Wa700 3

SEBM013312
Machine model Serial number
WA700-3 50001 and up

WA700-3D 50001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice.
• WA700-3, WA700-3D mount the SAA6D170E-2 or SAA6D170E-3 engine.

For details of the engine, see the 6D170-2 or 170-3 Series Engine Shop Manual.
© 2007
All Rights Reserved 00-1
Printed in Japan 10-07 (01) (12)
Contents
No. of page
01 General .......................................................................................................................... 01-1
10 Structure and function ...................................................................................... 10-1
20 Testing and adjusting ........................................................................................ 20-1
30 Disassembly and assembly .......................................................................... 30-1
40 Maintenance standard....................................................................................... 40-1
90 Others ............................................................................................................................. 90-1
00-2 WA700-3
(11)
List of revised pages
The affected pages are indicated by the use of the

following marks. It is requested that necessary Mark Indication Action required
actions be taken to these pages according to the
table below. Q Page to be newly added Add
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made additions.
Time of Time of Time of Time of Time of

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
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WA700-3 00-2-5
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30-33 (3) 30-67 (3) 30-107 (3) 30-145 (3) 30-185 (3)
30-34 (7) 30-68 (3) 30-108 (3) 30-146 (3) 30-186 (3)
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30-37 (7) 30-74 (3) 30-114 (3) 30-152 (3) 30-191-1 (9)
30-38 (3) 30-75 (3) 30-115 (3) 30-153 (3) 30-191-2 (9)
30-39 (7) 30-76 (3) 30-116 (3) 30-154 (3) 30-191-3 (4)
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30-204 (3) 30-239 (3) 40-13 (10) 40-57 (10)

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30-216 (3) 30-251 (3) 40-26 (10) 90-5 (10)
30-217 (3) 30-252 (7) 40-27 (10) 90-7 (10)
30-218 (3) 30-252-1 (7) 40-28 (10) 90-9 (10)
30-219 (3) 30-252-2 (7) 40-29 (10) 90-11 (10)
30-220 (3) 30-253 (3) 40-30 (10) 90-13 (10)
30-221 (3) 30-254 (10) 40-32 (10) 90-15 (10)
30-222 (3) 30-254-1 (10) 40-33 (10) 90-17 (10)
30-223 (3) 30-254-2 (10) 40-34 (10) 90-19 (10)
30-224 (3) 30-255 (10) 40-35 (10) 90-21 (10)
30-225 (7) 30-255-1 (10) 40-36 (10) 90-23 (10)
30-226 (7) 30-256 (10) 40-38 (10) 90-25 (10)
30-226-1 (7) 30-257 (10) 40-39 (10) 90-27 (10)
30-226-2 (7) 30-258 (10) 40-40 (10) 90-29 (10)
20-226-3 (7) 30-259 (3) 40-42 (10) 90-31 (10)
30-227 (10) 30-260 (3) 40-43 (10) 90-33 (10)
30-228 (10) 30-261 (3) 40-44 (10) 90-35 (10)
30-229 (10) 30-262 (7) 40-45 (10)
30-230 (3) 40-46 (10)
30-231 (7) 40-1 (10) 40-47 (10)
30-232 (7) 40-3 (10) 40-48 (10)
30-232-1 (7) 40-4 (10) 40-49 (10)
30-232-2 (7) 40-5 (10) 40-50 (10)
30-233 (3) 40-6 (10) 40-51 (10)
30-234 (3) 40-7 (10) 40-52 (10)
30-235 (3) 40-8 (10) 40-53 (10)
30-236 (3) 40-9 (10) 40-54 (10)
30-237 (3) 40-10 (10) 40-55 (10)
30-238 (3) 40-12 (10) 40-56 (10)
WA700-3 00-2-7
(12)
Safety Safety notice
Safety
Safety notice
Important safety notice

Proper service and repair is extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the
situation.
General precautions
6. Decide a place in the repair workshop to keep
Mistakes in operation are extremely dangerous. tools and removed parts. Always keep the tools
Read the Operation and Maintenance Manual care- and parts in their correct places. Always keep
fully BEFORE operating the machine. the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the
1. Before carrying out any greasing or repairs, read areas provided for smoking. Never smoke while
all the precautions given on the decals which working.
are fixed to the machine.
Preparations for work
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose 7. Before adding oil or making any repairs, park
work clothes, or clothes with buttons missing. the machine on hard, level ground, and block
• Always wear safety glasses when hitting the wheels or tracks to prevent the machine
parts with a hammer. from moving.
• Always wear safety glasses when grinding
parts with a grinder, etc. 8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work.
9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your
fellow workers before starting any step of the 10. Remove all mud and oil from the steps or other
operation. Before starting work, hang UNDER places used to get on and off the machine.
REPAIR signs on the controls in the operator's Always use the handrails, ladders or steps when
compartment. getting on or off the machine. Never jump on or
off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
Safety Safety notice
Precautions during work 19. Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or
Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen
• When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out.
that they will not be damaged by contact with
Before disconnecting or removing components
other parts when the machine is being
of the oil, water or air circuits, first remove the
operated.
pressure completely from the circuit.
20. When installing high pressure hoses, make sure
12. The water and oil in the circuits are hot when the
that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get
dangerous, so be extremely careful when install-
burned.
ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carrying
that connecting parts are correctly installed.
out any work on the oil or water circuits.
21. When assembling or installing parts, always use
13. Before starting work, remove the leads from the
the specified tightening torques. When installing
battery. Always remove the lead from the nega-
protective parts such as guards, or parts which
tive (–) terminal first.
vibrate violently or rotate at high speed, be par-
ticularly careful to check that they are installed
14. When raising heavy components, use a hoist or
correctly.
crane.
Check that the wire rope, chains and hooks are
22. When aligning two holes, never insert your fin-
free from damage.
gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample
caught in a hole.
capacity.
Install the lifting equipment at the correct places.
23. When measuring hydraulic pressure, check that
Use a hoist or crane and operate slowly to pre-
the measuring tool is correctly assembled
vent the component from hitting any other part.
before taking any measurements.
Do not work with any part still raised by the hoist
or crane.
24. Take care when removing or installing the tracks
of track-type machines.
15. When removing covers which are under internal
When removing the track, the track separates
pressure or under pressure from a spring,
suddenly, so never let anyone stand at either
always leave two bolts in position on opposite
end of the track.
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16. When removing components, be careful not to

break or damage the wiring. Damaged wiring
may cause electrical fires.
17. When removing piping, stop the fuel or oil from

spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18. As a general rule, do not use gasoline to wash

parts. In particular, use only the minimum of gas-
oline when washing electrical parts.
00-4
Foreword General
Foreword
General
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
Structure and function

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

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

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
Maintenance standard
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in “Structure and function”.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
Notice
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
Foreword General
How to read the shop manual Revised edition mark

W he n a m an ua l i s r ev i s e d, an e di t i on m a r k
Volumes ((1)(2)(3)....) is recorded on the bottom of the pages.
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
Revisions
Chassis volume: Issued for every machine model Revised pages are shown in the List of revised
Engine volume: Issued for each engine series pages next to the Contents page.
Each issued as one
Electrical volume:
volume to cover all
Attachments volume: Symbols
models
So that the shop manual can be of ample practical
use, important safety and quality portions are
These various volumes are designed to avoid dupli- marked with the following symbols.
cating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chas-
Symbol Item Remarks
sis, engine, electrical and attachment volumes be
available. Special safety precautions
k Safety are necessary when
performing the work.
Distribution and updating Special technical
Any additions, amendments or other changes will be precautions or other
sent to KOMATSU distributors. Get the most up-to- a Caution precautions for preserving
date information before you start any work. standards are necessary
when performing the work.
Filing method Weight of parts of systems.
1. See the page number on the bottom of the page. Caution necessary when
4
File the pages in correct order. Weight selecting hoisting wire, or
when working posture is
2. Following examples show how to read the page
important, etc.
number.
Places that require special
3
Example 1 (Chassis volume): Tightening
attention for the tightening
torque
10 - 3 torque during assembly.
Places to be coated with
2
Item number Coat adhesives and lubricants,
(10. Structure and Function) etc.
Consecutive page number for
Places where oil, water or
5
each item.
Oil, water fuel must be added, and
Example 2 (Engine volume): the capacity.
12 - 5 Places where oil or water
6
Drain must be drained, and
Unit number (1. Engine) quantity to be drained.
Item number
(2. Testing and Adjusting)
Consecutive page number for
each item.
3. Additional pages: Additional pages are indi-

cated by a hyphen (–) and number after the
page number. File as in the example.
Example:
10-4 20-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
Foreword Hoisting instructions
Hoisting instructions
Hoisting
Slinging near the edge of the hook may
k
cause the rope to slip off the hook during
Heavy parts (25 kg or more) must be lifted
hoisting, and a serious accident can result.
with a hoist, etc. In the Disassembly and
Hooks have maximum strength at the mid-
assembly section, every part weighing 25
dle portion.
kg or more is indicated clearly with the
symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks should
be made:
1) Check for removal of all bolts fastening the
part to the relative parts. 100% 88% 79% 71% 41%
2) Check for existence of another part causing SAD00479
interference with the part to be removed. 3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
Wire ropes symmetrically wound onto the load.
k
1) Use adequate ropes depending on the
Slinging with one rope may cause
weight of parts to be hoisted, referring to the
turning of the load during hoisting,
table below:
untwisting of the rope, or slipping of the
Wire ropes rope from its original winding position on
(Standard “Z” or “S” twist ropes the load, which can result in a dangerous
without galvanizing) accident.
Rope diameter Allowable load
mm kN tons 4) Do not sling a heavy load with ropes forming
10 9.8 1.0 a wide hanging angle from the hook.
11.5 13.7 1.4 When hoisting a load with two or more
12.5 15.7 1.6 ropes, the force subjected to each rope will
14 21.6 2.2 increase with the hanging angles. The table
16 27.5 2.8 below shows the variation of allowable load
18 35.3 3.6 kN {kg} when hoisting is made with two
20 43.1 4.4 ropes, each of which is allowed to sling up
22.4 54.9 5.6
to 9.8 kN {1000 kg} vertically, at various
30 98.1 10.0
hanging angles.
40 176.5 18.0
50 274.6 28.0 When two ropes sling a load vertically, up to
60 392.2 40.0 19.6 kN {2000 kg} of total weight can be
suspended. This weight becomes 9.8 kN
a The allowable load value is estimated to be {1000 kg} when two ropes make a 120?
one-sixth or one-seventh of the breaking hanging angle. On the other hand, two
strength of the rope used. ropes are subjected to an excessive force
as large as 39.2 kN {4000 kg} if they sling a
2) Sling wire ropes from the middle portion of 19.6 kN {2000 kg} load at a lifting angle of
the hook. 150°.
00-7
Foreword Method of disassembling, connecting push-pull type coupler
Method of disassembling, connecting push-pull type coupler

k Before carrying out the following work, release Type 1
the residual pressure from the hydraulic tank.
For details, see “Tes ting and adjus ting”,
Releasing residual pressure from hydraulic tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the
hydraulic tank. For details, see “Testing and
adjusting”, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

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

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

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

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

LT-1A 790-129-9030 150 g Tube
cushions, and cock plug from coming out.
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pcs.) container polyprophylene, tetrafluoroethlene and
vinyl chloride), rubber, metal and non-
metal.
• Features:
Polyethylene Resistance to heat and chemicals
LT-2 09940-00030 50 g
container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for metal,
790-129-9060
1 kg glass and plastic.
(Set of adhesive
LT-3 Hardening Can
and hardening
agent:
agent)
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for
790-126-9120 75 g Tube
MH 705 repairing engine.
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type
Aron-alpha Polyethylene
790-129-9130 2g (max. strength after 30 minutes)
201 container
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container
temperatures.
• Used as adhesive or sealant for gaskets
LG-1 790-129-9010 200 g Tube
and packing of power train case, etc.
• Used as sealant for various threads, pipe
joints, flanges.
LG-5 790-129-9080 1 kg Can
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance to
heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread.
• Used as sealant for oil pan, final drive
Gasket case, etc.
sealant • Features: Silicon based, quick hardening
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing,
intake manifold, oil pan, thermostat
housing, etc.
Three bond • Used as heat-resisting sealant for
790-129-9090 100 g Tube
1211 repairing engine.
• Features: Silicone type, heat resistant,
Three bond vibration resistant, and impact resistant
419-15-18131 100 g Tube
1207B sealing material
• Used as sealing material for transfer case
00-10
Foreword Coating materials
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to
LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion
SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease
SYGA-16CNM 16 kg Can
LM-G (G2-M)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
Foreword Standard tightening torque
Standard tightening torque

Standard tightening torque table (when using torque wrench)
a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the
table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5
8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

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

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0
8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below.
SAD00483
Thread diameter Width across flats Tightening torque

mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5
18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
Table of tightening torques for flared nuts

a In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table
below.
Thread diameter Width across flats Tightening torque

mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
Table of tightening torques for o-ring boss piping joints

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

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}
03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
Table of tightening torques for o-ring boss plugs

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

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
Tightening torque for 102 and 114 engine series

1) Bolt and nuts
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22
2) Eye joints
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) Tapered screws
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
Tightening torque table for hoses (taper seal type and face seal type)
a Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
a Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
Nominal type
Width
size of
hose across flats Thread size Nominal thread size Root diameter
Range Target – Threads per inch, (mm)
(mm) (Reference)
Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} — – 18UN 14.3
16
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 — —
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} — – 16UN 17.5
16
03
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 — —
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 — —
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 — —
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 — —
00-14
Foreword Electric wire code
Electric wire code

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
Classification by thickness
Copper wire
Norminal Cable O.D. Current rating
Number of Dia. of Cross section Applicable circuit
number (mm) (A)
strands strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Classification by color and code

Circuits
Priority Charging Ground Starting Lighting Instrument Signal Other
Classification
Code W B B R Y G L
1 Primary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
White & White & Red & Rellow & Green & Blue &
Color —
Red Black White Red White White
Code WB — BY RB YB GR LR
3
White & Black & Red & Yellow & Green & Blue &
Color —
Black Yellow Black Black Red Yellow
Code WL — BR RY YG GY LY
4 Auxiliary
White & Black & Red & Yellow & Green & Blue &
Color —
Blue Red Yellow Green Yellow Yellow
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
00-15
Foreword Conversion table
Conversion table
Method of using the conversion table
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
Example
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

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

Specifications .................................................01- 5
Weight table ...................................................01- 8
List of lubricant and water ..............................01- 10
WA700-3 01-1
(10)
General General assembly drawing
General assembly drawing

WA700-3
Serial No.: 50001 – 51000 Unit: mm
01-2 WA700-3
(10)
WA700-3D (TBG SPEC.)

Serial No.: 50001 – 51000 Unit: mm
WA700-3 01-3
(10)
WA700-3, WA700-3D
Serial No.: 51001 and up Unit: mm
01-4 WA700-3
(10)
General Specifications
Specifications
[ ]: WA700-3D
Machine model WA700-3
Serial No. 50001 – 51000 51001 and up
Operating weight kg 70,800 [ 71,200] 71,000 [ 71,390]

Weight
Distribution (front) kg 38,100 38,210 [ 38,200]

Distribution (rear) kg 32,700 [ 33,100] 32,790 [ 33,190]
3
Bucket capacity (piled) m 8.7
Rated load kN {kg} 153 {15,660}
Travel speed FORWARD 1st km/h 6.4
FORWARD 2nd km/h 11.1
FORWARD 3rd km/h 18.7
FORWARD 4th km/h 30.0
Performance
REVERSE 1st km/h 7.1

REVERSE 2nd km/h 12.3
REVERSE 3rd km/h 20.5
REVERSE 4th km/h 32.2
Max. rimpull FORWARD kN {kg} 470.7 {48,000}
Gradeability deg 25
Center of outside wheel mm 8,095 8,100
Min. turning
radius Outside portion of chassis
mm 9,615 9,590
(with tooth)
Overall length (with tooth) mm 12,500
Overall width (chassis) mm 4,040
Bucket width (tooth) mm 4,330
(tire guard) mm 4,570
Overall height (top of ROPS canopy) mm 4,790
(Bucket raised) mm 8,165
Dimensions
Wheelbase mm 4,800
Tread mm 3,000
Min. ground clearance mm 540
Height of bucket hinge pin mm 5,990
Dumping clearance (tip of edge) mm 4,380
Dumping reach (tip of edge) mm 1,910
Bucket dump angle deg 61.5
Bucket tilt angle (travel posture) deg 50
Digging depth (10° dump) (with tooth) mm 570
WA700-3 01-5
(10)
[ ]: WA700-3D
Serial No. 50001 – 51000 51001 and up
Model SAA6D170E-2 SAA6D170E-3

4-cycle, water-cooled, 4-cycle, water-cooled,
in-line, 6-cylinder, in-line, 6-cylinder,
Type direct injection, direct injection,
with 2-turbocharger, with turbocharger,
after-cooler after-cooler
No. of cylinders – bore × stroke mm 6 – 170 × 170
Piston displacement l {cc} 23.15 {23,150}
Flywheel horsepower kW/rpm {HP/rpm} 478/2,000 {641/2,000} 502/2,000 {672/2,000}
Engine
Nm/rpm 2,810/1,400 2,884/1,400

Performance
Maximum torque
{kgm/rpm} {286.5/1,400} {294/1,400}
Fuel consumption ratio (at rated output) g/kW·h {g/HP·h} 207 {154} 214 {160}
High idling speed rpm 2,240 [ 2,190] 2,240
Low idling speed rpm 650 725
Starting motor 24 V 7.5 kW × 2
Alternator 24 V 50 A
Battery 12 V 200 Ah × 2
Torque converter 3-element, 1-stage, single-phase
Planetary gear, constant-mesh multiple-disc,
Power train
Transmission hydraulically actuated, pressure rised

lubrication, 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
Front axle Fixed-frame, full-floating
Axle, wheel
Rear axle Center pin support type, full-floating

Tire 40/65-39-36PR(L-5)
Wheel rim 32.00 × 39-4WTB
2
Inflation pressure Front tire kPa {kg/cm } 441 {4.5}
Rear tire kPa {kg/cm2} 441 {4.5}
Front/rear wheel braking, separate front/rear
Main brake
wheel, wet disc, hydraulically actuated
Brakes
Drive shaft, dry caliper type disc brake,

Parking brake
hydraulically released spring type
01-6 WA700-3
(10)
Serial No. 50001 – 51000 51001 and up
Type Articulated type

Steering
system
Structure Fully hydraulically power steering
50001 – 50056 50057 and up

Torque converter, l/min 317 317
transmission pump (Gear type: (Gear type:
SAR(4)160) SAR(4)160)
Steering pump l/min 203 203
(Fixed capacity piston (Fixed capacity piston
pump: HPF90) pump: HPF95)
Switch pump l/min 203 203
Hydraulic (Fixed capacity piston (Fixed capacity piston
pump pump: HPF90) pump: HPF95)
Delivery
PPC pump l/min 43 43
(Gear type: SAR(1)20) (Gear type: SAR(1)20)
Cooling pump l/min 55 55
(Gear type: SAR(1)28) (Gear type: SAR(1)28)
Hydraulic system
Work equipment pump l/min 405 405

(Variable capacity (Variable capacity
piston pump: HPV90 + piston pump: HPV95 +
Fixed capacity piston Fixed capacity piston
pump: HPF90) pump: HPF95)
Transmission valve MPa {kg/cm2} 2.9 {30}
(Spool type, electric control)
Steering demand valve MPa {kg/cm2} 31.4 {320}
Control valve (Fully hydraulic type)
Set pressure PPC valve MPa {kg/cm2} 3.7 {38}
(2-lever type)
Main control valve MPa {kg/cm2} 31.4 {320}
(2-spool type)
Steering cylinder Reciprocating piston
No. – bore × stroke mm 2 – 130 × 532
Boom cylinder Reciprocating piston
Cylinder
No. – bore × stroke mm 2 – 225 × 1,196
Bucket cylinder Reciprocating piston
No. – bore × stroke mm 1 – 280 × 729
equipment
Link type Single Z bar link

Work
Bucket edge type Spade nose with teeth
WA700-3 01-7
(10)
General Weight table
Weight table
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Serial No. 50001 – 51000 51001 and up
Engine (dry) 2,900

Radiator (dry) 644 [ 688] 720
Torque converter (dry) 574
Transmission (dry) 1,720
Damper 170
Upper drive shaft 52
Center drive shaft 90
Front drive shaft 112
Rear drive shaft 83
Center support 67
Front axle 5,532
Rear axle 5,454
Front differential 826
Rear differential 854
Planetary carrier assembly (each) 357.5
Planetary hub (each) 298
Axle support (Rear axle) 331
Wheel (each) 617
Tire (each) 1,870
Steering demand valve 66
Steering cylinder (each) 159
Hydraulic tank (dry) 665
Work equipment pump 150
Torque converter charging + cooling + PPC + brake pump 37
Steering + Switch pump 145
[ ]: WA700-3D
01-8 WA700-3
(10)
General Weight table
Unit: kg
Serial No. 50001 – 51000 51001 and up
PPC valve 5.5

Main control valve 95
Boom cylinder (each) 674
Bucket cylinder 945
62 [ 87] (Top)
Engine hood
50 [ 59] (Side)
Front frame 4,960
Rear frame 5,761
Bucket link (with bushing) 340
Bellcrank (with bushing) 1,460
Boom (with bushing) 5,714
Bucket (with teeth) 7,090
Counterweight 2,510
Fuel tank 572
Battery (each) 64
Cab 448.5
Air conditioner unit 55
Operator’s seat 54.2
Floor board 348
Fender, ladder assembly 1,354
[ ]: WA700-3D
WA700-3 01-9
(10)
General List of lubricant and water
List of lubricant and water

AMBIENT TEMPERATURE CAPACITY
RESERVOIR KIND OF
–22 –4 14 32 50 68 86 104 122 F
FLUID –30 –20 –10 0 10 20 30 40 50 C Specified Refill
SAE 30 63 54
Serial No.: Serial No.:
SAE 10W 50001 – 51000 50001 – 51000
Engine oil pan
SAE 10W-30 61 52
SAE 15W-40 51001 and up 51001 and up
Engine SAE 30
Transmission case 120 105
oil SAE 10W
Hydraulic system SAE 10W 780 490
Brake SAE 10W 38 27
245 245
Axle
50001 – 50045 50001 – 50045
(Front and rear) See Note 1 315 315
(each) Serial No.: Serial No.:
50046 and up 50046 and up
Pins Grease NLGI No.2 — —
(Serial No.: ASTM D975 No.2

50001 – 51000)
Fuel Diesel 1,100 —
tank fuel
(Serial No.: ASTM D975 No.2
51001 and up)
200 190
50001 – 51000 50001 – 51000
Cooling system Water Add antifreeze
219 209
51001 and up 51001 and up
ASTM D975 No.1
Note 1:
For axle oil, use only recommended oil as follows.
SHELL: DONAX TD
MOBIL: MOBILFLUID 424
ESSO: TORQUE FLUID 56
It is possible to substitute engine oil CLASS-CD
SAE30 for axle oil.
If noise comes from the brake, it is no problem of
durability.
01-10 WA700-3
(10)
General List of lubricant and water
REMARK
• When fuel sulphur content is less than 0.5%,
ch ang e oi l i n t he o il pa n every p eri odi c
maintenance hours described in this manual.
Change oil according to the following table if fuel
sulphur content is above 0.5%.
Change interval of oil in
Fuel sulphur content
engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
• When starting the engine in an atmospheric

temperature of lower than 0°C, be sure to use
en gine oi l of SAE 10W , SA E10W -30 and
SAE15W-40, even though an atmospheric
temperature goes up to 10°C more or less in the
day time.
• Use API classification CD as engine oil and if API

classification CC, reduce the engine oil change
interval to half.
• There is no problem if single grade oil is mixed

with multigrade oil (SAE10W-30, 15W-40), but
be sure to add single grade oil that matches the
temperature in the table.
• We recommend Komatsu genuine oil which has

been specifically formulated and approved for
use in engine and hydraulic work equipment
applications.
Specified capacity: Total amount of oil including oil

for components and oil in piping.
Refill capacity: Amount of oil needed to refill system
during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
WA700-3 01-11
(10)
10 Structure and function
Outline ..................................................... 10- 2 Lubrication of work equipment .................10-172

Power train system .................................. 10- 4 Work equipment linkage...........................10-174
Damper .................................................... 10- 6 Bucket positioner and boom kick-out .......10-176
Radiator and oil cooler............................. 10- 7 Operation of proximity switch ...................10-178
Transmission hydraulic system diagram.. 10- 10 Air conditioner ..........................................10-182
Transmission hydraulic circuit diagram.... 10- 14 Electric circuit diagram .............................10-186
Torque converter and Machine monitor system ..........................10-186
transmission piping ............................ 10- 16 Main monitor.............................................10-187
Torque converter and PTO ...................... 10- 18 Maintenance monitor................................10-191
Torque converter regulator valve Automatic transmission system (ATM) .....10-193
(Serial No.: 51001 and up) ................. 10- 25 Joystick steering system
Transmission ........................................... 10- 26 (Serial No.: 50001 – 51000)................10-206
Transmission control valve ...................... 10- 36 AJSS (Advanced Joystick Steering
Torque converter oil cooler ...................... 10- 60 System)...............................................10-208
Transmission oil filter ............................... 10- 61 Transmission and joystick controller ........10-212
Transfer ................................................... 10- 63 Engine starting circuit ...............................10-215
Axle.......................................................... 10- 64 Engine stop circuit ....................................10-218
Differential................................................ 10- 66 Auto priming system (APS)
Final drive ................................................ 10- 68 (Serial No.: 50001 – 51000)................10-220
Steering piping diagram ........................... 10- 71 Preheating circuit
Steering and switch pump ....................... 10- 72 (Serial No.: 51001 and up)..................10-224
Steering unit (Orbit-roll valve) .................. 10- 76 Fuel system
Steering demand valve ............................ 10- 79 (Serial No.: 51001 and up)..................10-225
Two-way restrictor valve .......................... 10- 90 Electrical transmission control..................10-226
Stop valve ................................................ 10- 91 Kick-down, hold switch .............................10-229
Diverter valve........................................... 10- 92 Kick-down electrical circuit .......................10-230
Brake piping............................................. 10- 96 Electric parking brake control ...................10-236
Brake circuit diagram ............................... 10- 97 Electric circuit diagram of active power
Brake valve .............................................. 10- 98 maximizing system...........................10-244-1
Charge valve ........................................... 10-104
[Related to VHMS controller]
Accumulator (for brake) ........................... 10-108
VHMS controller .......................................10-245
Slack adjuster .......................................... 10-109
Blow-by pressure sensor..........................10-245
Brake ....................................................... 10- 112
Engine oil temperature sensor .................10-246
Parking brake .......................................... 10- 115
Exhaust temperature sensor/amp ............10-247
Spring cylinder ......................................... 10- 119
Ambient temperature sensor ....................10-247
Parking brake solenoid valve................... 10-120
Transmission pump oil pressure sensor...10-248
Hydraulic piping ....................................... 10-122
Brake oil temperature sensor ...................10-249
Hydraulic circuit diagram ......................... 10-124
Hydraulic oil temperature sensor..............10-249
Main piston pump .................................... 10-127
Brake oil pressure sensor.........................10-250
ES valve .................................................. 10-139
Steering oil pressure sensor.....................10-250
Servo valve .............................................. 10-140
Work equipment pump oil pressure
Pressure differential valve ....................... 10-141
sensor .................................................10-250
PPC valve (Proportional Pressure Valve) 10-142
Communications (ORB: Orbcomm)
PPC relief valve ....................................... 10-146
controller/antenna ...............................10-251
Accumulator (for PPC valve) ................... 10-147
Main control valve.................................... 10-148 a For details of VHMS, see Testing and adjusting.
WA700-3 10-1
(12)
Structure and function Outline
Outline
Outline
• Power from engine (7) is transmitted to damper 1. Center drive shaft
(6) through the engine flywheel. The damper 2. Transfer
output shaft is connected to torque converter (4) 3. Transmission
through upper drive shaft (5) and the torque 4. Torque converter
converter turbine is connected to transmission 5. Upper drive shaft
(3) input shaft. 6. Damper
• The transmission is equipped with 6 hydrau- 7. Engine
lically-actuated clutches, by which the speed can 8. Rear axle
be set in four stages for both FORWARD and 9. Rear drive shaft
REVERSE, and can be selected by the electric 10. Center support
control lever. 11. Front drive shaft
• Output shaft of transmission is connected to the 12. Front axle
transfer (2) gear and transmitted to the output
shaft.
Power is transmitted from the transfer output
shaft to front axle (12) through center drive shaft
(1), center support (10) and front drive shaft (11),
also power is transmitted from the transfer output
shaft to rear axle (8) through rear drive shaft (9).
10-2 WA700-3
(10)
Structure and function Power train system
Power train system
10-4 WA700-3
(10)
Structure and function Power train system
1. Engine
2. Damper
3. Upper drive shaft
4. Four tandem pump
(T/C charging + cooling + PPC + brake pump)
5. Piston pump (Steering + Switch pump)
6. Piston pump (work equipment pump x 2)
7. Torque converter
8. Transmission
9. Transfer
10. Emergency steering pump
11. Center drive shaft
12. Center support
13. Front drive shaft
14. Parking brake
15. Front axle
16. Front differential
17. Front brake
18. Front final drive
19. Front wheel
20. Rear drive shaft
21. Rear differential
22. Rear axle
23. Rear brake
24. Rear final drive
25. Rear wheel
WA700-3 10-5
(10)
Structure and function Damper
Damper
1. Shaft Operation
2. Rubber cushion • The motive force from the engine is transmitted
3. Inner body from the flywheel to outer body (4), and the
4. Outer body torsional vibration of the engine is absorbed by
rubber cushion (2). The power then passes
through inner body (3) to shaft (1), and is
transmitted to the upper drive shaft.
10-6 WA700-3
(10)
Structure and function Radiator and oil cooler
Radiator and oil cooler

Serial No.: 50001 – 51000
1. Radiator coolant level sensor Specification

2. Radiator Radiator
3. Fan guard • Core type: G-7
4. Hydraulic oil cooler • Total emission area: 167.97 m2
5. Torque converter oil cooler • Cross-sectional area of flow: 254.9 cm2
A. Coolant inlet Torque converter oil cooler

B. Coolant outlet • Type: PTO-LS
C. Hydraulic oil outlet port • Emission area: 4.065 m2
D. Hydraulic oil inlet port
E. Torque converter oil outlet port Hydraulic oil cooler
F. Torque converter oil inlet port • Type: J-4
• Total emission area: 100.76 m2
• Cross-sectional area of oil flow: 76.4 cm2
WA700-3 10-7
(10)
Structure and function Radiator and oil cooler
Serial No.: 51001 and up
1. Radiator coolant level sensor Specification

2. Radiator Radiator
3. Hydraulic oil cooler • Core type: PF2-7
4. After-cooler • Total emission area: 199.6 m2
5. Fuel cooler • Cross-sectional area of flow: 254.9 cm2
6. Torque converter oil cooler
Torque converter oil cooler
A. Coolant inlet • Type: PTO-LS
B. Coolant outlet • Emission area: 4.065 m2
C. Hydraulic oil inlet port
D. Hydraulic oil outlet port Hydraulic oil cooler
E. Torque converter oil inlet port • Type: J-4
F. Torque converter oil outlet port • Total emission area: 100.76 m2
• Cross-sectional area of oil flow: 76.4 cm2
10-8 WA700-3
(10)
Structure and function Transmission hydraulic system diagram
Transmission hydraulic system diagram

Serial No.: 50001 – 51000
10-10 WA700-3
(10)
1. Transmission case
2. Strainer
3. Torque converter charging pump
4. Oil filter (x 4)
5. Transmission main relief valve
6. Torque converter relief valve
7. Torque converter
8. Oil cooler
9. PTO case
10. Lubrication valve
11. Transmission lubrication
12. Lubrication bypass valve
13. Priority valve
14. Modulating valve
15. Quick return valve
16. Pilot reducing valve
17. Pilot filter
18. Reducing valve
19. Reverse spool
20. Forward spool
21. 4th spool
22. 3rd spool
23. 2nd spool
24. 1st spool
25. Emergency manual spool
26. Solenoid valve
27. Reverse clutch
28. Forward clutch
29. 4th clutch
30. 3rd clutch
31. 2nd clutch
32. 1st clutch
33. Quick fill valve
34. PTO lubrication
WA700-3 10-11
(10)
10-12 WA700-3
(10)
1. Transmission case
2. Strainer
4. Oil filter (x 4)
5. Transmission main relief valve
6. Torque converter relief valve
7. Torque converter
8. Oil cooler
9. PTO case
10. Lubrication valve
11. Transmission lubrication
13. Priority valve
14. Modulating valve
15. Quick return valve
16. Pilot reducing valve
17. Pilot filter
18. Reducing valve
19. Reverse spool
20. Forward spool
21. 4th spool
22. 3rd spool
23. 2nd spool
24. 1st spool
25. Emergency manual spool
26. Solenoid valve
27. Reverse clutch
28. Forward clutch
29. 4th clutch
30. 3rd clutch
31. 2nd clutch
32. 1st clutch
33. Quick fill valve
34. PTO lubrication
35. Torque converter regulator valve
WA700-3 10-13
(10)
Structure and function Transmission hydraulic circuit diagram
Transmission hydraulic circuit diagram

Serial No.: 50001 – 51000
1. Transmission case 17. Lubrication bypass valve

2. Strainer 18. Reverse spool
3. Torque converter charging pump 19. Forward spool
4. Oil filter (x 4) 20. 4th spool
5. Transmission main relief valve 21. 3rd spool
6. Pilot filter 22. Reducing valve
7. Pilot reducing valve 23. 2nd spool
8. Priority valve 24. 1st spool
9. Modulating valve 25. Emergency manual spool
10. Quick fill valve 26. Solenoid valve
11. Quick return valve 27. Reverse clutch
12. Torque converter 28. Forward clutch
13. Oil cooler 29. 4th clutch
14. Lubrication valve 30. 3rd clutch
15. Transmission lubrication 31. 2nd clutch
16. Torque converter relief valve 32. 1st clutch
10-14 WA700-3
(10)
Structure and function Transmission hydraulic circuit diagram
1. Transmission case 18. Reverse spool

2. Strainer 19. Forward spool
3. Torque converter charging pump 20. 4th spool
4. Oil filter (x 4) 21. 3rd spool
5. Transmission main relief valve 22. Reducing valve
6. Pilot filter 23. 2nd spool
7. Pilot reducing valve 24. 1st spool
8. Priority valve 25. Emergency manual spool
9. Modulating valve 26. Solenoid valve
10. Quick fill valve 27. Reverse clutch
11. Quick return valve 28. Forward clutch
12. Torque converter 29. 4th clutch
13. Oil cooler 30. 3rd clutch
14. Lubrication valve 31. 2nd clutch
15. Transmission lubrication 32. 1st clutch
16. Torque converter relief valve 33. Torque converter regulator valve
WA700-3 10-15
(10)
Structure and function Torque converter and transmission piping
Torque converter and transmission piping

Serial No.: 50001 – 51000
1. Transfer
2. Transmission control valve
3. Torque converter
6. Transmission
7. Torque converter oil filter
8. Transmission oil sight gauge
10-16 WA700-3
(10)
Structure and function Torque converter and transmission piping
1. Transfer
2. Transmission control valve
3. Torque converter
6. Transmission
7. Torque converter oil filter
8. Transmission oil sight gauge
WA700-3 10-17
(10)
Structure and function Torque converter and PTO
Torque converter and PTO

Serial No.: 50001 – 51000
Specifications
Type: 3-element, single stage, single phase
Stall torque ratio: 2.84
1. Torque converter outlet oil pressure pick-up

2. Torque converter inlet oil pressure pick-up
3. Steering and switch pump mounting
4. Main pump mounting
5. Coupling
6. Torque converter charging, cooling, PPC and
brake pump mounting
A. Torque converter outlet port

B. Torque converter oil temperature sensor mount-
ing port
C. Torque converter inlet port
D. Drain port (to transmission)
10-18 WA700-3
(10)
7. Turbine
8. Drive case
9. Pump
10. Transmission input shaft
11. Rear housing
12. Front housing
13. PTO gear (Teeth 86)
14. Stator
15. Gear (Teeth 81)
16. Gear (Teeth 81)
WA700-3 10-19
(10)
Flow of motive force

• The torque converter is installed between the
damper and transmission. The motive force from
the damper passes through the drive shaft and
enters coupling (1).
Coupling (1), drive case (8), pump (2) and PTO
gear (drive) (3) are fixed with bolts. They are
rotated directly by the rotation of the engine. The
motive force of pump (2) uses oil to rotate turbine
(4). This transmits motive force to transmission
input shaft (5).
• The motive force of coupling (1) passes through
PTO gear (drive) (3) and is also used as the
motive force to drive the pump.
Flow of oil
• The oil enters torque converter inlet port A,
passes through the oil hole in housing (6), and
flows to pump (2). The oil is given centrifugal
force by pump (2), enters turbine (4), and
transmits the energy of the oil to the turbine.
Turbine (4) is fixed to transmission input shaft
(5), so the power is transmitted to the
transmission. The oil from turbine (4) is sent to
stator (7), and enters the pump again. However,
part of the oil is sent from the stator through
torque converter outlet port B of housing (6) to
the oil cooler.
10-20 WA700-3
(10)
Specifications
Type: 3-element, single stage, single phase
Stall torque ratio: 2.84
1. Torque converter outlet oil pressure pick-up

2. Torque converter inlet oil pressure pick-up
3. Steering and switch pump mounting
4. Main pump mounting
5. Coupling
6. Torque converter charging, cooling, PPC and
brake pump mounting
A. Torque converter outlet port

B. Torque converter oil temperature sensor mount-
ing port
C. Torque converter inlet port
D. Drain port (to transmission)
10-22 WA700-3
(10)
7. Turbine
8. Drive case
10. Pump
11. Transmission input shaft
12. Rear housing
13. Front housing
14. PTO gear (Teeth 86)
15. Stator
16. Gear (Teeth 81)
17. Gear (Teeth 81)
WA700-3 10-23
(10)
Flow of motive force

• The torque converter is installed between the
damper and transmission. The motive force from
the damper passes through the drive shaft and
enters coupling (1).
Coupling (1), drive case (8), pump (2) and PTO
gear (drive) (3) are fixed with bolts. They are
rotated directly by the rotation of the engine. The
motive force of pump (2) uses oil to rotate turbine
(4). This transmits motive force to transmission
input shaft (5).
• The motive force of coupling (1) passes through
PTO gear (drive) (3) and is also used as the
motive force to drive the pump.
Flow of oil
• The oil enters torque converter inlet port A,
passes through the oil hole in housing (6), and
flows to pump (2). The oil is given centrifugal
force by pump (2), enters turbine (4), and
transmits the energy of the oil to the turbine.
Turbine (4) is fixed to transmission input shaft
(5), so the power is transmitted to the
transmission. The oil from turbine (4) is sent to
stator (7), and enters the pump again. However,
part of the oil is sent from the stator through
torque converter outlet port B of housing (6) to
the torque converter regulator valve (9).
The oil sent to torque converter regulator valve
(9) is passed and cooled through the oil cooler
and then used to lubricate the transmission.
10-24 WA700-3
(10)
Structure and function Torque converter regulator valve
Torque converter regulator valve

1. Valve body
2. Spring
3. Spool
A. Oil inlet port

(from torque converter)
B. Oil outlet port
(to torque convertor)
Function
• The torque converter regulator valve is installed
in the output circuit of the torque converter to
regulate the hydraulic pressure inside the torque
converter to the specified pressure.
Operation
• The oil from the torque converter flows from port
A to port B. However, the hydraulic pressure at
port B is lower than the tension of spring (2), so
spool (3) does not move.
• When the hydraulic pressure at port B becomes

higher than the tension of spring (2), it pushes
spool (3) in the direction of the arrow, and the oil
at port A flows to port C.
WA700-3 10-25
(10)
Structure and function Transmission
Transmission
Serial No.: 50001 – 51000
1. Transmission control valve 5. Coupling

2. Lubrication bypass valve 6. Oil filler
3. Transmission 7. Drain plug
4. Transfer 8. Strainer
10-26 WA700-3
(10)
1. Transmission control valve 5. Coupling

2. Lubrication bypass valve 6. Oil filler
3. Transmission 7. Drain plug
4. Transfer 8. Strainer
WA700-3 10-27
(10)
10-28 WA700-3
(10)
1. Input shaft
2. Sun gear (Teeth 32)
3. Planetary gear (Teeth 29)
4. Reverse clutch
5. Ring gear (Teeth 112)
8. Forward clutch
13. 4th clutch
15. 2nd clutch
16. Hub (Teeth 90)
17. 3rd clutch
21. 1st clutch
25. Output shaft
26. Carrier (1st)
27. Carrier (3rd)
28. Carrier (Forward and 4th)
29. Carrier (Reverse)
WA700-3 10-29
(10)
Outline
• The transmission consists of a 4-FORWARD, 4-
Speed range Clutch combination
REVERSE speed planetary gear transmission,
transfer, and transmission control valve. F1 Forward, 1st
• In the transmission, the motive force of the input F2 Forward, 2nd
shaft is changed by the combination of Forward
or Reverse clutch with 1st, 2nd, 3rd or 4th clutch F3 Forward, 3rd
to give FORWARD 1 – 4 or REVERSE 1 – 4 F4 Forward, 4th
speed, and is transmitted to the output shaft.
R1 Reverse, 1st
R2 Reverse, 2nd
R3 Reverse, 3rd
R4 Reverse, 4th
Operation of clutch
• Engaged
The oil sent from the transmission control valve
passes through the oil passage inside the trans-
mission. When it reaches the rear of piston (2), it
moves piston (2).
When piston (2) moves, disc (4) and plate (5)
are pressed together. Ring gear (6) is meshed
with disc (4), so the rotation is stopped.
• Disengaged
When the supply of oil from the transmission
control valve is shut off, the pressure of the oil
acting on the rear of piston (2) is reduced. The
piston is then pushed back to the right by return
spring (3), and disc (4) and plate (5) are sepa-
rated. Ring gear (6) then rotates freely, and no
motive force is transmitted.
10-30 WA700-3
(10)
Forward 1st
• In the case of FORWARD 1st, FORWARD clutch • The rotation of carrier (28) is transmitted along
(8) and 1st clutch (21) are engaged. The power two paths. One path goes through planet gear
transmitted from the torque converter to input (11) and ring gear (14) and rotates carrier (27).
shaft (1) is transmitted to output shaft (25). The other goes through planet gear (11) and sun
• FORWARD clutch (8) is actuated by the oil gear (12) and is transmitted to output shaft (25).
pressure applied by the clutch piston, and holds • The rotation of carrier (27) is also transmitted
ring gear (9) in position. 1st clutch (21) is along two paths. One path goes through planet
actuated by the oil pressure applied by the clutch gear (19) and ring gear (18) and is transmitted to
piston, and holds ring gear (22) in position. sun gear (24). The other goes through planet
• The power from the torque converter is gear (19) and sun gear (20) and is transmitted to
transmitted to input shaft (1). The rotation of output shaft (25).
input shaft (1) is transmitted through sun gear (7) • Ring gear (22) is held in position by 1st clutch
to planet gear (10). Ring gear (9) is held in (21), so the rotation of sun gear (24) passes
position by FORWARD clutch (8), so the rotation through planet gear (23) and is transmitted from
of planet gear (10) rotates carrier (28) inside ring carrier (26) to output shaft (25).
gear (9). • The rotation of output shaft (25) is output in
combination with the power transmitted from sun
gear (12), sun gear (20), and carrier (26).
WA700-3 10-31
(10)
Forward 2nd
• In the case of FORWARD 2nd, FORWARD • The rotation of carrier (28) is transmitted along
clutch (8) and 2nd clutch (15) are engaged. The two paths. One path goes through planet gear
power transmitted from the torque converter to (11) and rotates ring gear (14). The other goes
input shaft (1) is transmitted to output shaft (25). through planet gear (11) and sun gear (12) and
• FORWARD clutch (8) is actuated by the oil is transmitted to output shaft (25).
pressure applied by the clutch piston, and holds • Ring gear (14) and hub (16) are formed into one
ring gear (9) in position. 2nd clutch (15) is unit by 2nd clutch (15), and the rotation of hub
actuated by the oil pressure applied by the clutch (16) is transmitted to output shaft (25).
piston, and engages ring gear (14) and hub (16). • The rotation of output shaft (25) is output in
• The power from the torque converter is combination with the power transmitted from sun
transmitted to input shaft (1). The rotation of gear (12) and hub (16).
input shaft (1) is transmitted through sun gear (7)
to planet gear (10). Ring gear (9) is held in
position by FORWARD clutch (8), so the rotation
of planet gear (10) rotates carrier (28) inside ring
gear (9).
10-32 WA700-3
(10)
Forward 3rd
• In the case of FORWARD 3rd, FORWARD clutch • The rotation of carrier (28) is transmitted along
(8) and 3rd clutch (17) are engaged. The power two paths. One path goes through planet gear
transmitted from the torque converter to input (11) and ring gear (14) and rotates carrier (27).
shaft (1) is transmitted to output shaft (25). The other goes through planet gear (11) and sun
• FORWARD clutch (8) is actuated by the oil gear (12) and is transmitted to output shaft (25).
pressure applied by the clutch piston, and holds • Ring gear (18) is held in position by 3rd clutch
ring gear (9) in position. 3rd clutch (17) is (17), so the rotation of carrier (27) passes
actuated by the oil pressure applied by the clutch through planet gear (19) and is transmitted from
piston, and holds ring gear (18) in position. sun gear (20) to output shaft (25).
• The power from the torque converter is • The rotation of output shaft (25) is output in
transmitted to input shaft (1). The rotation of combination with the power transmitted from sun
input shaft (1) is transmitted through sun gear (7) gear (12) and sun gear (20).
gear (9).
WA700-3 10-33
(10)
Forward 4th
• In the case of FORWARD 4th, FORWARD clutch • Ring gear (14) is held in position by 4th clutch
(8) and 4th clutch (13) are engaged. The power (13), so the rotation of carrier (28) is transmitted
transmitted from the torque converter to input through planet gear (11) to sun gear (12) and
shaft (1) is transmitted to output shaft (25). rotates output shaft (25).
• FORWARD clutch (8) is actuated by the oil
pressure applied by the clutch piston, and holds
ring gear (9) in position. 4th clutch (13) is
actuated by the oil pressure applied by the clutch
piston, and holds ring gear (14) in position.
• The power from the torque converter is
transmitted to input shaft (1). The rotation of
input shaft (1) is transmitted through sun gear (7)
gear (9).
10-34 WA700-3
(10)
Reverse 1st
• In the case of REVERSE 1st, REVERSE clutch • The rotation of ring gear (6) is transmitted along
(4) and 1st clutch (21) are engaged. The power two paths. One path is transmitted to carrier (28)
transmitted from the torque converter to input and then goes through planet gear (11) and ring
shaft (1) is transmitted to output shaft (25). gear (14) and rotates carrier (27). The other goes
• REVERSE clutch (4) is actuated by the oil through planet gear (11) and sun gear (12) and
pressure applied by the clutch piston, and holds is transmitted to output shaft (25).
ring gear (5) in position. 1st clutch (21) is • The rotation of carrier (27) is also transmitted
actuated by the oil pressure applied by the clutch along two paths. One path goes through planet
piston, and holds ring gear (22) in position. gear (19) and ring gear (18) and is transmitted to
• The power from the torque converter is sun gear (24). The other goes through planet
transmitted to input shaft (1). The rotation of gear (19) and sun gear (20) and is transmitted to
input shaft (1) is transmitted through sun gear (2) output shaft (25).
to planet gear (3). Ring gear (5) is held in position • Ring gear (22) is held in position by 1st clutch
by REVERSE clutch (4), so carrier (29) rotates, (21), so the rotation of sun gear (24) passes
and the rotation of planet gear (3) rotates ring through planet gear (23) and is transmitted from
gear (6). Ring gear (6) rotates in the opposite carrier (26) to output shaft (25).
direction from input shaft (1). • The rotation of output shaft (25) is output in
combination with the power transmitted from sun
gear (12), sun gear (20), and carrier (26).
WA700-3 10-35
(10)
Structure and function Transmission control valve
Transmission control valve
1. Lower valve a. Pilot reducing pick-up (P5)

2. Upper valve b. Torque converter relief pressure pick-up (P8)
3. Main relief valve c. Transmission lubricating pressure pick-up (P9)
4. Transmission solenoid valve d. Main relief pressure pick-up (P6)
5. Emergency manual spool e. Priority pressure pick-up (P11)
6. Pilot oil filter f. Reducing pressure pick-up (P3)
7. Connector g. Modulating pressure pick-up (P1)
10-36 WA700-3
(10)
Upper valve
Main relief valve

Serial No.: 50001 – 51000 Serial No.: 51001 and up
1. Reducing valve 6. Torque converter relief valve

2. Quick return valve 7. Quick fill valve
3. Modulating valve 8. Modulating load piston
4. Priority valve 9. Main relief valve
5. Housing
WA700-3 10-37
(10)
Lower valve
10. 1st spool 13. FORWARD spool 16. Lubrication valve

11. 2nd spool 14. Pilot filter 17. REVERSE spool
12. 4th spool 15. Pilot reducing valve 18. 3rd spool
Outline
• The oil from the torque converter charging pump • The other oil line flows to modulating valve (3)
enters port A of main relief valve, and passes and quick return valve (2). The action of
through priority valve (4) via by main relief valve modulating valve (3) and quick return valve (2)
(9). It is then divided into three lines; there are; to raises the clutch pressure smoothly. This
the clutch pistons, to pilot reducing valve (4) and reduces the shock when actuating the
main relief valve. Priority valve (4) acts to control FORWARD, REVERSE and 1st, 2nd, 3rd and
the three lines so that pilot reducing valve (15) is 4th speed clutches to change gear.
the priority circuit. • The quick fill valve controls the oil pressure when
• The oil flowing to pilot reducing valve (15) oil fills the second clutch and reduces the filling
controls the pilot pressure used to actuate the time when shifting from 1st to 2nd or from 3rd to
directional and speed spools. The oil regulated 2nd.
by pilot reducing valve (15) presses through the • Lubrication valve (16) controls the lubrication oil
orifice in each spool and fills the spool. inside the transmission.
10-38 WA700-3
(10)
Transmission solenoid valve
1. Conncetor 6. FORWARD solenoid valve Actuation table for solenoid valve

2. 1st solenoid valve 7. REVERSE solenoid valve and clutch
3. 2nd solenoid valve 8. Body
F R 1 2 3 4
4. 3rd solenoid valve 9. Emergency manual sppol
5. 4th solenoid valve F1 Q Q
F2 Q Q
Structure
• The transmission solenoid valve is installed to F3 Q Q
the transmission together with the transmission F4 Q Q
valve.
N
When the directional lever or speed control lever
are operated, the solenoid valve is actuated and R1 Q Q
moves the spool inside the transmission valve. R2 Q Q
R3 Q Q
R4 Q Q
WA700-3 10-39
(10)
Pilot oil filter
1. Oil filter head Specification

2. Element • Filtration area: 370 cm2
3. Case • Filter mesh: 105 micrometer
10-40 WA700-3
(10)
Main relief valve

Serial No.: 50001 – 51000
Function
• The main relief valve acts to supply the
necessary oil to the clutch when shifting gear.
When the gears are not being shifted, it sends all
of the oil directly to the torque converter.
Operation
• The oil from the pump passes through the oil
filter and enters port A of main relief valve (1).
• Until the specified pressure is reached, the oil
flows to the priority valve.
• When the pressure goes above the specified

level, oil passes through the orifice in relief valve
(1), pushes poppet (2), and moves relief valve (1)
to the left. The oil is relieved to the torque
c o n v e r t er , s o t h e s p e c i f i e d p r e s s u r e i s
maintained.
a Specified pressure: 3.04 MPa {31.0 kg/cm2}
WA700-3 10-41
(10)
Function
• The main relief valve acts to supply the
necessary oil to the clutch when shifting gear.
When the gears are not being shifted, it sends all
of the oil directly to the torque converter.
Operation
• The oil from the pump passes through the oil
filter and enters port A of main relief valve (1).
• Until the specified pressure is reached, the oil
flows to the priority valve.
• When the pressure goes above the specified

level, oil passes through the orifice in relief valve
(1), pushes poppet (2), and moves relief valve (1)
to the left. The oil is relieved to the torque
c o n ve r t e r , s o t h e s p e ci f i e d p r e s s u r e i s
maintained.
a Specified pressure: 3.04 MPa {31.0 kg/cm2}
10-42 WA700-3
(10)
Pilot reducing valve
Function
• The pilot reducing valve acts to control the
pressure needed to actuate the transmission
spools.
Operation
• The oil from the pump passes through the pilot
filter and enters port A of pilot reducing valve (1).
The oil passes through port B and enters through
the orifice of transmission spool (2) to fill the
inside of port C.
• When the pressure inside port C rises,

pressurized oil flows from orifice "a" of pilot
reducing valve (1) and goes to port D.
As a result, pilot reducing valve (1) moves to the
right, and ports A and B are shut off, so the
pressurized oil at port C is maintained at the
same pressure.
WA700-3 10-43
(10)
Transmission solenoid valve
Function
• There is one solenoid valve installed for each
directional and speed spool in the transmission
valve.
When the directional lever and speed control
levers in the operator's compartment are
operated, the solenoid valve is actuated, and oil
is drained to actuate the directional and speed
spools.
Operation
1) Solenoid valve OFF
The oil of spool (2) enters port A. However,
valve (1) shuts off the oil, so directional and
speed spool (2) does not move.
2) Solenoid valve ON
When the directional and gear shift lever are
operated, solenoid valve (1) is pulled up.
The oil from directional and speed spool (2)
enters port A and flows from port B to the drain
circuit. Therefore, port A becomes the low pres-
sure circuit, and directional and speed spool (2)
is actuated.
10-44 WA700-3
(10)
Priority valve
Function
• Priority valve (1) controls the minimum pressure
of pilot reducing valve (2). In addition, priority
valve (1) gives the oil flow to pilot reducing valve
(2) priority over the other circuit.
Operation
• The oil from the pump flows to port A of priority
valve (1) and port B of pilot reducing valve (2).
• The oil entering port A flows from orifice "a" of

priority valve (1) to port D. The hydraulic
pressure and force of poppet spring (3) push
back spring (4) and move priority valve (1) to the
right.
When this happens, port A and port C are
connected, and the oil flows from port C to the
modulating valve.
WA700-3 10-45
(10)
Modulating valve and quick return valve
Function
• The modulating valve and quick return valve act
together to r aise the trans mis sion clutc h
pressure slowly. In this way, they reduce the
shock when shifting gear, and prevent the
generation of peak torque in the power train. As
a result, operator fatigue is reduced, and at the
same time, operator comfort and the durability of
the power train is increased.
1) Immediately after shifting gear (Point A)
• The oil sent from the pump flows from priority C. The quick return valve moves to the right and
valve (1) through port A, passes through the oil flows to clutch (5). In addition, when quick
modulating valve (2), and enters port B of quick return valve (3) moves to the right, drain port D is
return valve (3). The oil passes through orifice opened, and the pressurized oil at the rear of
"a" of quick return valve (3) and flows to the piston (4) flows to the drain circuit.
clutch piston, which has been actuated. However
when it passes through orifice "a" it creates a
difference in pressure between port B and port
10-46 WA700-3
(10)
2) Clutch pressure rising (Point B)
• As the pressure at the clutch piston rises, the

pressure at port C also rises. Quick return valve
(3) is pushed back to the left and drain port D is
closed. The oil from the pump flows from port C
to the clutch piston and at the same time it flows
from orifice "b" through quick return valve (3) and
enters port E.
The oil at port E acts on the modulating piston
(4). It pushes back spring (6) and moves piston
(4) to the right.
At the same time, pressurized oil also passes
through the orifice and enters poppet (7) of
modulating valve (2). It moves modulating valve
(2) to the left and some of the oil at port A flows
to port G.
WA700-3 10-47
(10)
3) Completion of rise in clutch pressure (Point C)
• The oil entering port E continues to push piston

(4). When the piston reaches the end of its
stroke, the rise in pressure stops. When this
happens, the pressure reaches the set pressure
of the modulating valve. In addition, port F and
port G are closed by piston (4).
10-48 WA700-3
(10)
Reducing valve
Function
• The reducing valve is in the circuit between the
quick return valve and the 2nd spool. It reduces
the pressure applied to the 2nd clutch.
The maximum pressure in the main circuit is kept
to the specified level by the main relief pressure.
Operation
• The oil from quick return valve enters port A, and
then flows from port B to 2nd spool (2).
• When the circuit to the 2nd clutch is filled with oil

and the hydraulic pressure rises, the oil from port
B which flows through orifice a to port C pushes
poppet (3). The reaction to this compresses
spring (4) and moves reducing spool (1) to the
left.
As a result, port A and port B are closed, and the
oil stops flowing.
The hydraulic pressure at this point is 2.3 MPa
{23.5 kg/cm2}.
WA700-3 10-49
(10)
Quick fill valve (for 2nd clutch)
• The quick fill valve is used to reduce the time lag

when shifting from 1st to 2nd or from 3rd to 2nd.
It raises the pressure for starting modulation
when engaging the 2nd clutch, and reduces the
time taken for the oil to fill the clutch piston.
• By installing a quick fill valve, it is possible to
obtain the oil pressure characteristics of the 2nd
clutch shown in the graph on the right.
Operation
• When 2nd spool (1) is switched, the oil from
modulating valve (2) passes through quick return
valve (3) and reducing valve (4), and enters the
clutch piston.
• At the same time, it enters port A of quick fill
valve (5), and quick fill valve (5) is pushed to the
right in the direction of the arrow.
• As a result, springs (6) and (7) are compressed,
the load becomes greater, and the actuation
starting pressure of modulating valve (2)
becomes higher than for the other clutches.
• The hydraulic pressure rises suddenly to the
pressure where the actuation of modulating
v a l v e ( 2 ) s t a r t s . F ol l o w i n g t hi s , n o r m a l
modulation is carried out to raise the pressure
until modulating valve (2) reaches the set
pressure.
• In this way, the pressure for the start of actuation
of modulating valve (2) is higher than for the
other clutches, and the time lag is reduced by a
corresponding amount.
10-50 WA700-3
(10)
Torque converter relief valve

Serial No.: 50001 – 51000
Function
• This valve acts to keep the oil entering the torque
converter to a constant pressure. It drains the oil
if the press ure goes abov e the spec ified
pressure.
Operation
• The oil from the pump passes through main relief
valve (1), enters port A, and flows to the torque
converter.
• If the oil at port A goes above the set pressure, it

enters port B from orifice a in torque converter
relief valve (2), and moves torque converter relief
valve (2) to the left.
As a result, the oil at port A goes from port C,
lubricate the transmission, and is drained.
WA700-3 10-51
(10)
Function
• This valve acts to keep the oil entering the torque
converter to a constant pressure. It drains the oil
if the pressure goes abov e the specified
pressure.
Operation
• The oil from the pump passes through main relief
valve (1), enters port A, and flows to the torque
converter.
• If the oil at port A goes above the set pressure, it

enters port B from orifice a in torque converter
relief valve (2), and moves torque converter relief
valve (2) to the left.
As a result, the oil at port A goes from port C,
lubricate the transmission, and is drained.
10-52 WA700-3
(10)
Lubricating relief valve
Function
• The lubricating relief valve protects the
transmission lubrication circuit from abnormal
high pressure.
Operation
• The oil from the oil cooler and torque converter
relief valve flows from port A and lubricates the
transmission.
• In this condition, if abnormal high pressure is

generated by throttling of the lubrication circuit,
the oil entering port A compresses spring (1),
moves spool (2) to the left, opens the circuit
between port A and port B, and relieves the oil in
the lubricating circuit to port B. The oil pressure
at this point is 0.29 MPa {3 kg/cm2}.
WA700-3 10-53
(10)
Emergency manual spool
Function
• A directional spool and the speed spools are
installed to make it possible to actuate the
transmission valve mechanically if there should
be a failure in the electrical system of the
transmission controller system and the solenoid
valve cannot be actuated.
(This spool is used to move the machine under
its own power to a place where it can be
serviced.)
a When using this spool, pay particularly
careful attention to safety.
Operation
• Normal position
When the solenoid valve is working normally,
spool (3) is held in the position shown in the dia-
gram.
The oil from the directional spool and speed
spool (1) enters port A, but it is shut off by sole-
noid valve (2).
• Clutch at OFF position

When emergency manual spool (3) is pushed in
to the left (screwed in 10 mm), the oil at port A is
shut off regardless of the operation of solenoid
valve (2). It cannot flow to port B, so the clutch is
not actuated.
• Clutch at ON position
When emergency manual spool (3) is pulled out
to the right (loosened 10 mm), the oil at port A is
drained to port B regardless of the operation of
solenoid valve (2). Therefore, the clutch is actu-
ated.
10-54 WA700-3
(10)
Lubrication bypass valve
Function
• When traveling in 4th gear, the transmission
gears are rotating at high speed. Because of this,
the churning resistance of the transmission
lubrication oil increases. To reduce this power
loss, only enough oil to lubricate the gears at 4th
speed is kept. All the rest of the oil is bypassed
to the transmission case.
Operation
• 4th clutch not being operated
When the 4th clutch is not being operated, there
is no hydraulic pressure at port a of spool (1). As
a result, spool (1) is pushed to the left by the
spring. The oil from the torque converter is
stopped by spool (1), so all the oil is used for
lubricating the transmission.
• 4th clutch being operated

When oil flows to the 4th clutch, pressure oil
flows from 4th spool (2) to port a of spool (1).
When pressure oil enters port a, it pushed back
the spring and moves spool (1) to the right. The
oil from the torque converter flows to the trans-
mission lubrication system and drain port b.
WA700-3 10-55
(10)
Hydraulic circuit schematics
Forward 1st
Serial No.: 50001 – 51000
10-56 WA700-3
(10)
Operation
• When the directional and speed levers are
operated to F1, solenoid valves (1) and (2) are
actuated.
• The oil from pump (3) is divided into three lines,
but during gearshifting, it flows mainly to each
clutch.
• One of the three lines passes from main relief
valve (4) through torque converter (5) and enters
oil cooler (6).
• The second line goes from pilot reducing valve
(7) through the orifice of each speed spool to the
solenoid valve, but solenoid valves (1) and (2) of
FORWARD spool (8) and 1st spool (9) are being
actuated, so the oil passing through the orifice
flows to the drain circuit, and a difference in
pressure is created between port A and port B.
This overcomes springs (10) and (11) and the
port to the clutch is connected.
• The oil flows in the third line goes from priority
valve (12) into quick return valve (14), passes
through orifice a, then flows to spools (8) and (9)
to forward clutch (15) and 1st clutch (16).
When the oil starts to flow into the clutches, it
passes through orifice a, so a difference in
pressure is created between port C and port D,
quick return valve (14) is moved to the right, and
the oil at the rear of piston (17) flows to drain
circuit E.
When each clutch becomes filled with oil, the
difference in pressure between port C and port D
disappears, so the valve is returned to the left by
the difference in the cross-sectional area of the
quick return valve (4), and drain circuit E is
closed.
At this point, each clutch is filled with oil, but the
set pressure is not being generated. The oil at
port D passes through orifice b, goes to the rear
face of piston (17), moves piston (17) to the right,
and gradually raises the clutch pressure. When
piston (17) reaches the end of its stroke, the set
clutch pressure is reached, and the clutch is
completely engaged.
WA700-3 10-57
(10)
10-58 WA700-3
(10)
Operation
• When the directional and speed levers are
operated to F1, solenoid valves (1) and (2) are
actuated.
• The oil from pump (3) is divided into three lines,
but during gearshifting, it flows mainly to each
clutch.
• One of the three lines passes from main relief
valve (4) through torque converter (5) and torque
converter regulator valve (18) and then enters oil
cooler (6).
• The second line goes from pilot reducing valve
(7) through the orifice of each speed spool to the
solenoid valve, but solenoid valves (1) and (2) of
FORWARD spool (8) and 1st spool (9) are being
actuated, so the oil passing through the orifice
flows to the drain circuit, and a difference in
pressure is created between port A and port B.
This overcomes springs (10) and (11) and the
port to the clutch is connected.
• The oil flows in the third line goes from priority
valve (12) into quick return valve (14), passes
through orifice a, then flows to spools (8) and (9)
to forward clutch (15) and 1st clutch (16).
When the oil starts to flow into the clutches, it
passes through orifice a, so a difference in
pressure is created between port C and port D,
quick return valve (14) is moved to the right, and
the oil at the rear of piston (17) flows to drain
circuit E.
When each clutch becomes filled with oil, the
difference in pressure between port C and port D
disappears, so the valve is returned to the left by
the difference in the cross-sectional area of the
quick return valve (4), and drain circuit E is
closed.
At this point, each clutch is filled with oil, but the
set pressure is not being generated. The oil at
port D passes through orifice b, goes to the rear
face of piston (17), moves piston (17) to the right,
and gradually raises the clutch pressure. When
piston (17) reaches the end of its stroke, the set
clutch pressure is reached, and the clutch is
completely engaged.
WA700-3 10-59
(10)
Structure and function Torque converter oil cooler
Torque converter oil cooler
1. Torque converter oil cooler Outline

• Oil which flows out from the torque conerter has
A. Inlet port high temperature due to energy from the power
B. Outlet port train. Oil flows into the inlet port A of torque
converter oil cooler (1) and is cooled by the
engine coolant. Then, it flows from outlet port B
to the transmission lubrication.
10-60 WA700-3
(10)
Structure and function Transmission oil filter
Transmission oil filter
1. Relief valve Specification

2. Element Filtration area: 8,900 cm2 x 4
3. Drain plug Relief pressure:
0.32 ± 0.02 MPa {3.25 ± 0.25 kg/cm2}
A. Inlet port (Bypass pressure)
B. Outlet port
WA700-3 10-61
(10)
Structure and function Transmission oil filter
Operation
• Oil flows from torque converter charging pump to
filter inlet port A. It passes from the outside to the
inside of element (2) and flows to outlet port B.
• If element (2) is clogged with foreign materials or

inlet port A is pressurized due to low
temperature, oil from inlet port A directly flows to
outlet port B by opening relief valve ( 1),
preventing breakage of the pump or element (2).
10-62 WA700-3
(10)
Structure and function Transfer
Transfer
1. Transmission output shaft Outline

2. Transfer input gear (Teeth 46) • The transfer is installed at the power output end
3. Transfer idler gear (Teeth 39) of the transmission and is secured to the
4. Idler gear (Teeth 40) transmission case by bolts.
5. Output shaft
6. Rear coupling
7. Strainer
8. Front coupling
9. Output gear (Teeth 41)
WA700-3 10-63
(10)
Structure and function Axle
Axle
Front axle
1. Front axle
2. Front differential
3. Brake
4. Final drive
5. Drain plug
6. Spring cylinder
7. Parking brake
10-64 WA700-3
(10)
Structure and function Axle
Rear axle
1. Rear differential
2. Rear axle
3. Brake
4. Final drive
5. Drain plug
WA700-3 10-65
(10)
Structure and function Differential
Differential
Front differential
1. Bevel gear (Teeth 43) 4. Shaft

2. Differential case 5. Bevel pinion (Teeth 9)
3. Side gear (Teeth 24) 6. Pinion gear (Teeth 17)
10-66 WA700-3
(10)
Structure and function Differential
Rear differential
1. Bevel pinion (Teeth 9) 4. Side gear (Teeth 24)

2. Bevel gear (Teeth 43) 5. Shaft
3. Pinion gear (Teeth 17) 6. Differential case
WA700-3 10-67
(10)
Structure and function Final drive
Final drive
Serial No.: 50001 – 50045
1. Axle shaft
2. Brake
5. Planetary carrier
6. Drain plug
7. Wheel hub
9. Wheel
10-68 WA700-3
(10)
1. Axle shaft
2. Brake
5. Planetary carrier
6. Drain plug
7. Wheel hub
9. Wheel
WA700-3 10-69
(10)
Outline
• To gain a large drive force, the final drive uses a
planetary gear system to reduce the speed and
send drive force to the tires.
Operation
• The motive force transmitted from the differential
through axle shaft (1) t o sun gear (8) is
transmitted to planetary gear (3). The planetary
gear rotates around the inside of fixed ring gear
(4) and in this way transmits rotation at a reduced
speed to planetary carrier. This motive force is
then sent to wheels (9) which are installed to
planetary carriers.
10-70 WA700-3
(10)
Structure and function Steering piping diagram
Steering piping diagram
1. Steering cylinder (R.H.)

