 (Female) (1) - body

Possible Harness disconnection or C44 (Female) (2) C45 (Female) (2)
ground fault
Causes and 3 ★ Fuse A-(7) blows in Between C43 (Female) (1) - C44
Standard Values Resistance 1 MΩ and above
ground fault case. (Female) (2) C45 (Female) (2) - body

2) Disconnect connectors L21, L31, FS4, R43, R45, C12, C15, C43,
C44, and C45.

FS4 (Female) (7)
Between C43 (Female) (3), FS4

(Female) (7) - and body
WA380-5L 40-625 3
40-626 3 WA380-5L
MEMORANDUM
WA380-5L 40-627 3
Action Code: [E-8]

The Window Washer Does Not Function
Failure code
code code
Trouble The window washer does not function
E-8 — —
Description of • Since a fault occurs in the window washer motor, switch, timer (Front only), or harness, the window
trouble washer does not function.
Controller
reaction
• —
Effect on
• The window washer does not function
machine
Related • When the wiper function is normal (When the wiper function is also abnormal, first diagnose the wiper
information function fault in E-5).

2) Disconnect connectors R43 and R45.
1 Washer motor fault • Front washer motor.
Between R43 (1) - body Voltage 20 - 30 V
• Rear washer motor.
Between R45 (1) - body Voltage 20 - 30 V

• Common to both front and rear switch.
Possible Between L21 (7) - body Voltage 20 - 30 V

Causes and
• Front switch.
Between L21 (Male) (7) - (6) (Washer

2 Wiper switch fault. Resistance 1 Ω and below
switch ON)
Between L21 (Male) (7) - (6) (Washer

switch OFF)
• Rear switch.

(Washer switch ON)

(Washer switch OFF)
Between L21 (Male) (7) - (9), and (10)

(Washer wiper Lo switch ON)
40-628 3 WA380-5L

Wiper timer (Relay) fault Between L31 (3) - body Voltage 20 - 30 V

3
(Front wiper only) Between L31 (2) - body (Washer
Voltage 20 - 30 V
switch ON)
Between L31 (5) - body (0.2 - 0.8 sec.

after the washer switch was turned Voltage 20 - 30 V
ON)

2) Disconnect connectors L21, R43, R45, and L31.
• Front wiper motor circuit.

R43 (Female) (1)
Between L21 (Female) (6), R43

(Female) (1) - body
Possible Harness between L21 (Female) (6) -

Causes and Resistance 1 Ω and below
L31 (Female) (2)
Standard Values
(Female) (2) - body

Harness disconnection or Resistance 1 Ω and below
ground fault L31 (Female) (3)
4 ★ Fuse A-(7) blows in
ground fault case. Resistance 1 MΩ and above
(Female) (3) - body
• Rear wiper motor circuit.

R45 (Female) (1)
Between L21 (Female) (10), R45

(Female) (1) - body

2) Disconnect connectors L21, L31, FS4, R43, R45, C12, C15, C43,
C44, and C45.

FS4 (Female) (7)

(Female) (7) - body
WA380-5L 40-629 3
40-630 3 WA380-5L
MEMORANDUM
WA380-5L 40-631 3
Action Code: [E-9]

The Headlamp (Lo Beam) Does Not Function
Failure code
code code
Trouble The headlamp (Lo Beam) does not function.
E-9 — —
Description of • Since a disconnection (Ground fault) occurs in the switch, lamp, or harness in the headlamp system, the
trouble headlamp (Lo beam) does not light on.
Controller
reaction
• —
Effect on
• The headlamp (Lo beam) does not light.
machine
Related
• —
information

2) Disconnect the connector HEAD of the left and right.
1 Lamp fault Between HEAD (2) (Left and right) -

Voltage 20 - 30 V
body (Lamp switch: 2nd row)
Between HEAD (1) (Left and right) -

body (Lamp switch: 2nd row, Dimmer Voltage 20 - 30 V
switch: Lo)

Causes and
Standard Values Between L02 (2) - body (Lamp switch:
Voltage 20 - 30 V
2nd row)
Between L02 (4) - body (Lamp switch:

2nd row, Dimmer switch: Lo)
Lamp switch or dimmer switch
2 Between L02 (4) - body (Lamp switch:
fault Voltage 20 - 30 V
OFF, Dimmer switch: Hi)

Between L02 (Male) (1) - (2) (Lamp

switch: 2nd row)
Between L02 (Male) (4) - (6) (Dimmer

switch: Lo)
40-632 3 WA380-5L

2) Disconnect connectors L02, FS4, FS5, left HEAD and right HEAD.

FS4 (Female) (11)
Between L02 (Female) (1) - FS4

(Female) (11) harness - body

FS5 (Female) (4)

Harness between FS5 (Female) (5) -

right HEAD (Female) (2)
Between FS5 (Female) (5) - right

HEAD (Female) (2) harness - body

left HEAD (Female) (2)
Harness disconnection or
Possible ground fault Between FS5 (Female) (6) - left
Causes and 3 ★ Fuses A-1, A-12, and HEAD (2) harness - body
Standard Values A-13 blow at occurrence
of a ground fault. Harness between L02 (Female) (4) -
Between L02 (Female) (4) - right



Harness between FS5 (Male) (4) - (5)

(Including fuse A-13)
Between FS5 (Male) (4) - (5) harness

- body


- body
WA380-5L 40-633 3
40-634 3 WA380-5L
MEMORANDUM
WA380-5L 40-635 3
Action Code: [E-10]

The Headlamp (Hi Beam) Does Not Function
Failure code
code code
Trouble The headlamp (Hi Beam) does not function.
E-9 — —
Description of • Since a disconnection (Ground fault) occurs in the switch, lamp, or harness in the headlamp system, the
trouble headlamp (Hi beam) does not light on.
Controller
reaction
• —
Effect on
• The headlamp (Hi beam) does not light.
machine
Related
• —
information

2) Disconnect the connector HEAD of the left and right.
1 Lamp fault Between HEAD (2) (Left and right) -

Voltage 20 - 30 V
body (Lamp switch: 2nd row)
Between HEAD (3) (Left and right) -

body (Lamp switch: 2nd row, Dimmer Voltage 20 - 30 V
switch: Hi)


Causes and
Standard Values Voltage 20 - 30 V
2nd row)

2nd row, Dimmer switch: Hi)
Lamp switch or dimmer switch Between L02 (3) - body (Lamp switch:
2 Voltage 20 - 30 V
fault OFF, Dimmer switch: Lo)


switch: 2nd row)
Between L02 (Male) (4) - (6) (Dimmer

switch: Hi)
40-636 3 WA380-5L

2) Disconnect connectors L02, FS4, FS5, left HEAD and right HEAD.

FS4 (Female) (11)


FS5 (Female) (4)


Between FS5 (Female) (5) - right


Possible ground fault Between FS5 (Female) (6) - left
Causes and 3 ★ Fuses A-1, A-12, and HEAD (2) harness - body
Standard Values A-13 blow at occurrence
right HEAD (Female)
Between L02 (Female) (3) - right

HEAD (Female) harness - body

left HEAD (Female)

left HEAD (Female) harness - body


- body


- body
WA380-5L 40-637 3
40-638 3 WA380-5L
MEMORANDUM
WA380-5L 40-639 3
Action Code: [E-11]

Clearance Lamps Do Not Function
Failure code
code code
Trouble Clearance lamps do not light (Small lamp).
E-11 — —
Description of • Since a disconnection (Ground fault) occurs in the switch, lamp, or harness in the clearance lamp system,
trouble • the clearance lamp does not light on.
Controller
• —
reaction
Effect on
• The clearance lamp does not light (Small lamp).
machine
Related
information
• —

2) Disconnect the connector COMB1 (Left and right).
1 Lamp fault 4) Turn starting switch ON.
Between COMB1 (1) (Left and right) -

Voltage 20 - 30 V
body (Lamp switch: 1st row)


Voltage 20 - 30 V
2 Lamp switch fault 1st row)

Causes and
switch: 1st row)

2) Disconnect connectors L02, FS4, FS5, and left HEAD and right
HEAD.

FS4 (Female) (11)
ground fault Between L02 (Female) (1) - FS4
3 ★ Fuses A-1, A-14, and (Female) (11) harness - body
A-15 blow at occurrence
FS5 (Female) (4)


COMB1 right (female) (1)
40-640 3 WA380-5L
Between FS5 (Female) (2) - COMB1

right (Female) (1) harness - body

COMB1 right (Female) (1)
Between FS5 (Female) (3) - COMB1

Harness disconnection or Harness between FS5 (Male) (1) - (2)
Possible ground fault Resistance 1 Ω and below
Causes and 3 ★ Fuses A-1, A-14, and
Standard Values A-15 blow at occurrence Between FS5 (Male) (1) - (2) harness
of a ground fault. - body


- body
Between COMB (Female) (Left and

right) (3) - body
WA380-5L 40-641 3
40-642 3 WA380-5L
MEMORANDUM
WA380-5L 40-643 3
Action Code: [E-12]

Turn Signal Does Not Function
Failure code
code code
Trouble Turn signal does not function.
E-12 — —
Description of • Since a disconnection (Ground fault) occurs in the switch, relay, or harness in the turn signal system, the
trouble turn signal does not blink.
Controller
reaction
• —
Effect on
• Turn signal does not function.
machine
Related
• —
information

Between L111 (4) - body (Power) Voltage 20 - 30 V
Between L111 (3) - body (Turn signal

Voltage 20 - 30 V
switch = Neutral)
1 Turn signal relay fault
Between L111 (2) - body (Turn signal
Voltage 20 - 30 V
switch = Neutral)


(Between contacts)
Possible
Between L03 (2) - body (Turn signal 20 - 30 V and

Voltage
switch: L or R) 0 V repeated
Between L03 (3) - body (Turn signal 20 - 30 V and

Voltage
switch: R) 0 V repeated
2 Turn signal switch fault Between L03 (4) - body (Turn signal 20 - 30 V and
Voltage
switch: L) 0 V repeated

Between L03 (Male) (2) - (3) (Turn

signal switch: R)
Between L03 (Male) (2) - (4) (Turn

signal switch: L)
40-644 3 WA380-5L
Between flasher unit pin (3) - body Voltage 20 - 30 V

3 Flasher unit fault
Between flasher unit pin (4) - body 20 - 30 V and
Voltage
(Turn signal switch L or R) 0 V repeated

2) Disconnect connectors L101, L03, FS3, COMB1 (Left and right), R30,
R31, and flasher unit pins 3 and 4.

flasher unit pin (3)
Between L101 (Female) (3) - flasher

unit pin (3) harness - body

flasher unit pin (4)
Between L03 (Female) (2) - flasher

unit pin (4) harness - body

FS3 (Female) (6)

Possible
Causes and Harness between L03 (Female) (3) -
Standard Values Harness disconnection or COMB1 right (Female) (3)
ground fault
Between L03 (Female) (3) - COMB1
4 ★ Fuse B-5 blow at Resistance 1 MΩ and above
occurrence of a ground
fault. Harness between L03 (Female) (4) -
COMB1 left (Female) (3)
Between L03 (Female) (4) - COMB1

left (Female) (3) harness - body

R31 (Female) (1)
Between L03 (Female) (3) - R31


R30 (Female) (1)
Between L03 (Female) (4) - R30

Between COMB1 (Female) (Left and

right) (3) - body
Between R30 (Female) (6), R31

(Female) (6) - body
Between flasher unit pin (1) - body Resistance 1 Ω and below
WA380-5L 40-645 3
40-646 3 WA380-5L
MEMORANDUM
WA380-5L 40-647 3
Action Code: [E-13]

Horn Does Not Sound
Failure code
code code
Trouble Horn does not sound.
— —
Description of • Since a disconnection or (Ground fault) occurs in the switch, relay, horn, or harness in the horn system,
trouble the horn does not sound.
Controller
reaction
• —
Effect on
• Horn does not sound.
machine
Related
• —
information

3) Connect T-adapter (Insert).
Between L119 (1), (3) - body (Power) Voltage 20 - 30 V
Between L119 (2) - body (Horn

Voltage 20 - 30 V
switch: OFF)

switch: ON)
1 Horn relay fault
Voltage 20 - 30 V
switch: ON)

Possible
Between L119 (Male) (1) - (2) (Coil
Causes and Resistance 200 - 400 Ω
Standard Values resistance)

(Between pins)
Between horn switch pin - body (Horn

switch: ON)
Between horn switch pin - body (Horn

Voltage 20 - 30 V
2 Horn switch fault. switch: OFF)

2) Disconnect the horn switch pin.
Between horn switch pin - body

(Switch: ON)

3 Horn fault. Between horn switch pin - body (Horn
switch: ON)
40-648 3 WA380-5L

2) Disconnect the horn pin, horn switch pin, and connectors L103 and
FS4.

L103 (Female) (9), (11)
Harness disconnection or Between FS4 (Female) (1), L103

Possible ground fault (Female) (9), (11) - body
Causes and 4 ★ Fuse A-1 blow at Harness between horn switch pin -
Standard Values occurrence of a ground Resistance 1 Ω and below
L103 (Female) (10)
fault.
Between horn switch pin, L103
(Female) (10) - body
Harness between horn pin - L103

(Female) (12)
Between horn pin, L103 (Female)

(12) - body
WA380-5L 40-649 3
Action Code: [E-14]

Air Conditioner Does Not Work or Does Not Shut Down
Failure code
code code
Trouble Air conditioner does not work or does not shut down.
E-14 — —
Description of
• The air conditioning system is out of order, and the air conditioner does not work or does not stop.
trouble
Controller
reaction
• —
Effect on
• The air conditioner does not work or does not stop.
machine
Related • This troubleshooting is only for the connection between the air conditioner and the operator cab.
information • For troubleshooting of air conditioner body, refer to the air conditioner Shop Manual.
Check fuse B-(14), when the fuse is blown:

2) Disconnect connectors FS3 and A7.
Among FS3 (female) (15), A7 (female) (2) and

machine body
In cases other than the above, relay A7, the blower motor and connection harness
are out of order.
Ground fault of
1 power supply Check fuse B-(15), when the fuse is blown,
harness 1) Starting switch OFF.
2) Disconnect the connectors FS3, C47, A7, A8, A9, A10, A11 and A14.
Among FS3 (female) (16), C47 (female) (8), A7

(female) (1), A8 (female) (1), A9 (female) (1),
Possible Resistance 1 MΩ and above
A10 (female) (1), A11 (female) (1), A14 (female)
Causes and (1) (2) and machine body
Standard Values
In cases other than the above, each relay, the control amplifier and connection
harness are out of order.

2) Disconnect the connector C47.
Harness between C47 Starting switch ON. Voltage 20 - 30 V

Defective power
supply of control (female) (8) and (11) Starting switch OFF. Voltage 1 V and below
amplifier
2 (Disconnection or When the above is abnormal,
short-circuit of 1) Starting switch OFF.
harness for control 2) Disconnect the connectors 47 and F3.
amplifier) 3) Insert a T-adapter.
Harness between C47 (female) (8) and FS3

(female) (16)
Between C47 (female) (11) and machine body. Resistance 1 Ω and below
40-650 3 WA380-5L

2) Disconnect the connectors A7, A8, A9, A10, A11 and A14.
Starting switch ON. Voltage 20 - 30 V

Between A7 (female) (1)
and machine body
Starting switch OFF. Voltage 1 V and below

Harness between A8

Harness between A8

Harness between A10
Harness between A11 Starting switch ON. Voltage 20 - 30 V

(female) (1) and machine
Defective power body Starting switch OFF. Voltage 1 V and below
supply of relay
3 (Disconnection Harness between A14 Starting switch ON. Voltage 20 - 30 V
or short-circuit of (female) (1) (2) and
Possible harness for relay) machine body Starting switch OFF. Voltage 1 V and below
Causes and
When the above six items are abnormal, check the following:
Standard Values
2) Disconnect the connectors A7, A8, A9, A10, A11, A14 and FS3.
Harnesses among A7 (female) (1), A8 (female)

(1), A9 (female) (1), A10 (female) (1), A11
(female) (1), A14 (female) (1) (2) and FS3 Resistance 1 Ω and below
(female) (16)
Among A8 (female) (4), A9 (female) (4), A10


2) Disconnect the connectors A12, A13 and A1.
Among A12 (female) (3) (4), A13 (female) (3) (4),

A1 (female) (1) and machine body.
In cases other than the above, each relay and its connection harness are abnormal.
Defective 1) Starting switch OFF.

condenser ground 2) Disconnect the connectors B01 and B02.
4 (Disconnection of
condenser Among B01 (female) (C) B02 (female) (C) and
harness) Resistance 1 Ω and below
machine body.
WA380-5L 40-651 3
40-652 3 WA380-5L
MEMORANDUM
WA380-5L 40-653 3
TROUBLESHOOTING ENGINE SYSTEM (S-MODE)
ENGINE SYSTEM (S-MODE)
Method Of Using Troubleshooting Charts

This troubleshooting chart is divided into three sections: Questions, Check Items, and Troubleshooting. The questions and
check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspection
without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability
causes to make final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corresponds to the items where answers can be obtained from the user. The items in
B are items that can be obtained from the user, depending on the user’s level.
[Check Items]
The serviceman carries out simple inspection to narrow down the causes. The items under (C) in the chart on the right
correspond to this. The serviceman narrows down the causes from information (A) that he has obtained from the user and the
results of (C) that he has obtained from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest
probability from information gained from [Questions] and [Check items].
Causes
(b) (2) (3)
(a) ❊
Questions
(A) (b) ❊
(c) ❊
(d) ❍
(e) ❍
(B)
Check items
(C)
i ●
Trouble-
shooting
ii ●
iii ●
40-654 3 WA380-5L
12
The basic method of using the troubleshooting chart is as follows.

Items listed for [Questions] and [Check items] that have a relationship with the
Cause items are marked with Δ, and these, causes that have a high probability are
marked with ❊. Causes
Check each of [Questions] and [Check items] in turn, and marked the Δ or ❊ in
the chart for items where the problem appeared. The vertical column (Causes)
)
ction
that has the highest number of points is the most probable cause, so start
troubleshooting for that item to make final confirmation of the causes.
inje
*1. For [Confirm recent repair history] in the [Questions] Section, ask the
ssive
user, and mark the Cause column with Δ to use as reference for locating
ozzle
renc
(exce
the cause of the failure. However, do not use this when making calcula-
g, cy ment
ir cle er, interfe
tion n
tions to narrow down the causes.
er
tion p g
ump
*2. Use the Δ in the Cause column as reference for [Degree of use (Operated
timin
ele
n
injec
li
aner
for long period)] in the [Questions] section as reference. As a rule, do
harg
ion
ized
not use it when calculating the points for locating the causes, but it can
n rin
t
injec
injec
rboc
be included if necessary to determine the order for troubleshooting.
e
pisto
s
a
e d tu
ctive
ged,
oper
ged
Worn
Defe
Clog
Clog
I mp r
Seiz
*1 Confirm recent repair history
*2 Degree of use of machine Operated for long period Δ Δ Δ
❊
WA380-5L 40-655 3
12
• Example of troubleshooting when exhaust gas is black
Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal
relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is
red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air Causes
• Improper condition of fuel injection
ad
)
ction
d he
• Excessive injection fuel
ized)
pray
, plun seat
e inje
er an
ger se
tive s
valve
harg
iv
ce
ce ss
tion ti le, defec
eren
rboc
Legend
and
x
g, cy ment
(rack
mp (e
❍: Possible causes (judging from Questions and
air cle er, interf
en tu
valve
r
n ce
uffler
linde
ming
ele
ump
nozz
check items)
leara
n pu
e
ed m
ct of
betw
aner
❊: Most probable causes (judging from Questions
tion p
harg
ction
jectio
c
conta
clogg
n rin
valve
and Check items)
of air
injec
rboc
injec
je
in
■: Possible causes due to length of use (used for a
in
pisto
ed tu
ctive
ctive
hed,
oper
oper
ctive
age
ged
ged
long period)
Worn
Leak
Crus
Defe
Defe
Clog
Clog
Impr
Impr
Defe
Seiz
●: Items to confirm the causes.
Confirm recent repair history
Degree of use Operated for long period Δ Δ Δ Δ
Suddenly became black ❊ ❍ ❍
❊ ❍ ❍
Questions
Color of exhaust gas Gradually became black

Black under light load ❊
Engine oil must be added more frequently ❊
Power was lost Suddenly ❊ ❍ ❍ ❍
Gradually ❍❍ ❍❍
Non-specified fuel is being used ❍ ❍
Noise of interference is heard from around tubo- ❊
Dust indicator lamp is red ❊
Blow-by gas excessive ❊
Engine pickup is poor and combustion is irregu- ❍ ❊ ❍❍❍ ❍
Check items
When exhaust manifold is touched immediately ❊ ❍

Match marks on fuel injection pump are out of ❊
Seal on injection pump has come off ❊
Clanging sound is heard from around cylinder ❊
Exhaust noise is abnormal ❍ ❍ ❊
Muffler is crushed ❊
Leakage of air between turbocharger and head, ❊
When turbocharger is rotated by hand, it is ●
When air cleaner element is inspected directly, it is ●
When compression pressure is measured, it is ● ●
Speed does not change when operation of ●
Troubleshooting
certain cylinders is stopped

When check is made using delivery method, ●
injection timing is found to be incorrect
Injection pump test shows that injection amount ●
When valve clearance is checked directly, it is ●
found to be outside standard value
When muffler is removed, exhaust color returns ●
When control rack is pushed, it is found to be ●
heavy, or does not return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Rem-
Clean
edy
40-656 3 WA380-5L
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Causes items in the vertical
column.
Three symptoms
Step 2
Add up the total of ❍ and ❊ marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect:
(1) Clogged air cleaner element: ❊❍❊
(2) Air leakage between turbocharger
and head ❍❍
(3) Clogged, seized injection nozzle: ❍
(4) Defective contact of valve, valve seat: ❍
(5) Worn position ring, cylinder: ❍
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked ●. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
WA380-5L 40-657 3
12
(S-1) Engine Starting Performance Is Poor
Causes
General causes why engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Insufficient intake of air supply
Defective contact of valves or valve seats
Leaking or clogged fuel piping (fuel inlet)

• Improper selection of fuel
Defective alternator (regulator section)

(At ambient temperature of -10°C or below, ASTM D975 No. 2 diesel fuel is used)
Defective intake air heating system

★ Battery charging rate
Worn piston rings or cylinder bore
Stuck, sized supply pump plunger

Clogged fuel tank vent system
Charging rate
Ambient 100% 90% 80% 75% 70%
temperature
Clogged fuel filter element

20°C (68°F) 1.28 1.26 1.24 1.23 1.22
Defective fuel injector

0°C (32°F) 1.29 1.27 1.25 1.24 1.23
Defective alternator
Clogged air clearer
-10°C (14°F) 1.30 1.28 1.26 1.25 1.24
Defective battery
• The common rail fuel injection system (CRI) recognizes the fuel injection timing
electrically. Accordingly, even if the starting operation is carried out, the engine
may not start until the crankshaft revolves 2 turns at maximum.
This phenomenon does not indicate a trouble, however

Degree of use of machine Operated for long period Δ Δ Δ
Ease of starting Gradually became worse ❍❊❊ ❍
Questions
Starts when warm ❊ ❊

Non-specified fuel has being used ❍❍❍
Replacement of filters has not been carried out according to operation Manual ❊ ❊❍❍
Engine oil replacement times are longer ❊
Preheat monitor does not indicate normal operation during a preheat at low temperatures ❊
Charge level monitor indicates abnormal charging during operation ❊❊
Air vent in fuel tank cap is clogged ❊
Fuel leaking from fuel piping ❊ ❍
When priming pump is operated, it makes no reaction or is too heavy ❊❍
Starter motor cranks slowly
When Engine is cranked with starting motor, ❊
❊
Check items
1) Little or no fuel comes out even when the plug is removed from the fuel filter
2) If fuel return line to fuel tank is removed little or no fuel comes out ❊
Exhaust manifold has cold areas after start up when touched ❊
Engine pick up is poor or irregular ❍❍ ❊
There is hunting from engine (rotation is irregular) ❍❊❍
Excessive blow-by gasses ❊
When air cleaner element is inspected directly, it is found to be clogged ●
When compression pressure is measured, it is found to be low ● ●
●
Troubleshooting
When air is bled from fuel system, air comes out

Inspect fuel filter, strainer directly ●
Carry out troubleshooting in “No-pressure feed by supply pump (1)* in code display ●
During cylinder cut-out mode engine speed does not change ●
Intake air heater mount does not warm up during preheat operations ●
Is voltage 26 to 30V between alternator “B” and “E” terminal during Yes ●
low engine idle No ●
What is the condition of the battery ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
(1)*See Failure Code [CA559] and [CA2249] Remedy
40-658 3 WA380-5L
(S-2) Engine Does Not Crank

General causes why engine does not turn Cause
• Internal parts of engine are seized
★ If internal parts of the engine are seized, carry out troubleshooting for
“Engine stops during operations”. (See S-4)
• Defective electrical system
Poor battery connections and grounds

• Failure in power train
Defective or deteriorated battery
Defective steering circuit wiring

Broken flywheel ring gear
Defective ignition switch
Defective starter motor

Defective battery relay
Defective safety relay

Questions
Degree of use of machine Operated for long period Δ Δ

Condition of horn when ignition switch Horn sounds ❍ ❍ ❊
is turned ON Horn volume is low ❊
Speed of rotation is low ❊
When ignition switch is turned to Makes grating noise ❊ ❊
START, pinion moves out, but Soon disengages pinion again ❊
Makes rattling noise and does not turn ❍ ❍❍
Check items
When ignition switch is turned to START, pinion does not move out ❍ ❍ ❊
When ignition switch is turned to ON, there is no clicking sound ❍ ❊
Battery terminal is loose ❊
When battery is checked, battery electrolyte is found to be low ❍
Specific gravity of electrolyte, voltage of battery is low ❊
For following conditions 1) - 5), turn the ignition switch OFF, connect remote switch, and carry out
troubleshooting
1) When terminal B and terminal C of ignition switch are connected, engine cranks ●
Troubleshooting
2) When terminal at safety switch and terminal B of starter motor are connected,
Applicable machine
●
engine cranks
3) When terminal B and terminal C of starting safety relay are connected, engine ●
cranks
4) Even if terminal B and C at safety relay are connected engine does not crank. ●
5) There is no 20 to 30V between battery relay terminal B and terminal E ●
When ring gear is inspected directly, tooth surface is found to be chipped ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
WA380-5L 40-659 3
12
Engine Cranks But No Exhaust Smoke Comes Out Of Stack
General causes why engine turns but no exhaust smoke comes out Causes
Defective operation of overflow valve (not closing)

• Supply of fuel depleted
• Supply of fuel is extremely low
Leaking or clogged fuel piping (entry of air)

• Improper selection of fuel (particularly in winter)
★ Standards for use of fuel
Defective common rail pressure limiter

Stuck or seized supply pump plunger
Seized, abnormally worn feed pump
AMBIENT TEMPERATURE
TYPS OF
Clogged air vent hole in fuel cap

-4 14 32 50 68°C
Defective supply pump MPROP

FLUID
-20 -10 0 10 20°F
Insufficient fuel in the tank
Clogged fuel filter element
Broken supply pump shaft

ASTM D975 No. 2
Defective fuel injector

Diesel fuel
Use of improper fuel

ASTM D975 No. 1

Questions

Exhaust smoke suddenly stops coming out (when starting again) ❊❍❊❊ Δ
Replacement of filters has not been carried out according to Operation Manual ❊ Δ ❍
Fuel tank is found to be empty ❊
There is leakage from fuel piping ❊
Mud is stuck to fuel tank cap ❍❊
When removed no fuel was found in fuel filter ❊ ❊
❊❍
Check items
When priming pump is operated, it makes no reaction or it is heavy

When engine is cranked with starting motor,
❍ ❍ ❊❍
1) No fuel comes out even when fuel filter air bleed plug is loosened
2) No fuel flows from fuel return line ❍ ❊❊❊ ❍
When air is bled from fuel system, air comes out ●

Inspect fuel filter directly ●
Inspect feed pump directly ●
Troubleshooting
Carry out troubleshooting according to the displayed code “No pressure feed by ● ●
supply pump (1)*
Carry out troubleshooting according to the displayed code. “Abnormality in supply ●
pump PCV (2)*
Inspect overflow valve directly ●
Engine can be started in reduced cylinder mode ●
Fuel flows out when pressure limiter return piping is disconnected ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair

Add
(2)*See Failure Code [CA271] and [CA272]
40-660 3 WA380-5L
12
Smoke Comes Out Of Stack But Engine Does Not Start
General causes why exhaust smoke comes out of stack but engine does not Causes
start
Defective coolant temperature sensor and harness

Worn dynamic valve system (Valve, rocker lever)
• Lack of cranking force due to defective electrical system
Leaking or clogged fuel system, entry of air

• Insufficient intake air
Clogged injector, defective spray pattern

• Improper selection of fuel and oil
Worn piston rings and cylinder bore
Stick, seized supply pump plunger
Defective intake air heater system

Defective or deteriorated battery
Clogged air cleaner element
Clogged fuel tank vent

Use of improper fuel
Clogged fuel filter

Suddenly failed to start ❊ ❊ ❍
❍❍
Questions
Non-specified fuel is being used

Replacement of filters has not been carried out according to OMM ❊ ❊
Engine oil usage has increased ❊
Preheat monitor does not indicate normal operation during cold temperatures ❊
Mud is stuck to fuel tank cap ❍
Rust and water are found when fuel tank is drained
When fuel filter is drained, no fuel comes out ❊
When priming pump is operated, it has no reaction or it is heavy ❊❍
Check items
Starter motor cranks engine slowly ❊

When engine is cranked abnormal sounds are heard around the cylinder head area ❊
When engine is cranked with starting motor,
❍ ❊
1) Little fuel comes out even when fuel filter air bleed plug is loosened
2) No fuel comes out when return line is removed ❊
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low ❊
Remove air cleaner and check directly ●

Inspect valve system and rocker arms ●
When compression pressure is measured, it is found to be low ●
Troubleshooting

Inspect fuel filter directly ●
Carry out troubleshooting according to the displayed code. No-pressure feed by
supply pump (1)* ●
Engine can be started in reduced cylinder mode ●

Either specific gravity of electrolyte or voltage of battery is low ●
Coolant temperature gauge does not indicate normally ●
Intake air heater mounting area does not warm during preheat ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
WA380-5L 40-661 3
(S-3) Engine Does Not Run Smoothly

General causes why engine does not run smoothly Causes
Leaking or clogged fuel piping, entry of air

Seizure or interference of the turbocharger
Defective contact of valve and valve seat
Stuck or seized supply pump plunger

Worn piston rings or cylinder liner
• Improper fuel used
• Controller in de-rated control mode
Clogged or defective injector

(limiting injection rate (output) because of an error in electrical system)
Improper valve clearance
Clogging of fuel filter

Clogged air cleaner
Degree of use of machine Operated for long period Δ Δ Δ Δ
Replacement of filters has not been carried out according to Operation Manual ❊ ❍❍ ❍
Questions
Engine pick-up suddenly became poor ❊❊❊

Non-specified fuel is being used ❊ ❊
Replacement of filters has not been carried out according to OMM ❊
Dust indicator lamp is red
Mud is stuck to fuel tank cap ❊
Rust and water are found when oil is drained ❊
When priming pump is operated, it has no reaction or it is heavy ❊❍
When exhaust manifold is touched immediately after starting engine, ❍❊
temperature of some cylinders is low
Check items
Noise of interference is heard from around turbocharger

Color of exhaust gas Blue under light load ❊❍ ❊ ❊
Black ❊
When engine is cranked abnormal sounds are heard around the cylinder head area ❊
When engine is cranked abnormal sounds are heard around the turbocharger ❊
High idling speed under no load is normal, but speed suddenly drops when load ❍ ❊
is applied
There is hunting from engine (rotation is irregular) ❍ ❍ ❍
When air cleaner element is inspected directly, it is found to be clogged ●

Troubleshooting
Check valve clearance ●

When turbocharger is rotated by hand, it is found to be heavy ●
Inspect fuel filter, strainer directly ●
Carry out troubleshooting according to the displayed code. No-pressure feed by supply
pump (1)* ●
When a cylinder cut-out operation is made engine speed does not change ●
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Clean
Clean
40-662 3 WA380-5L
12
(S-4) Engine Stops During Operations
General causes why engine stops during operations Causes
• Seized parts inside engine
Broken auxiliary equipment (pump, components)

Breakage of valve system (valves, rocker arm)

• Overheating
★ If there is overheating and the engine stops, carry out
troubleshooting for overheating.
Broken, seized piston, connecting rod
Stuck, seized supply pump plunger

• Failure in power train
Broken, sized crankshaft bearing

★ If the engine stops because of a failure in the power
Leaking or clogged fuel piping

train, carry out troubleshooting for the chassis.
Broken or seized gear train
Broken supply pump shaft

Broken, seized feed pump
Insufficient fuel in tank
Failure of power train

Degree of use of machine Operated for long period Δ
Abnormal noise was heard and engine ❊ ❊ ❊ ❊ ❍❊❍❊❊
stopped suddenly
❊❍ ❍
Questions
Condition when engine stopped Engine overheated and stopped

Engine stopped slowly ❊ ❍
There was hunting and engine stopped ❊❍ ❍❍
Non-specified fuel is being used ❍❍ ❍
Replacement of filters has not been carried out according to Operation ❊
Manual
Fuel level monitor indicates low fuel level (with monitor installed) ❊
Fuel is leaking from fuel piping ❊
When feed pump is operated, operation is too light or too heavy ❊❍
Check items
Rust and water are found when fuel tank is drained ❊

Engine rotates, but stops when power train is operated ❍
Metal particles are found when oil pan is drained ❊❊❊
Does not turn at all ❊❊
When it is attempted to turn by Turns in opposite direction ❊
hand using barring tool Moves amount of backlash ❊ ❊
Shaft does not turn ❊
Engine turns, but stops when load is applied to machine ❊
Remove head cover and inspect directly ●
Remove oil pan and inspect directly ●
Inspect pistons and connecting rods directly ●
Troubleshooting
See (H-mode)
Inspect crankshaft bearings directly ●

Inspect gear train directly ●
Inspect fuel filter and fuel strainer ●
Inspect feed pump directly ●
Carry out troubleshooting according to the displayed code. No-pressure feed ●
by supply pump (1)*
Engine rotates when pump or auxiliary equipment is removed ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean

Add
WA380-5L 40-663 3
12
(S-5) Engine Speed Hunts
General causes why engine does not idle smoothly Causes
• Air in fuel system
• Defective governor mechanism
Leaking or clogged fuel piping, entry of air

• Defective electric governor mechanism
Clogged injector, defective spray pattern

(engine with electric governor)
★ If hunting stops when electric governor rod is disconnected, carry out
Defective Bkup speed sensor system

Clogged air vent system in fuel tank
Defective Ne speed sensor system

troubleshooting for the chassis.
insufficient fuel in tank

Questions
Occurs at a certain speed range ❍❍

Condition of hunting Occurs at low idling ❍❍❍❍❍
Occurs even when speed is raised ❍ ❍❍
Occurs on slopes ❊
Replacement of filters has not been carried out according to Operation Manual ❊
Check items

Rust and water are found when tank is drained ❍
Fuel is leakage from fuel piping ❊
When feed pump is operated, operation is too light or too heavy ❊❍

Troubleshooting
Inspect fuel filter and strainer directly ●

When a cylinder cut-out operation is made engine speed does not change ●
Carry out troubleshooting according to the displayed code. Abnormality in Ne speed ●
sensor (1)*
Carry out troubleshooting according to the displayed code. Abnormality in Bkup speed ●
sensor (2)*
Replace
Replace
Replace
Replace
Replace
(1)*See Failure Code [CA689]

Clean
Remedy
Add
(1)*See Failure Code [CA778]
40-664 3 WA380-5L
12
(S-6) Engine Lacks Power
General causes why engine lacks power Causes
Defective boost pressure sensor installation

Defective boost pressure sensor system

• Improper fuel used
Seizure or interference in turbocharger
Worn piston rings and cylinder liners

(if non-specified fuel is used, output drops)
Defective fuel injector drive system

Air leakage from air intake piping
Clogged or defective fuel injector

• Lack of output due to overheating
Leaking or clogged fuel piping

★ If there is overheating and lack of output, carry out
Clogged fuel return piping

troubleshooting for overheating. See S14 Coolant temperature
Incorrect valve clearance

rises too high (overheating) for the troubleshooting.
• Controller in de-rate control mode (limiting injection rate (output)
Clogged air cleaner
Clogged fuel filter

because of an error in electrical system)

Suddenly ❍❊ ❍❍❍❍
Questions
Power was lost

Gradually ❍ ❍ ❍ ❍ ❍ ❍
Non-specified fuel is being used ❍❍❍
Replacement of filters has not been carried out according to ❊ ❊
Operation Manual
Engine oil must be added more frequently ❍ ❍
Dust indicator lamp is red ❊❊
Mud is stuck to fuel tank cap ❊ ❊
Leakage from fuel piping ❊
Output becomes insufficient after short stop of operation ❊
Color of exhaust gas Black ❊ ❊
Check items
When exhaust manifold is touched immediately after starting engine, ❊❊

When engine is cranked abnormal noise is heard around turbocharger ❊
When engine is cranked abnormal noise is heard around cylinder head ❊
High idle speed is too high ❍
High idle speed under no load is normal, but speed drops when load is ❍ ❊❍❍
applied
Engine does not pickup smoothly and combustion is irregular ❊❊ ❍❍ ❊
There is hunting from engine (rotation is irregular) ❍❍❍ ❍❍
Blow-by gasses are excessive ❊ ❊
WA380-5L 40-665 3
Inspect air cleaner directly ●

Inspect air intake piping ●
When boost pressure is measured pressure is low ● ● ●
When compression is measured pressure is low ● ●
Inspect valve clearance ●
Troubleshooting
Inspect fuel piping ●

Inspect fuel filter and strainer ●
Inspect spill port check valve ●
Carry out troubleshooting according to the displayed code. No pressure feed ●
from supply pump (1)*
When a cylinder cut-out operation is made engine speed does not change ● ●
Inspect boost pressure sensor installation ●
Carry out troubleshooting according to the displayed code. According to boost ●
pressure sensor (2)*
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
Repair
Clean
Clean
Remedy
40-666 3 WA380-5L
12
(S-7) Exhaust Smoke Is Black
General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and intake

Defective coolant temperature sensor system

• Improper selection of fuel

• Overheating
Seizure or interference of turbocharger

★ If there is overheating and lack of output, carry out

troubleshooting for overheating. See S14 Coolant temperature rises
Improper fuel injection pressure

Worn piston rings or cylinders
Improper fuel injection timing

too high (overheating) for the troubleshooting.
Clogged air cleaner element
Crushed or clogged muffler
Abnormal wear of injectors

Clogged or seized injector
• Controller in de-rate control mode (limiting injection rate (output)

because of an error in electrical system)

Suddenly became black ❊ ❊ ❍❍❍
Color of exhaust gas Gradually became black ❊ ❍
Questions

Non-specified fuel is being used ❍❍
Power was lost Suddenly ❊ ❍ ❍❍
Gradually ❍ ❍ ❍ ❍
Muffler is crushed ❊
Leakage of air between turbocharger and head, loose clamp ❊
Engine is operated in low-temperature mode at normal temperatures ❍❍❍
When exhaust manifold is touched immediately after starting engine, ❍❊
Check items
Noise of interference is heard from around turbocharger ❊

Clanging sound is heard from around cylinder head ❊
Pump relief speed is high (Fuel is injected excessively) ❍
Exhaust noise is abnormal ❍ ❊ ❍
Engine pickup is poor and combustion is irregular ❍ ❍❍❍ ❍❊
Fuel return line has an excessive amount of fuel returned ❊
Inspect air cleaner directly ●

When turbocharger is rotated by hand it is found to be tight ●
Troubleshooting
Inspect valve clearance ●

When muffler is removed, engine runs normal ●
Carry out troubleshooting according to the displayed code. No pressure feed from
supply pump (1)* ● ●
When cylinder cut out is performed, engine speed does not change ●
Carry out troubleshooting according to the displayed code. Abnormality in coolant
temperature sensor (2)* ●
Check using the monitor functions ● ●

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust

Clean
WA380-5L 40-667 3
(S-8) Oil Consumption Is Excessive Or Exhaust Smoke Is Blue

Causes
Oil leaking from oil pan or cylinder head

★ Do not run the engine at idling for more than 20 minutes
Worn or damaged valve stems or seals
Worn piston rings or cylinder liners

continuously. (Both low and high idling)
Dust sucked in from intake system

General causes why oil consumption is excessive
Worn or damaged rear oil seal

Worn seal at turbocharger end
• Abnormal combustion of oil
Oil leaking from drain plug

Oil leaking from oil piping
Oil leaking from oil cooler
Oil leaking from oil filter
• External leakage of oil
Worn seal at blower end

• Wear of lubrication system
Broken piston ring

• Low compression
Broken oil cooler

Questions
Oil consumption suddenly increased ❊ ❍

Engine oil must be added more frequently ❊ ❍
Engine oil becomes contaminated quickly ❍❍❊
Area around engine is dirty with oil ❊❊❊❊❊
Clamps for intake system are loose ❊
When turbocharger air supply pipe is removed, inside is found to be dirty
❍❊
Check items
with oil
When exhaust pipe is removed, inside is found to be dirty with oil ❊
There is oil in engine coolant ❊
Exhaust smoke is blue under light load ❊❊
Amount of blow-by gas Excessive ❍ ❍ ❊❊
None ❊
When intake manifold is removed, dust is found inside ●

●
Troubleshooting
When intake manifold is removed, inside is found to be excessively dirty

Excessive play of turbocharger shaft ● ●
Check breather and breather hose directly ●
When compression is measures it is excessively low ● ●
Inspect rear seal directly ●
Pressure test of oil cooler indicates there is leakage ● ●
There is external leakage of oil from engine ● ● ● ●
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Clean
Remedy
40-668 3 WA380-5L
12
(S-9) Oil Becomes Contaminated Quickly
General causes why oil becomes contaminated quickly Causes
• Entry of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper fuel
Defective seal at turbocharger turbine end

• Improper oil used
Worn valves and valve guides or seals

Worn piston rings and cylinder liners
• Operation under excessive load
Clogged turbocharger drain line

Defective oil filter bypass valve
Clogged breather, breather hose
Exhaust smoke is excessive

Clogged oil cooler
Clogged oil filter
Questions
Non-specified fuel is being used ❍ ❍

Metal particles are found when oil is drained ❍❍ ❊
Inside of exhaust pipe is contaminated with excessive oil ❊
Engine oil temperature rises quickly
Check items
Color of exhaust gas Black under light load ❊

Black ❊ ❊
Amount of blow-by gas Excessive ❍❍❊ ❍
None ❊
Excessive play of turbocharger shaft ●
● ●
Troubleshooting
When compression pressure is measured, pressure is low

Check breather and breather hose directly ●
Inspect oil cooler directly ●
See S-7
Inspect oil filter directly ●
Oil filter bypass valve is broken ●
Inspect turbocharger drain line directly ●
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
WA380-5L 40-669 3
12
(S-10) Fuel Consumption Is Excessive
General causes why fuel consumption is excessive Causes
• Leakage fuel
Defective coolant temperature sensor system

• Excessive injection of fuel
Fuel leakage from fuel filter piping
Defective common rail pressure

Defective injector spray pattern
Defective supply pump plunger
Fuel leakage inside valve cover
Defective operation of injector

Defective feed pump oil seal
Questions
More than for other machines of same model ❍ ❍❍❍

Condition of fuel
consumption Gradually increased ❍ ❍
Suddenly increased ❍❍
Fuel leakage around outside of system ❊
There is irregular combustion ❊
Seal on injection pump has come off
Engine oil level rises and smells of diesel fuel ❊ ❊
Check items
When exhaust manifold is touched immediately after starting engine, temperature of ❊

some cylinders is low
Engine low idling and high idling speeds are high ❍
Pump relief speed is high ❍
Color of exhaust smoke
Black ❍❍ ❍❍
Blue ❍
Remove valve cover and check directly ●

●
Troubleshooting
Inspect feed pump oil seal directly

Carry out troubleshooting for code. No pressure feed by supply pump (1)* ●
When a cylinder cut out is performed engine speed does not change ●
Remove fuel return line and inspect directly ●
Carry out troubleshooting for code. Abnormality in coolant temperature sensor (2)* ●
Check the system using the monitor ● ●
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair

40-670 3 WA380-5L
(S-11) Oil Found In Coolant, Or Coolant Spurts From Radiator

General causes why oil is in coolant Causes
• Internal leakage in lubrication system
• Internal leakage in cooling system
Leaking hydraulic or power train oil cooler

Cracked cylinder head or leaking gasket
Crack in cylinder block
Cylinder liners pitted
Leaking oil cooler
Questions

Oil level Suddenly increased ❍ ❍
Gradually increased ❍❍
Hard water is being used as cooling system ❍❍
Engine oil level has risen, oil is cloudy white ❍❍❊
Check items
Excessive air bubbles inside radiator spurts back ❊

Hydraulic oil, transmission oil is cloudy white ❊
When hydraulic oil transmission oil is drained, water is found ❊
Pressure-tightness test of oil cooler shows there is leakage ●

Trouble-
shooting
See H
mode
Remove oil pan and inspect directly ● ●
Pressure-tightness test of cylinder head shows there is leakage ●
Replace
Replace
Replace
Replace
Remedy Replace
WA380-5L 40-671 3
12
(S-12) Oil Pressure Caution Lamp Lights Up
General causes why oil pressure lamp lights up Causes
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
Leaking crushed or clogged oil piping

Clogged or broken oil pickup pipe
Defective oil level sensor system

Defective oil pressure regulator
Worn bearings and journals
Clogged oil pickup strainer

Coolant or fuel in the oil
Lack of oil in oil pan
Defective oil pump
Clogged oil filter

Questions
Oil pressure monitor indicates low oil pressure ❍❊

Non-specified fuel is being used ❍
Replacement of filters has not been carried out according to
Operation Manual ❊
Lights up at low idling ❊
Condition when oil pressure Lights up at low, high idling ❍ ❊❊❊❍
lamp lights up Lights up on slopes ❊
Sometimes lights up ❊ ❍
Check items
Oil pressure monitor indicates low pressure level ❊ ❊

Oil level in oil pan is low ❊
External oil piping is leaking or crushed
Oil is cloudy white or smells of diesel oil ❊
Metal particles are found when oil is drained ❊
Metal particles are stuck to oil filter element ❊ ❍
When oil filter is inspected, it is found to be clogged ●

Troubleshooting
Remove oil pan and inspect directly ● ●

●
See S-13
Oil pump rotation is heavy, there is play

There is catching of relief valve or regulator valve, spring or valve guide ●
is broken
Inspect oil filter directly ●
When oil pressure sensor is replace oil pressure is normal ●
Replace
Replace
Repair
Adjust
Clean
Clean
Clean
Clean
Remedy
⎯
Add
40-672 3 WA380-5L
(S-13) Oil Level Rises (Coolant Or Fuel Found In Oil)

Causes
Cracked cylinder head or leaking head gasket
Defective seal of auxiliary equipment

★ If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
Cracks inside cylinder block
Worn, damaged rear oil seal

• Coolant in oil (milky white)
Defects in supply pump

Leaking injector O-ring
Holes in cylinder liners

• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of oil from other component (See S-11)
Leaking oil cooler

Questions

Fuel must be added more frequently ❊ ❊
Coolant must be added more frequently ❍ ❍
There is oil in radiator coolant ❍❍❍❍ ❊
Engine oil smells of diesel fuel ❊ ❊
Engine oil is milky ❍ ❍
Check items
When engine is first started, drops of water come from muffler ❍

Leave radiator cap open. When engine is run at idling, an abnormal number of ❊ ❍
bubbles appear, or water spurts back
Exhaust smoke is white ❍
Oil level goes down in hydraulic tank ❊
Pressure-tightness test of oil cooler shows there is leakage ●

Pressure-tightness test of cylinder head shows there is leakage ●
Troubleshooting

Inspect rear seal directly ●
When pump auxiliary equipment is removed, seal is found to be damaged ●
Remove head cover and inspect directly ●
Remove injection pump and inspect directly ●
Defective contact with thermostat seal valve ●
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
WA380-5L 40-673 3
(S-14) Coolant Temperature Too High (Overheating)

General causes why coolant temperature becomes too high Causes
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature in power train
Slipping fan belt or worn pulley chives

Cracked cylinder head or head gasket
Defective coolant temperature gauge

★ Carry out troubleshooting for H-mode
Rise of hydraulic oil temperature

Clogged or leaking oil cooler
Damaged or blocked radiator

Holes in cylinder liners
Defective radiator cap

Plugged radiator core
Defective thermostat
Bad water pump
Lack of coolant
Suddenly overheated ❍❊ ❍
Questions
Condition of overheating
Always tends to overheat ❍❊❊ ❍
Water temperature gauge Rise quickly ❍ ❊
Does not go down from red range ❊
Radiator coolant level sensor lights up ❊
Engine oil level has risen, oil is milky ❊❍
Fan belt tension is low ❊
When fan pulley is turned it has play ❊
Milky oil is floating on coolant ❊
Excessive air bubbles in radiator (coolant spurts out of radiator) ❊
Check items
When light bulb is held behind radiator, no light passes through ❊

Radiator shroud, inside of undergird are clogged with dirt or mud ❊ ❊
Coolant is leaking because of cracks in hose or loose clamps ❊
Coolant flows from radiator overflow hose ❊
When belt tension is inspected, it is found to be loose ❊
Power train oil temperature enters red range faster than engine coolant ❊
temperature
Temperature difference between top and bottom radiator tanks is excessive ●

Temperature difference between top and bottom radiator tanks is slight ●
Troubleshooting
When water filler port is inspected, core is found to be clogged ●

See H-mode
When function test is carried out on thermostat, it does not open even at ●
When water temperature is measured, it is found to be normal ●
When oil cooler is inspected directly, it is found to be clogged ●
When measurement is made with radiator cap tester, set pressure is found to ●
be low
Remove oil pan and inspect directly ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy -
Add
40-674 3 WA380-5L
(S-15) Abnormal Noise Is Heard When Engine Is Running

Causes
Leakage of air between turbocharger and cylinder head

Interference of turbocharger, seized turbocharger
Excessive wear of piston rings or cylinder liners

Broken dynamic valve system (valves, rockers)
★ Judging if the noise is an internal noise or an external
noise.
General causes why abnormal noise is made
Defective cooling fan or fan belt

• Abnormality due to defective parts
Improper gear train backlash
Clogged or seized injector

• Abnormal combustion
Removed seized bushing

• Air sucked in from intake system
Dirt caught in injector

Defective muffler
Gradually occurred ❍ ❍
Questions
Condition of abnormal noise

Suddenly occurred ❍❍ ❍
Non-specified fuel is being used
Engine oil must be added more frequently ❍
Metal particles found in oil filter ❊
Air leaks between turbocharger and cylinder head ❊ ❊ ❊
Noise of interference is heard from around turbocharger ❊
When engine is cranked, abnormal noise is generated around cylinder head ❊ ❊
Abnormal noise is heard around muffler ❊
Check items
If exhaust manifold is touched after start up there are cold spots on manifold ❊❍
Color of exhaust smoke
Blue under light load ❊
Black ❍❊ ❍
Engine does not pick up smoothly and combustion is irregular ❊
Abnormal noise is heard when engine is accelerated ❍ ❍ ❍❍
Blow-by gasses are excessive ❊

When turbocharger is rotated by hand, it is found to be heavy ●
Remove gear cover and inspect directly ● ●
Troubleshooting
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 ●
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
Repair
Repair
Repair
remedy
WA380-5L 40-675 3
12
(S-16) Excessive Vibration When Engine Is Running
Causes
Stuck dynamic valve system (valves, rocker)

★ If there are abnormal noise together with the vibration,
carry out troubleshooting also for “Abnormal noise is
Worn or damaged connecting rod

made”. (See S-15)
Damage in power train system

Improper gear train backlash
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
Loose engine mountings

Worn camshaft bushing
• Improper combustion
• Abnormal combustion

Questions
Condition of vibration Suddenly increased ❍ ❍

Gradually increased ❍ ❍ ❍
Non-specified oil is being used ❍ ❍
Metal particles are found in oil filter ❊ ❊
Metal particles are found when oil is drained ❊ ❊
Check items
Oil pressure is low at low idling ❍ ❍

Vibration occurs at mid-range speed ❍❍
Vibration follows engine speed ❍ ❍❍
Exhaust smoke is black ❊ ❍
Inspect valve system directly ●

Troubleshooting
Inspect main bearings and connecting rods ●

Inspect gear train directly ●
Inspect cam shaft bushings directly ●
Check the monitoring functions ●
Check all engine mounting points ●
Injection power train ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
40-676 3 WA380-5L
50 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5

Removal and Installation of Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-5
Disassembly and Assembly of Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-7
SPECIAL TOOLS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-8
Special Tool Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-11
CONNECTOR REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20
Stripping Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20
Wire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20
Contact Terminal Removal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-21
Crimping Contact Terminal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-22
Insertion of Contact Terminal (HD30 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-23
Contact Terminal Removal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-24
Crimping Contact Terminal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-25
Insertion of Contact Terminal (DT Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-26
BULKHEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-27
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-28
ENGINE HOOD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-34
ENGINE CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-36
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-36
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41
RADIATOR FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-44
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-45
AFTERCOOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-46
WA380-5L 50-1 D
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-47
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50
NOZZLE HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-52
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-52
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-54
FAN AND FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-55
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-55
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-56
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-57
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-59
PARKING BRAKE DISCS AND PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-62
TORQUE CONVERTER AND TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-64
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-69
Bleeding the Hydraulic Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-69
TRANSMISSION ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-77
TRANSMISSION CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-86
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-86
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-86
Forward and Reverse Clutch Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-86
1st and 4th Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-88
2nd and 3rd Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-92
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-95
Forward and Reverse Clutch Packs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-95
1st and 4th Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-99
2nd and 3rd Clutch Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-103
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-108
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-108
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-108
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111
TORQUE CONVERTER (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-117
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-117
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-117
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120
TORQUE CONVERTER (LOCK-UP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-123
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-127
50-2 D WA380-5L
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-133
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-135
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-135
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-136
AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-137
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-137
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-137
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-142
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-148
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-148
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-149
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-157
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-172
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-172
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-172
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-178
CAB ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-182
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-182
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-183
CAB AND FLOOR FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-184
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-184
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-187
OPERATOR'S CAB GLASS (SEALED GLASS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-188
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-188
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-188
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190
HYDRAULIC PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-198
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-198
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-198
Steering, Switching, and Fan Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-199
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-199
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-199
STEERING DEMAND VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-200
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-200
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-201
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-202
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-206
ORBITROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-210
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-210
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-212
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-212
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-215
ECSS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-220
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-220
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-220
WA380-5L 50-3 D
WORK EQUIPMENT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-221

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-221
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-223
HYDRAULIC CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-224
Steering, Lift, and Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-224
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-224
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-225
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-229
HYDRAULIC TANK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-236
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-236
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-237
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-238
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-238
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-242
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-244
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-244
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-244
AIR CONDITIONER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-245
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-245
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-245
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-248
AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-250
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-250
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-250
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-251
OPERATOR’S SEAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-252
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-252
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-260
50-4 D WA380-5L
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
12
HOW TO READ THIS MANUAL
Removal and Installation of Assemblies

Special Tools
• Special tools which are deemed necessary for removal or installation of parts are described as A1,•••X1 etc. and their
part names, part numbers and quantities are described in the special tool list.
• Also the following information is described in the special tool list.
A. Necessity
■: Special tools that cannot be substituted and should always be used (installed).
●: Special tools that will be useful if available and are substitutable with commercially available tools.
B. Distinction of new and existing special tools

N: Tools newly developed for this model. They respectively have a new part number.
R: Tools with upgraded part numbers. They are remodeled from already available tools for other models.
Blank: Tools already available for other models. They can be used without any modification.
C. Circle mark ❍ in sketch column:

The sketch of the special tool is presented in the section of "Sketches of special tools".
This mark means part No. of special tools starting with 79*T-***-**** and that they can not be supplied from
Komatsu in Japan (i.e. locally made parts).
Removal
• The [Removal] section contains procedures and precautions for implementing the work, expertise, and the amount of oil
or coolant to be drained.
• General tools that are necessary for removal are described as [1], [2]•••etc. and their part names, part numbers and
quantities are not described.
• Various symbols used in the Removal Section are explained and listed below.
WARNING! This mark indicates safety-related precautions that must be followed when implementing
the work.
★ : Instructions or precautions for work

[*1] :This mark shows that there are instructions or precautions for installing parts.:
This mark shows the amount of oil or coolant to be drained.
Weight of part or component.
Installation
• Except where otherwise instructed, installation of parts is done in the reverse order of removal.
• Instructions and precautions for installing parts are shown with [*1] mark in the Installation Section, identifying which
step the instructions are intended for.
• General tools that are necessary for installation are described as [1], [2]•••etc. and their part names, part numbers and
• Marks shown in the Installation Section stand for the following.
WARNING! Precautions related to safety in execution of work.
WA380-5L 50-5 D
★ :This mark gives guidance or precautions when doing the procedure.
Type of coating material.
Tightening torque.
Quantity of oil or coolant to be added.
Sketches of special tools

• Various special tools are illustrated for the convenience of local manufacture.
Disassembly and Assembly of Assemblies

Special Tools
• Special tools which are deemed necessary for disassembly or assembly of parts are described as A1,•••X1 etc. and
their part names, part numbers and quantities are described in the special tool list.
• Also the following information is described in the special tool list.
A. Necessity
■ : Special tools that cannot be substituted and should always be used (installed).
• : Special tools that will be useful if available and are substitutable with commercially available tools.
B. Distinction of new and existing special tools

N : Tools newly developed for this model. They respectively have a new part number.
R : Tools with upgraded part numbers. They are remodeled from already available tools for other models.
Blank : Tools already available for other models. They can be used without any modification.
C. Circle mark ❍ in sketch column:

• The sketch of the special tool is presented in the section of "Sketches of special tools".
• This mark means part No. of special tools starting with 79*T-***-**** and that they can not be supplied from
Komatsu in Japan (i.e. locally made parts).
Disassembly
• In Disassembly section, the work procedures, precautions and expertise for carrying out those procedures, and quantity of
the oil and coolant drained are described.
• General tools that are necessary for disassembly are described as [1], [2]•••etc. and their part names, part numbers and
• The meanings of the symbols used in Disassembly section are as follows.
WARNING! This mark indicates safety-related precautions that must be followed when implementing
the work.
★ Instructions or precautions for work
Quantity of oil or coolant drained.
50-6 D WA380-5L
12
Assembly
• In Assembly section, the work procedures, precautions and expertise for carrying out those procedures, and quantity of the
oil and coolant added are described.
• General tools that are necessary for assembly are described as [1], [2]•••etc. and their part names, part numbers and
• The meanings of the symbols used in Assembly section are as follows.
WARNING! Precautions related to safety in execution of work.
★ : This mark gives guidance or precautions when doing the procedure.
Type of coating material.
Tightening torque.
Quantity of oil or coolant to be added.
Sketches of special tools

• Various special tools are illustrated for the convenience of local manufacture.
WA380-5L 50-7 D
DISASSEMBLY AND ASSEMBLY SPECIAL TOOLS LIST
12
SPECIAL TOOLS LIST
★ Tools with part number 79❍T-❍❍❍-❍❍❍❍ cannot be supplied (they are items to be locally manufactured).
★ Necessity:
■ ...........Cannot be substituted, must always be installed (used).
● ...........Extremely useful if available or can be substituted with commercially available part.
★ New/Remodel:
N...........Tools with new part numbers, newly developed for this model.
R:...........Tools with upgraded part numbers, remodeled from items already available for other models.
Blank: ...Tools already available for other models, can be used without any modification.
Tools marked ❍ in the Sketch column are tools introduced in the sketches of the special tools (See Sketches of special tools).
New/remodel
Necessity
Symbol
Sketch
Qty
Component Part number Part name Nature of work, remarks
A 1 790-331-1110 Wrench, angle tightening ● 1 Cylinder head mounting bolts

1 795-799-1130 Gear ● 1
Engine assembly 2 795-799-1900 Pin ● 1
G Removal of fuel injection pump
3 795-799-1950 Lock Pin ● 1
4 795-799-1390 Plate ● 1
1 793T-607-1190 Bracket ● 1 ❍
Removal, installation of parking
K 2 722-14-13130 Plate ● 1
brake disc and plate
3 01011-62020 Bolt ● 1
793T-607-1190 Bracket ● 1 ❍
1 722-14-13130 Plate ● 1
01011-62020 Bolt ● 1
793T-607-1130 Push tool ● 1 ❍
3 790-101-5421 Grip ● 1
Parking brake
01010-81240 Bolt ● 1
assembly Disassembly, assembly of
4 793T-607-1140 Spacer ● 1 ❍
H parking brake assembly
5 792T-446-1150 Push tool ● 1 ❍
6 797T-423-1141 Push tool ● 1 ❍
793T-512-1110 Push tool ● 1 N ❍
8 790-101-5421 Grip ● 1
01010-81240 Bolt ● 1
9 793T-607-1160 Spacer ● 1 ❍
10 793T-607-1180 Push tool ● 1 ❍ Press-fit front coupling cover
793T-607-1210 Lifting tool ● 2 ❍
F 2 Lifting clutch pack assembly
793-607-1230 Pin ● 2
1 790-201-2170 Plate ■ 1
2 790-201-2730 Spacer ■
Transmission C2 Press fit bearing
3 796-465-1120 Push tool ■
assembly
4 790-201-2740 Spacer ■
1 793-607-1110 Seal holder ■ N
C3 Assembe piston seal
2 793-607-1120 Seal holder ■ N
C12 799-301-1500 Oil leak tester kit ■ Check piston operation
50-8 D WA380-5L
New/remodel
Necessity
Symbol
Sketch
Qty
790-501-5000 Unit repair stand ● 1