2. Steering demand valve
3. Steering unit (Orbit-roll valve)
4. Stop valve (R.H.)
5. Hydraulic tank
6. Steering wheel
7. Steering and switch pump
8. Stop valve (L.H.)
9. Diverter valve (with emergency steering)
10. Emergency steering pump (with emergency
steering)
11. Steering cylinder (L.H.)
WA700-3 10-71
(10)
Structure and function Steering and switch pump
Steering and switch pump

Serial No.: 50001 – 50056
Model: HPF90 + 90
1. Shaft (front) 9. Impeller Specification

2. Cradle (front) 10. Cradle (rear) Steering and switch
3. Case (front) 11. Shaft (rear) pump
4. Swash plate 12. Case (rear)
5. Shoe 13. End cap (rear) Model HPF 90 + 90
6. Piston 14. End cap (front) Rated delivery pressure 31.4 MPa {320 kg/cm2}
7. Cylinder block 15. Servo piston
Rated rpm 2,120 rpm
8. Valve plate 16. Collar
Theoretical delivery (front) 97.4 cc/rev
Theoretical delivery (rear) 97.4 cc/rev
Max. delivery 206.5 + 206.5 l/min
Outline
• This pump consists of 2 fixed-displacement • For explanation of the operation, see the section
swash plate-type piston pumps and 1 impeller o f t h e w o r k e q ui p m en t p um p . T he w o r k
pump between them. equipment pump is of the variable displacement
• The front pump and rear pump are originally of type, however, since its swash plate (4) can
the variable displacement type, but their move.
displacement is fixed since inserted collar (16)
disables servo piston (15) and fix swash plate
(4).
10-72 WA700-3
(10)
WA700-3 10-73
(10)

Model: HPF95 + 95
1. Shaft (front) 9. Impeller Specification

2. Cradle (front) 10. Cradle (rear) Steering and switch
3. Case (front) 11. Shaft (rear) pump
4. Swash plate 12. Case (rear)
5. Shoe 13. End cap (rear) Model HPF 95 + 95
6. Piston 14. End cap (front) Rated delivery pressure 31.4 MPa {320 kg/cm2}
7. Cylinder block 15. Servo piston
Rated rpm 2,120 rpm
8. Valve plate 16. Collar
Theoretical delivery (front) 97.4 cc/rev
Theoretical delivery (rear) 97.4 cc/rev
Max. delivery 206.5 + 206.5 l/min
Outline
• This pump consists of 2 fixed-displacement • For explanation of the operation, see the section
swash plate-type piston pumps and 1 impeller o f t h e w o r k e q ui p m en t p um p . T he w o r k
pump between them. equipment pump is of the variable displacement
• The front pump and rear pump are originally of type, however, since its swash plate (4) can
the variable displacement type, but their move.
displacement is fixed since inserted collar (16)
disables servo piston (15) and fix swash plate
(4).
10-74 WA700-3
(10)
WA700-3 10-75
(10)
Structure and function Steering unit (Orbit-roll valve)
Steering unit (Orbit-roll valve)
1. Neutral position spring a. To hydraulic tank

2. Valve body b. To steering demand valve port Pb
3. Check valve c. To steering demand valve port Pa
4. Spool d. From PPC pump
5. Sleeve
6. Gear rim
7. Gear
8. Cover
9. Drive shaft
10. Center pin
10-76 WA700-3
(10)
Outline
• The steering unit is directly connected to the

shaft of the steering wheel. The oil from the PPC
pump passes through the steering demand
valve, and is switched to the left and right
steering cylinders to determine the direction of
travel of the machine.
• The steering unit can be broadly divided into the
following: spool (4) and sleeve (5), which have a
rotor type direction selection function, and the
gear set (combination of gear (7) and gear rim
(6)), which acts as a hydraulic motor when the
steering is operated.
Structure
• Spool (4) is interconnected with the drive shaft of

the steering wheel and is connected to sleeve (5)
by neutral position spring (1) and center pin (10)
(when the steering wheel is at neutral, it does not
contact the spool).
• The top of drive shaft (9) is meshed with center
pin (10) and forms one unit with sleeve (5). The
bottom is meshed with the spline of gear (7) of
the gear set.
• Valve body (2) has four ports. These are
connected respectively to the pump circuit, tank
circuit, and pilot circuit of the steering demand
valve.
In addition, the port at the pump end and the port
at the tank end are connected by check valve (3)
inside the housing. If there is any failure in the
PPC pump, oil is sucked in directly from the tank
end by the check valve.
WA700-3 10-77
(10)
Operation
When turning
• When the steering wheel is turned, spool (4) • When the steering wheel is turned, the oil inside
overcomes neutral position spring (1) and turns gear (7) flows, passes inside sleeve (5) and
slightly in relation to sleeve (5). Because of this spool (4), operates the spool of the steering
rotation, the ports of sleeve (5) and spool (4) demand valve, and actuates the steering
overlap, so a passage is formed for the oil to cylinders.
flow, and the oil flows to gear (7).
At neutral
• When the turning of the steering wheel is • When the non-reaction type steering valve is at
stopped (the rotation of the spool is stopped), the the neutral position, the steering cylinder and
return force of neutral position spring (1) returns spool (4) and sleeve (5) are blocked, so the
spool (4) and sleeve (5) to the neutral position, reaction from the machine is not transmitted to
so the oil passage is shut off and the oil stops the steering wheel.
flowing.
10-78 WA700-3
(10)
Structure and function Steering demand valve
Steering demand valve
1. Overload relief valve

2. Main relief valve
3. Steering spool
4. Demand spool
5. Surge cut relief valve
A. To steering cylinder
B. To steering cylinder
P1. From steering pump
P2. From switch pump
PB. To main control valve
T. To hydraulic tank
(through hydraulic oil cooler)
WA700-3 10-79
(10)
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 in the

cylinder circuit of the steering demand valve.
When the demand valve is at neutral and any
impact is applied to the steering cylinder and
abnormal pressure is generated, this valve
functions as a safety valve to relieve the circuit to
prevent breakage of the cylinder or hydraulic
piping.
It also functions to prevent any vacuum if any
negative pressure is generated at the cylinder
end.
Operation
1. Operation of relief valve

• Port A is connected to the cylinder circuit and
port B is connected to the drain circuit. The
oil passes through the hole in poppet (1) and
acts on the area of diameters d1 and d2.
Check valve poppet (3) and relief valve pop-
pet (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 goes around pilot poppet
(4) and flows to port B.
10-80 WA700-3
(10)
• When pilot poppet (4) opens, the pressure at the

rear of poppet (1) drops, poppet (1) moves to the
right, and it is seated with pilot poppet (4).
• Compared with the pressure at port A, the

pressure on the inside is low, so relief valve
poppet (2) opens and the oil flows from port A to
port B to prevent any abnormal pressure.
2. Operation of suction valve

• Negative pressure is generated at port A, the
difference in the area of diameters d3 and d4
opens check valve poppet (3), and the oil
flows from port B to port A to prevent a vac-
uum from forming in the circuit.
WA700-3 10-81
(10)
Main relief valve
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
• The main relief valve of the steering demand

valve is inside the valve and sets the maximum
pressure in the steering circuit when it is
operated. In other words, when the valve is being
operated and the steering circuit goes above the
set pressure of this valve, it relieves the oil and
actuates the flow control spool of the demand
valve to drain the oil to the steering circuit.
10-82 WA700-3
(10)
Operation of main relief valve
• When the pressure in the circuit rises and • When demand spool (4) moves, the oil from the
reaches the pressure set by spring (2) and steering pump is drained and the oil from the
adjustment screw (1), pilot poppet (3) opens and switch pump is relieved to the main control valve,
drains the oil. so the steering circuit pressure is prevented from
• When this happens, the balance of the pressure going above the set value.
in pressure receiving chamber (I) and pressure
receiving chamber (II) is lost, and demand spool
(4) moves to the left.
WA700-3 10-83
(10)
Operation of demand valve
When steering spool is at neutral
• The oil from the steering pump enters port A and • When the pressure in pressure receiving
the oil from the switch pump enters port B. chamber (I) reaches a certain value (set by
• When steering spool (2) is at the neutral position, spring (3)), notch f opens and the oil from the
pressure receiving pressure chamber (II) is steering pump goes to the drain circuit. Notch g
connected to the drain circuit through orifice b, is closed, so the oil from the switch pump all
and notch c is closed. flows to the main control valve.
• Notch c is closed, so the pressure of the oil at
port A and port B rises. This pressure passes
through orifice a, goes to pressure receiving
chamber (I) and moves demand spool (1) to the
left.
10-84 WA700-3
(10)
When steering spool is operated
Engine running at low speed
• When the steering is operated, oil flows from the • The merged oil passes through notches c and d,
Orbit-Roll to steering spool (2) and pushes pushes load check valve (5), and flows to the
steering spool (2) to the right. The circuit cylinder. The return oil from the cylinder passes
between pressure receiving chamber (II) and the through notch e and flows to the drain circuit.
drain circuit is shut off, and at the same time, • When this happens, the pressure before passing
notch c opens. through notch c is sent to pressure receiving
• As a result, the pressure in pressure receiving chamber (I) and the pressure after passing
chamber (II) rises, and demand spool (1) moves through notch c is sent to pressure receiving
to the right until notch h closes. chamber (II). Demand spool (1) is actuated so
• The passage from port B to the main control that the difference in pressure on both sides of
valve is shut off, so the oil from the switch pump notch c is kept constant. Therefore, an oil flow
pushes up pump merge-divider check valve (4) corresponding to the opening of notch c is
and merges with the oil from the steering pump supplied to the cylinder port. These pressure
at port A. differences (control pressure) are set by spring
(3).
WA700-3 10-85
(10)
Engine running at high speed
• There is no need for supply of extra oil from the • The oil from the steering pump passes through
switch pump, so the steering pump pressure notches c and d, pushes load check valve (5),
rises until notch g closes and shuts off the merge and flows to the cylinder. The return oil from the
passage from port B. cylinder passes through notch e and flows to the
• The pressure difference on both sides of notch c drain circuit.
is controlled only by notch f, and the excess oil • Notch g is closed, so the oil from the switch pump
from the steering pump is drained from notch f to all flows from port B and is sent to the main
the drain circuit. (At this point, notch g is control valve.
completely closed.)
10-86 WA700-3
(10)
Operation of steering valve
Neutral
• The steering wheel is not being operated, so • When the pressure at ports A and B rises,
steering spool (2) does not move. demand spool (1) moves to the left, so the oil
• The oil from the steering pump enters port A. The from the steering pump passes through port C of
oil from the switch pump enters port B. the spool and is drained.
The oil from the switch pump passes through
port D and all flows to the main control valve.
WA700-3 10-87
(10)
Turning right
• When the steering wheel is turned to the right, load check valve (5) of the steering spool and is
the Orbit-roll valve is operated and steering spool drained. The oil from the switch pump enters port
(2) moves to the left. B, goes through demand spool (1), pushes open
The oil from the steering pump enters port A, check valve (4), and is merged with the oil from
then flows to steering spool (2) through demand the steering pump.
spool (1). The oil pushes open load check valve
(6) 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 . The oil
from the left and right cylinders passes through
10-88 WA700-3
(10)
Turning left
• When the steering wheel is turned to the left, the load check valve (6) of the steering spool and is
Orbit-roll valve is operated and steering spool (2) drained. The oil from the switch pump enters port
moves to the right. B, goes through demand spool (1), pushes open
The oil from the steering pump enters port A, check valve (4), and is merged with the oil from
then flows to steering spool (2) through demand the steering pump.
spool (1). The oil pushes open load check valve
(5) of the spool, and flows to the rod end of the
left cylinder and the bottom end of the right
cylinder to Sturn the machine to the left. The oil
from the left and right cylinders passes through
WA700-3 10-89
(10)
Structure and function Two-way restrictor valve
Two-way restrictor valve
1. Poppet
2. Spring
3. Body
Function
• To reduce the shock caused by the inertia of the
machine when the steering is operated, an orifice
is installed in the oil line of the return circuit from
the cylinder. This applies pressure to the
returning oil, and regulates the movement of the
cylinder piston.
Operation
• When the oil is flowing to arrow o, it pushes
spring (2) and flows through the orifice, and
between poppet (1) and the poppet seat.
• When the oil is flowing to arrow i, the oil flows

only from orifice a inside poppet (1), so the flow
is controlled.
10-90 WA700-3
(10)
Structure and function Stop valve
Stop valve
1. Boot A : From orbit-roll

2. Wiper B : To steering demand valve
3. Seal DR : To drain
4. Poppet
5. Spring
6. Spool
7. Spring
WA700-3 10-91
(10)
Structure and function Diverter valve
Diverter valve
1. Check valve A. To emergency steering Function

2. Check valve pump • The diverter valve is a selector valve which
3. Check valve B. Sensor mounting port senses the pilot pressure from the steering pump
4. Check valve C. To hydraulic oil tank and if there is no abnormality in the steering
5. Spool D. To steering valve circuit, it drains the oil from the emergency pump
6. Valve body E. From hydraulic tank to the tank. If no pilot pressure from the steering
F. From steering circuit pump reaches the diverter valve, the oil from the
emergency steering pump is switched to the
steering circuit and flows to enable the machine
to be steered.
10-92 WA700-3
(10)
Operation
• Pump and engine are working normally.
When the steering pump and engine are working

normally, the steering pump, and switch pump are
rotated by the engine. Therefore, oil is sent to the
steering valve, and the machine can be steered. In
addition, the emergency steering pump is rotated by
the transmission, so oil from port A of the diverter
valve pushes open check valve (2) and enters port
B. Pressure oil from the steering pump is flowing to
port D, so it pushes spool (3) in the direction of the
arrow. As a result, the oil from port B flows to port C
and is drained to the hydraulic tank.
WA700-3 10-93
(10)
• Failure in pump or engine when machine is

traveling
If there is a failure in the pump or engine when the

machine is traveling, the rotation of the wheels is
transmitted through the transmission to rotate the
emergency steering pump.
The steering pump is not rotating, so no pressure oil
is formed at port D. As a result, spool (3) is pushed
in the direction of the arrow by spring (4).
The oil from the emergency steering pump passes
from port A through port B and flows to the steering
valve to make steering possible.
a The emergency steering pump is designed so

that it can rotate both directions.
10-94 WA700-3
(10)
Emergency steering relief valve

1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
Function
Compared to the steering valve relief pressure of
31.4 MPa {320 kg/cm 2 }, the rated pressure of the
emergency steering pump and diverter valve are
both 20.6 MPa {210 kg/cm2}. Therefore, to protect
the emergency steering pump and diverter valve,
there is a relief valve in the piping from the diverter
valve to the steering valve. When the emergency
steering is being operated, and the hydraulic pres-
sure generated by the steering exceeds 20.6 MPa
{210 kg/cm2}, the relief valve is actuated.
Operation
• Port A is connected to the pump circuit, and port
C is connected to the drain circuit. The oil passes
through the orifice in main valve (1) and fills port
B. Pilot poppet (3) is in contact with valve seat
(2).
• When the pressure inside port A and B reaches

the pressure set by the poppet spring (set
pressure), pilot poppet (3) opens and the
hydraulic pressure at port B escapes from port D
to port C. This lowers the pressure at port B.
• When the pressure at port B drops, the orifice of
main valve (1) generates a difference in pressure
between port A and port B. Main valve (1) is
opened by the pressure at port A and the oil at
port A is relieved.
WA700-3 10-95
(10)
Structure and function Brake piping
Brake piping
1. Front brake (right) 10. Strainer

2. Brake valve (right) 11. Charge valve
3. Parking brake switch 12. Transmission cut-off valve
4. Rear brake (right) 13. Brake valve (left)
5. Slack adjuster (rear) 14. Parking brake switch
6. Torque converter charging, cooling, 15. Parking brake solenoid valve
PPC, brake pump 16. Front brake (left)
7. Rear brake (left) 17. Parking brake spring cylinder
8. Accumulators 18. Slack adjuster (front)
9. Brake oil tank
10-96 WA700-3
(10)
Structure and function Brake circuit diagram
Brake circuit diagram
1. Brake oil tank 10. Brake valve (right)

2. Brake pump 11. Stop lamp switch
3. Strainer 12. Brake valve (left)
4. Accumulator charge valve 13. Transmission cut-off switch
4A. Safety relief valve 14. Rear slack adjuster
4B. Relief valve 15. Rear brake
4C. Relief valve 16. Front slack adjuster
4D. Relief valve 17. Front brake
5. Check valve 18. Parking brake solenoid valve
6. Emergency brake switch 19. Parking brake switch
7. Low pressure switch 20. Parking brake pilot lamp switch
8. Rear brake accumulator 21. Parking brake spring cylinder
9. Front brake accumulator
WA700-3 10-97
(10)
Structure and function Brake valve
Brake valve
Brake valve (right)
A
D
5 B
6
C
7
SDW00107
1. Brake pedal (left, right brake) A. Pilot port (right brake)

2. Rod (right brake) B. To rear brake (right brake)
3. Pilot piston (right brake) C. To front brake (right brake)
4. Spool (right brake) D. Drain (left, right brake)
5. Upper cylinder (right brake) E. To pilot port (left brake)
6. Spool (right brake)
7. Lower cylinder (right brake)
8. Rod (left brake)
9. Spool (left brake)
10. Cylinder (left brake)
10-98 WA700-3
(10)
Brake valve (left)
9
E
10
SDW00108
Outline
• There are two brake valves installed in parallel
under the front of the operator’s cab, and these
are actuated by depressing the pedal.
• When the right pedal is depressed, oil is sent to
the brake cylinder to apply the brakes.
• When the left pedal is depressed, oil is sent to
the right pedal to apply the brakes in the same
way as when the right pedal is depressed.
In addition, the left brake pedal operates the
transmission cut-off switch to actuate the
transmission solenoid valve electrically and set
the transmission to neutral.
WA700-3 10-99
(10)
Operation
Brake applied (right brake valve)
Upper portion
• When brake pedal (1) is depressed, the 1
operating force is transmitted to spool (3)
through rod (2) and spring (4). When spool (3) 2
goes down, drain port a is closed, and the oil
from the pump and accumulator flows from port
A to port C and actuates the rear brake cylinders.
3
Drain
Lower portion 4
• When brake pedal (1) is depressed, the a
Accumulator C
operating force is transmitted to spool (3)
A
through rod (2) and spring (4). When spool (3)
goes down, spool (5) is also pushed down by From pump To rear brake
Accumulator cylinder
plunger (6). When this happens, drain port b is b 6
closed, and the oil from the pump and 5
accumulator flows from port B to port D and From pump To front brake
cylinder
actuates the front brake cylinders. B D SED00109
Brake applied (left brake pedal)

• When pedal (7) is depressed, spool (10) is
pushed up by rod (8) and spring (9), and drain 7
port c is closed. The oil from the pump and the
accumulator flows from port E to port F. Left brake valve
• Port F of the left brake valve and port PP of the
right brake valve are connected by a hose, so the 8
oil flowing to port F flows to pilot port PP of the
right brake valve. 9
• The oil entering pilot port PP enters port G from C
orifice d, and pushes piston (11). The spring 10
pushes spool (3) down, so the operation is the F
same as when the right brake valve is E
depressed.
Right brake
valve
d
G PP
11 To rear brake
cylinder
From pump
3
From pump
To front brake
cylinder
SEW00110
10-100 WA700-3
(10)
Applying brake when upper valve fails (right

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

Upper portion
• When oil fills the rear brake cylinder and the From pump To fear brake
cylinder
pressure between port A and port C becomes
high, the oil entering port H from orifice e of spool
(3) pushes against spring (4). It pushes up spool From pump To front brake
cylinder
(3) and shuts off the circuit between port A and
5 SEW00111
port C. When this happens, drain port a stays
closed, so the oil entering the brake cylinder is
held and the brake remains applied.
Lower portion
• When spool (3) in the upper portion moves up
and the circuit between port A and port C is shut
off, oil also fills the front brake cylinder at the
same time, so the pressure in the circuit between
port B and port D rises. The oil entering port J
from orifice f of spool (5) pushes up spool (5) by
the same amount that spool (3) moves, and
shuts off port B and port D. Drain port b is closed,
so the oil entering the brake cylinder is held, and 4
the brake is applied. 3
a
• The pressure in the space in the upper portion is e H
To rear brake
balanced with the operating force of the pedal, A
From pump C cylinder
and the pressure in the space in the lower portion
5
is balanced with the pressure in the space in the b To front brake
f
upper portion. When spools (3) and (5) move to From pump Dcylinder
the end of their stroke, the circuits between ports
B
A and C and between ports B and D are fully J SEW00112
opened, so the pressure in the space in the
upper and lower portions and the pressure in the
left and right brake cylinders is the same as the
pressure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the
brake can be adjusted by the amount that the
pedal is depressed.
WA700-3 10-101
(10)
Brake released (right brake valve)

Upper portion
• When pedal (1) is released and the operating
1
force is removed from the top of the spool, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (3)
up. Drain port a is opened and the oil from the
brake cylinder flows to the hydraulic tank return
circuit to release the rear brake.
Lower portion
• When the pedal is released, spool (3) in the 3
upper portion moves up. At the same time, the a
back pressure from the brake cylinder and the
force of the spool return spring move spool (5) From pump From rear brake
up. Drain port b is opened and the oil from the cylinder
brake cylinder flows to the hydraulic tank return
circuit to release the front brake. From pump b From front brake
5 cylinder
SEW00113
10-102 WA700-3
(10)
Structure and function Charge valve
Charge valve
A. To brake oil tank Function

ACC. To brake valve • The charge valve is actuated to maintain the oil
PP. To brake valve pressure from the pump at the specified pressure
P. From pump and to store it in the accumulator.
T. To brake oil tank • When the oil pressure reaches the specified
pressure, the oil from the pump is connected to
the drain circuit to reduce the load on the pump.
10-104 WA700-3
(10)
Operation
1. When no oil is being supplied to accumulator
(cut-out condition)
• The pressure at port B is higher than the set

pressure of the relief valve (R1), so piston (8) is
forcibly pushed up by the oil pressure at port B.
Poppet (6) is opened, so port C and port T are
short circuited.
• The spring chamber at the right end of spool (15)
is connected to port C of the relief valve (R1), so
the pressure becomes the brak e oil tank
pressure. The oil from the pump enters port P,
pushes spool (15) to the right at a low pressure
equivalent to the load on spring (14), and flows
from port A to the brake oil tank.
At the same time, it also passes through orifices
(17), (18), and (16), and flows to the brake oil
tank.
2. When oil is supplied to accumulator
1) Cut-in condition
• When the pressure at port B is lower than the set
pressure of the relief valve (R1), piston (8) is
pushed back down by spring (5). Valve seat (7)
and poppet (6) are brought into tight contact, and
port C and port T are shut off.
is also shut off from port T, so the pressure rises,
and the pressure at port P also rises in the same
way.
• When the pressure at port P goes above the
pressure at port B (accumulator pressure), the
supply of oil to the accumulator starts
immediately. In this case, it is decided by the size
(area) of orifice (17) and the pressure difference
(equivalent to the load on spring (14)) generated
on both sides of the orifice. A fixed amount is
supplied regardless of the engine speed, and the
remaining oil flows to port A.
10-106 WA700-3
(10)
2) When cut-out pressure is reached

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

• If the pressure at port P (pump pressure) goes
above the set pressure of the relief valve (R3),
the oil from the pump pushes spring (3). Ball (11)
is pushed up and the oil flows to the brake oil
tank circuit, so this sets the maximum pressure in
the brake circuit and protects the circuit.
WA700-3 10-107
(10)
Structure and function Accumulator (for brake)
Accumulator (for brake)

1. Valve
2. Top cover
3. Cylinder
4. Piston
SEW00120
Function Specifications
• The accumulator is installed between the charge Gas used: Nitrogen gas
valve and the brake valve. It is charged with Charge amount: 4000 cc
nitrogen gas between cylinder (3) and free piston Charging pressure: 3.4 ± 0.15 MPa
(4), and uses the compressibility of the gas to (35 ± 1.5 kg/cm2) (at 50°C)
absorb the pulse of the hydraulic pump or to
maintain the braking force and to make it
possible to operate the machine if the engine
should stop.
10-108 WA700-3
(10)
Structure and function Slack adjuster
Slack adjuster
1. Cylinder Specification
2. Check valve Serial No.: 50001 – 50055
3. Bleeder Check valve cracking pressure:
4. Piston 0.93 MPa {9.5 kg/cm2}
5. Spring Check valve closing pressure:
0.59 MPa {6.0 kg/cm2}
A. Inlet port
B. Outlet port Serial No.: 50056 and up
Check valve cracking pressure:
0.59 MPa {6.0 kg/cm2}
Check valve closing pressure:
0.36 MPa {3.7 kg/cm2}
Function
• The slack adjuster is installed in the brake oil line
from the brake chamber to the brake piston. It
acts to keep the clearance between the brake
piston and discs constant even when the brake
discs are worn. In this way it acts to keep a
constant time lag when the brake is operated.
WA700-3 10-109
(10)
Operation
1. When brake pedal is depressed
• Before the brake is depressed, piston (4) is
returned by the distance of stoke S (full stroke).
When the brake pedal is depressed, the oil
discharged from the brake valve flows from port
P of the slack adjuster and is divided to left and
right cylinders (2), where it moves piston (4) by
stroke S to the left and right.
• When this is done, brake piston (7) moves by a

distance of stroke S. In this condition, the closer
the clearance between the brake piston (7) and
disc is to 0, the greater the braking force
becomes.
• If the brake pedal is depressed further, and the

oil pressure discharged from the brake valve
goes above the set pressure, check valve (3)
opens and the pressure is applied to port C to act
as the braking force.
Therefore, when the brake is applied, the time
lag is a fixed value.
10-110 WA700-3
(10)
2. When brake pedal is released

• When the brake is released, piston (4) is
returned by brake return spring (8) by an amount
equivalent to the oil for stroke S, and the brake is
released.
In other words, return stroke T of brake piston (7)
is determined by the amount of oil for stroke S of
the slack adjuster. The time lag of the brake is
always kept constant regardless of the wear of
the brake disc.
WA700-3 10-111
(10)
Structure and function Brake
Brake
Serial No.: 50001 – 50045
1. Guide pin
2. Return spring
3. Brake piston
4. Disc
5. Plate
6. Floating seal
10-112 WA700-3
(10)
1. Guide pin
2. Return spring
3. Brake piston
4. Disc
5. Plate
6. Floating seal
WA700-3 10-113
(10)
Function
• Main brakes are wet-type multiple-disc brakes
and are installed to all four wheels.
Operation
• When the brake pedal is depressed, the
pressure oil from the brake valve moves brake
piston (4) to the right in the direction of the arrow.
This brings disc (8) and plate (7) into contact,
and friction is generated between the disc and
plate. The wheel is rotating together with the
disc, so the machine speed is reduced and the
machine is stopped by this friction.
• When the brake pedal is released, the pressure

at the back face of brake piston (4) is released,
so the piston is moved to the left in the direction
of the arrow by the force of return spring (2), and
the brake is released.
10-114 WA700-3
(10)
Structure and function Parking brake
Parking brake
Serial No.: 50001 – 50044
1. Spring cylinder Outline

2. Parking brake disc • The parking brake is a disc type and is installed
on the front axle.
• The force of the spring inside spring cylinder (1)
is used to apply the brake mechanically; it is
released by oil pressure.
• The parking brake caliper is fixed to the front
differential case.
The disc is installed to the differential yoke and
rotates together with the coupling.
WA700-3 10-115
(10)
Parking brake caliper
1. Caliper Outline
2. Pad • Caliper (1) is fitted with a piston guide. Piston (3)
3. Piston and piston shaft (4) are fitted inside, and the
4. Piston shaft rotation of the piston shaft moves the piston in
5. Lever the axial direction to compress pad (2).
6. Adjustment bolt • Lever (5) is connected by a spline to the spline
side of the piston shaft.
Pad (2) is fitted and held in position together with
caliper (1) in the caliper mounting plate.
• The caliper body follows the wear of pad (2) and
slides in the axial direction on the plate.
Adjustment bolt (6) of lever (5) is used to adjust
the clearance between the pad and the disc.
Hold the lever and turn the adjustment bolt to
adjust the clearance as follows.
To INCREASE, turn COUNTERCLOCKWISE.
To DECREASE, turn CLOCKWISE.
10-116 WA700-3
(10)
1. Spring cylinder Outline

2. Parking brake disc • The parking brake is a disc type and is installed
3. Caliper return spring on the front axle.
• The force of the spring inside spring cylinder (1)
is used to apply the brake mechanically; it is
released by oil pressure.
• The parking brake caliper is fixed to the front
differential case.
The disc is installed to the differential yoke and
rotates together with the coupling.
• Caliper return spring (3) acts to separate the
brake pads.
WA700-3 10-117
(10)
Parking brake caliper
1. Caliper Outline
2. Pad • Caliper (1) is fitted with a piston guide. Piston (3)
3. Piston and piston shaft (4) are fitted inside, and the
4. Piston shaft rotation of the piston shaft moves the piston in
5. Lever the axial direction to compress pad (2).
6. Adjustment bolt • Lever (5) is connected by a spline to the spline
side of the piston shaft.
Pad (2) is fitted and held in position together with
caliper (1) in the caliper mounting plate.
• The caliper body follows the wear of pad (2) and
slides in the axial direction on the plate.
Adjustment bolt (6) of lever (5) is used to adjust
the clearance between the pad and the disc.
Hold the lever and turn the adjustment bolt to
adjust the clearance as follows.
To INCREASE, turn COUNTERCLOCKWISE.
To DECREASE, turn CLOCKWISE.
10-118 WA700-3
(10)
Structure and function Spring cylinder
Spring cylinder
1. Outer spring Outline

2. Inner spring • The oil pressure from the parking brake solenoid
3. Piston valve pushes the spring and releases the parking
4. Cylinder brake.
5. Boot When the engine is stopped, the parking brake is
6. Rod applied by spring (1), so the machine is
prevented from moving.
WA700-3 10-119
(10)
Structure and function Parking brake solenoid valve
Parking brake solenoid valve
1. Solenoid valve assembly Function

2. Block • The parking brake solenoid valve is installed to
the inside left of the front frame. When the
B: Outlet port parking brake switch is turned ON/OFF, the
P: Inlet port solenoid valve is energized or deenergized, so
T: Drain port the brake oil pressure is taken to the brake
cylinder or removed from the brake cylinder to
set the parking brake at the PARKED position or
TRAVEL position.
• Parking brake solenoid valve
Energized: TRAVEL
Deenergized: PARKED
10-120 WA700-3
(10)
Structure and function Hydraulic piping
Hydraulic piping
10-122 WA700-3
(10)
Structure and function Hydraulic circuit diagram
Hydraulic circuit diagram
10-124 WA700-3
(10)
Structure and function Hydraulic circuit diagram
WA700-3 10-125
(10)
Structure and function Main piston pump
Main piston pump

Serial No.: 50001 – 50056
Model: HPV90 + HPF90
1. ES valve (Engine sensing) Outline

2. Servo valve • This pump consists of 2 swash plate-type piston
3. Control pump (BAR025) pumps, 1 impeller pump (installed between the
4. Rear main pump (Fixed displacement type) front pump and rear pump), and 1 control pump.
5. Front main pump (Variable displacement type) • The rear pump is a variable-capacity pump, but a
6. Relief valve collar is inserted in it to disable the servo piston
7. Pump sub assembly from operating and fix the swash plate. As a
8. Servo valve assembly result, the capacity of this pump is fixed.
9. Impeller pump
WA700-3 10-127
(10)
WA700-3 10-129
(10)

Model: HPV95 + HPF95
1. ES valve (Engine sensing) Outline

2. Servo valve • This pump consists of 2 swash plate-type piston
3. Control pump (BAR025) pumps, 1 impeller pump (installed between the
4. Rear main pump (Fixed displacement type) front pump and rear pump), and 1 control pump.
5. Front main pump (Variable displacement type) • The rear pump is a variable-capacity pump, but a
6. Relief valve collar is inserted in it to disable the servo piston
7. Pump sub assembly from operating and fix the swash plate. As a
8. Servo valve assembly result, the capacity of this pump is fixed.
9. Impeller pump
WA700-3 10-131
(10)
WA700-3 10-133
(10)
Function
• The engine rotation and torque transmitted to the
pump shaft is converted into hydraulic energy,
and pressurized oil is discharged according to
the load.
• It is possible to change the delivery amount by
changing the swash plate angle.
Structure
• Cylinder block (7) is supported to shaft (1) by a surface is designed so that the oil pressure
spline, and shaft (1) is supported by the front and balance is maintained at a suitable level. The oil
rear bearings. inside each cylinder chamber of cylinder block
• The tip of piston (6) is spherical, and shoe (5) is (7) is sucked in and discharged through valve
caulked to it to form one unit. Piston (6) and shoe plate (8).
(5) form a spherical bearing. • Impeller (9) is connected to shaft (1) through the
• Swash plate (4) has plane surface A, and shoe spline boss (10) and rotates together with the
(5) is always pressed against this surface while shaft. The oil sucked in through the suction port
sliding in a circular movement. is sent to the cylinder chamber by centrifugal
Swash plate (4) brings high pressure oil at force to make suction easier.
cylindrical surface B with cradle (2), which is
secured to the case, and forms a static pressure
bearing when it slides.
• Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
• Cylinder block (7) seals the pressure oil to valve
plate (8) and carries out relative rotation. This
10-134 WA700-3
(10)
Operation
1. Operation of pump
• Cylinder block (7) rotates together with shaft (1),
and shoe (5) slides on flat surface A.
When this happens, rocker cam (4) moves along
cylindrical surface B, so angle a between center
line X of rocker cam (4) and the axial direction of
cylinder block (7) changes. (Angle a is called the
swash plate angle.)
1) Center line X of rocker cam (4) maintains swash

plate angle a in relation to the axial direction of
cylinder block (7), and flat surface A moves as a
cam in relation to shoe (5). In this way, piston (6)
slides on the inside of cylinder block (7), so a
difference between volume E and F is created
inside cylinder block (7). The suction and
discharge is equal to this difference E – F.
In other words, when cylinder block (7) rotates
and the volume of chamber E becomes smaller,
the oil is discharged during that stroke. On the
other hand, the volume of chamber F becomes
larger, and as the volume becomes bigger, the
oil is sucked in.
2) If center line X of rocker cam (4) is in line with

the axial direction of cylinder block (7) (swash
pl ate angle = 0), t he diff erence bet ween
volumes E’ and F’ inside cylinder block (7)
becomes 0, so the pump does not carry out any
suction or discharge of oil.
WA700-3 10-135
(10)
2. Control of discharge amount

If swash plate angle becomes larger, the dif-
ference in volumes E and F becomes larger and
the discharge volume increases.
Swash plate angle is changed by servo piston
(15). Servo piston (15) moves in a reciprocal
movement ( ) in accordance with the com-
mand from the servo valve. This straight line
movement is transmitted through the rod of
rocker cam (4) to rocker cam (4), and rocker
cam (4), which is supported by the cylindrical
surface to cradle (10), slides in an oscillating
movement in direction ( ) along the cylindri-
cal surface.
10-136 WA700-3
(10)
2. Control pump
Model: BAR025
1. Collar Outline
2. Body • The control pump is a gear pump for the ES
3. Housing (engine sensing) valve, and its specifications are
4. Drive gear as follows.
5. Driven gear
Specification
Model: BAR025
Theoretical delivery: 25 cc/rev.
Max. delivery pressure: 2.9 MPa {30 kg/cm2}
WA700-3 10-137
(10)
Control pump relief valve

1. Adjustment screw
2. Lock nut
3. Pilot valve spring
4. Pilot valve
5. Main valve spring
6. Main valve
Set pressure: 2.9 MPa {30 kg/cm2}

(at 50 l/min)
Function
The relief valve is built in the body of control pump. It
relieves the oil delivered from the pump.
Flow of the oil

• Chamber A forms a pump circuit and chamber C
forms a tank drain circuit. The oil flows into
chamber B through the main relief valve orifice to
keep the chamber filled.
Pilot valve is set in the valve seat.
• If the pressure in chamber B reaches the pilot

valve spring force (set pressure), the pilot valve
moves, allowing the oil in chamber B to flow into
chamber C. In addition, the oil flows from
chamber A to B through orifices.
• If the oil flows through the orifice of valve (6), a

differential pressure occurs between the
chambers A and B, moving valve (6) to the left.
This allows the oil in chamber A to flow into
chamber C.
10-138 WA700-3
(10)
Structure and function ES valve
ES valve (Engine Sensing valve)
1. Plug Function
2. Valve body • This valve acts to control the delivery amount of
3. Shaft the hydraulic pump to match the changes in the
4. Plug engine speed.
5. Plug
6. Spool
7. Spool
8. Plug
WA700-3 10-139
(10)
Structure and function Servo valve
Servo valve
1. Plug
2. Arm
3. Spool
4. Body
5. Sleeve
6. Sleeve
7. Spool
8. Plug
10-140 WA700-3
(10)
Structure and function Pressure differential valve
Pressure differential valve
1. Valve body Function

2. Spring • The pressure differential valve converts the
3. Shim hydraulic pressure for the engine speed into a
4. Valve differential pressure, and controls the ES valve
(engine sensing valve).
WA700-3 10-141
(10)
Structure and function PPC valve
PPC valve (Proportional Pressure Valve)
P : From pump
T : To tank (drain)
P1 : To bucket cylinder (Tilt)
P2 : To boom cylinder (Raise)
P3 : To boom cylinder (Lower)
P4 : To bucket cylinder (Dump)
10-142 WA700-3
(10)
1. Bolt
2. Piston
3. Plate
4. Collar
5. Retainer
6. Center spring
7. Metering spring
8. Valve
9. Body
WA700-3 10-143
(10)
Operation
1. Control lever at "neutral" (Fig. 1):

Ports PA1, P2, PB1 and P4 are connected to
drain chamber D through fine control hole (f) in
spool (10).
2. Control lever operated slightly (fine control)

(Fig. 2):
When piston (4) starts to be pushed by plate
(2), retainer (7) is pushed. Valve (10) is also
pushed by spring (9) and moves down.
When this happens, fine control hole (f) is
shut off from drain chamber D. At almost the
same time it is connected to pump pressure
chamber PP, and the pilot pressure of the
control valve is sent through fine control
hole (f) to port P2 and PA1. When the pres-
sure at port P2 rises, valve (10) is pushed
back. Fine control hole (f) is shut off from
pump pressure chamber PP. At almost the
same time it is connected to drain chamber
D, so the pressure at port P2 escapes to
drain chamber D.
(Fig. 1)
Valve (10) moves up and down until the

force of spring (9) is balanced with the pres-
sure of port P2.
The position of valve (10) and body (11)
(when fi ne con trol hol e (f) i s m idw ay
between drain chamber D and pump pres-
sure chamber PP) does not change until the
head of valve (10) contacts the bottom of
piston (4).
Therefore, spring (9) is compressed in pro-
portion to the travel of the control lever, so
the pressure at port P2 also rises in propor-
tion to the travel of the control lever. The
spool of the control valve moves to a posi-
tion where the pressure of port PA1 (same
as pressure at port P2) and the force of the
return spring of the control valve are bal-
anced.
(Fig. 2)
10-144 WA700-3
(10)
3. Control lever moved back from slightly

operated position to neutral (Fine control)
(Fig. 3):
When plate (2) starts to be pushed back, piston
(4) is pushed up by a force corresponding to the
force of centering spring (8) and the pressure at
port P2.
At the same time, fine control hole (f) of valve
(10) is connected to drain chamber D, so the oil
at port P2 escapes.
If the pressure at port P2 drops too far, valve
(10) is pushed down by spring (9). Fine control
hole (f) is shut off from drain chamber D, and at
almost the same time it is connected to pump
pressure chamber PP. The pump pressure is
supplied until the pressure at port P2 return to a
pressure equivalent to the position of the lever.
When the spool of the control valve returns, the
oil in drain chamber D flows in from fine control
hole (f’) of the valve which has not moved. The
extra oil then flows through port P4 to chamber
PB1.
(Fig. 3)
4. Control lever operated to end of travel

(Fig. 4):
Plate (2) pushes piston (4) down, and piston (4)
forcibly pushes in valve (10).
Fine control hole (f) is shut off from drain cham-
ber D, and is connected to pump pressure
chamber PP.
Therefore, pressure oil from the charging pump
passes through fine control hole (f), and flows
from port P2 to chamber PA1 to push the spool
of the control valve.
The oil returning from chamber A2 flows from
port PB1 through fine control hole (f’) to drain
chamber D.
(Fig. 4)
WA700-3 10-145
(10)
Structure and function PPC relief valve
PPC relief valve

1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
Function
• The PPC relief valve is between the PPC pump
and the PPC valve. When the PPC valve is not
being actuated, or when abnormal pressure is
generated, the oil sent from the pump is relieved
through this valve to protect the pump and circuit
from damage. (Sets maximum pressure in the
circuit).
Operation
C is connected to the drain circuit.
The oil passes through the orifice of main valve
(1) and fills port B. Pilot poppet (3) is in close
contact with valve seat (2).
• If the pressure at ports A and B reach the

pressure set by the poppet spring, pilot poppet
(3) opens and the pressure oil at port B flows
through port D to port C. As a result, the pressure
at port B drops.
• If the pressure at port B drops, a pressure

difference is generated between ports A and B
due to the orifice in main valve (1). Main valve (1)
is pushed open by the pressure at port A, and the
oil at port A is relieved.
10-146 WA700-3
(10)
Structure and function Accumulator (for PPC valve)
Accumulator (for PPC valve)

1. Cap
2. Nut
3. Body
4. Bladder
5. Oil port
6. Nut
Specifications
Type of gas: Nitrogen gas
Gas amount: 3,000 cc
Max. actuation pressure:2.9 MPa {30 kg/cm2}
Min. actuation pressure: 1.2 MPa {12 kg/cm2}
Function
• The accumulator is installed between the
hydraulic pump and PPC valve. An inflatable
bladder is filled with nitrogen gas, and the
compressibility is used to store the pressure of
the oil. As a result, the boom and bucket can be
lowered under their own weight even after the
engine has been stopped.
Operation Before operation After operation

• After the engine stops, when the PPC valve is a
NEUTRAL, chamber A (volume of nitrogen gas:
3000 cc) inside the bladder is compressed by
chamber B.
• When the PPC valve is operated, the pressure in

chamber B drops below 2.9 MPa {30 kg/cm2} and
the pressure of the nitrogen gas in chamber A
makes the bladder expand. The actuating
pressure is 1.2 to 2.9 MPa {12 to 30 kg/cm2}.
From PPC pump To PPC valve
WA700-3 10-147
(10)
Structure and function Main control valve
Main control valve

Serial No.: 50001 – 51000
PA1 : From P4 of PPC valve 1. Main relief valve

PA2 : From P3 of PPC valve 2. Bucket spool return spring
PB1 : From P1 of PPC valve 3. Boom spool return spring
PB2 : From P2 of PPC valve 4. Boom spool
A1 : To bucket cylinder bottom side 5. Body
A2 : To boom cylinder bottom side 6. Bucket spool
B1 : To bucket cylinder rod side 7. Suction valve
B2 : To boom cylinder rod side 8. Unloader valve
P : Pump port 9. Float selector valve
P1 : From P3 of PPC valve 10. Safety valve (with suction)
P2 : From P2 of PPC valve
T : To hydraulic tank
10-148 WA700-3
(10)
Outline
• A work equipment valve is installed. The control and boom spool are operated, the oil flows into
valve controls the operations of the bucket and the bucket cylinder and boom cylinder.
boom of the hydraulic system and has a tandem Since the bucket is given priority, however, the
circuit, in which the bucket circuit is given the boom dose not move even if the boom spool is
priority. The work equipment valve operates operated while the bucket spool is operated.
each spool with the hydraulic pressure from the
PPC valve. • The bucket circuit has 2 safety-suction valves
• The oil from the pump flows in port P and its (10), which protect the circuit when abnormal
maximum pressure is limited by the relief valve. pressure is generated.
Then, it flows through bucket spool (6), bypass When either of the 2 safety-suction valves
circuit of boom spool (4), port T, drain circuit, and operates as a relief valve, the other one supplies
filter and returns to the tank. If the bucket spool a deficiency of oil as a suction valve.
WA700-3 10-149
(10)
PA1 : From P4 of PPC valve 1. Main relief valve

PA2 : From P2 of PPC valve 2. Bucket spool return spring
PB1: From P1 of PPC valve 3. Boom spool return spring
PB2: From P3 of PPC valve 4. Boom spool
A1 : To bucket cylinder bottom side 5. Body
A2 : To boom cylinder bottom side 6. Bucket spool
B1 : To bucket cylinder rod side 7. Suction valve
B2 : To boom cylinder rod side 8. Unloader valve
P : Pump port 9. Float selector valve
P1 : From P3 of PPC valve 10. Safety valve (with suction)
P2 : From P2 of PPC valve
T : To hydraulic tank
10-150 WA700-3
(10)
Outline
• A work equipment valve is installed. The control and boom spool are operated, the oil flows into
valve controls the operations of the bucket and the bucket cylinder and boom cylinder.
boom of the hydraulic system and has a tandem Since the bucket is given priority, however, the
circuit, in which the bucket circuit is given the boom dose not move even if the boom spool is
priority. The work equipment valve operates operated while the bucket spool is operated.
each spool with the hydraulic pressure from the
PPC valve. • The bucket circuit has 2 safety-suction valves
• The oil from the pump flows in port P and its (10), which protect the circuit when abnormal
maximum pressure is limited by the relief valve. pressure is generated.
Then, it flows through bucket spool (6), bypass When either of the 2 safety-suction valves
circuit of boom spool (4), port T, drain circuit, and operates as a relief valve, the other one supplies
filter and returns to the tank. If the bucket spool a deficiency of oil as a suction valve.
WA700-3 10-151
(10)
Relief valve
Serial No.: 50001 – 51000
1. Main valve
2. Valve seat
3. Pilot poppet
4. Pilot poppet spring
5. Adjustment screw
6. Lock nut
Function
• The relief valve is installed at the inlet of the main
control valve. When the oil goes above the set
pressure, the relief valve drains the oil to the
tank. In this way, it sets the maximum pressure in
the hydraulic circuit and protects the circuit.
Operation
C is connected to the drain circuit. The oil passes
through the orifice of main valve (1) and flows to
port B. Pilot poppet (3) is in close contact with
valve seat (2).
• When the hydraulic pressure in the circuit inside
port A and port B reaches the set pressure of
pilot poppet spring (4), pilot poppet (3) opens,
and the pressurized oil from port B flows from
port D to port C, so the pressure at port B drops.
• When the pressure at port B drops, the orifice

effect of main valve (1) generates a difference in
pressure between port A and port B. The main
valve is pushed open and the oil from port A
passes through port C and flows to the drain
circuit to release the abnormal pressure.
10-152 WA700-3
(10)

1. Main valve
2. Piston
3. Piston spring
4. Poppet
5. Poppet spring
6. Plug with valve seat
7. Sleeve
8. Adjustment screw
9. Lock nut
10. Orifice
Function
• The relief valve is installed at 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
• Ports A and B are connected to the pump circuit
and drain circuit respectively. The oil pressure in
port A is applied through the hole of piston (3) to
port C.
• When the oil pressure is below the set relief
pressure, poppet (4) is in contact with the seat of
plug (6) and the oil does not flow from chamber
C into the drain circuit. Accordingly, the oil
pressure in port A is equal to that in chamber C.
• Since d2 < d3, main valve (2) is in contact with
the left side. The sectional areas are set in the
following order; d5 > d4 > d1 > d3 > d2.
• If the pump pressure is raised by spring (5) to the

relief pressure poppet (4) opens and the oil in
chamber C is drained through chamber D.
• If poppet (4) opens, the oil flows from A through
C to D.
• As the oil flows from A o C [hole through piston

(2)]. its pressure lowers. As a result, the pressure
in chamber C is lower than that in port A, thus
main valve (1) moves to the right.
• Then, the oil flows from port A to port B and limits
the maximum pressure to protect the circuit.
WA700-3 10-153
(10)
Safety valve (with suction valve)

1. Suction valve
2. Main valve
1 2 3 4 5 6 3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
SEW00166
Function
• The safety valve (with suction valve) is in the
bucket cylinder circuit in the main valve. If shock
causes any abnormally high pressure in the
cylinder when the main valve is at neutral, the
safety valve (with suction valve) releases the
abnormal pressure and protects the cylinder
from damage.
• This valve prevents generation of negative
pressure in the circuit.
Operation A B C 2 4 D
As a safety valve
• Port A is the cylinder circuit and port B is the
drain circuit.
• The pressure oil in port A flows to port D through
a hole in pilot piston (4). It also flows to port C
through an orifice consisting of the main valve
and pilot piston (4).
Pilot piston (4) is secured to the suction valve by
lock nut. The diameter of the cross section (cross
d1 d3 d4 d2
sectional area) gives a relationship of d2 > d1 > d3 SEW00167
> d4 .
• If abnormally high oil pressure occurs in port A, A B 1 2 3 D

suction valve (1) is not actuated because of the
relationship d2 > d1.
However, because of the relationship d3 > d4 in
port A and C, the hydraulic pressure on main
valve (2) is equivalent to the area difference
between d3 and d4. If this pressure goes up to the
main valve spring force (set pressure), main
valve (2) is actuated, and the oil in port A flows
into port B.
SEW00168
10-154 WA700-3
(10)
As a suction valve
• If negative pressure is generated in port A, port
D also has negative pressure, because port D
and A are connected with each other. The tank
pressure in port B is applied to port E.
Hydraulic pressure "a" equivalent to the area
difference between d2 and d1 is applied to the
safety valve because of the tank pressure in port
E. Therefore, hydraulic pressure "e" acts to open
the valve and hydraulic pressure "a" acts to close
suction valve (1).
• If the pressure in port A drops, (approaching
negative pressure) hydraulic pressure "a"
becomes smaller than oil pressure "e".
• When oil pressure "e" becomes larger than oil
pressure "a" + valve spring (5) force, suction
valve (1) opens, causing the oil to flow from port
B into port A. This prevents negative pressure
from building up in port A.
Suction valve
1. Main poppet
2. Sleeve
1 2 3 3. Spring
SEW00170
Operation
• If negative pressure is generated in port A (boom
cylinder rod end) (if the pressure is lower than in
port B in the tank circuit), main poppet (1) opens
because oil then flows from port B at the tank
end to port A at the cylinder port end.
WA700-3 10-155
(10)
Float selector valve and unloader valve

Serial No.: 50001 – 51000
Function
• The float selector valve (2) and the unloader
valve (3) are inside the main control valve. When
the boom control lever is moved to the float
position, the float selector valve (2) detects this.
When it is actuated, it actuates the unloader
valve (3) and sets the boom in the FLOAT
position.
Operation
1. LOWER position
This shows the condition with the boom control
lever in the LOWER position.
2. FLOAT position
When the boom control lever is pushed forward
from the LOWER position, it enters the FLOAT
position.
Boom spool (1) of the main control valve is in
the same condition as at the LOWER position.
The hydraulic pressure at port A is higher than
at the LOWER position, so float selector valve
(2) moves in the direction of the rightward. The
back pressure of unloader valve (3) is drained,
so unloader valve (3) opens to give the FLOAT
condition.
10-156 WA700-3
(10)
3. FLOAT position (pushed up)

If the machine moves in reverse and the boom
is pushed up, the pressure at the cylinder rod
end becomes high. It passes through port B and
is drained through unloader valve (3).
A vacuum is formed at the cylinder bottom end,
so oil flows in from port C.
4. FLOAT position (lowering under own weight)

When the machine is moving in reverse and the
boom comes down under its own weight, the
pressure at the cylinder bottom end is high, and
it is drained from port C.
A vacuum is formed at the cylinder rod end, so
oil flows in from port B.
WA700-3 10-157
(10)
Function
• The float selector valve (2) and the unloader
valve (3) are inside the main control valve. When
the boom control lever is moved to the float
position, the float selector valve (2) detects this.
When it is actuated, it actuates the unloader
valve (3) and sets the boom in the FLOAT
position.
Operation
1. LOWER position
This shows the condition with the boom control
lever in the LOWER position.
2. FLOAT position
When the boom control lever is pushed forward
from the LOWER position, it enters the FLOAT
position.
Boom spool (1) of the main control valve is in
the same condition as at the LOWER position.
The hydraulic pressure at port A is higher than
at the LOWER position, so float selector valve
(2) moves in the direction of the rightward. The
back pressure of unloader valve (3) is drained,
so unloader valve (3) opens to give the FLOAT
condition.
10-158 WA700-3
(10)
3. FLOAT position (pushed up)

If the machine moves in reverse and the boom
is pushed up, the pressure at the cylinder rod
end becomes high. It passes through port B and
is drained through unloader valve (3).
A vacuum is formed at the cylinder bottom end,
so oil flows in from port C.
4. FLOAT position (lowering under own weight)

When the machine is moving in reverse and the
boom comes down under its own weight, the
pressure at the cylinder bottom end is high, and
it is drained from port C.
A vacuum is formed at the cylinder rod end, so
oil flows in from port B.
WA700-3 10-159
(10)
Operation of hydraulic circuit

Serial No.: 50001 – 51000
Boom and bucket spools in "HOLD"
Operation
• The oil enters port A from the steering valve, and • The oil from the PPC pump passes through
the maximum pressure is set by relief valve (11). check valve (13), and enters port L of the PPC
• Bucket spool (1) is at the HOLD position, so the valve. However, the boom and bucket levers are
bypass circuit is open and the oil at port A at the HOLD position, so the oil returns to the
passes around the spool and flows to port B. hydraulic tank from PPC relief valve (12).
Boom spool (2) is also at HOLD, so the bypass
circuit is open and the oil at port B passes around
the spool, enters port C of the drain circuit,
passes through the filter in the hydraulic tank,
and returns to the tank.
10-160 WA700-3
(10)
Serial No.: 50001 – 51000

Boom spool in "RAISE"
Operation
• When boom lever (3) is pulled, the oil flows from • The oil from the steering valve passes through
port L of the PPC valve to port N and port S. In the bypass circuit of the bucket spool and flows
addition, the oil at port T passes through port M to the bypass circuit of boom spool (2). The
and flows to the drain circuit. The oil pressure at bypass circuit is closed by the spool, so the oil
port S pushes boom spool (2) and moves it to the pushes open check valve (10). The oil flows from
RAISE position. port H to port I, and flows to the cylinder bottom.
• At the same time, the oil at the cylinder rod end
enters drain port C from port K and returns to the
tank. Therefore, the boom rises.
WA700-3 10-161
(10)
Serial No.: 50001 – 51000

Boom spool in "LOWER"
Operation
• When boom lever (3) is pushed, the oil flows • The oil from the steering valve passes through
from port L of the PPC valve to port M and port the bypass circuit of the bucket spool and flows
T. In addition, the oil at port S flows to the drain to the bypass circuit of boom spool (2). The
circuit. bypass circuit is closed by the spool, so the oil
The oil pressure at port T pushes boom spool (2) pushes open check valve (10). The oil flows from
and moves it to the LOWER position. port J to port K, and flows to the cylinder rod end.
• At the same time, the oil at the cylinder bottom
enters drain port C from port I and returns to the
tank. Therefore, the boom goes down.
10-162 WA700-3
(10)
Serial No.: 50001 – 51000

Boom spool in "FLOAT"
Operation
• When boom lever (3) is pushed to the FLOAT port X, valve (7) moves to the right, opens port C1
position, the PPC valve spool moves beyond the and port C, and connects to the drain circuit.
LOWER position to the FLOAT position. The When port C1 is connected to the drain circuit,
pressure oil at port L flows to port M, and at the unload valve (8) moves up and the oil from the
same time, it also flows to port T and port W. In pump flows to the drain circuit.
addition, the pressurized oil at port S flows to port • Therefore, the oil at the cylinder rod end passes
N. from port K through unload valve (8) and flows to
• The pressurized oil at port T pushes boom spool the drain circuit. The oil at the cylinder bottom
(2) to the LOWER position. flows from port I to port C, and then flows to the
• If a difference in pressure greater than the drain circuit. Therefore, the boom is set to the
specified pressure is generated at port W and FLOAT condition.
WA700-3 10-163
(10)
Serial No.: 50001 – 51000

Bucket spool in "DUMP"
Operation
• When bucket lever (4) is pushed, the pressure oil port F to port G, and then flows to the cylinder rod
at port L of the PPC valve flows from port Q to end.
port V. In addition, the oil at port R flows to the • At the same time, the oil at the cylinder bottom
drain circuit. The pressure oil at port V moves flows from port D to drain port C, and returns to
bucket spool (1) to the DUMP position. the tank, so the bucket is dumped.
• The bypass circuit is closed by bucket spool (1),
so the oil from port A pushes open check valve
(10). The oil from check valve (10) flows from
10-164 WA700-3
(10)
Serial No.: 50001 – 51000

Bucket spool in "TILT BACK"
Operation
• When bucket lever (4) is pulled, the pressure oil port E to port D, and then flows to the cylinder
at port L of the PPC valve flows from port P to bottom.
port R. In addition, the oil at port V flows to the • At the same time, the oil at the cylinder rod end
drain circuit. The pressure oil at port R moves flows from port G to drain port C, and returns to
bucket spool (1) to the TILT position. the tank, so the bucket is tilted.
WA700-3 10-165
(10)

Boom and bucket spools in "HOLD"
Operation
• The oil enters port A from the steering valve, and • The oil from the PPC pump passes through
the maximum pressure is set by relief valve (11). check valve (13), and enters port L of the PPC
• Bucket spool (1) is at the HOLD position, so the valve. However, the boom and bucket levers are
bypass circuit is open and the oil at port A at the HOLD position, so the oil returns to the
passes around the spool and flows to port B. hydraulic tank from PPC relief valve (12).
Boom spool (2) is also at HOLD, so the bypass
circuit is open and the oil at port B passes around
the spool, enters port C of the drain circuit,
passes through the filter in the hydraulic tank,
and returns to the tank.
10-166 WA700-3
(10)

Boom spool in "RAISE"
Operation
• When boom lever (3) is pulled, the oil flows from flows to the bypass circuit of boom spool (2). The
port L of the PPC valve to port N and port T. In bypass circuit is closed by the spool, so the oil
addition, the oil at port S passes through port M pushes open check valve (10). The oil flows from
and flows to the drain circuit. The oil pressure at port H to port I, and flows to the cylinder bottom.
port T pushes boom spool (2) and moves it to the • At the same time, the oil at the cylinder rod end
RAISE position. enters drain port C from port K and returns to the
• The oil from the steering valve passes through tank. Therefore, the boom rises.
the bypass circuit of the bucket spool (1) and
WA700-3 10-167
(10)

Boom spool in "LOWER"
Operation
• When boom lever (3) is pushed, the oil flows flows to the bypass circuit of boom spool (2). The
from port L of the PPC valve to port M and port bypass circuit is closed by the spool, so the oil
S. In addition, the oil at port T flows to the drain pushes open check valve (10). The oil flows from
circuit. port J to port K, and flows to the cylinder rod end.
The oil pressure at port S pushes boom spool (2) • At the same time, the oil at the cylinder bottom
and moves it to the LOWER position. enters drain port C from port I and returns to the
• The oil from the steering valve passes through tank. Therefore, the boom goes down.
the bypass circuit of the bucket spool (1) and
10-168 WA700-3
(10)

Boom spool in "FLOAT"
Operation
• When boom lever (3) is pushed to the FLOAT port X, valve (7) moves to the right, opens port C1
position, the PPC valve spool moves beyond the and port C, and connects to the drain circuit.
LOWER position to the FLOAT position. The When port C1 is connected to the drain circuit,
pressure oil at port L flows to port M, and at the unload valve (8) moves up and the oil from the
same time, it also flows to port S and port W. In pump flows to the drain circuit.
addition, the pressurized oil at port T flows to port • Therefore, the oil at the cylinder rod end passes
N. from port K through unload valve (8) and flows to
• The pressurized oil at port S pushes boom spool the drain circuit. The oil at the cylinder bottom
(2) to the LOWER position. flows from port I to port C, and then flows to the
• If a difference in pressure greater than the drain circuit. Therefore, the boom is set to the
specified pressure is generated at port W and FLOAT condition.
WA700-3 10-169
(10)