Torque converter 790-501-5200 Unit repair stand ● 1 Torque converter disassembly
B
assembly 790-901-2110 Bracket ● 1 and assembly
790-901-2150 Plate ● 1
793T-522-1140 Push tool ■ 1 N ❍
1 Press fit bearing (wheel side)
793T-522-1150 Spacer ■ 1 N ❍
2 797T-423-1290 Push tool ■ 1 ❍ Press fit bearing (Deff. side)
Axle assembly J
3 793T-522-1160 Push tool ■ 2 N ❍ Press fit oil seal sleeve
793T-522-1171 Seal support ■ 2 N ❍
4 Assemble axle housing
01016-30860 • Bolt ■ 6
790-501-5000 ●
1 or Unit repair stand
D1 790-501-5200 ● Differential disassembly and
assembly
2 790-901-2110 Bracket ●
3 790-901-1331 Plate ●
1 793T-522-1110 Push tool ■ ❍
D2 2 790-101-5421 Grip ■ Press fit oil seal
3 01010-81240 Bolt ■
1 793T-522-1110 Push tool ■ ❍
Differential 2 793T-522-1120 Spacer ■ ❍

D3 Press fit dust seal
assembly 3 790-101-5421 Grip ■
4 01010-81240 Bolt ■
D4 790-201-2740 Push tool ■
Press fit pinion gear bearing
D5 793T-522-1130 Push tool ■ N ❍
1 790-301-1720 Adapter ■
2 799-101-5002 Hydraulic kit ■
D6 Check for brake oil leakage
3 793-605-1001 Brake tester ■
4 790-101-1102 Hydraulic pump ■
No-load operating torque of
D7 796-751-1510 Wrench ■ 1
limited slip differential
1 790-101-2300 Push puller ■ 1
2 793-520-2370 Push tool ■ 1
3 793-520-2350 Push tool ■ 1
Center hinge pin removal and
Center hinge pin E1 4 793-520-2540 Guide ■ 1
installation
5 793-520-2360 Bar ■ 2
6 790-101-1102 Hydraulic pump ■ 1
7 790-101-2102 Puller (30 tons) ■ 1
790-502-1003 Repair stand ● 1 Hydraulic cylinder disassembly
1
790-101-1102 Hydraulic pump ● 1 and assembly
Hydraulic cylinder 790-102-2303 ● 1

I 2 or Wrench assembly For steering cylinder head
assembly
790-330-1100 ● 1
Socket (Width
3 790-302-1270 ● 1 For steering cylinder piston nut
across flats: 50 mm)
WA380-5L 50-9 D
New/remodel
Necessity
Symbol
Sketch
Qty
790-102-4300 Wrench assembly ● 1 For boom and bucket cylinder

4
790-102-4310 Pin ● 1 pistons
5 790-720-1000 Expander ● 1
796-720-1640 Ring ● 1
07281-00909 Clamp ● 1
796-720-1680 Ring ● 1 For assembly of piston ring
6
07281-01589 Clamp ● 1
796-720-1690 Ring ● 1
07281-01919 Clamp ● 1
Hydraulic cylinder
I 790-201-1702 Push tool kit ● 1
assembly
• 790-101-5021 Grip ● 1
For assembly of cylinder head
7 • 01010-80816 Bolt ● 1
bushing
• 790-201-1751 Push tool ● 1
• 790-201-1841 Push tool ● 1
790-201-1500 Push tool kit ● 1
• 790-101-5021 Grip ● 1
For assembly of cylinder head
8 • 01010-80816 Bolt ● 1
dust seal
• 790-201-1560 Plate ● 1
• 790-201-1650 Plate ● 1
799-703-1200 Service tool kit ■ 1
799-703-1100 Vacuum pump (100V) ■ 1
Air conditioner Charging air conditioner with
X 799-703-1110 Vacuum pump (220V) ■ 1
assembly freon
799-703-1120 Vacuum pump (240V) ■ 1
799-703-1401 Gas leak detector ■ 1
2-1 793-498-1120 Clear plate ■ 2
2-2 793-498-1130 Plate ■ 2
Operator cab glass X Install operator cab glass
2-3 793-498-1110 Magnet ■ 2
3 793-498-1210 Lifter (Suction cups) ■ 2
50-10 D WA380-5L
Special Tool Illustrations

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D2-1 and D3-1 Push Tool
D3-2 Spacer
WA380-5L 50-11 D
D5 Push Tool
F2 Lifting Tool
50-12 D WA380-5L
H1 Bracket
H3 Push Tool
WA380-5L 50-13 D
H4 Spacer
H5 Push Tool
50-14 D WA380-5L
H6 Push Tool
H8 Push Tool
WA380-5L 50-15 D
H9 Spacer
H10 Push Tool
50-16 D WA380-5L
J1-1 Push Tool
J1-2 Spacer
WA380-5L 50-17 D
J2 Push Tool
J3 Push Tool
50-18 D WA380-5L
J4 Seal Support
K1 Bracket
WA380-5L 50-19 D
DISASSEMBLY AND ASSEMBLY CONNECTOR REPAIR PROCEDURES
12
CONNECTOR REPAIR PROCEDURES
These steps outline the proper repair procedures for the HD30 and DT type wire connectors. Failure to follow these procedures
may result in a failed contact situation in the electrical circuit or damage to the connector or wiring harness.
Stripping Insulation
After obtaining the proper terminal size for the wire gauge you will be using in the connector repair, remove all damaged or
corroded sections of the wire being repaired referring to the table below.
Deutsch Terminal Part Number Wire Gauge Range Strip Length: mm (in)
0460 - 202 - 20141 20 AWG 3.96 - 5.53 (0.156 - 0.218)

0462 - 201 - 20141 20 AWG 3.96 - 5.53 (0.156 - 0.218)
0460 - 202 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (0.250 - 0.312)
0462 - 201 - 16141 16, 18 and 20 AWG 6.35 - 7.92 (0.250 - 0.312)
0460 - 215 - 16141 14 AWG 6.35 - 7.92 (0.250 - 0.312)

0462 - 209 - 16141 14 AWG 6.35 - 7.92 (0.250 - 0.312)
0460 - 204 - 12141 12 and 14 AWG 5.64 - 7.21 (0.222 - 0.284)

0462 - 203 - 12141 12 and 14 AWG 5.64 - 7.21 (0.222 - 0.284)
0460 - 204 - 08141 8 and 10 AWG 10.92 - 12.47 (0.430 - 0.492)

0462 - 203 - 08141 8 and 10 AWG 10.92 - 12.47 (0.430 - 0.492)
0460 - 204 - 0490 6 AWG 10.92 - 12.47 (0.430 - 0.492)

0462 - 203 - 04141 6 AWG 10.92 - 12.47 (0.430 - 0.492)
Using wire insulation strippers, remove only the measured amount of

insulation from the wire according to the size contact terminal listed
in the "Strip Length" above.
Wire Inspection
After stripping insulation from wire, inspect wire strands for:
• Corrosion, straightness and uniformity
• Broken or nicked wire strands are unexcitable and may cause
high resistance in the circuit.
• Do not twist or wrap the wire strands as this may cause wire
strand breakage during the crimping process.
50-20 D WA380-5L
12
Contact Terminal Removal (HD30 Type)
1. Obtain the correct removal tool according to the wire size used in
the connector.
2. With the rear insert part of the connector facing you, snap the
removal tool over the wire of the contact terminal you will be
removing.
Remark
Using a removal tool that is too large or too small will
hinder wire removal and may damage the connector or
removal tool. Always use the correct removal tool size for
the wire gauge you are servicing.
3. In a straight line, carefully slide the removal tool along the wire
and into the grommet until a contact resistance is felt.
Remark
Do not pull on the wire or twist the tool when inserting
removal tool into the grommet. Damage to the tool or con-
nector may result.
4. Once tool is fully inserted into the connector, carefully pull the
removal tool and contact terminal-wire out of the connector.
5. If contact terminal-wire will not come out, remove tool and rein-
sert removal tool again.
WA380-5L 50-21 D
12
Crimping Contact Terminal (HD30 Type)
1. After insulation has been stripped from the wire and contact ter-
minal is ready for crimping, raise selector knob on Crimp Tool
#HDT48-00 and rotate until arrow is aligned with wire size to be
crimped.
2. Loosen locknut, turn adjusting screw in until it stops.
3. Insert contact terminal with barrel up. Turn adjusting screw coun-
terclockwise until contact terminal surface is flush with indenter
cover. Tighten locknut.
4. Insert wire into contact terminal. Be sure contact terminal is cen-

tered between indicators.
5. Close crimp tool handle until crimp cycle is completed.
6. Release the tool handle and remove the crimped contact terminal.
7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.
Remark
The tool must be readjusted for each type/size of contact.
Use Crimp tool HDT04-08 for size 8 and 4 contacts.
50-22 D WA380-5L
12
Insertion of Contact Terminal (HD30 Type)
1. Grasp contact terminal approximately 25.2 mm (1 in) behind the
crimped barrel.
2. Hold connector with rear grommet facing you.
3. Insert completed contact terminal straight into connector grom-

met until a positive stop is felt.
4. Once contact terminal is in connector, a slight tug will confirm

that the contact terminal is properly locked in place.
5. For unused wire cavities, insert sealing plugs for full environ-
mental sealing.
WA380-5L 50-23 D
12
Contact Terminal Removal (DT Type)
1. Remove the wedge lock using needle nose pliers or a hooked-
shaped wire.
2. Pull the wedge lock straight out and save for reinstallation.
3. To remove the contact terminal gently pull the wire backwards

while at the same time releasing the locking finger by pushing it
away from the terminal with a small screwdriver.
4. Hold the rear seal grommet in place and pull the contact terminal
out of the connector.
50-24 D WA380-5L
12
Crimping Contact Terminal (DT Type)
1. After insulation has been stripped from the wire and contact ter-
minal is ready for crimping, raise selector knob on Crimp Tool
#HDT48-00 and rotate until arrow is aligned with wire size to be
crimped.
2. Loosen locknut, turn adjusting screw in until it stops.
3. Insert contact terminal with barrel up. Turn adjusting screw coun-
terclockwise until contact terminal surface is flush with indenter
cover. Tighten locknut.
4. Insert wire into contact terminal. Be sure contact terminal is cen-

tered between indicators.
5. Close crimp tool handle until crimp cycle is completed.
6. Release the tool handle and remove the crimped contact terminal.
7. Using the inspection hole in the contact terminal inspect the

crimped contact terminal to ensure that all strands are in the
crimped barrel.
Remark
The tool must be readjusted for each type/size of contact.
Use Crimp tool HDT04-08 for size 8 and 4 contacts.
WA380-5L 50-25 D
12
Insertion of Contact Terminal (DT Type)
1. Grasp the crimped contact terminal approximately 25.2 mm (1 in)
behind the crimped barrel.
2. Hold the connector with the rear grommet facing you and insert
the completed wire into the connector.
3. Push the contact terminal straight into the connector until a

"click" is felt. A slight tug will confirm that the contact terminal
is properly locked in place.
4. Once all contact terminals are in place, insert the wedge lock with
the arrow pointing toward exterior locking mechanism. The
wedge lock will snap into place. Rectangular wedges are not ori-
ented and may fit either way.
Remark
As the connector receptacle is shown - use the same procedures for a
plug.
50-26 D WA380-5L
DISASSEMBLY AND ASSEMBLY BULKHEAD ASSEMBLY
BULKHEAD ASSEMBLY
Removal
WARNING! Park the machine on flat ground and set the frame lock safety bar to the frame.
Completely lower work equipment to the ground and stop the engine.
Apply the parking brake and put blocks under the wheels.
WARNING! Disconnect the battery negative (-) terminal..
1. Bulkhead assembly
A. Disconnect transmission breather hose (1).
B. Remove connector (3) of engine stop solenoid relay (2).
C. Disconnect air conditioner hoses (4) and (5), also disconnect

overflow hose of the reservoir tank from the clamp.
D. Disconnect air conditioner hoses (6) and (7) at air conditioner

compressor (8) and remove the hose clamps to bring them to
the bulkhead side.
WA380-5L 50-27 D
DISASSEMBLY AND ASSEMBLY BULKHEAD ASSEMBLY
E. Disconnect the dust indicator hose and air intake hose (9) and
remove air cleaner assembly (10).
F. Remove connector (11).

G. Sling the bulkhead assembly and remove mounting bolts (12)
and (13).
H. Remove lock bolts to the right and left of the rubber sheet.
★ Find them carefully because they are located below the
main frame and are not easily found.
I. Lift the bulkhead assembly slightly and pull out the two drain
hoses of the air conditioner unit from the clamp. (Right side of
machine)
J. Lift bulkhead assembly (14) slowly and remove it.

★ Lift the air conditioner hoses and rubber sheet at the same
time and remove them.
Bulkhead Assembly: 92 kg (203 lbs.)
Installation
• Perform installation in the reverse order of removal.
50-28 D WA380-5L
DISASSEMBLY AND ASSEMBLY ENGINE HOOD ASSEMBLY
ENGINE HOOD ASSEMBLY
Removal
1. Disconnect exhaust pipe (1).

2. Disconnect hose (2) between the reservoir tank and radiator on the
reserve tank side and remove it from the engine hood clamp.
3. Remove rubber sheet (3) and baffle (4).
4. Remove baffle mounting brackets (6) and (7).
WA380-5L 50-29 D
DISASSEMBLY AND ASSEMBLY ENGINE HOOD ASSEMBLY
5. Remove connector (8) and then remove back-up alarm (9).
6. Remove connector (10).
7. Remove the cover and then remove connector (11) of the fan motor.
8. Remove stays (12) and (13) and then remove rear mounting bolts
(14) and (15).
9. Use a lever block to sling the engine hood and remove the right and
left mounting bolts (16) and (17).
10. Lift engine hood assembly (18) slowly and remove it.
Engine hood assembly: 260 kg (573 lbs.)
Installation
50-30 D WA380-5L
DISASSEMBLY AND ASSEMBLY ENGINE ASSEMBLY
ENGINE ASSEMBLY
Removal
1. Evacuate freon gas from the air conditioner.
2. Drain coolant.
Cooling system capacity: 36 Liters (9.5 gallons)
3. See "ENGINE HOOD ASSEMBLY" in this section to remove the engine hood assembly.
4. See "BULKHEAD ASSEMBLY" in this section to remove the bulkhead assembly.
5. Disconnect starting motor wiring harness (15), air heater relay
wiring harness (R11) and (16), engine ground wiring harness (17),
emergency steering motor wiring harness (18), and connectors (19)
and (20).
6. Disconnect heater hose (21).
7. Disconnect heater hose (22) and remove the clamp.

8. Disconnect radiator outlet hose (23).
9. Lift and remove muffler assembly (24).
Muffler assembly: 36 kg (79 lbs.)
10. Disconnect aftercooler outlet hose (25).

11. Disconnect radiator inlet hose (26).
12. Disconnect aeration hose (27).
WA380-5L 50-31 D
13. Air cleaner bracket
A. Remove dust indicator connector (28).
B. Disconnect ground wiring harness (29) and remove heater
relay (30).
C. Disconnect breather hose (31) from the head cover, remove
clamps (32) and (33) and bring it to the left side of the engine.
D. Remove fuel filter (34) from the bracket.
E. Remove air cleaner bracket (35).
14. Disconnect spill hose (36).
15. Disconnect turbo outlet hose (37).
16. Disconnect accelerator cable (38).
17. Disconnect fuel suction hose (39) and return hose (40) and remove
the clamp from the engine.
18. Remove the clamp and disconnect tube (41) from the engine.
19. Disconnect wiring harness (42) from the emergency motor and
bring it to the engine side.
20. Remove engine oil drain valve (43).
50-32 D WA380-5L
21. Engine assembly
A. Use a lever block to sling the engine assembly.
B. Remove engine mounting bolts (44) and (45).
★ Hold the nuts at bottom side to prevent them from turning.
C. Use hydraulic jack ➀ and block ➁ to support the torque

converter of the torque converter and transmission assembly.
D. Remove flywheel case (46) and twelve mounting bolts (47) on

the torque converter side.
E. Turn the drain tube of the engine oil pan aside until it comes to
the fuel tank.
F. Separate the engine assembly from the torque converter by

adjusting the lifting height and angle with the lever block and
crane.
Engine assembly: 820 kg (1,808 lbs.)
WA380-5L 50-33 D
Installation
• Fill the air conditioner with freon gas (R134a).
• See the paragraph of "Adjustment of Accelerator Pedal" in Testing and Adjusting engine speed.
• Bleed air from the fuel system.
Mounting bolt: 490 - 608 Nm {50 - 62 kgf m} (361 - 448 lbf ft)
★ Check that the o-ring is nested in the torque converter housing.

★ Adjust height of the pilot cover very carefully so that it enters the hole of the flywheel smoothly. Never insert it in the
hole by force.
• Coolant supply
Fill coolant up to the neck of the radiator. Start the engine to circulate coolant and check the coolant level in the reservoir
tank.
• Oil supply
Fill engine oil (designated one) up to the specified level.
50-34 D WA380-5L
MEMORANDUM
WA380-5L 50-35 D
DISASSEMBLY AND ASSEMBLY ENGINE CYLINDER HEAD ASSEMBLY
ENGINE CYLINDER HEAD ASSEMBLY
Special Tool
New/remodel
Necessity
Symbol
Sketch
Qty
Part number Part name Nature of work, remarks
A 1 790-331-1110 Wrench, angle tightening ● 1 Cylinder head mounting bolts.
Removal
1. Drain coolant.
2. Remove engine hood assembly.
A. Disconnect exhaust pipe (1).

B. Disconnect hose (2) between the reservoir tank and radiator on
the reserve tank side and remove it from the engine hood
clamp.
C. Remove rubber sheet (3) and baffle (4).
50-36 D WA380-5L
D. Remove baffle mounting brackets (6) and (7).
E. Remove connector (8) and then remove back-alarm (9).

F. Remove connector (10).
G. Remove the cover and then remove connector (11) of the fan
motor.
H. Remove stays (12) and (13) and then remove rear mounting
bolts (14) and (15).
I. Use a lever block to sling the engine hood and remove the right
and left mounting bolts (16) and (17).
WA380-5L 50-37 D
J. Lift engine hood assembly (18) slowly and remove it.
Engine hood assembly: 260 kg (573 lbs.)
3. Disconnect the dust indicator hose and air intake hose (19) and
4. Lift and remove muffler assembly (21).

A. Remove dust indicator sensor connector (22).
B. Disconnect ground wiring harness (23), and remove heater
relay (24).
C. Disconnect breather hose (25) from the head cover, remove
clamps (26) and (27) and bring it to the left side of the engine.
D. Remove fuel filter (28).
50-38 D WA380-5L
6. Disconnect aftercooler outlet pipe (30).
7. Remove muffler mounting bracket (31).

8. Remove air intake connector (32).
9. Disconnect turbo outlet pipe (33).
10. Remove exhaust connector (34) and bracket (35).
11. Remove heat shield (36).
12. Disconnect turbo lubrication hose (37) and drain tube (38).
13. Remove turbocharger and exhaust manifold assembly (39).

14. Disconnect aeration hose (40).
WA380-5L 50-39 D
15. Remove head cover (41).
★ Before removing it, clean the area around it.

16. Disconnect six pieces of high-pressure injection pipe (42).
18. Remove holder (44) and then nozzle holder assembly (45).
19. Remove rocker arm assembly (46).
★ Loosen the locknut and adjustment nut 2 ~ 3 turns.
20. Remove push rod (47).
50-40 D WA380-5L
21. Cylinder assembly.
Remove twenty-six head bolts (48) and cylinder head assembly (49).
Cylinder head assembly: 52 kg (115 lbs.)
Installation
• Perform the installation in the reverse order of removal.
Air cleaner mounting clamp bolt: 9.8 ~ 11.76 Nm {1.0 ~ 1.2 kgf m} (7.2 ~ 8.7 lbf ft.)
Clamping bolt on air intake hose turbo side: 8.8 ± 0.5 Nm {0.9 ± 0.05 kgf m} (78 ± 4 lbf in.)
Air intake pipe intermediate clamp nut: 10.8 ~ 26.5 Nm {1.1 ~ 2.7 kgf m} (8 ~ 20 lbf ft.)
Clamp nut on turbo side: 6.9 ~ 8.8 Nm {0.7 ~ 0.9 kgf m} (61 ~ 78 lbf in.)
Nut of pipe intermediate clamp: 10.8 ~ 26.5 Nm {1.1 ~ 2.7 kgf m} (8 ~ 20 lbf ft.)
Exhaust connector clamp nut: 6.9 ~ 8.8 Nm {0.7 ~ 0.9 kgf m} (61 ~ 78 lbf in.)
Joint on the turbo lubrication hose cylinder block side: 19.6 ~ 28.4 Nm {2.0 ~ 2.9 kgf m} (15 ~ 21 lbf ft.)
Tighten the exhaust manifold mounting bolt following the procedures below and apply the torques below.
WA380-5L 50-41 D
• First turn: In the order from the first one shown in the figure
23.5 ± 4 Nm {2.4 +0.4 kgf m} (17 ± 3 lbf ft.)
• Second turn: From the 1st to 4th bolts only shown in the figure
23.5 ± 4 Nm {2.4 +0.4 kgf m} (17 ± 3 lbf ft.)
• Third turn: In the order from the first one shown in the figure
43.1 ± 6 Nm {4.4 ± 0.6 kgf m} (32 ± 4 lbf ft.)
• Fourth turn: From the 1st to 4th bolts only shown in the figure
43.1 ± 6 Nm {4.4 ± 0.6 kgf m} (32 ± 4 lbf ft.)
Head cover mounting bolts: 23.5 ±3.9 Nm ( 2.4 ±0.4 kgf m) {17 ±3 lbf ft}
High-pressure injection pipe sleeve nut: 24 ±4 Nm ( 2.45 ±0.41 kgf m) (18 ±3 lbf ft)
★ Clean the nozzle holder mounting portion, check that there is no foreign matter inside the sleeve and then assemble
the holder and the nozzle holder assembly.
★ Apply a little engine oil to the rubber boots.
• When installing the rocker arm assembly, check that the rocker arm ball is firmly nested in the push rod.
Rocker arm assembly mounting bolt: 65 ±5 Nm ( 6.6 ±0.5 kgf m) {48 ±4 lbf ft}
Rocker arm adjustment screw locknut: 24 ±2.4 Nm ( 2.45 ±0.24 kgf m) {18 ±2 lbf ft}
• See "Adjustment of Valve Clearance" in Inspection and Adjustment and adjust the valve clearance.
• Check that the push rod is firmly nested in the tappet.

★ Rotate the push rod to check if it rotates smoothly.
• Install the cylinder head assembly following the procedures below:

★ Check that there is no dust and foreign matter on the cylinder head mounting surface and inside the cylinder.
A. Attach the cylinder head gasket to the cylinder block.

★ Check that the gasket is correctly nested in the block hole.
B. Lift the cylinder head assembly and set it into place on the cylinder block.
C. Tighten the cylinder head mounting bolts in the order shown in the figure.
Apply engine oil to the threaded portion and the seat surface of the mounting bolt.
50-42 D WA380-5L
Cylinder head mounting bolts:
First time: Tighten the bolts in order from 1 ~ 26 to 70 ±5 Nm

(7.1 ±0.51 kgf m) {52 ±4 lbf ft}
Second time: Check that all of the bolts have been tightened in the
same order with the above torque.
Third time: Tighten the long bolts (1, 2, 7, 8, 9, 10 15, 16 17, 18, 23,
24, 25, 26) to 145 ± 10 Nm (14.8 ±1.0 kgf m) {107 ±7 lbf
ft.}
Fourth time: Check that the long bolts in the third time have been
tightened with the above torque values.
At the end: When A1 tool is used, tighten bolts an additional 90° ±5°
in the order from 1 to 26 with the angle tightening
wrench (Tool A1).
When tool A1 is not used, place counter marks on the

bolt heads and tighten bolts an additional 90° ±5°.
WA380-5L 50-43 D
DISASSEMBLY AND ASSEMBLY RADIATOR FAN MOTOR
RADIATOR FAN MOTOR
Removal
1. Drain engine coolant.
2. Remove the engine hood assembly. See "Removal of Engine Hood Assembly".
3. Remove the lock and the hinge mounting bolt, remove the
hydraulic oil cooler assembly (1) and bring it to the engine side.
4. Disconnect the fuel tank air bleeding hose (2).
5. Remove cover (3).
6. Disconnect hydraulic hoses (4), (5), and (6) from the motor.
7. Disconnect radiator outlet hose (7) on torque converter cooler side.
50-44 D WA380-5L
DISASSEMBLY AND ASSEMBLY RADIATOR FAN MOTOR
8. Disconnect radiator inlet hose (8) and aeration hose (9).
9. Disconnect the aftercooler inlet hose (10) and the outlet hose (11).
10. Use a lever block to sling the radiator fan motor assembly, and
remove the left mounting bolt (12) and the right mounting bolt (13).
11. Lift and remove the radiator fan motor assembly (14).
Radiator fan motor assembly: 195 kg (430 lbs.)
Installation
★ See "Bleeding Air from Fan Motor Circuit" in TESTING AND ADJUSTMENT; bleed air from the fan motor circuit.
Hose clamping bolt: 5.9 ± 0.5 Nm {4.4 ± 0.36 lbf ft.}
• Refill coolant up to the neck of the radiator. Start the engine to circulate coolant, and recheck coolant level in the reservoir
tank.
WA380-5L 50-45 D
DISASSEMBLY AND ASSEMBLY AFTERCOOLER
AFTERCOOLER
Removal
1. Remove the engine hood assembly. See "Removal of Engine Hood
Assembly".
2. Sling aftercooler assembly (3) and disconnect aftercooler inlet hose

(1) and outlet hose (2).
3. Remove the mounting bolts and then remove aftercooler assembly

(3).
Aftercooler assembly: 31 kg (68 lbs.)
Installation
Hose clamping bolt: 5.9 ±0.5 Nm (0.6 ±0.05 kgf m) {52 ±4 lbf in.}
50-46 D WA380-5L
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
FUEL INJECTION PUMP
Special Tools
New/Modified
Necessity
Quantity
Sketch
Symbol Part Number Part Name Nature of work, remarks
1 795-799-1130 Gear ● 1
2 795-799-1900 Pin ● 1
G Removal of injection pump.
3 795-799-1950 Lock pin ● 1
4 795-799-1390 Plate ● 1
Removal
WARNING! Disconnect the battery negative (—) terminal in advance.
1. Remove the rubber sheet (1) and baffle (2).
2. Remove the engine stop solenoid (3).
3. Disconnect the accelerator cable (4).
4. Disconnect the fuel tube (5).
5. Disconnect the lubrication hose (6).
6. Remove the oil filler port (7).

7. Disconnect the muffler drain tube (8).
WA380-5L 50-47 D
8. Disconnect fuel return hose (9).
9. Use tool G1 to rotate crankshaft in the positive rotation direction to

push the gear in the compression top dead point positioning pin
(10) of the No. 1 cylinder.
★ Press the pin lightly to the gear and rotate it slowly.
10. Disconnect wastegate hose (11) and then disconnect the boost
compensator tube (12).
11. Disconnect six pieces of the high-pressure injection pipe (13) from
the pump, and remove the clamp in the middle.
12. Remove cap (14).
13. Remove nut (15) and washer (16).

★ Carefully remove the nut and washer so they do not drop into
the case.
50-48 D WA380-5L
14. Use tool G4 to pull drive gear of the injection pump, and loosen the
engagement with the shaft.
15. Remove two mounting bolts (17) and four mounting nuts (18).
Remove fuel injection pump assembly (22).
WA380-5L 50-49 D
Installation
★ See "Adjustment of Engine Stop Solenoid" in Inspection and Adjustment; adjust the solenoid.
★ See the paragraph "Adjustment of Accelerator Pedal" in Inspection and Adjustment; adjust engine speed.
Joint bolt: 36 ±5 Nm (3.67 ±0.51 kgf m) {27 ± 4 lbf ft.}
Joint bolt: 8 ±2 Nm (0.8 ±0.2 kgf m) {71 ±18 lbf in}
Joint bolt: 36 ±5 Nm (3.67 ±0.51 kgf m) {27 ± 4 lbf ft.}
Sleeve nut: 24 ± 4 Nm (2.45 ±0.41 kgf m) {18 ±3 lbf ft}
l Install the fuel injection pump by following the procedures below:
A. Check that No. 1 cylinder is at the position of the compression

top dead point.
B. Remove the plug (19) and then remove the timing pin (20).
C. Reverse the position of the timing pin (20), bring the groove of
the timing pin to the pointer (21) in the pump and tighten the
plug (19) temporarily.
★ When the tooth of the pointer (21) does not match the hole
of the timing pin, turn the shaft of the fuel injection pump
to match the pointer tooth of the hole.
50-50 D WA380-5L
D. Align the pump cam shaft to the pump drive gear, assemble the
fuel injection pump assembly (22) and tighten mounting nut
(18) and bolt (17).
Nut: 44 ± 6 Nm (4.49 ± 0.6 kgf m) {33 ± 4 lbf ft}
E. Set washer (16) in and temporarily tighten nut (15).

★ Carefully attach the washer and nut so they do not drop in
the case.
★ Temporarily tighten the nut by applying a torque of about:
50 Nm (4.9 kgf m) {37 lbf ft}, disengage the timing pin
and re-tighten the nut by applying the specified torque.
F. Disengage timing pin (10).
G. Remove the plug (19), reverse the position of the timing pin
(20) to set it in and attach the plug to the injection pump.
Plug: 14.7 Nm (1.5 kgf m) {11 lbf ft.}
H. Permanently tighten drive nut (15) of the fuel injection pump.
Nut: 178 ± 13 Nm (18.2 ± 1.3 kgf m) {131 ± 10 lbf ft}
• Bleed the air from the fuel system.
WA380-5L 50-51 D
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
NOZZLE HOLDER
Removal
WARNING! Disconnect the battery negative (-) terminal in advance.
1. Remove the engine hood assembly. See "Removal of Engine Hood

Assembly".
2. Disconnect the dust indicator hose and air intake hose (1), and
3. Remove muffler assembly (3).

A. Remove dust indicator sensor connector (4).
B. Disconnect ground wiring harness (5), and remove heater relay
(6).
C. Remove clamps (8) and (9) of breather hose (7) from bracket
(11).
D. Remove fuel filter (10) from bracket (11).
50-52 D WA380-5L
5. Disconnect aftercooler outlet pipe (12).
6. Remove muffler mounting bracket (13).
7. Remove air intake connector (14).

★ Remove it for No. 4 and No. 5 nozzle holder assemblies.
8. Disconnect six high-pressure injection pipes (15).