Bucket spool in "DUMP"
Operation
• When bucket lever (4) is pushed, the pressure oil port F to port G, and then flows to the cylinder rod
at port L of the PPC valve flows from port Q to end.
port V. In addition, the oil at port R flows to the • At the same time, the oil at the cylinder bottom
drain circuit. The pressure oil at port V moves flows from port D to drain port C, and returns to
bucket spool (1) to the DUMP position. the tank, so the bucket is dumped.
10-170 WA700-3
(10)

Bucket spool in "TILT BACK"
Operation
• When bucket lever (4) is pulled, the pressure oil port E to port D, and then flows to the cylinder
at port L of the PPC valve flows from port P to bottom.
port R. In addition, the oil at port V flows to the • At the same time, the oil at the cylinder rod end
drain circuit. The pressure oil at port R moves flows from port G to drain port C, and returns to
bucket spool (1) to the TILT position. the tank, so the bucket is tilted.
WA700-3 10-171
(10)
Structure and function Lubrication of work equipment
Lubrication of work equipment
1. Bucket cylinder A. To center hinge pin (top)

2. Front frame B. To bucket cylinder bottom
3. Steering cylinder C. To boom pivot (left)
4. Boom cylinder D. To boom pivot pin (right)
5. Bellcrank E. To steering cylinder (left)
6. Transmission F. To steering cylinder (right)
7. Torque converter G. To center support
10-172 WA700-3
(10)
Structure and function Lubrication of work equipment
H. To front axle support J. To rear axle support

I. To torque converter trunnion K. To rear axle support cover
WA700-3 10-173
(10)
Structure and function Work equipment linkage
Work equipment linkage
1. Tooth with tip 6. Bucket cylinder

2. Sweeper wing 7. Boom
3. Bucket 8. Boom cylinder
4. Bucket link 9. Cord ring
5. Bellcrank
10-174 WA700-3
(10)
Structure and function Work equipment linkage
WA700-3 10-175
(10)
Structure and function Bucket positioner and boom kick-out
Bucket positioner and boom kick-out
1. Proximity switch (for bucket positioner)

2. Proximity switch (for boom kick-out)
3. Bucket cylinder rod
4. Lever
5. Plate
10-176 WA700-3
(10)
Structure and function Bucket positioner and boom kick-out
Bucket positioner
• The bucket positioner is electrically actuated and
is used to automatically obtain the optimum
digging angle for the bucket.
When the bucket is moved from the DUMP
position to the TILT position, and it reaches the
desired angle, the bucket lever is automatically
moved from the TILT position to the neutral.
• Lever (2) is secured by bolts to bucket cylinder
rod (1). A proximity switch (3) is fixed by bolts to
the cylinder.
• When the bucket is moved from the DUMP
position to the TILT position, the bucket cylinder
rod moves to the lift. At the same time, lever (2)
also moves to the left. When it reaches the
desired position, lever (2) separates from
proximity switch, and the bucket lever returns to
neutral.
Boom kick-out
• The boom kick-out is electrically operated and
acts to stop the boom. When the boom reaches
the desired position before the maximum height,
the boom lever is returned to neutral.
• Plate (4) is secured to the boom. A proximity
switch (5) is fixed to the frame. When the boom
is moved from the LOWER position to the RAISE
position, the boom rises. When it reaches the
desired position, the proximity switch and plate
come into contact and the boom lever is returned
to neutral.
WA700-3 10-177
(10)
Structure and function Operation of proximity switch
Operation of proximity switch

Boom RAISE
• When the boom is lower than the set position for
the kick-out, the detector (steel plate) is not
above the detection surface of the proximity
switch, so the proximity switch load circuit is shut
off.
The relay switch is turned OFF and the current
for the solenoid is shut off.
• When the boom lever is moved to the RAISE

position, the boom spool is held at the RAISE
position by the cam follower and cam on the
lever, and the boom rises.
10-178 WA700-3
(10)
• When the boom rises and reaches the set

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

Position
detection surface of proximity switch detection surface of proximity switch
Proximity switch
Lights up Goes out
actuation display
Proximity switch load circuit
Current flows Current is shut off
(relay switch circuit)
Relay switch load circuit
Current flows Current is shut off
(solenoid circuit)
WA700-3 10-179
(10)
Bucket TILT
• When the bucket is dumped beyond the set
position for the auto-leveler, the sensor (steel
plate) is above the detection surface of the
bucket proximity switch, so electric current flows
in the proximity switch load circuit. The positioner
relay is turned ON and the current for the
solenoid is shut off.
• When the bucket lever is moved to the TILT

position, the bucket spool is held at the TILT
position by the cam follower and cam on the
lever, and the bucket tilts.
10-180 WA700-3
(10)
• When the bucket tilts and reaches the set

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

Position
detection surface of proximity switch detection surface of proximity switch
Proximity switch
Lights up Goes out
actuation display
Positioner relay Current flows Current is shut off
Solenoid (for bucket) Current is shut off Current flows
WA700-3 10-181
(10)
Structure and function Air conditioner
Air conditioner
Air conditioner piping
Serial No.: 50001 – 51000
1. Vent 6. Compressor
2. Window defroster 7. Hot water inlet port
3. Vent 8. Hot water outlet port
4. Dry receiver 9. Air conditioner unit
5. Air conditioner condenser
10-182 WA700-3
(10)
1. Vent 6. Compressor
2. Window defroster 7. Hot water inlet port
3. Vent 8. Hot water outlet port
4. Dry receiver 9. Air conditioner unit
5. Air conditioner condenser
WA700-3 10-183
(10)
Air conditioner condenser
1. Refrigerant gas inlet port 3. Connector

2. Fan 4. Refrigerant gas outlet port
Air conditioner compressor
1. Refrigerant outlet port

2. Refrigerant inlet port
3. Charge port on suction side
4. Clutch
5. Relief valve
Specifications
Type: Piston pump type
Refrigerant used: R134a
10-184 WA700-3
(10)
Dry reservoir
1. Cap
2. Body
3. Drier
WA700-3 10-185
(10)
Electric circuit diagram
Structure and function Machine monitor system
Electric circuit diagram

a For details of this page, see Section 90.
Machine monitor system
Outline
• The machine monitor system uses the sensors • There are also various switches built into the
and other devices installed to various parts of the monitor panel which function to operate the
machine to observe the condition of the machine. machine.
It processes this information swiftly and displays
it on the monitor panel to inform the operator of a The main monitor uses the network wiring to
the condition of the machine. send signals to the controller, and functions to
• The machine monitor system consists of the display the following information.
main monitor, maintenance monitor, sensors, 1) Shift indicator: 1st – 4th, N, F, R (F, R are
switches, relays, alarm buzzer, and power optional) (When auto shift, joystick steering
source. are installed)
• The displays can be broadly divided into the 2) HOLD
following: Cautions displayed on the monitors 3) Failure action code, failure code, time
(abnormalities in the machine where an alarm is elapsed since failure (failure data display
given) and normal conditions which are always mode)
displayed on the instrument panel (pilot lamps
and readings for the gauges, speedometer, and
service meter).
10-186 WA700-3
(10)
Structure and function Main monitor
Main monitor
1. Check lamp 4D. Speedometer 5. Switches

2. Caution lamp 4E. Shift hold 5A. Auto grease switch
3. Caution items 4F. Parking brake 5B. Engine low idling switch
3A. Emergency steering 4G. Emergency steering normal (Serial No.: 50001 – 51000)
actuated 4H. Monitor pilop lamp 5C. Working lamp (front) switch
4. Pilot items (preheating, afterheating) 5D. Working lamp (rear) switch
4A. Turn signal (left) 4I. Failure action code 5E. Transmission cut-off switch
4B. Turn signal (right) 5F. Auto shift, manual selector
4C. Shift indicator switch
Outline
• The main motor has display function for the • A liquid crystal display and LEDs are used for the
speedometer and other gauges and a switching display. The switches are embossed sheet
function to control the electric components and switches.
controllers.
• There is one CPU (Central Processing Unit)
installed internally, and this processes the
signals from the sensors and outputs the display.
WA700-3 10-187
(10)
Main monitor display function
Display
Symbol Display item Display range Display method
category
When there is abnormality Display flashes (for details, see

Check CHECK Check display on maintenance MAINTENANCE MONITOR DIS-
monitor PLAY FUNCTION)
Emergency steering
actuated (when
When actuated Display flashes
equipped with
emergency steering)
Parking brake actuated,
Caution Display flashes and buzzer sounds
transmission not at neutral
Caution Display flashes (buzzer may also

CAUTION When there is abnormality
sound) (for details, see MAINTE-
display on maintenance
NANCE MONITOR DISPLAY
monitor
FUNCTION)
Turn signal
When operated Display lights up
(left, right)
Display lights up
Parking
brake P Parking brake When operated Buzzer sounds when parking brake
is applied and shift lever is not at N
Emergency steering
normal (when When normal (oil is flowing
Display lights up
equipped with emer- in hydraulic circuit)
Pilot gency steering)
Lights up
Lighting up time changes according
to engine water temperature when
Preheating When preheating
starting switch is turned ON (for
details, see PREHEATING CIR-
CUIT)
Shift hold
(Machine equipped When shift is held Display lights up
with auto shift)
Digital display (display switches

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

Digital display
failure and action by opera-
Failure Buzzer sounds
tor is needed, CALL is dis-
action Failure action code (For details of the travel data dis-
played, or CALL and E TT
code play mode, see TROUBLE DATA
(action code) are displayed
DISPLAY MODE)
in turn
F, R, display (when
Shift
equipped with joy- F, R Digital display
indicator
stick steering)
10-188 WA700-3
(10)
Main monitor switch function
Item Function Display Actuation
Lights up (goes out Auto-greasing control actuated

momentarily when (automatic greasing carried out at
switch is turned ON) fixed internal)
Forced greasing is carried out while Flashes (slowly) Grease empty
Auto-greasing switch is being pressed when dis-
play is lighted up (when equipped) Abnormality in auto-greasing con-
Flashes (rapidly)
troller system
Auto-greasing controller not
Goes out
installed
Engine low idling speed is changed Low idling speed set to approx.
Lights up
between two stages each time 850 rpm
Engine low idling
switch is pressed Low idling speed set to approx.
(Serial No.: 50001 – 51000) Goes out
650 rpm
Front working lamp lights up or goes Lights up Front working lamp lights up
Working lamp
out each time switch is pressed
(front)
when side lamps are lighted up Goes out Front working lamp goes out
Rear working lamp lights up or goes Lights up Rear working lamp lights up
Working lamp
out each time switch is pressed
(rear) Goes out Rear working lamp goes out
when side lamps are lighted up
Transmission cut-off function is Lights up Cut-off function actuated
Transmission
actuated or stopped each time
cut-off
switch is pressed Goes out Cut-off function stopped
Auto shift mode switches to manual Lights up Manual mode

Manual mode when switch is pressed (when
equipped with auto shift) Goes out Auto shift mode
WA700-3 10-189
(10)
Trouble data display mode
Item Switch operation Actuation
Method of switching to With engine stopped and starting All switch displays (LEDs) go out, and fail-
trouble data display switch turned ON, press 2nd switch ure code is displayed on speedometer dis-
mode from top on left side of main monitor play and time elapsed since failure is
(switch below emergency steering displayed on failure action code display.
display) and working lamp (front) 1) Failure code is a two-digit display
switch simultaneously for at least 5 given in numbers or letters.
seconds. T he displa y fo r the failure now
occurring flashes and the display for
past failures lights up.
If there is no failure, CC is displayed
ON
(000 is displayed for time elapsed
since failure)
2) The time elapsed since failure is
displayed as a three-digit number to
show how long ago the failure
occurred (the oldest failure time is
SDW00241
displayed. Any time greater than
999H is displayed as 999H).
3) A maximum of 9 items are stored in
memory for the failure code.
Method of sending fail- Press working lamp (front) switch Failure code and time elapsed since fail-
ure code ure change to next item.
ON
SPEED Failure code

x 100
RPM
km/h
MPH Time elapsed
since failure
SDW01254
SDW00242
Clearing failure code Press working lamp (rear) switch for Failure code and time elapsed since fail-
at least 2 seconds ure being displayed are cleared.
Failure code for problem now occurring
ON (flashing display) cannot be cleared.
SDW00243
Resetting from travel Press 2nd switch from top on left Changes to normal display
data display mode side of main monitor (switch below
emergency steering display) and
working lamp (front) switch simulta-
neously for at least 5 seconds, or
start the engine.
10-190 WA700-3
(10)
Structure and function Maintenance monitor
Maintenance monitor
1. Check items 2D. Air cleaner (L.H.) 3C. Torque converter oil tem-
(Checks before starting) (Serial No.: 50001 – 51000) perature
1A. Engine water level 2E. Air cleaner (R.H.) 4. Service meter
1B. Engine oil level (Serial No.: 50001 – 51000) 4A. Service meter numeric dis-
2. Caution items (warning items) 2F. Transmission oil filter play
2A. Engine oil pressure 3. Gauge items 4B. Service meter RUN pilot
2B. Brake oil pressure 3A. Fuel level lamp
2C. Battery charge 3B. Engine water temperature 5. Monitor module
6. Switch module
Outline
• The maintenance monitor has a display function • A liquid crystal display and LEDs are used for the
for the caution items and gauges. display portions. The switches are embossed
• The maintenance monitor consists of the monitor sheet switches.
module, switch module, service meter, case, and
other mechanisms.
• The monitor module has a built-in CPU (Central
Processing Unit). It processes the signal from the
sensors, and carries out the display and output.
WA700-3 10-191
(10)
Structure and function Maintenance monitor
Maintenance monitor display function

Display
Symbol Display item Display range Display method
category
Engine water level Below low level Displays when engine is stopped and
starting switch is ON
Display when normal: OFF
Engine oil level Below low level Display when abnormal: Flashes
Check CHECK lamp flashes
Transmission oil filter Above specified dif- Displays when engine is running
ferential pressure Display when normal: OFF
Dispplay when abnormal: Flashes
Engine water level Below low level Displays when engine is running
Display when abnormal: Flashes
Engine oil pressure Below specified pres- CAUTION lamp flashes
sure Buzzer sounds
Brake oil pressure Below specified pres-

sure
Engine water temper- Above 102°C Buzzer sounds if above 105°C

ature
Caution Torque converter oil Above 120°C Buzzer sounds if above 130°C
temperature
Fuel level Below low level Displays when engine is running

CAUTION lamp flashes
Battery charge When charge is Displays when engine is running
defective Display when normal: OFF
Air cleaner Above specified neg- CHECK lamp flashes
ative pressure
Service meter 0 – 9999.9h Actuated when charge is normal

Advances 1 for every hour
Service
meter Service meter indica- Lights up when service meter is running
tor
Fuel level EMPTY FULL

All lamps light up below applicable level
1 2 3 4 5 6 7
Flashes when level is 1
E F
Red Green
Engine water temper- 67 80 90 97 102 105˚C One place lights up to show applicable
ature level
Gauges 1 2 3 4 5 6 7 Flashes when level is 6 or 7
C H
White Green Red
Torque converter oil 50 70 90 110 120 130˚C One place lights up to show applicable
temperature level
1 2 3 4 5 6 7 Flashes when level is 6 or 7
C H
Green Red
10-192 WA700-3
(10)
Structure and function Automatic transmission system (ATM)
Automatic transmission system (ATM)

Outline of system
Auto shift
Hold function
Kickdown function
Safety function
Manual shift
Kickdown function
Engine selection function (Komatsu/Cummins)
Joystick steering control ( )
Self-diagnostic function
Condition display (output, failure code)
Troubleshooting (detection of system abnormality, system disconnection, short circuit)
Communications function
( ) For the machines, serial No. 51001 and up, see AJSS (Advanced Joystick Steering System).
• Automatic transmission system consists of the • The self-diagnostic function always observes the
transmission controller, directional and speed input and output condition, and displays the
levers, engine speed sensor, speed sensor and output condition on the two 7-segment LED
all-speed-range solenoid. displays on the transmission controller. There is
• The transmission controller controls the shifting also a failure detection function, and if any
to the appropriate speed range according to the abnormality occurs, it displays a failure code.
lever position and travel speed signal. Depending on the condition, it also displays a
• A travel damper function and joystick steering failure action code on the main monitor and
control function are available as options, and flashes the caution lamp to improve safety.
these controls are possible if the function is • The transmission controller has a
installed to the machine. communications function, and it sends the speed
• To improve durability, there is a safety function range (N, 1st – 4th) data to the main monitor,
which prevents the machine from moving which displays the speed range. (If the joystick
suddenly when the engine is started, and a mode is used, it also displays F and R.)
transmission protection function which protects
the clutch when the direction of travel is
changed.
WA700-3 10-193
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System structure diagram
Model selection signal
D Direction switch F solenoid D
D Range switch R solenoid D
D Transmission cut-off switch 1st solenoid D
D Kickdown switch (*1) 2nd solenoid D
P Engine speed 3rd solenoid D
P Travel speed 4th solenoid D

Transmission controller
D Neutralizer relay signal Kickdown signal D

<Display>
D Hold switch (*2) Failure code S-Net
<Display>
D Manual switch Shift indicator S-Net
<Display>
D Engine selection Abnormality display buzzer output S-Net
<Display>
D Auto-shift transmission signal Main monitor F-N-R S-Net
<Display>
Hold pilot lamp S-Net
D Joystick steering signal
Engine speed D
<Display>
Manual display lamp (*3)
D Joystick steering ON-OFF Backup lamp relay D
D Joystick lever F-N-R switch Steering left proportional solenoid A
A Steering lever angle potentiometer Steering right proportional solenoid A
D Steering neutral detection switch Steering solenoid cut relay D
D Shift-up switch (*2) Caution relay (steering) D
D Shift-down switch (*1) Engine speed P
Neutral safety output D

A: Analog signal
D: Digital signal Steering N LED D
P: Pulse signal
Steering F LED D
: Signal for joystick steering
(For serial No. 50001 – 51000) Steering R LED D
*1: Kick-down switch = shift-down switch

*2: Hold switch = shift-up switch
*3: The main monitor judges the output of the manual display lamp.
10-194 WA700-3
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Outline than 8 km/h, the gear shifts down to 2nd to

1. Auto-shift function make it easier to accelerate. If the travel
Shifting the transmission up or down is carried speed is more than 8 km/h, the speed range
out when the engine speed is above 1450 rpm. is maintained, and when the engine speed
Shifting is decided by signals from the direc- goes above 1450 rpm, the gear is shifted to
tional lever, speed lever, and travel speed sen- a range that matches the travel speed.
sor according to [Table 1 Automatic gear shift 6) Gear shift prevention interval
change point table] recorded in the memory of To prevent shift hunting after shifting gear, a
the transmission controller. time interval is set to maintain the speed
1) Speed lever (1st – 4th) range. The gear shift prevention interval dif-
This controls the maximum speed range fers according to the shift pattern. For
(available speed range) for automatic gear details, see [Table 1 Automatic gear shift
shifting. change point table].
Example:Speed lever at 4: 2nd – 4th
Speed lever at 2: 2nd only 2. HOLD function
Speed lever at 1: 1st only When the HOLD switch is pressed, the speed
2) Directional lever N position range is held at the optimum speed range, and
At the neutral position, only the speed range even if the travel speed goes down, the trans-
clutch is engaged in the transmission. mission does not shift down. However, when
3) Directional lever F position switching between forward and reverse, the
When the directional lever is operated from transmiss ion normally shifts down to 2nd
N to F, the transmission turns ON (F2) the F according to the travel speed, and then shifts up
and 2nd SOLs (solenoids). (Automatic start to the HOLD shift range according to the travel
in 2nd) speed and gear shifting conditions. (This pre-
a) Shift up (when speed lever is at 4) vents any unnecessary shift down when leveling
When the accelerator pedal is or when traveling downhill.)
depressed to increase the engine speed
and the travel speed rises, SOL 3rd is 3. Kickdown function
t urne d O N when t he t ra v el spe ed When the operator turns the kickdown switch
reaches approx. 9.3 km/h, and at the ON, it overrides the auto-shift and switches
same time, 2nd is turned OFF. (Shifts to down forcibly to 1st if the conditions (speed
F3) range, travel speed) in [Table 1 Automatic gear
When the travel speed rises further to shift change point table, Item 5 Kickdown] are
approx. 17.6 km/h, SOL 4th is turned fulfilled.
ON and at the same time, 3rd is turned The conditions for canceling this are if the travel
OFF. (Shifts to F4) speed rises or if the direction is shifted between
b) Shift down (speed lever at 4) forward and reverse. In these conditions, the
When traveling in 4th, if the accelerator gear is shifted to 2nd. This function is also active
pedal is let back, and the travel speed when holding the speed range (hold, engine
comes down to approx. 15.6 km/h, SOL speed OFF mode).
3rd is turned ON and 4th is turned OFF.
(Shifts to F3)
When the travel speed goes down fur-
ther to approx. 9.8 km/h, SOL 2nd is
t urned ON and 3rd is turned OFF.
(Shifts to F2)
4) Directional lever R position
Automatic gear shift ing is carr ied out
between 2nd and 4th speeds according to
the travel speed (when the speed lever is at
4) in the same way as when the directional
lever is at the F position.
5) Skip shift
When coasting (in engine speed OFF mode)
in 3rd or 4th speed with the accelerator
pedal depressed, if the travel speed is less
WA700-3 10-195
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When the speed range and travel speed

4. Travel mode fulfill the conditions for Range I, the
1) Manual mode (option) transmission shifts down to 2nd.
It is possible to switch between auto and When the speed range and travel speed
manual shift. fulfill the conditions for Range II, the
When using the manual mode, if the speed speed range is maintained and the
lever is operated, the gear is shifted immedi- transmission shifts down to 2nd accord-
ately according to the operation of the ing to the deceleration.
speed lever. When traveling in F2, it is also (For details, see Fig. 1 F – R selector
possible to use the kickdown function. shift pattern, [Table 1 Automatic gear
2) Joystick steering control function (option) shift change point table, Item 7 F – R
(Serial No.: 50001 – 51000) selection].)
a) If the machine is equipped with the b) Alarm buzzer
joystick steering function, the operator When the speed range and travel speed
can switch between steering wheel and are in Range III, the alarm buzz er
joystick steering mode as desired. sounds to warn the operator. (If the
b) When switching the steering between engine speed is above 1600 rpm and
steering wheel and joystick steering, the travel speed is above 13 km/h, or
always stop the machine first, return the the travel speed is above 14 km/h.)
speed lever to the N position, then switch (See Fig. 2 F – R selection alarm buzzer
the steering. When this is done, the range.)
transmission controller is set to the 5) Transmission protection in joystick manual
neutral safety condition to prevent the mode
machine from suddenly moving. Together with the easier shift down and
a For details, see [Transmission controller shifting between F and R, in the joystick
travel mode and function table]. manual mode, for 1st and 2nd also, there is
a function to protect the transmission by
5. Safety functions shifting up to 3rd or 4th according to the
1) Neutral safety travel speed and engine speed. The alarm
When the engine is started, if the directional buzzer also sounds in this case.
lever is at any position other than N, the 6) Manual shift
transmission controller keeps the transmis- If the travel speed sensor is abnormal and it
sion in neutral and prevents the machine is impossible to detect the travel speed
from moving. If the N signal is input after the data, the transmission is set to manual
engine is started, the neutral safety is can- (shift) mode.
celed.
2) Neutral interlock
(Serial No.: 50001 – 51000)
• When switching from steering wheel to
joystick steering, the transmission is
always set to neutral.
• When switching from joystick steering to
steering wheel, it is impossible to start
the machine until the N signal is input.
3) Speed lever priority
It is possible to shift down immediately by
operating the speed lever, so the engine can
be used as a brake when traveling downhill.
4) Transmission protection
When traveling in 3rd or 4th speed, the
travel speed range is controlled and a warn-
ing buzzer sounds to protect the transmis-
sion if the operator tries to shift between
forward and reverse.
a) Speed range control
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Table 1 Automatic gear shift change point table
Speed Gear shift prevention interval

Item Travel speed (km/h)
range (sec)
Basic shift change 1o2 5.3 (5.5) or above 2

2o3 10.0 (10.5) or above 2
3o4 17.0 or above 1
4o3 Less than 14.6 1
3o2 Less than 9.4 (8.9) 2
Engine speed 4o2 Less than 1.0 0
(less than 1450 rpm) 3o2 Less than 1.0 0
Engine speed 4o2 Less than 8.0 2
(less than 1450 rpm o more than 1450 rpm) 3o2 Less than 8.0 2
Shift up when HOLD is ON 1o2 5.3 0
2o3 10.0 0
3o4 17.0 0
Shift down when kickdown is ON 2o1 Whole range 5
FR selection (Fig. 1, Range I) 4o2 Note 1)
(F o) N o R 3o2 2
(R o) N o F 1o2
FR selection (Fig. 1, Range II) Note 2)
(F o) N o R o4 17.0 or above 2
(R o) N o F o3 Less than 10.0 – 17.0
FR selection o4 17.0 or above
FoNoF o3 Less than 10.0 – 17.0 0
RoNoR o2 Less than 10.0
Note 1: When the engine speed is less than 1800 rpm and the travel speed is less than 16 km/h, or when the
travel speed is less than 13 km/h.
Note 2: When the travel speed is 1800 rpm or above and the travel speed is 13 km/h or above, or when the
travel speed is 16 km/h or above, the speed range is maintained and the transmission shifts down to
2nd according to the deceleration.
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6. Transmission controller travel mode and function table
10-198 WA700-3
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WA700-3 10-199
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7. Switching transmission controller travel mode (Serial No.: 50001 – 51000)

1) Specification when shifting modes [steering wheel io joystick] and [auto io manual]
a) Neutral interlock function
When shifting the mode, the neutral condition is maintained until the N signal is correctly received.
b) Speed range
The output for the speed range changes according to the mode selected.
Table 2 Output speed range when mode is switched

Condition after switching mode
Steering wheel Joystick
Auto Manual Auto Manual
Position of speed
2nd (*1)
Condition before switching mode
Auto lever
(switches at N)
(*2 (1))
Steering wheel
2nd (*1)
Manual 2nd (*2 (3))
(switches at N)
Holds previous
2nd (*1)
Auto position
(switches at N)
(*2 (2))
Joystick
Position of speed
Manual lever 2nd (*2 (3))
(switches at N)
(*1): Normally, when switching the mode [steering wheel io joystick], the switching is carried out with the
machine stopped and in neutral, so the speed range becomes 2nd.
If the machine is moving, the auto-shift [restart data] is used, and the transmission is set to a speed range
that matches the travel speed. However, if the shift lever position is 1, the speed range becomes 1st.
(*2): It is possible to switch between auto and manual when traveling if the same mode is retained.
(1) Steering wheel mode: For auto o manual, the speed range is the position of the shift lever.
(2) Joystick mode: For auto o manual, the speed range before shifting the mode is maintained (the speed
range does not change).
(3) For manual o auto, the auto-shift data [Table 1 Automatic shift change point table, Item 8 Switching
between F and R] is used, and the transmission is set to a speed range that matches the travel speed.
However, if the shift lever position is 1, the speed range becomes 1st.
10-200 WA700-3
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8. Self-diagnostic function
The transmission controller always observes the input and output signals of the automatic gear-shifting sys-
tem. It carries out self-diagnosis and displays the results on the LEDs of the transmission controller. In addi-
tion, it sends the following data to the main monitor.
1) Normal display: Transmission controller LEDs display output speed range.
2) Failure code display: If an abnormality is detected, the nature of the failure is displayed as a code. For
details of the failure codes, see [Table 3 Failure code table].
Table 3 Failure code table

• Transmission controller
1) Auto/manual transmission control system
System Main monitor
Code Item Remarks
Short circuit Disconnection Action code
10 Backup lamp relay Q Q None
11 None — — — —
12 F solenoid Q Q CALL
13 R solenoid Q Q CALL
14 1st solenoid Q Q CALL
15 2nd solenoid Q Q CALL
16 3rd solenoid Q Q CALL
17 4th solenoid Q Q CALL
18 None — — — —
19 Joystick direction switch Q Q E00
20 Direction switch signal Q Q CALL
21 Speed switch signal Q Q None
22 Travel speed sensor Q E00
23 Engine speed sensor Q E00
2) Joystick control system (Serial No.: 50001 – 51000)

System Main monitor
Code Item Remarks
Short circuit Disconnection Action code
56 Joystick caution relay output Q None
57 Steering right solenoid (detected when output) Q Q E00
58 Steering left solenoid (detected when output) Q Q E00
59 Steering right solenoid Short circuit at HOT end Q E00
60 Steering left solenoid Short circuit at HOT end Q E00
61 Steering solenoid cut relay output Q Q E00
62 Abnormality in joystick neutral switch Q Q E00
Abnormality in joystick potentiometer
63 Q Q E00
(outside 0.5 – 4.5 V)
a E59 and E60 cannot be distinguished and are output at the same time.
a E56 always outputs ON, so it is impossible to judge if there is a disconnection.
WA700-3 10-201
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9. Communications function
The transmission controller is equipped with a When signal is OPEN, the transmission con-
communications function using S-NET, and it troller maintains the neutral condition.
always maintains communications with the main 24V: Parking brake released
monitor. When any abnormality occurs, it dis- OPEN: Parking brake applied
plays an action code on the main monitor 6) Transmission cut-off signal
according to the condition of the problem to This signal is a GND/OPEN digital signal,
warn the operator in order to increase safety. and when the transmission cut-off switch is
The failure code can recognize the codes operated (using the left brake), it changes to
recorded in the main monitor memory using the OPEN. When it is actuated, the transmis-
main monitor trouble data mode. For details of sion controller changes to the neutral output
operating the main monitor, see the section on condition, and when it is canceled, it sets to
the main monitor. a suitable speed range for the travel speed
at that point.
10. Transmission controller power source 7) Manual mode signal
When the starting switch is turned ON and the This signal is a GND/OPEN digital signal.
supply voltage is more than 20V, and +20V or When the manual mode switch is ON, GND
more is supplied to the transmission controller is input.
solenoid power source input, it is possible to
control the drive of each solenoid valve.
If the supply voltage is less than 19V, all outputs
are turned OFF and the solenoids cannot carry
out control (travel is impossible).
11. Input signals

1) Directional lever signal (F, N, R)
This signal is a +24V/OPEN digital signal,
and when it is normal, one of F, N, or R sig-
nals (+24V) is input.
2) Speed lever signal (1st – 4th)
This signal is a +24V/OPEN digital signal
and +24V is input for the signal for the lever
position.
3) Kickdown switch/shift-down switch
This signal is a +24V/OPEN digital signal.
When the kickdown switch installed to the
work equipment control lever is pressed,
+24V is input. The switch operation is
judged from the +24V starting signal from
the OPEN condition at that point.
In the joystick manual mode it is used as the
shift-down switch. (Serial No.: 50001 –
51000)
4) Hold switch/shift-up switch
This signal is a +24 V/OPEN digital signal.
When the HOLD switch installed to the work
equipment control lever is pressed, +24V is
input. The switch operation is judged from
the +24V starting signal from the OPEN
condition at that point.
In the joystick manual mode it is used as the
shift-up switch. (Serial No.: 50001 – 51000)
5) Neutralizer relay signal
This signal is a +24V/OPEN digital signal.
When the parking brake switch is released,
+24V is input and travel becomes possible.
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12. Function selection signal

This signal is a GND/OPEN digital signal. When
the engine is started, the function is judged from
this signal.
1) Model selection
Table 4 Machine model selection signal table
Machine model CN3B-2 CN3B-10 CN3B-3
WA600-3 OPEN OPEN GND
WA700-3 GND OPEN OPEN
2) Engine selection
Table 5 Engine selection table
Engine
Komatsu Cummins
Signal and data
Engine selection (CN3A-10) OPEN GND
3) Option function selection

Table 6 Option (function) selection table
Input signal Signal condition
Auto-shift transmission (opt) (CN3A-20) OPEN GND OPEN GND
Joystick steering (opt) (CN3B-1) OPEN OPEN GND GND
Applicable model Function
Transmission
WA600-3
Transmission auto/manual (opt)
Not set (*1) Not set (*1)
auto/manual (opt) & joystick auto/
WA700-3
manual (opt)
*1: When Not set condition is detected, all controller outputs are turned OFF and it is impossible to travel.
a After displaying the program part number, the LED display shows [0o0o].
13. Engine speed sensor signal

This signal is a pulse signal. It converts the
pulses from the electromagnetic pickup sensor
to rotation speed for control.
When the engine speed is 1450 rpm or above, it
is called the engine speed ON mode, and when
the speed is less than 1450 rpm, it is called the
engine speed OFF mode.
14. Travel speed sensor signal

This signal is a pulse signal. It converts the
pulses from the electromagnetic pickup sensor
to rotation speed for control.
15. Communications signal (S-NET)

This transmits the troubleshooting code to the
main monitor.
WA700-3 10-203
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16. Output signal
1) Transmission signal
Table 7 Combination of speed ranges and
solenoid
Q: ON
SOL
F R 1st 2nd 3rd 4th
Speed range
F1 Q Q
F2 Q Q
F3 Q Q
F4 Q Q
N
R1 Q Q
R2 Q Q
R3 Q Q
R4 Q Q
2) Backup lamp relay signal

This signal is a +24V digital (ON/OFF) out-
put. It is actuated when the directional lever
is placed at R and lights up the backup lamp
and caution lamp.
3) Engine speed signal

This outputs a signal at the same cycle as
the engine speed sensor signal input to the
transmission controller.
4) Communications signal (main monitor

display data)
For details of the display position and opera-
tion of the main monitor, see the section on
the main monitor.
a) Speed range display
1st speed range output: [1]
2nd speed range output: [2]
3rd speed range output: [3]
4th speed range output: [4]
Neutral: [N]
b) F, R display
F, R are displayed in the joystick steer-
ing mode (option).
c) HOLD display
The pilot display is given on the main
monitor when the HOLD function is ON.
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17. Led display
• When the engine is started, the display goes first

to 1. "Program quality display mode", and next to
2. "Output speed range display mode". However,
if any abnormality is detected, it goes
immediately to the troubleshooting mode.
1) Program quality display mode

When the power source is on, it switches
once every second.
–o –o 7o 8o 2o 3o 1o 6o Ao 1 o 0o 0 o o To display mode 2
2) Output speed range display mode

LED display Xo Y.. (Both dots are out)
X: Direction SOL drive condition
FORWARD [F]: F, REVERSE [R]: A, Neutral: 0
Y: Speed range SOL drive condition 1 – 4
Example
Display Content
'0o 2o' Neutral, 2nd
'Fo 1o' FORWARD, 1st
'Ao 2o' REVERSE, 2nd
'Fo Fo' Neutral safety condition
0o 2o Fo 2o o To display mode 3 if failure is detected
Gear shift (F2 speed range displayed continuously)
3) Troubleshooting display mode (currently

existing failure)
A cycle of [E-(2 sec)], [Code (2 sec)] is
repeated.
a) When there is one abnormal item
<Example>
Eo –o 2o 3o o Repeated
b) When there is two abnormal item
<Example>
Eo –o 2o 3o Eo – o 1o 8o o Repeated
WA700-3 10-205
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Structure and function Joystick steering system
Joystick steering system

Serial No.: 50001 – 51000
1. Joystick
2. Transmission and joystick steering controller
3. Proportional solenoid valve
4. Control pump
5. Stop valve
6. Steering demand valve
7. Steering cylinder
10-206 WA700-3
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Structure and function Joystick steering system
1. Combination of joystick steering, transmission control functions

Q: Function is employed
Steering wheel Joystick
Boom lever switch
Automatic Manual Automatic Manual
Kick-down function Q Q Q —
Hold function Q — Q
Up/down function — — — Q
CN C5-5 input signal Kick-down Kick-down Kick-down Shift down
CN C5-13 input signal Hold Hold Shift up
2. Controller input signals 4. Main monitor display

• Common signal input for kick-down/shift
down switch (CN C5-5 terminal)
• Common signal input for hold/shift up switch
(CN C5-13 terminal)
Whether the joystick or the steering wheel is
in use is indicated by the above signals.
3. Up/down shift switch function

• Shift up switch: Normal shift up is output by
signal input
• Shift down switch: Normal shift down is out-
put by signal input
• Judgement of the input of the switch uses the
change in the ON/OFF condition of the sig-
nal.
(When the switch is pushed, it becomes ON
(GND).)
In addition, it always uses the latest signal to
judge shift up or down.
• The maximum speed range is set by the
transmission lever.
Range lever position Speed range used
4 4–1
3 3–1
2 2, 1
1 1
WA700-3 10-207
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Structure and function AJSS (Advanced Joystick Steering System)
AJSS (Advanced Joystick Steering System)

System configuration diagram
Control circuit configuration diagram
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Control function Outline

• Potentiometer calibration function • The flow rate gain of the steering hydraulic
• Neutral interlock function system is controlled according to the difference
• Troubleshooting function between the joystick steering lever angle and the
frame angle to improve the narrow steering angle
characteristics and response in quick counter
steering. As a result, the controllability of the
vehicle is improved.
Potentiometer calibration function

• The angle difference (offset angle) between the steering lever and frame angle detecting potentiometer is
read and corrected automatically.
Neutral interlock function

• Interlock relays are installed to the engine and the starting line of the starting motor so that the frame will not
be bent and the vehicle will not start when the engine is started.
When the difference between the steering lever angle and frame angle is 6 degrees or more, the interlock
prevents the engine from starting. At this time, the buzzer sounds.
If the steering lever is set in the neutral position and the FNR switch is set in the "N" position, the interlock is
reset and the engine can start.
• When the FNR switch is not in the "N" position, the neutral safety function prevents the engine from starting.
WA700-3 10-209
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Troubleshooting function
The controller constantly checks that the electronic devices composing each potentiometer which collects input
signals, each solenoid valve which receives output signals, etc. are operating normally.
If any of those devices becomes abnormal, the controller detects it and indicate it by the "Failure code" on the
main monitor to notify the operator of it.
Failure codes table

System Main monitor
Code Item
Short circuit Disconnection action code
55 Travel speed sensor Q Q E00

56 Joystick caution buzzer relay Q Q None
57 Steering lever angle sensor Q Q E01 + CALL
Shifting of steering lever angle sensor, frame angle sensor,
58 — — E01 + CALL
or potentiometer signal
59 Frame angle sensor Q Q E01 + CALL
60 Steering lever lock switch Q Q E01 + CALL
62 Joystick neutral interlock relay Q Q E00
63 Joystick basic pressure control EPC solenoid Q Q E01 + CALL
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Potentiometer
1. Connector 5. Bearing
2. Case 6. Contact
3. Shaft 7. Mold
4. Element
Function
The potentiometer senses the operating angle. In short circuit, etc. Since the correct position cannot
the potentiometer, the source voltage of 5 V is con- be sensed in this case, the control output is turned
verted with a variable resistor into a signal voltage off and the failure code is displayed on the main
according to the angle, then sent to the controller. monitor.
The hatched area in the above figure is the abnor-
mality detection area. If the controller receives the
above signal in this area, it judges that the potenti-
ometer system has a trouble such as wire breakage,
WA700-3 10-211
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Structure and function Transmission and joystick controller
Transmission and joystick controller
10-212 WA700-3
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Connector signal (Serial No.: 50001 – 51000)
CN1 CN3A CN4

Pin Input/ Pin Input/ Pin Input/
Name of signal Name of signal Name of signal
No. output No. output No. output
1 S/T SOL. cut relay Output 1 NC — 1 NC —
2 T/M F SOL. Output 2 NC — 2 Engine revolution sensor (+) Input
3 T/M 1 SOL. Output 3 S/T lever potentio meter Input 3 RS232C TXD Input
4 Engine revolution output Output 4 NC — 4 RS232C RXD Input
5 T/M 3 SOL. Output 5 NC — 5 NC —
6 GND Input 6 Pressure sensor power supply Output 6 NC —
7 Power supply (+24V) Input 7 Potentio power supply Output 7 NC —
8 Back lamp relay Output 8 NC — 8 Flash write sig. Input
9 T/M R SOL. Output 9 NC — 9 Engine rev./speed sensor (+) Output
10 T/M 2 SOL. Output 10 Engine select Input 10 RS232C GND Input
12 GND Input 12 NC — 12 NC —
13 Power supply (+24V) Input 13 NC —
CN5
14 NC —
CN2 Pin Input/
15 NC — Name of signal
Pin Input/ No. output
Name of signal 16 GND (for pressure sensor) Output
No. output 1 GND (for Plus) Output
17 GND (for potentio) Output
1 SOL. power supply (+24V) Input 2 Speed sensor (+) Input
18 NC —
2 S/T RH SOL. (+) Output 3 GND Output
19 Neutralizer relay Input
3 S/T LH SOL. (+) Output 4 GND Output
20 Auto shift T/M option Input
4 F LED (S/T) Output 5 Kick down SW/Shift down SW Input
5 R LED (S/T) Output CN3B 6 T/M cut off switch Input
6 NC — Pin Input/ 7 Joystick N (NC) Input
Name of signal
7 N LED (S/T) Output No. output 8 Joystick F (NC) Input
8 Neutral safety output (+) Output 1 Joystick S/T option Input 9 Joystick R (NC) Input
9 Caution relay (S/T) (+) Output 2 Machine select 1 Input 10 GND (for Plus) Output
10 Caution (monitor) (+) Output 3 Machine select (EVEN parity) Input 11 S/T lever neutral switch Input
11 PGND Input 4 S-NET + Input 12 NC —
12 SOL. power supply (+24V) Input 5 Direction F Input 13 Hold SW/ Shift up SW Input
13 S/T RH SOL. (+) Output 6 Direction R Input 14 Manual SW Input
14 S/T LH SOL. (+) Output 7 Range SW1 Input 15 Joystick N (NO) Input
15 NC — 8 Range SW3 Input 16 Joystick F (NO) Input
16 NC — 9 NC — 17 Joystick R (NO) Input
17 NC — 10 Machine select 2 Input
Joystick System Functional
18 NC — 11 NC — Selection Table
19 Caution relay (S/T) (+) Output 12 S-NET + Input
20 NC — 13 Direction N Input OFF ON
Pin
21 PGND Input 14 Joystick ON/OFF switch Input CN3B-1 OPEN GND
15 Range SW2 Input
Machine Select Table GND: connect CN2-9.
16 Range SW4 Input
Machine
WA600-3 WA700-3 Engine Selection Table
Pin Automatic T/M Functional
CN3B-2 OPEN GND Selection Table Engine
KOMATSU CUMMINS
CN3B-10 OPEN OPEN Pin
OFF ON
CN3B-3 GND OPEN Pin CN3A-10 OPEN GND
CN3A-20 OPEN GND GND: connect CN2-9.
GND: connect CN2-9.
GND: connect CN2-9.
WA700-3 10-213
(10)
Connector signal (Serial No.: 51001 and up)
CN1 CN3A CN4

Pin Input/ Pin Input/ Pin Input/
Name of signal Name of signal Name of signal
No. output No. output No. output
1 Damper SOL. — 1 NC — 1 NC —
2 T/M F SOL. Output 2 NC — 2 Engine revolution sensor (+) Input
3 T/M 1 SOL. Output 3 S/T lever potentiometer Input 3 RS232C TXD Input
4 Engine revolution output Output 4 NC — 4 RS232C RXD Input
6 GND Input 6 Pressure sensor power supply (+24V) Output 6 NC —
7 Power supply (+24V) Input 7 Potentio power supply (+5V) Output 7 NC —
8 Back lamp relay Output 8 NC — 8 Flash write switch. Input
9 T/M R SOL. Output 9 NC — 9 Puls GND Output
10 T/M 2 SOL. Output 10 Engine select Input 10 RS232C GND Input
11 T/M 4 SOL. — 11 NC — 11 NC —
12 GND Input 12 NC — 12 NC —
13 Power supply (+24V) Input 13 FRAME ANGLE POTENTIOMETER Input
CN5
14 NC —
CN2 Pin Input/
15 NC — Name of signal
Pin Input/ No. output
Name of signal 16 GND (for pressure sensor) Output
No. output 1 GND (for Plus) Output
17 GND (for potentio) Output
1 SOL. power supply (+24V) Input 2 Speed sensor (+) Input
18 NC —
2 AUTO 1 RANGE LED (+) Output 3 GND Output
19 POTENTIOMETER CAL SWITCH Input
3 AUTO 3 RANGE LED (+) Output 4 GND Output
20 NC —
4 AUTO 2 RANGE LED Output 5 Kick down switch Input
5 AUTO 4 RANGE LED — CN3B 6 T/M cut off switch Input
6 NC — Pin Input/ 7 NC —
Name of signal
7 S/T EPC SOL (+) Output No. output 8 NC —
8 J/S LEVER NEUTRAL SAFETY RELAY (+) Output 1 NC — 9 NC —
9 J/S CAUTION BUZZER RELAY (+) Output 2 Machine select 1 Input 10 GND (for Plus) Output
10 Caution (monitor) (+) Output 3 Machine select (EVEN parity) Input 11 NC —
11 PGND Input 4 S-NET (+) Input 12 NC —
12 SOL. power supply (+24V) Input 5 Direction F Input 13 HOLD SWITCH Input
13 NC — 6 Direction R Input 14 AUTO/MANUAL SWITCH Input
14 NC — 7 SHIFT UP SWITCH (N. O.) Input 15 NC —
15 NC — 8 SHIFT DOWN SWITCH (N. O.) Input 16 NC —
16 NC — 9 S/T LEVER LOCK PRESSURE SWITCH Input 17 NC —
17 S/T EPC SOL (–) Output 10 Machine select 2 Input
18 NC — 11 Memory clear —
19 J/S CAUTION BUZZER RELAY (–) Output 12 S-NET (+) Input
20 NC — 13 Direction N Input
21 PGND Input 14 NEUTRALIZER RELAY Input
15 SHIFT UP SWITCH (N. C.) Input
Machine Select Table
16 SHIFT DOWN SWITCH (N. C.) Input
Machine
WA700-3 Engine Selection Table
Pin
C3B-2 GND Engine
KOMATSU CUMMINS
C3B-10 OPEN Pin
C3B-3 OPEN C3A-10 OPEN GND
GND: connect GND. GND: connect GND.

OPEN: Disconnect. OPEN: Disconnect.
10-214 WA700-3
(10)
Structure and function Engine starting circuit
Engine starting circuit

Serial No.: 50001 – 51000
Function
• It is possible to start or stop the engine by turning terminal C o neutral relay terminals 3 – 5 o
the starting switch ON or OFF. An electrical starting motor terminal C o starting motor
device is used which controls the fuel injection terminal E o ground.
amount and improves the ease of operation. • At the same time, the electric current from
starting switch terminal ACC flows to the engine
Operation throttle controller as the governor cut relay and
• When the directional lever is placed at the N starting motor signal. Here, various signals, such
position, the neutral contacts of the directional as the water temperature, are calculated, and a
lever switch are closed. In this condition, if the signal is sent to the fuel injection pump to set the
starting switch is turned to the ON position, fuel injection amount to the optimum value.
electric current flows from the starting switch • A circuit is formed from the battery o battery
terminal BR o battery relay coil o ground, and relay o starting motor terminal B, so the engine
the switch of the battery relay coil is closed. The starts.
power supply from the battery passes through • If the directional lever is not at the N position, the
the directional lever switch, the neutral relay is neutral relay is not actuated, so the circuit is not
actuated, and terminals 3 – 5 close. formed and the engine does not start.
• When the starting switch is turned to START,
electric current flows from starting switch
WA700-3 10-215
(10)
APS completely
APS started stopped
Passage of time
Glow plug Starting Engine starts,
preheats motor turns intake air
heated
Starting switch ON START ON
Heater switch OFF ON AUTO OFF
APS water temp. sensor ON (Max. 20˚C ) OFF
Glow plug OFF ON OFF
Monitor pilot lamp (preheating) OFF ON OFF
Fuel injection nozzle No injection Injection (intermittently) No injection
Monitor pilot lamp (afterheating) OFF ON OFF
Starting with APS (actuated when engine water

temperature is below 20°C)
1. Open the APS fuel valve in the center of the left 6. Depress the accelerator pedal half way.
side of the engine. 7. The preheating stops after approx. 12 seconds
a Leave the fuel valve open during the cold and the monitor pilot lamp goes out. Turn the
season when the temperature goes down starting switch key to the START position to start
and the APS is used. the engine.
2. Turn the starting switch ON. a If the starting switch is turned to the START
3. Turn the fuel cut-off switch OFF, then turn the position while the monitor pilot lamp is still
starting switch to the START position and crank lighted up, the glow plug will become wet and
the starting motor for approx. 10 seconds. it will be impossible to carry out ignition.
a Do this to lubricate the whole engine with oil. 8. When the engine starts, return the starting
a When the fuel cut-off switch is turned OFF, switch to the ON position.
the fuel cut solenoid is turned OFF and the 9. After the engine starts, when the engine rotation
f ue l i nj ec t i on pum p i s s e t t o t he NO becomes smooth and the exhaust gas color
INJECTION position. becomes normal, turn the heater switch OFF.
4. Turn the fuel cut-off switch ON. a After the engine is started and the engine
a Release the switch and it will automatically water temperature reaches approx. 20°C,
return to the ON position. the monitor pilot lamp flashes to inform the
5. If the heater switch is set to the ON position, the operator that the afterheating has been
monitor pilot lamp will light up and the glow lamp completed. At the same time, the
will preheat. afterheating is automatically canceled.
a When the monitor pilot lamp lights up, set the
heater switch to AUTO.
10-216 WA700-3
(10)
Function
• For the safety at the time of starting engine, the • The ECM controller controls fuel injection
neutral safety circuit prevents the engine from amount and injection timing according to input
starting when the directional lever is at other than signals.
N (neutral) position. • Battery, battery relay and starting motor B
• When the starting switch is turned OFF, the fuel terminal are electrically connected, and then
supply is shut off and the engine stops. engine starts.
When the directional lever is at other than N
Operation (neutral) position, the engine does not start
• When the directional lever is at the N (neutral) because the neutral relay is not actuated, and
position, the neutral contacts of the directional the circuit (1) is not composed.
lever close. When the starting switch is turned
ON, the neutral relay is ac tuated and its
terminals 3 to 5 are closed. The current flows
from starting switch BR terminal, to battery relay
coil, and to the ground, then battery relay
becomes closed.
When starting switch is turned to START, the
current flows from battery positive terminal, to
starting switch B to C, and to neutral relay
terminals (5) to (3), and to starting motor C to E
,and to the ground (circuit (1)).
WA700-3 10-217
(10)
Structure and function Engine stop circuit
Engine stop circuit

Serial No.: 50001 – 51000
Function
• An electrical device is used which controls the
fuel injection amount and improves the ease of
operation by making it possible to start or stop
the engine by turning the starting switch ON or
OFF.
Operation
• When the starting switch is turned OFF, starting
switch terminal B and terminals BR and Care
opened.
• The current to the engine throttle controller is
also shut off, so there is no injection from the
injection pump, and the engine stops.
10-218 WA700-3
(10)
Structure and function Engine stop circuit
Operation
• When the starting switch is turned OFF, the
starting switch B, BR and ACC terminals are
disconnected with each other.
• The ECM controller outputs signal to shut off the
fuel supply, then engine stops.
WA700-3 10-219
(10)
Structure and function Auto priming system (APS)
Auto priming system (APS)

Serial No.: 50001 – 51000
1. Main monitor
2. Monitor pilot lamp
(preheating, afterheating)
3. Heater switch
4. Starting switch
5. Fuel cut-off switch
6. APS controller
7. APS water temperature sensor
8. Battery
9. Fuel tank
10. Fuel injection pump
11. Engine cut-off valve
12. Fuel filter
13. Fuel valve
14. APS fuel injection nozzle
15. Glow plug
16. APS assister
Function Outline
• The APS system is used in cold areas to make it • The fuel flows from the tank through the feed
easier to start the engine. It works by burning fuel pump of fuel injection pump (10) and is sent to
inside the intake manifold to heat the intake air. fuel filter (12). At the outlet port of the fuel filter, it
• The APS assister turns OFF the spray signal to is connected to the APS fuel circuit.
t he AP S co nt r ol l e r w he n s t a r t in g i n l ow • The APS fuel circuit consists of fuel valve (13),
temperatures, when the engine speed pick-up is bracket which divides the fuel, and APS fuel
slow, or when the starting switch is released injection nozzle (14) which uses APS controller
before the engine speed picks up (when the (6) to automatically adjust the amount of the fuel
engine speed has not reached the speed spray.
required for the alternator to start generating).
Therefore, it acts to hold the starting switch
signal and maintain a continuous spray by the
APS.
10-220 WA700-3
(10)
APS controller
APS assister
WA700-3 10-221
(10)
Operation of APS
1. Operation of preheating
• When the starting switch is ON and the ground, and the glow plugs become red hot.
preheating switch is turned ON, electricity flows While glow plugs 1 and 2 are being heated, the
to the APS controller and APS assister power output signal is also sent to the preheating lamp
source circuit and makes it possible for it to be ci rc ui t i nsi de t he APS cont roll er, so t he
actuated. preheating/afterheating pilot lamp lights up.
• When this happens, if the engine cooling water • After the preheating pilot lamp lights up for the
temperature is below 13°C, the APS water set time (approx. 12 sec), it goes out.
temperature sensor is closed (ON). For this This shows that glow plugs 1 and 2 have been
reason, even if the preheating switch is returned heated enough by the action of the APS.
from ON o AUTO, electric power is flowing to the • The APS assister acts to hold the starting switch
APS controller, so the circuit is connected inside signal and maintain a continuous spray by the
the controller. APS when starting in low temperatures, when
When the water temperature is below 20°C, the the engine speed pick-up is slow, or when the
APS water temperature sensor closes (is turned starting switch is released before the engine
ON). speed picks up.
When the APS water temperature sensor is
turned ON, the output signal is sent to glow 1 and
glow 2 circuits inside the APS controller. Electric
current flows in a circuit from glow plugs 1, 2 o
10-222 WA700-3
(10)
2. Operation of afterheating
• After the preheating pilot lamp goes out, if the After the engine starts, the signal from the
starting switch is turned to the START position, preheating switch – APS water temperature
electric current flows to neutral relay terminals 3 sensor actuates the fuel injection nozzle and
– 5 and the starting motor starts to turn. At the carries out afterheating.
same time, electric current flows from APS After the engine starts and the warming-up
assister terminal S through terminal C to the operation raises the engine cooling water
circuit of starting switch terminal C of the APS temperature to 20°C or above, the APS water
controller and actuates the controller. temperature sensor opens (OFF). As a result,
• The APS fuel injection nozzle inside the intake the water temperature sensor signal to the APS
manifold is switched ON/OFF to inject fuel controller is turned OFF. The output signal to
intermittently (10 times/sec) to glow plugs 1 and glow plugs 1 and 2 is cut off, and at the same
2. (When electric power is applied, the APS time the afterheating pilot lamp flashes.
controller sends the start signal, or when the stop When starting work when the engine is running
signal is input because the starting safety relay is with the APS actuated and the engine water
actuated, the intermittent injection signal is temperature above 20°C, if the preheating switch
output to the APS fuel injection nozzle.) is turned OFF, the APS controller power circuit is
The fuel injection to glow plugs 1 and 2 is burned cut off, and the operation of the APS is stopped.
inside the intake manifold and heats the intake At the same time, the afterheating pilot lamp
air. display goes out.
WA700-3 10-223
(10)
Structure and function Preheating circuit
Preheating circuit
(Automatic preheating system)
Outline Operation
• An automatic preheating system is provided to • When the starting switch is turned ON, the ECM
improve engine starting performance in cold controller outputs a signal to actuate the
area. By turning the starting switch ON, the preheating relay contacts to be closed. Then, the
system sets the preheating time automatically current flows from the preheating relay terminal
according to the coolant temperature, it causes (5) to the heater relay, then the heater relay is
reducing preheating time. actuated.
• By turning the starting switch ON, electrical • The current flows from battery to battery relay, to
intake air heater preheats the intake air. The heater relay, and to electrical intake air heater,
preheating time is controlled by the ECM then the preheating is carried out.
controller according to the coolant temperature • When preheating time is finished, the ECM
which is detected by the coolant temperature controller outputs a signal to cut off the current to
sensor. the preheating relay, and the heater relay
• The preheating pilot lamp lights up while contacts open, thereby preheating is finished.
preheating. The lamp goes out when preheating • While preheating, the current flows to the main
is finished. monitor to light up the preheating pilot lamp.
10-224 WA700-3
(10)
Structure and function Fuel system
Fuel system
1. Fuel filter Fuel cooler specification

2. Strainer (150 mesh) Type: CF40-1
3. Stop valve Radiation area: 5.73 m2
4. Fuel tank (capacity: 1,100 l) Fuel flow area: 19.34 m2
5. Fuel cooler Core area: 0.230 m2
6. Breather Radiation capacity: 11.63 kW {10,000 kcal/h}
7. Fuel level sensor
8. Filler cap Function
9. Fan • Returned fuel from engine becomes high
10. Radiator temperature.
To reduce high temperature of fuel, use the fuel
a. to Engine cooler.
b. from Engine
WA700-3 10-225
(10)
Structure and function Electrical transmission control
Electrical transmission control
1. Transmission cut-off selector switch 8. Fuse boxes

2. Parking brake switch 9. Transmission controller
3. Directional lever 10. Transmission control valve
4. Speed lever 11. Speed sensor
5. Kick-down switch 12. Transmission cut-off switch
6. Maintenance monitor 13. Brake valve (left)
7. Relays 14. Brake valve (right)
Function
1 Selection of F, R, and N position Using directional lever
2 Selection of speed range Using speed lever
When traveling in F2, it is possible to shift down to 1st using this switch without
3 Kick-down switch using the speed lever. If directional lever is operated to R or N, speed range auto-
matically returned to 2nd.
4 Transmission cut-off function Transmission is shifted to neutral when left brake is operated.
It is possible to select whether to actuate or not actuate the transmission cut-off
Transmission cut-off selector function. In this way, it is possible to obtain the same or greater ease of operation
5
function as on conventional loaders with the left brake when carrying out scooping work or
when loading or unloading the machine from a trailer.
To prevent seizure of the parking brake when traveling with the parking brake
6 Neutralizer
applied, the transmission is shifted to neutral when the parking brake is applied.
If the directional lever is not at the N position, the engine will not start when the
7 Neutral safety function starting switch is turned. This prevents the machine from starting suddenly. (For
details, see STARTING CIRCUIT.)
When traveling in reverse, the backup lamp lights up and the backup horn sounds
8 Warning function
to warn people in the area.
10-226 WA700-3
(10)
Combination switch
1 8 7
2 3 9 10 4 6 5
SDW00301
Outline
• The directional lever has three positions and the two pins, and is secured to the body by three
speed lever switch has four positions. As an screws. When each lever is operated to the
individual part, the switch does not have a detent desired position, the switch, which is
mechanism; the detent mechanism is in the interconnected by a shaft, acts to allow electric
combination switch. Each switch is positioned by current to flow to that circuit only.
General locations, function

1 Directional lever switch Switches between F, R, and N
2 Speed lever switch Selects speed range
3 Speed lever stopper Stopper used to prevent speed lever from entering 3rd or 4th during operations
4 Turn signal indicators Direction indicator lamps used when turning left or right
Turn signal indicator lever automatically returns to central position after machines
5 Self cancel
turns left or right
6 Lamp switch Switches on clearance lamp, head lamp, parking lamp, etc.
Selects high beam for travel and low beam for passing (WA700-3 does not have
7 Dimmer switch
this function.)
8 Hazard switch Makes both left and right turn signal indicator lamps flash at the same time
9 Emergency flashing pilot lamp Flashes at the same time as the emergency flashing lamp flashes
10 Parking brake switch Applies or releases parking brake
WA700-3 10-227
(10)
Operation
• Directional lever (1) and shaft (2) of the speed F
lever of the combination switch form one unit with
magnet (3), and magnet (3) also moves together
with lever (1). N
• Control switch (5) with built-in hole IC (4) is
installed at the bottom of magnet (3), and hole IC
(4) is positioned on the board to match each R
2
position.
1
• When directional lever (1) is operated to the F
position, magnet (3) is immediately above hole
IC (4) for the F position of the control switch. The
magnetism from magnet (3) passes through the
gap and case (6), and magnetism is applied to
hole IC (4).
• When this happens, hole IC (4) is inside a
3
magnetism detection circuit, so it detects the
magnetism of magnet (3) and sends the F
position signal to the electric current 4
6
amplification circuit. In the electric current
amplification circuit, a signal is output to actuate 5
the transmission.
SEW00302
10-228 WA700-3
(10)
Structure and function Kick-down, hold switch
Kick-down, hold switch
1. Kick-down switch
2. Spring
3. Spring
4. Hold switch
5. Wiring harness
Kick-down switch Hold switch
Operation • The hold switch is installed to the boom lever,

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

• When directional lever is at N
• When directional lever is at R
• When speed lever is not at 2nd
• When starting switch is OFF
WA700-3 10-229
(10)
Structure and function Kick-down electrical circuit
Kick-down electrical circuit

(Normal operation)
When directional lever is operated to F When speed lever is set to 2nd

• When the directional lever is operated to F, • When the speed lever is set to 2nd, electric
electric current flows in the following circuit. current flows from battery o transmission lever
Battery o directional lever switch terminal F o power source o speed lever switch 2nd terminal
FORWARD solenoid relay terminal 5 – 6 o o 2nd-1st selector relay terminals 3 – 6 o 2nd
ground. solenoid o ground, and the 2nd solenoid is
Because of this, the FORWARD solenoid relay is actuated.
actuated, and the circuits between terminals 1 • When the kick-down switch is operated, the kick-
and 2, and between terminal 3 and 4 are closed. down relay is actuated, so the circuit between
• In addition, electric current flows in the following 2nd-1st selector relay terminals 3 – 6 opens, and
circuit. the contacts of terminals 3 – 6 close. As a result,
Battery o parking brake safety relay terminals 5 electricity flows to the 1st solenoid and the
– 3 o parking brake switch terminals 3 – 2 o transmission is shifted to 1st.
neutralizer relay terminals 1 – 2 o ground, and
neutralizer relay terminals 3 – 5 are connected.
• Next, electric current flows from battery o
neutralizer relay terminals 3 – 5 o transmission
cut-off switch o FORWARD solenoid relay
terminals 1 – 2 o FORWARD solenoid o
ground, so the FORWARD solenoid is actuated
and the FORWARD clutch is engaged.
10-230 WA700-3
(10)
When kick-down switch is operated

(When operating or traveling with transmission lever at F2 position)
When kick-down switch is pushed ON

• When the directional lever is operated to F, terminals 5 – 6 o ground. As a result, even if the
electric current flows in the circuit from battery o kick-down switch is returned, the kick-down relay
directional lever switch terminal F o FORWARD continues to be actuated. (Self-hold circuit of
solenoid relay terminals 5 – 6 o ground. kick-down relay)
Because of this, the FORWARD solenoid relay is • When the kick-down relay is actuated, electric
actuated, and the circuits between terminals 1 current flows from battery o kick-down relay
and 2, and between terminal 3 and 4 are closed. terminals 3 – 4 o 2nd-1st selec tor relay
In addition, if the speed lever is at 2nd, electric terminals 1 – 2 o ground in the 2nd-1st selector
current flows from the battery o speed lever 2nd relay coil, the relay coil is actuated, the circuit
switch o FORWARD solenoid relay terminals 3 between terminals 3 – 6 is opened, and the
– 4 o kick-down switch and kick-down relay circuit between terminals 3 – 5 is closed.
terminal 1. • When 2nd-1st selector relay terminals 3 – 5 are
• In this condition, if the kick-down switch is connected, electric current flows from battery o
pushed, electric current flows from FORWARD 2nd-1st selector relay terminals 3 – 5 o 1st
solenoid relay terminals 3 – 4 o kick-down solenoid o ground, and the transmission is
switch o kick-down relay 5 – 6 o ground. shifted down from 2nd to 1st.
Because of this, the kick-down relay is actuated, After the kick-down is operated, even if the kick-
and the circuits between terminals 1 and 2, and down switch is pressed many times, it is
between terminals 3 and 4 are closed. connected in parallel and the circuit between
• When this happens, a circuit is formed from kick-down terminals 1 – 2 is closed, so it has no
FORWARD solenoid relay terminal 4 o kick- effect on the actuation of the kick-down.
down relay terminals 1 – 2 o kick-down relay
WA700-3 10-231
(10)
Operation for canceling kick-down I