10. Remove holder (17) and then nozzle holder assembly (18).
WA380-5L 50-53 D
Installation
• Perform installation in the reverse order to removal.
Air cleaner mounting clamp bolt: 9.8 ~ 11.76 Nm (1.0 ~ 1.2 kgf m) {87 ~ 104 lbf in}
Air intake pipe intermediate clamp nut: 10.8 ~ 26.5 Nm (1.1 ~ 2.7 kgf m) {8 ~ 20 lbf ft}
High-pressure injection pipe sleeve nut: 24 ± 4 Nm (2.45 ± 0.41 kgf m) {18 ± 3 lbf ft}
★ Clean the nozzle holder mounting portion. Check that no foreign matter is inside the sleeve. Assemble it.
★ Apply a little engine oil to the rubber boots.
50-54 D WA380-5L
DISASSEMBLY AND ASSEMBLY FAN AND FAN MOTOR
FAN AND FAN MOTOR
Removal
WARNING! Disconnect the battery negative (-) terminal in advance.
1. Grille
A. Open the grille and sling it. Then, remove the right and left
dampers (1).
B. Remove connectors (2) and (3) of the working lamp and then
remove the wiring harness clamp.
C. Remove four mounting bolts and then grille (4).
2. Remove connector (5) and then remove back-up alarm (6).
3. Remove connector (7) of the fan motor solenoid.
4. Remove motor cover (8).
WA380-5L 50-55 D
DISASSEMBLY AND ASSEMBLY FAN AND FAN MOTOR
5. Disconnect hydraulic hoses (9), (10) and (11).
6. Remove fan guards (12), (13), (14), and (15).
7. Sling fan and fan motor assembly (16) and remove right and left
mounting bolts to remove it.
Fan and motor assembly: 45 kg (99 lbs.)
Installation
★ Install the fan and fan motor assembly so that clearance between the fan outside diameter and shroud inside diameter
become even all around.
★ See "Bleeding Air of Fan Motor Circuit" in Testing and Adjusting. Bleed air from fan motor circuit.
50-56 D WA380-5L
DISASSEMBLY AND ASSEMBLY FUEL TANK
FUEL TANK
Removal
1. Drain fuel.
Fuel tank capacity: 300 Liters (79.25 gallons)
2. Disconnect air bleeding hose (1) of the fuel tank from radiator.
3. Remove engine oil drain valve (2) from the fuel tank.
4. Disconnect fuel sensor connector (3).
5. Remove coolant drain valve (4) and hose clamp (5) from the fuel
tank.
6. Remove clamp (6) of the fuel tank air bleeding hose (1) from frame
(7).
7. Remove clamps (8) and (9) of the fan motor hose from fuel tank.
WA380-5L 50-57 D
8. Remove clamp (10) of the fan motor hose from fuel tank.
★ Around the center on top of the fuel tank.
9. Disconnect fuel suction hose (11), return hose (12), and spill hose
(13) from the fuel tank side.
10. Remove left mounting bolt (14) and right mounting bolt (15) of the
transmission oil cooler from the fuel tank.
★ Keep the cooler body as it is.
11. Fuel tank assembly
A. Support front of fuel tank (16) from below with transmission

jack b.
B. Sling the rear part of fuel tank (16).

★ Since the sling is apt to slip backward, use bolts to prevent
it from slipping.
50-58 D WA380-5L
C. Remove left mounting bolt (17), right mounting bolt (18), and
rear mounting bolt (19) of the fuel tank.
D. Lower transmission jack 1 and crane at the same time, and

remove fuel tank assembly (16).
Fuel tank dry weight: 180 kg (397 lbs.)
Installation
Fuel tank mounting bolt: 824 ~ 1,030 Nm (84 ~ 105 kgf m) {608 ~ 760 lbf ft.}
WA380-5L 50-59 D
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISCS AND PLATES
PARKING BRAKE DISCS AND PLATES
Special Tools
New/Modified
Necessity
Quantity
Sketch
1 793T-607-1190 Bracket ● 1
Removal, installation of parking brake discs
K 2 722-14-13130 Plate ● 1 and plates.
3 01011-62020 Bolt ● 1
Removal
1. Drain the transmission oil.
Transmission oil capacity: 54 Liters (14.25 gallons)
2. Remove drive shaft (2).
3. Remove bolt (3), washer (4), retainer (5), and coupling (6).
50-60 D WA380-5L
4. Remove mounting bolt (8) of cage (7), and use forcing screw b to
remove cage (7).
★ Check the thickness and quantity of the shims in advance and
mark where the shims are to be placed.
5. Remove level gauge cover (9).
6. Loosen mounting bolts (11) of brake cover (10) equally, and

remove cover (10) and spring (12).
★ Because mounting bolts are pressed with the brake spring,
loosen them equally.
7. Keep guide bolt c attached to housing (13).
8. Remove bearing assembly (14).
9. Attach the 2 bolts d to the piston (15) and pry the bolts with the bar
e to remove the piston.
★ Ensure that the O-ring does not come off; the piston will drop
without the O-ring.
WA380-5L 50-61 D
10. Use tools K1, K2, and K3 to push the brake disc and plate inside
and to remove snap ring (16).
★ For tools K2 and K3, the yoke mounting bolt and retainer can
be used.
11. Remove hub (17) then plate (18), spring (19), and disc (20).
★ 10 plates, 9 springs, and 9 discs
Installation
★ When installing the drive shaft, check that the spider cap key is perfectly nested into the key slot of the counter yoke,
and then tighten the bolt.
Mounting bolt: 98 ~ 123 Nm (10 ~ 12.5 kgf m) {72 ~ 91 lbf ft.}
Coupling mounting bolt: Adhesive (LT-2)
Coupling mounting bolt: 490 ~ 608 Nm (50 ~ 62 kgf m) {361 ~ 448 lbf ft.}
★ Set the shim to where it was.
50-62 D WA380-5L
★ Align counter mark a of the piston with counter mark b of the

housing, and then install them.
Piston O-ring: Grease (G2-LI)
★ Set hub (17) first, then set plate (18), spring (19), and disc (20)
in this order.
★ Ensure that spring (19) is not pinched between them.
• Oil supply
Add the specified transmission oil to the recommended level.
Note: When replacing any parts other than the discs and plates, see "Disassembly and Assembly of Parking Brake
Assembly".
WA380-5L 50-63 D
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER AND TRANSMIS-
TORQUE CONVERTER AND TRANSMISSION
Removal
1. Evacuate freon gas from the air conditioner.
2. Drain oil from the transmission and the hydraulic tank.
Transmission oil capacity: 54 Liters (14.25 gallons)

Hydraulic tank capacity: 129 Liters (34.1 gallons)
5. See "CAB AND FLOOR FRAME ASSEMBLY" to remove the cab and floor frame assembly.
6. Remove universal joint assembly (1).
7. Remove drive shaft (2).
50-64 D WA380-5L
8. Wiring and piping of emergency steering pump
A. Disconnect connector (3).
B. Disconnect pump inlet hose (4) and outlet hose (5).
C. Disconnect motor wiring harness (6) and ground wiring

harness (7).
9. Remove oil filler port (8).
10. Disconnect hoses (9) and (10).

★ Disconnect hose (9) because it touches the transmission when
the assembly is lifted.
11. Remove the cover (11).
12. Piping of torque converter and transmission
A. Remove clamp (12) of the wiring harness.
B. Disconnect outlet hose (13) to the oil cooler and return hose
(14) from the cooler.
WA380-5L 50-65 D
13. Disconnect the steering, switch, and fan pump suction tube (15).
14. Disconnect suction tube (16) of the work equipment and PPC
pump.
15. Pump outlet piping
A. Remove clamp (17) and disconnect steering pump outlet pipe

(18), switch pump outlet pipe (19) and the work equipment
pump outlet pipe (20).
B. Disconnect steering pump outlet pipe (18) and switch pump

outlet pipe (19) from the pump.
C. Remove the connector from pressure switch (21).
D. Remove clamps (22) and (23) and then bracket (24) of pipes
(18) and (19).
50-66 D WA380-5L
16. Pump piping
A. Remove clamp (25) and disconnect pump outlet pipe (20) of

the work equipment.
B. Disconnect PPC pump outlet hose (26).
C. Disconnect fan pump control pressure hose (27), pump outlet

hose (28), fan pump drain hose (29) and fan motor drain hose
(30).
★ Before disconnecting them, place counter marks on them.
17. Disconnect hose (31) from the transmission filter, and remove
elbow (32).
18. Remove the clamp of transmission wiring harness (33).
19. Disconnect strainer (34) from the bracket and bring it to the frame
side.
20. Torque converter and transmission assembly
A. Use a lever block to sling the torque converter and

transmission assembly.
B. Loosen left mounting bolt (35) and right mounting bolt (36) of
the engine.
C. Remove the left mounting bolt (37) and the right mounting bolt
(38) of the transmission and lift it a bit, then remove the left
bracket (39).
★ Do not loosen adjustment bolt (43) for positioning at the

time of installation.
WA380-5L 50-67 D
D. Lift the torque converter and transmission assembly (42) about
100 mm (3.9 in.), place block b between the engine flywheel
case and rear axle and hold the engine rear portion.
E. Remove twelve mounting bolts (41) of flywheel case (40) and

on the torque converter side.
F. Pull out and remove the torque converter and transmission

assembly (42) from the flywheel.
Torque converter and transmission: 910 kg (2,006 lbs.)
50-68 D WA380-5L
Installation
• Fill the air conditioner with freon gas (R134a).
★ When installing the coupling and the drive shaft, check that the spider cap key is perfectly nested in the key slot of the
counter yoke, and tighten the bolts
.
Mounting bolt: 98 ~ 123 Nm (10 ~ 12.5 kgf m) {72 ~ 91 lbf ft}
Mounting bolt: 490 ~ 608 Nm (50 ~ 62 kgf m) {361 ~ 448 lbf ft}
Mounting bolt: 490 ~ 608 Nm (50 ~ 62 kgf m) {361 ~ 448 lbf ft}
★ In order to position the transmission, tighten the mounting bolts so

that the clearance a with the adjustment screw becomes even.
★ Ensure an O-ring is in the torque converter housing.
★ Adjust the height so that the pilot cover enters the flywheel hole
smoothly, and never assemble them by force.
Bleeding the Hydraulic Brake Circuit

• After completing the installation, see "Bleeding Air of Brake Circuit" in Inspection and Adjustment to bleed air of the
brake circuit.
• Add the specified hydraulic oil to the "full" level.
• Add the specified transmission oil to the "full’ level.
WA380-5L 50-69 D
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
TRANSMISSION ASSEMBLY
Special Tools
New/Modified
Necessity
Quantity
Sketch
793T-607-1210 Lifting tool ● 2 {

F 2 Lifting clutch pack assembly
793-607-1230 Pin ● 2
Disassembly
1. Transmission, work equipment, and PPC pump assembly
A. Set the torque converter and transmission assembly (1) on

blocks b and c.
B. Disconnect suction tube (2).
C. Disconnect hoses (3) and (4) and breather hose (5).
D. Remove retainer (10).
E. Sling pump assembly (6) and remove two mounting bolts (7).
50-70 D WA380-5L
2. Sling steering, switch, and pump assembly (8) and remove two
mounting bolts (9).
3. Remove the plate mounting bolt and then remove emergency

steering pump assembly (11).
4. Piping
A. Remove connector (12), then block (13).
B. Disconnect hose (14).
C. Remove flow control valve (15).
D. Disconnect tube (16) and nipple (17).
5. Transmission mount and level gauge.
A. Remove the left transmission mount (18).
B. Remove level gauge (19).

★ Fix the upper and lower holders (20) with a wrench so that
they do not rotate, then remove the bolt.
WA380-5L 50-71 D
6. Filter and brake hose
A. Disconnect hose (21) and remove filter (22).
B. Disconnect brake hose (23).
7. Valve assembly
A. Remove sixteen sets of connector (24), then remove wiring

harness assembly (25).
★ Before removing the connectors, check their numbers.
B. Use eyebolt d and shackle e to sling valve assembly (26), and

remove the ten mounting bolts.
8. Remove speed sensor (27) and transmission oil temperature sensor

(28).
9. Torque converter and rear case assembly.
A. Turn the torque converter and transmission assembly (29) to

show the torque converter side up and set it on block f.
B. Remove twenty mounting bolts (30).
50-72 D WA380-5L
C. Use a lever block to sling the torque converter and rear case
assembly (31), and disconnect and remove the transmission
case with forcing screw g.
10. Torque converter assembly
A. Face the torque converter side down and lift rear case assembly
(31). Then, set block h below torque converter assembly (32).
★ Keep the case upright.
B. Remove stator shaft mounting bolt (33) and lift the rear case to
remove the torque converter assembly (32).
11. PTO gear (for transmission and work equipment PPC pump)
A. Remove snap ring (34).
WA380-5L 50-73 D
B. Face the PTO side up and set the rear case to the block.
C. Remove snap ring (37), plate (38) and woodruff thrust plate
(39).
D. Pull out shaft (40) and remove PTO gear (41).
E. Remove snap ring (35) and plate (36) from shaft (40).
F. Remove bearing (43) and inner race (59) from shaft (40).
★ Repeat the same procedures to remove the PTO gear on
the opposite side. Plate (36) is not mounted on this side.
50-74 D WA380-5L
12. Clutch pack assembly
A. Remove seal ring (44) from the shaft.
B. Use tool F2 to lift and remove the 1st speed and 4th speed
clutch assembly (45) and the 2nd speed and 3rd speed clutch
assembly (46) at the same time.
C. Use eyebolt 1! to lift and remove the forward-reverse clutch

assembly (47).
13. .Remove yoke (48).
14. Reverse idle gear
A. Remove bolt (49) and plate (50).
WA380-5L 50-75 D
B. Use puller 1@ to remove gear (51) and bearing (52).
C. Remove bearing (52) and plate (53).
15. Remove bearing (54) (on the 1st speed clutch side).
16. Cover (on the 2nd speed clutch side).
A. Remove cover (55).
B. Use a forcing screw to remove cover (56).
★ Check the thickness and the quantity of shims (57) in

advance.
C. Remove outer race (58) from cover (56).
50-76 D WA380-5L
Assembly
1. Cover (on the 2nd speed clutch side)
A. Attach outer race (58) to cover (56).
B. Set the removed shim (57) into cover (56) and tack-weld the
cover.
★ In order to adjust the shim here after the clutch assembly is
assembled.
2. Use a push-tool to attach bearing (54) (on the 1st speed clutch side)
to the housing.
3. Reverse idle gear
A. Attach plate (53).
B. Use a push-tool to attach bearing (52) with counter mark B.
C. Attach outer race (52-1) to gear (51).
D. Set spacer (52-2) and attach gear (51).
E. Use a push-tool to attach the bearing with counter mark A.
WA380-5L 50-77 D
F. Attach plate (50) and tighten bolt (49).
Bolt: Adhesive (LT-2)
Bolt: 98 ~ 123 Nm (10 ~ 12.5 kgf m) {72.3 ~ 90.7 lbf ft}
4. Attach yoke (48).
5. Clutch assembly
A. Face the brake side down and set the front case on the block.
B. Attach eyebolt 1! to forward-reverse clutch assembly (47).
C. Use tool F2 to combine the 1st speed and 4th speed clutch
assembly (45) and 2nd speed and 3rd speed clutch assembly
(46), attach them at the same time.
★ When it is difficult to set the roller bearing on the 1st
speed clutch side, remove the bearing and set it to the shaft
side to attach it.
D. Attach seal ring (44) to the shaft.
Seal Ring: Grease (G2-LI)
50-78 D WA380-5L
6. PTO gear (for transmission, work equipment and PPC pump)
A. Attach bearing (60) to rear case (31).

★ The snap ring is mounted on the steering, switch, and fan
pump sides.
B. Use a push-tool to attach inner race (59) and bearing (43) to

shaft (40).
C. Attach plate (36) and snap ring (35).
D. Set PTO gear (41) to the case and attach shaft (40).
E. Attach woodruff thrust plate (39), plate (38), and snap ring (37)
to the shaft.
WA380-5L 50-79 D
F. Attach snap ring (34).

★ Repeat the same procedures to attach PTO gear on the
opposite side. But plate (36) is not mounted on this side.
7. Torque converter assembly
A. Set torque converter assembly (32) on block h, and attach

guide bolt i.
B. Lift rear case (31), meet respective bolt holes with each other
and attach the rear case to the torque converter.
C. Tighten six stator shaft mounting bolts (33).
Bolt: 98 ~ 123 Nm (10 ~ 12.5 kgf m) {72 ~ 91 lbs.}
50-80 D WA380-5L
8. Rear case assembly
A. For each clutch assembly, make the extension of the seal ring
from the shaft equal.
B. Attach guide bolt j to the front case.
C. Use the lever block to lift rear case assembly (31) and to attach
it to the shaft of the clutch assembly.
Case mating face: Gasket sealant (LG-4)
• For the applying procedures, see the illustration

DJW05923.
D. Tighten the 20 mounting bolts (30).
Mounting bolt: 98 ~ 123 Nm (10 ~ 12.5 kgf m)

{72 ~ 91 lbf ft.}
9. Adjusting procedures of taper roller bearing shim of 2nd speed and

3rd speed clutch assembly
A. Face the parking brake side up and set transmission assembly

on the block.
B. Pull the brake piston with bolt (63) to release parking brake.
WA380-5L 50-81 D
C. Pull out the shim temporarily set in the paragraph of 1-2) of
Assembly. Attach cover (56) and torque all mounting bolts to
9.8 ± 0.98 Nm (1.0 ± 0.1 kgf m) {87 ± 9 lbf in}.
D. Use the hole on the end face of shaft (64) or the output shaft
coupling to give the shaft 20 turns. Recheck bolt torques.
E. When bolt torques are different, repeat steps C) and D).
F. When bolt torques become equal, measure the clearances at
four places (circular equal division) (3-place equal division is
also acceptable) to find the average clearance.
★ Check if the bearing is set properly or if there is any
reason when measurements differ more than 0.15 mm
(0.006 in.). Measure when the bearing is not inclined.
G. A shim increases measured clearances by + 0.35 ~ + 0.4 mm

(0.014 ~ 0.016 in.).
H. Set selected shim (57) in and attach cover (56).
I. Attach cover (55).
10. Attach the oil temperature sensor (28).
Oil temperature sensor: Gasket sealant (LG-5)
Oil temperature sensor: 29.4 ~ 49 Nm (3 ~ 5 kgf m)

{22 ~ 36 lbf ft.}
11. Speed sensor

A. Screw sensor (27) in until it touches the outside surface of gear
(61).
★ Before attaching the sensor, make sure that the gear is at
the most outside of the mounting face.
★ When you screw the sensor in with a wrench, stop
screwing just before the gear then let the sensor touch the
gear by hand.
B. After sensor (27) touched gear (61), give the sensor a half to
one turn in reverse and tighten locknut (62).
★ When tightening the sensor with the locknut, hold the
other nut with a wrench and tighten the locknut.
Sensor threaded portion: Gasket sealant (LG-5)
Sensor locknut: 58.8 ~ 78.4 Nm (6 - 8 kgf m) {43 ~ 58 lbf ft}
50-82 D WA380-5L
12. Valve assembly
A. Attach two pieces of guide bolt 1) to the case.
B. Use eyebolt d and shackle e to lift and install valve assembly
(26).
2 mounting bolts a: 44.1 ~ 53.9 Nm (4.5 ~ 5.5 kgf m)

{33 ~ 40 lbf ft}
8 other bolts: 58.8 ~ 73.5 Nm (6 ~ 7.5 kgf m)

{43 ~ 54 lbf ft}
C. Attach wiring harness assembly (25) and connect sixteen sets

of connector (24).
13. Filter and brake hose
A. Connect brake hose (23).
B. Attach filter (22) and connect hose (21).
14. Transmission mount and level gauge
A. Attach the level gauge (19).

★ Fix the upper and lower holders (20) with a wrench so that
they do not rotate, and tighten the bolts.
Mounting bolt: 12.7 ~ 13.7 Nm (1.3 ~ 1.4 kgf m) {9 ~ 10 lbf ft}
B. Attach left transmission mount (18).
15. Pipes
A. Attach nipple (17) and connect tube (16).
Mounting bolt: 9.8 ~ 12.7 Nm (1.0 ~ 1.3 kgf m) {7 ~ 9 lbf ft}
B. Attach front control valve (15) and connect hose (14).
Mounting bolt: Adhesive (LT-2)
Mounting bolt: 29.4 ~ 39.2 Nm (3 ~ 4 kgf m) {22 ~ 29 lbf ft}
C. Attach block (13), and connect mounting connector (12).
WA380-5L 50-83 D
16. Install emergency steering pump assembly (11).
17. Lift and install pump assembly (8), and tighten two mounting bolts
(9).
18. Transmission, work equipment and PPC pump assembly.
A. Lift and install pump assembly (6), and tighten two mounting
bolts (7).
B. Attach the strainer (10).
50-84 D WA380-5L
C. Connect hoses (4) and (3) and breather hose (5).
D. Connect suction tube (2).
WA380-5L 50-85 D
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
TRANSMISSION CLUTCH PACK
Special Tools
New/Modified
Necessity
Quantity
Sketch
1 790-201-2170 Plate ■ 1
2 790-201-2730 Spacer ■
C2 Press fit bearing
3 796-465-1120 Push tool ■
4 790-201-2740 Spacer ■
1 793-607-1110 Seal holder ■ N

C3 Assembe piston seal
2 793-607-1120 Seal holder ■ N
Oil leak tester

C12 799-301-1500 ■ Check piston operation
kit
Disassembly
WARNING! When loading the clutch pack on the block, ensure that the clutch pack does not slip from your oily
hands.
Be careful that your finger do not get caught between the block and clutch pack.
Forward and Reverse Clutch Packs

Forward Clutch Side
1. Mount bearing race puller 1 on bearing (3) and push the shaft with
a press. Remove the bearing (3).
★ After removing the bearing, the clutch assembly drops.
So catch the clutch assembly with a cushion seat to prevent
damage.
50-86 D WA380-5L
2. Forward gear.
A. Remove spacer (1), thrust washer (4), and forward gear (2).
B. Remove needle bearing (5) from the forward gear.
3. End plate
A. Use C clamp 3 to press end plate (6) and to dismount snap

ring (7).
B. Remove end plate (6).
4. Clutch plate
A. Dismount spring plate (8) from the housing.
B. Remove plate (9), disc (10) and spring (11).
WA380-5L 50-87 D
C. Remove thrust washer (12).
5. Blow air into the forward side oil hole of the shaft and remove
piston (14).
★ If the piston is tilted and will not move, push the piston again.
★ Do not force the piston off. Forcing the piston off will damage
the cylinder’s inside surface.
Reverse Clutch Side
1. Mount bearing race puller 4 on reverse gear (16) and use hydraulic
cylinder 5 to remove bearing (15).
2. Reverse gear
A. Remove spacer (17), thrust washer (18) and reverse gear (16).
B. Remove needle bearing (19) from the reverse gear.
3. Remove the end plate. The operation is similar to removing the end
plate for the other clutch packs.
4. Remove the clutch plate. The operation is similar to removing the

clutch plate for the other clutch packs.
5. Remove the piston. The operation is similar to removing the piston

for the other clutch packs.
1st and 4th Clutch Pack

50-88 D WA380-5L
1st Clutch Side
1. Use puller h to remove the inner race (30) and idler gear (31).
2. 1st gear
A. Remove snap ring (32), thrust washer (33), and 1st gear (34).
B. Remove needle bearing (35) from the 1st gear.
3. End plate
A. Use C clamp i or the like to press end plate (36) and remove
snap ring (37).
WA380-5L 50-89 D
4. Clutch plate
A. Remove plate (38), disc (39) and spring (40) from the housing.
B. Remove thrust washer (41).
5. Blow air into the reverse side oil hole of the shaft and remove the
piston (42).
50-90 D WA380-5L
4th Clutch Side
1. Use puller 9 to remove 4-spool gear (46) and remove bearing (43).
2. 4th gear
A. Remove spacer (44), thrust washer (45) and 4th gear (46).
B. Remove needle bearing (47) from the 4th gear.
3. Remove the end plate. The operation is similar to removing the end
4. Remove the clutch plate. The operation is similar to removing the

5. Remove the piston. The operation is similar to removing the piston

WA380-5L 50-91 D
2nd and 3rd Clutch Pack

3rd Clutch Side
1. Apply puller to 3-spool gear (53) and remove bearing (49) and
4th gear (50).
2. 3rd gear
A. Remove thrust washer (52) and 3rd gear (53).
B. Remove needle bearing (53a) from 3-spool gear (53).
3. End plate
A. Use C clamp 1! or the like to press end plate (54) and remove
snap ring (55).
50-92 D WA380-5L
4. Clutch plate
A. Remove plate (56), disc (57) and spring (58) from the housing.
B. Remove thrust washer (58a).
5. Blow air into the 3rd clutch side oil hole of the shaft and remove
piston (59).
WA380-5L 50-93 D
2nd Clutch
1. Bearing
A. Use forcing screw 1@ to remove output gear (60) and bearing

(60a).
B. Remove output gear (60).
2. 2nd gear
A. Remove thrust washer (62) and 2nd gear (63).
B. Remove needle bearings (64) from 2nd gear (63).
3. Remove the end plate. The procedure is similar to removing the end
4. Remove the clutch plate. The procedure is similar to removing the

5. Remove the piston. The procedure is similar to removing the piston

50-94 D WA380-5L
Assembly
Forward and Reverse Clutch Packs
Reverse Clutch Side
1. Assemble the piston seal (66) into the piston (65).

★ When assembling a new piston seal, use tool C3-1 to expand
the seal so it can be installed.
★ Allow the tool to stretch the seal from two to three minutes so
that it can be installed, without damage.
★ Do not assemble the cylinder without stretching the seal, or the
seal is damaged.
Tool C3-1 inside surface: Transmission oil
2. Reverse side piston
A. Install reverse side piston (65).

★ Ensure that the piston seal will not be damaged.
Piston sliding surface: Transmission oil
B. Install thrust washer (67).
3. Clutch plate
A. Alternately assemble plate (68), disc (69) and spring (70) in

this order.
★ Assemble disc (69) after having immersed it in clean
transmission oil for two minutes or more.
★ Ensure that spring (70) and disc (69) do not overlap.
★ Carefully assemble the plate and spring so they will not
bite into the ring groove of the clutch housing.
WA380-5L 50-95 D
B. Mount spring plate (71)
★ Mount it facing identification mark U upward.
4. End plate
A. Mount end plate (72).
B. Use a C clamp 1# or the like, to press end plate (72).
C. Install snap ring (73).
5. Reverse gear, bearing
A. Assemble needle bearing (19) into reverse gear (16) and install
it, fitting the internal gear of the disc.
B. Install thrust washer (18), spacer (17) and bearing (15) in this
order.
C. Clearance a between spacer (17) and thrust washer (18) is

within the standard value.
Standard value a: 0.3 ~ 0.7 mm (0.011 ~ 0.027 in.).
★ Measure clearance a using dial gauge or clearance gauge.
50-96 D WA380-5L
Forward Clutch Side
1. Forward side piston
A. Stretch the piston seal in the same manner as in the reverse

clutch and assemble the seal into piston (14).
B. Assemble piston (14) in the same manner as the reverse piston.
C. Mount thrust washer (12).
2. Clutch plate
A. Alternately assemble plate (9), disk (10) and spring (11) in this
order.
★ Assemble them in the same manner as the reverse clutch.
B. Mount spring plate (8)

★ Mount the plate with the "U" mark facing sideways.
3. End plate
A. Mount end plate (6).
B. Use C clamp d or the like to press needle plate (6) and install
snap ring (7).
WA380-5L 50-97 D
4. Reverse gear, bearing
A. Assemble needle bearing (5) in forward gear (2) and install it,
fitting the internal gear of the disc.
B. Install thrust washer (4) and spacer (1).
C. Press-fit bearing (3) and check that clearance b between spacer

(1) and thrust washer (4) is within the standard value.
Standard value b: 0.24 ~ 0.76 mm (0.009 ~ 0.030 in.)
★ Measure clearance b using a dial gauge or clearance
gauge.
5. Clutch pack operation test. Use tool C12 to direct the compressed
air into the oil hole of the shaft. Check that each clutch operates.
★ If the gear is secured at the side where air blew in, the clutch
operates normally.
50-98 D WA380-5L
1st and 4th Clutch Pack

4th Clutch Side
1. Piston seal.
Assemble piston seal (76) into piston (75).
it can be installed, without damage.
seal is damaged.
2. 4th piston
A. Install the 4th side piston.

★ Take care not to damage the piston seal.
Contact surface of piston seal: Transmission oil
B. Install the thrust washer (78).
3. Clutch plate
Alternately assemble plate (79), disc (80) and spring (81) in this
order.
★ Carefully assemble plate (79) and spring (81) so they will not
bite into the ring groove of the clutch housing.
4. End plate
A. Install the end plate (82).
B. Use a C clamp 1$ or the like to press on the end plate (82).

Install the snap ring (83).
★ Check that the snap ring (83) is correctly inserted in the
groove.
WA380-5L 50-99 D
5. 4th gear, bearing
A. Assemble the needle bearing (47) in the 4-spool gear (46) and
install it, fitting the internal gear of the disc.
B. Install the thrust washer (45) and spacer (44), then use tools
C2-1 and C2-2 to press-fit bearing (43).
C. Check that the clearance c between spacer (44) and thrust

washer (45) is within the standard value.
Standard value c: 0.28 ~ 0.72 mm (0.011 ~ 0.028 in.).
★ Measure the clearance c using dial gauge or clearance
gauge.
50-100 D WA380-5L
1st Clutch Side
1. 1st side piston
A. Make the piston seal run in the same manner as the 4th clutch
side and assemble piston (42).
B. Assemble the piston (42) in the same manner as the 4th clutch
side piston.
C. Install the thrust washer (41).
2. Clutch plate
Alternately assemble plate (38), disc (39) and spring (40) in the
housing.
★ Assemble them in the same manner as the 4th side.
3. End plate
A. Install the end plate (36).
B. Use a C clamp i or the like to press the end plate (36) on.
Mount the snap ring (37).
4. 1st gear
A. Assemble needle bearing (35) in 1st gear (34).
B. Install the 1st gear, fitting the internal gear of the disc.
WA380-5L 50-101 D
C. Assemble thrust washer (33) and snap ring (32).
5. Idler gear
A. Assemble the idler gear (31) and use tools C2-1 and C2-2 to
press-fit the inner race (30).
B. Check that clearance d between idler gear (31) and thrust

Standard value d: 0.26 ~ 0.74 mm (0.010 ~ 0.029 in.)
★ Measure the clearance d using a dial gauge or clearance
gauge.
50-102 D WA380-5L
6. Clutch pack operation test. Use tool C12 to direct the compressed
air into the oil hole of the shaft. Check that each clutch operates.
★ If the gear at the side where air blew in is secured, the clutch
operates normally.
2nd and 3rd Clutch Pack

2nd Clutch Side
1. Piston seal
Assemble piston seal (86) in the piston (85).
it can be installed, without damage.
seal is damaged.
2. 2nd side piston
A. Mount 2nd side piston (85).

★ Take care so that the piston seal is not damaged.
Piston seal sliding surface: Transmission oil
WA380-5L 50-103 D
3. Clutch plate
Alternately assemble plate (88), disc (89) and spring (90) in this
order.
★ Carefully assemble the plate and spring so they will not bite
into the ring groove of the clutch housing.
4. End plate
A. Install end plate (91).
B. Use a C clamp 1% or the like to press the end plate (91) on.
Install the snap ring (92).
5. 2nd gear
A. Install needle bearings (64) into 2nd gear (63) and install it,
fitting the internal section of the gear.
★ If the internal section of the gear does not fit, install the
needle bearings while turning the disc. Never press on the
bearings or the gear’s inner section forcefully.
50-104 D WA380-5L
6. Idler gear, bearing
A. Install idler gear (60).
B. Use tool C2-3 to press-fit bearing (60a).
C. Check that clearance e between idler gear (60) and thrust

Standard value e: 023 ~ 0.77 mm (0.009 ~ 0.030 in.)
★ Measure clearance e using dial gauge or clearance gauge.
WA380-5L 50-105 D
3rd Clutch Side
1. 3rd side piston
A. Make the piston seal run in the same manner as the 2nd clutch
side and assemble the piston (59).
B. Assemble the piston (59) in the same manner as the 2nd clutch
side piston.
C. Install the thrust washer (58a).
2. Clutch plate
Alternately assemble plate (56), disc (57) and spring (58) in the
housing.
★ Assemble them in the same manner as the 2nd side.
3. End plate
Use a C clamp 1! or the like to press the end plate (54) on. Install
snap ring (55).
4. 3rd gear
A. Assemble the needle bearing (53a) in 3rd gear (53) and install
it, fitting the internal section of the disc.
B. Install the thrust washer (52).
50-106 D WA380-5L
5. 4th gear, bearing
A. Assemble the 4th gear (50).
B. Use tool C2-4 to press-fit bearing (49).
C. Check that clearance f between 4-spool gear (50) and thrust

Standard value f: 0.28 ~ 0.72 mm (0.011 ~ 0.028 in.)
★ Measure clearance f using dial gauge or clearance gauge.
6. Clutch pack operation test.

Use tool C12 to direct compressed air into the oil hole of the shaft.
Check that each clutch operates.
★ If the gear at the side where air blew in is secured, the clutch
operates normally.
WA380-5L 50-107 D
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
PARKING BRAKE
Special Tools
New/Modified
Necessity
Quantity
Sketch
793T-607-1190 Bracket ● 1 ❍
1 722-14-13130 Plate ● 1
01011-62020 Bolt ● 1
793T-607-1130 Push tool ● 1 ❍
3 790-101-5421 Grip ● 1
01010-81240 Bolt ● 1
Disassembly, assembly of
4 793T-607-1140 Spacer ● 1 ❍
H parking brake assembly
5 792T-446-1150 Push tool ● 1 ❍
6 797T-423-1141 Push tool ● 1 ❍
793T-512-1110 Push tool ● 1 N ❍
8 790-101-5421 Grip ● 1
01010-81240 Bolt ● 1
9 793T-607-1160 Spacer ● 1 ❍
10 793T-607-1180 Push tool ● 1 ❍ Press-fit front coupling cover
Disassembly
1. Remove coupling (2).
2. Coupling (front drive)
A. Remove bolt (3), washer (4) and holder (5).
B. Remove coupling (6).
50-108 D WA380-5L
3. Gauge assembly
A. Remove the six mounting bolts and use the forcing screw b to
remove gauge assembly (7) and shim (8).
★ For the shim, check the thickness and number of shims.
B. Remove dust seal (9), oil seal (10) and outer race (11) from
gauge (7).
4. Bearing assembly
A. Remove the bearing assembly (12).
B. Remove the bearing (14) from the boss (13).
5. Loosen mounting bolts (15) evenly and remove cover (16).

★ Because the mounting bolt is pressed with the brake spring,
loosen evenly the total number of mounting bolts.
6. Remove spring (17).
7. Use the eyebolt c to lift and remove the piston (18).
WA380-5L 50-109 D
8. Plate, spring, disc
A. Use tool H1 to remove snap spring (19).
B. Remove hub (20).
C. Remove plate (21), spring (22) and disc (23).

★ Ten plates, nine springs and nine discs.
9. Use eyebolt d to lift and remove brake housing (24).
10. Output shaft assembly
A. Use eyebolt e to lift and remove output shaft assembly (27).
B. Remove gear (28) from output shaft assembly (27).
C. Remove bearing (29).
50-110 D WA380-5L
11. Remove oil guide (30).
12. Outer race, oil seal (rear drive side)
A. Remove outer race (31).
B. Remove dust seal (32).
C. Remove oil seal (33).
Assembly
1. Outer race, oil seal (rear drive side)
A. Use push tool f to install outer race (31) into the transmission
case.
B. Use tool H8 to install the oil seal (33) on the transmission case.
Oil seal press fit surface: Liquid gasket (Three Bond 1110B)
• Lightly cover the inner face of the housing and wipe off
excess.
Oil seal lip surface: Silicone grease (Three Bond 1855)
C. Use tools H8 and H9 to mount dust seal (32).
Clearance portion between oil seal and dust seal: Silicone

grease (Three Bond 1855)
WA380-5L 50-111 D
2. Install the oil guide (30).
3. Output shaft assembly
A. Use tool H6 to install the bearing (29) onto output shaft (34).
★ Coat the bearing with oil seal.
B. Install the gear (28) onto output shaft (34).

★ Face the gear with a long flange to the bearing side.
C. Use the eyebolt e to install the output shaft (27).

★ Ensure that the oil seal will not be damaged.
4. Brake housing
A. Attach the snap ring (25) to the brake housing (24) and install
the plate (26).
50-112 D WA380-5L
B. Install the guide bolt g.
C. Use the eyebolt d to install the brake housing (24) onto the
transmission case.
O-ring: Grease (G2-LI)
5. Install hub (20).
Both ends of the hub: Antifriction composition (LM-G)
★ To accurately measure the rotation torque of only the bearing,

do not install the parking brake disc, oil seal, and dust seal of
the output shaft when assembling.
6. Piston
A. Assemble the O-ring in the piston.
O-ring: Grease (G2-LI)
B. Use the eyebolt to install piston (18).

★ Install the piston aligning counter mark a of the piston
with counter mark b of the housing.
C. Install spring (17).
7. Spring cover
Use eyebolt d to install spring cover (16) aligning it to pilot g.
★ Check that the spring is correctly contained in the cover.
WA380-5L 50-113 D
8. Bearing assembly
A. Use tool H5 to install bearing (14) on boss (13).
B. Install bearing assembly (12).
9. Gauge assembly
A. Use push tool h to install outer race (11) on the gauge.
B. Mount gauge assembly (7).
Mounting bolt: 9.8 ±0.98 {1 ±0.1 kgf m} (87 ±9 lbf in)
★ Do not install the shim.

★ When adjusting the shim after installing the coupling,
permanently tighten the bolts.
A. Mount coupling (6).
B. Attach holder (5) and washer (4) and tighten bolt (3).
Mounting bolt: 490 - 608 Nm {50 - 62 kgf m}
50-114 D WA380-5L
11. Adjusting rotation torque of output shaft with shim.
A. Tighten six cage mounting bolts (40) temporarily without

setting the shim.
Mounting bolt: 9.8 ±0.98 {1 ±0.1 kgf m} (87 ±9 lbf in)
B. Rotate the shaft to the right by 10 turns and to the left by 10

turns, and then check the tightening torque.
C. If the tightening torque has changed, repeat A) and B).
D. When the tightening torque does not change any more, insert
the shim and tighten 6 cage mounting bolts (40) to the specified torque.
Mounting bolt: 98 - 123 {10 0 12.5 kgf m} (72 - 91 lbf ft)
E. Adjust the shim thickness so that the rotation torque of the shaft becomes 0.49 - 0.98 Nm {0.05 - 0.1kgf m}
(4 - 9 lbf in).
F. Make sure that there is no looseness after the shim is adjusted.

★ Perform the above adjustment while parking brake "P.B." is not installed.
★ Perform the above adjustment while the dust seal and oil seal "S" are not installed.
★ Replace O-ring (Part No. 07000 - 15140).
12. Install 2 parking brake release bolts B (M12, L = 45 mm).
13. Remove the assembly of cover K and piston P.

★ Do not remove cage mounting bolts (40).
14. Plate, spring, disc
A. Alternately assemble plate (21), spring (22) and disc (23).

★ Ten plates, nine springs and nine discs.
WA380-5L 50-115 D
B. Use tool H1 to press the plate down and install snap ring (19).
★ Ensure that the spring will not be loaded on the disc.
★ Check that the snap ring is fully seated in the groove.
15. Gauge assembly
A. Use tool H3 to mount oil seal (10) on the gauge.
Oil seal press fit surface: Liquid gasket (Three Bond 1110B)
• Lightly cover the inner face of the housing and wipe off
excess.
Oil seal lip surface: Silicone grease (Three Bond 1855)
B. Use tools H3 and H4 to mount dust seal (9) on the gauge.
Clearance portion between the oil seal and dust seal: Silicone
grease (Three Bond 1855)
A. Mount coupling (6).
B. Attach holder (5) and washer (4), then tighten bolt (3).
Mounting bolt: 490 - 608 Nm {50 - 62 kgf m} (361 - 448 lbf ft)
17. Raise the transmission case assembly and mount coupling (2).
50-116 D WA380-5L
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER (STANDARD)
TORQUE CONVERTER (STANDARD)
Special Tools
New/Modified
Necessity
Quantity
Sketch

B Torque converter disassembly and assembly
790-901-2110 Bracket ● 1
790-901-2150 Plate ● 1
Disassembly
1. With reference to items 1 to 10 in the "Disassembly and Assembly
of Transmission Assembly", remove the torque converter and load
it on the block or install it on tool B.
2. Turbine and case assembly
A. Mount eyebolts on the stator shaft and remove bolt (2a), then
remove stator shaft pump assembly (2) from turbine case
assembly (3).
WA380-5L 50-117 D
B. Disassemble the turbine and case assembly in the following
procedure.
i. Remove the pilot (4).
ii. Remove the snap ring (5) and plate (1).
iii. Press the boss portion of turbine (6) and remove it from
the case (7).
iv. After removing the mounting bolt, disconnect the turbine

(6) and boss (18).
v. Remove bearing (8) from the case.
3. Stator
A. Remove the snap ring (9).
B. Remove the stator (10).
50-118 D WA380-5L
4. Use two bolts b to press it from the side of stator shaft (11) and
remove it from the pump assembly (12).
5. Remove gear (13) from pump (14).
6. Remove bearing (15) from the gear (13).
WA380-5L 50-119 D
Assembly
★ Assemble each component after thoroughly cleaning and checking to be sure there is no dirt and scratches.
★ Check be sure the snap ring is inserted correctly into the groove.
1. Install the bearing (15) onto the gear (13).
Bearing: Engine oil
2. Install the gear (13) onto the pump (14).
Mounting bolt: 58.8 - 73.5 Nm (6.0 - 7.5 kgf m) {43 - 54 lbf ft.}
3. Stator shaft
A. Install the seal ring (16) onto the stator shaft (11).
Seal ring: Grease (G2-LI)
★ Average the overhang of the seal ring.
B. Press the inner race side of the bearing and install the pump
assembly (12) onto shaft (11).
50-120 D WA380-5L
4. Stator
A. Install the stator (10).
B. Install the snap ring (9).
5. Turbine, case assembly
A. Assemble the turbine and the case assembly in the following

procedure.
i. Install the bearing (8) onto the case.

★ Press-fit the ring until it touches the case.
ii. Install turbine (6) on the boss (18).
iii. Press the inner race of the bearing and install turbine (6)
onto the case (7).
WA380-5L 50-121 D
iv. Attach plate (1) and install the snap ring (5).
v. Install the pilot (4).
B. Install the stator shaft pump assembly (2) on turbine case

assembly (3).
50-122 D WA380-5L
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER (LOCK-UP)
TORQUE CONVERTER (LOCK-UP)
Special Tools
New/Modified
Necessity
Quantity
Sketch
1 790-501-5000 Unit repair stand ● 1
B1 2 790-901-2110 Bracket ● 1
Torque converter disassembly and assembly
3 790-901-4240 Plate ● 1 R
B2 793-647-1110 Wrench ● 1 N
Disassembly
1. Execute disassembly procedures 1 - 8 in "Disassembling and Assembling Transmission Assembly".
★ Subsequently, perform work loading the torque assembly on the block (or mount it on tool B1).
2. Stator shaft and pump assembly.
A. Remove pump mounting bolt (1).
B. Mount eyebolt ➁ to hang stator shaft and pump assembly (2)

and dismount it from turbine and case assembly (3).
C. Disassembly of stator shaft and pump assembly
i. Use tool B2 to dismount nut (4).

★ Screw the bolt in the stator shaft and loosen the nut.
Use bar 3 to prevent the stator shaft from turning.
WA380-5L 50-123 D
ii. Use eyebolt 4 to pull out stator shaft (5).
iii. Remove seal ring (6) from stator shaft (5).
iv. Remove mounting bolt (7), gear (10), then remove guide
and bearing assembly (8) from pump (9).
v. Remove bearing (11) from guide (12).
3. Stator assembly
A. Remove stator assembly (13).
B. Disassembly of stator assembly
i. Remove upper and bottom snap rings (14), then remove

race and free wheel assembly (15).
ii. Remove bushings (18) and (19) from race and free wheel
assembly (15), then remove free wheel (20) from race
(21).
50-124 D WA380-5L
4. Disassembly of turbine and case assembly
A. Remove bolt (17a) and pilot (22).
B. Remove snap ring (23) and plate (24).
C. Press the boss portion of turbine (25) and remove it from case
(26).
D. Remove bolt (25a) and disconnect turbine (25) and boss (27).
E. Remove bearing (28) from complete housing (36).
F. Remove complete housing mounting bolt (30).
WA380-5L 50-125 D
G. Fine disassembly of complete housing assembly
i. Remove piston (37) from complete housing (36).
ii. Remove seal ring (38) from piston (37).
iii. Remove seal ring (39) from complete housing (36).
H. Remove disc (40) from drive case (33).
50-126 D WA380-5L
Assembly
★ Assemble each component after thoroughly cleaning and checking to be sure there is no dirt and scratches.
★ Check and be sure the snap ring is inserted correctly into the groove.
1. Complete turbine
Mount turbine (25) on boss (27) and tighten bolt (25a).
Bolt: 58.8 - 73.5 Nm {6.0 - 7.5 kgf m} (21 - 54 lbf ft)
2. Turbine and case

Load complete turbine (31) on block 5 and set drive case (33).
★ Height h of block 5: About 90 mm {3.5 in.}
3. Disc
Mount disc (40).
★ Coat the sliding surface of the disc with engine oil and mount
the disc.
4. Complete housing assembly
A. Assembly of complete housing
i. Mount seal ring (39) on complete housing (36).
External surface of seal ring: Grease (G2-LI)
ii. Mount seal ring (38) on piston (37), then mount it on

complete housing (36).
WA380-5L 50-127 D
★ Because seal ring (38) has the assembly orientation,
assemble it as shown.
B. Use eyebolt 9 to hang complete housing assembly (32) and

load it on drive case (33).
C. Tighten mounting bolt (30).
Mounting bolt: 27.5 - 34.3 Nm {2.8 - 3.5 kgf m} (21 - 25 lbf ft)
5. Bearing
Use push tool to press-fit bearing (28).
★ After having press-fit the bearing, drop engine oil (about 6 cc)
and rotate the bearing ten times.
6. Plate, snap ring

Assemble spacer (24) and mount snap ring (23).
7. Pilot
Mount pilot (22) and tighten bolt (17a).
50-128 D WA380-5L
8. Stator assembly
A. Assembly of stator association
i. Assemble free wheel (20) in race (21) and mount bushings

(18) and (19) using an expansion fit.
★ Coat the sliding surface of the bushing and free wheel
with engine oil.
★ Take care not to damage the sprag of the free wheel.
★ Assembly the free wheel facing arrow mark displayed
on the cage end surface to the turbine side (input side).
ii. Mount snap ring (17) on stator (16).
iii. Attach race free wheel association (15) to stator (16) and
mount snap ring (14).
9. Stator shaft and pump assembly
A. Assembly of stator shaft pump assembly
i. Use push tool [12] to press-fit bearing (11) in guide (12).

★ After having press-fit the bearing, drop the engine oil
(about 6 cc) and rotate the bearing ten times.
ii. Set guide bearing assembly (8) and gear (10) in pump (9)
and tighten mounting bolt (7).
WA380-5L 50-129 D
iii. Mount seal ring (6) on stator shaft (5).
iv. Use push tool [13] to press inner race side of the bearing
and mount pump assembly (9) on stator shaft (5).
v. Use tool B2 to tighten nut (4).

★ Screw the bolt in the stator shaft and tighten the nut.
Use bar [3] so the stator shaft does not turn.
Nut: Adhesive (LT-2)
Nut: 147.1 - 176.5 Nm {15 - 18 kgf m} (109 - 130 lbf ft)
vi. Mount stator assembly (13) rotating it clockwise.

★ Check the direction of stator rotation viewed from the
turbine side (input side).
★ Clockwise direction: Turn with no load
★ Counterclockwise: Lock
★ When the direction of stator rotation differs from the
above description, reverse the race and the free wheel
assembly and rearrange them in the stator, then
recheck the direction of rotation.
B. Use eyebolt [14] to load turbine case assembly (3) on stator

shaft pump assembly (2), then temporarily tighten mounting
bolt (1).
C. Reverse the turbine case and tighten the mounting bolt.
50-130 D WA380-5L
DISASSEMBLY AND ASSEMBLY REAR AXLE
REAR AXLE
Removal
1. Jack up the machine body and put block b under the frame in front
of the rear wheel, then raise the rear of the machine body.
2. Remove the rear axle assembly by lifting tire (1), and sling the tire.
Remove mounting bolts (2).
★ Remove the opposite side in the same procedure.
3. See "Dismounting Fuel Tank Assembly" and remove the fuel tank
assembly.
4. Disconnect lubrication tubes (3) and (4) and remove elbow (5).
5. Loosen the nut (6) and face engine oil drain hose (7) to the rear.
6. Disconnect connector (8) (R56) of the rear brake oil temperature

sensor.
WA380-5L 50-131 D
7. Remove universal joint (9).
8. Disconnect brake hose (10).
9. Rear axle assembly
A. Temporarily lift rear axle assembly (11) and hold support (12)
with transmission jack c. Remove the right and left mounting
bolts (13).
B. Simultaneously drop the crane and the transmission jack c and

remove the rear axle assembly (11).
Rear axle assembly (with a support):

1,050 kg (2, 315 lbs.)
50-132 D WA380-5L
C. Removing the rear support
i. Remove cover (12), holder (13), thrust (14) and spacer

(15) and dismount rear support (16).
Rear support: 140 kg (309 lbs.)
ii. Remove the cover (17) from the rear support. Remove the
dust seal (18) and bushing (19).
D. Remove cover (20) from the front support. Remove the dust
seals (21) and (22) and bushing (23).
Installation
Mounting bolt: 823 - 1,029 Nm (84 - 105 kgf m) {607 - 758 lbf ft.}
Mounting bolt: 98 - 123 Nm (10 - 12.5 kgf m) {72 - 91 lbf ft.}
★ Bleed air from the brake circuit. See Testing and Adjusting "Air Bleeding of Brake Circuit."
Mounting bolt: 1,029 ±98 Nm (105 ±10 kgf m) {758 ±72 lbf ft.}
★ With reference to the item of Testing and Adjusting "Air Bleeding of Brake Circuit", bleed air from the brake circuit.
Busing portion of support: Grease (G2-LI)
WA380-5L 50-133 D
Mounting bolt for cover (12) and holder (13): Adhesive (LT-2).
Mounting bolt for cover (12) and holder (13): 245 - 309 Nm (25 - 31.5 kgf m) {181 - 228 lbf ft.}
★ Install the bushing with the chamfer facing the opposite side of cover (17).
★ Install the dust seal (18) facing the lip outwards.

• (19) is a bushing.
★ Install the dust seal (21) facing the "thick lip" outwards.
• (20) is a cover.
★ Install the dust seal (22) facing the lip outwards.

• (23) is a bushing.
50-134 D WA380-5L
DISASSEMBLY AND ASSEMBLY FRONT AXLE
FRONT AXLE
Removal
1. Push up the machine body by work equipment and put block b under the frame in front of the rear wheel. Raise the rear
of the machine body.
★ Lower the bucket in the dump position to the ground.
2. Remove the rear axle assembly by lifting the tire (1) using a sling
and removing the mounting bolt (2).
3. Remove the cover (3) of the machine body front.
4. Disconnect the brake tube (4).
5. Disconnect the drive shaft (5).
WA380-5L 50-135 D
DISASSEMBLY AND ASSEMBLY FRONT AXLE
6. Remove the front axle assembly by temporarily lifting the front
axle assembly. Remove the four mounting bolts (7) at the left and
right.
Front axle assembly: 930 kg (2,050 lbs.)
Installation
• Perform the installation in reverse order of removal
Mounting bolt: 823 - 1,029 Nm (84 - 105 kgf m) {607 - 758 lbf ft.}
★ Bleed the air from the brake system. See "Air Bleeding of Brake System."
★ When installing the propeller shaft, tighten the bolt after having checked that the key of the standby cap is completely
inserted in the key groove of the mating yoke.
Front axle assembly mounting bolt: 1,029 ±98 Nm (105 ±10 kgf m) {758 ±72 lbf ft.}
50-136 D WA380-5L
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
AXLE HOUSING
Special Tools
New/Modified
Necessity
Quantity
Sketch
793T-522-1140 Push tool ■ 1 N ❍

1 Press fit bearing (wheel side)
793T-522-1150 Spacer ■ 1 N ❍
2 797T-423-1290 Push tool ■ 1 ❍ Press fit bearing (Deff. side)

J
3 793T-522-1160 Push tool ■ 2 N ❍ Press fit oil seal sleeve
793T-522-1171 Seal support ■ 2 N ❍

4 Assemble axle housing
01016-30860 • Bolt ■ 6
Disassembly
★ The subsequent photographs and illustrations are shown using the front axle assembly as an example.
★ The front axle housing and the rear axle housing have the same internal structure except their external appearance shape.
1. Oil drain
Remove plug (1) and drain the oil. (Front, rear)
2. Axle assembly
Place the axle assembly on block b.
★ After removing the one-sided housing assembly, place the axle
assembly on block b so that it will not tilt.
WA380-5L 50-137 D
3. Axle housing assembly
Temporarily lift (hang) axle housing assembly (8) and remove the
housing mounting bolt.
★ When removing the axle housing assembly on both left and
right, place an alignment mark on the housing and differential
case so to not be confused at reassembly.
A. Remove axle housing assembly (8).
B. Change the hanging position of the lifting tool and vertically

raise axle housing assembly (8).
4. Planetary carrier assembly
A. Remove axle shaft mounting bolt (9), then lift and remove
planetary carrier assembly (10).
50-138 D WA380-5L
B. Remove the shim (11).
★ Record thickness of the shim and refer to it at assembly.
5. Use puller c to remove ring gear (12) from housing assembly (13).
★ Assemble spacer d on bolt tip of the puller and adjust height.
★ Take care so that the pawl of the puller will not be removed
from the ring gear.
6. Axle shaft
A. Lift axle housing (14)
B. Punch and pull out the end surface of axle shaft (15) using a
brass hammer or the like.
WA380-5L 50-139 D
7. Axle shaft bearing
WARNING! Do not remove the bearing by applying heat

or dismount it by fusing it.
A. Mount bearing race puller g at the bottom of bearing (16) and

secure it correctly.
B. Tighten the bolt and remove the bearing (16).
C. Remove the sleeve (17a).
8. Remove the bearing outer races (18) and (19) and oil seal (17) from
axle housing (14).
9. Planetary carrier
A. Punch in the spring pin (21) of the planetary carrier (20) so that
it is contained in shaft (22).
★ Be careful not to punch the spring pin in too far.
50-140 D WA380-5L
B. Use the press to pull out the shaft (22).
C. Pull out spring pin (21) from planetary carrier (20).
D. Remove pinion gear (23) and spacer (24) from the planetary
carrier (20).
E. Remove bearing (25) from the pinion gear (23).
WA380-5L 50-141 D
Assembly
1. Axle housing
A. Press-fit the bearing outer races (18) and (19) into the axle
housing (14).
B. Use push tool i to install oil seal (17) on housing (14).
Oil seal lip surface: Grease (G2-LI)
★ Make flange of oil seal adhere to the housing end surface.

★ Clearance between the oil seal flange and housing surface:
Less than 0.2 mm (0.008 in.).
2. Axle housing, shaft
A. Use tool J3 to install oil seal sleeve (17a) on shaft (15).
Sleeve mounting surface: Axle oil or antifriction composition

(LM-P)
★ Check that dimension a from the bearing mounting surface

is 10.1 ± 0.2 mm (0.397 ± 0.008 in.).
B. Use tool J1 to press-fit bearing (16) in axle shaft (15).
50-142 D WA380-5L
C. Raise axle shaft (15) on block h and secure it correctly.
D. Install tool J4 under the oil seal (17a).

★ Adjust oil seal (17a) with tool J4 so that the top of tool J4
will be lightly in contact with oil seal (17a) and clearance
will be even.
E. Sling axle housing (14) horizontally and mount it on the shaft

slowly.
F. Press-fit bearing (26).

★ Produce running in rotating with tool J2 on the housing.
★ Rotate the housing by hand while pressing the bearing in
until the end play reaches 0.1 mm (0.004 in.).
G. Pull out tools J4 horizontally.
Bearing: Axle oil
WA380-5L 50-143 D
3. Selecting shims
A. After bearings (16) and (26) are fitted well, measure turning
force of hole h of axle housing (14).
★ Turning force (static friction): 49.0 - 93.1 N (5 - 9.5 kg)
{11 - 21 lbf} - (Front, Rear).
★ Do not install planetary carrier (20).
★ Include seal resistance.
★ If the turning force is below the standard value, press fit
the bearings again and perform the work in step 1.
★ If the turning force exceeds the standard value, adjust it
according to steps 2 through 4.
B. Hold 2 parts, axle shaft and housing assembly (8) and sling it
by 20-30 mm (.031-.05 in), as you installed the axle housing.
C. Rotate axle shaft (15), hit the flange with a brass hammer in the
direction of the arrow several times to drive out axle shaft (15).
D. Adjust turning force to the standard value according to step A.
E. Install planetary carrier (20) to the spline of axle shaft (15)

without the gear and place spacer (24).
★ Just place spacer (24) on planetary carrier (20). Do not
tighten the bolt.
F. Use a depth micrometer to measure distance H from the end

surface of spacer (24) to the axle shaft end surface.
Assume the value in which thickness t of spacer (24) is
subtracted from H is (H-t) + 0.05.
★ Thickness of shim= (H-t) +0.05
G. Remove planetary carrier (20) and spacer (24) after having

determined the shim.
50-144 D WA380-5L
4. Planetary carrier
A. Install the previously assembled spacer (24) in the planetary

carrier (20).
★ Assemble the spacer from the brake housing side.
B. Assemble bearing (25) in gear (23) and lift spacer (24), then
assemble gear (23).
C. Press-fit the shaft aligning shaft (22) and the spring pin hole
(22a).
Shaft: Oil (axle oil)
★ Align shaft (22) and spring pin hole (21) and punch in the
spring pin (21) so that it is level (j portion) with the carrier
(20).
D. 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
rotates gently.
WA380-5L 50-145 D
5. Ring gear
Press-fit the ring gear (12) into the axle housing (14) and insert the
pin (12a).
★ Assemble the housing by aligning the housing and the pin hole
of the ring gear.
★ Carefully press-fit the ring gear horizontally so that the ring
gear will not be tilted.
6. Planetary carrier assembly
A. Assemble shim (11), which was selected in item 6 of procedure

3 on the axle shaft end surface.
B. Install the planetary carrier assembly (10) and tighten the

mounting bolt (9).
★ Correctly degrease and clean the bolt mounting hole and
mounting bolt of the axle shaft.
WARNING! When assembling the planetary shaft,

be careful so that the finger will not be
caught in the gears.
Mounting bolt: 662 - 829 Nm (67.5 - 84.5 kgf m) {488 - 611 lbf ft}
★ Thoroughly clean and assemble the shaft end surface and the planetary carrier spline portion.
C. After having made the bearing run in fully, check the activa-
tion turning force "X" in drill hole h portion of axle housing
(14).
★ Refer to Step 3.
D. Position stand e of the dial gauge onto axle housing (14) and
measure the planetary carrier end play at the end surface of the
planetary carrier.
★ Reference value.
★ Planetary carrier end play: 0 ~ 0.1 mm (0 ~ 0.004 in.)
50-146 D WA380-5L
7. Axle housing assembly
A. Degrease and clean axle housing (14) and the mounting surface
of differential housing (30) and evenly coat mounting surface
with the liquid gasket.
Housing mating face: Liquid gasket LG-6 (Locktite 515)
B. Horizontally hang the axle hosing assembly (8) and assemble

it, fitting the spline groove and guide bolt f.
★ Do not damage the brake piston surface and plate surface
while assembling the axle housing assembly.
C. Tighten the mounting bolt by mounting it on a diagonal line.
Housing mounting bolt: 490 ~ 680 Nm (9.2 ~ 69.3 kgf m) {361 ~ 502 lbf ft.}
8. Lubrication
A. Tighten the drain plug and lubricate to a specified level from the oil filler port.
Axle oil, front and rear: 38 Liters (10 gal.)
B. Remove the oil level plug and check that the oil is provided near the lower edge of the plug hole.
WA380-5L 50-147 D
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DIFFERENTIAL
Special Tools
New/Modified
Necessity
Quantity
Sketch
790-501-5000 ●
1 or Unit repair stand
790-501-5200 ●
D1 Differential disassembly and assembly
2 790-901-2110 Bracket ●
3 790-901-1331 Plate ●
1 793T-522-1110 Push tool ■ ❍
D2 2 790-101-5421 Grip ■ Press fit oil seal
3 01010-81240 Bolt ■
1 793T-522-1110 Push tool ■ ❍
2 793T-522-1120 Spacer ■ ❍
D3 Press fit dust seal
3 790-101-5421 Grip ■
4 01010-81240 Bolt ■
D4 790-201-2740 Push tool ■

Press fit pinion gear bearing
D5 793T-522-1130 Push tool ■ N ❍
1 790-301-1720 Adapter ■
2 799-101-5002 Hydraulic kit ■

D6 Check for brake oil leakage
3 793-605-1001 Brake tester ■
4 790-101-1102 Hydraulic pump ■
No-load operating torque of

D7 796-751-1510 Wrench ■ 1
limited slip differential
50-148 D WA380-5L
Disassembly
★ The photos and illustrations below show the front differential as an example, excluding the portions described separately.
★ For the front and rear differentials, the internal structures are the same, excluding the appearance.
1. Disconnect brake piping tube (1).
2. Oil temperature sensor (rear differential)
A. Remove the cover (3).
B. Disconnect the connector and remove oil temperature sensor

(5).
3. Remove the axle housing assembly on the left and right referring to
section, "Disassembling Axle Housing Assembly."
4. Put the differential assembly (7) on the block b to make it stable.