(When directional lever is placed at N or R)
• When the directional lever switch is at a position • In addition, the circuit between 2nd-1st selector
other than F, the F terminal contact is OFF, so relay terminals 3 – 6 is closed, so the electric
the electric current from the battery is cut off. No current from the battery flows to the 2nd
electric current flows to FORWARD solenoid solenoid, and the transmission speed range is
relay terminals 5 – 6 and the FORWARD set to 2nd, the same as the position of the speed
solenoid is reset. lever.
• When this happens, FORWARD solenoid relay • In this way, the actuation of the kick-down switch
terminals 3 – 4 are opened, so the electric is canceled and travel operations are carried out
current stops flowing to kick-down relay coil according to the normal lever commands. If the
terminals 5 – 6, the kick-down relay is reset, and directional lever is set to R, the machine will
the self-hold circuit is canceled. travel in R2.
• When the kick-down relay is reset, kick-down
relay terminals 3 – 4 are opened, so the electric
current from the battery is cut off and stops
flowing. The 2nd-1st selector relay is reset, the
circuit between relay terminals 3 – 5 is opened,
and the circuit between terminals 3 – 6 is closed.
• The electric current flowing to the 1st solenoid is
cut off and the kick-down setting to 1st is
canceled.
10-232 WA700-3
(10)
Operation for canceling kick-down II

(When speed lever is at a position other than 2nd)
• When the speed lever is operated to a position speed range set by the position of the speed
other than 2nd, speed lever switch 2nd terminal lever.
is cut off. The electric current stops flowing from • The speed lever switch 2nd terminal is opened,
battery o FORWARD solenoid relay terminals 3 so even if 2nd-1st selector relay terminals 3 – 6
– 4 o kick-down relay terminals 1 – 2, 5 – 6 o are closed, electric current does not flow to the
ground, and the kick-down relay is reset. 2nd solenoid and it is not actuated.
• When this happens, the circuit between kick- • In this way, the actuation of the kick-down switch
down relay terminals 1 – 2 is opened and the is canceled and travel operations are carried out
self-hold is canceled, so even if the speed lever according to the normal lever commands.
is again set to 2nd, the kick-down switch is not
actuated.
• At the same time, kick-down relay terminals 3 –
4 are also opened, so electric current from the
battery stops flowing. To 2nd-1st selector relay
terminals 2 – 1, and 2nd-1st selector relay is
reset.
When the relay is reset, relay terminals 3 – 5 are
opened, and electric current stops flowing to the
1st solenoid, so the kick-down setting to 1st
canceled and the transmission returns to the
WA700-3 10-233
(10)
Operation for canceling kick-down III

(When parking brake is applied)
• When the parking brake switch is turned ON • As a result, electricity flows from the battery o
(applied), electric current stops flowing to the kick-down relay terminals 3 – 4 o 2nd-1st
parking brake valve and the parking brake is selector relay terminals 2 – 1. The relay is
actuated. At the same time, the neutralizer relay actuated, so electric current flows from terminals
is also reset, so neutralizer relay terminals 3 – 5 3 – 5 o 1st solenoid o ground, and the 1st clutch
are opened. is actuated.
The electric current from the battery is cut off and • In this way, when the parking brake is applied,
does not flow to the FORWARD solenoid, so the the actuation of the kick-down switch is not
transmission is set to neutral. canceled, but the directional lever switch is set to
At the same time, in directional lever switch neutral and the speed range to 1st, and the
terminal F, electric current flows from the battery machine is stopped from moving.
o FORWARD solenoid relay terminals 5 – 6 o
ground, so the circuits between terminals 1 – 2
and between terminals 3 – 4 are closed.
• The speed lever switch is at 2nd, so electric
current flows from FORWARD solenoid relay
terminals 3 – 4 o kick-down switch o kick-down
relay terminals 6 – 5 o ground, the relay is
actuated, and the circuit between terminals 1 – 2
and between terminals 3 – 4 are closed.
10-234 WA700-3
(10)
Operation for canceling kick-down IV

(When starting switch is turned OFF)

battery relay is opened, so electric current stops
flowing to the transmission directional circuit and
speed circuit, and the kick-down switch operation
is canceled.
• If the starting switch is at OFF, even if the kick-
down switch is turned ON (actuated), the kick-
down switch will not work.
WA700-3 10-235
(10)
Structure and function Electric parking brake control
Electric parking brake control
Outline
• When electric current flows to the parking brake 1. Parking brake switch
valve (solenoid valve), the hydraulic pressure 2. Accumulator
from the accumulator is applied to the spring 3. Emergency brake switch
cylinder to release the parking brake. 4. Parking brake display switch
On the other hand, if the electric current is turned 5. Parking brake valve
off, the oil pressure from the accumulator is cut 6. Spring cylinder
off, so the oil pressure inside the spring cylinder 7. Neutralizer relay
passes through the parking brake valve and is 8. Parking safety relay
drained, the parking brake is actuated by the
force of the spring.
10-236 WA700-3
(10)
Function
1. Applying and releasing parking brake : The parking brake is applied or released by using the
parking brake switch (combination switch).
2. Emergency brake : If there is damage to the hydraulic circuit, and the
pressure inside the accumulator drops and it is
impossible to guarantee the braking force of the
brake, the parking brake is automatically applied to
act as an emergency brake.
3. Parking brake safety : It is dangerous if the parking brake can be released
simply by turning the starting switch ON after the
automatic parking brake has been applied. There-
fore, to ensure safety, the system is designed so the
brake cannot be released unless the starting switch
is turned ON and then the parking brake switch is
also turned ON.
4. Neutralizer : The parking brake may seize if the machine is driven
with the parking brake still applied. To prevent this
problem, the caution lamp lights up and the alarm
buzzer sounds to warn the operator of the mistaken
operation. In addition to this, when the parking brake
is applied, the transmission is forcibly shifted to neu-
tral to make it impossible to drive the machine.
However, the braking distance will become longer if
the transmission is shifted to neutral when the
e me r ge nc y br a k e is a ppl i ed . I t m a y a ls o be
necessary to move the machine if it stops in places
where it is prohibited to stop (such as on railway
crossings). To overcome this, the circuit is designed
so that the transmission is not shifted to neutral
when the emergency brake is applied.
Parking brake switch
WA700-3 10-237
(10)
Parking brake valve
Parking safety relay

Neutralizer relay
Relay actuation table
Terminal No.
Electricity 3 5 6
between 1 and 2
OFF Q Q
ON Q Q
Emergency brake switch
10-238 WA700-3
(10)
Operation
1. Starting switch OFF

battery relay is opened, so electricity does not
flow to the parking brake circuit. For this reason,
if the starting switch is at the OFF position, no
electric current flows to the parking brake
solenoid valve, regardless of whether the
parking brake switch is ON (applied) or OFF
(released), so the parking brake is actuated.
WA700-3 10-239
(10)
2. Starting switch ON
2-1 When parking brake switch is ON (actuated) before starting switch is turned ON
• The electric current flows in circuit (1) from the relay is in the condition of circuit (3) until the
battery o starting switch o battery relay coil o starting switch is turned OFF.
ground, so the battery relay is closed. When this • In this condition, electric current does not flow to
happens, electric current flows in circuit (2) from the parking brake solenoid valve, so the parking
the battery o battery relay o parking brake brake is actuated.
switch terminal 1 – 3 o parking brake safety • In addition, in this condition, neutralizer relay
relay terminal 1 – 2 o ground. In this way, the terminals 3 and 5 are open, so electric current
parking safety relay is actuated and safety relay does not flows to the transmission directional
terminals 3 – 5 are closed. circuit, and the transmission is shifted to neutral.
• When this happens, circuit (3) is formed from the
battery o battery relay o parking safety relay
terminal 5 – 3 o parking safety relay terminal 1 –
2 o ground. From this point, the parking safety
10-240 WA700-3
(10)
2-2 When parking brake switch is OFF (actuated) before starting switch is turned ON
• Electric current flows in circuit (1) from the

battery o starting switch o battery relay coil o
ground, so the battery relay is closed. However,
in this case, the parking brake switch is OFF
(released), so the parking safety relay is not
actuated. For this reason, the electric current
does not flow to the parking brake solenoid
valve, so after the automatic parking brake is
applied, the parking brake is not released
automatically even when the starting switch is
turned ON.
• In addition, the electric current does not flow to
the transmission directional circuit, so the
machine does not move.
WA700-3 10-241
(10)
3. Parking brake switch OFF (released)

When the parking brake switch is turned from ON to OFF after the starting switch is turned ON
• If the parking brake switch is turned from ON battery relay o neutralizer relay terminal 3 – 5 o
(actuated) to OFF (released), the circuit for transmission directional circuit, so when the
terminals 2 and 3 of the parking brake switch is directional lever is operated, the machine will
connected, and the parking brake safety relay is move.
also actuated. For this reason, electric current
flows in circuit (1) from the battery (+) o battery
relay o parking brake safety relay o parking
brake switch, and then flows to circuit (2) and (3)
given below.
(2) This circuit is formed from the emergency
brake switch o parking brake solenoid valve o
ground, and the parking brake is released.
(3) This circuit is formed from the battery (+) o
10-242 WA700-3
(10)
4. Parking brake switch ON (actuated)
• If the parking brake switch is turned ON (applied) transmission directional circuit, so the
after carrying out operations with the parking transmission is shifted to neutral. This kind of
brake switch OFF (released), the circuit in the neutralizer relay shuts off the electric current
diagram above is formed. going to the transmission solenoid valve when
• Electric current does not flow to the parking the parking brake is applied and shifts the
brake solenoid valve, so the oil pressure from the transmission to neutral to prevent seizure of the
accumulator to the spring cylinder is shut off. At parking brake if the operator should drive the
the same time, the oil pressure inside the spring machine with the parking brake still applied.
cylinder passes through the parking brake valve
and is drained, so the parking brake is applied by
the force of the spring.
• In addition, at the same time, the neutralizer
relay is reset, so the circuit between terminals 3
and 5 is opened, and no electricity flows to the
WA700-3 10-243
(10)
5. When main brake oil pressure drops (emergency brake actuated)
Operation
• If the accumulator pressure drops, the to engage the transmission clutch. In this way, it
emergency brake swit ch inst al led t o t he is possible to use the engine brake when the
accumulator is opened. emergency brake is applied, so the braking
For this reason, the electric current stops flowing distance becomes shorter. At the same time, if
to the parking brake solenoid valve, so the oil the emergency brake has been applied and it is
pressure inside the spring cylinder is drained and necessary to move the machine (for example, if
the parking brake is applied. the emergency brake is applied when the
However, in this case, the condition is different machine is on a railway crossing), it is possible to
from the case where the parking brake switch is move the machine by operating the transmission
ON (applied), because there is electric current lever.
flowing to the neutralizer relay coil.
• For this reason, electric current flows to the
transmission directional circuit, and it is possible
10-244 WA700-3
(10)
Structure and function Electric circuit diagram of active power maximizing system
Electric circuit diagram of active power maximizing system
Outline
• When the work equipment circuit does not need Powerful Loading: Delivery of switching pump is
much oil flow during digging operation, the active reduced during digging operation.
power maximizing hydraulic system minimizes Drive force is increased and work
the delivery from the switching pump (variable- equipment speed is decreased
capacity piston pump) to reduce the load on the during digging operation.
engine and increase the drive force. Normal Loading: Delivery of switching pump is not
• When the active working switch is set in reduced even during digging
"Powerful Loading" and the lift arm is at the operation.
digging position (height) and the oil pressure on Work equipment speed is high.
the lift arm cylinder bottom side increases, the
solenoid valve is operated to change the oil flow
for the switching pump servo valve to minimize
the delivery.
WA700-3 10-244-1
(12)
When directional lever is in "N"
Operation
• If the starting switch is turned ON, power is • Accordingly, even if the active working switch is
supplied to the active working switch and neutral set in "Powerful Loading", the current from it is
1 relay terminal (3). blocked by neutral 2 relay and the active power
• When the directional lever is in "N" (Neutral), the maximizing system does not work.
neutral signal (+24 V) flows to neutral 1 relay
terminal (1) to "close" contacts (3) and (5).
Then, the current flows through neutral relay
terminals (3) and (5) and neutral 2 relay
terminals (1) and (2) to the ground to "open"
neutral 2 relay contacts (3) and (6).
10-244-2 WA700-3
(12)
Powerful Loading Mode (Start of digging operaton)
Operation
• If the directional lever is set in the forward Accordingly, no current flows in the lift arm
position, the neutral signal does not flow and cylinder bottom pressure relay coil and contacts
neutral 1 relay contacts (3) and (5) are "open". (3) and (6) are "closed", thus the current flows
Accordingly, no current flows in the neutral 2 from neutral 2 relay terminal (6) through lift arm
relay coil and contacts (3) and (6) are closed. bottom pressure relay terminals (3) and (6) to
Then, power is supplied from the active working timer 1 terminal (14).
switch through neutral 2 relay terminals (3) and • If the current keeps flowing through timer 1
(5) to the position sensing proximity switch and terminals (14) and (13) to the ground for the set
lift arm cylinder bottom pressure switch. time, contacts (8) and (12) are "closed".
• If the lift arm is lowered and the lift arm position Then, the current flows from timer 1 terminal (12)
sensing proximity switch is turned ON, the through no-load relay terminals (1) and (2) to the
ground side (terminal (6)) of the pump cut-off ground, and consequently contacts (3) and (5)
relay coil is connected to the ground through the are "closed".
proximity switch. Since the current keeps flowing through no-load
• Since the lift arm cylinder bottom pressure is not relay terminals (5) and (1) to the ground, no-load
increased at the start of digging operation, the oil relay terminals (3) and (5) are kept "closed".
pressure switch is turned OFF.
WA700-3 10-244-3
(12)
Powerful Loading Mode (During digging operaton)
Operation
• If the lift arm cylinder bottom pressure increases through the load relay coil to the ground, and
and the oil pressure switch is turned ON because consequently load relay contacts (3) and (5) are
of digging operation, the current stops flowing to "closed".
the lift arm cylinder bottom pressure relay coil • Then, the current flows from neutral 2 relay
and the current to timer 1 terminal (14) is cut off. terminal (6) through no-load relay terminals (3)
Timer 1 contacts (8) and (12) are "opened" and and (5), load relay terminals (5) and (3), timer 2
the current flowing from timer 1 terminal (12) to terminals (4) and (12), pump cutoff relay coil and
the no-load relay coil is cut off. Since the current proximity switch to the ground, and consequently
flows from no-load relay terminal (5) to the coil, pump cutoff relay contacts (3) and (4) are
however, no-load relay contacts (3) and (5) are "closed". Then, a circuit is made up from the
kept "closed". active working switch through the neutral 2 relay,
• At this time, the current also flows through lift arm pump cutoff relay and solenoid valve to the
cylinder bottom pressure relay terminals (1) and ground. As a result, the solenoid valve operates
(2) and oil pressure switch to the ground, and and the delivery of the switching pump is
consequently contacts (3) and (5) are "closed". minimized.
As a result, the current flows from terminal (5)
10-244-4 WA700-3
(12)
Powerful Loading Mode (End of digging operaton)
Operation
• After digging operation is finished, if the lift arm Accordingly, the delivery of the work equipment
cylinder bottom pressure decreases and the oil pump is returned to the normal level.
pressure switch is turned OFF, the current to the • After digging operation is finished, if the lift arm
lift arm cylinder bottom pressure relay coil is cut rises to the position (height) where the proximity
off and contacts (3) and (5) are "opened", and switch is turned OFF, the circuit from pump cutoff
consequently the current to the load coil is cut relay terminal (6) through the proximity switch to
off. the ground is turned OFF, thus pump cutoff relay
Load relay contacts (3) and (6) are "closed" and contacts (3) and (4) are "opened" and the current
the current flows from terminal (6) to timer 2 to the solenoid valve is cut off.
terminal (14). • After digging operation is finished, if the
• If the current keeps flowing from terminal (14) directional lever is set in "N" (Neutral), the neutral
through terminal (13) to the ground for the set 1 relay coil is energized and the current flows
time, timer 2 "opens" contacts (4) and (12). from neutral 1 relay to neutral 2 relay coil and
• Then, the current from timer 2 to pump cut-off contacts (3) and (6) are "opened"
relay coil is cut off and contacts (3) and (4) are Then, the current flowing from neutral 2 relay
"opened" and the current to the solenoid valve is terminal (6) is cut off and each relay and timer is
cut off. reset to the initial state.
WA700-3 10-244-5
(12)
Normal Loading Mode
Operation
• In the normal loading mode, no current flows
from the active working switch to the neutral 2
relay. Accordingly, no current flows to the
solenoid valve and the delivery of the switching
pump is kept in the normal level.
10-244-6 WA700-3
(12)
VHMS controller
Structure and function Blow-by pressure sensor
VHMS controller
VHMS : Vehicle Health Monitoring System
a For details of the basic precautions, outlines,

method of sending and receiving data, and the
procedure for the initial setup, see Testing and
adjusting.
Specifications
1. Voltage of power supply : DC20V - DC30V
2. Size : W272 x D169 x H72
(mm)
Function
The VHMS controller collects and stores signals
from each sensor and signals from the machine con-
troller. It also gives commands for transmitting the
accumulated data through the communications sat-
ellite.
Blow-by pressure sensor

Specifications
1. Voltage of power supply : DC5V
2. Output voltage : Min. 0.5V
(at engine stopped)
3. Size: Mount (portion a) : R 1/4
: Outside diameter of
seat receiving
pressure : ø 37 mm
: Length of cable :
1,110 mm
Function
The blow-by sensor converts the pressure inside the
engine crankcase into a voltage and inputs this into
the VHMS controller as the blow-by pressure.
WA700-3 10-245
(11)
Structure and function Engine oil temperature sensor
Engine oil temperature sensor

Specifications
1. Type of sensor : Thermistor
2. Range of measurement : 40 – 130°C
: 80 – 130°C
(guaranteed precision
± 2°C)
3. Max. power consumption: 0.5 mW
4. Pressure resistance : 4.9 MPa {50 kg/cm2}
5. Temperature range : -30 to 140°C
6. Performance table
Temper- Resis- Temper- Resis- Temper- Resis-

ature tance ature tance ature tance
(°C) (kz) (°C) (kz) (°C) (kz)
30 35.27 80 6.571 110 2.887

40 24.28 85 5.682 115 2.544
50 17.05 90 4.931 120 2.248
60 12.20 95 4.293 125 1.992
70 8.884 100 3.750 130 1.769
a: Heat sensing portion of sensor, outside diameter

of mount R 1/4
Function
The engine oil temperature sensor is installed to the
engine oil filter. It inputs the change in temperature
to the VHMS controller as a change in the resistance
of the thermistor.
10-246 WA700-3
(11)
Exhaust temperature sensor/amp
Structure and function Ambient temperature sensor
Exhaust temperature sensor/

amp
Specifications
1. Rated voltage : DC24V
2. Detection temperature range : 100 – 1,000°C
: 300 – 800°C
(guaranteed accuracy ± 10°C)
3. Output voltage characteristics : See table below
4. Actuation temperature range : -40 to 110°C
5. Consumption current : Max. 30 mA
a. Heat sensing portion of sensor, outside diameter
of mount R 1/8
b. Amp
c. Connector (power source end)
d. Connector (sensor end)
Output voltage characteristics

(ambient temperature: 20°C) : Reference value
Detection
temperature 50 100 400 700 800
(°C)
Output
1.191 1.397 2.626 3.899 4.316
voltage (V)
Function
The exhaust temperature sensor is a thermoelectric
type temperature sensor. It is installed to the turbo-
charger inlet port and outputs the exhaust tempera-
ture data to the VHMS controller.
Ambient temperature sensor

Specifications
1. Electricity consumption : Max. 0.5 mW
2. Pressure resistance : 0.98 MPa {10 kg/cm2}
3. Detected temperature range (surrounding)
: -30 to 120°C
4. Retention temperature range
: -30 to 140°C
5. Performance table below
Detection
temperature -20 -10 0 10 20 50
(°C)
Resistance
30.32 18.58 11.74 7.623 5.077 1.712
(kz)
a: Heat sensing portion of sensor, diameter of

mount 16 x 1.5
Function
The ambient temperature sensor inputs the ambient
temperature to the VHMS controller as a change in
the resistance of the thermistor.
WA700-3 10-247
(11)
Structure and function Transmission pump oil pressure sensor
Transmission pump oil

pressure sensor
Specifications
1. Current consumption : Max. 20mA
2. Output current : Max. 5mA
3. Pressure range : 0 – 4.9 MPa
{0 – 50 kg/cm2}
4. Using temperature : -30 to 110°C
5. Output characteristics
Function
The transmission pump oil pressure sensor is
installed to the transmission pump. It converts the
transmission pump pressure into a voltage and
inputs the converted voltage as the transmission
pump pressure to the VHMS controller.
10-248 WA700-3
(11)
Brake oil temperature sensor
Structure and function Hydraulic oil temperature sensor
Brake oil temperature sensor

Hydraulic oil temperature
sensor
Specifications
1. Type of sensor : Thermistor
2. Using temperature range: -50 to 150°C
(Liquid)
-50 to 80°C
(Ambient)
3. Max. power consumption : 0.5 mW
4. Resisting pressure : 0.98 MPa
{10 kg/cm2}
5. Performance table
Temperature Resistance Temperature Resistance

(°C) (kz) (°C) (kz)
25 42.7 100 3.75

30 35.13 105 3.288
80 6.556 110 2.892
85 5.672 115 2.551
90 4.925 120 2.257
95 4.29 130 1.781
Performance
The brake oil temperature sensor and hydraulic oil
temperature sensor are installed to the right side of
the front axle. They input changes of temperature
as changes of resistance of thermistors to the
VHMS controller.
WA700-3 10-249
(11)
Brake oil pressure sensor
Steering oil pressure sensor
Structure and function Work equipment pump oil pressure sensor
Brake oil pressure sensor

Steering oil pressure sensor
Work equipment pump oil
pressure sensor
Specifications
1. Type of sensor : Strain gauge type
2. Using temperature range : -40 to 120°C
(Liquid)
-40 to 120°C
(Ambient)
3. Current consumption : Max. 10 mA
(When rated voltage
is applied)
4. PV characteristics : 20 – 80°C
10-250 WA700-3
(11)
Structure and function Communications (ORB: Orbcomm) controller/antenna
Communications (ORB: Orb-

comm) controller/antenna
Controller
Specifications
1. Power supply voltage: DC12V – DC30V
2. Size : W306 x D152 x H52 (mm)
Installation location
Installed at inside console box.
Connector portion
CN1A (ORB-A) : AMP070-14
CN1B (ORB-B) : AMP070-10
CN2 : Communications antenna cable connector
Antenna
Specifications
1. Type : Helical whip antenna (1)
2. Impedance : 50 z
3. Input terminal: M-P type
4. Length : 165 ± 20 mm
a: Communications antenna mount
Installation location
Installed at left rear of cab
Function
The antenna transmits the data collected and accu-
mulated by the VHMS controller through the com-
munications satellite to the computer center.
WA700-3 10-251
(11)
20 Testing and adjusting
Standard value table

Standard value table for engine............................................................................................................20- 2
Standard value table for chassis ..........................................................................................................20- 4
Standard value table for electrical parts ...............................................................................................20- 9
Testing and adjusting ..................................................................................................................................20- 101
Troubleshooting ..........................................................................................................................................20- 201
a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert
k When carrying out work together with other workers, always use signals and do not let unauthorized
the safety pins, and use blocks to prevent the machine from moving.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed
people near the machine.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
when the water is still hot, the water will spurt out and cause burns.
WA700-3 20-1
(10)
Testing and adjusting Standard value table for engine
Standard value table for engine

Serial No.: 50001 – 51000
Mchine model WA700-3
Engine SAA6D170E-2
Cate- Standard value

Item Measurement conditions Unit Service limit value
gory for new machine
High idling 2,270 ± 30 2,270 ± 30
Low idling
Engine speed rpm 650 +50 650 +50
(mounted on machine) 0 0
Rated speed 2,000 —
Sudden acceleration Bosch Max. 4.5 6.0

Exhaust gas color
At high idling index Max. 1.5 2.5
Valve clearance Intake valve 0.4 —

mm
(normal temperature) Exhaust valve 1.0 —
Oil temperature: 40 – 60°C

Compression pressure MPa Min. 2.9 2.1
(Engine speed:
(SAE30 oil) {kg/cm²} {Min. 30} {21}
210 – 250 rpm)
(Water temperature: Max. 3.92 {Max. 400} 7.85 {800}

Blow-by pressure kPa
Operating range) (at rated: (at rated:
(SAE30 oil) {mmH2O}
At high idling Max. 3.92 {400}) Max. 7.85 {800})
Engine
(Water temperature:
Operating range)
0.39 – 0.54 0.21

At high idling (SAE30)
{4.0 – 5.5} {2.1}
MPa 0.34 – 0.49 0.18

Oil pressure At high idling (SAE10W)
{kg/cm²} {3.5 – 5.0} {1.8}
Min. 0.12 0.07

At low idling (SAE30)
{Min.1.2} {0.7}
Min. 0.98 0.07

At low idling (SAE10W
{Min.1.0} {0.7}
Oil temperature Whole speed range (oil pan) °C 80 – 110 120
Fuel injection timing Compression B.T.D.C. deg. 22 ± 0.5 22 ± 0.5
Deflection when pressed

Fan belt tension
with finger force of approx. mm 10 – 15 10 – 15
(Alternator)
59 N {approx. 6 kg}
20-2 WA700-3
(10)
Testing and adjusting Standard value table for engine
Mchine model WA700-3
Engine SAA6D170E-2
Cate- Standard value

gory for new machine
Low idling 725 ± 25 725 ± 25
Engine speed High idling rpm 2,270 ± 30 2,270 ± 30
Rated speed 2,000 —
Whole speed range

Exhaust temperature °C 650 700
(ambient temperature: 20°C)
Air supply pressure kPa Min. 120 107

At rated output
(boost pressure) {mmHg} {Min. 900} {800}
At sudden acceleration Bosch Max. 4.5 5.5

Exhaust gas color
At rated output index Max. 1.0 2.0
Valve clearance Intake valve 0.32 —

mm
(normal temperature) Exhaust valve 0.62 —
Oil temperature: 40 – 60°C

Compression pressure MPa Min. 2.9 2.1
(Engine speed:
(SAE30 oil) {kg/cm²} {Min. 30} {21}
210 – 250 rpm)
(Water temperature:
Blow-by pressure kPa
Green range) Max. 3.92 {Max. 400} 7.9 {800}
Engine
(SAE30 oil) {mmH2O}

At high idling
(Water temperature:
0.39 – 0.54 0.21
Green range)
{4.0 – 5.5} {2.1}
At high idling (SAE30)
(Water temperature:
0.34 – 0.49 0.18
Green range) MPa
Oil pressure {3.5 – 4.0} {1.8}
At high idling (SAE10W) {kg/cm²}
Min. 0.12 0.07
At low idling (SAE30)
{Min.1.2} {0.7}
Min. 0.1 0.05

At low idling (SAE10W
{Min.1.0} {0.5}
Whole speed range

Oil temperature °C 90 – 110 120
(inside oil pan)
Deflection of one belt when

Alternator belt tension pressed with finger force of mm 10 – 15 10 – 15
approx. 58.8 N {approx. 6 kg}
Deflection when preseed

Air conditioner
with finger force of approx. mm 10 – 15 10 – 15
compressor belt tension
58.8 N {approx. 6 kg}
WA700-3 20-3
(10)
Testing and adjusting Standard value table for chassis
Standard value table for chassis
Cate- Standard value for

gory new machine
Operating N–FORWARD, • Engine stopped
Directional
N {kg} 5.88 +4.9 +0.5

–2.94 {0.6 –0.3 } Max. 16.7 {1.7}
effort REVERSE • Measure at center of lever knob
lever
N–FORWARD,
Travel mm 35 ± 10 35 ± 10
REVERSE
1st – 2nd • Engine stopped 5.88 +4.9 +0.5

–2.94 {0.6 –0.3 } Max. 16.7 {1.7}
• Measure at center of lever knob
Operrating
Speed control lever
2nd – 3rd N {kg} 5.88 +4.9 +0.5

–2.94 {0.6 –0.3 } Max. 16.7 {1.7}
efffort
3rd – 4th 5.88 +4.9 +0.5
–2.94 {0.6 –0.3 } Max. 16.7 {1.7}
1st – 2nd 35 ± 10 35 ± 20
Travel 2nd – 3rd mm 35 ± 10 35 ± 20
3rd – 4th 35 ± 10 35 ± 20
HOLDoRAISE • Engine speed: Low idling Max. 23.5 {2.4} Max. 35.3 {3.6}
• Hydraulic oil temperature:
RAISEoHOLD 45 – 55°C Max. 15.7 {1.6} Max. 23.5 {2.4}
HOLDoLOWER Max. 24.5 {2.5} Max. 37.3 {3.8}

Boom
Operating ffort
LOWERoHOLD — —
Work equipment control lever
LOWERoFLOAT N {kg} Max. 34.3 {3.5} Max. 52.0 {5.3}
FLOAToHOLD Max. 14.7 {1.5} Max. 22.6 {2.3}
HOLDoDUMP Max. 23.5 {2.4} Max. 35.3 {3.6}
Bucket HOLDoTILT Max. 23.5 {2.4} Max. 35.3 {3.6}
TILToHOLD Max. 14.7 {1.5} Max. 22.6 {2.3}
HOLDoRAISE • Engine speed Low idling 67 ± 15 67 ± 30

Boom HOLDoLOWER 45 – 55°C 53 ± 15 53 ± 30
Travel
HOLDoFLOAT mm 67 ± 15 67 ± 30
HOLDoDUMP 60 ± 15 60 ± 30
Bucket
HOLoDTILT 60 ± 15 60 ± 30
• Engine stopped
Play mm Max. 20 Max. 20
• Machine facing straight to front
• Flat, horizontal, straight, dry 10.0 ± 3.0
Operating effort N {kg} Max. 19.6 {2.0}
Steering wheel
paved road surface {1.0 ± 0.3}

• Engine speed: High idling
Turns Turns 4.0 ± 0.7 Max. 4.5
• Leftt lock – righ lock
Low idling • Engine running Max. 5.5 Max. 6.5

Operating • Hydraulic oil temperature:
sec.
time 45 – 55°C
High idling Max. 4.7 Max. 5.0
• Leftt lock – righ lock
20-4 WA700-3
(10)

gory new machine
Operating effort • Engine speed: Low idling

(Measure at 150 mm point • Hydraulic oil temperature: N{kg} 59 {6.0} Max. 88.3 {9.0}
from pedal fulcrum) 45 – 55°C
Accelerator pedal
Operating angle
Neutral ( 1) 45 —
deg.
Max. ( 2) 30 —
Stopper height (L) mm 51 —
Operating effort • Engine speed: Low idling

• Hydraulic oil temperature: 294 ± 29.4
(Measure at 150 mm point N{kg} 421.4 {43}
45 – 55°C {30 ± 3}
from pedal fulcrum)
Operating effort
Neutral ( 1) 45 —
Brake pedal
deg.
+1
Max. ( 2) 15 0 —
Play mm 5 ± 0.5 —
• Tire inflation pressure:

A Specified value Max. 2.5 —
Fitting of wheel lock ring

Lock ring
Tire
B mm Max. 4.0 —
B
C
TEW00003 TEW00004
Clearance of wheel lock
C 20 – 35 —
ring
• Engine water temperature:

Torque converter stall Green range 2,175 ± 50 2,175 ± 200
• Torque converter oil tempera-
Engine speed
ture: 60 – 80°C
Hydraulic stall 45 – 55°C rpm 2,150 ± 50 2,150 ± 200
• Gearshift lever: F4 or R4
Torque converter stall +

1,620 ± 100 1,620 ± 300
hydraulic stall
WA700-3 20-5
(10)

gory new machine
• Torque converter oil temperature: 1.06 ± 0.10 1.06 ± 0.10
Pilot reducing pressure
60 – 80°C {10.8 ± 1.0} {10.8 ± 1.0}
3.09 ± 0.15 3.09 ± 0.15
Modulate pressure • Measure torque converter inlet port
{31.5 ± 1.5} {31.5 ± 1.5}
pressure with the transmission
Lubricating valve pres- speed set to Neutral. 0.20 ± 0.10 0.20 ± 0.10
Transmission, torque converter
sure (except F4, R4) {2 ± 1} {2 ± 1}

Reducing valve pressure 2.30 ± 0.10 2.30 ± 0.10
(for F1, F2) {23.5 ± 1} {23.5 ± 1}
MPa 0.59 ± 0.05 0.59 ± 0.05
Serial No.: 50001 – 51000
Torque converter outlet {kg/cm2} {6.0 ± 0.5} {6.0 ± 0.5}
port pressure 0.59 ± 0.10 0.59 ± 0.10
{6.0 ± 1.0} {6.0 ± 1.0}
Torque converter inlet 0.75 ± 0.10 0.75 ± 0.10
port pressure {7.6 ± 1} {7.6 ± 1}
2.84 ± 0.15 2.84 ± 0.15
Low idling
Main relief {29.0 ± 1.5} {29.0 ± 1.5}
pressure 3.19 ± 0.15 3.19 ± 0.15
High idling
{32.5 ± 1.5} {32.5 ± 1.5}
• Hydraulic oil temperature: +0.5 +0.98
31.4 0 31.4 –0.3
Steering relief pressure 45 – 55°C
+5 +10
Steering
• Engine speed: High idling MPa {320 0 } {320 –3 }

{kg/cm2} +0.19 +0.39
Orbit-roll output pres- 3.72 0 3.72 –0.19
sure +2 +4
{38 0 } {38 –2 }
• Point when brake
+0.49 +0.98
oil pressure 5.88 0 5.88 –0.49
Charge cut-in pressure • Engine speed:
Accumulator
warning lamp +5 +1
Low idling {60 0 } {60 0 }
goes out MPa
• Hydrualic oil 2
• Point when oil {kg/cm }
temperature: +0.98 +1.47
45 – 55°C pressure is going 9.8 0 9.8 –0.49
Charge cut-out pressure
up and then starts +10 +15
{100 0 } {100 –5 }
to go down
1st 6.4 ±0.5 6.4 ±0.5
2nd 11.1 ±0.5 11.1 ±0.5

FORWARD
3rd 18.7 ±0.5 18.7 ±0.5
Power train
4th 30.0 ±0.5 30.0 ±0.5

Travel speed km/h
1st 7.1 ±0.5 7.1 ±0.5
2nd 12.3 ±0.5 12.3 ±0.5

REVERSE
3rd 20.5 ±0.5 20.5 ±0.5
4th 32.3 ±0.5 32.3 ±0.5
20-6 WA700-3
(10)

gory new machine
• Hydraulic oil temperature: 4.9 ±0.49 4.9 ±0.69
Brake oil pressure
45 – 55°C {50 ±5} {50 ±7}
• Engine stopped MPa
• Keep brake pedal depressed at {kg/cm2}
Drop in brake pressure Max. 0.49 {5} 0.49 {5}
4.9 MPa {50 kg/cm2} and measure
drop in oil pressure after 5 min.
Wheel brake
Specified pressure
• Flat, horizontal, straight, dry paved
road surface
• Speed when applying brake:
Performance m Max. 6 6
20 km/h, braking delay: 0.1 second
• Brake pedal operating effort:
Specified operating effort
(294 ±29.4 N {30 ± 3 kg})
• Measure stopping distance.
Disc wear • Measure piston stroke mm 3.6 ± 1.9 Max. 9.7
Parking Brake 5.9 – 9.8 5.9 – 9.8

released • Torque converter oil temperature: {60 – 100} {60 – 100}
brake inlet MPa
60 – 80°C
port Brake {kg/cm2} Max. 0.14 0.14
• Engine at high idling
pressure operated {Max. 1.4} {1.4}
Specified pressure
• Flat dry paved road with 1/5
(11°20') grade
Parking brake
• Machine at operating condition
Performance — Stopped Stopped
Pad thickness Including back metal 31.7 ±0.3 12.7

mm
Clearance Total of each end 1.06 ±0.18 Max. 2.1

PPC valve source pressure 3.72 0 3.72 –0.2
45 – 55°C +2 +2
(Orbit-roll source pressure) {38 0 } {38 –2 }
Boom RAISE, • Hydraulic oil temperature: MPa +0.2 +0.2
PPC
3.72 0 3.72 –0.2

PPC valve FLOAT: bucket 45 – 55°C {kg/cm2} +2 +2
DUMP, TILT {38 0 } {38 –2 }
output • Engine speed: High idling
pressure Boom • Work equipment control lever: 2.54 ± 0.05 2.54 ± 0.05
LOWER Operated fully {26 ± 0.5} {26 ± 0.5}
WA700-3 20-7
(10)

gory new machine
Work equipment relief MPa 31.4 0 31.4 –0.3
45 – 55°C +5 +10
pressure {kg/cm2} {320 0 } {320 –3 }

45 – 55°C
Boom RAISE 9.1 ± 0.5 Min. 11.6
• No load
Boom LOWER 3.6 ± 0.5 Min. 6.1

Work equipment speed
• Hydraulic oil temperature: sec.

45 – 55°C
When fully
• No load 3.7 ± 0.3 Min. 4.8
operated
Work equipment
Bucket tiltback
Bucket horizontal
1.9 ± 0.3 Min. 2.7
(above ground)

45 – 55°C
• Leave for 5 minutes after stopping
Retraction of boom engine then measure for next 15 Max. 40 Max. 40
cylinder rod minutes
• Bucket empty, boom, bucket
Hydraulic drift
horizontal
mm
Retraction of bucket
Max. 20 Max. 20
cylinder rod
Clearance of bucket
3–5 —
Proximity
positioner proximity switch

switch
mm
Clearaance of boom kick
3–5 —
out proximity switch
20-8 WA700-3
(10)
Testing and adjusting Standard value table for electrical parts
Standard value table for electrical parts

Sys- Name of Connector Inspection Measurement
Judgement table
tem component No. method condition
If the condition is as shown in the table below, it is 1) Turn starting switch
resistance
Measure
normal. OFF.
T01
Solenoid (1st) 2) Disconnect
(male) Between (B) – (H) 50 – 70 z
connectors.
Between (B), (H) – chassis Max. 1 Mz 3) Connect T-adapter.
resistance
Measure
normal. OFF.
T01
Solenoid (2nd) 2) Disconnect
(male) Between (B) – (G) 50 – 70 z
connectors.
Between (B), (G) – chassis Max. 1 Mz 3) Connect T-adapter.
resistance
Measure
normal. OFF.
T01
Solenoid (3rd) 2) Disconnect
(male) Between (B) – (F) 50 – 70 z
connectors.
Between (B), (F) – chassis Max. 1 Mz 3) Connect T-adapter.
resistance
Measure
normal. OFF.
T01
Solenoid (4th) 2) Disconnect
(male) Between (B) – (E) 50 – 70 z
connectors.
Between (B), (E) – chassis Min. 1 Mz 3) Connect T-adapter.
resistance
Measure
normal. OFF.
T01
Solenoid (F) 2) Disconnect
(male) Between (A) – (D) 50 – 70 z
Transmission control
connectors.
Between (A), (D) – chassis Max. 1 Mz 3) Connect T-adapter.
resistance
Measure
normal. OFF.
T01
Solenoid (R) 2) Disconnect
(male) Between (A) – (C) 50 – 70 z
connectors.
Between (A), (C) – chassis Max. 1 Mz 3) Connect T-adapter.
resistance
Measure
normal. OFF.
T05
Speed sensor 2) Disconnect
(male) Between (1) – (2) 500 – 1000 z
connectors.
Between (1), (2) – chassis Max. 1 Mz 3) Connect T-adapter.
1) Screw in until speed sensor contacts rin
Adjust
ggear, then turn back 3/4 – 1 turn.

Speed sensor — —
2) Sensor should work normally after adjusted
as above.
normal. OFF.
resistance
Measure
2) Disconnect
L15 Kick down switch
Kick down switch Max. 1 z connectors.
(male) ON Between
3) Connect T-adapter.
Kick down switch (1) – (2)
Min. 1 Mz
OFF
normal. OFF.
resistance
Measure
2) Disconnect
Transmission cut L12 Normal condition Max. 1 z
Between connectors.
off switch (male) Left brake pedal is (1) – (2) Min. 1 Mz 3) Connect T-adapter.
depressed
WA700-3 20-9
(10)

Judgement table
Measure
normal. OFF.
voltage
Power supply L05 2) Insert T-adapter.
Between (1), (2) – chassis
20 – 30 V 3) Turn starting switch
Between (1), (2) – (3) ON.
Measure voltage
normal. OFF.
2) Insert T-adapter.
Engine running (at
Battery charge Between 28 ± 2V
L05 above 1/2 throttle)
(alternator) (5) – (3)
Starting switch ON Max. 1 V
If the battery is old, or after starting in cold
areas, the voltage may not rise for some time.
Measure voltage
normal. OFF.
Directional switch Directional lever at
L05 20 – 30V 3) Turn starting switch
(N) N Between
ON.
Directional lever (8) – (3)
Max. 1 V
not at N
Measure voltage
normal. OFF.
Starting switch L09 Starting switch at
20 – 30V
terminal C (male) START
(3) – chassis
Starting switch at
Max. 1 V
Main monitor
OFF or ON
Measure voltage
normal. OFF.
Starting switch Starting switch at
20 – 30V
terminal C START Between
Starting switch at (4) – (3)
Max. 1 V
OFF or ON
L05 If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
Measure voltage
APS preheating 2) Insert T-adapter.

Starting switch at 20 – 30V
signal (a)
START Between o 1V
Starting switch at (19) – (3)
Preheating ON Max. 1 V
signal (aa) OFF
During preheating, lamp lights up; when pre-
heating is completed, lamp goes out.
normal. OFF.
Measure
voltage
Starting switch L09 2) Disconnect

Starting switch ON 20 – 30V
terminal BR (male) connector
Starting switch (2) – chassis
Max. 1 V 3) Insert T-adapter.
OFF
normal. OFF.
Measure
voltage
Starting switch 2) Insert T-adapter.

L07 Starting switch ON 20 – 30V
terminal BR Between
Starting switch (10) – (12) Max. 1 V
OFF
(a) Serial No.: 50001 – 51000

(aa) Serial No.: 51001 and up
20-10 WA700-3
(10)

Judgement table
normal. OFF.
resistance
Measure
Parking brake F12 2) Disconnect
Parking brake ON Max. 1 z
indicator switch (male) Between connectors.
Parking brake (1) – (2) 3) Connect T-adapter.
Min. 1 Mz
OFF
Measure voltage
normal. OFF.
Main monitor
(F) F Between
ON.
Directional lever (7) – chassis
Max. 1 V
not at F
L08
Measure voltage
normal. OFF.
(R) R Between
ON.
Max. 1 V
not at R
Measure
normal. OFF.
voltage
Power supply L18 2) Insert T-adapter.

Between (1), (2) – chassis
Between (1), (2) – (3) ON.
normal. OFF.
resistance
Measure
Engine water 2) Disconnect

E09 Normal Approx.
temperature connectors.
(male) temperature (25°C) Between 40 kz
sensor 3) Connect T-adapter.
(1) – (2) Approx.
130°C
1.7 kz
normal. OFF.
Maintenance monitor
resistance
Measure
Torque converter 2) Disconnect

T06 Normal Approx.
oil temperature connectors.
(male) temperature (25°C) Between 40 kz
sensor 3) Connect T-adapter.
(1) – (2) Approx.
130°C
1.7 kz
normal. OFF.
2) Disconnect
Float raised connectors.
to stopper 3) Drain fuel.
Measure resistance
Approx. 4) Remove fuel level

4z sensor.
R05 5) Connect T-adapter.
Fuel level sensor
(male)
Float lowered
to stopper
Approx.
85 z
WA700-3 20-11
(10)

Judgement table
resistance
Measure
normal. OFF.
Radiator water G03
2) Disconnect
level sensor (male) Water level normal Between Max. 1 z
connectors.
Water level low (1) – (2) Min. 1 Mz 3) Connect T-adapter.
normal. OFF.
Measure resistance
2) Disconnect
Engine oil pressure:
terminal.
Min. 0.07 MPa
2 Min. 1 Mz 3) Engine running
ER1 {0.7 kg/cm }
(a) (Engine running) Between
Engine oil pressure: (2) – (7)
Max. 0.03 MPa
Engine oil Max. 1 z
{0.3 kg/cm2}
pressure switch
(Engine stopped)
Measure voltage
normal. OFF.
POW Min. 0.05 MPa
Between 20 – 30 V 3) Start engine
(aa) {0.5 kg/cm2}
sensor POW
Max. 0.05 MPa (A) – chassis Max. 1 V
Maintenance monitor
{0.5 kg/cm2}
normal. OFF.
2) Disconnect
Measure resistance
Accumulator
connectors.
pressure:
Brake Max. 1 z 3) Connect T-adapter.
C03 Min. 5.39 ± 0.49MPa
accumulator low {55 ± 5 kg/cm2}
C04 Between
pressure switch Depress brake and (1) – (2)
lower accumulator
pressure to below Min. 1 Mz
4.41 ± 0.49 MPa
{45 ± 5 kg/cm2}
Measure voltage
normal. OFF.
Engine running
Charge Between 28 ± 2 V 3) Start engine.
L18 (above half throttle)
(Alternator) (12) – (3)
Starting switch ON Max. 1 V
If the battery is old, or after starting in cold
areas, the voltage may not rise for some time.
Measure resistance
normal. OFF.
2) Disconnect
Engine oil level ER1 Engine oil level
Max. 1 z terminal.
sensor (male) normal Between
Engine oil level (3) – chassis
Min. 1 Mz
abnormal
(a) Serial No.: 50001 – 51000

20-12 WA700-3
(10)

Judgement table
normal. OFF.
continuity
Measure
Dust indicator 2) Disconnect
Air cleaner normal Continuity
(L.H.) BR1 Between connector
(a) Air cleaner BR1 (6) – (9) No Continuity 3) Starting engigne.
clogged 4) Measure continuity

normal. OFF.
continuity
Measure
Dust indicator 2) Disconnect
Air cleaner normal Continuity
(R.H.) BR1 Between connector
(a) Air cleaner BR1 (7) – (9) No Continuity 3) Starting engigne.
clogged 4) Measure continuity

normal. OFF.
continuity
Measure
2) Disconnect
Dust indicator Air cleaner normal Between Continuity
ER1 connector
(aa) Air cleaner ER1 (5) –
No Continuity 3) Starting engigne.
clogged chassis
4) Measure continuity
If the condition is as shown in the table below, monitor panel is normal. 1) Insert T-adapter.
Maintenance monitor
Table 1 (CHECK lamp & CAUTION lamp)

Connector Monitor item Measurement Sensor
Display
No. (input connector) conditions signal input
Engine water level Engine stopped Flashing 15 – 20 V
((8) – (3)) Starting switch ON OFF Max. 1 V
Engine oil level Engine stopped Flashing 15 – 20 V
((13) – (3)) Starting switch ON OFF Max. 1 V
Engine oil pressure Flashing 15 – 20 V
Engine running
((10) – (3)) OFF Max. 1 V
CHECK items L18 Brake oil pressure Flashing 15 – 20 V
Engine running
(male) ((11) – (3)) OFF Max. 1 V
CAUTION items Battery charge Flashing Max. 10 V
Engine running
((12) – (3)) OFF Min. 12 V
Air cleaner (L.H) Flashing 15 – 20 V
Engine running
((15) – (3)) OFF Max. 1 V
Air cleaner (R.H) Flashing 15 – 20 V
Engine running
((14) – (3)) OFF Max. 1 V
(a) Serial No.: 50001 – 51000

WA700-3 20-13
(10)

Judgement table
Table 2 (Gauge) 1) Turn starting switch
OFF, then insert
Display level resistance
dummy resistance
Gauge display position (monitor panel input
or measure
resistance)
resistance of
Starting switch ON Starting switch OFF sensor.
2) Turn starting switch
Fuel level Min. Green 6 0 – 15.7 ON and check
Green 1
Green 2
Green 3
Green 4
Green 5
Green 6
gauge Green 5 12.6 – 24.0 display.
Red
L18 (male) Green 4 20.5 – 30.6
Measure Green 3 26.7 – 39.6
E F
resistance Green 2 35.2 – 51.6
Red Green
between Max. Green 1 46.5 – 80.6
Flash-
(6) – (3) ing ON (kz) Red 73.8 –
Maintenance monito
Engine water 67 102 130°C

Gauge temperature Min. Red 2 0.24 – 3.47
Green 1
Green 2
Green 3
Green 4
gauge Red 1 3.13 – 3.75

Red 1
Red 2
White
Green 4 3.39 – 4.26

L18 (male)
Green 3 3.85 – 5.14
Measure
E F Green 2 4.65 – 6.94
resistance
between White Green Red Max. Green 1 6.27 – 10.26
ON Flashing (kz) White 9.19 –
(4) – (3) (1 place) (1 place)
Torque
50 120 130°C
converter oil Min. Red 2 0.24 – 1.90
temperature
Green 1
Green 2
Green 3
Green 4
Green 5
Red 1 1.68 – 2.40

Red 1
Red 2
gauge Green 5 2.15 – 3.05

L18 (male) Green 4 2.74 – 5.14
Measure E F Green 3 4.65 – 9.39
resistance Green Red Max. Green 2 8.43 – 18.18
between ON Flashing (kz) Green 1 15.88 –
(1 place) (1 place)
(5) – (3)
20-14 WA700-3
(10)

Judgement table
normal. OFF.
2) Disconnect
Measure resistance
Accumulator
connectors.
pressure:
Max. 1 z 3) Connect T-adapter.
Min.3.92±0.49MPa
Emergency brake C07, C08
{40 ± 5 kg/cm2} Between
switch (male)
Depress brake and C07, C08
lower accumulator (1) – (2)
pressure to below Min. 1 Mz
3.63 ± 0.49 MPa
{37 ± 5 kg/cm2}

normal. OFF.
Accumulator
Measure voltage

pressure:
20 – 30 V ON.
Min.3.92±0.49MPa
Emergency brake
BC01 2
{40 ± 5 kg/cm }
switch Between
Depress brake and (4) – (5)
lower accumulator
pressure to below Max. 1 V
3.63 ± 0.49 MPa
{37 ± 5 kg/cm2}

normal. OFF.
Measure voltage
Others
When When
screwdriver screwdriver is 3) Turn starting switch
Bucket positioner is brough not brough ON.
F05
proximity switch close close
Between (1) – (2) 20 – 30 V Max. 3 V
Between (1) – (3) 20 – 30 V 20 – 30 V
Between (2) – (3) Max. 3 V 20 – 30 V
normal. OFF.
Measure voltage
When When
screwdriver screwdriver is 3) Turn starting switch
Boom kick-out is brough not brough ON.
F06
proximity switch close close
Between (1) – (2) 20 – 30 V Max. 3 V
Between (1) – (3) 20 – 30 V 20 – 30 V
Between (2) – (3) Max. 3 V 20 – 30 V
resistance
Measure
normal. OFF.
Boom kick-out
L16 2) Disconnect
solenoid Between (1) – (2) 19 – 23 z
connectors.
Between (1), (2) – chassis Min. 1 Mz 3) Connect T-adapter.
resistance
Measure
normal. OFF.
Bucket positioner
L17 2) Disconnect
solenoid Between (1) – (2) 19 – 23 z
connectors.
Between (1), (2) – chassis Min. 1 Mz 3) Connect T-adapter.
WA700-3 20-15
(10)

Judgement table
Measure voltage
normal. OFF.
C1 Between C1(7), (13) – chassis
Power supply 3) Turn starting switch
C2 Between C2(1), (12) – chassis ON.
20 – 30 V
Between C1(7), (13) – (6), (12)
Between C2(1), (12) – (11), (21)
normal. OFF.
Measure
voltage
Power supply Between (6) – (17)
C3A 20 – 30 V 3) Turn starting switch
(for signal) Between (6) – chassis ON.
4) Turn parking brake
switch ON.
Measure voltage
normal. OFF.
Parking brake Turn parking brake
L01 20 – 30 V 3) Turn starting switch
switch switch ON Between
ON.
Turn parking brake (1) – (3)
Max 1 V
switch OFF
Transmission & Joystick steering controller

Measure voltage
normal. OFF.
Speed control Speed control
lever (1st) lever at 1st Between
ON.
Speed control (7) – chassis
Max 1 V
lever not at 1st
Measure voltage
normal. OFF.
lever (2nd) lever at 2nd Between
ON.
Max 1 V
lever not at 2nd
Measure voltage
normal. OFF.
Speed control C3B Speed control
lever (3rd) (female) lever at 3rd Between
ON.
Max 1 V
lever not at 3rd
Measure voltage
normal. OFF.
lever (4th) lever at 4th Between
ON.
Max 1 V
lever not at 4th
Measure voltage
normal. OFF.
Directional lever Directional lever at
(F) F Between
ON.
Max 1 V
not at F
20-16 WA700-3
(10)

Judgement table
normal. OFF.
Measure
voltage
(R) R Between
ON.
Max 1 V
not at R
C3B
(female) If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
Measure
voltage
(N) N Between
ON.
Max 1 V
not at N
normal. OFF.
resistance
Measure
T05 2) Disconnect
Speed Between (1) – (2) 500 – 1000 z
(male) connectors.
1) Screw in until the tip of sensor contact gear,

Adjust
then turn back 3/4 –1 turn.

Speed — —
2) Sensor should work normally when adjusted as
above.
E10 (a) normal. OFF.
resistance
Measure
Engine speed (male) 2) Disconnect

Between (1) – (2) 500 – 1000 z
sensor E13 connectors.
(male) Between (1), (2) – chassis Min. 1 Mz 3) Connect T-adapter.
Measure in AC range 1) Turn starting switch

Controller
Measure
voltage
OFF.
Engine speed C4 Between (2) – (9) Min. 0.5 V
3) Start engine.
1) Screw in until the tip of sensor contacts gear,
Adjust
then turn back 3/4 – 1 turn.

Engine speed — —
above.
S-NET If the condition is as shown in the table below, it is 1) Turn starting switch
Controller
Measure
(between normal. OFF.

voltage
transmission C3B 2) Insert T-adapter.

Between (4), (12) – chassis 4–8V
controller and 3) Turn starting switch
main monitor) ON.
normal. OFF.
resistance
Measure
Kick-down switch 2) Disconnect

Kick-down switch
(Shift down Max. 1 z connector.
ON Between
switch) 3) Connect T-adapter.
Kick-down switch (1) – (2)
Min. 1 Mz
L15 OFF
(male)
normal. OFF.
resistance
Measure
Hold switch (Shift 2) Disconnect

Hold switch ON Between Max. 1 z
up switch) connector.
Hold switch OFF (3) – (4) Min. 1 Mz 3) Connect T-adapter.
(a) Serial No.: 50001 – 51000
WA700-3 20-17
(10)

Judgement table
normal. OFF.
resistance
Measure
Transmission cut- L12 2) Disconnect
Normal condition Max. 1 z
off switch (male) Between connectors.
L.H. brake pedal is (1) – (2) 3) Connect T-adapter.
Min. 1 Mz
depressed
normal. OFF.
Controller
Measure 2) Insert T-adapter.

voltage
Manual Manual switch is at
C5 Max. 1 V 3) Turn starting switch
switch ON Between
ON.
Manual switch is at (14) – chassis
20 – 30 V
OFF
normal. OFF.
resistance
Measure
Joystick R (right) L84 2) Disconnect

Between (1) – (2) 10 – 20 z
solenoid (male) connectors.
Between (1) – chassis Min. 1 Mz 3) Connect T-adapter.

normal. OFF.
resistance
Measure
Joystick L (Left) L83 2) Disconnect

Between (1) – (2) 10 – 20 z
solenoid (male) connectors.
Between (1) – chassis Min. 1 Mz 3) Connect T-adapter.

normal. OFF.
resistance
Measure
Joystick neutral Joystick neutral switch between (6) – (7) 5) Disconnect

JL1
switch connectors.
Not at N Max. 1 z
At N Min. 1 Mz

normal. OFF.
resistance
Measure
Joystick JL1 2) Disconnect

Between (3) – (4) 0 – 5 kz
potentiometer (male) connectors.
Between (4) – (5) 4 – 5 kz 3) Connect T-adapter.
Between (3) – (5) 0 – 5 kz
normal. OFF.
Measure
voltage
Joystick Between (3) – (17) 2) Insert T-adapter.

C3A
potentiometer 3) Turn starting switch
When actuated 0.5 – 4.5 V
ON.
20-18 WA700-3
(10)

Judgement table
normal. OFF.
Measure continuity
2) Disconnect
Between (1) – (2) Continuity
ON connectors.
Between (3) – (4) Continuity 3) Connect T-adapter.
APS switch L74
Between (1) – (2) No continuity
AUTO
Between (3) – (4) Continuity
OFF
resistance
Measure
APS water normal. OFF.
E08
temperature 2) Disconnect
(male) Between Up to 20°C Max. 0.5 z
sensor connectors.
terminal – chassis 20°C and up Min. 1 Mz

normal. OFF.
APS controller system (a)
resistance
Measure
2) Disconnect
E17 Between
Glow plug No. 1 glow plug connectors.
(male) (1) – chassis
0.8 – 1.3 z
Between
No. 2 glow plug
(4) – chassis
resistance
Measure
normal. OFF.
APS nozzle — 2) Disconnect
Between nozzle terminals 1.5 – 2.5 z
terminals.

Measure
normal. ON.
voltage
L71
Power source 2) Insert T-adapter.
L72 Between L72 (1) – L71 (1) 20 – 30 V
APS controller

Measure
APS water normal. ON.

voltage
temperature L71 2) Insert T-adapter.

Up to 20°C Max. 1 V
sensor Between (1) – (2)
20°C and up 7 – 10 V

Measure
normal. ON.
voltage
L72
Glow plug 1 2) Insert T-adapter.
L71 Between APS stopped Max. 1 V
L72 (2) – L71 (1) APS operating 4 – 12 V
(a) Serial No.: 50001 – 51000
WA700-3 20-19
(10)

Judgement table
normal. ON.
Measure
voltage
L72 2) Insert T-adapter.
Glow plug 2 Between APS stopped Max. 1 V
L71
L72 (3) – L71 (1) APS operating 4 – 12 V

normal. ON.
Measure
voltage
APS controller system (a)

APS nozzle Between APS stopped Max. 1 V
L71
L72 (4) – L71 (1) APS operating 0.4 – 5 V
APS controller

Engine
Measure
normal. ON.
voltage
starting signal
of starting Between (3) – (1) 10 – 24 V
switch

normal. ON.
Measure voltage
Monitor lamp APS stopped Max. 1 V
Between (4) – (1)
signal of L71 APS operating 4 – 12 V
preheating
Voltage is kept 12 – 20 V for 12 seconds after
starting switch ON, then goes down to below
1 V.
Pre-heat system (aa)
normal. OFF.
Measure voltage
Between (2) – chassis 20 – 30 V
When water temperature is maintained at lower ON.
Pre-heat power HEAT than 0°C for more than 30 seconds.
(a) Serial No.: 50001 – 51000

20-20 WA700-3
(10)
AJSS (Advanced Joystick Steering System) specification

Judgement table
Measure voltage
normal. OFF.
C1 Between C1(7), (13) – chassis
Power supply 3) Turn starting switch
C2 Between C2(1), (12) – chassis ON.
20 – 30 V
Between C1(7), (13) – (6), (12)
Between C2(1), (12) – (11), (21)

Measure voltage
normal. OFF.
Power supply Between (6) – (16)
C3A 20 – 30 V 3) Turn starting switch
(for signal) Between (6) – chassis ON.
4) Turn parking brake
switch ON
normal. OFF.
Measure
voltage
Parking brake Turn parking brake

L01 20 – 30 V 3) Turn starting switch
switch switch ON Between
ON.
Turn parking brake (1) – (3)

Max. 1 V
switch OFF
resistance
Measure
normal. OFF.
T01
Solenoid (1st) 2) Disconnect
(male) Between (H) – (B) 5 – 15 z
connectors.
Between (H), (B) – chassis Max. 1 Mz 3) Connect T-adapter.

resistance
Measure
normal. OFF.
T01
Solenoid (2nd) 2) Disconnect
(male) Between (G) – (B) 5 – 15 z
connectors.
Between (G), (B) – chassis Max. 1 Mz 3) Connect T-adapter.

resistance
Measure
normal. OFF.
T01
Solenoid (3rd) 2) Disconnect
(male) Between (F) – (B) 5 – 15 z
connectors.
Between (F), (B) – chassis Max. 1 Mz 3) Connect T-adapter.

resistance
Measure
normal. OFF.
T01
Solenoid (4th) 2) Disconnect
(male) Between (E) – (B) 5 – 15 z
connectors.
Between (E), (B) – chassis Max. 1 Mz 3) Connect T-adapter.

resistance
Measure
normal. OFF.
T01
Solenoid (F) 2) Disconnect
(male) Between (D) – (B) 5 – 15 z
connectors.
Between (D), (B) – chassis Max. 1 Mz 3) Connect T-adapter.

resistance
Measure
normal. OFF.
T01
Solenoid (R) 2) Disconnect
(male) Between (C) – (B) 5 – 15 z
connectors.
Between (C), (B) – chassis Max. 1 Mz 3) Connect T-adapter.
WA700-3 20-21
(10)

Judgement table
resistance
Measure
normal. OFF.
Engine speed E13
2) Disconnect
sensor (male) Between (1) – (2) 500 – 1000 z
connectors.
Measure in AC range 1) Turn starting switch

Controller
Measure
voltage
Engine speed OFF.
C4 Between (2) – (9) Min. 0.5 V
sensor 2) Insert T-adapter.
3) Start engine.
1) Screw in the engine speed sensor until it
Adjust
Engine speed
— contacts the ring gear, then turn it back 1 turn. —
sensor
2) It works normally by adjustment above.
resistance
Measure
normal. OFF.
T05
Speed sensor 2) Disconnect
(male) Between (1) – (2) 500 – 1000 z
connectors.
1) Screw in until the tip of sensor contact gear,

Adjust
then turn back 3/4 –1 turn.

Speed sensor — —
above.

normal. OFF.
Measure
voltage

lever (1st) lever at 1st Between
ON.
Max. 1 V
lever not at 1st
normal. OFF.
Measure
voltage

lever (2nd) lever at 2nd Between
ON.
Max. 1 V
lever not at 2nd
normal. OFF.
Controller
Measure
voltage

C3B 20 – 30 V 3) Turn starting switch
lever (3rd) lever at 3rd Between
ON.
Max. 1 V
lever not at 3rd
normal. OFF.
Measure
voltage

lever (4th) lever at 4th Between
ON.
Max. 1 V
lever not at 4th
normal. OFF.
Measure
voltage
Directional Directional lever at

lever (F) F Between
ON.
Max. 1 V
not at F
20-22 WA700-3
(10)

Judgement table
normal. OFF.
Measure
voltage
Directional Directional lever at
lever (R) R Between
ON.
Max. 1 V
not at R
Controller
normal. OFF.
Measure
voltage
Directional C3B Directional lever at
lever (N) N Between
ON.
Max. 1 V
not at N
System If the condition is as shown in the table below, it is 1) Turn starting switch
network normal. OFF.
Measure
voltage
(S-NET) 2) Insert T-adapter.

(Between T/M Between (4), (12) – chassis 4–8V
controller and ON.
main monitor)
normal. OFF.
resistance
Measure
Kick-down switch 2) Disconnect

Kick-down switch
& shift-down Max. 1 z connectors.
at ON Between
switch 3) Connect T-adapter.
Kick-down switch (1) – (2)
Min. 1 Mz
at OFF
L15
(male) If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
resistance
Measure
2) Disconnect
Shift-up switch at
Shift-up switch Max. 1 z connectors.
ON Between
Shift-up switch at (3) – (4)
Min. 1 Mz
OFF
normal. OFF.
resistance
Measure
Transmission L12 2) Disconnect

Normal condition Max. 1 z
cut-off switch (male) Between connectors.
L.H. brake pedal is (1) – (2) 3) Connect T-adapter.
Min. 1 Mz
depressed

normal. OFF.
Measure
voltage
Manual Manual switch at

C5 Max. 1 V 3) rting switch ON.
switch ON Between
Manual switch at (14) – chassis
20 – 30 V
OFF
Normal ranges are as follows. 1) Turn starting switch
Controller
OFF.
Measure
Joystick When joystick FNR

voltage
17 –30 V 2) Insert T-adapter.

FNR button switch is in “F” Between
switch “F” When joystick FNR (5) – chassis
Max. 1 V ON.
switch is not in “F”
C3B
OFF.
Measure
Joystick When joystick FNR

voltage

FNR button switch is in “N” Between
switch “N” When joystick FNR (13) – chassis
Max. 1 V ON.
switch is not in “N”
WA700-3 20-23
(10)

Judgement table
OFF.
Measure
When joystick FNR
voltage
Joystick gear 17 –30 V 2) Insert T-adapter.
switch is in “R” Between
shift switch R 3) Turn starting switch
When joystick FNR (6) – chassis
Max. 1 V ON.
switch is not in “R”
OFF.
Measure
When joystick FNR
voltage
Neutralizer 17 –30 V 2) Insert T-adapter.
switch is in “N” Between
relay signal 3) Turn starting switch
When joystick FNR (14) – chassis ON.
Max. 1 V
switch is not in “N”
OFF.
Measure
Joystick When joystick shift-

voltage
Max. 1 V 2) Insert T-adapter.

shift-up up switch is “ON” Between
switch (N.O) When joystick shift- (7) – chassis
17 – 30 V ON.
up switch is “OFF”

OFF.
When joystick shift-
Measure
Joystick Max. 1 V 2) Insert T-adapter.

voltage
down switch is “ON”

shift-down Between 3) Turn starting switch
C3B When joystick shift- (8) – chassis
switch (N.O) ON.
down switch is 17 – 30 V
“OFF”
Controller

OFF.
Measure
Joystick When joystick shift-

voltage

shift-up up switch is “ON” Between
switch (N.C) When joystick shift- (15) – chassis
Max. 1 V ON.
up switch is “OFF”
OFF.
When joystick shift-
Measure
Joystick 17 –30 V 2) Insert T-adapter.

voltage
down switch is “ON”

shift-down Between 3) Turn starting switch
switch (N.C) When joystick shift- (16) – chassis ON.
down switch is Max. 1 V
“OFF”
OFF.
Measure
When steering lock

voltage
Steering lock 17 –30 V 2) Insert T-adapter.

lever is in “LOCK” Between
signal 3) Turn starting switch
When steering lock (9) – chassis
Max. 1 V ON.
lever is in “FREE”
OFF.
When steering
Measure
3.5 – 4.5 V 2) Insert T-adapter.

voltage
Steering lever angle is RIGHT. Between

C3A 3) Start engine.
angle sensor When steering (3) – (16)
0.5 – 1.5 V 4) Move joystick to
angle is LEFT. left or right stoke
end.
20-24 WA700-3
(10)

Judgement table
OFF.
When frame angle
Measure
voltage
Frame angle is RIGHT. Between
C3A 3) Start engine.
sensor When frame angle (13) – (16)
is LEFT. left or right stoke
end.
Controller

OFF.
When joystick
steering lever is in Max. 1 V
resistance
Joystick lever Measure 3) Turn starting switch
neutral Between
neutral C2 ON.
When joystick (8) – chassis
interlock relay
steering lever is 17 – 30 V
not in neutral
a Set machine in straight travel position.
OFF.
When steering
lever angle is 3.5 – 4.5 V
3) Start engine.
RIGHT. Between
4) Move joystick to
When steering (1) – (3)
left or right stoke
Measure
voltage
Steering lever lever angle is 0.5 – 1.5 V end.

JS2
angle sensor LEFT.

OFF.
Between (1) – (2) 0 – 5 kz
2) Disconnect
Between (3) – (2) 4 – 5 kz connector.
OFF.
When frame angle
is RIGHT. Between
3) Start engine.
When frame angle (A) – (C)
resistance
Measure
is LEFT. left or right stoke

Frame angle
L84 end.
sensor
OFF.
Between (A) – (B) 0 – 5 kz
2) Disconnect
Between (B) – (C) 4 – 5 kz connector.
WA700-3 20-25
(10)
Table of tools for testing, adjusting, and troubleshooting ............................................................................ 20-102

Adjusting valve clearance ........................................................................................................................... 20-105
Testing and adjusting injector lift ................................................................................................................. 20-107
Measuring compression pressure ............................................................................................................... 20-109
Measuring blow-by pressure ....................................................................................................................... 20- 112
Testing and adjusting fuel injection timing................................................................................................... 20- 113
Measuring exhaust gas color ...................................................................................................................... 20- 115
Testing and adjusting alternator belt tension............................................................................................... 20- 116
Testing and adjusting air conditioner compressor belt tension ................................................................... 20- 117
Handling equipment in fuel circuit ............................................................................................................... 20- 118
Measuring fuel pump outlet port pressure .................................................................................................. 20- 118
Bleeding air from fuel circuit........................................................................................................................ 20- 119
Measuring exhaust temperature ................................................................................................................. 20-121
Measuring exhaust temperature (overall engine) ....................................................................................... 20-122
Measuring exhaust gas temperature (each cylinder) .................................................................................. 20-123
Measuring air supply pressure (boost pressure)......................................................................................... 20-124
Measuring accelerator pedal....................................................................................................................... 20-125
Adjusting accelerator pedal travel, potentiometer ....................................................................................... 20-126
Adjusting accelerator pedal micro switch .................................................................................................... 20-128
Measuring torque converter, transmission oil pressure .............................................................................. 20-129
Method for operation of emergency manual spool...................................................................................... 20-131
Testing and adjusting steering oil pressure ................................................................................................. 20-133
Adjusting steering stopper bolt.................................................................................................................... 20-134
Adjusting joystick steering........................................................................................................................... 20-135
Adjusting joystick lever neutral detection switch ......................................................................................... 20-137
Testing brake oil pressure ........................................................................................................................... 20-138
Measuring wear of brake disc ..................................................................................................................... 20-139
Measuring brake performance .................................................................................................................... 20-140
Testing and adjusting parking brake ........................................................................................................... 20-141
Testing and adjusting accumulator charge pressure................................................................................... 20-143
Measuring PPC relief valve hydraulic pressure .......................................................................................... 20-144
Testing and adjusting work equipment hydraulic pressure ......................................................................... 20-146
Bleeding air from piston pump .................................................................................................................... 20-148
Adjusting work equipment lever linkage...................................................................................................... 20-149
Testing and adjusting bucket positioner ...................................................................................................... 20-151
Testing and adjusting boom kick-out ........................................................................................................... 20-152
Testing proximity switch actuation pilot lamp .............................................................................................. 20-153
Adjusting main monitor (speedometer module) .......................................................................................... 20-154
Bleeding air ................................................................................................................................................. 20-155
Releasing remaining pressure in hydraulic circuit....................................................................................... 20-156
[Related to VHMS]
Basic precautions........................................................................................................................................ 20-157
Outline......................................................................................................................................................... 20-160
Setting up VHMS controller......................................................................................................................... 20-166
Collection, transmission of data .................................................................................................................. 20-168
Inspection and maintenance ....................................................................................................................... 20-173
Replacing parts ........................................................................................................................................... 20-173
a For the functions and structures of the controllers, sensors, etc., see Structure and function.
WA700-3 20-101
(11)
Testing and adjusting Table of tools for testing, adjusting, and troubleshooting
Table of tools for testing, adjusting, and troubleshooting

Serial No.: 50001 – 51000
Check or measurement Sym-
Part No. Part Name Remarks
item bol
Digital L: 60 – 2,000 rpm
Engine speed A 799–203–8001 Multi-tachometer display H: 60 – 19,999 rpm
Kit part No.: 799-203-9000
Water, oil, exhaust Digital temperature
A 799-101-1502 –99.9 to +1,299°C
temperatures gauge
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Analog hydraulic tester
1 {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester Pressure gauge: 68.6 MPa {700 kg/cm2}
Oil pressure C 2 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}

Both male and female 14 ×1.5
790-261-1311
(female PT 1/8)
3 Adapter
790-261-1321
(female PT 1/8)
1 795-502-1590 Compression gauge 0 – 6.9 MPa {0 – 70 kg/cm2}
Compression pressure D
2 795-502-1350 Adapter Kit part No.: 795-502-1205
1 799-201-1504 Blow-by checker —

Blow-by pressure E
2 799-201-1590 Gauge 0 – 9.8 kPa {0 – 1,000 mmH2O}
Commercially
Valve clearance F Feeler gauge
available
1 799-201-9000 Handy smoke checker Discoloration 0 – 70%
Exhaust color G Commercially (with standard color)
2 Smoke meter (Discoloration × 1/10 C Bosch index)
available
Air supply pressure –101.3 – 199.9 kPa
H 799-201-2202 Pressure gauge
(boost pressure) {–760 – 1,500 mmHg}
1 793-520-1805 Brake tester kit —
Brake oil pressure I 2 • 793-520-1851 Nipple —
3 790-301-1230 Elbow Kit part No.: 799-101-5002
1 79A-264-0020 0 – 294.2 N {0 – 30 kg}
Operating effort J Push-pull scale
2 79A-264-0090 0 – 490.3 N {0 – 50 kg}
Commercially
Stroke, hydraulic drift K Scale
available
Commercially
Work equipment speed L Stop watch —
available
Measuring brake disc Commercially
M Caliper gauge —
wear available
Moving voltage,
N 79A-264-0211 Tester —
resistance value
Adjusting fuel injection
P 795-471-1200 Gauge ass’y —
timing
1 799-601-7400 T-adapter assembly —
Troubleshooting of wiring 2 799-601-3460 MS 10P

Q
harness, sensors 3 799-601-7360 Adapter Relay 5P
4 799-601-7370 Relay 6P
20-102 WA700-3
(10)

item bol
Digital L: 60 – 2,000 rpm
799-203-8001 Multi-tachometer display H: 60 – 19,999 rpm
Engine speed A Kit part No.: 799-203-9000
• 799-203-8240 Nut 7/8 – 18 NS
Water, oil, exhaust Digital temperature
B 799-101-1502 –99.9 to +1,299°C
temperatures gauge
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Analog hydraulic tester
1 {25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester Pressure gauge: 68.6 MPa {700 kg/cm2}
Oil pressure C 2 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm 2}

790-261-1311
(female PT 1/8)
3 Adapter
790-261-1321
(female PT 1/8)
1 795-201-9000 Handy smoke checker Discoloration 0 – 70%
Exhaust color D Commercially (with standard color)
2 Smoke meter (Discoloration × 1/10 C Bosch index)
available
Heat gun (surface
Exhaust temprature R —
temperature gauge)
1 795-502-1590 Compression gauge 0 – 6.9 MPa {0 – 70 kg/cm2}
Compression pressure E
2 795-502-1350 Adapter Kit part No.: 795-502-1205
Commercially
Valve clearance F Feeler gauge
available
799-201-1504 Blow-by checker
Blow-by pressure G 799-201-1590 Gauge —
6162-23-4500 Barring device 0 – 98 kPa {0 – 1,000mm H2O}
Air supply pressure –101.3 to + 199.9 kPa
H 799-201-2202 Pressure gauge
(boost pressure) {–760 to + 1,500 mmHg}
1 793-520-1805 Brake tester kit —
Brake oil pressure I 2 • 793-520-1851 Nipple —
3 790-301-1230 Elbow Kit part No.: 799-101-5002
1 79A-264-0020 0 – 294.2 N {0 – 30 kg}
Operating effort J Push-pull scale
2 79A-264-0090 0 – 490.3 N {0 – 50 kg}
Commercially
Stroke, hydraulic drift K Scale
available
Commercially
Work equipment speed L Stop watch —
available
Measuring brake disc Commercially
M Caliper gauge —
wear available
Measuring voltage,
N 79A-264-0211 Tester —
resistance value
Adjusting fuel injection
P 795-471-1200 Gauge ass’y (Dial gauge is commercially available)
timing
WA700-3 20-103
(10)

item bol
1 799-601-7400 T-adapter assembly —
2 799-601-3460 MS 10P
3 799-601-7360 Adapter Relay 5P
4 799-601-7370 Relay 6P
Troubleshooting of wiring 5 795-799-5460

Q
harness, sensors 6 795-799-5470 Cable
7 795-799-5480
For engine
8 795-799-5520
9 795-799-5530 Adapter
10 795-799-5540
20-104 WA700-3
(10)
Testing and adjusting Adjusting valve clearance
Adjusting valve clearance

Serial No.: 50001 – 51000
1. Remove the cylinder head cover.
2. Rotate the crankshaft in the normal direction to align

the 1.6TOP line on vibration damper (2) with pointer
(1) to set the No. 1 cylinder at compression top
dead center. When rotating, check the movement
of the intake valves of the No. 6 cylinder.
a When the No. 1 cylinder is near the compression
top dead center, the intake valves of No. 6
cylinder move (are closed).
a When No. 1 cylinder is at compression top dead
center, adjust the valves marked q in the valve
arrangement chart.
Next, rotate crankshaft one turn (360°) in the
normal direction, set No. 6 cylinder to the com-
pression top dead center, and adjust the valve
clearance of the valves marked Q.
3. To adjust the valve clearance, insert feeler gauge F

between crosshead (5) and rocker arm (6), and
adjust with adjustment screw (3) until the clearance
is a sliding fit.
4. Tighten locknut (4) to hold adjustment screw (3) in
3 Locknut: 58.8 ± 5.9 Nm {6 ± 0.6 kgm}

position.
5. Repeat the above procedure to adjust the valves

marked q in the valve arrangement chart.
6. Next, rotate crankshaft one turn (360°) in the normal

direction and adjust the valve clearance of the
remaining valves marked Q.
a After adjusting No. 1 cylinder at compression top

dead center, it is also possible to turn the crankshaft
120° each time and adjust the clearance of the
valves of each cylinder according to the firing order.
Firing order : 1–5–3–6–2–4
a After tightening the locknut, check the valve
clearance again.
7. After adjusting, install the cylinder head cover.
WA700-3 20-105
(10)
Testing and adjusting Adjusting valve clearance
Serial No.: 51001 and up 5. Tighten locknut (4) to hold adjustment screw (3)
3 Locknut: 57.8 – 77.4 Nm {5.9 – 7.9 kgm}

in position.
1. Remove the cover of the flywheel housing, then
install barring device F1.
After tightening the locknut, check the clearance
again.
3. Using barring device F1, rotate the crankshaft in 6. Turn the crankshaft 120° each time in the nor-
the normal direction to set the No. 1 cylinder at mal direction and repeat the procedure in Steps
compression top dead center, and align pointer 3 to 5 to adjust the valves of each cylinder
b with the [1.6TOP] line a on the crankshaft pul- according to the firing order.
ley. a Firing order : 1 – 5 – 3 – 6 – 2 – 4
a At compression top dead center, the valve
rocker arm can be moved by hand by the 7. After completing the measurement, set to the
3 Cylinder head cover mounting bolt :

amount of the valve clearance. If the rocker original condition.
arm does not move, the crankshaft is not at
compression dead center, so rotate it one 9.8 ± 1.0 Nm {1 ± 0.1 kgm}
more turn.
4. To adjust the valve clearance, insert feeler

gauge F2 into clearance c between rocker arm
(1) and crosshead (2), and adjust the valve
clearance with adjustment screw (3).
a Insert the feeler gauge and turn the
adjustment screw until the clearance is a
sliding fit.
a Valve clearance
Intake valve: 0.32 mm
Exhaust valve: 0.62 mm
20-106 WA700-3
(10)
Testing and adjusting Testing and adjusting injector lift
Testing and adjusting injector 5. Crank the crankshaft and measure the lift of the
plunger at the point where the deviation of the
lift dial gauge is the maximum.
a Max. lift c: 20.00 mm
Inspection
1. Remove the cover of the flywheel housing, then
install barring device F1.
3. Using barring device F1, rotate the crankshaft in

the normal direction to set the No. 1 cylinder at
compression top dead center, and align pointer
b with the [1.6TOP] line a on the crankshaft pul-
ley.
a Watch the movement of the rocker arm and
check that the No. 1 cylinder is at the Adjusting
compression stroke. (If the rocker arms for a If the lift is not correct, adjust as follows.
both the intake and exhaust sides move only 1. Use the inspection procedure to set the cylinder
the amount of the valve clearance, the at the compression top position so that the injec-
cylinder is at the compression stroke). tor can be adjusted.
a The cylinder where at compression top is a The cylinder where at compression top is
different from the cylinder where the injector different from the cylinder where the injector
is being checked, so check the table below is being checked, so check the table below
when carrying out the operation. when carrying out the operation.
a Cylinder at compression top and cylinder for a Cylinder at compression top and cylinder for
inspection of injector: inspection of injector:
Compression top 1 5 3 6 2 4 Compression top 1 5 3 6 2 4
Injector to inspect 2 4 1 5 3 6 Injector to inspect 2 4 1 5 3 6
4. Set dial gauge to the head of the plunger of 2. Fully loosen adjustment screw (1) of the injector
the injector to be inspected. to be adjusted, then tighten it by hand.
a Use a dial gauge with a stroke of at least 30 a Check that the socket at the tip of the rocker
mm. arm and the ball of the push rod are both
fitted securely into the injector and push rod,
respectively.
WA700-3 20-107
(10)
Testing and adjusting Testing and adjusting injector lift
3. Tighten adjustment screw (1), repeat the loosen-
3 Adjustment screw:
ing operation, then tighten finally.
1st time: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

2nd time: Loosen fully
3rd time: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4th time: Loosen fully
5th time: 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4. Hold adjustment screw (1) in position, then
3 Locknut: 205.8 – 245 Nm {21 – 25 kgm}

tighten locknut (2).
a After completing the adjustment, carry out

the inspection procedure to check the lift
again.
5. After completing the inspection and adjustment,
3 Cylinder head mounting bolt :

set to the original position.
9.8 ± 1.0 Nm {1 ± 0.1 kgm}
20-108 WA700-3
(10)
Testing and adjusting Measuring compression pressure
Measuring compression
pressure
Serial No.: 50001 – 51000
a If performance tests or troubleshooting shows that

the piston, piston ring or cylinder liner may be worn,
measure the compression pressure.
k When measuring the compression pressure, be
careful not to touch the exhaust manifold or
muffler, or to get caught in rotating parts.
1. Adjust valve clearance.

a For details, see ADJUSTING VALVE CLEAR-
ANCE.
2. Warm up engine (oil temperature 40 to 60°C).
3. Remove the nozzle holder assembly of the cylinder

to be measured.
a For details, see REMOVAL OF NOZZLE
HOLDER ASSEMBLY.
4. Install tool D1 and D2 in mount of nozzle holder

assembly.
5. Disconnect wiring connector (E20) of the fuel cut

solenoid, then crank the engine with the starting
motor and measure the compression pressure.
a Measure the compression pressure at the point
where the pressure gauge indicator remains
steady.
a When measuring the compression pressure,
measure the engine speed to confirm that it is
within the specified range.
a Installing the nozzle holder assembly after

measuring the compression pressure.
For details, see INSTALLATION OF NOZZLE
HOLDER ASSEMBLY.
WA700-3 20-109
(10)
Serial No.: 51001 and up 4. Fit adapter of compression gauge D1, then
k When measuring the compression pressure, be
connect to the compression gauge.
a Hold the adapter in position with an injector
careful not to touch the exhaust manifold or
3 Mounting bolt:
holder.
muffler, or to get caught in rotating parts.
a Measure the compression pressure with the
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
engine warmed up.
(Oil temperature: 40°C – 60°C)
2. Remove rocker arm assembly (1).
5. Install rocker arm assembly (1), then adjust the
2 Mounting bolt thread, seat:

valve clearance.
3 Mounting bolt:
Engine oil (EO30CD)
235.2 – 254.8 Nm {24 – 26 kgm}

3. Remove injector push rod (2) and injector (3).
a For details, see ADJUSTING VALVE
a Use a special tool to remove the injector (see
CLEARANCE.
DISASSEMBLY AND ASSEMBLY).
6. Disconnect 2 large-sized intermediate connec-
tors (4) of the engine.
a This sets so that no fuel is supplied form the
fuel pump to the injector.
7. Measure the compression pressure when the

engine is cranked with the starting motor.
a Measure the compression pressure when
the gauge indicator is stable.
20-110 WA700-3
(10)
8. After completing the measurement, remove the

measurement equipment and set to the original
condition.
a Check the length under the head of the
mounting bolt of the injector holder. If it is
more than 80 mm, replace the bolt with a
2 Injector mounting bolt thread, seat:

new part.
3 Injector mounting bolt:

Engine oil (EO30CD)
1st time: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
2 Rocker arm mounting bolt thread, seat:

2nd time: Tighten 90° – 120°
3 Rocker arm assembly mounting bolt:

Engine oil (EO30CD)
235.2 – 254.8 Nm {24 – 26 kgm}

a Adjust the valve clearance. For details, see
ADJUSTING VALVE CLEARANCE.
a Adjust the injector. For details, see TEST-
3 Cylinder head cover mounting bolt:

ING AND ADJUSTING INJECTOR LIFT.
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
WA700-3 20-111
(10)
Testing and adjusting Measuring blow-by pressure
Measuring blow-by pressure

Serial No.: 50001 – 51000
a Raise the water temperature to the operating range

before measuring.
1. Install blow-by checker E1 to the end of engine

blow-by hose (1), then connect gauge E2 (0 – 9.8
kPa {0 – 1,000 mmH2O}).
2. Run the engine at high idling, and measure the

blow-by pressure.
k When measuring, be careful not to touch any

hot parts or rotating parts.
Caution for measuring blow-by

a Blow-by varies greatly according to the condition
of the engine. Therefore, if the blow-by value is
considered abnormal, check for problems
c o n c e r n i n g d e f e c t i v e b l o w - b y , s uc h a s
excessive oil consumption, defective exhaust
gas color, or prematurely dirty or deteriorated
oil.
1. Install the nozzle of pressure test kit E to blow-by

hose (1), then connect to the pressure test kit.
2. Run the engine at near rated output, and measure

the blow-by pressure.
k When measuring, be careful not to touch any

hot parts or rotating parts.
Note:
a Blow-by varies greatly according to the condition
of the engine. Therefore, if the blow-by value is
considered abnormal, check for problems
connected with defective blow-by, such as
excessive oil consumption, defective exhaust
gas color, and prematurely dirty or deteriorated
oil.
20-112 WA700-3
(10)
Testing and adjusting Testing and adjusting fuel injection timing
Testing and adjusting fuel

injection timing
Serial No.: 50001 – 51000
1. Remove the injection pump coupling cover.
2. Remove the head cover, disconnect spill tube (1)

and delivery tube (2) of the No. 1 piston, then
remove No. 1 cylinder nozzle holder assembly (3).
3. Align No. 1 cylinder with the compression top dead

center line (1:6).
a When doing this, check that the fuel injection
timing line on the fuel injection pump is near the
line on the fuel injection pump body.
4. Set dial gauge P to the nozzle holder hole where

the nozzle holder assembly has been removed.
(See the diagram).
5. Set the scale on dial gauge P to 0 when the piston

is at top dead center.
a Rotate the crankshaft in the normal direction
and in the reverse direction in turn to align the
top dead center.
a Record the value indicated by the short indicator
on dial gauge P.
6. Rotate the crankshaft approx. 45° in the reverse

direction from the No. 1 cylinder TOP position.
7. Rotate the crankshaft again slowly in the normal

direction and set to specified dimension “c”.
a Specified dimension c: 7.86 ± 0.2 mm
(29° before top dead center)
a Always rotate the crankshaft in the normal
direction to align the position.
a Continue to rotate in the normal direction, and
when the No. 1 cylinder reaches the TOP (top
dead center) position (the indicator on the dial
gauge rotates in reverse), check that dial gauge
reading is 0 ± 0.2 mm. If it is not within 0 ± 0.2
mm, carry out Steps 4 and 5 again.
8. Check that fuel injection timing line “a” on the fuel

injection pump is aligned with line “b” on the cou-
pling.
WA700-3 20-113
(10)
Testing and adjusting Testing and adjusting fuel injection timing
9. If the lines are not aligned, loosen bolt (4) in the

oblong hole, move coupling to align the lines, then
tighten the bolt.
10. After adjusting, install No. 1 nozzle holder assem-

bly.
For details, see INSTALLATION OF NOZZLE
HOLDER ASSEMBLY.
20-114 WA700-3
(10)
Testing and adjusting Measuring exhaust gas color
Measuring exhaust gas color
• When measuring in the field when there is no air or

power supply, use handy smoke checker G1; when
recording official data, use smoke meter G2.
• Raise the coolant temperature to the green range
before measuring.
k When removing or installing the measuring

equipment, be careful not to touch any high
temperature part.
1. Measuring with handy smoke checker G1

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

1) Insert probe of tool G2 into the outlet port of
exhaust pipe, then tighten the clip to secure it to
the exhaust pipe.
2) Connect the probe hose, accelerator switch
plug, and air hose to tool G2.
a The pressure of the air supply should be
less than 1.5 MPa {15 kg/cm2}.
3) Connect the power cord to the AC outlet.
a When connecting the port, check first that
the power switch of tool G2 is OFF.
4) Loosen the cap nut of the suction pump, then fit
the filter paper.
a Fit the filter paper securely so that the
exhaust gas does not leak.
5) Turn the power switch of tool G2 ON.
6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
tool G2 and catch the exhaust gas color on the
filter paper.
7) Lay the filter paper used to catch the exhaust
gas color on top of unused filter papers (10
sheets or more) inside the filter paper holder,
and read the indicated value.
20-109
WA700-3 20-115
(10)
Testing and adjusting Testing and adjusting alternator belt tension
Testing and adjusting alternator

belt tension
Serial No.: 50001 – 51000
Testing
• Measure deflection a of the belt when each belt is
pushed with a force of approx. 59 N {approx. 6 kg} at
a point midway between the alternator pulley and the
drive pulley.
a Deflection a of belt (standard value):
approx. 10 – 15 mm
Adjusting
1. Loosen the alternator assembly mounting bolts (1)

and lock nut (2).
2. Turn adjustment bolt (3) to adjust the tension of belt.
3. After positioning the alternator, secure it by tighten-

ing lock nut (2), mounting bolts and nuts (1).
4. After adjusting the belt tension, check that deflec-

tion is the standard value according to the above
procedure.
Testing
• Measure deflection a when the belt is pressed with a
finger at a point midway between the alternator
pulley and drive pulley.
a Pushing force when measuring:
Approx. 98 Nm {approx. 10 kg}
a Deflection a: 10 – 15 mm
Adjusting
a If the deflection is not within the specified range,
adjust as follows.
1. Loosen 2 mounting bolts of alternator (1) and the
lock bolt of the bar.
2. Loosen locknut (2), move alternator (1) with adjust-
ment nut (3), and adjust the tension of belt (4).
a Deflection: 10 – 15 mm
3 Locknut: 147 – 245 Nm {15 – 25 kgm}

3. Tighten locknut (2).
4. Tighten 2 mounting bolts of alternator (1) and the
3 Top mounting bolt:

lock bolt of the bar.
3 Bottom mounting bolt:

65 – 85 Nm {6.7 – 8.7 kgm}
108 – 132 Nm {11 – 13.5 kgm}
20-116 WA700-3
(10)
Testing and adjusting Testing and adjusting air conditioner compressor belt tension
Testing and adjusting air conditioner

compressor belt tension
Serial No.: 50001 – 51000
1. Testing
• Measure deflection b of the belt when it is
pushed with a finger force of approx. 58.8 N
{approx. 6 kg} at a point midway between the
compressor pulley and the engine drive pulley.
a Deflection b of V-belt (standard value):
10 – 15 mm
2. Adjusting
1) Loosen compressor mount bolt (1) and
adjustment bolt (2).
2) Move the position of compressor (3) to adjust
the tension of belt (4).
3) After adjusting the belt tension to the standard
value, tighten adjustment bolt (2) and mount
bolt (1).
1. Testing
• Measure deflection b of the belt when it is
pushed with a finger force of approx. 58.8 N
{approx. 6 kg} at a point midway between the
compressor pulley and the engine drive pulley.
a Deflection b of V-belt (standard value):
10 – 15 mm
2. Adjusting
1) Loosen air compressor mounting bolts (1) and
(2), nut (3) and adjusting bolt lock nut (4) and
adjusting bolt (5).
2) Adjust the tension of fan belt (7) by shifting the
position of compressor (6).
3) After adjusting the fan belt tension to the
specified value, tighten adjusting bolt lock nut
3 Nut (3): 98 – 123 Nm {10.0 – 1.25 kgm}

(4), mounting bolts (1) and (2), and nut (3).
WA700-3 20-117
(10)
Handling equipment in fuel circuit
Testing and adjusting Measuring fuel pump outlet port pressure
Handling equipment in fuel Measuring fuel pump outlet

circuit port pressure
Serial No.: 51001 and up Serial No.: 51001 and up
a Precautions when carrying out inspection and a Measure the outlet port pressure of the fuel
maintenance of fuel system. pump with the signal voltage of the fuel pump
With the HPI type fuel injection system, more pressure sensor.
precise equipment is used than on the conven-
tional fuel injection pump and nozzle. Problems 1. Insert a T-adapter into the connector of fuel
may occur if dirt or dust get in, so always be pump pressure sensor (1), then connect to T-
careful of the following points. adapter box Q.
When carrying out inspection or maintenance of
the fuel line, pay more attention than usual to
prevent dirt or dust from getting in. If there is any
dirt stuck to any part, use clean fuel to wash it off
completely.
a Precautions when replacing fuel filter cartridge.
Always use a genuine Komatsu part for the fuel
filter cartridge.
With the HPI type fuel injection system, more
precise equipment is used than on the conven-
tional fuel injection pump and nozzle. Problems
may occur if dirt or dust get in, so a special filter
with highly efficient filtering performance is
used.
For this reason, do not use imitation filters. If 2. Start the engine and measure the power source
they are used, there is danger of problems voltage of the fuel pump pressure sensor.
occurring in the fuel line. a Check that the power source voltage is
within the following range.
a Sensor power source voltage (between (A)
and (B)): 4.75 – 5.25 V.
3. Run the engine at each speed and measure the

signal voltage of the fuel pump pressure sensor.
a Check that the power source voltage is
within the following range.
a Sensor power source voltage (between (C)
and (B)):
Fuel pump outlet port
Engine Signal
pressure (reference)
speed (rpm) voltage (V)
(MPa {kg/cm2})
0.83±0.14
600 1.78±0.21
{8.45±1.41}
0.93±0.1
700 1.94±0.21
{9.50±1.41}
1.03±0.14
800 2.10±0.21
{10.53±1.41}
1.14±0.14
900 2.26±0.21
{11.60±1.41}
1.25±0.14
1,000 2.42±0.21
{12.70±1.41}
1.34±0.14
1,100 2.59±0.21
{13.70±1.41}
1.46±0.14
1,200 2.76±0.21
{14.90±1.41}

measuring equipment and set to the original
condition.
20-118 WA700-3
(10)
Testing and adjusting Bleeding air from fuel circuit
Bleeding air from fuel circuit

a Bleed the air from the fuel circuit as follows if the a Fill with fuel through the 8 inlet port portions
engine does not start or is difficult to start after a of the filter. Portion b is the outlet port
the following operations. (clean side) after filtering, so fuel must not be
• When starting the engine for the first time added from here.
• When the fuel filter has been replaced
• When the fuel tank has been cleaned
• When fuel has been added after the engine
stopped
1. Open the valves at the supply side and return

side of the fuel tank.
a At the same time, check that there is ample
fuel in the tank.
2. Fill the fuel filter with fuel.

a Do this only after the fuel filter has been
replaced.
a If the fuel filter has not been replaced, there
is danger of dirt or dust getting in, so do not
remove the fuel filter.
WA700-3 20-119
(10)
Testing and adjusting Bleeding air from fuel circuit
a There is no problem with starting if a small

amount of air gets in, so if fuel flows out, the
operation is completed.
3. Crank the engine with the starting motor, push

air bleed valve (2) at the discharge side, and
bleed the air from the discharge circuit.
a There is no problem with starting if a small
amount of air gets in, so if fuel flows out, the
operation is completed.
4. Start the engine and run at low idling.

a The injector forms an open circuit, so when
the engine is operated, the air remaining in
the circuit escapes from the injector to the
inside of the cylinder or the fuel tank.
a After starting the engine, there is a small
amount of variation in the engine speed until
the air is completely removed, so continue to
run the engine at low idling until the speed
becomes stable.
20-120 WA700-3
(10)
Testing and adjusting Measuring exhaust temperature
Measuring exhaust temperature

Serial No.: 50001 – 51000
k The temperature sensor must be installed to the

exhaust manifold, so if the machine has been
operated, wait for the manifold temperature to drop
before installing the sensor.
a Raise the temperature of the cooling water so that
the water temperature gauge is in the green range
before measuring.
1. Open the engine side cover, remove exhaust mani-
fold plug (1), then install the temperature sensor
(contained in digital temperature gauge set B).
• Temperature sensor B:
6215-11-8180 (cable length 610 mm) or
6215-11-8170 (cable length 490 mm)
2. Connect to digital temperature gauge B with the wir-
ing harness (799-201-1110).
Measurement procedure
1. When measuring the maximum value during trou-
bleshooting
Carry out actual work and measure the maximum
value during operation.
a Use the PEAK mode (it can store the maximum
value in memory) of the temperature gauge
function.
Note:
The exhaust temperature varies greatly according
to the ambient temperature (temperature of the
engine intake air), so if any abnormal value is
obtained, carry out temperature compensation.
a Compensation = Measured value + 2 ×
(converted ambient temperature – actual
ambient temperature).
a The converted ambient temperature is
taken as 20°C.
2. When measuring periodically (during preventive
maintenance, etc.)
1) Raise the exhaust temperature by using full
stall (torque converter stall + hydraulic pump
relief).
(Standard value: Approx. 700°C)
2) From the above condition, cancel the hydraulic
pump relief and continue only the torque
converter stall. (The temperature will start to go
down. If it does not go down, but goes up,
increase the set temperature at point shown
in the diagram on the right.)
3) Note the stable temperature when the
temperature starts to go down.
a If only torque converter stall is used when
measuring the exhaust temperature, torque
converter will overheat before a stable value
is obtained.
WA700-3 20-121
(10)
Testing and adjusting Measuring exhaust temperature (overall engine)
Measuring exhaust temperature

(overall engine)
k Wait for the exhaust manifold temperature to go

down before removing or installing the measuring
equipment.
1. Remove exhaust temperature measurement plug

(1).
2. Fit the sensor of digital temperature gauge B, then

connect to the digital temperature gauge.
3. Start the engine and measure the exhaust tempera-

ture when the engine is running at rated horse-
power.

measurement equipment and set to the original
condition.
20-122 WA700-3
(10)
Testing and adjusting Measuring exhaust gas temperature (each cylinder)
Measuring exhaust gas

temperature (each cylinder) a Method of judgement
After compensating, add up the values for the
Serial No.: 51001 and up exhaust gas temperature and calculate the aver-
age value. Any cylinder that is more than 20°C
a If the engine output has dropped or any other lower than the average value can be considered
problem has occurred, and there is a possibility abnormal.
that it is caused by defective combustion due to a Measurement and judgement example 1
defective injection by the injector, use the Unit: °C
following procedure to measure the exhaust gas
Cylinder No.1 No.2 No.3 No.4 No.5 No.6
temperature of each cylinder and determine the
cylinder with the defective injection (defective Measured
85 62 79 112 89 82
value
combustion).
Compensation
105 67 79 112 94 102
value
1. Stop the engine and wait for it to cool down.
a A guideline for judging if the engine has Average
93
value
cooled down is that the temperature of the
exhaust manifold is less than 20°C above
No. 2 cylinder is more than 20°C lower than the
the ambient temperature.
average value, so judge it as abnormal.
2. Start the engine and run at low idling for at least
a Measurement and judgement example 2
10 minutes.
Unit: °C
a Run for at least 10 minutes to stabilize the
exhaust gas temperature. Cylinder No.1 No.2 No.3 No.4 No.5 No.6
Measured
86 96 73 91 94 103
3. Using heat gun R, measure the temperature at value
the exhaust manifold outlet port of each cylinder. Compensation
105 101 79 91 99 123
a Measure the exhaust gas temperature of value
each cylinder at the same place at the top of Average
99
the outlet port of the manifold. value
No. 3 cylinder is more than 20°C lower than the

average value, so judge it as abnormal.
a Measurement and judgement example 3

Unit: °C
Measured
70 88 88 93 86 7
value
Compensation
90 93 88 93 91 92
value
Average
91
value
4. Compensate the measured value for each cylin- No cylinder is more than 20°C lower than the aver-
der and judge if there is any cylinder with a prob- age value, so judge all cylinders as normal.
lem.
a Compensation value
Unit: °C
Compensation
+20 +5 0 0 +5 +20
value
WA700-3 20-123
(10)
Testing and adjusting Measuring air supply pressure (boost pressure)
Measuring air supply pressure

(boost pressure)
k Be careful not to touch any hot or rotating parts
Serial No.: 50001 – 51000
when measuring or when removing or installing the

measuring tools.
1. Open the engine side cover (top right), remove air

supply pressure measurement plug (1) (PT 1/8),
and install the coupler (contained in oil pressure kit
C1).
2. Connect the oil pressure measurement hose to the

coupler and pressure gauge H (–101.3 to + 199.9
kPa {–760 to + 1,500 mmHg}).
Note: Operate the engine at midrange speed or Serial No.: 51001 and up
above, and use the self-seal portion of the
gauge to bleed the oil inside the hose.
• Insert the gauge about half way, repeat the
action to open the self-seal portion, and
bleed the oil.
a If there is oil inside the hose, the gauge will

not work, so always bleed the oil.
3. Carry out the torque converter stall operation at

high and read the gauge indicator.
a The air supply pressure (boost pressure) should be

measured with the engine running at rated output.
However, when measuring in the field, a similar
value can be obtained by operating at torque
converter stall.
20-124 WA700-3
(10)
Testing and adjusting Measuring accelerator pedal
Measuring accelerator pedal

a Measurement conditions
• Engine water temperature: Within green range on
engine water temperature gauge
m
0m
15
Operating force of accelerator pedal
a
Measuring Top surface of floor
1. Set push-pull scale J at a position 150 mm from
pedal fulcrum a.
a Put the center of push-pull scale J in contact with
a point 150 mm from the pedal fulcrum.
TEW00056
2. Start the engine, then measure the maximum value
when the pedal is moved from the pushed position
(low idling) to the end of its travel (high idling).
WA700-3 20-125
(10)
Testing and adjusting Adjusting accelerator pedal travel, potentiometer
Adjusting accelerator pedal

travel, potentiometer
1. Measuring
Accelerator pedal travel
1) Stop the engine.
2) Put angle gauge in contact with the

accelerator pedal, and measure operating
angle ( = 1 – 2 ) when the pedal is
operated from low idling position 1 to high
idling position 2.
Output voltage of accelerator pedal

potentiometer
1) Measure the output voltage of the
potentiometer when the engine is running at low
idling and high idling.
a Connect a T-adapter to CNL13 and measure the
voltage between (1) and the ground.
LY
B
Depress pedal
LR
CNL13
Potentiometer connection diagram
TEW00060
Potentiometer
TEW00061
20-126 WA700-3
(10)
Testing and adjusting Adjusting accelerator pedal travel, potentiometer
2. Adjusting
Adjusting output voltage of potentiometer
1) Check that punch mark (2) made on
intermediate connector (1) between the case
and potentiometer is on the side where it can be
seen.
Insert the protruding part of the potentiometer
into the groove in the intermediate connector, 1
2 Potentiometer mounting surface:

then temporarily tighten the mounting screw.
2
2 Potentiometer mounting screw: LT-2

Cemedyne POS seal
Turn potentiometer
to adjust TEW00062
2) Set the pedal to the low idling position, impress
a voltage of DC5V on the potentiometer, and
turn the potentiometer to the left and right to set
it within the range for the low idling output
voltage.
• Output voltage at low idling: 4.1 V +0.2
–0.1
Operate the pedal 2 or 3 times and check that
the voltage is within the specified output voltage
range at the low idling position. If the voltage is
not within the specified range, carry out the
adjustment again.
a When adjusting the low idling output
voltage, first operate the pedal 2 or 3 times
at the lowest output voltage position, then
turn the potentiometer to increase the
voltage until it is within the specified voltage
range. This will keep the play on one side
and make it easier to adjust.
3 Move bolt up
3) Next, operate the pedal to the high idling or down
position and check that the voltage is within the
high idling output voltage range.
• Output voltage at high idling: 0.7 ± 0.2 V
If the voltage is not within the specified range,
adjust the low idling voltage again within the
Remove
specified range and adjust so that both the low pin
idling and high idling voltages are the specified
voltage.
4) If the high idling voltage does not enter the

voltage range with the procedure up to Step 3),
remove the pin from the bottom of stopper bolt
(3), loosen the stopper bolt, and move it up or
down to adjust so that the high idling voltage is
within the voltage range.
a Adjust the position of the hole so that the pin
can enter the hole at the bottom of the bolt. Align position of bolt
a The stopper bolt is already properly hole so that pin enters
adjusted, so do not adjust it unless there is
some special reason.
5) Tighten the potentiometer mounting screw. TEW00063
WA700-3 20-127
(10)
Testing and adjusting Adjusting accelerator pedal micro switch
Adjusting accelerator pedal

micro switch
1. Remove the accelerator pedal assembly.
2. Remove case (1).
3. Set so that rod (2) pushes against body (3) and

guide (4) pushes against the step portion of the rod.
Then insert a clearance gauge between the guide 3
and bracket, and tighten screw (6) so that the clear-
ance between spring guide (4) and bracket (5) is 0.1 Rod flange
contacts
– 0.2 mm 6
2
5
Microswitch
Clearance
4 0.1 – 0.2mm
Contact Spring
TEW00065
4. Installation of case
2 Mounting surface of case:

1) Install case (1) to body (3).
3
Cemedyne POS seal
2 Rod guide mounting surface:

2) Install rod guide (7).
Sealant
Cemedyne POS seal

1
5. Install the accelerator pedal assembly to the
machine.
Sealant
7 TEW00066
20-128 WA700-3
(10)
Testing and adjusting Measuring torque converter, transmission oil pressure
Measuring torque converter,

transmission oil pressure
• Engine water temperature: Within operating range
• Torque converter oil temperature: 60 - 80°C
k Put blocks under the wheels.
Method of measuring
a The following work is necessary before measuring
the hydraulic pressure.
• Open inspection cover (1) at the rear of the cab.
• Turn transmission cut-off switch (2) OFF, and
use the left brake. (Check that the pilot lamp
goes out.)
• Install the hydraulic test kit to the measurement port,

extend the gauge to the operator’s compartment,
then start the engine and measure the pressure.
a Check that there is no oil leaking from any joint.
1. Torque converter inlet port pressure

1) Measurement port (P10) or (P8)
2) Start the engine and measure the pressure at
high idling.
3) Measure with the speed range at Neutral.
2. Torque converter outlet port pressure

1) Measurement port (P11)
high idling.
WA700-3 20-129
(10)
Testing and adjusting Measuring torque converter, transmission oil pressure
3. Main relief pressure

low idling and high idling.
4. Pilot reducing pressure

2) Place the directional lever at neutral, operate
the speed lever, and measure the pressure.
5. Modulating pressure
2) Place the directional lever at neutral, operate
the speed lever, and measure the pressure.
a Do not measure at F3 or R3.
6. Lubricating valve pressure

high idling.
7. Reducing valve pressure

high idling and low idling.
20-130 WA700-3
(10)
Testing and adjusting Method for operation of emergency manual spool
Method for operation of

emergency manual spool
Outline
• The transmission valve is controlled electrically.
Therefore, the emergency manual spool is installed
to enable the machine to be moved if there is any
failure in the electrical system, or in the solenoid
valve and spool.
k The emergency manual spool is for use when failure

in the transmission control prevents the machine
from being moved. It allows the machine to be
moved from a dangerous place to a place where
repairs can be carried out safety.
The emergency manual spool must never be used
except when the transmission control has broken
down.
k When operating the emergency manual spool,

follow the correct order of operation exactly, and pay
full attention to safety when moving the machine.
k To prevent the machine from moving, lower the

bucket to the ground, apply the parking brake, and
put blocks under the tires.
Check that the brake accumulator pressure is the
specified pressure.
Operation
1. Open cover (1) on rear side of cab.
k Always stop the engine before operating the

spool
2. Remove lock plate (3) of the emergency manual

spool (2) of the transmission valve.
a Simply loosen the mounting bolts to remove the
lock plate (3).
3. Decide the direction to move the machine (forward

or in reverse), ten move the emergency manual
spool to the operating position.
FORWARD: Rotate FORWARD clutch spool and
1st spool counterclockwise, and pull
out approx. 10 mm to the operating
position.
REVERSE: Rotate REVERSE clutch spool and 1st

spool counterclockwise, and pull out
approx. 10 mm to the operating opera-
tion.
WA700-3 20-131
(10)
Testing and adjusting Method for operation of emergency manual spool
4. Check that the area around the machine is safe,

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

pedal fully.
6. Start the engine, release the parking brake, then

release the brake pedal gradually to start the
machine.
k When the engine is started, the transmission is

engaged and the machine will start. Therefore,
before starting the engine, always check that
the direction of travel is safe, and always keep
the brake pedal depressed.
If the machine does not start with the above
operation, return the 1st spool to the neutral
position, then turn the 2nd spool, 3rd spool, or
4th spool clockwise (screw in approx. 10 mm),
to set to the STOP (OFF) position.
k If two or more spools for the speed ranges are

screwed in at the same time, the transmission
is locked, and the machine does not move.
7. After moving the machine, stop the engine, apply

the parking brake, and block the wheels.
8. Return the emergency manual spool to the neutral

position, and install the lock plate.
20-132 WA700-3
(10)
Testing and adjusting Testing and adjusting steering oil pressure
Testing and adjusting steering

oil pressure
a Hydraulic oil temperature: 45 – 55°C
Measuring
1. Measuring steering relief pressure
k Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank. Then operate the
steering wheel and control levers several times to
release the remaining pressure in the hydraulic
piping.
k Install the safety bar to the frame.
1) Remove oil pressure measurement plug (PT1/

8) (1) from the elbow at the right steering
cylinder head end, then install oil pressure
gauge C1 (39 MPa {400 kg/cm2}).
2) Start the engine, run the engine at high idling,

then turn the steering wheel to the right and
measure the pressure when the relief valve is
actuated.
a When removing the oil pressure measure-
ment plug on the left steering cylinder, turn
the steering wheel to the left.
Adjusting
k Always stop the engine before adjusting the

pressure.
1. Adjusting steering relief valve

Loosen locknut (2) of steering relief valve (1), then
turn adjustment nut (3) to adjust.
a Turn the adjustment screw to adjust the set
pressure as follows.
• To INCREASE pressure, turn CLOCKWISE
• To DECREASE pressure, turn COUNTER-
CLOCKWISE
a Pressure adjustment for one turn of adjustment
3 Lock nut: 29.4 ± 2.0 Nm {3 ± 0.2 kgm}

screw: Approx. 14.2 MPa {145 kg/cm2}
WA700-3 20-133
(10)
Testing and adjusting Adjusting steering stopper bolt
Adjusting steering stopper bolt

Preparatory work
Operate the steering before adjusting the stopper bolt
and check that there is contact of the frame stopper at
the steering end.
a If there is no contact because of chipping of the
frame stopper, carry out repairs so that there is
contact on both the left and right sides.
Adjusting
1. Set the stopper bolt to the minimum length.
2. Run the engine at low idling and operate the steer-

ing slowly to contact the frame end.
In this condition, loosen the bolt to pull it out until
the head of the stopper bolt contacts the tip of the
stop valve spool.
a Be careful not to loosen the bolt too far and push
the spool.
3. From this condition, turn the chassis back to make a

clearance of approx. 20 mm between the tip of the
stop valve and the head of the stopper bolt, then
stop the engine.
4. From the condition in Step 3), loosen the bolt 8.5 –

9 turns (14.9 – 15.8 mm), and secure it in position
with the lock nut.
5. Carry out Steps 1) to 4) on the opposite side.
20-134 WA700-3
(10)
Testing and adjusting Adjusting joystick steering
Adjusting joystick steering

Preparatory work
Loosen the potentiometer mounting screw and connect
a T-adapter (X type, 3 pin) between the potentiometer
connect and connector JS2.
a Turn the starting switch OFF before doing this.
1. Adjusting neutral position

1) Set the joystick selector switch to the OFF
position wheel mark side) and set the joystick
lever to the N position.
2) Turn the starting switch ON.

a Turn only to the ON position, do not start the
engine.
3) Check the voltage between pins and of

the T-adapter.
• Voltage between pins: DC 5V ± 0.05V
Adjust the voltage by turning the
potentiometer slowly so that the voltage
between pins and of the T-adapter
become the standard value.
• Voltage between pins: DC 2.5V ± 0.1V (set
value)
WA700-3 20-135
(10)
Testing and adjusting Adjusting joystick steering
• After adjusting the voltage, tighten the potentiometer

mounting screws.
2. Adjusting left and right turning position

1) Operate the potentiometer to adjust the voltage
at the left and right turn positions.
Voltage between
Lever position
pins (1) and (3)
Left turn DC 0.83V ± 0.1V
Right turn DC 4.17V ± 0.1V
2) After adjusting the voltage, lock the stopper bolt

in position.
20-136 WA700-3
(10)
Testing and adjusting Adjusting joystick lever neutral detection switch
Adjusting joystick lever neutral

detection switch
Preparatory work
After adjusting the neutral position with the potenti-
ometer, set the lever to the neutral position and
loosen the nut of the cam plate.
Adjusting
1) Set so that the tip of the roller of the neutral
detection switch contacts the concave portion of
the cam plate, then tighten the switch mounting
bolts.
a Never make the roller of the neutral
detection switch push into the concave
portion of the cam plate.
2) Tighten the nut so that the cam plate is not at an

angle.
WA700-3 20-137
(10)
Testing and adjusting Testing brake oil pressure
Testing brake oil pressure

1. Inspecting brake oil pressure
1) Remove bleeder screw (1), then install oil
pressure gauge tool I (19.6 MPa {200 kg/cm2}),
the elbow, joint, bleeder screw, and nipple,
2) Connect hose (2) to the bleeder screw and
bleed the air from the brake circuit. For details,
see BLEEDING AIR.
3) Depress the left brake and measure the brake
oil pressure.
2. Measuring drop in brake piston pressure

1) Remove bleeder screw (1), then install oil
pressure gauge tool I (19.6 MPa {200 kg/cm2}),
the elbow, joint, bleeder screw, and nipple.
2) Connect hose (2) to the bleeder screw and
bleed the air from the brake circuit. For details,
see BLEEDING AIR.
3) Stop the engine, depress the left brake pedal,
leave for 5 minutes with the oil pressure at 4.9
MPa {50 kg/cm 2 }, and measure the drop in
pressure.
a Be careful not to move the brake pedal for 5
minutes.
a After completing the operation, bleed the air
from the brake circuit again.
20-138 WA700-3
(10)
Testing and adjusting Measuring wear of brake disc
Measuring wear of brake disc

a Brake oil pressure: 4.9 ± 0.49 MPa {50 ± 5 kg/cm2}
k Park the machine on horizontal ground and put

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

end face of the housing to the spring guide.
a When measuring, keep the brake pedal
depressed.
4. Install a vinyl hose (3) to bleeder (2), then loosen

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

to the spring guide.
Calculating piston stroke

• S=a–b
S: Max. 9.7 (mm)
WA700-3 20-139
(10)
Testing and adjusting Measuring brake performance
Measuring brake performance

• Road surface: Flat, horizontal, dry paved
surface.
• Travel speed: 20 km/h when brakes are applied
• Delay in applying brakes: 0.1 sec.
• Tire inflation pressure: Specified pressure
Measurement method
1. Start the engine and move the machine.
2. Set the speed lever to the highest speed position

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

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

brakes were applied to the point where the machine
stopped.
a Repeat this measurement three times and take
the average.
20-140 WA700-3
(10)
Testing and adjusting Testing and adjusting parking brake
Testing and adjusting parking

brake
k Put blocks securely under the tires.
Measuring pad
1. Turn the starting switch ON, then turn the parking
brake switch OFF to release the brake.
2. Remove pad (1) from clipper (2) and measure the

thickness of the pad.
a If the starting switch is turned OFF, the parking
brake is actuated, so be extremely careful not to
turn the starting switch OFF.
a For details of removing and replacing the pad,
see DISASSEMBLY AND ASSEMBLY.
a Measure the two pads.
a If the measurement is not within the standard
value, replace the two pads as one set.
Measuring clearance
1. Turn the parking brake switch OFF to release the
brake.
2. Insert feeler gauge F between pad (1) and disc (3),

and measure the clearance.
a The clearance is the total value (a + b) of the
measurements at both sides.
WA700-3 20-141
(10)
Testing and adjusting Testing and adjusting parking brake
Adjusting
a If the measurement is not within the standard value,
adjust as follows.
1. Turn the starting switch ON, then turn the parking

brake switch OFF to release the brake.
a If the starting switch is turned OFF, the parking
brake is actuated, so be extremely careful not to
turn the starting switch OFF.
2. Turn adjustment bolt (4) at the caliper lever counter-

clockwise until pad (1) and disc (3) are brought into
tight contact and resistance is felt when turning the
bolt.
3. From the above position, turn adjustment bolt (4)

180° ± 30° (3 notches) back in the clockwise direc-
tion.
This adjusts the total clearance on the left a and
right b between pad (1) and disc (3) to the standard
value of 1.06 ± 0.18 mm.
a After completing the above adjustment, measure the

performance of the parking brake to check that it is
the standard value.
20-142 WA700-3
(10)
Testing and adjusting Testing and adjusting accumulator charge pressure

accumulator charge pressure
Measuring
k Depress the brake pedal at least 100 times with the

engine stopped to release the pressure inside the
accumulator circuit.
1. Disconnect hose (port PP) (2) from accumulator

charge valve (1).
2. Install the adapter C3 to elbow (3) at the charge
valve end, then assemble hose (2) again.
3. Install oil pressure gauge C1 (39 MPa {400 kg/cm2})
to adapter C3.
4. Measure the accumulator charge cut-in pressure.
Start the engine, run the engine at low idling, and
measure the oil pressure when the accumulator
pressure warning pilot lamp on the maintenance
meter goes out.
5. Measure the accumulator charge cut-out pressure.
After the accumulator charge cut-in is actuated,
measure the oil pressure when the indicator of the
oil pressure gauge has risen and suddenly starts to
drop.
Adjusting
a When the accumulator charge cut-out pressure is
adjusted, the cut-in pressure also changes in
proportion to the ratio of the valve area. For this
reason, there is no adjustment nut for the cut-in
pressure.
1. Loosen locknut (5) of accumulator charge cut-out

valve (4), then turn adjustment screw (6) to adjust.
a Turn the adjustment screw to adjust the
• To RAISE pressure, turn CLOCKWISE
• To LOWER pressure, turn COUNTER-
CLOCKWISE
a Pressure adjustment for 1 turn of adjustment
screw: 5.59 MPa {57 kg/cm2}
3 Lock nut: 9.8 ± 11.8 Nm {1 – 1.2 kgm}
a After completion of adjustment, repeat the

measurement procedure given above to check
the accumulator cut-in pressure and cut-out
pressure again.
WA700-3 20-143
(10)
Testing and adjusting Measuring PPC relief valve hydraulic pressure
Measuring PPC relief valve

hydraulic pressure

pressure inside the hydraulic tank.
k Operate the control levers several times to release

the pressure in the PPC accumulator circuit.
• Raise the lift arm, set a support in position under the

lift arm, then remove front frame inspection cover
(1).
Measuring
1. Measuring PPC relief valve pressure
1) Remove plug (2) for measuring the hydraulic
pressure in the dump cylinder circuit of the main
control valve.
2) Install the hydraulic tester kit to the

measurement port.
a Check that there is no oil leaking from any
joint.
a Use a hose which is long enough to reach
the operator’s compartment.
3) Start the engine, raise the lift arm approx. 400

mm from the ground, then operate the control
lever to tilt back the bucket and measure the
pressure when the relief valve is actuated.
k When removing the oil pressure gauge, release

the pressure inside the circuit in the same way
as when installing the gauge.
20-144 WA700-3
(10)
Testing and adjusting Measuring PPC relief valve hydraulic pressure
Adjusting
1. Adjusting PPC relief valve
k Always stop the engine before adjusting the oil

pressure.

k Operate the control levers several times to release

the pressure in the PPC accumulator circuit.
1) Remove cap nut (3) of PPC relief valve (1).
2) Loosen locknut (4), then turn adjustment screw

(5) to adjust.
a Turn the adjustment screw to adjust the
• To INCREASE pressure, turn CLOCKWISE
• To DECREASE pressure, turn COUNTER-
CLOCKWISE
screw: Approx. 0.96 MPa {9.8 kg/cm2}
WA700-3 20-145
(10)
Testing and adjusting Testing and adjusting work equipment hydraulic pressure
Testing and adjusting work

equipment hydraulic pressure

Measuring
1. Measuring work equipment relief pressure
1) Set the bucket so that portion a is raised 30 mm
– 50 mm, then lower portion b to the ground.
2) Stop the engine, then operate the work

equipment control lever, and check that both
bottom surfaces of the bucket (portions a and b)
are in contact with the ground surface.
kAfter lowering the bucket to the ground,

operate the control levers several times to
release the remaining pressure in the
hydraulic piping.
3) Remove oil pressure measurement plug (1)

from the dump cylinder circuit and install the
hydraulic tester kit.
4) Start the engine, raise the lift arm approx. 400

mm, then operate the control lever to tilt back
the bucket, and measure the pressure when the
relief valve is actuated.
k When removing the oil pressure gauge, release

the pressure inside the circuit in the same way
as when installing the gauge.
20-146 WA700-3
(10)
Testing and adjusting Testing and adjusting work equipment hydraulic pressure
Adjusting
k Always stop the engine before adjusting the oil

pressure.
1. Raise the lift arm, set a support in position under the

lift arm, then remove front frame inspection cover
(1).
2. Remove locknut (3) of relief valve (2).
3. Turn adjustment screw (4) to adjust.

a Turn the adjustment screw to adjust the set
• TIGHTEN to INCREASE pressure
• LOOSEN to DECREASE pressure
screw: Approx. 12.6 MPa {Approx. 128 kg/cm2}
a Do not carry out any adjustment if the relief
pressure cannot be measured accurately.
WA700-3 20-147
(10)
Testing and adjusting Bleeding air from piston pump
Bleeding air from piston pump
a If the oil in the hydraulic tank has been changed, or

the piston pump has been removed, or the piston
pump piping has been removed, bleed the air as
follows to prevent seizure of the pump.
1. Check that the oil in the hydraulic tank is at the

upper level.
a The cap of the hydraulic tank remains removing,
until the air bleeding of the piston pump finishes.
2. Loosen plugs (1) and (2) of the tube at the suction

side of the piston pump.
3. Let oil flow out in turn from plugs (1) and (2), and
when the air is completely bled from the piston
pump, tighten the plugs. After that, in order to fill the
inside of the pump with the hydraulic oil, leave it for
10 minutes.
a The oil level in the hydraulic tank is higher than the

positions of parts (1) and (2), so it is possible to
bleed the air easily.
4. Loosen the mouthpiece of the case drain hose (3),

starting an engine at the condition of low idling.
Tighten the mouthpiece, confirming that hydraulic
oil flows from the mouthpiece.
20-148 WA700-3
(10)
Testing and adjusting Adjusting work equipment lever linkage
Adjusting work equipment lever

linkage
If the operating effort or travel of the work equipment
control lever is not within the standard value, or the work
equipment control lever, PPC valve, or bucket solenoid
have been removed, adjust as follows.
a Carry out the adjustment with the engine
stopped.
a Check if the operating effort of the work
equipment lever is within the standard value.
a Remove the side cover at the bottom of the work
equipment lever
1. PPC valve linkage

1) Adjust dimension a from the center-of trunnion
(1) of the PPC valve linkage to the top surface
of the floor.
• Dimension a (target value): 54 mm
2) Loosen nuts (2) and (3), and adjust the
installation height of trunnion (1) so that there is
no play at lever (4).
3) After adjusting, tighten nuts (2) and (3).
2. Work equipment linkage

1) Operate boom lever (5) and adjust rod (8) so
that boom lever cam follower (6) enters the
detent at both ends of cam (7) uniformly and
clearance b is 0 – 1 mm.
a Installed dimension d of rod (8):
337 mm (reference value)
2) Operate bucket lever (9) and adjust rod (12) so
that bucket lever cam follower (10) enters the
detent at both ends of cam (11) without any play
and clearance c is 0 – 1 mm.
a Installed dimension d of rod (12):
337 mm (reference value)
WA700-3 20-149
(10)
Testing and adjusting Adjusting work equipment lever linkage
3. Installation of solenoid
• Do as follows to set boom kickout solenoid (13)
and bucket positioner solenoid (14) at the pulled
(electricity flowing) condition.
i) Disconnect wiring connectors (F05) (15) and
(F06) (16).
a F05 (15): Proximity switch for bucket
positioner
F06 (16): Proximity switch for boom kick-
out
ii) Connect a T-adapter and short circuit the
terminals between connectors (1) and (2).
a Check that the solenoid is pulled 12 mm.
1) Set with boom kickout solenoid (13) pulled, then

move the solenoid so that clearance e between
boom lever cam (7) and cam follower (6) is 0 –
0.5 mm.
a Adjust with the boom lever at HOLD.
2) Set with bucket positioner solenoid (14) pulled,

then move the solenoid so that clearance f
between bucket l ever cam (11) and cam
follower (10) is 0 – 0.5 mm.
a Adjust with the bucket lever at HOLD.
3) If the operating effort for releasing the boom

lever and bucket lever lever is not within 23.5 N
{2.4 kg}, change the position of the mounting
holes (4 places) of spring (17) to adjust the
release effort.
a When the machine is shipped from the
factory, the spring is hooked to the 2nd
mounting hole from the top.
4) After adjusting, operate the boom lever and

bucket lever and check that the work equipment
moves normally.
20-150 WA700-3
(10)
Testing and adjusting Testing and adjusting bucket positioner
Testing and adjusting bucket

positioner
a Engine water temperature: Within green range on
Testing
1. With the engine stopped, check that clearance a
between proximity switch (1) and detector bar (2) is
the standard value.
a Clearance a: 3 – 5 mm
2. Start the engine, run at high idling and check the

actuating position.
(Check three times and take the average.)
Adjusting
1. Lower the bucket to the ground, set the bucket to
the desired digging angle, return the lever to the
HOLD position, and stop the engine.
2. Adjust nut (4) of the switch so that clearance b

between the tip of switch protector (3) and the sens-
ing surface and the switch is the standard value,
then secure in position.
3 Proximity switch mounting nut:

• Standard clearance b: 0.5 – 1.0 mm
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
3. Secure detector bar (2) in position so that clearance

a between the sensing surface of proximity switch
(1) and detector bar (2) is the standard value.
a Adjust so that the clearance a is within the
standard value for the whole stroke of detector
bar (2).
4. Secure switch protector (3) to the bucket cylinder so

that tip c of detector bar (2) matches the center of
proximity switch (1).
a After adjusting, operate the bucket lever and
check that the bucket positioner is actuated at
the desired position.
WA700-3 20-151
(10)
Testing and adjusting Testing and adjusting boom kick-out
Testing and adjusting boom

kick-out
a Engine water temperature: Within green range on
Testing
1. With the engine stopped, check that clearance a
between proximity switch (1) and sensor plate (2) is
the standard value.
2. Start the engine, run at high idling and check the

actuating position.
(Check three times and take the average.)
Adjusting
1. Raise the boom to the desired height, then mark the
boom to show the position where the center of prox-
imity switch (1) is at the top of sensor plate (2).
k Always be sure to apply the safety lock to the

work equipment control lever.
2. Lower the boom and stop the engine.
3. Align the marks and adjust the position of sensor

plate (2) so that the center of proximity switch (1) is
at the top of sensor plate (2), then secure in posi-
tion.
4. Adjust proximity switch (1) so that clearance a

between the sensing surface of proximity switch (1)
and sensor plate (2) is the standard value, then
secure in position.
3 Proximity switch mounting nut:

• Standard clearance b: 0.5 – 1.0 mm
14.7 – 19.6 Nm {1.5 – 2.0 kgm}

a After adjusting, operate the boom lever and
check that the boom kickout is actuated at the
desired position.
20-152 WA700-3
(10)
Testing and adjusting Testing proximity switch actuation pilot lamp
Testing proximity switch

actuation pilot lamp
Proximity switch actuation pilot lamp (red)
The proximity switch is equipped with a pilot lamp which
shows when it is being actuated, so use this when
adjusting.
Proximity switch
Lights up Goes out
actuation pilot lamp
When detector is positioned at detection When detector has moved away from
Detector position
surface of proximity switch detection surface of proximity switch
Bucket positioner
Boom kick-out
WA700-3 20-153
(10)
Testing and adjusting Adjusting main monitor (speedometer module)
Adjusting main monitor