(Otherwise, attach to tool D1.)
★ When using tool D1, remove the cage assembly according to
step 7.
6. Brake
A. Remove the shaft (9).
B. Remove the bolt (10) and also remove the outer plate (11).
C. Remove the disk (12), spring (13), and plate (14).

★ Mark the parts so the left and right are not mixed up.
WA380-5L 50-149 D
D. Blow air into brake tube joint unit (15) and remove piston (16).
7. Cage assembly
A. Lift the differential case and turn up the cage assembly.
B. Remove the bolt (17) and also remove the coupling (19) with
the protector (18).
★ Do not remove the protector from the coupling unless
required.
C. Attach the lift bolt c and temporarily lift the cage assembly
(20).
★ Mark index symbols on the cage and differential case so
that they match at assembly.
D. Remove the bolt (21).
E. Screw the pull-up bolt and pull up the case assembly until the
O-ring appears.
F. Lift the cage assembly and remove it.
G. Remove the shim (22).

★ Record the number of shims to refer to at assembly.
50-150 D WA380-5L
8. Bearing carrier
A. Temporarily lift the differential carrier assembly (23).
B. Remove all the bearing carrier attachment bolts, and attach the
guide bolt d.
C. Screw the pull-up bolt 4, and remove the bearing carrier (24).
★ Identify so that the bearing carriers on the left and right are
not mixed.
★ Confirm the shim thickness and number of shims to refer
to during assembly.
9. Differential carrier assembly
A. Remove differential carrier assembly (23) from the differential

case (25).
★ Take care not to remove the lift tool.
B. Remove the gear cover (26) from the differential case.
WA380-5L 50-151 D
10. Detailed disassembly of differential carrier assembly (standard
spec.)
★ Identify so that the parts on the left and right are not mixed.
A. Remove plane half cover (28) together with bearing (27).

★ Mark index symbols on the plane half cover (28) and
bevel gear case flange half (29).
B. Remove bearing (27) from the plane half (28).
C. Remove thrust washer (30) from the bevel gear flange half
assembly (29), also remove side gear (34).
D. Remove the pinion gear (35), spider shaft (36), and spherical
bushing (37) together.
50-152 D WA380-5L
E. Remove the spherical washer (37) and pinion gear (35) from
the detached spider shaft (36).
F. Remove the side gear (34) and thrust washer (30).
G. Reverse the bevel gear flange half assembly (29) and remove
the bolt. Then detach the bevel gear (43) and bearing (27).
11. Disassembly of differential carrier assembly (Limited slip

differential specification)
★ Identify right and left parts to avoid confusion.
A. Remove cover (58).

★ Put mating marks on cover (58) and case (59) for reference
purposes when reassembling.
WA380-5L 50-153 D
★ When removing cover (58), it is detached with the washer
(60) fitted in a groove at the back.
B. Remove two plates (61) and two disks (62).
C. Remove pressure ring (63) and side gear (64).
D. Remove pinion gear (65) and spider shaft (66).
50-154 D WA380-5L
E. Remove side gear (67) and pressure ring (68).
F. Remove two disks (69) and two plates (70).
G. Remove washer (71).
H. Reverse case (59) and remove bolt (72) to detach bevel gear
(73).
I. Using push tool [8], remove outer race (75) from inside of case
(59).
WA380-5L 50-155 D
J. Using puller [9], remove bearing (76) from bearing carrier
(24).
12. Pinion gear and cage
A. Use the press to pull out pinion gear (45) from cage (44).
B. Remove dust seal (49), oil seal (50), spacer (42), bearing (46),
and outer races (47), (48) from the cage (44).
★ The spacer is attached only to the front.
C. Remove the spacer (51) and bearing inner race (52) from the
pinion gear (45).
50-156 D WA380-5L
Assembly
1. Pinion gear and cage
A. Attach the bearing outer races (47) and (48) to cage (44).
B. Use tool D5 to press the bearing inner race (52) into pinion
gear (45).
C. Attach spacer (51).
D. Stand pinion gear (45) and attach cage (44).
E. Use tool D4 to press bearing (46) into the pinion gear while
turning cage (44).
★ Coat accelerator oil on the bearing inner race.
WA380-5L 50-157 D
F. Use the push-pull gauge 5 to turn cage (44) and measure the
activation rotation power.
★ Activation rotation power: 58.8 N {6 kg} (13 lbf) or less
★ When activation rotation power exceeds the reference
value or the cage does not rotate by hand (rotates
heavily), replace the bearing and spacer. Then confirm
the activation rotation power again.
G. Assemble spacer (42).

★ The spacer is attached only to the front.
H. Use tool D2 to press oil seal (50) in cage (44).

★ Confirm that dimension C is 10 ± 0.5 mm.
(0.394 ± 0.019 in.).
Oil seal lip unit: Grease (G2-LI)
I. Use tool D3 to press dust seal (49) in cage (44) until its end
surface becomes equal to the one of the cage.
Dust seal lip unit: Grease (G2-LI)
2. Coupling
Attach coupling (19), O-ring (19a), and holder (17a) to the pinion
gear (45). Fasten the attachment bolt (17).
★ In this case, temporarily fasten the attachment bolt (17). After
coupling is assembled in the differential case, securely fasten
the bolt.
★ Take care not to damage the seal at insertion of coupling (19).
Attachment bolt: Adhesive (LT-2) (At actual fastening)
Attachment bolt: 490 - 608 Nm (50 - 62 kgf m)

{361 - 448 lbf ft.} (At actual fastening)
50-158 D WA380-5L
3. Detailed assembly of differential carrier assembly (standard spec.)
★ Assemble parts on the left and right according to identification
determined at disassembly.
A. Press bearing outer race (24a) into bearing carriers (24) on the
left and right until it reaches the carriers.
B. Press bearing (27) in flange half (29).
C. Press bearing (27) in plane half (28).
D. Put bevel gear (43) on block g, turning down the gear side.
E. Attach guide bolt h to bevel gear (43).
F. Lift flange half (29), attach it to bevel gear (43), and fasten the
bevel gear attachment bolt (42).
Attachment bolt: Adhesive (LT-2)
Attachment bolt:
157 - 196 Nm (16 - 20 kgf m) {116 - 145 lbf ft.}
WA380-5L 50-159 D
G. Attach the thrust washer (30) and side gear (34).
H. Attach pinion gear (35) and spherical washer (37) to the spider
shaft (36).
I. Attach the spider shaft (36), pinion gear (35), and spherical
washers (37).
J. Assemble the side gear (34) in the bevel gear flange half
assembly (29).
K. Grease the thrust washer (30) and adhere the thrust washer (30)
matching the dowel pin of the plane half (28), so that it does
not drop at assembly.
★ Take care of the front and back at assembly of the thrust
washer.
★ Take care not to overgrease.
Thrust washer: Grease (G2-LI)
50-160 D WA380-5L
L. Attach the plane half (28) to flange half (29).
★ At attachment, match the index marks made during
disassembly.
Attachment bolt:
157 ~ 196 Nm (16 - 20 kgf m) {116 ~ 145 lbf ft.}
4. Assembly of differential carrier assembly (Limited slip differential

specification)
★ Assemble right and left parts according to identifications made
at the time of disassembly.
A. Press bearing outer race (24b) until it comes into contact with
the right and left bearing carriers (24) using push tool [10].
B. Press fit outer race (75) to case (59).
C. Press fit cover (58) similarly.
D. Place the bevel gear (73) on the block [6] with the gear side
down.
E. Install guide bolt [7] to bevel gear (73).
F. Lower the case (59) and install it in the bevel gear (73) and
tighten the bevel gear mounting bolts.
Mounting bolt: 157-196 Nm {16 - 20 kgf m} (116 - 145 lbf-ft)
WA380-5L 50-161 D
G. Reverse the case (59) and install the washer (71), and disk (69)
in this order.
★ When installing the disk, set cuts a and b accurately.

★ Part No. of disc (t: 3 mm only)
(Part No. 423-22-37410)
Plate and disk: Axle oil
H. Install pressure ring (68) and side gear (67).
I. Install pinion gear (65) and spider shaft (66).
50-162 D WA380-5L
J. Install side gear (64) and pressure ring (63).
K. Install disk (62) and plate (61) in this order.
★ When installing the disk, set cuts a and b accurately.

★ Part. No. of disc (t: 3 mm only)
(Part No. 423-22-37410)
Plate and disk: Axle oil
L. Adjust the clearance between the case and plate.
i. Using depth gauge [11], measure distance d from the end

face of case (59) to the end face of plate (61).
• Distance d: 0.2 - 0.6 mm (0.008 - 0.024 in.)
ii. If distance d is out of the standard range, replace the plate

with the one with proper thickness so that distance d will
be in the standard range.
★ Replace the plates on both right and left sides so that
the total thickness of the 2 plates on each side will be
the same, and then perform the above procedure from
step 7).
• Thicknesses of plates (Rear)
: 3.0 mm (Part No. 424-22-27450)
: 3.1 mm (Part No. 424-22-27460)
WA380-5L 50-163 D
M. Install the washer (60) on the cover (58).
★ Coat the washer with thin coat of grease and stick it to the
cover.
N. Install cover (58) on case (59).

★ Install them by aligning the mating marks put when
disassembling.
Mounting bolt: 98 - 123 Nm {10 - 12.5 kgf m} (72 - 91 lbf-ft)
O. Adjust the axial clearance of the side gear.
i. Using feeler gauges, measure clearance e between the side

gear and washer through the shaft holes on the right and
left sides of the anti-slip differential.
• Clearance e:
: 0.15-.35 mm (.006-.014 in) [Both front and rear]
ii. If clearance e is out of the standard range, replace the

washer with the one with proper thickness so that the
clearance will be in the standard range.
★ When replacing the washer, perform above procedure
from step 7).
• Thickness of washer (Both front and rear)
: 2.0 mm (08 in) [Part No. 423-22-27370]
: 2.1 mm (.08 in) [Part No. 423-22-27380]
50-164 D WA380-5L
P. Measure the differential torque while no load is applied.
i. Install and fix sun gear shaft (81) to either side of the dif-
ferential carrier assembly.
ii. Install wrench D7 to the side gear on the opposite side

with the M6 bolt.
iii. Install torque wrench [12] and measure the rotation torque.
★ When measuring, let the case turn freely.
• Rotation torque (Both front and rear)
Max. 10 Nm (7 lbf-ft) {Max. 1.0 kgm}
iv. If rotation torque exceeds the above value, disassemble

differential carrier again and perform steps 12) and 15).
5. Attach the gear cover (26) to the differential case.
6. Adjustment of bearing carrier shim
A. Lift the differential carrier assembly (23) and set it to the

differential case (25) and attachment unit.
B. Attach O-ring (24a) and seal (25b) to the bearing carriers (24)
on the left and right.
WA380-5L 50-165 D
C. Attach the guide bolt d in the bearing carrier attachment holes
on the left and right of the differential case.
D. Attach the removed shim (22) to the bearing carriers (24) on

the left and right, then fasten the bearing carrier attachment
bolt (24c).
★ Fasten the bevel gear while turning it.
Bearing: Axle oil
Mounting bolt: 157 - 196 Nm (16 - 20 kgf m) {116 - 145 lbf

ft.}
E. Use the push-pull gauge f to measure the preload of the bevel

gear.
★ Activational rotation power: 13.7 - 37.3 N (1.4 - 3.8 kg.)
{3 - 8 lbf}
★ When the activation rotation power is outside the
reference value, adjust the shim thickness.
7. Cage assembly
A. Insert the O-ring (20a) in the groove of the cage assembly (20).
O-ring: Oil (Axle oil)
★ Coat with oil lightly.
50-166 D WA380-5L
B. Attach the guide bolt G to the differential carrier assembly (7),
assemble the removed shim (22), and mount the cage assembly
(20).
★ At assembly, turn the thinner side of the shim to the cage.
Attachment bolt:
245 - 309 Nm (24.9 - 31.5 kgf m) {181 - 228 lbf ft.}
C. Securely fasten the coupling attachment bolt temporarily

tightened in step 2.
Attachment bolt: Adhesive (LT-2)
Attachment bolt: 490 - 608 Nm (50 - 62 kgf m) {361 - 448 lbf ft.}
8. Backlash adjustment
A. Use a dial gauge h to measure the bevel gear backlash.

★ Backlash: 0.25 ~ 0.33 mm (0.009 ~ 0.012 in.)
★ Measure backlash at three spots around the circumference
of the bevel gear. Tolerance is 0.1 mm (0.004 in.).
B. To obtain the backlash in the reference value, move a part of

the shim of the bevel gear to the reverse side.
★ At movement of the shim, do not change the total
thickness of the left and right.
★ When the backlash is too high, move a part of shim b to
shim a.
★ When the backlash is too low, move a part of shim a to
shim b.
WA380-5L 50-167 D
9. Tooth contact inspection
Knead the Komeitan with the spindle oil and coat it on 7 ~ 8 teeth of the bevel gear. While holding down the bevel gear by
hand and braking, turn the pinion gear forward and backward, and inspect the tooth contact.
Follow the procedure to adjust the tooth contact state.
Tooth Contact Cause Adjustment

Correct contact To adjust the pinion gear, increase or decrease the gauge
Remain the tow side about 5 mm(0.2 in.) and shim.
confirm that all teeth to the heel side come into To adjust the bevel gear, follow the same procedure as of the
contact 50%, centering the pitch line. backlash.
DEW00910
The bevel pinion gear is too far the gear. Decrease the shim from the pinion gear and approach to the
bevel gear.
Separate the bevel gear from the pinion gear and correctly
adjust the backlash.
DEW00904
DEW00908
The bevel pinion gear is too near the gear. Increase the shim of the pinion gear and separate it from the
bevel gear.
Approach the bevel gear to the pinion gear and correctly
DEW00905
The bevel gear is too near the pinion gear. Decrease the shim of the pinion gear and approach it to the
bevel gear.
Separate the bevel gear from the pinion gear and correctly
DEW00906
DEW00908
The bevel gear is too far from the pinion gear. Increase the shim of the pinion gear and separate it from the
bevel gear.
Approach the bevel gear to the pinion gear and correctly
DEW00907
★ When adjusting the bevel gear in-out state, do not change the total thickness of the left and right by moving the shim.
50-168 D WA380-5L
10. Brake
A. Assemble the seal in the piston (16) and attach it to the differ-
ential carrier assembly.
★ (15) is the brake tube joint unit.
B. Attach the disk (12), spring (13), and plate (14) in sequence.
★ Put a spring on another, matching their notched parts, and

attach the springs together so that the notched parts are in
the range marked by ★ below. (A indicates the brake oil
port.)
C. Attach the outer plate (11) and shaft (9), then fasten the bolt
(10).
WA380-5L 50-169 D
D. Blow compressed air into brake oil port A and adjust the piston
operation.
11. Attach cover (8) to the differential case (7).
Cover attachment side: Liquefied gasket (Lock tight 515)
Mounting bolt: 157 ~ 196 Nm {116 ~ 145 lbf ft.}
12. Attach the accelerator housing assembly on the left and right. See
"Assembly of Accelerator Housing Assembly."
13. Brake oil leakage inspection
A. Attach tools D6-1 and D6-2 to the brake tube attachment port
(A) of the differential case (7), then bleed the attachment cylin-
der.
B. Use tool D6-4 to increase the pressure to 14 kg/cm2 (199 psi).

★ Leave the unit with 14 kg/cm2 (199 psi) for five minutes.
Confirm that pressure lowers to 3.5 kg/cm2 (50 psi).
C. If no oil leakage is found using the method above, increase the

pressure to 50 kg/cm2 (711 psi).
★ Leave the unit with 50 kg/cm2 (711 psi) for five minutes.
Confirm that pressure lowers to 1 kg/cm2 (14 psi).
★ If there is no oil leakage, remove the brake piston and
check the O-ring and seal for damage before assembling
them.
50-170 D WA380-5L
14. Oil temperature sensor (rear differential)
A. Attach oil temperature sensor (5) and connect the connector.
Oil temperature sensor screw unit: Liquified gasket (LG-5)
Oil temperature sensor: 29.4 - 49.0 Nm (3 - 5 kgf m) {22 - 36 lbf ft.}
B. Attach the cover (3).
15. Attach brake tube (1).
16. Fasten the drain plug. Pour in the specified amount of oil.
Axle oil: 38 liters (10 gal.)
WA380-5L 50-171 D
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
CENTER HINGE PIN
Special Tools
New/Modified
Necessity
Quantity
Sketch
1 790-101-2300 Push puller ■ 1
2 793-520-2370 Push tool ■ 1
3 793-520-2350 Push tool ■ 1
E1 4 793-520-2540 Guide ■ 1 Center hinge pin removal and installation
5 793-520-2360 Bar ■ 2
6 790-101-1102 Hydraulic pump ■ 1
7 790-101-2102 Puller (30 tons) ■ 1
Removal
WARNING! Park the machine on a horizontal plane and put the bucket on the ground.
WARNING! Disconnect the battery negative (—) terminal.
1. Remove the work equipment assembly, referring to section "Removal and Installation of Work Equipment Assembly."
2. Remove the cab and floor frame assembly. See "Removal and Installation of Cab and Floor Frame Assembly."
3. Steering cylinder pin and bracket
A. Remove the bolt (4) and detach the rod pins (3) of the steering
cylinders on the left and right.
B. Disconnect the steering rod (4) and remove the bracket.
50-172 D WA380-5L
4. Center drive shaft
Remove four bolts (5a), and disconnect the center drive shaft (5).
5. Disconnect harness connectors (15), (FF1), (16), (FF2), and ground

(17).
★ For the machine with a load meter, also disconnect (FL3.)
6. Hydraulic piping
★ Tag the detached hose so that it can be identified.
A. Detach PPC hoses (6, 7, 8 and 9).
B. Detach hoses (10, 11, 12, 13 and 14) in the front frame side.
WA380-5L 50-173 D
C. Detach work equipment valve drain hose (14a) and front brake
hose (14b).
7. Frame support
A. Jack up the rear frame (17a). While adjusting the height, insert
blocks b on the left and right of the rear frame.
B. Jack up the front frame (17b). While adjusting the height,

insert the blocks c on the left and right of the rear frame.
C. Insert rollers d between blocks c and frame so that the front

frame can be pulled out.
8. Remove lock bolt (18) and detach the lower hinge pin (18a).
50-174 D WA380-5L
9. Upper hinge pin
A. Remove mounting bolts and retainer (19).

★ Confirm the number of shims inserted between the retainer
and frame, and their thickness.
B. Remove lock bolt (20). While adjusting the height, pull out
upper hinge pin (21).
★ Carefully adjust the height so that the pin can be pulled out
by hand.
C. Remove spacer (22).
10. Carefully pull the front frame (17b) forward and detach it from the
rear frame (17a).
★ Confirm whether the front frame is completely detached from
the rear frame.
★ Remove the frame lock bar.
★ Take care that the lower spacer of the upper hinge does not
engage with the rear frame.
★ Take care of the balance at detachment.
11. Lower hinge
A. Pull out bushing (23) from the rear frame.

★ Remove the upper and lower bushings of the lower hinge
together.
WA380-5L 50-175 D
B. Remove the retainer (24) from the front frame.
C. Remove the dust seal (25) from the retainer.

★ Also remove the dust seal from the frame.
D. Remove the bearing (26).
12. Upper hinge
A. Remove the attachment bolt and detach the retainer (27).

50-176 D WA380-5L
B. Remove the dust seal (28) from the retainer.
C. Remove the spacer (29) and dust seal (30) from the front
frame.
D. Remove the bearing (31).
WA380-5L 50-177 D
Installation
• Perform installation in reverse order for removal.
1. Upper hinge
A. Attach tool E1-1 to the top of the upper hinge of the front
frame (17b) and set the bearing (31) onto tool E1-4. Then
install the hinge from the upper side and press it.
★ At pressing, use tool E1-4 as a guide.
★ Take care that the bearing does not tilt.
★ Sufficiently grease the bearing.
★ The bearing is clearance-adjusted. Bearing (31) must be
replaced together with spacers (22) and (29).
B. Press the dust seal (28) in the retainer (27).

★ At pressing, turn the dust seal lip outside.
Seal lip: Grease (G2-LI)
C. Fasten the retainer (27) equally with three mounting bolts and
select a shim so that the maximum clearance at "a" (between
the retainer and hinge) is 0.1 mm (0.004 in.) or less. Assemble
the retainer.
Mounting bolt: 19.6 ±2.0 Nm (2.0 ±0.2 kgf m) {14 ±2 lbf ft.}
(At adjustment of shim)
D. After adjusting the shim, fasten all the retainer mounting bolts
with the specified torque.
Mounting bolt: Adhesive (Lock tight 2701)
50-178 D WA380-5L
E. Assemble the dust seal (30) and spacer (29) from the lower
side of the front frame.
★ At pressing, turn the dust seal lip outside.
★ Assemble the spacer (29) from the lower side so that the
larger chamfered side faces the bearing side.
2. Lower hinge
A. Use tool E1 to press the bearing (26) in the front frame (17b).
★ At pressing, use tool E1-4 as a guide.
★ Take care that the bearing does not tilt.
★ Sufficiently grease the bearing.
B. Press the dust seal (25) in the retainer (24).

★ At pressing, turn the dust seal lip outside
C. Fasten the retainer (24) equally with three mounting bolts and
select a shim so that the maximum clearance at b (between the
retainer and hinge) is 0.1 mm (0.004 in.) or less. Assemble the
retainer.
Mounting bolt: 19.6 ±2.0 Nm (2.0 ±0.2 kgf m) {14 ±2 lbf ft.}
WA380-5L 50-179 D
D. After adjusting the shim, fasten all the retainer mounting bolts
with the specified torque.
Mounting bolt: Adhesive (Lock tight 2701)
Press the dust seal (25) from the upper side of the front frame.
★ At pressing, face the dust seal lip outside.
E. Using puller E, press bushing (23) into the lower hinge of the
rear frame
3. Frame coupling
WARNING! Use a bar to match the pin holes.

Absolutely do not insert fingers.
★ Be sure to match the pin holes.
A. Insert upper hinge pin (21) and assemble the spacer (22).
Hinge pin circumference: Grease (G2-LI)
50-180 D WA380-5L
B. Attach retainer (19) to the upper hinge pin (21) and fasten it
equally with three bolts. Select a shim so that clearance c
(between the hinge and retainer) is 0.2 mm (0.008 in.) or less.
Assemble the retainer.
★ After adjusting the shim, temporarily fasten the retainer
mounting bolt so that it does not turn.
Pin mounting bolt: 205.9 ± 19.6 Nm (21 ± 2 kgf m)
{152 ± 15 lbf ft.} (At adjustment of shim)
C. Fasten all the pins and retainer mounting bolts with the
specified torque.
Pin mounting bolt:
205.9 ± 19.6 Nm (21 ± 2 kgf m) {152 ± 15 lbf ft.}
Retainer mounting bolt:

98 - 123 Nm (10 - 12.5 kgf m) {72 - 91 lbf ft.}
Pin and retainer mounting bolt: Adhesive (Lock tight 2701)
D. Insert the lower hinge pin (18a) and fasten the lock bolt (18).
WA380-5L 50-181 D
DISASSEMBLY AND ASSEMBLY CAB ASSEMBLY
CAB ASSEMBLY
Removal
WARNING! Park the machine on a horizontal plane. Set the safety bar in the frame, and ground the work equipment.
Stop the engine, apply the parking brake, and put the blocks under the wheels.
1. Disconnect the negative (-) terminal of the battery.
2. Remove the left and right covers under the cab assembly.
3. Remove the left ladder and fender assembly and right fender and step assembly, referring to items 5 and 6 in section
"Removal of Cab and Floor Frame Assembly."
4. Remove covers (1) and (2).

★ Slightly pull out the cover (2) toward you, then disconnect the
connector of the cigarette lighter (3).
5. Wiring connectors
A. Disconnect 11 pairs of connectors (4) in front of the cab.

★ Connector numbers: SO1, SO2, SO3, SO7, CL6, CL7,
CL8, CL9, CL10, LO7, and LO8.
B. Disconnect connectors (5), (6), and (7) in the right front.

★ Connector numbers: CL1, CL2, and CL5.
6. Detach the window washer hoses (8) and (9).
50-182 D WA380-5L
DISASSEMBLY AND ASSEMBLY CAB ASSEMBLY
8. Disconnect the connectors (11), (12), and (13).
9. Cab assembly
A. Temporarily lift the cab assembly and remove the attachment

bolts: (14) three for each on the left and right, (15) one for each
on the left and right, and (16) two for each on the left and right.
B. Remove the mounting bolts (17) one for each on the left and
right, in the lower front of the cab.
★ Width across flats for only this bolt: 19 mm (0.75 in.)
C. Lift the cab assembly (18) and remove it.
Cab assembly: 690 kg (1,521 lbs.)
Installation
• Perform installation in reverse order of removal.
Mounting bolt: 471 ~ 530 Nm {347 ~ 391 lbf ft.}
Mounting bolt: 98 ~ 123 Nm (10 - 12.5 kgf m) {72 ~ 91 lbf ft.}
WA380-5L 50-183 D
DISASSEMBLY AND ASSEMBLY CAB AND FLOOR FRAME
CAB AND FLOOR FRAME
Removal
WARNING! Park the machine on a horizontal plane.

Set the safety bar in the frame, and ground the work equipment.
Stop the engine, apply the parking brake, and put blocks under the wheels.
WARNING! Collect the air conditioner refrigerant (R134a).
1. Disconnect the negative (—) terminal of the battery.
4. Remove the left and right covers under the cab assembly.
5. Left ladder and fender assembly
A. Remove the stay (1).
B. Disconnect two hoses (2) of the washer tank, motor connector

(3), R43 and R45, and then detach the clamp (4).
C. Temporarily lift the left ladder and fender assembly (5), and
remove the attachment bolts.
Left ladder and fender assembly: 86 kg (190 lbs.)
6. Temporarily lift the right fender assembly step (6), and remove the
attachment bolts.
Right ladder and fender assembly: 50 kg (110 lbs.)
50-184 D WA380-5L
7. Disconnect 11 pairs of wiring connectors (7).
★ Connector numbers: LT1, FL1, FL2, FL3, LR1, LR4,
LR5, LR6, LR8, LR9, and LR10.
8. Detach the steering rod (8).
9. Detach the accelerator cable (9) from the injection pump and
remove the clamp of the torque converter case.
10. Detach the ground harness (10) and heater hoses (11) and
(12).
11. Detach the PPC valve inlet hose (13) and return hose (14).
★ Remove the clamp on the brake accumulator and pull up
hose (13) above the floor frame.
WA380-5L 50-185 D
12. Brake valve hose.
A. Detach the left brake valve inlet hose (15).
B. Detach the brake valve outlet hose rear brake (16) and front
brake (17).
C. Detach the right brake valve inlet hose rear brake (18) and
front brake (19).
D. Detach the brake valve return hose right brake (20) and left
brake (21).
13. Detach PPC hoses (22), (23), (24), (25), and remove the clamp of
the hoses.
★ Mark index symbols on each hose before detaching.
14. Cab and floor frame assembly
A. Remove the left and right mounting bolt and covers (26) in
front of the floor frame.
B. Remove the lock bolt (27) and remove the lock plate (28).
Detach the mounting bolt nuts (29) on the left and right.
C. Lift the cab and floor frame assembly and remove it.
★ Pull up the PPC hose and accelerator cable and remove the
assembly.
Cab and floor frame assembly: 1,290 kg (2,844 lbs.)
50-186 D WA380-5L
Installation
★ Adjust the engine rotation speed, referring to the section "Adjustment of Accelerator Pedal" in "Testing and Adjust-
ing."
★ Bleed the brake circuit, referring to the section "Bleeding of Brake Circuit" in "Testing and Adjusting."
Mounting bolt nut: 1,175 ~ 1,470 Nm (119.8 ~ 149.9 kgf m) {867 ~ 1,084 lbf ft.}
WA380-5L 50-187 D
DISASSEMBLY AND ASSEMBLY OPERATOR'S CAB GLASS (SEALED
OPERATOR'S CAB GLASS (SEALED GLASS)
Special Tools
New/Modified
Necessity
Quantity
Sketch
2-1 793-498-1120 Clear plate ■ 2
2-2 793-498-1130 Plate ■ 2

X 2-3 793-498-1110 Magnet ■ 2 Install operator cab glass
Lifter (Suction
3 793-498-1210 ■ 2
cups)
Removal
★ All sides of each glass of the operator's cab of this vehicle are sealed.
★ Remove the window glass to be replaced according to the following procedure.
1. Using seal cutter [1], cut the adhesive between broken window
glass (1) and operator's cab (2).
★ If the glass is narrow, you may cut the adhesive by the

following method.
• Insert a fine wire [2] (piano wire, etc.) in the adhesive and
grip its both ends with plyers [3], etc. (or hold them by
winding them onto something) and cut the adhesive with
the wire.
50-188 D WA380-5L
★ The broken window glass may be removed with knife [4] and a
screwdriver. (If the screwdriver is applied directly to normal
window glass, the glass will brake.)
★ When using knife [4], insert a screwdriver in the cut to widen it
and move the knife forward.
2. Remove the window glass.
WA380-5L 50-189 D
Installation
1. Using scraper [5], remove the remaining adhesive.
★ Do not scratch the paint.
2. Remove oil, dust, dirt, etc. from the sticking surfaces of cab (2) and
window glass (3) with white gasoline.
★ If the sticking surfaces are not cleaned well, the glass may not
be sealed perfectly.
★ Clean the all black part on the back side of the window glass.
★ After cleaning the sticking surfaces, leave them for at least 5
minutes to dry.
3. When the adhesive was removed with the scraper, if any paint was
flaked off, coat the bare part with paint.
★ If the glass is installed without repairing the bare part, that part
will be rusted.
★ Do not apply paint to a part which will be coated with primer.
4. Stick both-sided adhesive tape (4) along the inside edge of the glass
sticking section.
★ Size of both-sided adhesive tape: 7 x 4.8mm
★ When sticking the both-sided adhesive tape, do not touch the
cleaned surface as long as possible.
★ Do not remove the release tape of the both-sided adhesive tape
on the glass sticking side before sticking the glass.
50-190 D WA380-5L
★ Take care the corner (part "b") of both-sided adhesive
tape (4) will not float.
★ When sticking two-sided adhesive tape around a side or a rear

window glass, start at center of the top and make a clearance of
about 5 mm at end joint (c).
5. Position the replacement glass.
A. Stick X2-2 (thin steel sheet) to tool X2-1 (spacer) with adhe-
sive.
• Spacer thickness (t): 5 mm
B. Match tool X2-3 (magnet) to tools X2-1 and X2-2 and set them
to the 2 lower places of the window glass sticking part of oper-
ator's cab (2).
WA380-5L 50-191 D
C. Using tool X3 (suction cups), place window glass (3) on tool
X2-1 (5 mm spacer) and match it to the operator's cab.
D. Check the clearance between window glass (3) and operator's

cab (2) on both sides and adjust it evenly.
E. Stick tape [6] between window glass (3) and operator's cab (2)
and draw positioning line (a).
F. Cut the tape between the window glass (3) and operator's cab
(2) with a knife, and then remove the window glass.
★ Do not remove the tape left on the window glass and
operator's cab before installing the window glass.
6. Apply primer.
★ The using limit of primer (5) is 4 months after the date of manufacture. Do not use primer (5) after this limit.
★ Use the primer within 2 hours after unpacking it.
★ Even if the primer is packed again just after it is unpacked, use it within 24 hours after it is unpacked for the first time.
(Discard the primer 24 hours after it is unpacked.)
A. Stir the primers for paint and glass sufficiently before using them.
★ If the primer has been stored in a refrigerator, leave it at the room temperature for at least half a day before stir-
ring it.
(If the primer is unpacked just after taken out of the refrigerator, water will be condensed. Accordingly, leave the
primer at the room temperature for a sufficient time.)
B. When reusing primer brush (6), wash it in white gasoline.

★ After washing the brush, check it again for dirt and foreign
matter.
★ Prepare respective brushes for the paint primer glass
primer.
50-192 D WA380-5L
C. Evenly apply paint primer (7) to the parts on the outside of
both-sided adhesive tape on operator's cab (2) which will be
coated with the adhesive
Paint Primer:
SUNSTAR PAINT PRIMER 580 SUPRE
★ Do not apply the primer more than 2 times.

(If it is applied more than 2 times, its performance will be
lowered.)
★ Parts to be coated with primer: Apply the primer all over
dimension (d) on the outside of the both-sided adhesive
tape.
• Dimension to apply primer (d): 23 mm
★ After applying the primer, leave it for at least 5 minutes
(within 8 hours) to dry.
★ If the glass primer is applied by mistake, wipe it off with
white gasoline. (If wrong primer is applied, the glass will
not be stuck.)
D. Evenly apply glass primer (8) to the black part of window glass
(3) to be stuck.
Glass primer: SUNSTAR GLASS PRIMER 580 SUPRE
★ Do not apply the primer more than 2 times. (If it is applied

more than 2 times, its performance will be lowered.)
★ Parts to be coated with primer: Apply primer to sticking
surface of window glass (3) and all over dimension (d) on
both-sided adhesive tape (4) and operator's cab (2).
• Dimension to apply primer (d): 23mm (1 in.)
★ Do not apply the primer to the boarder about 5 mm wide

between the black part and transparent part of the glass.
★ After applying the primer, leave it for at least 5 minutes
(within 8 hours) to dry.
★ If the paint primer is applied by mistake, wipe it off with
white gasoline. (If wrong primer is applied, the glass will
not be stuck.)
WA380-5L 50-193 D
7. Apply adhesive.
★ Use either of the 2 types of adhesive.
Adhesive (Summer): SUNSTAR PENGUINE SEAL 580

SUPER "S"
Adhesive (Winter): SUNSTAR PENGUINE SEAL 580

SUPER "W"
★ The using limit of the adhesive is 4 months after the date of manufacture. Do not use the adhesive after this limit.
★ Keep the adhesive in a dark place where the temperature is below 25° C (77° F).
★ Never heat the adhesive higher than 30° C (86° F).
★ When reusing the adhesive, remove the hardened part from the nozzle tip.
A. Break aluminum seal (10) of the outlet of adhesive cartridge

(9) and install the nozzle.
B. Cut the tip of the adhesive nozzle (11) so that dimensions (f)
and (g) will be as follows.
• Dimension (f ) : 10 mm
• Dimension (g): 12 mm
C. Set adhesive cartridge (9) to caulking gun [7].

★ An electric caulking gun is more efficient.
50-194 D WA380-5L
D. Remove release tape (13) of the both-sided adhesive tape on
the glass side.
E. Apply adhesive (12) to the outside of both-sided adhesive tape

(4) of the operator's cab.
★ Before applying the adhesive, check that the primer is
applied to the surface to which the adhesive will be
applied.
★ Apply adhesive (12) to dimensions (h) and (j) of

both-sided adhesive tape (4) of operator's cab (2).
★ Dimension (h): 10 mm
★ Dimension (j ) : 12 mm (Approx. twice as high as adhesive
tape)
★ Apply adhesive (12) higher than both-sided adhesive tape
(4).
★ Apply the adhesive evenly.
8. Install window glass (3).

★ If the glass is positioned wrongly, the adhesive must be
removed and cleaned, and then the primer and adhesive must
be applied again. Accordingly, position the glass carefully
when sticking it.
A. Similarly to step 1, match tools X2-1, X2-2, and X2-3 and set
them to the 2 lower places of the window glass sticking part of
operator's cab (2).
WA380-5L 50-195 D
B. Using tool X3, raise and place window glass (3) on tool X2-1
(5-mm spacer) and stick it to the operator's cab.
★ Match the lines of the match tapes stuck in step 1.
★ Stick the glass within 10 minutes after applying the adhe-
sive.
★ Before sticking the glass, check that the primer is applied
to the surface to which the glass will be stuck.
★ Check clearance (k) between the front side of the front

glass and each side and adjust it evenly.
• Clearance (k) : 5 mm
C. After sticking window glass (3), press it evenly.

★ Press all over window glass to the degree that the window
glass will be stuck to the both-sided adhesive tape.
★ Do not press the window glass too strongly.
9. Cure the stuck window glass for a certain time.

★ Curing time before removing tool X2-1 (5-mm spacer)
(at temperature of 20° C (68° F) and humidity of 60%):
10 hours
★ Curing time before operating vehicle: 1 day
10. If the front glass and both front glasses are replaced, seal them.
A. Stick masking tapes (14) along the parts to be sealed shown in

the figure.
50-196 D WA380-5L
★ Stick the masking tapes to both inside and outside of the
operator's cab.
B. Fill the joint of the glasses with caulking material (15).

★ Fill the joint of the glasses with caulking material (15).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.
Caulking material: SUNSTAR PENGUINE SEAL NO. 2505
C. Remove the caulking material projected from the joint with

cardboard [8], etc.
D. Remove the masking tapes from the window glass.
11. Remove the primer and adhesive from operator's cab and window
glass.
★ Using white gasoline, wipe off the adhesive before it is dried
up.
★ When cleaning the glass, do not strike it.
WA380-5L 50-197 D
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY
HYDRAULIC PUMP ASSEMBLY
Removal
WARNING! Park the machine on a horizontal plane.

3. See "BULKHEAD ASSEMBLY" in this section to remove the

bulkhead assembly.
4. Remove the cab floor frame assembly, referring to "Removal of

Cab and Floor Frame Assembly."
5. Detach suction tube (1), PPC pump outlet hose (2), work equipment
pump outlet tube (3), transmission pump suction tube (4), and
outlet hose (5).
★ For tube (1), remove clamp (6), in advance.

★ For tube (3), loosen clamp (7), in front of the transmission, in
advance.
6. Temporarily lift the transmission, work equipment, and PPC pump

assembly (8). Remove the attachment bolts.
Transmission, work equipment, and control

pump assembly: 37 kg (82 lbs.)
Installation
• Fill with the specified hydraulic oil up to the predetermined level.
50-198 D WA380-5L
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP ASSEMBLY
Steering, Switching, and Fan Pump Assembly

Removal
WARNING! Park the machine on horizontal and flat ground.
3. See "BULKHEAD ASSEMBLY" in this section to remove the

bulkhead assembly.
4. Remove the cab floor frame assembly, referring to "Removal of

Cab Floor Frame Assembly."
5. Detach suction tube (1), transmission pump outlet hose (2), steering
pump outlet tube (3), and switch pump outlet tube (4).
★ For tube (1), remove clamp (5), in advance.
6. Detach the fan pump wiring connector (6), pump outlet hose (7),
control pressure supply hose (8), fan motor drain hose (9), and fan
pump drain hose (10).
7. Temporarily lift the steering, switching, and fan pump assembly

(11), and remove the mounting bolts.
Steering, switching, fan pump assembly: 57 kg (126 lbs.)
Installation
★ Perform installation in reverse order of removal.
★ Fill with the specified hydraulic oil up to the predetermined
level.
WA380-5L 50-199 D
DISASSEMBLY AND ASSEMBLY STEERING DEMAND VALVE ASSEMBLY
STEERING DEMAND VALVE ASSEMBLY
Removal
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent
the machine from moving.
WARNING! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
Operate the steering wheel and control levers several times to release the remaining pressure
trapped in the hydraulic piping.
★ Raise the boom and place support under the boom. Remove the
inspection cover (1).
WARNING! Make sure the boom support is securely

positioned.
1. Cover removal
A. Remove the mounting bolts. Remove the inspection cover (2).

★ Remove the covers on the front and right side at the bottom
of the cab.
B. Loosen the plugs (3) on top of the hydraulic tank filter and the
pump piping plugs (4) to prevent the oil inside from flowing
out.
50-200 D WA380-5L
2. Disconnect the following hoses and tubes:
★ Remove the clamps and brackets.
A. Hoses (6) and (6A) from the stop valves at the steering valve.
B. Tube (8) from the switch pump at the steering valve.
C. Tube (9) from the steering pump at the steering valve
D. Tube (10) from the main control valve at the steering valve.
E. Tubes (11, 12) from the steering cylinder at the steering valve.
F. Tube (13) from the hydraulic tank at the steering valve.
3. Sling steering valve (6). Remove mounting bolts (14), lift the
steering valve free.
Steering valve: 24 kg (53 lbs.)
★ Two workers should perform this step.
WARNING! The steering valve is oily. Thus, take

measures to prevent it from slipping and
dropping, or equipment damage results.
Installation
• Installation is the reverse of removal.
• Install new O-rings

• Remove the clamp to avoid applying force when installing the tube.
• Tighten the plug at the top of the hydraulic tank filter, add oil through the oil filter to the specified level. Run the engine to
circulate oil through the system. Check the oil level again.
Plug on top of the filter: 11.8 ± 1.0 Nm {1.2 ± 0.1 kgf m} (104 ± 9 lbf in.)
WA380-5L 50-201 D
Disassembly
★ Use a wire brush to remove the dirt and debris from the unit exterior.
★ Perform this procedure in a clean work area to prevent dirt or dust from sticking to the valve.
★ Use a vise to hold the steering valve during disassembly whenever possible. Be careful not to overtighten the vise or the
valve will be damaged.
1. Remove safety valve assembly (1).

★ The safety valve’s pressure point is fixed.
Therefore, DO NOT disassemble the safety valve.
2. Remove main relief valve assembly (2).

★ The pressure point of the main relief valve is fixed.
Therefore, DO NOT disassemble the main relief valve.
3. Removing the demand spool.
A. Remove plug (3).
50-202 D WA380-5L
B. Remove spring (4).
C. Remove demand spool (5).

★ Remove the demand spool slowly so as not to damage the
spool.
★ Check the number and thickness of the installed shims.
Store the shims in a clean, safe place.
D. Remove plug (6).
4. Removing the steering spool.
A. Remove two bolts (7).

★ Two bolts and one case exist on each side of the valve
body. At this time remove the two case bolts on the other
side of the valve body.
WA380-5L 50-203 D
B. Remove case (8) and spring (9).
★ At this time remove the case on the other side of the valve
body.
C. Remove spring seat (10).

★ Slowly remove the spring seat so the spool is not
damaged.
★ At this time remove the spring seat from the other side of
the valve body assembly.
D. Remove steering spool assembly (13).

★ Remove the spool assembly slowly as not to bend it or
damage it.
★ Remove the poppets from both ends to prevent them from
falling into the valve body.
5. Disassemble the steering spool assembly.
50-204 D WA380-5L
A. Remove cap screw (14).
★ This screw was coated with Loctite #271 at the factory.
Thus, to remove the screws, heat them to 200° ~ 250° C
(392° ~ 482° F) with an electric heat gun prior to attempt-
ing to remove them.
B. Remove spring (15) and poppet (16).

★ Remove the spring and poppet from the other side.
6. Disassembling the check valve.
A. Remove plug (17).
B. Remove spring (18) and poppet (19).
7. Remove plug (20).
WA380-5L 50-205 D
Assembly
★ Check all parts for damage and burrs.
★ Wash all metal parts in clean solvent and blow dry with compressed air.
★ Do not file or polish any parts with rough sandpaper.
★ Coat the O-rings with clean grease.
1. After installing an O-ring to the plug (20), thread it into the valve
body.
Plug: 93.2 ± 4.9 Nm {9.5 ± 0.5 kgf m} (697 ± 4 lbf ft.)
2. Assembling the check valve.
A. Install poppet (19) and spring (18).
B. After installing a new O-ring to plug (17), thread it into the

valve body.
50-206 D WA380-5L
3. Assembling the steering spool.
A. Install poppet (16) and spring (15) to the spool.
B. After installing a new O-ring to cap screw (14), thread it onto

the steering spool.
Spool thread: Loctite #271
Cap screw: 8.8 ± 1.0 Nm {0.9 ± 0.1 kgf m} (78 ± 9 lbf in.)
4. Installing the demand spool.
A. After installing a new O-ring to plug (6), thread it into the

valve body.
B. Insert demand spool (5) into the valve body.

★ Install the shims removed during disassembly.
★ Insert the spool slowly and carefully so as not to damage
the spool or valve body.
C. Install demand valve spring (4).
WA380-5L 50-207 D
D. After installing a new O-ring and backup ring to plug (3),
thread it into the valve body.
5. Installing the steering spool assembly.
A. Insert the steering spool assembly (13) into the valve body.
★ Ensure that section A of the spool valve faces the correct
direction.
B. Install spring seat (10).
C. Install spring (9).

★ Install the other spring and seat to the opposite side of the
valve body.
D. After installing an O-ring to the case (8), install it onto the

valve body.
E. Install the two bolts (7) that secure the case to the valve body.
★ Install the other case and bolts to the opposite side of the
valve body.
Bolts: 41.2 ± 2.0 Nm {4.2 ± 0.2 kgf m} (30 ± 2 lbf ft.)
50-208 D WA380-5L
6. Install the main relief-valve assembly (2) to the valve body.
Main relief-valve assembly:

73.5 ± 4.9 Nm {7.5 ± 0.5 kgf m} (54 ± 4 lbf ft.)
7. Install the safety-valve assembly (1) to the valve body.
Safety-valve assembly:
73.5 ± 4.9 Nm {7.5 ± 0.5 kgf m} (54 ± 4 lbf ft.)
WA380-5L 50-209 D
DISASSEMBLY AND ASSEMBLY ORBITROL VALVE
ORBITROL VALVE
Removal
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the
ground and stop the engine. Apply the parking brake and block the wheels to prevent the machine
from moving.
WARNING! Loosen the oil filler cap slowly to release pressure inside the hydraulic tank. Operate the steering
wheel and control levers several times to release remaining pressure in the hydraulic piping.
• Loosen the plug on top of the hydraulic tank filter to prevent oil inside the tank from flowing out.
1. Remove steering post cover (1).
2. Remove the plug and lift up the boot (2).

★ Remove the floor mat.
3. Remove the steering column connecting bolts (3).
4. Remove covers (4, 5, 6) from under the floor.
50-210 D WA380-5L
5. Removing the piping.
A. Disconnect hose (8) from between the orbitrol valve and the
accumulator valve. Remove the nipple.
B. Disconnect the hose (10) from between the orbitrol valve and
the hydraulic valve.
C. Disconnect the hose (11) from between the orbitrol valve and
the right-hand stop valve. Remove the nipples (12, 13).
D. Disconnect the hose (14) from between the orbitrol valve and
the accumulator valve. Remove the nipple.
Remove the bolts that secure the mounting bracket (15) in
place. Remove the bracket and orbitrol valve (16) as an assem-
bly.
Orbitrol valve: 8 kg (18 lbs.)
WA380-5L 50-211 D
Installation
★ Installation is the reverse of removal.
Orbitrol valve bolt: 52 ± 6.8 Nm {5.3 ± 0.7 kgf m} (38 ± 5 lbf ft.)
Mounting bracket bolt: 88.3 ± 34.3 Nm {9.0 ± 3.5 kgf m} (65 ± 25 lbf ft.)
Steering column connecting bolt: 55.9 ± 7.8 Nm {5.7 ± 0.8 kgf m} (41 ± 6 lbf ft.)
★ Add oil to the specified level through the hydraulic tank oil filler
★ Run the engine to circulate oil through the system. Re-check the oil level.
Disassembly
★ Check all parts for damage or burrs.
★ Wash all metal parts in clean solvent and blow dry with air.
★ Do not use a file of polish any part with rough sandpaper.
★ Coat the O-rings with clean grease.
Rotor
1. Place the orbitrol valve in a vise b, with the rotor side facing up.
★ Insert copper plates over the vise’s jaws. Tighten the vise just
enough to hold the valve in place. DO NOT excessively
tighten the vise or equipment damage will result.
2. Remove the screw (1) and end cap (2).
3. Remove the O-ring (3) from the end cap.
50-212 D WA380-5L
4. Pull out rotor set (4) and remove the O-ring.
★ Be careful not to drop or damage the star gear from inside the
rotor set. The rotor set parts are precision matched. Any
damage to the rotor set will cause problems.
5. Remove spacer (6)
6. Remove drive shaft (7)
7. Remove spacer plate (8)
8. Remove O-ring (9) from housing (10).
Control Side
1. Remove orbitrol valve (10) from the vise and place it on a clean
cloth in a clean work area. Be careful not to damage any finished
surfaces.
2. Use a screwdriver to pry up the tip of snap ring (11) and remove it
from the housing.
3. Rotate the spool and sleeve so the pin is horizontal. Push in the
spool and sleeve with your thumb and remove bushing (12) from
the housing.
WA380-5L 50-213 D
4. Remove the X-ring seat seal (13) from bushing (12).
5. Use a screwdriver to remove dust seal (14) from bushing (12).

★ Be careful not to damage the bushing when removing the dust
seal.
6. Remove both bearing races (15) and thrust needle (16) from the
spool and sleeve.
7. Pull out, in the direction of the large arrow, the spool and sleeve
assembly (17) from housing (10).
★ To prevent damage to the spool and valve assembly, rotate the
spool and sleeve assembly to the left and right while slowly
removing it from the housing.
8. Remove pin (18) from the spool and valve assembly (17).
9. Push spool (20), in the direction of the large arrow, into sleeve (19)
slightly to the front. Carefully remove six centering springs (21) by
hand from spool (20).
10. Rotate spool (20) and pull it out, in the direction of the large arrow,
from the rear of sleeve (19).
50-214 D WA380-5L
11. Remove O-ring (22) from the housing.
12. Remove set screw (23) from the housing.
13. Screw a threaded bar into check valve (24). Then pull out the check
valve.
14. Remove O-rings (25, 26) from check valve (24).
15. Tap the housing to remove ball (27) and retainer (28).
Assembly
★ Check all parts for damage or burrs.
★ Wash all metal parts in clean solvent and blow dry with air.
★ DO NOT file any parts or polish them with rough sandpaper.
★ Replace all O-rings with new and coat with clean grease; no need to grease the new X-rings.
Control Side
1. Use tweezers to insert retainer (28) into the orbitrol valve housing.
★ Make sure retainer (28) is inserted straight down and not at an angle.
2. Insert ball (27).
3. After fitting O-rings (25, 26) to check valve (24), install it inside the housing.
4. Install set screw (23).

★ Make sure set screw (23) is slightly recessed from the end face of the housing.
Set screw: Loctite adhesive
Set screw: 11.8 Nm {1.2 kgf m} (9 lbf ft.)
5. Assemble the spool (20) into the sleeve (19) so the spring slots
align.
★ Rotate the spool slowly while installing it inside the sleeve.
★ Ensure that the spool rotates smoothly inside the sleeve.
★ Check that the identification marks on the spool and spring
align.
WA380-5L 50-215 D
6. Align the spring grooves in the spool (20) with the sleeve (19). Set
the assembly on a flat surface and insert the spring (21) into the
spring groove.
★ Position the assembly so that the notches at both ends are at the
bottom.
7. Insert the pin (18) into the spool and sleeve assembly (17).
8. Insert spool and sleeve assembly (17) into housing (10).

A. Keep the pin horizontal but rotate the assembly slightly to the
left and right during insertion.
★ Be extremely cautious not to get assembly caught during
insertion.
B. Position the spool and sleeve flush with the rear end face of the
orbitrol valve housing.
★ The pin will fall out if the spool and sleeve are inserted
beyond the end face.
C. Make sure the spool and sleeve rotate smoothly inside the
housing.
9. Install O-ring (22) into valve housing (10).
10. Fit both bearing races (15) and thrust needle (16) into housing (10).
50-216 D WA380-5L
11. Install the dust seal (14) into the bushing (12).
12. Install the X-ring seal (13) into the bushing (12).
13. Insert the bushing (12) into the spool. Rotate the bushing to install it
in place.
★ Use a plastic hammer to tap the bushing into its final position.
★ The bushing must horizontally contact the bearing race.
14. Use a screwdriver to fit the snap ring (11) into its groove in the
orbitrol valve housing.
Rotor
15. Place the orbitrol valve housing in a vise as shown.

★ Position copper plates over the vise jaws. Tighten the vise just
enough to hold the valve in place. DO NOT tighten the vise
excessively or the valve will be damaged.
★ Make sure the spool and sleeve are recessed inside the housing.
16. Install O-ring (9) into the orbitrol valve housing.
17. Install spacer plate (8). Align the bolt holes into the spacer plate
with the tap holes in the housing.
WA380-5L 50-217 D
18. Rotate the spool and sleeve assembly until pin (18) and port surface
of the housing are parallel. Mesh the pin and yoke of drive shaft (7).
★ Draw a line on the end face of the drive shaft spline to assist in
precise positioning of the assembly.
19. Insert O-ring (5) into rotor set (4).
20. After mating the O-ring end of the rotor set to the spacer plate end,
align the rotor star with the drive.
A. Check that lines A, B, C and D are parallel.
B. Position the rotor set bolt holes, without removing drive shaft
joint (7).
★ This procedure is critical for setting the valve timing.
21. Insert spacer (6) inside the rotor set.
22. Place end cap (2) on the rotor set and align the bolt holes.
23. Coat end-cap mounting screw threads with grease, then install the
end-cap mounting screws finger tight.
★ Install the handle to the spool and check that the spool rotates.
50-218 D WA380-5L
24. After installing all the screws, torque them as specified below and
in the tightening sequence at right.
First round:
14.7 Nm {1.5 kgf m} (11 lbf ft.)
Second round:
27.0 ± 1.5 Nm {2.8 ± 0.2 kgf m} (19.9 ± 1.1 lbf ft.)
WA380-5L 50-219 D
DISASSEMBLY AND ASSEMBLY ECSS VALVE
ECSS VALVE
Removal
WARNING! Park the machine on a horizontal plane. Set the steering to the full right, and ground the work
equipment. Stop the engine, apply the parking brake, and put blocks under the wheels.
WARNING! Remove remaining pressure of the circuit. See "Removal of Remaining Pressure From ECSS Circuit."
1. Detach lift cylinder bottom-side hose (1), head-side hose (2), and
work equipment valve return hose (3).
2. Detach the work equipment pump hose (4) and accumulator hose
(5).
3. Disconnect the wiring connector (6).
4. Use the lift bolt 1 and shackle 2 to temporarily lift the ECSS
valve assembly (7) and remove the plate attachment bolts.
ECSS valve assembly: 27 kg (60 lbs.)
Installation
• Perform installation in reverse order of removal.
• Fill with the specified hydraulic oil to the predetermined level.
50-220 D WA380-5L
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT VALVE
WORK EQUIPMENT VALVE
Removal
WARNING! Park the machine on a horizontal plane. Set the safety bar in the frame, and ground the work equipment.
WARNING! Dump the work equipment bucket and raise the

lift arm until it becomes horizontal.
While supporting the lift arm with stand B and
jack C, stop the engine. Use the work equipment
lever to remove accumulated pressure in the
accumulator.
1. Loosen plug (1) of the hydraulic tank filter to prevent oil from
flowing out.
2. Drain oil from the hydraulic tank.
Hydraulic tank capacity: 20 Liters (5.3 gallons)
3. Remove cover (2) in front of the machine.
4. Detach horns (3) and (4).

★ Horns: 303 Hz for connectors F03 and F04, 333 HZ for
connectors F05 and F06.
WA380-5L 50-221 D
5. Disconnect wiring connector (5).
6. Detach PPC tube for bucket side (6) and lift arm side (7).
7. Detach PPC tube for bucket side (8) and lift arm side (9) from the
rear of the work equipment valve.
8. Loosen the mounting bolts of work equipment pump outlet tube

(10), lift cylinder head-side tube (11), and bottom-side tube (12) up
to the arrow-indicated level of the drawn line.
★ For tube (10), remove the clamp.
9. Detach steering demand valve hose (13), work equipment pump

outlet tube (10), and E.C.S.S. valve → lift arm head hose (14).
Then detach E.C.S.S. valve return hose (15) and work equipment
valve return hose (16).
★ Remove the bolts, first loosen in the rear of the valve and shift
the work equipment pump outlet tube (10) backward.
10. Detach bucket cylinder head-side hose (17) and bottom-side hose
(18).
50-222 D WA380-5L
11. Detach lift cylinder head-side tube (11) and bottom-side tube (12).
★ Remove the tubes (11) and (12) first loosened in the rear of the
valve, and shift backward.
12. Remove the attachment bolts of work equipment valve assembly

(19). Use lift bolt ➀ and shackle ➁ to remove it.
Work equipment valve assembly: 78 kg (172 lbs.)
Installation
• Perform the installation in reverse order of removal.
• Fill with the specified hydraulic oil to the predetermined level.
WA380-5L 50-223 D
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDERS
HYDRAULIC CYLINDERS
Steering, Lift, and Bucket
Special Tools
New/Modified
Necessity
Quantity
Sketch
790-502-1003 Repair stand ● 1

1 Hydraulic cylinder disassembly and assembly
790-101-1102 Hydraulic pump ● 1
790-102-2303 ● 1
I 2 or Wrench assembly For steering cylinder head
790-330-1100 ● 1
Socket (Width
3 790-302-1270 across flats: 50 ● 1 For steering cylinder piston nut
mm)
790-102-4300 Wrench assembly ● 1

4 For boom and bucket cylinder pistons
790-102-4310 Pin ● 1
5 790-720-1000 Expander ● 1
796-720-1640 Ring ● 1
07281-00909 Clamp ● 1
796-720-1680 Ring ● 1 For assembly of piston ring

6
07281-01589 Clamp ● 1
796-720-1690 Ring ● 1
07281-01919 Clamp ● 1
I 790-201-1702 Push tool kit ● 1
• 790-101-5021 Grip ● 1
7 • 01010-80816 Bolt ● 1 For assembly of cylinder head bushing
• 790-201-1751 Push tool ● 1
• 790-201-1841 Push tool ● 1
790-201-1500 Push tool kit ● 1
• 790-101-5021 Grip ● 1
8 • 01010-80816 Bolt ● 1 For assembly of cylinder head dust seal
• 790-201-1560 Plate ● 1
• 790-201-1650 Plate ● 1
50-224 D WA380-5L
Disassembly
1. Set cylinder assembly (1) to tool I-1.
2. Cylinder head piston rod assembly

★ Steering cylinder assembly
A. Use tool I-2 to detach cylinder head (2) from the cylinder.
B. Pull out cylinder head piston rod assembly (3) from cylinder
(4).
★ When piston rod assembly is pulled out from the cylinder,
oil leaks. Prepare an oil receiver.
i. Lift and bucket cylinder assembly
ii. Remove cylinder head (2) attachment bolts.
Cylinder Width across bolt flats

Lift cylinder 24mm
Bucket cylinder 27mm
iii. Pull out cylinder head piston rod assembly (3) from
cylinder (4).
★ When the piston rod assembly is pulled out from the
cylinder, oil leaks. Prepare an oil receiver.
WA380-5L 50-225 D
3. Piston and cylinder head
• Steering cylinder assembly
A. Set the cylinder head and piston rod assembly (3) to tool I-1.
B. Use tool I-3 to remove nut (5).

★ Width across flats of nut: 50 mm.
C. Remove piston (6) and detach cylinder head (2).
• Lift/bucket cylinder assembly
i. Position cylinder head and piston rod assembly (3) to tool

I-1.
ii. Remove the piston assembly, turn stopper screw (3).

★ Screw size: M12 X 1.75.
★ When screw (7) is too tight and it is not removed,

insert screw into the inside once, and apply a tap to the
screwing part. Then remove it.
50-226 D WA380-5L
D. Use tool I-4 to remove piston assembly (6).
★ When not using tool I-4, use the notch hole (diameter
10.2) to loosen the piston assembly.
E. Remove the head assembly (2).
4. Detailed disassembly of piston assembly

• Steering cylinder assembly.
Detach wear ring (8) and piston ring (9) from piston (6).
• Lift/bucket cylinder assembly.

Detach wear ring (8), piston ring (9), O-ring ring (10) from the
piston.
WA380-5L 50-227 D
5. Detailed disassembly of cylinder head assembly
A. Steering cylinder assembly
i. Remove the O-ring backup ring (11).
ii. Remove the snap ring (12), and detach the dust seal (13).
iii. Remove the rod packing (14).
iv. Remove the buffer ring (15).
v. Remove the bushing (16).
vi. Remove the O-ring (17).
B. Lift/bucket cylinder assembly

i. Remove the O-ring backup ring (11).
ii. Remove the snap ring (12) and detach the dust seal (13).
iii. Remove the rod packing (14).
iv. Remove the buffer ring (15).
v. Remove the bushing (16).
50-228 D WA380-5L
Assembly
★ Take care not to damage the packing, dust seal, and O-ring.
★ To insert the backup ring, do not put it in the assembly unreasonably. Heat it with hot water around 50° ~ 60° C (120° ~
140° F), and then insert it.
1. Detailed assembly of head assembly
i. Use tool l7 to press the bushing (16).
ii. Assemble the buffer ring (15).
iii. Assemble the rod packing (14).
iv. Use tool l8 to attach the dust seal (13), and fix it with the
snap ring (12).
v. Attach the backup ring and O-ring (13).
vi. Attach the O-ring (17).
B. Lift/bucket cylinder
i. Use tool l7 to press the bushing (16).
ii. Assemble the buffer ring (15).
WA380-5L 50-229 D
iii. Assemble the rod packing (14).
iv. Use tool l8 to attach the dust seal (13) and fix it with the
snap ring (12).
v. Attach the backup ring and O-ring (11).
2. Detailed assembly of piston assembly
i. Use tool l5 to expand the piston ring (9).