(speedometer module)
• The speedometer on the main monitor is a common
part for all machines, and the input signal for the
travel speed differs according to the machine, so it is
necessary to adjust the monitor for use with the
particular model.
• In addition, the tire diameter also differs according to
the type of tire fitted, so it is necessary to adjust to
give the correct travel speed.
Adjustment procedure
• Turn off the power, then remove the machine
monitor and adjust the switches at the back of the
speedometer.
1. Setting machine model

1) Remove the rubber caps from dipswitches (1),
(2) and (3) at the back of the speedometer.
2) When the rubber cap is removed, a rotary
switch can be seen inside. Using a flat-headed
screwdriver, turn this switch to adjust it to the
settings in the table below.
DIP SW 1 DIP SW 2 DIP SW 3
(speedo- (tacho-
Tire size (model
meter meter input
selection)
correction) selection)
46/65-39-36PR 7 7 0
3) After completing the adjustment, fit the rubber

caps securely and install the main monitor.
Reference
Amount of correction for switch (2)
Switch position 0 1 2 3 4 5 6 7
Amount of
+14 +12 +10 +8 +6 +4 +2 0
correction (%)
Switch position 8 9 A B C D E F
Amount of
0 –2 –4 –6 –8 –10 –12 –14
correction (%)
a DIP SW4 is set as shown in the table below when

DIP SW4
delivered. Serial No. Specification
If it is changed, machine system will not work nor- 1 2 3 4
mally. Accordingly, do not change it. Without auto
ON ON OFF ON
When the main monitor is replaced, check the set- 50001 – shift system
ting of DIP SW4. 51000 With auto
ON ON OFF OFF
shift system
Without auto
ON ON ON ON
54001 and shift system
up With auto
ON ON ON OFF
shift system
20-154 WA700-3
(10)
Testing and adjusting Bleeding air
Bleeding air
1. Bleeding air from brake system
1) After charging the accumulator, stop the engine,

insert vinyl hose (2) into bleeder screw (1), and
put the other end in a container.
2) Depress the brake pedal, then loosen bleeder
screw (2) and bleed the air. Tighten bleeder
screw (1), then slowly release the brake pedal.
a When depressing the brake pedal, use the
left pedal.
3) Repeat the above operation, and when no more
bubbles come out with the fluid from vinyl hose
(2), depress the pedal fully and tighten bleeder
screw (1) while the oil is still flowing.
4) Repeat the procedure to bleed the air from each
brake cylinder.
a To bleed the air completely, start with the
brake cylinder that is farthest from the brake
pedal.
a If the accumulator pressure goes down,
start the engine and charge the accumulator
again.
a Repeat the operation to bleed the air from
the other cylinders, and after completing the
operation, check the level in the oil tank and
add more oil if necessary.
2. Bleeding air from hydraulic cylinders

1) Start the engine and run at idling for approx. 5
minutes.
2) Run the engine at low idling, then raise and
lower the boom 4 – 5 times in succession.
a Operate the piston rod to a point approx.
100 mm before the end of its stroke. Do not
relieve the circuit under any circumstances.
3) Run the engine at full throttle and repeat Step
2). After that, run the engine at low idling, and
operate the piston rod to the end of its stroke to
relieve the circuit.
4) Repeat Step 2) and 3) to bleed the air from the
bucket and steering cylinder.
a When the cylinder has been replaced, bleed
the air before connecting the piston rod.
WA700-3 20-155
(10)
Testing and adjusting Releasing remaining pressure in hydraulic circuit
Releasing remaining pressure in

hydraulic circuit
1. Releasing remaining pressure between each
hydraulic cylinder and control valve
a If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure from the circuit as
follows.
1) Stop the engine.
2) Loosen the oil filler cap slowly to release the
pressure inside the tank.
3) Operate the control levers.
a When the levers are operated 2 – 3 times,
the pressure stored in the PPC accumulator
is removed. Start the engine, run at low
idling for approx. 5 minutes, then stop the
engine and operate the control levers.
a Repeat the above operation 2 – 3 times to
release all the remaining pressure.
2. Releasing remaining pressure in brake accumu-

lator circuit
a If the piping between the brake accumulator and
parking brake solenoid valve, between the
accumulator and accumulator check valve, or
between the accumulator and brake valve was
disconnected, release the remaining pressure
from the circuit as follows.
1) Stop the engine.
2) Depress the brake pedal at least 100 times to
release the pressure inside the brake
accumulator circuit.
3. Releasing remaining pressure in PPC circuit

a If the piping between the PPC relief valve and
PPC valve is to be disconnected, release the
remaining pressure from the circuit as follows.
• Operate the control levers 2 – 3 times to release
the remaining pressure in the circuit.
20-156 WA700-3
(10)
Testing and adjusting Basic precautions
Basic precautions
always supplies electricity (permanent
1. Handling machine, safety, inspection and power source) in addition to the power
maintenance source (switch power source) that is cut
For details of safety items, operation, inspection, when the starting switch is turned OFF or
and maintenance of the machine, see the Oper- the engine is stopped.
ation and Maintenance Manual for the machine. Because this switch power source and per-
manent power source are provided, the
2. Handling monitoring system period needed for collecting data is clearly
Always obey the following precautions when known and it becomes possible to store this
handling the monitoring system. data in the internal memory.
1) When disassembling, repairing, or modifying In other words, the VHMS uses the perma-
the machine or system, follow the nent power source to save to memory the
instructions in the manual. data accumulated from the moment the
2) Do not touch the system (equipment) when starting switch is turned ON to the moment
operating the machine. the starting switch is turned OFF. Then the
3) Do not damage or get the wiring harnesses, VHMS controller itself turns off the perma-
connectors, or sensors of the system nent power source.
(equipment) caught or pulled by force. This 2) Precautions when turning the permanent
may cause short circuits or disconnections power source OFF
that will lead to failure or fire on the machine When the starting switch is turned OFF, the
or system (equipment). power supply is maintained for at least 3
4) Do not get water, dirt, or oil on the system minutes (the VHMS system shut-down time:
(equipment). the time taken for the VHMS system to save
the data to memory and switch off), and
3. Permanent power source for VHMS (battery then the permanent power source is turned
direct power source) OFF.
1) Meaning and need of permanent power If the VHMS system shut-down time is
source shorter than 3 minutes, the accumulated
The VHMS has the function of checking data may be damaged.
and collecting data on the condition of the i) When removing VHMS from permanent
machine from the moment the starting power source
switch is turned ON to the moment the start- When removing the VHMS from the per-
ing switch is turned OFF. Therefore, its manent power source (for example,
power supply is different from many of the when carrying out repairs), check that
electronic equipment and electrical parts. the monitor display (7-segment LED in
For the system to provide the above func- the diagram below) of the VHMS con-
tions, it is necessary to have a power supply troller is out.
that is connected directly to the battery and
WA700-3 20-157
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ii) When installing battery isolator or other

battery shut-down device
a. Basic connections
It is a basic assumption that the
engine stop switch is a type that will
not shut off the permanent power
source when the engine is stopped.
b. When safety regulations for user
make it impossible to avoid shutting
down all electric power
• Install a battery isolator so that
the permanent power source is
kept in the specified condition
for at least 3 minutes after the
starting switch is turned OFF
before the permanent power
source is shut down.
• If there is no timer, wait for at
least 3 minutes before turning
off the permanent power
source.
• If the above shut-down time is
shorter than 3 minutes, the
accumulated data may be
damaged.
4. Precautions when VHMS power source is ON

• For the first few seconds after the power is
switched ON, the VHMS controller carries
out the initial check (LEDs flash). Do not car-
ry out any of the following operations until the
initial check is completed.
• Operation of manual snapshot switch
• Downloading from PC
(Check that the LEDs are displaying the
aggregate numerals in turn before
operating.)
5. Precautions when replacing VHMS and

transmission controller
1) Before starting replacement
i) Download VHMS data
When the VHMS controller is replaced,
the data collected up to that point is lost,
so be sure to download the accumu-
lated data before starting the replace-
ment operation.
Next, send the accumulated data to
"WebCARE".
For details of the method of download-
ing, see the separate instruction manual
for the technical analysis tool box.
20-158 WA700-3
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ii) Specified method of shutting down

VHMS power source
a. Use the starting switch to turn the
normal power source OFF
b. Maintain the permanent power
source in the specified condition for
at least 3 minutes.
c. Turn the permanent power source
(battery direct) OFF.
2) Method of replacement, action after
replacement
When replacing the VHMS controller, be
careful not to subject the VHMS controller or
wiring harnesses to any excessive force or
impact, and carry out the initial setup. For
details, see the separate instruction manual
for the technical analysis tool box.
6. Handling communications controller (ORB :

Orbcomm)
1) The ORB controller must be used. If the
ORB controller is not used, it is impossible
to carry out the request to open communica-
tions before starting to use.
If the control power is turned on before com-
pleting the request, the transmission will be
unauthorized and there will be problems
with the communications system.
If there are any problems or any part is
unclear, please contact Komatsu or the per-
son responsible for operation.
2) Finally, turn on the ORB power ON (connect
the connector). After the VHMS controller
confirmation is completed, connect the ORB
controller connector (ORB-A, ORB-B).
WA700-3 20-159
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Testing and adjusting Outline
Outline
a It is also possible to add this system to a machine that has already been shipped.
1. Basic structure (1)
20-160 WA700-3
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2. Basic structure (2)
WA700-3 20-161
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3. Position of equipment
Install monitoring controller (VHMS controller)
(1) on the machine, and collect the operation
data for the engine, transmission, and PLM.
1) Data collection function
i) Data from connected sensors
• Engine oil temperature {Sensor (2)}
• Exhaust temperature {Sensor (3)}
• Blow-by pressure {Sensor (4)}
• Transmission pump oil pressure
{Sensor (5)}
• Atmospheric temperature
{Sensor (6)}
• Work equipment pump oil pressure
{Sensor (7)}
• Steering pump oil pressure
{Sensor (8)}
• Work equipment oil temperature
{Sensor (9)}
• Brake oil pressure {Sensor (10)}
• Brake oil temperature {Sensor (11)}
20-162 WA700-3
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WA700-3 20-163
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ii)
Data from controller mounted on machine
• Engine speed
• Fuel injection amount
• Engine oil pressure
• Data from transmission controller
• SMR (service meter)
2) Saving data
• The above data is saved to memory.
20-164 WA700-3
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3) External communication function

• Connect the PC (personal computer) to
the VHMS controller, download the data,
and transmit the data through the
Internet.
• Send the data automatically from remote
areas through the communications
satellite (ORB).
(12): Ground level download connector
(13): Download connector inside cab
2 Antenna mount:
(14): Communications antenna/pole
Thread tightener (LT-2)
WA700-3 20-165
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Testing and adjusting Setting up VHMS controller
Setting up VHMS controller

1. Setting up VHMS controller 2. Setting items
• In the following cases, always carry out the • VHMS: For details of the setup method, see
setup. the instruction manual for the technical anal-
1) When making the initial installation of ysis tool box (for service).
the VHMS system 1) Calendar (data, time, time difference
2) When replacing or overhauling the from GM T, s umme r ti me ( day lig ht
following components saving time))
• VHMS controller 2) Machine model, Serial No., variation
• Engine code
• Transmission 3) Engine model, Serial No.
• PLM II (if equipped) 4) Transmission Serial No.
• When carrying out the setup, the following
are needed
1) PC (personal computer)
2) VHMS analysis tool (software)
(799-608-3211)
3) Download cable (799-608-3220)
• For details of the setup method, see
the i nstr uc tion ma nual for the
technical analysis tool box (for
service).
• The setup operation is carried out by
trained personnel under the
guidance of the person responsible
at your company.
• Or contact Komatsu.
3. Setup flow (outline)
Procedure Method (specific content, points to remember, etc.)
Turn starting switch ON Check that no error is generated by the VHMS controller or other
1 • Check for generation of errors controller
• Start setup tool If there is any error, repair or correct to return condition to normal
• Calendar (data, time, time difference from GMT, summer time
(daylight saving time))
2 Setting up VHMS • Machine model, Serial No., variation code
• Engine model, Serial No.
• Transmission Serial No.
3 Starting switch OFF • Saving settings
4 Starting switch ON • Checking VHMS functions
Start engine • Performing test (quick PM)
5 Test (quick PM) • Downloading
Starting switch OFF • Checking data (content of data)
• Checking operation of Orbcomm
Starting switch ON
• Setting up communications
6 • Check for errors
(need for communications file, communications frequency, GCC
• Start setup tool
code)
• Setup completion report, content of setup (data), sending checksheet
7 Starting switch OFF
• Sending download data
20-166 WA700-3
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Testing and adjusting Setting up VHMS controller
4. Checking operation, actuation

a Check the functions of the VHMS system as follows.
Start
Turn starting switch to [ON] position
Display Display
VHMS controller starts up, LEDs flash
Engine, transmission controllers show
(see diagram below) and aggregate
Normal past errors, then give [00] display (no Normal
numerals are displayed in order (no
error exists)
error exists)
No display No display
Turn starting switch [OFF], then check connection of wiring harnesses again
Turn starting switch again to [ON] position
Display Display
VHMS controller starts up, LEDs flash
Engine, transmission controllers show
(see diagram below) and aggregate
Normal past errors, then give [00] display (no Normal
numerals are displayed in order (no
error exists)
error exists)
No display No display
Abnormality in machine syastem Possible abnormality in VHMS cont-

See troubleshooting of shop manual roller
5. Collection of data
a If there is no abnormality in the system, the machine will operate and the operation data for the machine
will automatically be saved by the VHMS controller.
WA700-3 20-167
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Testing and adjusting Collection, transmission of data
Collection, transmission of data

1. Collection of data
1) Downloading with PC (personal computer) a For details of downloading and sending
<Necessary tools> the data, see the instruction manual for
• PC (personal computer) the technical analysis tool box (for
• VHMS analysis tool (software) service).
(799-608-3211) 2) Automatic transmission by communications
• Download cable (799-608-3220) satellite (machines with Orbcomm
When using a PC to download the collected specification)
data, send the data to the file server in the • Error data and other specified data are
computer center by e-mail (Internet). automatically sent by communications
(There are limitations to the capacity of sat- satellite to the file server in the computer
ellite communications, so use this method to center.
send all the data.)
2. Setup flow (outline)
Procedure Method (specific content, points to remember, etc.)
Turn starting switch ON (starting switch ON)

Check that no error is generated by VHMS controller or other controller
1 • Check for generation of errors
If there is any error, repair or correct to return condition to normal
• Start setup tool
• Checking satellite communications data, setting communications fre-
2 Setting up communications quency
• Setting GCC code
• Saving set values
3 Starting switch OFF (turn key to OFF)
• Reporting completion of setup
3. Carrying out quick PM

a For details, see Testing and adjusting,
Performing PM clinic using manual snapshot.
• To collect data under the normal working
conditions, and to collect data when operat-
ing under such conditions as torque convert-
er stall or high idle, carry out the quick PM
(equivalent to PM clinic) before downloading
with the PC.
4. Method of downloading with PC (personal

computer)
k To ensure safety, stop the machine on flat
ground and put blocks under the tires to
k When turning the starting switch ON, check

prevent the machine from moving.
that the parking brake is ON and that the
k Sound the horn to warn people in the

gearshift lever is at the N position.
surrounding area before starting the engine.

a For details of the method of using the PC,
see the instruction manual for the technical
analysis tool box (for service).
<Preparatory work>
• Prepare a PC for downloading and a download
wiring harness.
a The download connectors are provided in 2
places: rear of operator’s seat inside cab (13)
and behind front left tire of machine (12).
20-168 WA700-3
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<Downloading from connector inside cab> <Downloading from ground level connector>
1) Remove the connected wiring harness and 1) Remove the clamp at the top of the download
install the download cable. box.
2) Connect the other end of the download wiring 2) Use the engine key to open the cover at the
harness to the PC. front of the box.
3) Turn the machine starting switch ON, check that 3) Remove the cap of the download connector (12)
the monitor controller is working, then download and install the download cable.
to the PC. 4) When turn (wake-up) switch (15) is turned, the
a To check that the VHMS controller is VHMS is actuated and pilot lamp (16) lights up.
working, check that the VHMS controller 5) Check that pilot lamp (16) is lighted up, then
starts up, LEDs flash (see diagram below), carry out the PC download.
and aggregate numerals are displayed in 6) When [complete] is displayed on the download
order. PC, the download operation is completed.
4) When [complete] is displayed on the download 7) Return the turn switch to its original position,
PC, the download operation is completed. remove the download cable, then install the cap.
5) Turn the machine starting switch OFF, then turn 8) Check that pilot lamp (16) is out, then close the
the PC power OFF, remove the download cable, box cover. If the turn switch is not off, the cover
and return the wiring harness to its original will not close.
condition. 9) Turn the engine key and lock the front cover.
Close the clamps at the top of the box also.
5. Types of data collection files

1) Index file : This records the common data for the machine model, serial No., and service meter
(SMR).
2) VHMS history : This records changes in the VHMS.
3) Machine history : This records the actual engine operation data.
4) Fault history : This records errors that occurred in order of occurrence.
5) Trend analysis : This records the maximum or minimum values for each measurement device at the
specified intervals. (See Table 1)
6) Trend analysis 2 : This records the trends for the torque converter and transmission oil temperatures. (see
Table 2)
7) Snapshot : This records the data for a specified time before and after the occurrence of an error
(see Table 3.1, 2)
8) Load map : This records the frequency of the applicable area, taking the engine speed and fuel
injection amount as the axes
9) Cycle interval : This records the aggregate frequency of the changes in engine speed
10) Running area : This records the operation distribution for each area on the engine performance graph
11) Running direction: This records the track of movement for each area on the engine performance graph
12) Transmission shift change map : This records the transmission gearshift data
13) Transmission fill time trend : This records the transmission clutch engagement time data (See table 4)
14) Payload data (if equipped) : This records the payload meter data
15) Payload data cycle (if equipped) : This records the operating cycle data for the machine
WA700-3 20-169
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Trend data items
Table 1: Trend analysis data

No. Item Content Unit Data collection point Remarks
1 SMR Service meter h
2 Calendar Calendar y/m/d h:m:s
Maximum value within
3 Engine speed max. Engine speed (max.) rpm Engine controller
set trend data
Crankcase internal pressure (Every 20 hours) See
4 Blow-by press. max. Blow-by pressure (max.) mmAg
sensor as below
5 F. Exh. temp. max. Front engine exhaust temperature (max.) deg C Exhaust temperature sensor
6 R. Exh. temp. max. Rear engine exhaust temperature (max.) deg C Exhaust temperature sensor
7 E. oil press. max. Engine oil pressure (max.) kg/cm2 Engine controller
8 E. oil P. L min. Engine oil pressure at low idle (min.) kg/cm2 Engine controller
9 E. oil P. H min. Engine oil pressure at high idle (min.) kg/cm2 Engine controller
10 Eng. oil temp. max. Engine oil temperature (max.) deg C Engine oil temperature sensor
11 Fuel rate Fuel consumption rate (average) Liter/h Engine controller
12 Cool temp. max. Engine coolant temperature (max.) deg C Engine controller
13 Cool temp. min. Engine coolant temperature (min.) deg C Engine controller
Engine controller
14 Ambient temp. max. Ambient temperature (max.) deg C
(ambient temperature sensor)
Engine controller
15 Ambient temp. ave. Ambient temperature (average) deg C
Engine controller
16 Ambient temp. min. Ambient temperature (min.) deg C
17 Atmos. press. ave. Atmospheric pressure (average) hPa Engine controller
18 F. brake P. max. Front brake oil pressure (max.) kg/cm2 Retarder controller
19 R. brake P. max. Rear brake oil pressure (max.) kg/cm2 Retarder controller
Table 2: Machine trend data

T/C oil temp. 120–
Time of use for each torque converter oil
3 T/C oil temp. 130– Transmission controller
temperature
T/C oil temp. 140–
sec.
Rtrdr. oil temp. T120–
Time of use for each retarder oil temper-
4 Rtrdr. oil temp. T130– Retarder controller
ature
Rtrdr. oil temp. T140–
Table 3.1 Observation items (trigger items) for auto snapshot

No. Content Failure code No. Content Failure code
No. 1,2,3 cylinder exhaust temperature 11 Problem with No. 2 clutch 15L0MW(b025)
1 F@BYNS(M361)
is high (stage 1) 12 Problem with No. 3 clutch 15M0MW(b026)
No. 4,5,6 cylinder exhaust temperature 13 Problem with No. 4 clutch 15N0MW(b027)
2 F@BZNS(M371)
is high (stage 1)
14 Problem with engine speed senser C115KZ
3 Blow-by pressure is high F@BBZL(M338)
15 Overheating of water C151NS
No. 1,2,3 cylinder exhaust temperature
4 F@BYNR(M362) 16 Overheating of fuel C261NS
is high (stage 2)
No. 4,5,6 cylinder exhaust temperature 17 Overheating of torque converter B@CENS(A0d2)
5 F@BZNR(M362)
is high (stage 2) 18 Overheating of rear brake oil B@C7NS(A0d4)
6 Double meshing of transmission clutch 1500L0(b005) 19 Overrun A00N1(M201)
7 Problem with lock-up clutch 1380MW(b021) 20 Abnormal drop in engine oil pressure C143ZG
8 Problem with High clutch 15H0MW(b022)
9 Problem with Low clutch 15J0MW(b023)
10 Problem with No. 1 clutch 15K0MW(b024)
20-170 WA700-3
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Table 3.2 Data items for manual snapshot

1 Time Elapsed time sec. VHMS
2 Eng. speed Engine speed rpm Engine controller
3 Fuel inject Fuel injection amount mm3/st Engine controller
Crankcase internal pressure
4 Blow-by press. Blow-by pressure mmAg
sensor
Exhaust temperature (No. 1,2,3 cylin-
5 F. exh. temp. deg C Exhaust temperature sensor
ders)
Exhaust temperature (No. 4,5,6 cylin-
6 R. exh. temp. deg C Exhaust temperature sensor
ders)
7 Eng. oil. press. Engine oil pressure kg/cm2 Engine controller
8 Eng. oil. temp. Engine oil temperature deg C Oil temperature sensor
9 Eng. cool. temp. Engine coolant temperature deg C Engine controller
Engine controller (ambient
10 Ambient temp. Ambient temperature deg C
temperature sensor)
11 Boost press. Engine boost pressure mmHg Engine controller
12 Accelerator pos. Accelerator angle % Engine controller
FLOAT = 0, HOLD = 1,
LOWER = 2, RAISE = 3,
13 Hoist lev. pos. Hoist lever position — Retarder controller
Max height = 4,
Other = 5
14 T/C oil temp. Torque converter oil temperature deg C Transmission controller
Transmission output shaft
15 T/M out. speed Transmission output speed rpm
speed sensor
R = 10, N = 0, F1 = 1,
16 Shift indicator Gearshift range (position) — Transmission controller
••• F7= 7
17 Lockup signal Lock-up clutch ON-OFF Transmission controller
18 Retarder temp. Retarder oil temperature deg C Retarder controller
19 F. brake press. Front brake oil pressure kg/cm2 Retarder controller
2
20 R. brake press. Rear brake oil pressure kg/cm Retarder controller
21 Retarder position Retarder brake use ON-OFF Retarder controller
22 Foot brake position Foot brake use ON-OFF Retarder controller
Table 4: Transmission trend data

Trig. time Low
(fill time)
Trig. time High
(fill time)
Trig. time Rev.
(fill time)
Trig. time 4th
3 Transmission fill-up time msec. Transmission controller (Every 200 h)
(fill time)
Trig. time 3rd
(fill time)
Trig. time 1st
(fill time)
Trig. time 2nd
(fill time)
WA700-3 20-171
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6. Confirming data <Checking quick PM data>

For details of the method of confirming the data, • Engine speed (high idle, torque converter stall)
see the instruction manual for the technical • Blow-by pressure (high idle, torque converter
analysis tool box. stall)
a Check that each file has been saved. Check • Exhaust temperature (torque converter stall)
also that there is no abnormal data. • Engine oil pressure (low idle, high idle, torque
a Compare the quick PM data and the PM converter stall)
clinic data to check that there are no • Engine oil temperature (no PM data: reference
abnormal values. value)
a After downloading, if there is no problem with
the data, clear only the snapshot data.
For details of the method of clearing, see
the instruction manual for the technical anal-
ysis tool box (for service).
20-172 WA700-3
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Inspection and maintenance
Testing and adjusting Replacing parts
Inspection and maintenance Replacing parts

1. Inspection interval: Inspection and If initial setup of VHMS system has been made or
maintenance interval for machine VHMS controller has been replaced
Check the system at the same time as carrying If the system has been newly installed or the VHMS
out maintenance on the machine. controller or other components (transmission,
engine, etc.) have been replaced, it is necessary to
2. Inspection items carry out the initial setup of the system.
a Carry out inspection and maintenance, and • Necessary tools
take the necessary action if there are any 1) PC (personal computer)
abnormalities. 2) VHMS analysis tool (software) (799-608-
1) Checks before starting (ask the customer 3211)
also to carry out this inspection) 3) Download cable (799-608-3220)
i) Check that the sensors are installed • For details of the setup method, see the
properly. (Check that there are no loose, instruction manual for the technical analysis tool
damaged, or dirty mounts) box (for service).
• Engine oil temperature sensor • The setup operation is carried out by trained per-
• Exhaust temperature sensor sonnel under the guidance of the person respon-
• Blow-by pressure sensor sible at your company. Or contact Komatsu.
• Transmission pump oil pressure
sensor When replacing communications controller
• Atmospheric temperature sensor • In the following cases, there are important
• Work equipment pump oil pressure procedures to be carried out, such as opening
sensor and closing of the communications controller, so
• Steering pump oil pressure sensor follow the instruction of the person in charge at
• Work equipment oil temperature your company. Or contact Komatsu.
sensor 1) When replacing the controller installed on
• Brake oil pressure sensor the machine with another controller.
• Brake oil temperature sensor 2) When removing the controller installed on
• Communications antenna one machine and installing it on another
ii) Check that there are no disconnected or machine.
damaged wiring harnesses, cables, or 3) When disposing of the controller.
connectors. 4) When giving away or selling the machine
iii) Check that there is no leakage of oil or with the controller installed.
gas from the sensor mounts. 5) When disposing of a machine with a control-
2) Every 1,000 hours service ler installed.
i) Communications antenna
• Check that there is no looseness at
the antenna mount.
• Check that there is no damage or
looseness of the antenna itself.
• If there is any abnormality, replace
the antenna.
3) When required
i) If there is any abnormality in the
downloaded values, check all sensors.
3. Remedy
If there is any abnormality, repair, replace, or
reinstall (tighten).
WA700-3 20-173
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Troubleshooting
Points to remember when troubleshooting ................................................................................................. 20-202

Sequence of events in troubleshooting ....................................................................................................... 20-203
Points to remember when carrying out maintenance.................................................................................. 20-204
Checks before troubleshooting ................................................................................................................... 20-212
Connector types and mounting locations .................................................................................................... 20-214
Connector arrangement diagram ................................................................................................................ 20-220
Connection table for connector pin numbers .............................................................................................. 20-231
Electric engine throttle controller system .................................................................................................... 20-254
Method of displaying action code and failure code ..................................................................................... 20-257
Chart of action codes and failure codes, and re-enaction........................................................................... 20-259
Transmission controller LED display........................................................................................................... 20-261
Method of using troubleshooting charts ...................................................................................................... 20-262
Troubleshooting of engine body (S mode) .................................................................................................. 20-301
Troubleshooting of main monitor system (M mode) .................................................................................... 20-351
Troubleshooting of maintenance monitor system (K mode)........................................................................ 20-401
Troubleshooting of electrical system (E mode) ........................................................................................... 20-451
Troubleshooting of electric engine throttle controller & APS controller system system (G mode) .............. 20-551
Troubleshooting of hydraulic and mechanical system (H mode) ................................................................ 20-601
Troubleshooting of transmission control system (T mode) ......................................................................... 20-651
Troubleshooting of joystick steering controller system (J mode) ................................................................ 20-751
Troubleshooting of AJSS (advanced joystick steering system) control system (A mode) .......................... 20-801
Troubleshooting of engine control system (EA mode) ................................................................................ 20-851
Troubleshooting of VHMS controller system (VHMS mode) ..................................................................... 20-1001
WA700-3 20-201
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Troubleshooting Points to remember when troubleshooting
Points to remember when troubleshooting

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k 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.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
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 3) Check the travel of the control levers.
hurry to disassemble the components. 4) Check the stroke of the control valve spool.
If components are disassembled immediately 5) Other maintenance items can be checked
any failure occurs: ex t ern al l y, s o ch eck a ny i t e m t h at i s
• Parts that have no connection with the failure considered to be necessary.
or other unnecessary parts will be
disassembled. 4. Confirming failure
• It will become impossible to find the cause of • Confirm the extent of the failure yourself, and
the failure. judge whether to handle it as a real failure or
It will also cause a waste of manhours, parts, or as a problem with the method of operation,
oil or grease, and at the same time, will also lose etc.
the confidence of the user or operator. a When operating the machine to reenact
For this reason, when carrying out troubleshoot- the troubleshooting symptoms, do not
ing, it is necessary to carry out thorough prior carry out any investigation or measure-
investigation and to carry out troubleshooting in ment that may make the problem worse.
accordance with the fixed procedure.
5. Troubleshooting
2. Points to ask user or operator • Use the results of the investigation and
1) Have any other problems occurred apart inspection in Items 2 – 4 to narrow down the
from the problem that has been reported? causes of failure, then use the
2) Was there anything strange about the troubleshooting flowchart to locate the
machine before the failure occurred? position of the failure exactly.
3) Did the failure occur suddenly, or were there a The basic procedure for troubleshooting
problems with the machine condition before is as follows.
this? 1) Start from the simple points.
4) Under what conditions did the failure occur? 2) Start from the most likely points.
5) Had any repairs been carried out before the 3) Investigate other related parts or
failure? information.
When were these repairs carried out?
6) Has the same kind of failure occurred 6. Measures to remove root cause of failure
before? • Even if the failure is repaired, if the root
cause of the failure is not repaired, the same
3. Check before troubleshooting failure will occur again.
1) Check the oil level To prevent this, always investigate why the
2) Check for any external leakage of oil from problem occurred. Then, remove the root
the piping or hydraulic equipment. cause.
20-202 WA700-3
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Troubleshooting Sequence of events in troubleshooting
Sequence of events in troubleshooting
WA700-3 20-203
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Troubleshooting Points to remember when carrying out maintenance
Points to remember 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 gear oil and hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing 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 care-
ful when handling wiring harnesses.
TEW00191
Main failures occurring in wiring harness

1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to Improper insertion
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
oxidization of the contact surfaces.
TEW00192
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors Crimped portion
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
TEW00193
20-204 WA700-3
(10)
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
TEW00194
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water
should get into the connector, the pins will TEW00195
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.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con- TEW00196
tact restorer.
a When wiping the mating portion of the
c o n n e ct o r , b e c a r e f u l n o t t o u s e
excessive force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compress ed air completely before
cleaning with compressed air.
WA700-3 20-205
(10)
2) Removing, installing, and drying connectors

and wiring harnesses
• Disconnecting connectors
1) Hold the connectors when disconnecting.
Press lightly
When disconnecting the connectors, hold when removing
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw Lock stopper
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull TEW00197
the connectors apart.
a Never pull with one hand.
2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
a If the connector is twisted up and down
or to the left or right, the housing may
break.
TEW00212
Stopper
TEW00213
3) 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.
a If the machine is left disassembled for a
long time, it is particularly easy for
improper contact to occur, so always
cover the connector.
TEW00198
20-206 WA700-3
(10)
• Connecting connectors
1) Check the connector visually.
i) Check that there is no oil, dirt, or water
stuck to the connector pins (mating
portion).
ii) Check that there is no deformation,
defective contact, corrosion, or damage Cliks into position
to the connector pins.
iii) Check that there is no damage or
breakage to the outside of the
connector.
a If there is any oil, water, or dirt stuck to TEW00199
the connector, wipe it off with a dry cloth.
If any water has got 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.
a If there is any damage or breakage,
replace the connector.
2) Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position. TEW00200
3) Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
4) If the connector clamp has been removed,

be sure to return it to its original position. TBW00487
Check also that there are no loose clamps.
• Since the DT 8-pole and 12-pole heavy duty wire

connectors have 2 latches respectively, push
them in until they click 2 times.
1. Mail connector, 2 Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
WA700-3 20-207
(10)
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
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 fol-

lows.
1) Disconnect the connector and wipe off the
water with a dry cloth.
a If the connector is blown dry with TEW00196
compressed air, there is the risk that oil
in the air may cause defective contact,
so remove all oil and water from the
compressed air before blowing with air.
2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or
related parts too hot, as this will cause
deformation or damage to the
connector.
TEW00202
3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
a After completely drying the connector,
b l ow i t w i t h c on t a ct r e s t or er a n d
reassemble. T-adapter
TEW00203
20-208 WA700-3
(10)
3) Handling control box

1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.
TEW00204
3) Do not place objects on top of the control

box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with
your hand.
5) During rainy weather, do not leave the
control box in a place where it is exposed to
rain.
TEW00205
6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand)
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc
welding ground close to the welding point.
TEW00206
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in that circuit.
WA700-3 20-209
(10)
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
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. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a s pec ially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test TEW00207
equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
TEW00208
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 clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
TEW00209
20-210 WA700-3
(10)
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. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Flushing oil
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
TEW00210
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c ont r ol v al v e , et c . ) or w he n r un ni ng t h e
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
TEW00211
WA700-3 20-211
(10)
Troubleshooting Checks before troubleshooting
Checks before troubleshooting
Judgement
Item Remedy
standard
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain

Lubricating oil, cooling water
3. Check hydraulic oil level — Add oil
4. Check hydraulic filter (Torque converte, Transmission hydraulic oil) — Clean, drain
5. Check brake oil level — Add oil
6. Check engine oil level — Add oil
7. Check coolant level — Add water
8. Check dust indicator for clogging — Clean or replace
9. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace

equipment
Electrical
10. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
12. Check operation of instruments — Repair or replace

Hydraulic, mechani-
13. Check for abnormal noise, smell — Repair

cal equipment
14. Check for oil leakage — Repair
15. Carry out air bleeding — Bleed air
16. Check effect of parking brake, wheel brake — Repair or replace
17. Check battery voltage (engine stopped) 24 – 26 V Replace
18. Check battery electrolyte level — Add or replace

Electrics, electrical equipment
19. Check for discolored, burnt, exposed wiring — Replace
20. Check for missing wiring clamps, hanging wiring — Repair
21. Check for water leaking on wiring (be particularly careful attention to Disconnect
—
water leaking on connectors or terminals) connector and dry
22. Check for blown, corroded fuses — Replace
23. Check alternator voltage (engine running at 1/2 throttle or above)

(If the battery charge is low, the voltage may be approx. 25V 28.5 – 29.5 V Replace
immediately after starting.)
24. Sound of actuation of battery relay
— —
(when starting switch is turned ON, OFF)
20-212 WA700-3
(10)
Troubleshooting Connector types and mounting locations
Connector types and mounting locations

Serial No.: 50001 – 51000
The Address column in the table below shows the address in the connector arrangement drawing
Con- No. Con- No.
Add- Add-
nector Type of Mounting location nector Type of Mounting location
ress ress
No. pins No. pins
CNA4 X 2 Air servo motor X1 CNE08 — 1 APS water temperature sensor C7
Engine water temperature sensor
CNA5 SWP 2 Air conditioner thermistor S1 CNE09 X 2 (monitor) C7
CNA7 M 6 Blower motor, resistor S3 CNE10 X 2 Engine speed sensor B d5

Air conditioner relay intermediate
CNA8A S 10 connector T1 CNE11 X 2 Engine water temperature sensor C7
Air conditioner relay intermediate
CNA8B S 8 connector S1 CNE12 X 3 Governor solenoid d4
CNA14 X 2 Air conditioner Me switch R3 CNE13 X 2 Engine speed sensor A d5
CNA15 Yazaki 2 Air conditioner Hi/Lo switch R3 CNE14 X 4 Rack sensor d4
CNB02 KES0 2 F window washer D5 CNE15 X 2 Governor solenoid d4
CNB04 KES0 2 R Window washer D5 CNE16 X 3 Pre-stroke solenoid d4

1-pin
CNB06 connector 1 Dust indicator L8 CNE17 X 4 Connector for nozzle, glow d6
1-pin
CNB07 connector 1 Dust indicator L8 CNE18 — 1 Engine oil pressure switch d5
1-pin
CNB08 connector 1 Dust indicator H7 CNE19 X 1 Engine oil level sensor c4
1-pin
CNB09 connector 1 Dust indicator H7 CNE20 X 2 Fuel cut-off solenoid d4
CNB10 X 2 Air conditioner condenser left C5 CNE21 X 1 Air conditioner magnet clutch b6
CNB11 X 1 Air conditioner condenser left C5 CNER1 SWP 12 Intermediate connector A8
CNB12 X 2 Air conditioner condenser right C6 CNER2 X 4 Intermediate connector A7
CNB13 X 1 Air conditioner condenser right C6 CNER3 SWP 12 Intermediate connector C7
CNBC01 SWP 6 Intermediate connector L7 CNER4 SWP 8 Intermediate connector A7
CNC01 X 2 Torque converter oil filter sensor L5 CNF01 M 4 Lamp intermediate connector Y2
Turn signal, side lamp intermediate
CNC03 X 2 Brake pressure switch L6 CNF02 M 3 connector Y2
Turn signal, side lamp intermediate
CNC04 X 2 Brake pressure switch L6 CNF03 M 3 connector b2
CNC07 X 2 Emergency brake switch L5 CNF04 M 4 Lamp intermediate connector b2
CNC08 X 2 Emergency brake switch L5 CNF05 X 3 Bucket proximity switch D1
CNCL1 S 12 Intermediate connector G8 CNF06 X 3 Boom kick-out proximity switch C2

Air conditioner intermediate
CNCL2 S 10 connector G8 CNF07 — 1 Horn (303 Hz) Y3
Air conditioner intermediate
CNCL3 S 6 connector G9 CNF08 — 1 Horn (333 Hz) b3
CNCL4 M 6 Intermediate connector G7 CNF09 — 1 Horn (334 Hz) b2
CNE01 — 1 Slow blow fuse A9 CNF10 — 1 Horn (303 Hz) Y2
CNE02 — 1 GND C8 CNF11 X 2 Parking brake solenoid H2
CNE03 X 2 Connector for starting motor F6 CNF12 X 2 Parking brake display switch H1
CNE04 X 2 Connector for starting motor F6 CNFR1 S 10 Intermediate connector A1
CNE05 — 1 Alternator E9 CNFR2 SWP 6 Intermediate connector B1
CNE06 — 1 Alternator D9 CNFS1 L 2 Fuse box S6
CNE07 — 1 Alternator D9 CNFS2 S 12 Fuse box T6
20-214 WA700-3
(10)
Con- No. Con- No.

Add- Add-
ress ress
No. pins No. pins
CNFS3 M 6 Fuse box T5 CNL16 KES1 2 Boom kickout solenoid T9
CNFS4 L 2 Fuse box T5 CNL17 KES1 2 Bucket positioner solenoid T8
CNFS5 M 6 Fuse box T5 CNL18 AMP040 16 Maintenance monitor Q9
CNFS6 M 4 Fuse box U5 CNL19 AMP040 8 Maintenance monitor R9
CNFS7 M 2 Fuse box S5 CNL21 KES1 2 Maintenance monitor R8
CNFS8 1 Fuse box S6 CNL22 KES1 2 Maintenance monitor R8
CNFS9 1 Fuse box S6 CNL40 Yazaki 7 Power window right switch Q8
CNFS10 1 Fuse box S5 CNL41 Yazaki 7 Power window left switch R8

1-pin
CNFS11 1 Fuse box S5 CNL42 connector 1 Alarm buzzer S8
1-pin
CNG01 M 6 Rear combination lamp right b8 CNL43 connector 1 Alarm buzzer S7
CNG02 M 2 Rear working lamp right b7 CNL44 KES0 6 Wiper relay T7

1-pin
CNG03 M 2 Radiator water level sensor a9 CNL63 connector 1 Horn switch O7
CNG04 — 1 Backup buzzer a6 CNL69 SWP 6 APS assister T7
CNG05 — 1 Backup buzzer Z6 CNL73 KES1 2 Fuel cut switch O8
CNG06 X 2 Rear working lamp right a9 CNL74 KES1 4 Heater switch O9
CNG07 M 2 Rear working lamp left Z9 CNL78 — — Emergency engine stop switch T3
CNG08 M 2 Rear working lamp left Y7 CNL79 — — Emergency engine stop switch S3
CNG09 M 6 Rear combination lamp left Y8 CNL81 X 2 Stop lamp switch H4
CNGR1 SWP 12 Intermediate connector E9 CNLR1 SWP 12 Intermediate connector A2

When auto-greasing system is
CNGRE SWP 6 installed A3 CNLR2 SWP 14 Intermediate connector A2
CNL01 SWP 6 Parking brake switch Q7 CNLR3 X 4 Intermediate connector A2
CNL02 SWP 6 Lighting switch Q7 CNLR4 SWP 14 Intermediate connector A3
CNL03 SWP 6 Turn signal, hazard switch Q7 CNLR5 X 4 Intermediate connector C2
CNL04 SWP 14 Directional, speed switch P7 CNLR6 L 2 Intermediate connector C3
CNL05 AMP040 20 Main monitor M2 CNLR7 SWP 8 Intermediate connector C2
CNL06 AMP040 16 Main monitor M3 CNLR8 SWP 12 Intermediate connector C2
CNL07 AMP040 12 Main monitor M3 CNR05 X 2 Fuel level sensor F7
CNL08 AMP040 8 Main monitor N2 CNR10 — 1 GND C9
CNL09 M 6 Starting switch O6 CNRA1 X 2 Intermediate connector L9
CNL10 S 10 Wiper switch O6 CNT01 MS 10 Transmission valve solenoid H5
CNL12 X 2 Transmission cut-off switch L3 CNT05 X 2 Speed sensor L4

Torque converter oil temperature
CNL13 X 3 Accelerator pedal H3 CNT06 X 2 sensor H5
CNL14 X 3 Accelerator pedal L2 CNTL1 SWP 12 Intermediate connector

(transmission) C1
CNL15 M 2 Kickdown switch V9
WA700-3 20-215
(10)

a The Address column in the table below shows the address in the connector arrangement drawing
(3-dimensional drawing).
Con- No. Con- No.

Add- Add-
ress ress
No. pins No. pins
Connector for connecting J1939
1939 HD 9 equipment — BC01 — 6 Intermediate connector L8
A02 Connector 1 Battery relay (BR) — BR1 SWP 12 Intermediate

(bulk head)
connector F7
A03 Terminal 1 Battery relay (E) — C01 X 2 Torque converter oil filter sensor L5
A04 Connector 1 Battery relay (BR) — C01 M 6 Front wiper motor —
A4 X 2 Air conditioner air servo motor V1 C01 Yazaki 9 Cassette stereo —
A05 Terminal 1 Battery relay (E) — C03 X 2 Low pressure switch 1 L7
A5 M 2 Air conditioner thermistor R1 C03 M 2 Front working lamp (R.H.) —
A6 SWP 6 Air conditioner air mixing motor Q3 C04 M 2 Low pressure switch 2 L7
Air conditioner blower motor,
A7 M 6 resistor Q1 C04 M 2 Front working lamp (L.H.) —
Intermediate connector
A8A S 10 (air conditioner) R1 C05 Kyouritsu 4 Beacon lamp switch (OP) —
Intermediate connector
A8B S 8 (air conditioner) R1 C06 KES 1 2 Room lamp —
A9 Yazaki 4 Air conditioner blower relay (M) — C07 M 4 Rear wiper motor —
A10 Yazaki 4 Air conditioner blower relay (Hi) — C07 X 2 Emergency brake switch 1 L6
A11 Yazaki 4 Air conditioner blower relay (M2) — C08 Connector 1 Cigar lighter —
A12 Yazaki 4 Air conditioner condenser relay — C08 X 2 Emergency brake switch 1 L6
A13 Yazaki 4 Air conditioner blower relay (M1) — C09 Terminal 1 Cigar lighter —
A14 X 2 Air conditioner switch — C1 MIC 13 Transmission & joystick steering —

controller
A14 Yazaki 4 Air conditioner condenser relay P1 C2 MIC 21 Transmission & joystick steering —
controller
A15 Yazaki 2 Air conditioner switch — C3A AMP040 20 Transmission & joystick steering —
controller
A15 Yazaki 4 Air conditioner condenser relay Q1 C3B AMP040 16 Transmission & joystick steering —
controller
A16 AMP 12 Air conditioner controller — C4 AMP040 12 Transmission & joystick steering —
controller
A17 AMP 16 Air conditioner controller — C5 MIC 17 Transmission & joystick steering —
controller
Air conditioner air servo motor
A18 SWP 8 (L.H.) — C11 Terminal 1 Door switch (R.H.) —
Air conditioner air servo motor
A19 SWP 8 (R.H.) — C12 Terminal 1 Door switch (L.H.) —
AAPR Connector 3 Air pressure sensor — C13 KES 0 2 Speaker (L.H.) —
ASS X 2 Air suspension seat P3 C14 KES 0 2 Speaker (R.H.) —
B02 KES 1 2 Window washer (front) C6 C16 M 2 Side working lamp (L.H.) (OP) —
B03 KES 1 2 Diode (window washer) — C17 M 2 Side working lamp (R.H.) (OP) —
B04 KES 1 2 Window washer (rear) C5 CAN Terminal 3 CAN connector —
B05 KES 1 2 Diode (window washer) — CL1 S (blue) 12 Intermediate connector G3

(cab harness)
B10 X 1 Air conditioner condenser (L.H.) C6 CL2 S 10 Intermediate connector G4
(air conditioner)
B11 X 2 Air conditioner condenser (L.H.) C6 CL3 S 6 Intermediate connector
(air conditioner)
G4
B12 X 1 Air conditioner condenser (R.H.) C7 CL4 M 6 Intermediate connector G3

(power window)
B13 X 2 Air conditioner condenser (R.H.) C7 CLTP Connector 2 Engine cooling water —
temperature sensor
20-216 WA700-3
(10)
Con- No. Con- No.

Add- Add-
ress ress
No. pins No. pins
E01 Terminal 1 Slow blow fuse (80A) — F02 M 3 Intermediate connector Y2
(combination lamp R.H.)
E02 Terminal 1 GND B8 F03 M 3 Intermediate connector AB2
(combination lamp L.H.)
E03 X 2 Starting motor F7 F04 M 4 Intermediate connector AB2
(head lamp L.H.)
E04 X 2 Starting motor F7 F05 X 3 Bucket positioner proximity switch C1
E05 Terminal 1 Alternator (B) AB5 F06 X 3 Boom kick-out proximity switch C2
E06 Terminal 1 Alternator (R) AB5 F07 — 1 Horn (L.H.) Y3
E07 Terminal 1 Alternator (E) AB5 F08 — 1 Horn (R.H.) AB3
E09 X 2 Engine water temperature sensor C8 F09 — 1 Horn (R.H.) AB3
E10 Terminal 1 Slow blow fuse — F10 — 1 Horn (L.H.) Y3
E11 Terminal 1 Slow blow fuse — F11 X 2 Parking brake solenoid H3
E13 X 2 Engine speed sensor C7 F12 X 2 Parking caution (monitor) H2
E14 KES 1 2 Diode (heater relay) — F13 Terminal 1 GND (front frame) F2
E15 KES 1 2 Diode (heater relay) — FLTP Connector 2 Fuel temperature sensor —
E16 Terminal 1 Heater relay G9 FOP1 — 1 Intermediate connector —
E19 X 1 Engine oil level switch AC4 FOP4 — 1 Intermediate connector —
E21 — 1 Air conditioner magnet clutch AB6 FR1 S 10 Intermediate connector A1

(front lamp)
E22 KES 1 2 Diode (starting motor) — FR2 SWP 6 A1
E23 KES 1 2 Diode (starting motor) — FSO- Terminal 1 Fuel shutoff valve (–) —
E24 KES 1 2 Diode (starting motor) — FSO+ Terminal 1 Fuel shutoff valve (+) —
E25 KES 1 2 Diode (starting motor) — FS1 L 2 Fuse I W3
E26 KES 1 2 Diode (starting motor) — FS2 S (blue) 12 Fuse I W3
E27 Terminal 1 Heater relay G8 FS3 M 6 Fuse I W3
E28 Connector 1 Dust indicator C6 FS4 L 2 Fuse II W3
E29 Connector 1 Dust indicator C6 FS5 M 6 Fuse II X3
E2B DT 2 Diode — FS6 M 4 Fuse II X3
ECMA DRC 40 Engine controller — G01 M 6 Rear combination lamp (R.H.) AB9
ECMB DRC 40 Engine controller — G02 M 2 Working lamp (R.H.) (OP) AB8
ER1 SWP 12 Intermediate connector B7 G03 M 2 Radiator water level sensor AA9
(engine harness)
ER2 X 4 Intermediate connector A8 G04 Terminal 1 Back buzzer AB8
(engine harness)
ER3 SWP 14 Intermediate connector A7 G05 Terminal 1 Back buzzer AB7
F01 M 4 Intermediate connector Y2 G06 X 2 Working lamp (R.H.) AA9

(head lamp R.H.)
WA700-3 20-217
(10)
Con- No. Con- No.

Add- Add-
ress ress
No. pins No. pins
G07 S 2 Working lamp (L.H.) Z9 L13 DT-T 3 Accelerator potentiometer H4
G08 M 2 Working lamp (L.H.) (OP) Y9 L14 DT-T 3 Accelerator limit switch L3
G09 M 6 Rear combination lamp (L.H.) Y9 L15 M 2 Kick-down switch & hold T8
GR1 SWP 6 Intermediate connector F9 L16 KES 1 2 Boom kick-out solenoid S8
GRE SWP 6 Auto-grease (OP) A3 L17 KES 1 2 Bucket positioner solenoid S7
GND Terminal 1 Engine block GND — L18 AMP040 16 Maintenance monitor (sub motor) R9
GND M 1 Front combination lamp — L19 AMP040 8 Maintenance monitor (sub motor) R9
GND Terminal 1 GND — L21 KES 1 2 Maintenance monitor (sub motor) R8
GND1 Terminal 1 GND (OP) G5 L22 KES 1 2 Maintenance monitor (sub motor) Q8
GND2 Terminal 1 GND (OP) G5 L31 — 5 Dust indicator relay —
HF-1 M 4 Intermediate connector — L40 Yazaki 7 Power window switch (R.H.) P8

(head lamp)
HF-2 M 3 Intermediate connector — L41 Yazaki 7 Power window switch (L.H.) Q8
(front combi. lamp)
HEAD M 2 Head Lamp — L42 Connector 1 Caution buzzer V8
HEAT DT 2 Intermediate connector AC6 L43 Connector 1 Caution buzzer V7

(electronically governor)
IMPR Connector 3 Suction air pressure sensor — L44 KES 0 6 Wiper relay W7
IMTP Connector 2 Suction air temperature sensor — L46 KES 1 3 Flasher unit W7
JC01 DT 6 Joint connector — L48 — 5 Bucket relay —
JC02 DT 8 Joint connector — L49 — 5 Boom relay —
JC03 DT 8 Joint connector — L52 — 5 Hazard relay —
JC04 DT 8 Joint connector — L53 — 5 Stop lamp relay —
JC11 DT 6 Joint connector — L55 — 5 Horn relay —
JC12 DT 6 Joint connector — L56 — 5 Side working lamp relay —
JC13 DT 8 Joint connector — L57 — 5 Neutral relay —
JC14 DT 8 Joint connector — L58 — 5 Neutralizer relay —
JC15 DT 6 Joint connector — L59 — 5 Parking brake safety relay —
L01 SWP 6 Parking brake switch P4 L60 — 6 Front working lamp relay —
L02 SWP 6 Light & dimmer switch N5 L61 — 6 Rear working lamp relay —
L03 SWP 6 Turn signal switch P4 L63 Connector 8 Horn switch O6
L04 SWP 14 Transmission switch N4 L64 — 5 Engine oil pressure switch relay —
L05 AMP040 20 Main monitor M2 L65 — 5 Transmission cut off relay

(joy stick caution relay) —
L06 AMP040 16 Main monitor M2 L66 — 6 Traveling FORWARD relay —

(5) (joy stick selector relay)
L07 AMP040 12 Main monitor M2 L67 — 6 Traveling REVERSE relay —
(5) (joy stick solenoid relay)
L08 AMP040 8 Main monitor N2 L68 — 6 Kick down relay —
L09 M 6 Starting switch O6 L70 — 5 Power window relay (left rise) —
L10 S 10 Wiper switch O7 L75 — 5 Power window relay (left lower) —
L12 X 2 Transmission cut off switch L3 L76 — 5 2nd – 1st selector relay —
20-218 WA700-3
(10)
Con- No. Con- No.

Add- Add-
ress ress
No. pins No. pins
L77 — 5 Power window relay (right lower) — R06 Terminal 1 Slow blow fuse (30A) —
L80 — 5 Power window relay (right raise) — R07 Terminal 1 Slow blow fuse (30A) —
L81 X 2 Stop lamp switch H5 R08 Terminal 1 Slow blow fuse (80A) —
L82 — 5 Preheatomg relay — R09 Terminal 1 Slow blow fuse (80A) —
L83 Terminal 1 Diagnosis switch O9 R10 Terminal 1 GND —
L84 Terminal 1 Diagnosis switch P9 R11 Terminal 1 Battery relay (M) —
L85 Terminal 1 Selector switch M9 R12 Terminal 1 Battery relay (B) —
L86 Terminal 1 Selector switch M9 RA1 X 2 Intermediate connector L9

(battery relay)
L87 Terminal 1 Selector switch N9 RAIL Connector 3 Fuel rail actuator —
L89 Connector 1 LED (red) M9 RPR Connector 3 Fuel rail pressure sensor —
L90 Connector 1 LED (red) N9 SIG HD-24 31 Intermediate connector —

(engine wiring harness)
L91 Connector 1 LED (yellow) M8 SMALL M 1 Front combination lamp —
L92 Connector 1 LED (yellow) N8 SL1 — 2 Intermediate connector (step light) —
L93 Connector 1 LED (orange) M8 SL2 — 2 Rear step light switch —
L94 Connector 1 LED (orange) N8 SL3 — 5 Rear step light relay —
LINK DT 6 Data link crossover — SL4 — 6 Rear step light timer —
LR1 SWP 12 Intermediate connector A2 SL5 — 2 Step light —

(lamp, horn)
LR2 SWP 14 Intermediate connector
(air conditioner, washer)
A2 SL5 — 1 Step light switch (auto-return) —
LR3 SWP 14 Intermediate connector (engine) B1 SL6 — 1 Step light switch (auto-return) —
LR4 SWP 14 Intermediate connector (engine) A3 SP1 Connector 2 Engine revolution sensor (master) —
LR5 X 4 Intermediate connector (GND) B2 SP2 Connector 2 Engine revolution sensor (backup) —
LR6 L 2 Intermediate connector B3 T01 MS 10 Transmission control valve H6

(power supply)
LR7 SWP 6 Intermediate connector (LED) B2 T02 KES 1 2 Diode (transmission control valve) —
OLPR Connector 3 Engine oil pressure sensor — T03 KES 1 2 Diode (transmission control valve) —
OP1 Connector 1 Connector for connecting H5 T04 KES 1 2 Diode (transmission control valve) —
windshield heater (OP) V2
OP2 Connector 1 Connector for connecting 24V W2 T05 X 2 Speed sensor L4
OP3 Connector 1 Connector for connecting 24V W2 T06 X 2 Torque converter temperature —
sensor (monitor)
PMPR Connector 3 Fuel pump pressure sensor — TAC — 1 Tachograph (OP) G5
POW HD-24 21 Intermediate connector

(engine wiring harness) — TIMG Connector 3 Timing rail actuator —
PUMP Connector 3 Fuel pump actuator — TL1 SWP 2 Intermediate connector B1
PWR1 Connector 1 Power window regulator — TPR Connector 3 Timing rail pressure sensor —
PWR2 Connector 1 Power window regulator — TURN M 1 Front combination lamp —
R01 X 2 Emergency steering switch F6 WORK M 2 Work lamp —
R03 KES 1 2 Diode (battery relay) —
R04 KES 1 2 Diode (battery relay) —
R05 KES 1 2 Fuel level sensor F8
WA700-3 20-219
(10)
Troubleshooting Connector arrangement diagram
Connector arrangement diagram (1/3)

Serial No.: 50001 – 51000
20-220 WA700-3
(10)
WA700-3 20-221
(10)
(2/3)
20-222 WA700-3
(10)
WA700-3 20-223
(10)
(3/3)
20-224 WA700-3
(10)
(1/3)
20-226 WA700-3
(10)
WA700-3 20-227
(10)
(2/3)
20-228 WA700-3
(10)
WA700-3 20-229
(10)
(3/3)
20-230 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
Connection table for connector pin numbers

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
No. X-type connector

of
T-adapter
pins Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491
Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390

• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20

• Electric wire size: 2.0 • Electric wire size: 2.0
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
WA700-3 20-231
(10)
No. SWP-type connector

of
T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
20-232 WA700-3
(10)
No. SWP-type connector

of
T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691
Terminal part No.: Terminal part No.:

— • Electric wire size: 0.85 • Electric wire size: 0.85 —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
Terminal part No.: Terminal part No.:

— • Electric wire size: 1.25 • Electric wire size: 1.258 —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
WA700-3 20-233
(10)
No. M-type connector

of
T-adapter
Part No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
20-234 WA700-3
(10)
No. S-type connector

of
T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
WA700-3 20-235
(10)
No. S-type connector

of
T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
20-236 WA700-3
(10)
No. MIC-type connector

of
T-adapter
Part No.
Body part No.: 79A-222-2640 Body part No.: 79A-222-2630

7 —
(Q’ty: 5) (Q’ty: 5)

11 —
(Q’ty: 5) (Q’ty: 5)
5 799-601-2710

(Q’ty: 5) (Q’ty: 5)
9 799-601-2950

(Q’ty: 5) (Q’ty: 5)
13 799-601-2720

(Q’ty: 2) (Q’ty: 2)
WA700-3 20-237
(10)
No. MIC-type connector

of
T-adapter
Part No.
17 799-601-2730

(Q’ty: 2) (Q’ty: 2)
21 799-601-2740

(Q’ty: 2) (Q’ty: 2)
—
(Q’ty: 50) (Q’ty: 50)
20-238 WA700-3
(10)
No. AMP040-type connector

of
T-adapter
Part No.
8 799-601-7180
Housing part No.: 79A-222-3430

—
(Q’ty: 5)
12 799-601-7190

—
(Q’ty: 5)
16 799-601-7210

—
(Q’ty: 5)
20 799-601-7220

—
(Q’ty: 5)
a Terminal part No.: 79A-222-3470 (No relation with number of pins)
WA700-3 20-239
(10)
No. AMP070-type connector

of
T-adapter
Part No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
20-240 WA700-3
(10)
No. L-type connector

of
T-adapter
Part No.
2 —
— —
No. Connector for PA

of
T-adapter
Part No.
9 —
— —
No. Bendix MS connector

of
T-adapter
Part No.
10 799-601-3460
— —
WA700-3 20-241
(10)
No. KES 1 (Automobile) connector

of
T-adapter
Part No.
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
20-242 WA700-3
(10)
No. KES 1 (Automobile) connector

of
T-adapter
Part No.
8 —
08027-10820 (Black) 08027-10870 (Black)
WA700-3 20-243
(10)
No. Connector for relay (Socket type)

of
T-adapter
Part No.
5 799-601-7360
— —
6 799-601-7370
— —
20-244 WA700-3
(10)
No. F-type connector

of
T-adapter
Part No.
4 —
— —
WA700-3 20-245
(10)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector
(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
(1) Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
799-601-9220
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102,

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-246 WA700-3
(10)
(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102

799-601-9230
Part No.: 08191-32201, 08191-32202 Part No.: 08191-33101, 08191-33102

799-601-9240
18-21 Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102

799-601-9240
Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102
WA700-3 20-247
(10)
(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102

799-601-9250
Part No.: 08191-52201, 08191-52202 Part No.: 08191-53101, 08191-53102

799-601-9260
Part No.: 08191-61201, 08191-62202, Part No.: 08191-64101, 08191-64102,

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
20-248 WA700-3
(10)
(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
WA700-3 20-249
(10)
(shell
size T-adapter
code) Part No.
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
20-250 WA700-3
(10)
No. DT Series connector

of
T-adapter
pins Body (plug) Body (receptacle)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 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
WA700-3 20-251
(10)
No. DT Series connector

of
T-adapter
Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
12GR:799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
20-252 WA700-3
(10)
No. DTM Series connector

of
T-adapter
Part No.
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100
No. DTHD Series connector

of
T-adapter
Part No.
1 —
Part No.: 08192-31200 (Contact size#12) Part No.: 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)
WA700-3 20-253
(10)
Troubleshooting Electric engine throttle controller system
Electric engine throttle controller system
20-254 WA700-3
(10)
1. Functions of equipment at input end 2. Control functions of controller

1) Working mode switch • All-speed governor control:
This detects the condition of operation of the An analog (electric current) signal is output
working mode switch and inputs it to the to the governor actuator to control the
controller as a digital (ON-OFF) signal. engine speed over the whole range accord-
2) Accelerator sensor ing to the signal from the accelerator sensor.
This detects the low idling position and • Sudden acceleration control (soft boost
angle (amount) of operation of the accelera- compensator):
tor pedal and inputs the low idling position to An analog (voltage) signal is output to the
the controller as a digital (ON-OFF) signal governor actuator to prevent the emission of
and the angle (amount) of operation as an black smoke by limiting the maximum rack
analog (voltage) signal. position (= fuel injection amount) when
3) Engine speed sensor A accelerating suddenly.
This detects the speed of the engine fly- • Automatic warming-up operation:
wheel as engine speed A and inputs it to the An analog (voltage) signal is output to the
controller as a pulse (rotation) signal. governor actuator to automatically raise the
4) Engine speed sensor B engine speed and reduce the warming-up
This detects the speed of the engine fly- time when the engine water temperature is
wheel as engine speed B and inputs it to the low according to the signal from the engine
controller as a pulse (rotation) signal. water temperature sensor.
5) Engine water temperature sensor The automatic warming-up speed is set at
This detects the temperature of the engine two levels according to the engine water
cooling water and inputs it to the controller temperature.
as an analog (voltage) signal. • Fuel amount adjustment (start mode)
6) Rack position sensor function when starting:
This detects the rack position inside the fuel An analog (voltage) signal is output to the
injection pump and inputs it to the controller governor actuator to adjust the fuel injection
as an analog (voltage) signal. amount and improve the ease of starting
7) Starting switch (terminal C) according to the engine water temperature
This detects the condition of operation of the when starting.
starting switch to the START position and When the engine speed goes above the set
inputs it to the controller through the neutral speed inside the controller and the starting
relay as a digital (ON-OFF) signal. is completed, the start mode is canceled
and the system returns to normal control.
• Overrun prevention function:
If the engine speed rises abnormally and
exceeds the set speed of the accelerator
sensor, it stops the output to the governor
actuator to cut the fuel injection and prevent
overrun.
When the engine speed goes down below
the set speed of the accelerator sensor, the
system returns to normal control.
• Self-diagnostic function:
The controller always observes the condi-
tion to check that there is no abnormality in
the accelerator sensor, engine speed sen-
sor A, engine speed sensor B, engine water
temperature sensor, and rack position sen-
sor at the input end and the governor and
pre-stroke control systems and the control-
ler itself at the output end.
• Network communication with main monitor:
If the self-diagnostic function detects any
abnormality, it communicates the details of
the abnormality as a digital (ON-OFF) signal
to the main monitor.
WA700-3 20-255
(10)
3. Functions of equipment at output end

1) Governor actuator
This receives the signal from the controller
and controls the fuel injection pump control
rack position to control the fuel injection
amount steplessly between no injection and
the maximum injection.
2) Cut-off solenoid relay
This receives the signal from the controller
and drives the solenoid to open or close the
hydraulic circuit before and after the valve.
4. Main monitor display

a For details, see MAIN MONITOR SYSTEM.
20-256 WA700-3
(10)
Troubleshooting Method of displaying action code and failure code
Method of displaying action

code and failure code
1. Outline
The speedometer display on the main monitor is
used to display the troubleshooting for each
control system. The nature of the troubleshoot-
ing is displayed as the failure action code, failure
code, and the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the
network circuit. (Only the engine controller uses
a special parallel signal.)
2. Display of failure action code