★ After the piston ring is set to the tool, turn the handle 8
~ 10 times to expand it.
ii. Remove the piston ring (9) from tool l5 and assemble it in
the piston (6).
iii. Use tool l6 and fasten the piston ring (9).
iv. Assemble the wear ring (8).
i. Use tool l5 to expand the piston ring (9).

★ After the piston ring is set to the tool, turn the handle 8
~ 10 times to expand it..
★ For illustration, see CWW11008.
ii. Remove the piston ring (9) from tool l5, then assemble it
in the piston (6).
iii. Use tool l6 to fasten the piston ring (9).
iv. Assemble the wear ring (8).
v. Assemble the O-ring and backup ring (10).

★ To insert the backup ring, do not put it in the assembly unsafely. Heat it with hot water from 50° to 60 ° C
(122° to 140° F). Insert the ring.
50-230 D WA380-5L
3. Cylinder head piston rod assembly
i. Set the piston rod (3) to tool l1.
ii. Assemble the cylinder head (2) and piston (6) in the
piston rod.
iii. Assemble the nut (5). Use tool l3 to tighten the nut with
the specified torque.
★ Width across flats of nut: 50 mm (2 in.).
Piston rod screw unit: Adhesive (LT-2)
Nut: 785 ± 78.5 Nm (80.0 ± 8.0 KGF M) {922 ± 92 lbf-ft}
i. Set the piston rod (18) to tool l1.
ii. Assemble the head assembly (2).
iii. Assemble the piston assembly (6) in the procedure below:

★ When reusing the rod and piston assembly (6)
★ Carefully clean them to eliminate chips and dusts.
a. Use screwing tool I-4 to tighten piston assembly
(6) until the screw hole positions match.
★ Use a file to eliminate burrs and returns of the screw.
WA380-5L 50-231 D
iv. Tighten the screw (7).
Screw: 66.2 ± 7.35 Nm (6.8 ± 0.8 kgf m) {49 ±5.4 lbf ft.}
v. Fasten the screw at four portions using a drift.
C. When one or either of pistons are new.
i. Use screwing tool l4 to tighten the piston assembly (6)

with the specified torque until it is pressed against the rod
end.
Piston assembly: 294 ± 29.4 Nm (30.0 ± 3.0 kgf m)
{217 ±22 lbf ft.}
ii. Process one tapped hole for mounting the screw (7).
★ Use a drill to horizontally process the V grooves of the
screw parts of the piston (6) and rod (3).
Lower hole drill Lower hole Tap used Tap depth

diameter depth
10.3 mm 27 mm 12 X 1.75 mm 20 mm
iii. After processing, eliminate chips and dusts, then carefully

clean the tapped hole part.
iv. Fasten the screw (7).
Screw: 66.2 ± 7.35 Nm (6.8 ± 0.8 kgf m) {49 ±5.4 lbf ft.}
v. Tighten the screw part at four portions using a punch.
50-232 D WA380-5L
4. Cylinder head
i. Set the cylinder (4) to tool l1.
ii. Lift the cylinder head piston rod assembly (3) and assem-
ble it in the cylinder (4).
iii. Use tool l2 to attach the cylinder head assembly (2) to the
cylinder.
Screw: 676 ± 67.6 Nm (68.9 ± 6.9 kgf m) {499 ±50 lbf ft.}
iv. Remove the cylinder assembly (1) from tool l1.
i. Set the cylinder (4) to tool l1.
ii. Lift the cylinder head piston rod assembly and assemble it
in the cylinder (4).
iii. Attach the cylinder head assembly (2) to the cylinder.

★ Fasten the bolt so that the dimension of the leveler
plate of the bucket cylinder is as shown in the illustra-
tion.
Attachment bolts:
Lift cylinder: 250 ± 25 Nm (25.5 ± 2.6 kgf m)
{184 ± 18 lbf ft}
Bucket cylinder: 343 ± 34.3 Nm (35.0 ± 3.5)
{253 ± 25 lbf ft}
WA380-5L 50-233 D
iv. Remove the cylinder assembly (1) from tool I-1.
50-234 D WA380-5L
MEMORANDUM
WA380-5L 50-235 D
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
HYDRAULIC TANK ASSEMBLY
Removal
WARNING! Park the machine on a horizontal place. Set the safety bar in the frame, and lower work equipment to the
ground. Stop the engine, apply the parking brake, and put blocks under the wheels.
WARNING! Operate the work equipment operation lever 10 times or more to remove the accumulated pressure of
the PPC circuit.
1. Drain the hydraulic tank of oil.
Hydraulic oil tank capacity: 129 Liters (34.1 gallons)
2. Remove the right fender step assembly, referring to item 6 in

"Detachment of Cab and Floor Frame Assembly."
3. Remove the cover on the lower right of the cab.
4. Remove the ladder (1) and covers (2, 3).
5. Detach the brake valve return tube (4), work machine valve return
tube (5), PPC valve return hose (6), and hydraulic oil cooler return
tube (7).
6. Detach the work machine pump suction tube (8) and steering
switch fan pump suction tube (9).
7. Detach the emergency pump suction tube (10).
50-236 D WA380-5L
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK ASSEMBLY
8. Hydraulic tank assembly
A. Temporarily lift the hydraulic tank assembly.
B. Remove the attachment bolts (11) under the hydraulic tank.
C. Remove the attachment bolts (12) and (13) before and after the
hydraulic tank.
D. Lift the hydraulic tank assembly (14) to remove it.
Hydraulic tank assembly: 175 kg (386 lbs.)
Installation
• Fill with the specified hydraulic oil up to the predetermined level.
WA380-5L 50-237 D
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
WORK EQUIPMENT
Removal
WARNING! Park the machine on a horizontal place. Set the safety bar in the frame, and ground the work
equipment. Stop the engine, apply the parking brake, and put blocks under the wheels.
1. Bucket
A. Remove the bucket link attachment pin (1).
★ Fix the bucket link to the bell crank using a wire.

★ If shims are inserted, check the number of shims.
B. Remove the bucket hinge attachment pin (2).
WARNING! Never insert fingers into the pin hole.
C. Move the machine backward and detach the bucket.
2. Temporarily lift the bucket cylinder (3) and pull out the rod pin (4).
Detach the cylinder rod and bell crank.
★ Install the block B between the cylinder bottom and frame.
Bucket cylinder: 170 kg (375 lbs.)
50-238 D WA380-5L
3. Lift cylinder rod pin
A. Remove the rod pin plate (5-1).

★ Install the support stand C at the end of the lift arm and
remove the accumulated pressure in the hydraulic pipe.
B. Temporarily raise the lift cylinder (6) and detach the attach-
ment pin (5).

★ When lowering the cylinder, put the block into the top of
the accelerator.
Bucket cylinder: 170 kg (375 lbs.)
4. Lift arm, bell crank, and bucket link
A. Remove the lift arm (boom) kick-out switch (7).
B. Remove the potentiometer (22).
WA380-5L 50-239 D
C. Temporarily lift the lift arm, bell crank, and bucket link (8).
Then remove the lift arm attachment pin, and lift arm for
removal.
Lift arm, bell crank, and bucket link: 1,450 kg (3,197 lbs.)
5. Bell crank and bucket link
A. Temporarily lift the bucket link (9), pull out the attachment pin
(10), then remove from the bell crank.
Bucket link: 55 kg (121 lbs.)
B. Temporarily lift the bell crank (11), pull out the attachment pin
(12), then remove from the lift arm.
Bell crank: 320 kg (705 lbs.)
6. Dust seal and bushing.
A. Remove the dust seal (14) and bushing (15) from the lift arm
(13).
50-240 D WA380-5L
B. Pull out the dust seal (16) and bushing (17) from the bell crank
(11).
C. Pull out the dust seal (18) and bushing (19) from the bucket
link (9).
WA380-5L 50-241 D
Installation
• Installation is in reverse order of removal.
Bucket link
1. Lift the bucket link, and attach the cord ring (21), fitting the hole of
the attachment pin (1). Insert shims so that clearance a is equal on
the left and right, assemble the pin (1), and tighten with the bolt.
★ Take care that the cord ring is not engaged.
★ Clearance a: 1.5 mm (0.059 in.) or less.
WARNING! When fitting the pin hole position, never insert

fingers in the pin hole.
Bucket
2. Use the operation lever to fit the hole of the bucket attachment pin
(2). Attach the cord ring (20). Insert shims so that clearance b is
equal on the left and right. Assemble the pin (1) and tighten the
bolt.
★ Clearance b: 1.5 mm (0.059 in.) or less.

Bucket cylinder
3. Adjust the bucket positioner. See "Adjustment of Bucket Positioner" in Inspection and Adjustment.
WARNING! When fitting the pin hole position, never insert fingers in the pin hole.
Lift cylinder
WARNING! When starting the engine, confirm that the

forward/backward lever is set to the neutral
level and the parking brake is applied.
WARNING! When fitting the pin hole position, never

insert fingers in the pin hole.
★ Clearance c: 1.5 mm (0.059 in.) or less.
50-242 D WA380-5L
Confirm the operation. Refer to "Inspection and Adjustment of Lift Arm Kick-Out" in Inspection and Adjustment.
Perform the calibration, referring to the "Handling of Load Meter".

★ Clearance d: 1.5 mm (0.059 in.) or less.
★ Fix the bucket link to the bell crank using a wire.

Dust seal, bushing
• Press bushing (15) into the bucket link, bell crank, and lift arm
respectively using a press. Assemble the dust seal.
Bushing: Grease (G2-LI)
Greasing
• Grease each pin.
WA380-5L 50-243 D
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
COUNTERWEIGHT
Removal
WARNING! Disconnect the negative (—) terminal of the battery.
1. Grill
A. Open the grill and temporarily lift it. Disconnect the damper
gas cylinders (1) on the left and right.
B. Disconnect connectors (2, 3) of the work lamp, and remove the

harness clamp.
C. Remove four attachment bolts, and detach the grill (4).
2. Temporarily lift counterweight (5). Remove two attachment bolts

(6) and (7) for each side. Remove the counterweight.
Counterweight: 1,210 kg (2,668 lbs.)
Installation
• Installation is in reverse order of removal.
Attachment bolt: 824 - 1,030 Nm (84.0 - 105.0 kgf m) {608 - 760 lbf ft.}
50-244 D WA380-5L
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER ASSEMBLY
AIR CONDITIONER ASSEMBLY
Special Tools
New/Modified
Necessity
Quantity
Sketch
799-703-1100 Vacuum pump (100V) ■ 1
X 799-703-1110 Vacuum pump (220V) ■ 1 Charging air conditioner with freon
799-703-1120 Vacuum pump (240V) ■ 1
Removal
WARNING! Park the machine on a horizontal place. Set the safety bar in the frame, and lower the work
equipment to the ground. Stop the engine, apply the parking brake, and put blocks under the
wheels.
1. Collect the air conditioner refrigerant (R134a).
2. Detach the cab assembly, referring to "Removal and Installation of

Cab Assembly".
3. Air conditioner unit hose

• Detach the air conditioner unit hose (1) under the floor.
4. Cover
A. Remove the cover (2) on the lower left of the operator seat.
WA380-5L 50-245 D
B. Remove the cover (3) on the lower rear right of the operator’s
seat.
C. Detach the connector (4) (CN-L11) at the rear of the operator’s

seat, and remove the covers (5) and (6).
5. Remove duct (7).
6. Cool-heat box assembly
A. Detach five connectors of the fuse box.

• (8): CN-FS1 • (9): CN-FS2
• (10): CN-FS3 • (11): CN-FS4
• (12): CN-FS5
50-246 D WA380-5L
B. Disconnect the connectors (12) (CN-L19), (13) (CN-L20), and
(14) (CN-DL) at the rear of the operator’s seat.
C. Disconnect six connectors of the relay case.

• (15): CN-L101 • (16): CN-L102
• (17): CN-L103 • (18): CN-L104
• (19): CN-L105 • (20): CN-L106
D. Remove the relay cases (21) and (22).
E. Remove the cool-heat box assembly (23).
F. Remove the box (24).
7. Inside-outside switching damper
A. Disconnect connector (25) (CN-A4).
B. Remove the attachment bolts, and shift the inside-outside

switching damper (26) to the side.
WA380-5L 50-247 D
8. Air conditioner unit assembly
A. Loosen the bolt (27), and detach the air conditioner unit pipe
(28).
★ After the pipe is detached, cover the pipe with a cap so that
no foreign matter will contaminate the pipe openings.
B. Disconnect connectors (29) (CD-A3), (30) (CN-A1), and (31)

(CN-A2).
C. Remove mounting bolts of the air conditioner unit assembly.
D. Lift the air conditioner unit assembly (32), detach hose (33),
then remove the air conditioner unit assembly.
Installation
★ Using tool X, charge the air conditioner circuit with air conditioner refrigerant (R134a).
★ Do not remove the cap until just before the pipe is attached.
O-ring and screw unit: Compressor oil for R134a (DENSO ND-OIL8, ZEXEL: ZXL 100PG (Equivalent to PAG46))
Pipe mounting bolt: 8 - 12 Nm (0.8 - 1.2 kgf m) {71 - 106 lbf in.}
50-248 D WA380-5L
MEMORANDUM
WA380-5L 50-249 D
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
AIR CONDITIONER COMPRESSOR
Special Tools
New/Modified
Necessity
Quantity
Sketch
799-703-1100 Vacuum pump (100V) ■ 1
X 799-703-1110 Vacuum pump (220V) ■ 1 Charging air conditioner with freon
799-703-1120 Vacuum pump (240V) ■ 1
Removal
WARNING! Park the machine on a horizontal plane. Set the safety bar in the frame, and lower the work
equipment to the ground. Stop the engine, apply the parking brake, and put blocks under the
wheels.
1. Open the left engine side cover.
2. Collect the air conditioner refrigerant (R134a)
3. Detach the V-belt tension adjusting bolt (1) and fixing bolt (2), then
remove plate (3).
4. Slide the air conditioning compressor to the engine side. Remove

V-belt (4) from the pulley of the compressor.
5. Disconnect pipe connector (5).
6. Disconnect hoses (6) (7).
7. Remove four bolts (8) or attachment bolts in the bottom, and nuts.
Detach the compressor assembly.
50-250 D WA380-5L
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
Installation
Compressor oil for R134a (DENSO ND-OIL8, ZEXEL: ZXL100PG (Equivalent to PAG46)) 180 ml
• Using tool X, Charge the gas (R134a) in the air conditioning unit.
• Adjusting the tension of the air conditioner compressor belt.

★ Let the compressor fall down to the side of the side cover, then adjust the V-belt tension. (For the belt tension
dimension, refer to the standard value table).
O-ring and screw portions.

Compressor oil for R134a (DENSO ND-OIL8, ZEXEL: ZXL100PG (Equivalent to PAG46)
Pipe mounting bolt: 8 - 12 Nm (0.8 - 1.2 kgf m) {71 - 106 lbf in.}
WA380-5L 50-251 D
DISASSEMBLY AND ASSEMBLY OPERATOR’S SEAT ASSEMBLY
OPERATOR’S SEAT ASSEMBLY

★ The procedure for disassembling and assembling the operator's seat assembly [air-suspension (manufactured by
ISRIUG HAUSEN)] is shown below.
★ Although machines with joystick steering specification is not equipped with the left armrest, its operator's seat assembly
are also disassembled and assembled according to the following procedure.
A: Headrest E: Left-hand armrest
B: Back seat F:Suspension cover
C: Cushion seat G: Rails
D:Right-hand armrest
Disassembly
1. Headrest
A. Referring to the figure, check the positions of two clips (2) of

headrest stay (1) on both sides.
50-252 D WA380-5L
B. Apply force (b) to part (a) of each clip (2) in the direction of
the arrow to turn the clip and release it from part (d) of headrest
stay (1), and then pull out up headrest (3).
★ Pushing in both clips (2) simultaneously, remove headrest

(3).
2. Back seat
A. Disconnect three air hoses (5) from the rear left of back seat
(4).
★ Before disconnecting the air hoses, check their types.
WA380-5L 50-253 D
B. Remove back seat hinge mounting bolt (6) (M8bolt).
C. Bring back seat (4) down forward.
D. Apply force (E) to the right side of back seat (4) in the direc-
tion of the arrow.
E. Applying the force to back seat (4), pull its right side up.
F. Slide back seat (4) sidways and remove it.
50-254 D WA380-5L
3. Cushion seat
A. Push cushion adjuster lever (7) inward and slide cushion seat
(8) to the front end.
B. Push cushion slide stopper wire (9) down with screwdriver [1],
etc.
C. Keeping the state in B), pull out cushion seat (8) forward and
remove it.
4. Armrest
• The procedure for disassembling right-hand armrest (10) is
shown below.
(Disassemble left-hand armrest (11) similarly.)
A. Remove plastic cap (12) from the armrest hinge.

★ Use a flat-head screwdriver, etc. to remove the cap.
B. Loosen armrest hinge mounting bolt (13).
WA380-5L 50-255 D
C. Remove plastic cap (14), and then remove lower mounting bolt
(15A) (M8 bolt) of right-hand armrest (10).
D. Turn right-hand armrest (10) up by 180 degrees.

★ If the armrest is not turned, you cannot apply the tool to
upper mounting bolt (15B).
E. Remove plastic cap (14) and upper mounting bolt (15B).
F. Remove the right-hand armrest (10).

★ There are 2 position adjustment washers (16) installed to
each bolt between the armrest and back seat. Take care not
to lose them.
50-256 D WA380-5L
5. Suspension cover
A. Remove right-hand hinge cover (17).
B. Remove plastic plate (18) from the year with screwdriver [1],
etc.
★ Take care not to damage the plastic plate by prying it off
forcibly with a screwdriver, etc.
C. Remove 4 suspension cover fixing rings (19).
D. Remove 4 mounting bolts (20), cushion rear fixing plate (21),

2 cushion rails (22), and 4 bushings (23).
WA380-5L 50-257 D
E. Remove 3 metallic suspension cover clips (24).
F. Remove 6 plastic suspension cover clips (small) (25) and 2

plastic suspension cover clips (large) (26).
★ Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
G. Remove suspension cover (27).

★ If you remove the suspension cover without performing
the work in steps E) and F), the suspension cover may be
broken.
H. Rails
i. Turn over the seat assembly to set rails (28) on the upside.
ii. Slide rails (28) to the rear end.
iii. Remove one hexagon socket head bolt (29) and one lock
washer (30) from the front part of each rail.
50-258 D WA380-5L
iv. Slide rails (28) to the front end.
v. Remove one hexagon socket head bolt (29) and one lock
washer (30) from the rear part of each rail, and then
remove rails (28).
★ Take care not to lose height adjustment washers (31)

between the rails and suspension.
WA380-5L 50-259 D
Assembly
1. Rails
A. Put height adjustment washers (31) between rails (28) and

suspension, then set rails (28) in position.
B. Set rails (28) to the front end and install 1 lock washer (30) and
1 hexagon socket head bolt (29) to each rail.
Hexagon socket head bolt:

21.4 - 27.6 Nm (2.2 - 2.8 kgf m) {16 - 20 lbf-ft}
C. Set rails (28) to the rear end and install 1 lock washer (30) and
1 hexagon socket head bolt (29) to each rail.
Hexagon socket head bolt:

21.4 - 27.6 Nm (2.2 - 2.8 kgf m) {16 - 20 lbf-ft}
2. Suspension cover
A. Set suspension cover (27) in position and install six plastic

suspension cover clips (small) (25) and two 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):
Front lower part; 2 places
50-260 D WA380-5L
B. Install three metallic suspension cover clips (24).
C. Set 4 bushings (23) and 2 cushion rails (22), and then install
cushion rear fixing plate (21), and 4 mounting bolts (20).
Cushion rail mounting bolt:

21.4 - 27.6 Nm (2.2 - 2.8 kgf m) {16 - 20 lbf-ft}
D. Install 4 suspension cover fixing rings (19).
E. Install plastic plate (18) to the rear.
F. Install right-hand hinge cover (17).
WA380-5L 50-261 D
3. Armrest
• The procedure for assembling right-hand armrest (10) is shown
below. (Assemble left-handed armrest (11) similarly.)
A. Install 2 position adjustment washers (16) for each bolt and set
right-hand armrest )10) in position.
B. Tighten lower mounting bolt (15A) lightly and turn armrest

(10) by 180 degrees.
C. Tighten upper mounting bolt (15B) lightly.
D. Tighten lower mounting bolt (15A) and upper mounting bolt

(15A) permanently.
Upper and lower armrest mounting bolt:

21.4 - 27.6 Nm (2.2 - 2.8 kgf m) {16 - 20 lbf-ft}
E. Install two plastic caps (14).
F. Tighten armrest hinge mounting bolt (13).

★ Tighten the bolt so that the arm will move smoothly.
• Operating effort at armrest end:49-78.4 N {36-58 lbf-ft}
G. Install plastic cap (12).
50-262 D WA380-5L
4. Seat cushion
A. Slide in the seat cushion from the front of the fitting position.
★ If seat cushion (8) is slid to the rear, it is locked by cushion
stopper wire (9).
5. Back seat
A. Insert the left side of back seat (4), and then lower and set the
right side.
WA380-5L 50-263 D
B. Install back seat hinge mounting bolt (6).
Back seat hinge mounting bolt:

21.4 - 27.6 Nm (2.2 - 2.8 kgf m) {16 - 20 lbf-ft}
C. Connect three air hoses (5) to the rear left of back seat (4).
D. Headrest
i. Insert headrest (3) in back seat (4).

★ Check that two clips (2) on both sides are securely
locked.
50-264 D WA380-5L
90 OTHERS
POWER TRAIN OIL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2

WITHOUT TORQUE CONVERTER LOCKUP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-2
WITH TORQUE CONVERTER LOCKUP CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3
BRAKE OIL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
HYDRAULIC CIRCUIT SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-5
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
FLOOR HARNESS - CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-7
FLOOR HARNESS - TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-9
FLOOR HARNESS - TRANSMISSION HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
FLOOR HARNESS - REAR HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-13
FLOOR HARNESS - RELAY UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-15
WITH JOYSTICK STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
FLOOR HARNESS - CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-17
FLOOR HARNESS - TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . 90-19
FLOOR HARNESS - JOYSTICK HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-21
FLOOR HARNESS - TRANSMISSION HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-23
FLOOR HARNESS - REAR HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-25
FLOOR HARNESS - RELAY UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-27
ENGINE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-29
REAR HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-31
FRONT FRAME HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-33
CAB HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-35
MONITOR PANEL CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-37
A/C RELAY HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-39
TRANSMISSION HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-41
JOYSTICK CONTROLLER HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-43
KOMTRAX HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-45
WA380-5L 90-1 2
OTHERS POWER TRAIN OIL CIRCUIT DIAGRAM
12
POWER TRAIN OIL CIRCUIT DIAGRAM
WITHOUT TORQUE CONVERTER LOCKUP CLUTCH
90-2 WA380-5L
OTHERS POWER TRAIN OIL CIRCUIT DIAGRAM
12
WITH TORQUE CONVERTER LOCKUP CLUTCH
WA380-5L 90-3
OTHERS BRAKE OIL CIRCUIT DIAGRAM
12
BRAKE OIL CIRCUIT DIAGRAM
90-4 WA380-5L
OTHERS HYDRAULIC CIRCUIT SCHEMATIC
HYDRAULIC CIRCUIT SCHEMATIC
WA380-5L WA380-5L 90-5 2

OTHERS HYDRAULIC CIRCUIT SCHEMATIC
12
90-6 1 WA380-5L
OTHERS ELECTRICAL SCHEMATIC
12
ELECTRICAL SCHEMATIC
STANDARD
FLOOR HARNESS - CAB
WA380-5L 90-7 2
90-8 1 WA380-5L
12
FLOOR HARNESS - TRANSMISSION CONTROLLER
WA380-5L 90-9 2
12
90-10 1 WA380-5L
12
FLOOR HARNESS - TRANSMISSION HARNESS
WA380-5L 90-11 2
12
90-12 1 WA380-5L
12
FLOOR HARNESS - REAR HARNESS
WA380-5L 90-13 2
12
90-14 1 WA380-5L
12
FLOOR HARNESS - RELAY UNITS
WA380-5L 90-15 2
12
90-16 1 WA380-5L
12
WITH JOYSTICK STEERING
FLOOR HARNESS - CAB
WA380-5L 90-17 2
12
90-18 1 WA380-5L
12
FLOOR HARNESS - TRANSMISSION CONTROLLER
WA380-5L 90-19 2
12
90-20 1 WA380-5L
12
FLOOR HARNESS - JOYSTICK HARNESS
WA380-5L 90-21 2
12
90-22 1 WA380-5L
12
FLOOR HARNESS - TRANSMISSION HARNESS
WA380-5L 90-23 2
12
90-24 1 WA380-5L
12
FLOOR HARNESS - REAR HARNESS
WA380-5L 90-25 2
12
90-26 1 WA380-5L
12
FLOOR HARNESS - RELAY UNITS
WA380-5L 90-27 2
12
90-28 1 WA380-5L
12
ENGINE HARNESS
WA380-5L 90-29 2
12
90-30 1 WA380-5L
12
REAR HARNESS
WA380-5L 90-31 2
12
90-32 1 WA380-5L
12
FRONT FRAME HARNESS
WA380-5L 90-33 2
12
90-34 1 WA380-5L
12
CAB HARNESS
WA380-5L 90-35 2
12
90-36 1 WA380-5L
12
MONITOR PANEL CONTROLLER
WA380-5L 90-37 2
12
90-38 1 WA380-5L
12
A/C RELAY HARNESS
WA380-5L 90-39 2
12
90-40 1 WA380-5L
12
TRANSMISSION HARNESS
WA380-5L 90-41 2
12
90-42 1 WA380-5L
12
JOYSTICK CONTROLLER HARNESS
WA380-5L 90-43 2
12
90-44 1 WA380-5L
12
KOMTRAX HARNESS
WA380-5L 90-45 2
12
90-46 2 WA380-5L

SM Wa380-5l A52001-Up Cebm009703

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

SM Wa380-5l A52001-Up Cebm009703

Uploaded by

Copyright:

Available Formats

CEBM009703

April 2009 Copyright 2009 Komatsu

10 STRUCTURE AND FUNCTION AND MAINTENANCE STANTARDS . . . . . . . . . . . . . . . 10-1

20 STANDARD VALUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

50 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-1

● Page to be replaced Replace

( ) Page to be deleted Discard

● 00-1 3 ● 00-11 3 ● 10-3 3 ● 10-31 3

● 00-2 3 ● 00-12 3 ● 10-4 3 ● 10-32 3

● 00-2-1 3 ● 00-13 3 ● 10-5 3 ● 10-33 3

● 00-2-2 3 ● 00-14 3 ● 10-6 3 ● 10-34 3

● 00-2-3 3 ● 00-15 3 ● 10-7 3 ● 10-35 3

● 00-2-4 3 ● 00-16 3 ● 10-8 3 ● 10-36 3

● 00-2-5 3 ● 00-17 3 ● 10-9 3 ● 10-37 3

● 00-2-6 3 ● 00-18 3 ● 10-10 3 ● 10-38 3

● 00-2-7 3 ❍ 00-19 3 ● 10-11 3 ● 10-39 3

● 00-2-8 3 ❍ 00-20 3 ● 10-12 3 ● 10-40 3

● 00-2-9 3 ❍ 00-21 3 ● 10-13 3 ● 10-41 3

● 00-2-10 3 ❍ 00-22 3 ● 10-14 3 ● 10-42 3

❍ 00-2-11 3 ● 10-15 3 ● 10-43 3

❍ 00-2-12 3 01-1 ● 10-16 3 ● 10-44 3

❍ 00-2-13 3 ● 01-2 3 ● 10-17 3 ● 10-45 3

❍ 00-2-14 3 01-3 1 ● 10-18 3 ● 10-46 3

❍ 00-2-15 3 ● 01-4 3 ● 10-19 3 ● 10-47 3

❍ 00-2-16 3 ● 01-5 3 ● 10-20 3 ● 10-48 3

❍ 00-2-17 3 ● 01-6 3 ● 10-21 3 ● 10-49 3

❍ 00-2-18 3 ● 01-7 3 ● 10-22 3 ● 10-50 3

● 00-3 3 ● 01-8 3 ● 10-23 3 ● 10-51 3

● 00-4 3 ● 01-9 3 ● 10-24 3 ● 10-52 3

● 00-5 3 ● 01-10 3 ● 10-25 3 ● 10-53 3

● 00-6 3 ❍ 01-11 3 ● 10-26 3 ● 10-54 3

● 00-7 3 ❍ 01-12 3 ● 10-27 3 ● 10-55 3

● 00-8 3 ● 10-28 3 ● 10-56 3

● 00-9 3 ● 10-1 3 ● 10-29 3 ● 10-57 3

● 00-10 3 ● 10-2 3 ● 10-30 3 ● 10-58 3

WA380-5L WA700-3L 00-2-1 3

● 10-59 3 ● 10-92 3 ● 10-125 3 ● 10-158 3

● 10-60 3 ● 10-93 3 ● 10-126 3 ● 10-159 3

● 10-61 3 ● 10-94 3 ● 10-127 3 ● 10-160 3

● 10-62 3 ● 10-95 3 ● 10-128 3 ● 10-161 3

● 10-63 3 ● 10-96 3 ● 10-129 3 ● 10-162 3

● 10-64 3 ● 10-97 3 ● 10-130 3 ● 10-163 3

● 10-65 3 ● 10-98 3 ● 10-131 3 ● 10-164 3

● 10-66 3 ● 10-99 3 ● 10-132 3 ● 10-165 3

● 10-67 3 ● 10-100 3 ● 10-133 3 ● 10-166 3

● 10-68 3 ● 10-101 3 ● 10-134 3 ● 10-167 3

● 10-69 3 ● 10-102 3 ● 10-135 3 ● 10-168 3

● 10-70 3 ● 10-103 3 ● 10-136 3 ● 10-169 3

● 10-71 3 ● 10-104 3 ● 10-137 3 ● 10-170 3

● 10-72 3 ● 10-105 3 ● 10-138 3 ● 10-171 3

● 10-73 3 ● 10-106 3 ● 10-139 3 ● 10-172 3

● 10-74 3 ● 10-107 3 ● 10-140 3 ● 10-173 3

● 10-75 3 ● 10-108 3 ● 10-141 3 ● 10-174 3

● 10-76 3 ● 10-109 3 ● 10-142 3 ● 10-175 3

● 10-77 3 ● 10-110 3 ● 10-143 3 ● 10-176 3

● 10-78 3 ● 10-111 3 ● 10-144 3 ● 10-177 3

● 10-79 3 ● 10-112 3 ● 10-145 3 ● 10-178 3

● 10-80 3 ● 10-113 3 ● 10-146 3 ● 10-179 3

● 10-81 3 ● 10-114 3 ● 10-147 3 ● 10-180 3

● 10-82 3 ● 10-115 3 ● 10-148 3 ● 10-181 3

● 10-83 3 ● 10-116 3 ● 10-149 3 ● 10-182 3

● 10-84 3 ● 10-117 3 ● 10-150 3 ● 10-183 3