This code informs the operator directly of the
abnormality, and takes action, such as stopping
the machine immediately.
There are three types of action code: E00, E01
+ CALL (E01 and CALL are displayed alter-
nately), and CALL. If a failure occurs suddenly,
one of these codes is shown on the speedome-
ter display.
3. Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible
to tell from this code which system in which con-
troller has failed, so carry out troubleshooting for
the applicable controller.
4. Saving failure code

The transmission controller writes the failure
codes to memory.
1) A total of 9 failure codes can be saved in
memory.
2) The data that is saved to memory is as
follows:
(1) Failure code
(2) Time elapsed since failure
(up to 1000 hours)
3) The failures are saved in the order that they
occur. If a failure code already exists in the
memory, the repeat failure code is not
saved.
4) If there are already 9 items in memory, and
a 10th failure occurs, the oldest item is
deleted and the new item is saved.
a It is possible to display the failure code and
time elapsed since failure for items saved in
memory by operating the main monitor set
switch.
WA700-3 20-257
(10)
Troubleshooting Method of displaying action code and failure code
5. Switch operation procedure and actuation
Switch operation Actuation

Trouble data memory
mode display
1) Stop engine. • The failure code is
2) Turn starting switch displayed on the
ON. speedometer display
3) Push operation mode and the time elapsed
switch (1) and head since failure is displayed
lamp switch (2) on the action code
simultaneously and display.
keep pressed for at • If there is no failure, the
least 5 seconds. speedometer display
shows [CC] and the
action code display
shows [0000].
Going to nest failure

code
4) Press head lamp switch • The failure code and
(2). time elapsed since
failure are displayed in
turn (when this is done,
the failure code for the
latest failure is displayed
first).
• If the failure still exists,
the display flashes; if the
failure has been
restored, the display
lights up.
Clearing failure code

5) Keep rear lamp switch • The failure code and
(3) pressed for at least elapsed time on the
2 seconds. display are cleared.
• If the failure still exists,
the failure code is not
cleared.
Quitting trouble data

memory display mode
6) Push operation mode • The display returns to
switch (1) and head the normal display.
lamp switch (2)
simultaneously and
keep pressed for at
least 5 seconds. Or
start the engine.
20-258 WA700-3
(10)
Troubleshooting Chart of action codes and failure codes, and re-enaction
Chart of action codes and failure codes, and re-enaction

• After an error occurs, turn the starting switch OFF, and if the display goes out, it is possible to re-enact the
problem as follows.
• Re-enaction marks.
a: Turn stating switch ON (with engine stopped)
T: Start engine
t: Carry out operation to actuate actuator.
1. Transmission and joystick steering controller

(1) Transmission control system
Main Failed system Re-enaction
monitor Failure Alarm
Item Short Discon- Short Discon- Memory buzzer
action code
code circuit nection circuit nection
None 10 Back lamp relay Q Q t a Q
12 F solenoid Q Q t a Q Q
13 R solenoid Q Q t a Q Q
14 1st solenoid Q Q t a Q Q
CALL
15 2nd solenoid Q Q t a Q Q
16 3rd solenoid Q Q t a Q Q
17 4th solenoid Q Q t a Q Q
E00 19 Joystick directional switch Q Q t t Q
CALL 20 Directional switch signal Q Q a a Q Q
None 21 Range switch signal Q Q a a Q
22 Travel speed sensor Q a a Q Q
E00
23 Engine speed sensor Q Q a Q
(2) Joystick control system

Main Failed system Re-enaction
monitor Failure Alarm
Item Short Discon- Short Discon- Memory buzzer
action code
code circuit nection circuit nection
None 56 Joystick caution relay output Q Q a t Q
57 Steering right solenoid (detect when output) Q Q t t Q Q
58 Steering left solenoid (detect when output) Q Q t t Q Q
59 Steering right solenoid (short circuit at HOT side) Q a a Q Q
E00 60 Steering left solenoid (short circuit at HOT side) Q a a Q Q
61 Steering solenoid cut relay output Q Q a t Q Q
62 Joystick neutral switch abnormal Q Q a a Q Q
63 Joystick potentiometer abnormal (other than 0.5 – 4.5 V) Q Q a a Q Q
a E59 and E60 cannot be distinguished, so they are issued at the same time.
Disconnection cannot be detected for E56. It is always ON and is called up when there is a failure warning.
WA700-3 20-259
(10)
Troubleshooting Chart of action codes and failure codes, and re-enaction
2. Action code table
Action Transmission control system Joystick control system Action

Action by operator
code Problem system Action of machine Problem system Action of machine buzzer
Disconnection in Automatic
travel speed sensor gearshifting not
Normal operation
system carried out — —
possible at manual
(changes to manual
gearshifting)(OP)
Disconnection in Gearshifting not
engine speed carried out in Auto
Normal operation
E00 sensor system mode. (OP) — — No
possible at manual
Breakage, short Set to neutral

circuit with chassis position. (Can be Normal operation
— — ground or short changed to steering possible at wheel
circuit of joystick wheel mode.) steering mode
FNR signal line
Shift lever system Become neutral
disconnection, and cannot travel
short circuit with (Judges controller — —
GND, short circuit input as N)
F, R solenoid signal Become neutral Stop travelling

system and cannot travel immediately, Turn
CALL disconnection, (Output off) — — Yes starting switch OFF,
short circuit with Call service after
GND, short circuit action above.
1st, 2nd, 3rd, 4th Become neutral
solenoid system and cannot travel
disconnection, (Output off) — —
short circuit with
GND, short circuit
20-260 WA700-3
(10)
Troubleshooting Transmission controller LED display
Transmission controller LED display

The transmission controller uses two 7-segment LEDs to display the internal condition of the controller and
input/output errors. The display shows two characters at the same time, and changes these in turn to give the
display.
a When the engine is started, “Program part No. display mode” appears, follwed by “Output speed range
display mode”. If there is any abnormality in the controller, it changes to “Troubleshooting mode”.
a The failure mode is saved to memory by the main monitor.
Table 1 (Output speed range display mode)

Display Content Display Content
0. 1o Neutral, 1st F. 3o FORWARD, 4th
0. 2o Neutral, 2nd A. 1o REVERSE, 1st
0. 3o Neutral, 3rd A. 2o REVERSE, 2nd
0. 4o Neutral, 4th A. 3o REVERSE, 3rd
F. 1o FORWARD, 1st A. 4o REVERSE, 4th
F. 2o FORWARD, 2nd Neutral safety condition or
E. 0o
F. 3o FORWARD, 3rd abnormality in selection signal
WA700-3 20-261
(10)
Troubleshooting Method of using troubleshooting charts
Method of using troubleshooting charts

1. Category of troubleshooting code number
Troubleshooting Code No. Component
S-QQ Troubleshooting of engine system
M-QQ Troubleshooting of main monitor system
K-QQ Troubleshooting of maintenance monitor system
E-QQ Troubleshooting of electrical systems
Troubleshooting of electric engine throttle controller & APS controller system
G-QQ
(Serial No.: 50001 – 51000)
H-QQ Troubleshooting of hydraulic, mechanical system
T-QQ Troubleshooting of transmission controller system
J-QQ Troubleshooting of joystick steering controller system
A-QQ Troubleshooting of AJSS (Advanced Joystick Steering System)
EA-QQ Troubleshooting of engine control system (Serial No.: 51001 and up)
2. Method of using troubleshooting table

1) Troubleshooting code number and problem
The top left of the troubleshooting chart gives the troubleshooting code number and the problem with
the machine.
2) General precautions
When using the troubleshooting chart, precautions that apply to all items are given at the top of the
page and marked with a.
The precautions marked a are not given in the , but must always be followed when carrying out the
check inside the .
3) Distinguishing conditions
Even with the same problem, the method of troubleshooting may differ according to the model, compo-
nent, or problem. In such cases, the troubleshooting chart is further divided into sections marked with
small letters (for example, a), b)), so go to the appropriate section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check item.
4) Method of following troubleshooting chart
YES
• Check or measure the item inside NO
, and according to the answer follow either the YES line
or the NO line to go to the next . (Note: The number written at the top right corner of the is
an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead finally
to the Cause column. Check the cause and take the action given in the Remedy column on the right.
• Below the there are the methods for inspection or measurement, and the judgement values. If
the judgement values below the are correct or the answer to the question inside the is YES,
follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow
the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and the
judgement values. If this preparatory work is neglected, or the method of operation or handling is
mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged.
Therefore, before starting inspection or measurement, always read the instructions carefully, and
start the work in order from Item 1).
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin number con-
nection. When carrying out troubleshooting, see this chart for details of the connector pin number and
location for inspection and measurement of the wiring connector number appearing in the troubleshoot-
ing flow chart.
20-262 WA700-3
(10)
<Example>
1) M-13 Abnormality in buzzer
2) a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
3) a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)
b) Buzzer always sounds
4)
Cause Remedy
Defective contact or discon-

YES nection in wiring harness Repair or
1 between L06 (female) (8) replace
and L43 (male) (1)
Does buzzer
sound? 2 YES
Defective buzzer Replace
Is voltage between
• Turn starting L42 (female) and
switch ON. NO chassis ground Defective contact or discon-
• Contact L43 normal? nection in wiring harness Repair or
(female) to chassis • 20 – 30 V between L42 (female) (1) replace
NO
ground. • Turn starting switch and FS2 (female) (9)
ON.
M-13 Related electrical circuit diagram
WA700-3 20-263
(10)
Troubleshooting of engine body
(S mode)
Method of using troubleshooting charts ...................................................................................................... 20-302
S-1 Starting performance is poor (Starting always takes time).................................................................. 20-306
S-2 Engine does not start.......................................................................................................................... 20-308
a) Engine turns but no exhaust smoke comes out (fuel is not being injected) ................................. 20-308
b) Exhaust smoke comes out but engine does not start (fuel is being injected) .............................. 20-309
S-3 Engine does not pick up smoothly (Follow-up is poor) ....................................................................... 20-310
S-4 Engine stops during operations .......................................................................................................... 20-312
S-5 Engine does not rotate smoothly (Hunting) ........................................................................................ 20-314
S-6 Engine lacks output (or lacks power).................................................................................................. 20-315
S-7 Exhaust smoke is black (Incomplete combustion).............................................................................. 20-316
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................. 20-317
S-9 Oil becomes contaminated quickly ..................................................................................................... 20-318
S-10 Fuel consumption is excessive........................................................................................................... 20-319
S-11 Oil is in cooling water, or water spurts back, or water level goes down.............................................. 20-320
S-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................................. 20-321
S-13 Oil level rises ...................................................................................................................................... 20-322
S-14 Water temperature becomes too high (Overheating) ......................................................................... 20-323
S-15 Abnormal noise is made..................................................................................................................... 20-324
S-16 Vibration is excessive ......................................................................................................................... 20-326
WA700-3 20-301
(10)
Method of using troubleshooting charts

Using troubleshooting chart for engine-
related failure
This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspeciton without using
troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation. Causes
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in (B) are items that can be
obtained from the user, depending on the user’s
level.
(1) (2) (3)
[Check items]
The serviceman carries out simple inspection to nar-
row 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
(a)
Questions
own inspection.
(A) (b)
[Troubleshooting] (c)
Troubleshooting is carried out in the order of proba- (d)
bility, starting with the causes that have been (e)
marked as having the highest probability from infor- (B)
Check items
mation gained from [Questions] and [Check (C)

items].
i
shooting
Trouble-
ii
iii
20-302 WA700-3
(10)
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 Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with E to use as refer-
ence for locating the cause of the failure. Causes
However, do not use this when making cal-
culations to narrow down the causes.
2. Use the E in the Cause column as refer-
)
tion
ence for [Degree of use (Operated for long
njec
period)] in the [Questions] section as refer-
ve i
ence.
si
e
renc
xces
zzle
As a rule, do not use it when calculating the
ent
n no
erfe
p (e
points for locating the cause, but it can be
der
ing
lem
, int
ctio
pum
cylin
included if necessary to determine the order
m
er e
i
rger
inje
on t
for troubleshooting.
ion
,
lean
ring
cha
ecti
zed
ject
air c
urbo
, sei
ston
r inj
e in
rope
ged
ged
ctiv
n pi
ed t
Clog
Clog
Defe
Wor
Seiz
Imp
*1 Confirm recent repair history

*2 Degree of use Operatred for long period
WA700-3 20-303
(10)
• 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
• Excessive injection of fuel
d)
ad
ion)
eize
d he
ject
er s
r an
e in
lung
seat
arge
ssiv
ck, p
elem rence
alve
zzle
och
exce
p (ra
ent
n no
e, v
terfe
turb
(
der
r
ed m ce
mp
uffle
valv
pum
timin
io
r, in
een
ran
ylin
t
u
c
p
rope ized inje
clea
t of
etw
n pis cleaner
arge
ion
ion
rope jection
ing,
ntac
ject
air b
ject
e
logg
Clog urboch
valv
r
Legend
e in
to n
e co
, se
in
e in
air
e of
: Possible causes (judging from Questions and check items)
d, c
r
ectiv
ged
ged
ctiv
ctiv
ed t
: Most probable causes (judging from Questions and Check items)
she
kag
: Possible causes due to length of use (used for a long period)
Clog
Defe
Defe
Wor
Seiz
Deff
Imp
Imp
Cru
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Questions
Color of exhaust gas Gradually became black

Blue under light load
Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
Check items
starting engine, temperature of some cylinders is low

Match marks on fuel injection pump are out of alignment
Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Speed of some cylinders does not change when operating
Troubleshooting
on reduced cylinders
When check is made using delivery method, injection timing

is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-304 WA700-3
(10)
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 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.
WA700-3 20-305
(10)
Troubleshooting S- 1
S-1 Starting performance is poor (Starting always takes time)

General causes why exhaust smoke comes out but engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Insufficient supply of air Causes
• Improper selection of fuel (At ambient temperature of 10°C or below, use ASTM D975 No. 1)
iner
a Battery charging rate
stra
t
elem alve sea
Charging rate
ump
Ambient 100% 90% 80% 75% 70%
)
temperature
er (
p
ve, v
ent
g
r
heat
20°C 1.28 1.26 1.24 1.23 1.22
imin
inde
f val
0°C 1.29 1.27 1.25 1.24 1.23
vice
r, pr
, cyl
ner
r
act o
–10°C 1.30 1.28 1.26 1.25 1.24
lato
e
filte
ring
clea
d
• The specific gravity should exceed the value for the charging rate of 70% in the above table.
regu
cont
APS
fuel
ston
r
• In cold areas the specific gravity must exceed the value for the charging rate
a i
ctive
ctive
ctive
ged
ged
n pi
of 75% in the above table.
Defe
Defe
Defe
Clog
Clog
The item marked ( ) is applicable for serial No.: 50001 – 51000.
Wor
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Starting again takes time after warming-up

Preheating indicator lamp is light up
Replacement of filters has not been carried out according to Operation Manual
Non-specified fuel has being used
Battery charge caution lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
Check items

Timing lock on fuel injection pump does not match
Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
When priming pump strainer is inspected directly, it is found to be clogged
Glow plug mount does not become warm
Is voltage 26 - 30V between alternator terminal B and terminal E Yes
with engine at low idling?
Troubleshooting
No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When check is made using delivery method, injection timing is found to be incorrect
When control rack is pushed, it does not return (when rack stopper
bolt at rear of pump is removed, and rack piston is pushed with a
screwdriver during cleaning, rack does not move)
When fuel tank cap is inspected directly, it is found to be clogged
Inspect governor oil pump directly
Inspect governor spool valve directly
When governor oil supply pipe is inspected directly, it is found to be clogged
When governor oil strainer is inspected directly, it is found to be clogged
When overflow valve is inspected, it is found to be stiff or open
Legend
Q : Possible causes (judging from Questions and check items)
Replace
Replace
Replace
Correct
w : Most probable causes (judging from Questions and check items)

Clean
Clean
E : Possible causes due to length of use (used for a long period) Remedy
q : Items to confirm the cause.
20-306 WA700-3
(10)
Replace Defe
ctive
Replace Defe alter
nato
ctive
o r
Replace Defe r de
WA700-3
ctive terio
rate
Adjust Defe injec
tion d ba
tive n ozzl
ttery
Replace Defe
injec
ti o e
tive n timi
Correct injec ng
Leak tion
Troubleshooting
age, pum
Clean Clog clog
ging p (rack
ged , air , plu
nger
Replace Stuc air b
reat
in in
jecti stuc
k go her on s k)
vern yste
Adjust Seiz or s
hole
in fu m
ed g poo el ta
l val nk
Replace Defec
over
nor ve
tive o oil p
Replace Defec
perat
ion o
ump
gear
Causes
tive o f relie , sha

Clean verflo f valv ft
Clog w valv e of g
ged e o f f
overn
Clean Clog gov
erno uel in
jectio
or oil
pump
ged r oil n pum
gov
erno supp p
ly pi
r oil
stra pe
iner
(10)
20-307
S- 1
Troubleshooting S-2
S-2 Engine does not start
a) Engine turns but no exhaust smoke comes out

(fuel is not being injected)
General causes why engine turns but no exhaust smoke
comes out
• Supply of fuel impossible
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
a Standards for use of fuel Causes

Standards for use of fuel
ump
Ambient temprature
ed)
oil p
t)
Type of fuel
f
seiz
–22 –4 –14 32 50 68 86 104°F
a
r, sh
nor
–30 –20 –10 0 10 20 30 140°C
ger
over
key
gea
haft
nk
ASTM D975 No.2
plun
el ta
aft,
g
on (
Diesel oil
ipe
ar, s
e of
r
ASTM D975A
e sh
ack,
in fu
p
pist
No.1
rain
iner
valv
p ge
ply
ng
alve
r
driv
er
(
mp
p st
stra
sup
e
pipi
a In winter, if No. 3 diesel oil is not available, a 50-50
f
ump
m
prim r, strain
relie
ol
ol v
u
u
mp
h
pum
p
oil p
mixture of No. 2 diesel oil and kerosene can be used.
r oil
r oil
fuel
her
p
n of
spo
eed
n pu
d
ion
use
erno
erno
reat
lte
ing
king
ratio
rnor
Legend en f
r
ject
ctio
o
el fi
l
air b
vern
r fue
gov
gov
, lea
e
ove
brok
e in
el
p
inje
u
o
of fu
f
k go
ed g
rope
ctive
ged
ged
ged
ged
ged
ged
ctiv
E : Possible causes due to length of use (used for a long period)

ed,
ken
Clog
Clog
Defe
Clog
Stuc
Clog
Clog
Lack
Clog
Defe
Seiz
Seiz
Imp
Bro

Exhaust smoke suddenly stops coming out (when starting again)
Questions
Replacement of filters has not been carried out according to

Operation Manual
When fuel tank is inspected, it is found to be empty
There is leakage from fuel piping
When fuel filter is drained, fuel does not come out
1) Injection pump coupling does not turn
Check items
2) No fuel comes out even when fuel filter air bleed plug is
loosened
3) No fuel spurts out even when injection pipe sleeve nut is
loosened
Rust and water are found when fuel is drained
Inspect fuel pump directly

Control rack does not move
Inspect feed pump directly
When fuel filter, strainer are inspected directly, they are found
Troubleshooting
to be clogged
When priming pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
Inspect governor spool valve directly
When governor oil supply pipe is inspected directly, it is found
to be clogged
When governor oil strainer is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
Add
20-308 WA700-3
(10)
Troubleshooting S-2
b) Exhaust smoke comes out but engine does not start

(fuel is being injected) Causes
General causes why exhaust smoke comes out but engine
, etc.)
does not start
uck)
lever
• Lack of rotating force due to defective electrical system
t
ocker
er s
ray
• Insufficient intake of air
e sp
ung
lve, r
em
• Improper selection of fuel and oil
tank
ctiv
l
syst
m (va
k, p
tter y
r
line
defe
(rac
fuel
syste
fuel
high
ent
iner
d ba
a The item marked ( ) is applicable for
ump iner
der
le in
zle,
m
mp
( )
valve
ir in
stra
serial No.: 50001 – 51000.
r ate
too
e
a
n
noz
n pu
o
i
er e
vice
, cyl
h
amic
terio
sity
d
ing,
her
lter,
u se
ion
lean
o
S de
ring
n dyn
isco
reat
ject
ed p
e
ogg
Legend
el fi
ject
d
fuel
air c
e AP
ston
air b
broke
e or
oil v
e in
e, cl
n
u
f e
i
f
r
rope
ged
ged
ged
ged
ctiv
ctiv
ctiv
n pi
ged
tive,
kag
ine
Clog
Defe
Clog
Clog
Clog
Defe
Defe
Clog
Defec
Wor
Imp
Eng
Lea
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from around head

Non-specified fuel is being used
Operation Manual
Rust is found when fuel is drained
Preheating pilot lamp does not light up
Starting motor cranks engine slowly
Check items
1) Little fuel comes out even when injection pump sleeve nut
is loosened
2) Little fuel comes out even when fuel filter air bleed plug is
loosened
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or does not return
Troubleshooting
to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
When air cleaner element is inspected directly, it is found to be clogged
Glow plug mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
WA700-3 20-309
(10)
Troubleshooting S-3
S-3 Engine does not pick up smoothly (Follow-up is poor)
a Check that there is no abnormality display for the governor Causes

control system on the monitor panel.
General causes why engine does not pick up smoothly

• Insufficient supply of air
ap
ray
seat
nk c
e sp
lve
el ta
• Improper condition of fuel injction
e
ctiv
d va
renc
r
• Improper fuel used
in fu
line
nge
defe
e an
ent
g
terfe
iner
n
r
u
der
aine
pipi
e
hole
lem
zle,
p pl
valv
anc
stra
r, in
cylin
noz
r
er e
fuel
pum
r, st
r
her
clea
t of
ump
arge
n
lean
ng,
reat
filte
king
ntac
ctio
tion
lve
ed p
h
Legend
i
c
r
air b
air c
urbo
uel
, lea
inje
r va
ston
e co
njec
e
f
f
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
ed i
n pi
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
Questions
Operation Manual
Rust and water are found when fuel tank is drained
Dust indicator caution is red
Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
When air cleaner element is inspected directly, it is found to

be clogged
When fuel filter, strainer are inspected directly, they are
found to be clogged
When feed pump strainer is inspected directly, it is found to be
Troubleshooting
clogged
Speed does not change when operation of certain cylinders
is stopped
When valve clearance is checked directly, it is found to be
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-310 WA700-3
(10)
Troubleshooting S-4
S-4 Engine stops during operations
General causes why engine stops during operations

Causes
• Seized parts inside engine
c.)
r, e t
• Overheating
leve
a If there is overheating and the engine stops, carry out
cker
ey
troubleshooting for overheating.
rod
ent
e , ro
aft,k
m
g
ting
arin
valv
quip
er
e sh
• Failure on machine
rain
nec
ft be
m (
a If the machine stopped because of a failure on the
ry e
driv
er
con
p st
yste
train
in
ksha
a
machine, carry out troubleshooting for the chassis.
p
r tra
pum
on,
l
pum
lve s
i
aux
s
cran
,
gea
pist
r
filte
ic va
ing
p or
tion
zed
ze d
zed
Legend
prim
y na m
fuel
c
pum
l
inje
, sei
, sei
, sei
e
of fu
ged
ged
en d
ken
ken
ken
ken
ken
Clog
Clog
Lack
Brok
Bro
Bro
Bro
Bro
Bro
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Engine overheated and stopped
stopped
Questions
Engine stopped slowly

There was hunting and engine stopped
Fuel level lamp is lighted up
Replacement of filters has not been carried out according
to Operation Manual
Engine turns but stops when transmission lever is operated
Does not turn at all
Check items
When it is attempted to Turns in opposite direction

turn by hand using
barring tool Moves amount of backlash
Shaft does not rotate
Rust and water are found when fuel tank is drained
Metal particles are found when oil is drained
Remove oil pan and inspect directly

Remove head cover and inspect directly
When gear train is inspected, it does not turn
When pump auxiliarry equipment is remove, punp turns
Troubleshooting

found to be clogged
When priming pump strainer is inspected directly, it is found to be clogged
Inspect feed pump directly
Control rack does not move
When governor oil supply pipe is inspected directly, it is found
to be clogged
When governor oil strainer is inspected directly, it is found to
be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Remedy
Add
20-312 WA700-3
(10)
Replace Bro
ken
, sei
Correct Clog zed
ged gea
r, sh
Clean , lea aft
WA700-3
Clog king
ged fuel
Replace Defe a i r brea p i ping
ctiv ther
— Carry out troubleshooting for the chassis. e in
Fail
ure j ec tion
hole
in fu
at c pum el ta
Replace p nk
Troubleshooting
Bro has (rac

ken sis e k, p
, sei nd
Replace Defe zed
gov
lung
er s
ctive tuck
Clean oper erno
r oil )
Clog
ged
ation
of re p ump
Clean Clog g o vern lie f val gear,
ged or o ve o sha
gov il su f gov ft
Causes
erno pply erno

r oil pipe r oil
pum
stra
iner p
(10)
20-313
S-4
Troubleshooting S-5
S-5 Engine does not rotate smoothly (Hunting)
General causes why engine does not rotate smoothly Causes

• Air in fuel system
ump
zzle
• Defective governor mechanism
ol)
e
, pip
, spo
ing p
no
and
ilter
prim
noid
ilter
ort f
m p
tank
(sole
k and
pum creen f
d pu
let p
rack
l t an
l
rnor
nor
e
iner
n fee
in fu
p in
trol
s
n fue
over
ove
low
ump
stra
twee
er
con
e
t wee
rain
of g
l
of g
r ho
o
ump
p
it be
is to
n of
l
r oil
r, st
it be
i
ent
or o
athe
ion
ng p
circu
o
eed
erno
stm
u
filte
i
erat
erat
n
e
in cir
Legend
r
r br
rimi
e
g sp
adju
air in
gov
gov
fuel
e op
e op
e l
i
, air
p
a
of fu
idlin
ctive
ged
ged
ged
ged
ged
ged,
ctiv
ctiv
ging
Lack
Defe
Clog
Clog
Clog
Clog
Defe
Clog
Low
Defe
Clog
Clog
Occurs at a certain speed range
Questions
Condition of hunting Occurs at low idling

Occurs even when speed is raised
Occurs on slopes
to Operation Manual
Rust is found when fuel is drained
When priming pump is operated,
Check items
1) No response, light, return is quick

2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
Movement of governor lever (solenoid plunger) is stiff

Movement of spool valve is stiff
When control rack is pushed, it is found to be heavy, or
Troubleshooting
does not return

When priming pump strainer is inspected directly, it is found
to be clogged
to be clogged
When governor oil screen filter is inspected directly, it is found
to be clogged
When governor oil inlet port filter, supply pipe are inspected
directly, they are found to be clogged
Replace
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
20-314 WA700-3
(10)
Troubleshooting S-6
S-6 Engine lacks output (or lacks power)
General causes why engine stops during operations Causes

noid
• Improper fuel used
ray
seat
sole
(if non-specified fuel is used, output drops)
e sp
nk
lve
el ta
ool
• Lack of output due to overtaking
ctiv
e
d va
enc
e sp
a If there is overheating and lack of output, carry out
in fu
er
defe
e an
rfer
ung
ng
ent
er
trok
troubleshooting for overheating.
pum ainer
r
rain
ole
pipi
e
e
inde
zle,
lem
p pl
valv
anc
, int
re-s
h
p st
noz
tr
fuel
er e
pum
, cyl
ther
lear
rger
er, s
le p
t of
ion
lean
king
ring
brea
ntac
ri a b
cha
tion
t
lve
l
ject
i
Legend
f
feed
air c
fuel
urbo
, lea
e va
e co
r va
ston
njec
r
n
a i
i
rope
ged
ged
ged
ged
ged
ctiv
ged
ctiv
ed t
n pi
ed i
Clog
Clog
Clog
Defe
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
Suddenly
Power was lost
Gradually
Questions

to Operation Manual
Black
High idling speed under no load is normal, but speed
Check items
suddenly drops when load is applied

High idling speed of engine is low
When air cleaner element is inspected directly, it is found to be

clogged
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
Inspect sliding of spool valve solenoid for variable pre- stroke
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
—
WA700-3 20-315
(10)
Troubleshooting S-7
S-7 Exhaust smoke is black (Incomplete combustion)
General causes why exhaust smoke is black Causes

sole zed)
ad
)
tion
d he
noid
i
e sp nger se
njec
seat
ray
r an
e sp
ve i
e
arge
valv
ool
lu
essi
e
ctiv
k, p
renc
och
and
(exc
defe
(rac
ent
turb
erfe
trok
r
lve
g
r
ce
inde
mp
p
lem
zle,
e
imin
, int
pum
re-s
l
een
aran
f va
f f
u
z
u
er e
, cyl
n no
ed m
rger
le p
on t
w
ct o
e cle
ion
ion
t
lean
ir be
ring
riab
ctio
cha
ecti
onta
ject
ject
logg
Legend
valv
air c
a
inje
urbo
e va
r inj
ston
e in
e in
c
e of
d, c
e
r
rope
rope
ged
ctiv
ctiv
ged
ctiv
ctiv
n pi
ed t
she
kag
Defe
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Exhaust noise is abnormal
Muffler is crushed

When air cleaner is inspected directly, it is found to be clogged
Troubleshooting
is stopped
When check is made using piston displacement method,
injection timing is found to be incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
does not return
Inspect sliding of spool valve solenoid for variable pre- stroke
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
—
20-316 WA700-3
(10)
Troubleshooting S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
a Do not run the engine at idling for more than 20 minutes Causes
continuously. (Both low and high idling)
r
arge
General causes why oil consumption is excessive
och
• Abnormal combustion of oil
Turb
• External leakage of oil
al
d
hea
n se
ce
• Wear of lubrication system
em
e
ping l cooler
urfa
hos
der
oke
syst
er
s
r lin
cylin
her
), br
seal
plug
i
e
or o
reat
k
inde
nd
nd
uide
inta
n or
eal,
ain
e
roke ower e
or b
ilter
, cyl
bine
m, g
om
ar s
il pa
il dr
il pi
ing
oil f
ther
r
ring
in fr
n re
oole
t tur
(ste
mo
mo
mo
l
on r
Legend
at b
m
brea
ston
cked
al a
e fro
oil c
e fro
e fro
e fro
lve
pist
al
n va
n se
n se
ged
n, b
n pi
t su
kag
kag
ken
kag
kag
ken
Clog
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Lea
Bro
Lea
Lea
Bro
Questions
Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
Oil is in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil rises in clutch or TORQFLOW transmission damper
chamber
Clamps for intake system are loose

When breather element is inspected, it is found to be
clogged with dirty oil
Troubleshooting
There is external leakage of oil from engine

Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty
with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
WA700-3 20-317
(10)
Troubleshooting S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly

• Entry of exhaust gas due to internal wear
Causes
• Clogging of lubrication passage
• Improper fuel
• Improper oil used
• Operation under excessive load
end
bine
r tur
pipe
ose
er
e
r lin
er h
harg
rain
inde
er d
uide
t
boc
lack
a
, bre
e
, cyl
valv
harg
ded
t tur
g
is b
r
e
ther
oole
ring
valv
ilter
l ad
fety
al a
rboc
oke
Legend
brea
oil c
h oi
oil f
ston
e se
e sa
lve,
t sm
t u
muc
ged
n va
ged
ged
ged
ctiv
ctiv
n pi
aus
Clog
Defe
Defe
Clog
Clog
Clog
Wor
Wor
Too
Exh
Questions

Non-specified oil is being used
Black
Excessive
Amount of blow-by gas
None
Carry out troubleshooting for EXHAUST SMOKE IS BLACK.

Check items
When oil filter is inspected, metal particles are found

When exhaust pipe is removed, inside is found to be dirty
with oil
Engine oil temperature rises quickly
Oil is higher than H line on level gauge

When breather element is inspected directly, hose is
broken or is found to be clogged with dirty oil
Troubleshooting
When oil filter is inspected directly, it is found to be clogged

When oil cooler is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to
be catching or broken
Oil is higher than H line on level gauge
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
20-318 WA700-3
(10)
Troubleshooting S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive Causes

• Leakage of fuel
)
tion
ge
ter
on)
njec
linka
el fil
(pist
ive i
g, fu
trol
ump
r
ger
ce ss
cove
l con
pipin
p
plun
ng
y
p (ex
eed
spra
f fue
head
timi
fuel
ump
ide f
pum
lder
nt o
tion
from
side
l ins
on p
le ho
stme
injec
tion
el in
Legend
age
a
jecti
e
injec
nozz
adju
oil s
fuel
of fu
leak
n
i
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Defe
Defe
Leak
Defe
Defe
Defe
Defe
Exte
Questions

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items
When exhaust manifold is touched immediately after starting engine,

temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling speed is high
When injection pump is tested, injection amount is found to be excessive

Troubleshooting

When check is made, injection timing is found to be incorrect
Remove feed pump and inspect directly
When engine speed is measured, low idling speed is found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
WA700-3 20-319
(10)
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water Causes

• Internal leakage in lubrication system
• Internal leakage in cooling system
)
gged
ting
y pit
r clo
de b
athe
et
in
gask
s ma
(bre
k
r tra
bloc
r
ing
e
of lin
head
hole
seal
o we
, O-r
der
mp
fo r p
ing,
cylin
sion
core
ead,
r pu
r
rotru
-
er h
Legend
oler
oler
O
s in
wate
liner
ylind
rack
il co
il co
nt p
aged
aged
nal c
fficie
en o
en o
en c
Dam
Dam
Brok
Brok
Brok
Inter
Insu
Questions

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Check items
Engine oil level has risen, oil is cloudy white

Excessive air bubbles inside radiator, spurts back
Power train oil is milky white
When power train oil is drained, water comes out

Pressure-tightness test of cylinder head shows there is leakage
shooting
Trouble-
Remove cylinder head and inspect directly

When water pump is inspected, there is an abnormal noise
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-320 WA700-3
(10)
S-12 Oil pressure caution lamp lights up (drop in oil pressure)
General causes why oil pressure caution lamp lights up

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
Causes
a Check that the engine oil level is correct before starting
troubleshooting.
a Standards for engine oil selection

Ambient temprature
ng
Type of oil –22 –4 –14 32 50 68 86 104°F
pipi
n
pan
–30 –20 –10 0 10 20 30 140°C
l pa
sor
ing
ulic
sen
l
SAE30
e oi
r
alve
o
braz
nso
ydra
e
l
d
sure
d
urna
e
tor v
el se
insi
SAE10W
insi
pipe
valv
ed h
mp
Engine oil
pres
n oi
g, jo
il
ilter
iner
gula
pipe
l lev
l pu
SAE10W-30
in o
lief
ion
ush
il pa
stra
oil f
l
arin
e re
e re
e oi
e oi
e oi
suct
l
uel
i
SAE15W-40
c
o
of o
n be
,
ctiv
ctiv
ctiv
ged
ged
ged
ctiv
ctiv
king
er, f
ken
Defe
Defe
Defe
Defe
Defe
Lack
Clog
Clog
Clog
Wor
Wat
Lea
Bro
Questions

Operation Manual
Caution lamp is ON
Lights up at low idling
Condition when oil Lights up at high idling
pressure lamp lights up Lights up on slopes
Sometimes lights up
There is crushing, leakage from hydraulic piping (external)
Check items
Oil level sensor lights up

When oil level in oil pan is inspected, it is to found to be low
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
When oil filter is inspected, it is found to be clogged

Carry out troubleshooting

Troubleshooting
for OIL LEVEL RISES.
Oil pump rotation is heavy, there is play

There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil level sensor is replaced, oil level sensor lamp
goes out
When oil pressure is measured, it is found to be within
standard value
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
—
Legend
WA700-3 20-321
(10)
S-13 Oil level rises
a If there is oil in the cooling water, carry out trouble- Causes

shooting for “Oil is in cooling water”.
)
mber
er
aids
eath
er
n cha
General causes why oil level rises
cov
ting
p br
g
bustio
• Water in oil
ittin
ead
star
m
• Fuel in oil (diluted, and smells of diesel fuel)
recom
by p
u
h
mp
ter p
ther
e
• Oil leaking in from other component
ce
nsid
n pu
ing p
ade
urfa
or o
a
e
-ring
includ
w
leev
ng i
les m
ctio
k
s
ged
bloc
mp
l
pipi
(
er s
inje
re, O
, ho
r se
gaske
clog
f pu
der
hold
from
stat
side
-ring
a
r co
head
ng o
e
cylin
ng,
r
rmo
rt in
ged
zzl e
oole
er O
fuel
head,
i
l
Legend
l
a
side
e
e se
ama
e no
e pa
e se
d lin
oil c
e th
e of
nder
ks in
ctiv
n, d
ctiv
ctiv
ctiv
ctiv
age
n cyli
kag
ken
Defe
Defe
Defe
Defe
Defe
Dam
Wor
Crac
Broke
Lea
Bro
Questions

When engine is first started, drops of water come from
muffler
Exhaust smoke is white
There is oil in radiator cooling water
Leave radiator cap open. When engine is run at idling,
an abnormal number of bubbles appear, or water spurts back
Water pump breather is clogged with mud
Check items
When water pump breather is cleaned, water comes out

Oil level in damper chamber goes down
Oil level in hydraulic tank goes down
Engine oil smells of diesel fuel
Fuel must be added more frequently

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting
Remove water pump and check directly

Remove rear seal and inspect directly
When pump is removed, seal is found to be broken
Remove thermostat cover and inspect directly
Defective contact with thermostad seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
20-322 WA700-3
(10)
S-14 Water temperature becomes too high (Overheating)
General causes why water 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
re
ratu
)
pen
e
a Carry out troubleshooting for chassis.
ket
mpe
g
lley
ot o
gau
gas
ns
n pu
il te
es n
ure
or fi
ead
oler
er o
n fa
erat
t (do
alve
diat
d, h
o
vert
g
e
wor
p
r
oil c
ittin
r
v
osta
d ra
hea
ump
tem
o
wat
e
c
con
r
ng,
ator
by p
u
ken
she
erm
der
ater
er p
s
ling
Legend
rque
ippi
e
, bro
radi
, cru
cylin
e pr
e th
ade
ew
wat
o
l
o
s
in to
of c
ged
ged
ged
sm
ctiv
ctiv
ctiv
belt
ken
ken
Clog
Defe
Hole
Clog
Defe
Clog
Defe
Lack
Rise
Bro
Bro
Fan
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Radiator water level caution lamp is lighted up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
There is play when fan pulley is rotated

Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Torque converter oil temperature gauge enters red range
before engine water temperature gauge
Temperature difference between top and bottom radiator tanks

is excessive
Carrey out troubleshooting for the
Temperature difference between top and bottom radiator tanks

is slight
When water filler port is inspected, core is found to be clogged
Troubleshooting
When function test is carried out on thermostat, it does not

open even at cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
chassis.

Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
WA700-3 20-323
(10)
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an external Causes

noise.
.)
, et c
d)
n)
General causes why abnormal noise is made
eize
ever
ctio
r
line
• Abnormality due to defective parts
er s
ker l
inje
ce
der
• Abnormal combustion
aran
lung
, roc
ive
e
ylin
• Air sucked in from intake system
enc
e
e cle
cess
alve
ck, p
renc
pum ozzle
g, c
rfer
m (v
x
valv
p (ra
erfe
n rin
p (e
inte
on n
yst e
, int
ing
t of
pum
isto
belt
ecti
lve s
ush
men
rger
of p
ion
ion
n
n
ic va
b
n, fa
i
cha
just
d
ject
ject
ear
zed
Legend
ynam
z
urbo
d fa
e ad
, sei
ve w
e in
, sei
e in
rme
ctiv
ged
ctiv
en d
ctiv
ed t
sing
essi
Defe
Defo
Defe
Defe
Clog
Brok
Seiz
Mis
Exc
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
stopped
Troubleshooting
When control rack is pushed, it is found to be heavy, or does

not return
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Inspect air compressor piping for leakage
Remove oil pan and inspect
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Remedy
20-324 WA700-3
(10)
Correct Imp
rope
Correct Lea r ge
ar tr
kag ain
e of
Replace a bac
WA700-3
Defe ir be klas
ct in twe h
Replace side
m
en t
Leak
age u ffler urbo
cha
Replace from (divi rger
Seiz air c ding and
ed c o m b o hea
rank pres ard o d
Troubleshooting
shaf sor p ut of
t bea iping posi
ring tion)
Causes
(10)
20-325
S-15
S-16 Vibration is excessive
a If there is abnormal noise together with the vibration, Causes

carry out troubleshooting also for “Abnormal noise is
uck)
made”.
tc. st
ion
)
tion
d
gne
er, e
ush
General causes why vibration is excessive
njec
r)
r lev
isali
e
en c
• Defective parts (abnormal wear, breakage)
ve i
(dam
ocke
ring
in m
brok
• Improper alignment
essi
r
bea
,
r tra
e
• Abnormal combustion
haft
(valv
lts,
(exc
h
ing
klas
ain
per
s
e
g bo
stem
h
mp
utpu
d, m
bus
zle
d po
dam
bac
ntin
y
u
noz
s
p
de o
am
g ro
n
train
alve
ion
mou
ion
a
tion
er, c
gine
mic v
ctin
insi
brat
ject
Legend
ear
njec
e
lanc
nne
ngin
f en
dyna
e in
part
e vi
g
i
r
n ba
n co
rope
ter o
ged
ctiv
ctiv
se e
ctive
ken
Defe
Clog
Defe
Wor
Wor
Imp
Cen
Loo
Defe
Bro
Questions
Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black

Remove side cover and inspect directly
Inspect directly for loose engine mounting bolts, broken cushion
Troubleshooting
Inspect inside of output shaft (damper) directly

When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Remove vibration damper and inspect directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-326 WA700-3
(10)
Troubleshooting of main monitor system
(M mode)
Electrical circuit diagram for M mode system ............................................................................................. 20-354
M-1 Main monitor does not work ............................................................................................................... 20-358
M-2 When starting switch is turned ON and engine is started immediately,
all lamps stay lighted up..................................................................................................................... 20-359
M-3 Speedometer display does not work properly .................................................................................... 20-360
M-4 Abnormality in shift indicator .............................................................................................................. 20-361
a) Displays N even when directional lever is at F ............................................................................ 20-361
b) Displays N even when directional lever is at R ............................................................................ 20-361
c) Does not display N even when directional lever is at N, and displays E when
directional lever is at F................................................................................................................. 20-361
d) Does not display N even when directional lever is at N, and displays E when
directional lever is at R ................................................................................................................ 20-362
e) Does not display 1st even when speed lever is at 1 (directional lever at F or R) ........................ 20-362
f) Does not display 2nd even when speed lever is at 2 (directional lever at F or R) ........................ 20-362
g) Does not display 3rd even when speed lever is at 3 (directional lever at F or R) ........................ 20-363
h) Does not display 4th even when speed lever is at 4 (directional lever at F or R) ........................ 20-363
M-5 Turn signal display does not light up.................................................................................................. 20-365
a) L.H. turn signal display does not light up ..................................................................................... 20-365
b) R.H. turn signal display does not light up .................................................................................... 20-365
M-6 Abnormality in parking display ........................................................................................................... 20-366
a) Parking lamp display does not light up ........................................................................................ 20-366
b) Parking lamp display stays lighted up.......................................................................................... 20-366
M-7 Night lighting does not light up........................................................................................................... 20-367
M-8 Abnormality in front working lamp...................................................................................................... 20-368
a) Neither monitor display nor front working lamp light up ............................................................... 20-368
b) Working lamp lights up but monitor display does not light up ...................................................... 20-368
c) Monitor display lights up but working lamp does not light up ....................................................... 20-368
M-9 Abnormality in rear working lamp....................................................................................................... 20-370
a) Neither monitor display nor rear working lamp light up................................................................ 20-370
b) Working lamp lights up but monitor display does not light up ...................................................... 20-370
c) Monitor display lights up but working lamp does not light up ....................................................... 20-370
M-10 Abnormality in transmission cut-off .................................................................................................... 20-372
Standard specification
a) When transmission cut-off switch is pressed, cut-off function is not switched
and display does not change ....................................................................................................... 20-372
b) When transmission cut-off switch is turned OFF, cut-off function is always actuated. ................. 20-372
c) Transmission cut-off switch turned ON, but cut-off function is not actuated ................................ 20-373
WA700-3 20-351
(10)
Auto-shift specification
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is
not switched and display does not change 5 ............................................................................... 20-374
b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out
but cut-off function is actuated when pedal is depressed ............................................................ 20-374
c) When monitor display is turned off (transmission cut-off switch turned OFF),
cut-off function is always actuated ............................................................................................... 20-374
d) Cut-off function is always actuated regardless of monitor display
(transmission cut-off switch ON or OFF)...................................................................................... 20-374
e) Monitor display lights up (transmission cut-off switch turned ON),
but cut-off function is not actuated ............................................................................................... 20-375
M-11 Abnormality in parking brake dragging warning ................................................................................. 20-376
a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp flashes even when
directional lever is at N................................................................................................................. 20-376
b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when
directional lever is at position other than N .................................................................................. 20-376
M-12 When parking brake dragging warning is given, buzzer and caution lamp are actuated
continuously, or they are not actuated ............................................................................................... 20-378
a) Actuated continuously.................................................................................................................. 20-378
b) Not actuated................................................................................................................................. 20-378
M-13 Abnormality in buzzer ........................................................................................................................ 20-379
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check) ......... 20-379
b) Buzzer always sounds ................................................................................................................. 20-379
M-14 Condition of monitor switches is not stored in memory...................................................................... 20-380
M-15 Abnormality in failure display mode ................................................................................................... 20-381
a) Does not enter failure display mode ............................................................................................ 20-381
b) Count for time elapsed since failure in failure display mode does not advance........................... 20-381
M-16 Abnormality in electric engine throttle controller error display ........................................................... 20-382
a) There is no abnormality on machine but error code [91] is displayed.......................................... 20-382
b) There is no abnormality on machine but error code [92] is displayed.......................................... 20-382
c) Problem is error code [90(94)] but error code [91(93)] is displayed ............................................. 20-382
d) Problem is error code [90(96)] but error code [92(95)] is displayed............................................. 20-383
M-17 Abnormality in emergency steering actuation display........................................................................ 20-384
a) Emergency steering actuation display does not light up .............................................................. 20-384
b) Emergency steering actuation display stays lighted up ............................................................... 20-384
M-18 Abnormality in auto-greasing system................................................................................................. 20-385
a) Forced greasing cannot be carried out ........................................................................................ 20-385
b) Monitor display flashes rapidly (2 times/sec) ............................................................................... 20-385
c) When no more grease remains, monitor display flashes rapidly (2 times/sec) ............................ 20-385
d) Monitor display flashes slowly (1 time/sec) .................................................................................. 20-386
e) Monitor display goes out .............................................................................................................. 20-386
M-19 Abnormality in low idling select system.............................................................................................. 20-387
a) Display does not change when switch is pressed........................................................................ 20-387
b) Monitor display lights up but low idling select function does not work ......................................... 20-387
20-352 WA700-3
(10)
Troubleshooting Electrical circuit diagram for M mode system
Electrical circuit diagram for M mode system

Serial No.: 50001 – 51000
20-354 WA700-3
(10)
WA700-3 20-355
(10)
20-356 WA700-3
(10)
WA700-3 20-357
(10)
Troubleshooting M-1
M-1 Main monitor does not work
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
YES
Defective main monitor Replace
1
Is voltage
between L05 (1), Defective contact or discon-
(2) – (3) normal? 2 YES nection in wiring harness Repair or
Is resistance bet- between L05 (female) (1), replace
• 20 – 30 V ween L05 (female) (2) and FS2 (female) (9)
• Turn starting NO (3) and chassis Defective contact or discon-
switch ON. ground normal? Repair or
nection in wiring harness
• Turn starting NO between L05 (female) (3) replace
switch OFF. and LR5 (male) (3)
• Disconnect L05.
• Max. 1 z
20-358 WA700-3
(10)
Troubleshooting M-2
M-2 When starting switch is turned ON and engine is started immediately, all lamps
stay lighted up
Cause Remedy
1 YES
Is voltage between
L05 (4) and chassis
ground normal? Defective contact or discon-
nection in wiring harness Repair or
• 20 – 30 V NO between L05 (female) (4) replace
• Turn starting switch and L57 (female) (3)
to START.
WA700-3 20-359
(10)
Troubleshooting M-3
M-3 Speedometer display does not work properly
a Check that the gap between the speed sensor and gear is normal.
Cause Remedy
2 YES
Is resistance
YES between L07
1 (female) (1) and (2) Defective contact or discon-
normal? nection in wiring harness
Is resistance Repair or
between L07 (female) (1),
between T05 • 500 z – 1 kz NO replace
(2) – TL1 (11), (12) – T05
(male) (1) and (2) • Turn starting switch (female) (1), (2)
normal? OFF.
• 500 z – 1 kz • Disconnect L07.
• Turn starting switch NO Defective speed sensor Replace
OFF.
• Disconnect T05.
20-360 WA700-3
(10)
Troubleshooting M-4
M-4 Abnormality in shift indicator
a Before carrying out troubleshooting, check that all the related connectors are properly inserted..
a Always connect any disconnected connectors before going on the next step.
a Check that the transmission shifts.
a Check that the output of the directional lever and speed lever is normal before starting troubleshooting.
a Check that the steering is in the steering wheel mode.
a) Displays N even when directional lever is at F

Cause Remedy
1 YES
Is voltage
between L08 (7)
Defective contact or
and chassis
disconnection in wiring
ground normal? Repair or
harness between L08
• 20 – 30 V NO (female) (7) and L04 replace
• Turn starting (female) (2)
switch ON.
• Directional lever: F
b) Displays N even when directional lever is at R

Cause Remedy
1 YES
Is voltage
between L08 (8)
and chassis
harness between L08
• 20 – 30 V NO (female) (8) and L04 replace
switch ON.
• Directional lever: R
c) Does not display N even when directional lever is at N,

and displays E when directional lever is at F Cause Remedy
1 YES
Is voltage
between L08 (7)
and chassis Short circuit with power
ground normal? source in wiring harness Repair or
•0– 5V NO between L08 (female) (7) replace
• Turn starting and L04 (female) (2)
switch ON.
• Directional lever: N
WA700-3 20-361
(10)
Troubleshooting M-4
d) Does not display N even when directional lever is at N,

Cause Remedy
and displays E when directional lever is at R
1 YES
Is voltage
between L08 (8)
and chassis Contact of power source
ground normal? with wiring harness Repair or
•0– 5V NO between L08 (female) (8) replace
switch ON.
e) Does not display 1st even when speed lever is at 1

Cause Remedy
(directional lever at F or R)
1 YES
Is voltage between
L05 (female) (12) <Standard specification>
and chassis Defective contact or
• 20 – 30 V NO harness between L05 replace
• Turn starting (female) (12) and L04
switch ON. (female) (5)
<Auto-shift specification>
disconnection in wiring Repair or
harness between L05 replace
(female) (12) and TL1 (1)
(female)
f) Does not display 2nd even when speed lever is at 2

Cause Remedy
1 YES
Is voltage between
(female)
20-362 WA700-3
(10)
Troubleshooting M-4
g) Does not display 3rd even when speed lever is at 3

Cause Remedy
1 YES
Is voltage between
(female)
h) Does not display 4th even when speed lever is at 4

Cause Remedy
1 YES
Is voltage between
(female)
WA700-3 20-363
(10)
Troubleshooting M-4

20-364 WA700-3
(10)
Troubleshooting M-5
M-5 Turn signal display does not light up
a Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not
blown
a) L.H. turn signal display does not light up

Cause Remedy
1 YES
Is voltage between
L06 (14) and
chassis ground
normal? Repair or
• Repeats 0V and NO between L06 (female) (14) replace
20 – 30V. and L03 (female) (4)
• Turn starting switch ON.
• Turn L.H. turn signal ON.
b) R.H. turn signal display does not light up

Cause Remedy
1 YES
Is voltage between
L06 (15) and
chassis ground
normal? Repair or
• Repeats 0V and NO between L06 (female) (15) replace
20 – 30V. and L03 (female) (3)
• Turn R.H. turn signal ON.
WA700-3 20-365
(10)
Troubleshooting M-6
M-6 Abnormality in parking display
a) Parking lamp display does not light up

Cause Remedy
3 YES
Is resistance
YES between F12
(female) (2) and
2 chassis ground Defective contact or discon-
Is voltage between normal? nection in wiring harness Repair or
YES L06 (11) and replace
• Max. 1 z NO between F12 (female) (1)
chassis ground • Turn starting switch and chassis ground
1 normal? OFF.
Is resistance Defective contact or discon-
• 20 – 30 V • Disconnect F12. nection in wiring harness Repair or
between F12
(male) (1) and (2) • Turn starting switch NO between L06 (female) (11) – replace
normal? ON. LR2 (14) – FR2 (6) – F12
• Turn parking switch (female) (1)
• Max. 1 z ON.
• Disconnect F12. Defective parking brake Replace
• Turn starting switch NO indicator switch
ON.
• Turn parking switch
ON.
b) Parking lamp display stays lighted up

Cause Remedy
2 YES
Is voltage between
YES F12 (1) and chassis
1 ground normal?
Short circuit with power
Is resistance source in harness between Repair or
between F12 •0– 2V NO L06 (female) (11) – LR2 (14) replace
(male) (1) and (2) • Turn starting switch – FR2 (6) – CN19 (female)
normal? ON. (1)
• Max. 1 z • Turn parking switch OFF. Defective parking brake
• Disconnect F12. Replace
NO indicator switch
• Turn starting switch
ON.
OFF.
20-366 WA700-3
(10)
Troubleshooting M-7
M-7 Night lighting does not light up
a Before starting troubleshooting, check that the lamp bulbs are not blown.
a Check that fuse I-6 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring
harness between FS2 (female) (5) and L05 (female) (16).
Cause Remedy
1 YES
Is voltage between
L05 (16) and
chassis ground
normal? Repair or
• 20 - 30 V NO harness between L05 replace
• Turn starting switch (female) (16) and FS2 (5)
ON.
• Turn small lamp switch
ON.
WA700-3 20-367
(10)
Troubleshooting M-8
M-8 Abnormality in front working lamp
a Before starting troubleshooting, check that the monitor lighting is lighted up.
a) Neither monitor display nor front working lamp light up

Cause Remedy

between L60 (female) (1) – replace
L05 (17), CL1 (female) (7)
1 YES Defective front working

Replace
Is voltage between 3 lamp relay
L60 (1) and chassis Is voltage between
ground normal? YES
L60 (6) and chassis Defective contact or discon-
ground normal? 4 YES nection in wiring harness Repair or
•0– 3V between L06 (female) (1) replace
2 Is voltage between and L60 (female) (6)
• Turn starting switch •0– 3V
Is voltage between L06 (1) and chassis
ON. • Turn starting NO ground normal?
L60 (2), (5) and
switch ON.
NO chassis ground Defective main monitor Replace
normal? • 20 – 30 V NO
• 20 – 30 V
ON.
• Turn starting switch Defective contact or discon-
ON. nection in wiring harness Repair or
NO between L60 (female) (2), replace
(5) and FS5 (female) (1)
b) Working lamp lights up but monitor display does not light up

Cause Remedy
1 YES
Is voltage between
L05 (17) and
chassis ground
normal? Repair or
ON.
c) Monitor display lights up but working lamp does not light up

Cause Remedy
harness between L60
(female) (1) – CL1 (7) – C03
(female) (1), C04 (female) Repair or
(1), or between L60 replace
(female) (3) – LR1 (12) – FR1
(7) – F01 (1), F04 (1) – front
working lamp, or blown
bulb in front working lamp
20-368 WA700-3
(10)
Troubleshooting M-8
WA700-3 20-369
(10)
Troubleshooting M-9
M-9 Abnormality in rear working lamp
a Before starting troubleshooting, check that the monitor lighting is lighted up.
a) Neither monitor display nor rear working lamp light up

Cause Remedy
YES disconnection in wiring
Repair or
harness between L61
(female) (1) – L05 (female) replace
(18), LR1 (female) (8)
1 YES Defective rear working

Replace
Is voltage between 3 lamp relay
L61 (1) and chassis Is voltage between
ground normal? YES
• 20 – 30 V between L06 (female) (2) replace
2 Is voltage between and L61 (female) (6)
• Turn starting switch •0– 3V
Is voltage between L06 (2) and chassis
ON. • Turn starting NO ground normal?
L61 (2), (5) and
switch ON.
NO chassis ground Defective main monitor Replace
normal? •0– 3V NO
• 20 – 30 V
ON. Defective contact or discon-
ON. nection in wiring harness Repair or
NO between L61 (female) (2), replace
(5) and FS5 (female) (2)
b) Working lamp lights up but monitor display does not light up

Cause Remedy
1 YES
Is voltage between
L05 (18) and
chassis ground
normal? Repair or
ON.
c) Monitor display lights up but working lamp does not light up

Cause Remedy
harness between L61
(female) (1) – LR1 (8) – GR1
(7) – G06 (female) (1), G07 Repair or
(female) (1), or between replace
L61 (female) (3) – LR1 (9) –
GR1 (9) – G02 (1), G08 (1),
or blown bulb in working
lamp
20-370 WA700-3
(10)
Troubleshooting M-9
WA700-3 20-371
(10)
Troubleshooting M-10
M-10 Abnormality in transmission cut-off
a Before disconnecting or connecting connectors, always turn starting switch OFF.

a) When transmission cut-off switch is pressed, cut-off function is not switched and display does not
change
Cause Remedy
b) When transmission cut-off switch is turned OFF, cut-off function is always actuated.
Cause Remedy
YES
Defective monitor panel Replace
1 4 YES disconnection in wiring Repair or

harness between L65
Is voltage Is voltage replace
(female) (5) and L66
between L06 (3) YES between L65 (5) (female) (1)
and chassis 3 and chassis
ground normal? Is voltage ground normal? Defective transmission
Replace
• 20 – 30 V
YES between L65 (1) • 20 – 30 V NO cut-off relay
• Turn cut-off and chassis • Turn starting switch ON.
2 ground normal? • Turn parking switch Defective contact or
switch ON. Is resistance disconnection in wiring
OFF.
between L06 • 20 – 30 V harness between L65 Repair or
(female) (3) and • Turn starting NO (female) (1), FS2 (female) replace
NO L65 (female) (2)
switch ON. (8) and fuse
normal?
• Disconnect L65
• Max. 1 z Defective contact or
• Turn starting disconnection in wiring
NO Repair or
switch OFF. harness between L06
replace
• Disconnect L05 (female) (3) and L65
and L65. (female) (2)
20-372 WA700-3
(10)
c) Transmission cut-off switch turned ON, but cut-off function is not actuated
Cause Remedy
3 YES
Defective monitor panel Replace
YES Does cut-off
2 function work? Short circuit with chassis
Is voltage ground in harness Repair or
YES between L65 (5) • Disconnect L06 NO between L06 (female) (3) replace
and chassis • Turn starting and L65 (female) (2)
1 ground normal? switch ON.
• Turn parking switch OFF.
•0– 3V Defective cut-off relay Replace
Does cut-off NO
• Turn starting
function work?
switch ON.
• Turn parking switch
• Turn starting Short circuit between L65
OFF. Repair or
switch ON. (female) (3) and (5) or
NO defective cut-off switch replace
• Remove cut-off
relay.
• Turn parking
switch OFF.
WA700-3 20-373
(10)
a) When monitor switch (transmission cut-off switch) is pressed,

Cause Remedy
cut-off function is not switched and display does not change 5
b) When monitor switch (transmission cut-off switch) is OFF,

Cause Remedy
monitor display goes out but cut-off function is actuated when
pedal is depressed
1 YES nection in wiring harness Repair or
between L06 (female) (3) replace
Is voltage between and C5 (female) (6)
L06 (3) and chassis
ground normal?
•0– 3V NO
ON.
• Disconnect L12.
c) When monitor display is turned off (transmission cut-off

Cause Remedy
switch turned OFF), cut-off function is always actuated

Is resistance bet- between L12 (female) (1) replace
and C5 (female) (6)
YES ween L12 (female)
1 (2) and chassis
Is resistance ground normal? nection in wiring harness Repair or
between L12 • Max. 1 z NO between L12 (female) (2) replace
(male) (1) and (2) • Turn starting switch and chassis ground
normal? OFF.
• Max. 1 z • Disconnect L12. Defective transmission
• Turn starting switch NO Replace
cut-off switch
OFF.
• Disconnect L12.
d) Cut-off function is always actuated regardless of monitor dis-

Cause Remedy
play (transmission cut-off switch ON or OFF)
1 YES Defective transmission

Replace
controller
Is voltage between
C5 (6) and chassis
ground normal?
between C5 (female) (6)
• Max. 3 V NO replace
and L06 (female) (3), L12
(female) (1)
20-374 WA700-3
(10)
e) Monitor display lights up (transmission cut-off switch turned

Cause Remedy
ON), but cut-off function is not actuated
YES Defective transmission

Replace
cut-off switch
1
Does cut-off
function work
YES
when L12 is Defective main monitor Replace
disconnected?
2
Does cut-off
• Disconnect L12.
function work
• Turn starting
NO when L06 is 3 YES Defective transmission
switch ON. disconnected? Replace
controller
Is voltage between
• Disconnect L06. C5 (6) and chassis
• Turn starting NO ground normal? Short circuit with power
switch ON. source in harness between Repair or
• Disconnect L12. NO L06 (female) (3) – C5 (female) replace
• Turn starting switch (6) – L12 (female) (1)
ON.
• 20 – 30 V
WA700-3 20-375
(10)
M-11 Abnormality in parking brake dragging warning
a With or without auto-shift, use the flowchart below when in the steering wheel mode.
a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp flashes even when
directional lever is at N
Cause Remedy
1 YES
Is voltage between
L05 (8) and chassis
ground normal? Defective contact or discon-
• 20 – 30 V NO between L05 (female) (8) – replace
L04 (female) (3)
ON.
b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even
when directional lever is at position other than N
a Check that the synchronous flash signal is normal.
Cause Remedy
YES
1
Is voltage between Short circuit with power
L05 (8) and chassis source in wiring harness
ground normal? 2 YES Repair or
between L05 (female) (8)
replace
Is resistance bet- – L04 (female) (3), or
•0– 5V
ween L05 (male) defective directional lever
• Turn starting NO (8) and (3) normal?
switch ON.
• Directional lever: Defective main monitor Replace
• 3 kz – 4 kz NO
Other than N • Turn starting switch
OFF.
• Disconnect L05.
20-376 WA700-3
(10)
WA700-3 20-377
(10)
M-12 When parking brake dragging warning is given, buzzer and caution lamp are
actuated continuously, or they are not actuated
a) Actuated continuously
Cause Remedy
2 YES Defective maintenance Replace

monitor
YES Does buzzer stop
1 and lamp go out? Defective contact or discon-
Does buzzer stop • Turn starting switch NO between L07 (female) (6) replace
and lamp go out? ON. and L19 (female) (5)
• Connect L19 (female) (5)
• Turn starting switch to chassis ground.
ON. Defective main monitor Replace
NO
• Connect L07 (6) to
chassis ground.
b) Not actuated
Cause Remedy
2 YES Defective maintenance Replace

monitor
YES Do buzzer and
1 lamp work? Short circuit with power
source in harness between Repair or
Do buzzer and • Turn starting switch NO L07 (female) (6) and L19 replace
lamp work? ON. (female) (5)
• Disconnect L19.
ON. Defective main monitor Replace
NO
• Disconnect L07.
20-378 WA700-3
(10)
M-13 Abnormality in buzzer
a) Buzzer does not sound when starting switch is at ON

Cause Remedy
(for 3 seconds) (during self-check)

1 between L06 (female) (8) replace
and L43 (male) (1)
Does buzzer
sound? 2 YES
Is voltage between
• Turn starting switch L42 (female) and
ON. NO chassis ground Defective contact or discon-
• Contact L43 (female) normal? nection in wiring harness Repair or
to chassis ground. • 20 – 30 V between L42 (female) (1) replace
NO
• Turn starting switch and FS2 (female) (9)
ON.
b) Buzzer always sounds

Cause Remedy
YES
1
Does buzzer stop
when L06 is YES Go to Troubleshooting
disconnected? —
2 for maintenance monitor
• Disconnect L06. Does buzzer stop

• Turn starting when L19 is Short circuit with power
NO disconnected? 3 YES source in harness between Repair or
switch ON.
L06 (female) (8) and L43 replace
Does buzzer stop (male) (1)
• Disconnect L19. when L43 is
• Turn starting NO disconnected?
switch ON.
• Disconnect L43. NO
ON.
WA700-3 20-379
(10)
M-14 Condition of monitor switches is not stored in memory
Cause Remedy
1 YES
Is voltage between
L07 (10) and
chassis ground
normal? Repair or
ON.
20-380 WA700-3
(10)
M-15 Abnormality in failure display mode
a) Does not enter failure display mode

Cause Remedy
1 YES
Is voltage between
L05 (5) and chassis Short circuit with power
ground normal? source in wiring harness
between L05 (female) (5) – Repair or
•0– 5V NO LR4 (6) – ER1 (9) – replace
• Turn starting switch alternator terminal R, or
defective alternator
ON.
b) Count for time elapsed since failure in failure display mode

Cause Remedy
does not advance
1 YES
Is voltage between
ground normal? nection in wiring harness
• 20 – 30 V NO LR4 (6) – ER1 (9) – replace
• Start engine. alternator terminal R, or
defective alternato
WA700-3 20-381
(10)
M-16 Abnormality in electric engine throttle controller error display

Serial No.: 50001 – 51000
a) There is no abnormality on machine but error code [91] is displayed

Cause Remedy
YES
1
Is voltage
between L07 (9)
See Troubleshooting (G
and chassis 2 YES mode) of electric engine —
ground normal?
Is voltage between throttle controller
• 20 – 30 V EC1 (female) (15)
• Turn starting NO and chassis Short circuit with chassis
switch ON. ground normal? ground in wiring harness Repair or
NO
• Disconnect EC1. and EC1 (female) (15)
• Turn starting
switch ON.
b) There is no abnormality on machine but error code [92] is displayed

Cause Remedy
YES
1
Is voltage
between L07 (5)
and chassis 2 YES mode) of electric engine —
ground normal?
Is voltage between throttle controller
• 20 – 30 V EC1 (female) (6)
• Turn starting NO and chassis Short circuit with chassis
NO
• Disconnect EC1 and EC1 (female) (6)
(female).
• Turn starting
switch ON.
c) Problem is error code [90(94)] but error code [91(93)] is displayed

Cause Remedy
YES
1
Is voltage
between L07 (5)
and chassis 2 YES Repair or
harness between L07
ground normal? replace
Is voltage between (female) (5) and EC1
• Max. 3 V EC1 (female) (6) (female) (6)
• Turn starting NO and chassis
switch ON. ground normal? See Troubleshooting (G
• Max. 3 V mode) of electric engine —
NO
• Turn starting throttle controller
switch ON.
20-382 WA700-3
(10)
d) Problem is error code [90(96)] but error code [92(95)] is displayed

Cause Remedy
YES
1
Is voltage
between L07 (9) Defective contact or
and chassis disconnection in wiring
2 YES harness between L07 Repair or
ground normal?
Is voltage between (female) (9) and EC1 replace
• Max. 3 V EC1 (female) (15) (female) (15)
switch ON. ground normal? See Troubleshooting (G
mode) of electric engine —
• Max. 3 V NO throttle controller
• Turn starting
switch ON.
WA700-3 20-383
(10)
M-17 Abnormality in emergency steering actuation display
a) Emergency steering actuation display does not light up
Cause Remedy
1 YES
Is voltage
between L05 (11) Short circuit with chassis
and chassis ground in wiring harness
ground normal? between L05 (female) (11)
Repair or
– LR4 (13) – R01 (female)
• 20 – 30 V NO replace
(1) or defective
• Turn starting emergency steering
switch ON. actuation sensor
b) Emergency steering actuation display stays lighted up
Cause Remedy
1 YES
Is voltage
between L05 (11) Defective contact or Repair or
and chassis disconnection in wiring replace
ground normal? harness between L05
(female) (11) – LR4 (13) –
•0– 2V NO R01 (female) (1)
• Turn starting or defective emergency Replace
switch ON. steering actuation sensor
20-384 WA700-3
(10)
M-18 Abnormality in auto-greasing system
a) Forced greasing cannot be carried out

Cause Remedy
See “ Handling auto-greasing

2 YES
system” in Operation and —
Is voltage between Maintenance Manual
YES GRE (1) and
1 chassis ground
normal? Repair or
Is voltage between nection in wiring harness
L06 (5) and chassis • Max. 3 V NO between L06 (female) (5) replace
• Turn starting switch ON. and GRE (1)
ground normal?
• Turn auto-greasing
• Max. 3 V switch ON.
Defective main monitor Disconnect
• Turn starting switch NO
ON.
• Turn auto-greasing
switch ON.
b) Monitor display flashes rapidly (2 times/sec)

Cause Remedy
YES Defective main monitor Replace

1
Is voltage between
Is voltage between between L08 (female) (5) replace
• 20 – 30 V and GRE (3)
GRE (3) and
• Turn starting NO chassis ground
switch ON. normal? See “ Handling auto-greasing
• 20 – 30 V NO Maintenance Manual
ON.
c) When no more grease remains, monitor display flashes

Cause Remedy
rapidly (2 times/sec)
YES
1
Is voltage between
L07 (11) and
chassis ground 2 YES nection in wiring harness Repair or
normal? between L07 (female) (11)
Is voltage between replace
• 20 – 30 V GRE (2) and and GRE (2)
• Turn starting NO chassis ground
switch ON. normal? See “ Handling auto-greasing
• 20 – 30 V NO Maintenance Manual
ON.
WA700-3 20-385
(10)
d) Monitor display flashes slowly (1 time/sec)

Confirm that grease is not empty. Cause Remedy
See “ Handling auto-greasing

Maintenance Manual
e) Monitor display goes out

Cause Remedy
YES
1
Is voltage between
L07 (11) and
chassis ground 2 YES source in wiring harness Repair or
normal? between L07 (female) (11)
• Max. 3 V GRE (female) (2) and GRE (female) (2)
switch ON. ground normal? See “ Handling auto-greasing
•2– 3V NO Maintenance Manual
ON.
• Disconnect GRE.
Table (Relationship between input signal

and display)
L07(11) L08(5) Display
L L Repid flashing (2 times/sec)
H L Slow flashing (1 time/sec)
H H OFF
L H ON
20-386 WA700-3
(10)
M-19 Abnormality in low idling select system

Serial No.: 50001 – 51000
a) Display does not change when switch is pressed

Cause Remedy
b) Monitor display lights up but low idling select function does

Cause Remedy
not work
2 YES mode) of electric engine —
Is voltage throttle controller
YES between EC5A (5)
1 and chassis Defective contact or
Is voltage ground normal? disconnection in wiring Repair or
between L06 (7) • Max. 3 V NO harness between L06 replace
and chassis • Turn starting (female) (7) and EC5A (5)
ground normal? switch ON.
• Max. 3 V
• Turn starting Defective main monitor Replace
NO
switch ON.
WA700-3 20-387
(10)

a) Display does not change when switch is pressed

Cause Remedy
b) Monitor display lights up but low idling select function does

Cause Remedy
not work
See Troubleshooting (EA

2 YES mode) of engine —
Is voltage controller
YES between ECMB
1 (36) and chassis Defective contact or
Is voltage ground normal? disconnection in wiring
Repair or
between L06 (7) harness between L06
and chassis (female) (7) and ECMB
ground normal? switch ON.
• Max. 3 V
• Turn starting Defective main monitor Replace
NO
switch ON.
20-388 WA700-3
(10)
Troubleshooting of maintenance
monitor system
(K mode)
Electrical circuit diagram for K mode system .............................................................................................. 20-402
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up
for 3 seconds, maintenance monitor does not work ........................................................................... 20-404
a) No lamps on maintenance monitor light up................................................................................... 20-404
b) Some lamps do not light up .......................................................................................................... 20-404
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but
do not go out (even after 3 seconds) .................................................................................................. 20-405
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), no lamps on
maintenance monitor go out ............................................................................................................... 20-406
K-4 When starting switch is turned ON (engine stopped), CHECK items flash......................................... 20-407
a) Engine oil level display flashes ..................................................................................................... 20-407
b) Engine water level display flashes ................................................................................................ 20-408
K-5 When starting switch is turned ON (engine started), CAUTION items flash....................................... 20-410
a) Engine oil pressure display flashes (Check that the engine oil pressure is correct.) .................... 20-410
b) Battery charge level display flashes.............................................................................................. 20-412
c) Brake oil pressure display flashes (Check that the brake oil pressure is correct.)........................ 20-413
d) Air cleaner (L.H.) display flashes .................................................................................................. 20-414
e) Air cleaner (R.H.) display flashes.................................................................................................. 20-415
f) Air cleaner display flashes ............................................................................................................. 20-416
K-6 CAUTION items are flashing but caution buzzer does not sound ...................................................... 20-417
K-7 There is no abnormality in monitor display but caution buzzer sounds .............................................. 20-418
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not flash....... 20-419
a) CHECK lamp................................................................................................................................. 20-419
b) CAUTION lamp............................................................................................................................. 20-419
K-9 There is no abnormality in maintenance monitor display but warning lamp
(CHECK lamp, CAUTION lamp) lights up........................................................................................... 20-420
a) CHECK lamp................................................................................................................................. 20-420
b) CAUTION lamp............................................................................................................................. 20-420
K-10 Night lighting does not light up when lamp switch is turned ON
(only lighting of maintenance monitor does not light up)..................................................................... 20-421
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up....................... 20-422
K-12 Service meter does not work.............................................................................................................. 20-423
K-13 Service meter is running even when engine is stopped ..................................................................... 20-423
K-14 Abnormality in gauge items ................................................................................................................ 20-425
a) Abnormality in fuel gauge ............................................................................................................. 20-425
b) Abnormality in engine water temperature gauge .......................................................................... 20-426
c) Abnormality in torque converter oil temperature gauge ................................................................ 20-427
WA700-3 20-401
(10)
Troubleshooting Electrical circuit diagram for K mode system
Electrical circuit diagram for K mode system

Serial No.: 50001 – 51000
20-402 WA700-3
(10)
Troubleshooting Electrical circuit diagram for K mode system
WA700-3 20-403
(10)
Troubleshooting K-1
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not
light up for 3 seconds, maintenance monitor does not work
a) No lamps on maintenance monitor light up

Cause Remedy
YES Defective monitor module

Replace
of maintenance monitor

1 nection in wiring harness Repair or
YES between L18 (female) (1), replace, or
Is voltage between
3 (2) – FS2 (9) – fuse – FS1
replace fuse
L18 (1), (2) – (3)
(male) (2), or blown fuse
normal? Is voltage between
YES FS1 (female) (2)
• 20 – 30 V and chassis
• Turn starting switch 2 ground normal? Defective contact or discon-
ON. nection in wiring harness
Is resistance • 20 – 30 V between FS1 (female) (2) – Repair or
between L18 • Disconnect FS1. LR6 (1) – slow blow fuse - replace, or
(female) (3), L19 (8) NO
NO and chassis • Turn starting switch battery relay, or blown slow replace fuse
ground normal? ON. blow fuse (80A)
• Max. 1 z Defective contact or discon-

• Turn starting switch nection in wiring harness
Repair or
between L18 (3), L19
ON. NO replace
(female) (8) – LR4 (12) –
• Disconnect L18, chassis ground
L19.
b) Some lamps do not light up

Cause Remedy
Defective monitor module

Replace
20-404 WA700-3
(10)
Troubleshooting K-2
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up
but do not go out (even after 3 seconds)
Cause Remedy
Defective monitor module

Replace
K-1, 2 Related electrical circuit diagram
WA700-3 20-405
(10)
Troubleshooting K-3
K-3 When engine is started immediately after starting switch is turned ON (within 3
seconds), no lamps on maintenance monitor go out
Cause Remedy
1 YES
Defective monitor module Replace
When starting engine,
is voltage between
L19 (female) (1) and
chassis ground Defective contact or discon-
normal? nection in wiring harness Repair or
• Disconnect L19. and neutral relay
• Start engine.
• Measure when starting
motor is turning
(starting switch at START).
K-3 Related electrical circuit diagram
20-406 WA700-3
(10)
Troubleshooting K-4
K-4 When starting switch is turned ON (engine stopped), CHECK items flash
a) Engine oil level display flashes

a Before starting troubleshooting, check the engine oil level again.
(Check that the engine oil level is correct.)
Cause Remedy
2 YES Defective monitor module

of maintenance monitor Replace
Is resistance bet-
1 (13) and chassis Defective contact or
ground normal? disconnection in wiring
Is resistance bet- Repair or
harness between L18
ween E19 (male) • Max. 1 z NO (female) (13) – LR4 (4) – replace
(1) and chassis • Turn starting switch ER1 (3) – E19 (female) (1)
ground normal? OFF.
• Max. 1 z • Disconnect L18. Defective engine oil level Replace
• Turn starting switch NO sensor
OFF.
• Disconnect E19.
K-4 a) Related electrical circuit diagram
WA700-3 20-407
(10)
Troubleshooting K-4
b) Engine water level display flashes

Serial No.: 50001 – 51000
a Before starting troubleshooting, check the engine water level again.
(Check that the engine water level is correct.)
Cause Remedy

Replace
Is resistance bet- of maintenance monitor
2 (8) and chassis Defective contact or discon-
YES ween G03 (female) between L18 (female) (8) –
• Max. 1 z NO LR3 (1) – GR1 (8) – G03 replace
(1) and chassis • Turn starting switch (female) (1)
1 ground normal? OFF. Defective contact or discon-
Is resistance
• Max. 1 z • Disconnect L18. nection in wiring harness Repair or
between G03
(male) (2) and (1) • Turn starting switch NO between G03 (female) (2) – replace
OFF. GR1 (11) – chassis ground
normal?
• Disconnect G03.
• Max. 1 z
• Turn starting switch Defective radiator water
Replace
OFF. NO level sensor
• Disconnect G03.
K-4 b) Related electrical circuit diagram
20-408 WA700-3
(10)
Troubleshooting K-4
b) Engine water level display flashes

a Before starting troubleshooting, check the engine water level again.
(Check that the engine water level is correct.)
Cause Remedy

Replace
YES ween G03 (female) between L18 (female) (8) –
• Max. 1 z NO LR3 (1) – GR1 (8) – G03 replace
(1) and chassis • Turn starting switch (female) (1)
1 ground normal? OFF. Defective contact or discon-
Is resistance
between G03
(male) (2) and (1) • Turn starting switch NO between G03 (female) (2) – replace
OFF. GR1 (11) – chassis ground
normal?
• Disconnect G03.
• Max. 1 z
• Turn starting switch Defective radiator water
Replace
OFF. NO level sensor
• Disconnect G03.
WA700-3 20-409
(10)
Troubleshooting K-5
K-5 When starting switch is turned ON (engine started), CAUTION items flash
Serial No.: 50001 – 51000
a) Engine oil pressure display flashes

(Check that the engine oil pressure is correct.)
Cause Remedy
YES Defective engine oil

Replace
pressure switch
1
Does display go
Replace
out when E18 is
pressure relay
disconnected?
2
• Start engine. Does condition
• Disconnect E18. become normal 4 YES Defective monitor module
when engine oil
Replace
NO pressure relay L64 is
interchanged?
• Interchange engine
oil pressure relay Repair or
Is voltage between between L18 (female) (10) –
L64 with a normal • Max. 1 z NO L64 (3), (6) – LR5 (2) – replace
E18 and chassis
relay. NO ground normal? • Disconnect L18. chassis ground
• Turn starting switch Contact of ground with
OFF. wiring harness between Repair or
• 20 – 30 V
• Disconnect E18. NO ring terminal – ER1 (2) – replace
• Start engine. LR4 (3) - L64 (female) (2)
20-410 WA700-3
(10)
Troubleshooting K-5
a Check that Error Code [527] is not displayed in the engine controller.
a) Engine oil pressure display flashes

(Check that the engine oil pressure is correct.)
Cause Remedy

Replace
1 pressure relay
Is indication set
normal when
engine oil pressure 2 YES Defective maintenance
relay L64 is Replace
replaced? Is resistance bet- monitor module
• Replace engine oil ween L18 (female)
pressure relay with (10) and chassis
dust indicator relay ground normal? harness between L18 Repair or
(L80). NO (female) (10) and L64 (3), replace
NO • Max. 1 z (6), CL1 (12) and chassis
• Disconnect L18. ground
• Turn starting
switch OFF.
WA700-3 20-411
(10)
Troubleshooting K-5
b) Battery charge level display flashes
Cause Remedy

Replace
Is voltage between of maintenance monitor
YES L18 (female) (12)
1 and chassis Defective contact or discon-
Is voltage between ground normal? nection in wiring harness
Repair or
between L18 (female) (12) –
alternator terminal • 20 – 30 V NO replace
LR4 (6) – ER1 (9) –
R and chassis • Start engine. alternator terminal R
ground normal?
• 20 – 30 V
Defective alternator Replace
• Start engine. NO
20-412 WA700-3
(10)
Troubleshooting K-5
c) Brake oil pressure display flashes

(Check that the brake oil pressure is correct.)
Cause Remedy

Replace
Is voltage between of maintenance monitor
YES L18 (11) and
3 chassis ground
Is resistance bet- normal? between L18 (female) (11) – Repair or
YES ween C03 (female) • Start engine. NO LR4 (11) – BC01 (3) – C03 replace
(2) and chassis (female) (1)
• Max. 3 V
2 ground normal? Defective contact or discon-
Is resistance nection in wiring harness
YES between C04 • Max. 1 z between C03 (female) (2) – Repair or
(male) (1) and (2) • Turn starting switch NO C04 (female) (1), or between replace
normal? OFF. C04 (female) (2) – BC01 (1) –
1 chassis ground
• Disconnect C03.
Is resistance • Max. 1 z Defective brake
between C03 • Start engine. accumulator charge oil Replace
(male) (1) and (2) • Disconnect C04. NO pressure switch (C04 end)
normal?
• Max. 1 z Defective brake
• Start engine. accumulator charge oil Replace
• Disconnect C03. NO pressure switch (C03 end)
K-5 c) Related electrical circuit diagram
WA700-3 20-413
(10)
Troubleshooting K-5
d) Air cleaner (L.H.) display flashes

Cause Remedy
(Check that there is no clogging of the air cleaner.)
Serial No.: 50001 – 51000
YES Defective dust indicator

Replace
sensor
1
Does display go Defective dust indicator
YES
out when B07 is Replace
relay
disconnected?
2
• Start engine. Does display go
• Disconnect B07. out when dust 4 YES
To A
NO indicator relay L31 Is resistance bet-
is interchanged? YES ween L31 (female)
ground normal? nection in wiring harness Repair or
B07 (female) (1) • Max. 1 z NO replace
LR5 (2) – chassis ground
NO and chassis • Turn starting switch
ground normal? OFF. Short circuit with chassis
• Disconnect L31. ground in wiring harness
• Turn starting switch between B07 (female) (1) – Repair or
ON. NO BR1 (6) – LR2 (8) – L31 replace
• Disconnect B07. (female) (2) (short circuit or
• 20 – 30 V contact with chassis ground)
Replace
ween L18 (female)
From A (15) and chassis
• Max. 1 z NO between L18 (female) (15) replace
and L31 (female) (3)
OFF.
• Disconnect L18.
K-5 d) Related electrical circuit diagram
20-414 WA700-3
(10)
Troubleshooting K-5
e) Air cleaner (R.H.) display flashes

Cause Remedy
Serial No.: 50001 – 51000

Replace
sensor
1
YES
out when B09 is Replace
relay
disconnected?
2
• Disconnect B09. out when dust 4 YES
To A
B09 (female) (1) • Max. 1 z NO replace
NO and chassis • Turn starting switch
ground normal? OFF. Short circuit with chassis
• Turn starting switch between B09 (female) (1) – Repair or
ON. NO BR1 (7) – LR2 (9) – L32 replace
• Disconnect B09. (female) (2) (short circuit or
• 20 – 30 V contact with chassis ground)
Replace
ween L18 (female)
OFF.
• Disconnect L18.
K-5 e) Related electrical circuit diagram
WA700-3 20-415
(10)
Troubleshooting K-5
f) Air cleaner display flashes

Cause Remedy

Replace
sensor
1
YES
out when E29 is Replace
relay
disconnected?
2
• Disconnect E29. out when dust 4 YES
To A
E29 (male) (1) and • Max. 1 z NO replace
NO chassis ground • Turn starting switch
normal? OFF. Short circuit with chassis
• Turn starting switch between E29 (male) (1) – Repair or
ON. NO L31 (female) (2) (short circuit replace
• Disconnect B07. or contact with chassis
• 20 – 30 V ground)
Replace
ween L18 (female)
OFF.
• Disconnect L18.
K-5 f) Related electrical circuit diagram
20-416 WA700-3
(10)
Troubleshooting K-6
K-6 CAUTION items are flashing but caution buzzer does not sound
a The buzzer does not sound for CHARGE or ENGINE OIL LEVEL.
a Check that fuse I-10 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring
harness between fuse – FS2 (9) – L42 (1).
Cause Remedy

Replace
2 of maintenance monitor
Does buzzer sound
YES when L19 (female) Defective contact or discon-
(4) is connected to 3 YES nection in wiring harness Replace
chassis ground? between L19 (female) (4)
1 Does buzzer sound
• Turn starting when L43 (female) and L43 (male) (1)
Is voltage between
L42 (female) (1)
switch ON. NO (1) is connected to
chassis ground?
and chassis Defective buzzer Replace
ground normal? • Turn starting NO
switch ON.
• 20 – 30 V
• Disconnect L42. Defective contact or discon-
• Turn starting switch nection in wiring harness Repair or
ON. NO between fuse – FS2 (9) – replace
L42 (female) (1)
WA700-3 20-417
(10)
Troubleshooting K-7
K-7 There is no abnormality in monitor display but caution buzzer sounds
a Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
(Note: When joystick steering is not installed)
Cause Remedy

Replace
1 (4) and chassis Short circuit with chassis
ground normal? ground in wiring harness
Is resistance bet- between L19 (female) (4) – Repair or
ween L43 (female) • Min. 1 Mz NO L43 (male) (1) – L06 replace
(1) and chassis • Turn starting switch OFF. (female) (8) (contact with
ground normal? • Disconnect L06, L19, chassis ground)
• Min. 1 Mz and L43.
• Turn starting NO
switch OFF.
• Disconnect L42 and L43.
K-7Related electrical circuit diagram
20-418 WA700-3
(10)
Troubleshooting K-8
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp)
does not flash
a Before carrying out troubleshooting, check that there are no blown lamp bulbs.
a) CHECK lamp
Cause Remedy

1
Does CHECK lamp
light up when L19
(female) (2) is Defective contact or discon-
connected to chassis 2 YES nection in wiring harness Repair or
ground? Does CHECK lamp between L19 (female) (2) replace
• Disconnect L19. light up when L06 and L06 (female) (10)
(male) (10) is
• Turn starting NO connected to chassis
switch ON. ground?
ON.
b) CAUTION lamp
Cause Remedy

1
Does CAUTION
lamp light up when
L19 (female) (3) is Defective contact or discon-
connected to chassis 2 YES nection in wiring harness Repair or
ground? Does CAUTION between L19 (female) (3) replace
• Disconnect L19. lamp light up when and L06 (female) (10)
L06 (male) (9) is
• Turn starting NO connected to chassis
switch ON. ground?
ON.
K-8 a), b) Related electrical circuit diagram
WA700-3 20-419
(10)
Troubleshooting K-9
K-9 There is no abnormality in maintenance monitor display but warning lamp

(CHECK lamp, CAUTION lamp) lights up
a Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
a) CHECK lamp
Cause Remedy
1 YES
ween L19 (female)
(2) and chassis Short circuit with chassis
ground normal? ground in wiring harness Repair or
• Min. 1 Mz NO and L06 (female) (10)
replace
• Turn starting switch (contact with chassis
OFF. ground)
b) CAUTION lamp
Cause Remedy
1 YES
ween L19 (female)
ground normal? ground in wiring harness Repair or
• Min. 1 Mz NO and L06 (female) (9) (contact
replace
• Turn starting switch with chassis ground)
OFF.
20-420 WA700-3
(10)
Troubleshooting K-10
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of
maintenance monitor does not light up)
a Before carrying out troubleshooting, check that there are no blown lamp bulbs.
Cause Remedy
1 YES Disconnection in wiring

Replace
harness of lamp holder
Is voltage between
L21 (female) (1)
and (2) normal? Defective contact or discon-
• Disconnect L21. and FS2 (5)
ON.
• Turn lamp switch ON.
WA700-3 20-421
(10)
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays
lighted up
Cause Remedy
Contact of +24V with wiring

2 YES harness between FS2 Repair or
(male) (4) – fuse box – FS2 replace
Is voltage between
(5) – L21 (female) (1)
YES FS2 (female) (4)
1 and chassis Contact of +24V with wiring
ground normal? harness between L02 Repair or
Is lamp switch • Max. 1 V NO (female) (5) and FS2 replace
normal? • Disconnect FS2. (female) (4)
• Turn lamp switch OFF.
• Turn starting switch • Turn starting switch ON.
OFF. Defective lamp switch Replace
NO
• Disconnect L02.
• Check that continuity between
L02 (male) (1) and (5) is as
shown in table below when
lamp switch is turned ON-OFF.
Switch Continuity
ON YES
OFF NO
20-422 WA700-3
(10)
Troubleshooting K-12, 13
K-12 Service meter does not work
Cause Remedy
YES
Defective service meter Replace

1 Is resistance bet- replace
LR4 (6) – ER1 (9) –
YES ween L22 (female) alternator terminal R
Is voltage between (1) and chassis
2 Defective contact or discon-
L22 (female) (2) ground normal?
Is voltage between nection in wiring harness Repair or
and (1) normal?
alternator terminal • Turn starting NO between L22 (female) (1) – replace
• 20 – 30 V NO R and chassis switch OFF.
ground normal? • Disconnect L22.
• Start engine.
• Disconnect L22. • 20 – 30 V Replace
Defective alternator
• Start engine. NO
K-13 Service meter is running even when engine is stopped
Cause Remedy
YES
Defective service meter Replace
1
Is voltage bet-
ween L22 (female) Contact of +24V with wiring
(2) and (1) normal? 2 YES harness between L22 Repair or
Is voltage between (female) (2) – LR4 (6) – ER1 replace
• Max. 3 V alternator terminal (9) – alternator terminal R
• Turn starting NO R and chassis
switch ON. ground normal?
• Disconnect L22. Defective alternator Replace
• Max. 3 V NO
ON.
WA700-3 20-423
(10)
Troubleshooting K-12, 13
K-12, 13 Related electrical circuit diagram
20-424 WA700-3
(10)
K-14 Abnormality in gauge items
a) Abnormality in fuel gauge

a Before carrying out troubleshooting, check the fuel level again.
Cause Remedy
(Check that the fuel level is correct.)
(1) Little or nothing is displayed in display area
YES
Defective fuel sensor Replace

Replace
Is resistance between of maintenance monitor
1 L18 (female) (6) and
YES chassis ground
Does fuel gauge normal when short
show FULL when 2 connector is Defective contact or discon-
short connector is
Is resistance bet-
connected to R05? nection in wiring harness Repair or
connected to R05 • Max. 1 z between R05 (female) (1) – replace
(female)? ween R05 (female) NO
• Turn starting switch OFF. LR4 (10) – L18 (female) (6)
(2) and chassis
• Disconnect R05. NO ground normal? • Connect short connector to R05 (female).
• Connect short Defective contact or discon-
• Disconnect L18. Repair or
connector to R05 • Max. 1 z nection in wiring harness
• Turn starting NO between R05 (female) (2) replace
(female).
and chassis ground
• Turn starting switch switch OFF.
ON. • Disconnect R05.
(2) Display always shows FULL and does not move

Cause Remedy
YES
Defective fuel sensor Replace
1
Do all display areas
on fuel gauge go
out when R05 is 2 YES Defective monitor module
disconnected? Replace
• Disconnect R05. ween R05 (female)
• Turn starting NO (1) and chassis Short circuit with chassis
• Min. 1 Mz NO between R05 (female) (1) – replace
• Turn starting switch LR4 (10) – L18 (female) (6)
OFF.
• Disconnect L18 and R05.
WA700-3 20-425
(10)
b) Abnormality in engine water temperature gauge

(1) Nothing is displayed in display area
Cause Remedy
YES Defective engine water

Replace
1 temperature sensor
Does engine water
temperature gauge
show minimum level
when E09 is 2 YES Defective monitor module
Replace
disconnected? Is resistance bet- of maintenance monitor
• Disconnect E09. ween E09 (female)
Short circuit with chassis
• Turn starting NO (1) and chassis ground in wiring harness
switch ON. ground normal? between E09 (female) (1) – Repair or
• Min. 1 Mz NO ER1 (6) – LR4 (1) – L18 replace
• Turn starting switch (female) (4) (contact with
OFF. chassis ground)
• Disconnect L18 and E09.
(2) Display shows lowest level and does not move

Cause Remedy
YES Defective engine water

Replace
temperature sensor
1
When short connec-
tor is connected to
E09 (female), does
Replace
engine water temper- Is resistance between of maintenance monitor
ature gauge display L18 (female) (4) and
area rise one stage at YES chassis ground nor-
a time, and finally do mal when short con-
all lamps go out? nector is connected
to E09 (female)? nection in wiring harness Repair or
Is resistance bet- between E09 (female) (1) –
• Disconnect E09.
ween E09 (female) • Max. 1 z NO ER1 (6) – LR4 (1) – L18
replace
• Connect short
NO (2) and chassis • Turn starting switch OFF. (female) (4)
connector to E09 ground normal? • Connect short connector to E09 (female).
(female). Defective contact or discon-
• Turn starting • Disconnect L18. nection in wiring harness Repair or
• Turn starting
switch ON. switch OFF. NO between E09 (female) (2) – replace
• Disconnect E09. ER1 (7) – chassis ground
• Max. 1 z
20-426 WA700-3
(10)
c) Abnormality in torque converter oil temperature gauge

(1) Nothing is displayed in display area
Cause Remedy
YES Defective torque conver-

Replace
1 ter oil temperature sensor
Does torque conver-
ter oil temperature
gauge show mini-
mum level when T06 2 YES Defective monitor module
Replace
is disconnected? Is resistance of maintenance monitor
• Disconnect T06. between T06
(female) (1) and Short circuit with chassis
• Turn starting NO chassis ground ground in wiring harness
switch ON. normal? between T06 (female) (1) – Repair or
• Turn starting NO TL1 (9) – L18 (female) (5) replace
switch OFF. (contact with chassis
• Disconnect L18 and T06. ground)
• Min. 1 Mz
(2) Display shows lowest level and does not move

Cause Remedy
YES Defective torque conver-

Replace
ter oil temperature sensor
1
When short connec-
tor is connected to
T06, does torque
Replace
converter oil temper- Is resistance between of maintenance monitor
ature gauge display L18 (female) (5) and
area rise one stage at YES chassis ground nor-
a time, and finally do mal when short con-
2 nector is connected Defective contact or discon-
all lamps go out?
Is resistance to T06 (female)? nection in wiring harness Repair or
• Disconnect T06. between T06 • Max. 1 z NO between T06 (female) (1) – replace
• Connect short (female) (2) and TL1 (9) – L18 (female) (5)
NO chassis ground • Turn starting switch OFF.
connector to
normal? • Connect short connector to T06 (female). Defective contact or discon-
T06 (female).
• Turn starting between T06 (female) (2) –
switch ON. • Turn starting NO replace
TL1 (10) – LR5 (3) – chassis
switch OFF. ground
• Disconnect T06.
K-14 c) Related electrical circuit diagram
WA700-3 20-427
(10)
Troubleshooting of electrical system
(E mode)
Electrical circuit diagram for E mode system .............................................................................................. 20-454
E-1 Engine does not start.......................................................................................................................... 20-458
a) Starting motor does not turn......................................................................................................... 20-458
b) Starting motor turns...................................................................................................................... 20-464
E-2 Abnormality in APS system ................................................................................................................ 20-474
a) When preheating switch is turned AUTO, preheating lamp does not light up,
but no pilot LED on APS controller lights up. ............................................................................... 20-476
b) When preheating switch is turned AUTO and engine water temperature is below 20ºC,
preheating lamp flashes, but pilot LED on APS controller shows normal.................................... 20-477
c) After preheating, fuel is not injected from APS nozzle when starting switch is
turned START, but pilot LED on APS controller shows normal.................................................... 20-478
d) LED 1 of pilot LED on APS controller shows abnormal ............................................................... 20-479
e) LED 2 of pilot LED on APS controller shows abnormal ............................................................... 20-479
f) LED 3 of pilot LED on APS controller shows abnormal ................................................................ 20-480
g) LED 4 of pilot LED on APS controller shows abnormal ............................................................... 20-480
h) LED 5 of pilot LED on APS controller shows abnormal ............................................................... 20-481
i) LED 6 of pilot LED on APS controller shows abnormal ................................................................ 20-481
j) When preheating switch is OFF, preheating lamp lights up .......................................................... 20-482
E-3 Parking brake does not have effect .................................................................................................... 20-483
a) Parking brake has no effect when parking brake switch is turned ON......................................... 20-483
b) Parking brake has no effect and does not work as emergency brake when
parking brake pressure drops ...................................................................................................... 20-483
E-4 Parking brake is applied when machine is traveling........................................................................... 20-484
E-5 Parking brake is released when starting switch is turned ON............................................................. 20-486
E-6 Transmission does not change to neutral when parking brake is applied,
but parking brake works normally ...................................................................................................... 20-486
E-7 Transmission does not work properly ................................................................................................. 20-489
a) Abnormality in parking brake circuit, transmission cut-off switch circuit or
neutralizer relay circuit................................................................................................................. 20-490
b) No continuity in travel FORWARD solenoid circuit ...................................................................... 20-494
c) No continuity in travel REVERSE solenoid circuit........................................................................ 20-496
d) Short circuit to chassis ground in directional solenoid circuit....................................................... 20-498
e) Abnormality in shift solenoid circuit.............................................................................................. 20-504
f) Short circuit to chassis ground in shift solenoid circuit.................................................................. 20-507
E-8 Kick-down switch does not work......................................................................................................... 20-512
E-9 Kick-down works only when kick-down switch is being turned ON..................................................... 20-515
E-10 Kick-down always works .................................................................................................................... 20-516
WA700-3 20-451
(10)
E-11 Kick-down swich works even when traveling forward in 2nd .............................................................. 20-518
E-12 Boom Kick-out does not work............................................................................................................. 20-520
E-13 Defective bucket positioner ................................................................................................................ 20-522
E-14 Power window does not work ............................................................................................................. 20-524
a) Window does not go up ............................................................................................................... 20-524
b) Window does not go down........................................................................................................... 20-525
E-15 Abnormality in front working lamp ...................................................................................................... 20-527
E-16 Abnormality in rear working lamp ....................................................................................................... 20-527
E-17 Abnormality in transmission cut-off..................................................................................................... 20-527
E-18 Abnormality in parking brake dragging warning ................................................................................. 20-527
E-19 Abnormality in buzzer ......................................................................................................................... 20-527
20-452 WA700-3
(10)
Troubleshooting Electrical circuit diagram for E mode system
Electrical circuit diagram for E mode system

Serial No.: 50001 – 51000
20-454 WA700-3
(10)
WA700-3 20-455
(10)
20-456 WA700-3
(10)
WA700-3 20-457
(10)
Troubleshooting E-1
E-1 Engine does not start

Serial No.: 50001 – 51000
a) Starting motor does not turn
YES
3
5 YES
Is voltage between
YES starting motor Is voltage between
terminal (B) and YES battery relay
chassis normal? terminal M and
chassis normal?
• 20 -– 30 V
• Turn starting 4 • 20 – 30 V NO
switch OFF. Does battery • Turn starting
relay make sound switch ON.
NO of actuation? YES
2
• Starting switch 6
Is there continuity ON i o OFF. Is voltage between both
YES between starting connection terminals
motor terminal (E) A02 and A03 and
connection terminals
and chassis? NO A04 and A05 of battery
relay normal?
• Turn starting
switch OFF. • 20 – 30 V
• Turn starting
switch ON.
1 NO
Is voltage
between E03, E04
(female) (1) and
chassis normal?
• 20 – 30 V
• Disconnect E03
and E04. NO
• Directional lever:
Neutral
• Turn starting
switch to START.
NO
20-458 WA700-3
(10)
Troubleshooting E-1
Cause Remedy
Defective starting motor

Replace
assembly
disconnection in cable Repair or
between battery relay replace
and starting motor
Defective battery relay,
or defective contact of Repair or
wiring harness between replace
battery and battery relay
Defective battery relay Replace

harness between starting
8 YES switch terminal BR – L09
Repair or
Is resistance (2) – LR4 (9) – R03 (diode) replace
YES between A03, (2), (1) – RA1 (1) – A02, A04
7 A05 – chassis (female)
normal? Defective contact or
Is voltage between disconnection in wiring Repair or
starting switch • Max. 1 z NO harness between A03, A05 replace
terminal BR and • Turn starting – RA1 (2) – chassis ground
chassis normal? switch OFF.
• 20 – 30 V • Disconnect A03 and A05.
Defective starting switch Replace
switch ON.
Repair or
disconnection in starting
replace
motor ground cable
Go to A on next page
WA700-3 20-459
(10)
Troubleshooting E-1
YES
YES
11
Is voltage
YES between L57 13 YES
9 (female) (5) and Is voltage between
Does starting chassis normal? YES starting switch
From A 12 terminal C and
motor rotate • 20 – 30 V chassis normal?
when neutral • Disconnect L57. Is voltage between
relay is replaced? • Turn starting starting switch • 20 – 30 V NO
• Replace neutral switch to START.NO terminal B and • Turn starting
chassis normal? switch to START.
relay (L57) with
stop lamp relay • 20 – 30 V
(L53). • Turn starting NO
• Directional lever: switch OFF.
Neutral
• Turn starting 16 YES
switch to START. 10
Is voltage
Is voltage YES between L04 (3)
between L57
and chassis
NO (female) (1) and normal?
(2) normal?
• 20 – 30 V NO
• Disconnect L57. • Connect T-
15
• Directional lever: adapter to L04.
Neutral Is voltage
YES between L04 • Directional lever: 18 YES
• Turn starting N
switch to START. (female) (1) and Is voltages between
• Turn starting YES battery relay
chassis normal?
switch ON. terminal M and
• 20 – 30 V chassis normal?
• Disconnect L04.
switch ON. Does battery • Turn starting
14
• Turn starting 19
Is resistance switch ON io Is voltage between both
between L57 OFF. connection terminals
NO (female) (2) and A02 and A03 and
chassis normal? connection terminals
NO A04 and A05 of battery
• Max. 1 z relay normal?
• Turn starting • 20 – 30 V
switch OFF. • Turn starting
• Disconnect L57. switch ON.
NO
NO
20-460 WA700-3
(10)
Troubleshooting E-1
Cause Remedy
Defective neutral relay Replace

harness between L57
(female) (3) – LR4 (8) – ER1 Repair or
(10) – E24 (2) – (1) – E04 replace
(female) (1) or E22 (2) – (1)
– E03 (female) (1)
harness between starting replace
switch terminal C – L09
(3) – L57 (female) (5)

switch terminal B – L09 (1)
Repair or
– FS3 (4) – fuse – FS3 (6) – replace
LR5 (1) – slow blow fuse
30A – battery relay
(female) (1)
Defective directional
Replace
lever switch
harness between battery Repair or
relay – slow blow fuse 80A replace
– LR6 (1) – FS1 (2) fuse –
FS2 (8) – L04 (female) (1)
Defective battery relay or
defective contact or Repair or
disconnection in wiring replace
harness between battery
and battery relay

21 YES switch terminal BR – L09 Repair or
20 (female)
A05 – chassis
Is voltage between normal? Defective contact or
starting switch • Max. 1 z NO harness between A03, A05
terminal BR and replace
• Turn starting – RA1 (2) – chassis ground
switch ON.
harness between L57 Repair or
(female) (2) – LR5 (2) – replace
chassis ground
WA700-3 20-461
(10)
Troubleshooting E-1
E-1 a) Related electrical circuit diagram
20-462 WA700-3
(10)
Troubleshooting E-1
b) Starting motor turns
YES
3
Is voltage
YES between EC5B
(female) (4) and YES
chassis normal? 4
When fuel cut
• 20 – 30 V switch is operated,
2 • Disconnect EC5B. is No-injection
NO cranking relay (L82)
5 YES
Is voltage • Turn starting
actuated? Does condition
YES between EC1 switch ON.
become normal
(female) (9), (17) • Turn starting
when No-injection
– chassis normal? switch ON. NO cranking relay (L82)
• Turn fuel cut is replaced?
• 20 – 30 V switch ON io
• Disconnect EC1. • Replace with NO
OFF. other relay.
1 • Turn starting
Is voltage switch ON. • Turn starting
between EC1 switch ON.
(female) (4) and NO
chassis normal?
• 20 – 30 V
• Disconnect EC1. YES
• Turn starting 6
switch ON. Does condition
become normal
when governor cut
NO relay (L30) is 7 YES
replaced? Is voltage
• Replace with between L30
other relay. NO (female) (1), (3) –
• Turn starting chassis normal?
switch ON. • 20 – 30 V NO
• Disconnect L30.
• Turn starting
switch ON.
20-464 WA700-3
(10)
Troubleshooting E-1
Cause Remedy
Defective electric engine

Replace
throttle controller
Repair or
harness between EC5B
replace
(female) (6)
Defective No-injection
Replace
cranking relay (L82)
Short circuit with wiring
harness between L82
(female) (1) – L73 (2) – fuel Repair or
cut switch, or defective fuel replace
cut switch
harness between EC1 Repair or
(female) (9), (17) – FS7 (2) – replace
fuse – FS7 (1) – L09
(female) (5)
Defective governor cut

Replace
relay (L30)
Short circuit with wiring

harness between EC2 Repair or
(female) (1) and L30 replace
(female) (6)
(female) (1), (3) – FS7 (2) replace
– fuse – FS7 (1) – L09
(female) (5)
WA700-3 20-465
(10)
Troubleshooting E-1
E-1 b) Related electrical circuit diagram
20-466 WA700-3
(10)
Troubleshooting E-1

a When the error code appears in the engine controller, refer to the troubleshooting of engine controller (EA
mode).
YES
3
5 YES
Is voltage between
YES starting motor Is voltage between
terminal (B) and YES battery relay
chassis normal? terminal M and
chassis normal?
• 20 -– 30 V
switch OFF. Does battery • Turn starting
2
• Starting switch 6
Is there continuity ON i o OFF. Is voltage between both
YES between starting connection terminals
motor terminal (E) A02 and A03 and
connection terminals
and chassis? NO A04 and A05 of battery
relay normal?
• Turn starting
switch OFF. • 20 – 30 V
• Turn starting
switch ON.
1 NO
Is voltage
between E03, E04
(female) (1) and
chassis normal?
• 20 – 30 V
• Disconnect E03
and E04. NO
• Directional lever:
Neutral
• Turn starting
switch to START.
NO
20-468 WA700-3
(10)
Troubleshooting E-1
Cause Remedy
Defective starting motor

Replace
assembly
disconnection in cable Repair or
between battery relay replace
and starting motor
Defective battery relay,
or defective contact of Repair or
battery and battery relay

8 YES switch terminal BR – L09
Repair or
7 A05 – chassis (female)
normal? Defective contact or
Is voltage between disconnection in wiring Repair or
starting switch • Max. 1 z NO harness between A03, A05 replace
terminal BR and • Turn starting – RA1 (2) – chassis ground
switch ON.
Repair or
disconnection in starting
replace
motor ground cable
Go to A on next page
WA700-3 20-469
(10)
Troubleshooting E-1
YES
YES
11
Is voltage
YES between L57 13 YES
9 (female) (5) and Is voltage between
Does starting chassis normal? YES starting switch
From A 12 terminal C and
motor rotate • 20 – 30 V chassis normal?
when neutral • Disconnect L57. Is voltage between
relay is replaced? • Turn starting starting switch • 20 – 30 V NO
• Replace neutral switch to START.NO terminal B and • Turn starting
chassis normal? switch to START.
relay (L57) with
stop lamp relay • 20 – 30 V
(L53). • Turn starting NO
• Directional lever: switch OFF.
Neutral
switch to START. 10
Is voltage
Is voltage YES between L04 (3)
between L57
and chassis
NO (female) (1) and normal?
(2) normal?
• 20 – 30 V NO
• Disconnect L57. • Connect T-
15
• Directional lever: adapter to L04.
Neutral Is voltage
YES between L04 • Directional lever: 18 YES
• Turn starting N
switch to START. (female) (1) and Is voltages between
• Turn starting YES battery relay
chassis normal?
switch ON. terminal M and
• 20 – 30 V chassis normal?
• Disconnect L04.
switch ON. Does battery • Turn starting
14
• Turn starting 19
Is resistance switch ON io Is voltage between both
between L57 OFF. connection terminals
NO (female) (2) and A02 and A03 and
chassis normal? connection terminals
NO A04 and A05 of battery
• Max. 1 z relay normal?
• Turn starting • 20 – 30 V
switch OFF. • Turn starting
• Disconnect L57. switch ON.
NO
NO
20-470 WA700-3
(10)
Troubleshooting E-1
Cause Remedy
Defective neutral relay Replace

harness between L57
(female) (3) – LR4 (8) – ER1 Repair or
(10) – E24 (2) – (1) – E04 replace
(female) (1) or E22 (2) – (1)
– E03 (female) (1)
switch terminal C – L09
(3) – L57 (female) (5)

switch terminal B – L09 (1)
Repair or
– FS3 (4) – fuse – FS3 (6) – replace
LR5 (1) – slow blow fuse
30A – battery relay
(female) (1)
Replace
lever switch
relay – slow blow fuse 80A replace
– LR6 (1) – FS1 (2) fuse –
FS2 (8) – L04 (female) (1)
Defective battery relay or
defective contact or Repair or
disconnection in wiring replace
harness between battery
and battery relay

21 YES switch terminal BR – L09 Repair or
20 (female)
A05 – chassis
Is voltage between normal? Defective contact or
starting switch • Max. 1 z NO harness between A03, A05
terminal BR and replace
• Turn starting – RA1 (2) – chassis ground
switch ON.
chassis ground
WA700-3 20-471
(10)
Troubleshooting E-1
E-1 Related electrical circuit diagram
20-472 WA700-3
(10)
Troubleshooting E-2
E-2 Abnormality in APS system
Preheating lamp and pilot LED on APS controller

1) Preheating lamp
a Preheating lamp shows normal or abnormal APS conditions as below, after turning starting switch ON,
according to the time clasped.
Starting APS Preheating Engine Water temprature APS switch

switch ON switch ON finished started switch OFF OFF
Water
Normal condition
temprature Lighted up for Flashing once

Lighted off Lighted off Lighted off
below 12 seconds a 1 second
20ºC
Water
temprature Lighted off Flashing once a 1 second
above
20ºC
abnormal
Lighted off Lighted up Lighted off
condition
APS water temprature sensor goes ON at below 20ºC and goes OFF at above 20ºC.
2) Pilot LED on APS controller

a APS controller carrys out self-checking for bad contact and short circuit to chassis ground in glow plug
1 circuit, glow plug 2 circuit and nozzle circuit, and then shows conditions as below.
a All LED go out when there is short circuit or bad contact in power supply circuit.
a APS controller does not carry out self- checking for APS water temperature switch circuit.
LED No. Color of LED Abnormal condition When normal When abnormal
1 Red Short circuit to GND in glow plug 1 circuit Q (Lighted off) q (Lighted up)
2 Green Bad contact in glow plug 1 circuit q (Lighted up) Q (Lighted off)
3 Red Short circuit to GND in glow plug 2 circuit Q (Lighted off) q (Lighted up)
4 Green Bad contact in glow plug 2 circuit q (Lighted up) Q (Lighted off)
5 Red Short circuit to GND in nozzle circuit Q (Lighted off) q (Lighted up)
6 Green Bad contact in glow nozzle circuit q (Lighted up) Q (Lighted off)
20-474 WA700-3
(10)
Troubleshooting E-2
E-2 Electrical circuit diagram for APS system
WA700-3 20-475
(10)
Troubleshooting E-2
Abnormality in APS system

a) When preheating switch is turned AUTO, preheating lamp does not light up, but no pilot LED on APS
controller lights up.
a Check for power supply circuit.
a Check whether engine cranking is possible or not. In case cranking is impossible, check for E-1 then check
for E-4.
a Check whether fuse 9 is blown or not. If fuse 9 is blown, check for short circuit to GND in fuse 9 related circuit.
a When carrying out troubleshooting, turn preheating switch AUTO.
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance bet-
YES ween L71 (female) Defective contact or disco-
(1) and chassis nnection in wiring harness
ground normal? between L71 (female) (1), Repair or
• Max. 1 z NO CL1 (12) and chassis replace
• Turn starting ground
1
switch OFF. Defective contact or disco-
Is voltage between • Disconnect L71. 4 YES nnection in wiring harness Repair or
L72 (female) (1)
and chassis Is resistance between L74 (female) (4) replace
ground normal? YES between L74 and L72 (female) (1)
3 (male) (3) and (4)
• 20 – 30 V Defective preheater
normal?
• Turn starting Is voltage between switch Replace
switch ON. L74 (female) (3) • Max. 1 z NO
• Disconnect L72. NO and chassis • Turn starting Defective contact or disco-
ground normal? switch OFF. nnection in wiring harness
• Disconnect L74. between L74 (female) (3),
• 20 – 30 V Repair or
FS6 (3) and fuse II (9)
• Turn starting NO replace
switch ON.
• Disconnect L74.
E-2 a) Related APS controller electrical circuit diagram
20-476 WA700-3
(10)
Troubleshooting E-2
b) When preheating switch is turned AUTO and engine water temperature is below 20ºC, preheating
lamp flashes, but pilot LED on APS controller shows normal
a Check APS water temperature switch circuit.
a Check engine water temperature.
Cause Remedy
4 YES Replace
Defective APS controller
Is resistance
YES between L74
3 (male) (1) and (2)
Is resistance normal? Defective preheater
YES between L74 Replace
• Min. 1 z NO switch
(female) (1) and (2) • Turn starting
2 normal? Short circuit between L74
switch OFF. (female) (1) and L71
Is resistance bet- • Disconnect L74.
YES ween L74 (female) • Min. 1 z (female) (2) or between L74 Repair or
• Turn starting NO (female) (2) and chassis replace
(2) and chassis
switch OFF. ground
1 ground normal?
• Disconnect L74, Defective contact or
Is resistance • Turn starting L71 and E08. disconnection or short
between E08 switch OFF. circuit with chassis ground
Repair or
(male) and chassis • Disconnect L71 NO in wiring harness between replace
ground normal? and L74 L71 (female) (2), LR4 (2),
• Resistance must be ER1 (8) and E08 (female)
• Turn starting
the same as Section 1. Defective APS water
switch OFF. Replace
• Disconnect E08. NO temperature sensor
• When water temperature
is below 20 C: Max. 1 z
• When water temperature
is above 20 C: Min. 1 z
WA700-3 20-477
(10)
Troubleshooting E-2
c) After preheating, fuel is not injected from APS nozzle when starting switch is turned START, but pilot
LED on APS controller shows normal
a Check starting switch circuit.
Cause Remedy
YES Defective APS controller

Replace
1
Is voltage between Defective contact or
L71 (female) (3) disconnection in wiring
and chassis 2 YES harness between L71
Repair or
ground normal? (female) (3) – L69 (4) –
L69 (2) – L09 (3) –
• 20 – 30 V terminal C of
starting switch and terminal C of starting
• Starting switch: NO switch
chassis ground
START normal?
• Disconnect L71. Defective starting switch Replace
• 20 – 30 V NO
• Starting switch:
START
E-2 c) Related electrical circuit diagram
20-478 WA700-3
(10)
Troubleshooting E-2
d) LED 1 of pilot LED on APS controller shows abnormal
Cause Remedy
2 YES
Is resistance bet-
Is resistance ground normal? ground in harness between Repair or
between terminal of
glow plug 1 and • 0.8 – 1.3 z NO L72 (female) (2) and replace
chassis ground • Turn starting terminal glow plug 1
normal? switch OFF.
• 0.8 – 1.3 z • Disconnect L72.
Defective glow plug 1 Replace
switch OFF.
• Disconnect plug
terminal.
e) LED 2 of pilot LED on APS controller shows abnormal
Cause Remedy
2 YES
Is resistance bet-
between terminal of
normal? switch OFF.
• 0.8 – 1.3 z • Disconnect L72.
switch OFF.
• Disconnect plug
terminal.
E-2 d, e) Related electrical circuit diagram
WA700-3 20-479
(10)
Troubleshooting E-2
f) LED 3 of pilot LED on APS controller shows abnormal
Cause Remedy
2 YES
Is resistance bet-
between terminal of
normal? switch OFF.
• 0.8 – 1.3 z • Disconnect L72.
switch OFF.
• Disconnect plug 2.
g) LED 4 of pilot LED on APS controller shows abnormal
Cause Remedy
2 YES
Is resistance bet-
between terminal of
normal? switch OFF.
• 0.8 – 1.3 z • Disconnect L72.
switch OFF.
• Disconnect plug
terminal.
E-2 f, g) Related electrical circuit diagram
20-480 WA700-3
(10)
Troubleshooting E-2
h) LED 5 of pilot LED on APS controller shows abnormal
Cause Remedy
2 YES
Is resistance bet-
Is resistance ground normal? ground in harness Repair or
between each
nozzle terminal and • 1.5 – 2.5 z NO between L72 (female) (4) replace
chassis ground • Turn starting and each nozzle terminal
normal? switch OFF.
• 3– 5 z • Disconnect L72. Nozzle having improper
Replace
• Turn starting NO resistance
switch OFF.
• Disconnect nozzle
terminal.
i) LED 6 of pilot LED on APS controller shows abnormal
Cause Remedy
2 YES Replace
Defective APS controller
Is resistance bet-
Is resistance ground normal? ground in harness Repair or
between each
nozzle terminal and • 1.5 – 2.5 z NO between L72 (female) (4) replace
chassis ground • Turn starting and each nozzle terminal
normal? switch OFF.
•3–5z • Disconnect L72. Nozzle having improper
Replace
• Turn starting NO resistance
switch OFF.
• Disconnect nozzle
terminal.
E-2 h, i) Related electrical circuit diagram
WA700-3 20-481
(10)
Troubleshooting E-2
j) When preheating switch is OFF, preheating lamp lights up

a Before checking, turn preheating switch OFF
Cause Remedy

1 YES source in wiring harness Repair or
Is resistance between L74 (female) (4) replace
between L74 and L72 (female) (1)
(male) (3) and (4)
normal?
Defective preheater Replace
• Min. 1 z NO switch
• Turn starting
switch OFF.
• Disconnect L74.
E-2 j) Related electrical circuit diagram
20-482 WA700-3
(10)
Troubleshooting E-3
E-3 Parking brake does not have effect
a When carrying out troubleshooting of the brake system, stop the machine on flat ground.
a) Parking brake has no effect when parking brake switch is turned ON
Cause Remedy
YES Defective parking brake

Replace
switch
1
Does condition
become normal Contact of wiring harness Repair or
YES
when L01 is at L01 (female) (2) end
2 replace
disconnected? and (3) end
Is resistance
• Start engine.
between L01
(Charge brake oil
pressure) NO (female) (2) and (3) 3 YES Defective parking brake
Replace
normal? solenoid
Is voltage between
• Disconnect L01. F11 (female) (1)
• Turn starting NO and chassis Contact of wiring harness
switch OFF. normal? Repair or
at L01 (female) (2) end
• Disconnect L58. • Max. 1 V NO replace
and (1) end
• Disconnect L59. • Start engine.
(Charge brake oil
pressure)
• Turn parking brake
switch ON.
b) Parking brake has no effect and does not work as emergency brake when parking brake pressure
drops
Cause Remedy
1 YES Defective emergency

Replace
Is parking brake brake switch (C07, C08)
normal when C07
and C08 are
disconnected? Defective parking brake Replace
• Turn starting NO solenoid
switch ON.
switch ON, then OFF.
WA700-3 20-483
(10)
Troubleshooting E-4
E-4 Parking brake is applied when machine is traveling
a When carrying out troubleshooting of the brake system, stop the machine on flat ground.
2 YES
Is resistance
YES between F11
(female) (2) and
chassis normal?
• Max. 1 z NO
• Turn starting
switch OFF.
YES
1
Is voltage between
4
F11 (female) (1)
Does condition YES
and chassis
normal? YES become normal
when parking brake
• 20 – 30 V safety relay is
• Start engine. replaced?
(Charge brake oil • Replace parking
pressure) brake safety relay
(L59) with stop
lamp relay (L53).
• Start engine.
(Charge brake oil
3 pressure)
5
Is continuity of Does condition
L01 (male) become normal
NO (1)(2)(3) as shown when C07 and C08
in Table 1? NO are connected to
short connector?
• Turn starting
• Connect short
switch OFF.
connector to C07 YES
• Operate parking
(female) and C08
brake switch
(female). 7
ON/OFF.
• Start engine.
• Disconnect L01. Is resistance
(Charge brake oil
pressure) YES between L59
(female) (1) and (3)
6 normal?
Is voltage between • Max. 1 z

L59 (female) (5) • Turn starting
NO and chassis switch OFF. NO
normal? • Disconnect L59.
• 20 – 30 V
• Turn starting
switch ON. NO
• Disconnect L59.
NO
Table 1)
Operation Between L01 (2) – (3) Between L01 (1) – (3)
ON (Parking) Min. 1 Mz Max. 1 z
OFF (Travel) Max. 1 z Min. 1 Mz
20-484 WA700-3
(10)
Troubleshooting E-4
Cause Remedy
Defective parking brake

solenoid Replace

between F11 (female) (2) replace
and chassis

Replace
safety relay
Defective emergency
Replace
brake switch

between C08 (female) (2) –
Is voltage between BC01 (4) – FR2 (5) – F11 replace
YES C08 (female) (1) (female) (1)
10 and chassis
Is voltage between normal? nection in wiring harness Repair or
YES C07 (female) (1) • 20 – 30 V NO between C07 (female) (2) replace
and chassis • Turn starting switch ON. and C08 (female) (1)
9 normal? • Turn parking brake Defective contact or discon-
Is resistance switch ON o OFF. nection in wiring harness
YES between L59 • 20 – 30 V • Disconnect C08. Repair or
• Turn starting between C07 (female) (1) –
(female) (2) and NO BC01 (5) – LR2 (12) – L01 replace
switch ON.
8 chassis normal? (female) (2)
Is voltage between • Max. 1 z switch ON o OFF. Defective contact or disco-
L59 (female) (1) • Turn starting • Disconnect C07. nnection in wiring harness Repair or
and chassis switch OFF. NO between L59 (female) (2) replace
normal? • Disconnect L59. CL1 (2) and chassis
• 20 – 30 V Defective contact or discon-

nection in wiring harness bet- Repair or
• Turn starting
ween L59 (female) (1) and L01
switch ON. NO (female) (3), or between FS2 replace
• Turn parking brake (female) (7) and L01 (female) (1)
switch ON.
• Disconnect L59. Defective contact or discon-

between L59 (female) (5) – replace
FS2 (7) – fuse

Replace
switch
WA700-3 20-485
(10)
Troubleshooting E-5, E6
E-5 Parking brake is released when starting switch is turned ON

Cause Remedy
YES Defective parking safety

Replace
relay
1
Is problem removed
when parking
YES Defective parking brake
safety relay (L59) is Replace
replaced?
2 switch
• Replace parking Does it become

safety relay (L59) normal when L01 Contact of wiring harness
with stop lamp NO is disconnected? 3 YES Repair or
between L59 (5) and
relay (L53). Is there continuity replace
(female)(3)(1)
• Turn starting • Disconnect L01. between L59
switch ON.
• Turn starting NO (female) (3) and
• Start engine. (5)? Contact of wiring harness
switch ON. Repair or
(Stop engine after • Start engine. between L01 (female) (1)
• Disconnect L59. NO replace
charging brake (Stop engine after and (2)
oil • Turn starting
charging brake oil switch OFF.
pressure) • Turn parking brake
switch OFF.
E-6 Transmission does not change to neutral when parking brake is applied, but
parking brake works normally
Cause Remedy
1 YES Defective neutralizer

Replace
Is voltage between relay
neutralizer relay
L58 (female) (5) –
chassis normal? Short circuit with power
Repair or
source in wiring harness
• Disconnect
neutralizer relay
L58.
• Turn starting
switch ON.
• Shift directional
lever between F, N,
and R, and check
each voltage.
20-486 WA700-3
(10)
Troubleshooting E-3, E-4, E-5, E-6
E-3, E-4, E-5, E-6 Related electrical circuit diagram
WA700-3 20-487
(10)
Troubleshooting E-7
E-7 Transmission does not work properly
a Before disconnecting or connecting connectors, surely turn starting switch OFF.

Perform tester check of the transmission solenoid Table 1 Normal operation table of transmission
control circuit according to the following procedure. Pin No.
T01
k Stop the machine on flat ground and put blocks

Ope- Remedy
ration (1) (2) (3) (4) (F) (R) (GND) (GND)
of lever H G F E D C B A
under the tires. Forward
q Q Q
FR lever
(F) Go to
Table 2.
1. Install a T-adopter (or socket adopter) to trans- Reverse
(R)
Q q Q
mission connector T01, then check the voltage
1st q Q Q Q Q
between the pins in Table 1 and chassis ground.
Gear shift lever

2nd Q q Q Q Q
Go to
2. Turn starting switch ON. Table 3.
Q Q q Q Q
k Do not start the engine.

3rd
4th Q Q Q q Q
3. Turn the parking brake switch ON, then OFF Q: 0 – 0.5V (Continuity)
(release) again. q: 20 – 30V (Battery voltage)
4. If required, press the right-hand foot brake Table 2 Result of check during operation of
directional lever
pedal.
a If the left-hand brake pedal is pressed, the Trouble-
Check result Cause
shooting
transmiss ion is cut off and cannot be
Defective transmission cut-off
checked. q [Battery volt- switch, parking brake or neu- Go to E-7-a).
age] is zero. tralizer relay circuit
5. Check the voltage and continuity according to
Table 1. Then, go to the troubleshooting shown Q There is not Defective circuit on forward
[continuity] Go to E-7-b).
in the right columns of Table 2 and Table 3 side.
(Forward side).
according to the inspection result shown in
those tables.
Q There is not Defective circuit on reverse
[continuity] Go to E-7-c).
side.
(Reverse side).
Q [Continuity] is Contact of circuits on forward

higher than and reverse sides with each Go to E-7-d).
specification. other
Table 3 Result of check during operation of gear

shift leverr
Trouble-
Check result Cause
shooting
q [Battery volt- Defective power supply circuit

age] is zero.
Go to E-7-e).
Q There is not Defective circuit on gear shift-
[continuity] ing side
Q[Continuity] is Contact of circuits on gear

higher than Go to E-7-f).
shifting side
specification.
WA700-3 20-489
(10)
Troubleshooting E-7
a) Abnormality in parking brake circuit, transmission cut-off switch circuit or neutralizer relay circuit
3 YES
Is resistance
YES between L12
(male) (1) and (2)
normal?
• Max. 1 z NO
2 • Turn starting
Does condition
switch OFF.
YES become normal • Disconnect L12.
when transmission YES
cut-off selector
switch to turn OFF?
• Start engine.
4
Does condition YES
become normal
when replacing
NO neutralizer relay is
replaced?
• Replace neutralizer YES
relay (L58) with stop 5
lamp relay (L53). Does condition 7
• Start engine. become normal
1 when parking brake Is voltage between
NO safety relay is YES L58 (fremale) (1)
Is resistance bet-
replaced? and chassis
ween L04 (female)
• Replace parking ground normal?
(10) and chassis
ground normal? brake relay (L59) • 20 – 30 V
with stop lamp 6
• Max. 1 z • Turn starting
relay (L53). Is resistance of L01 switch ON.
• Turn starting
• Start engine. (male) (1), (2) and • Disconnect L58.
switch OFF. NO
• Disconnect L04. NO (3) conformed to • Turn on parking
Table 1? brake switch, then
• Turn starting release it.
switch OFF.
• Disconnect L01.
NO
NO
Table 1)
Operation Terminals (1) – (3) Terminals (1) – (3)
ON (Parking) Max. 1 z Min. 1 z
OFF (Travel) Min. 1 z Max. 1 z
20-490 WA700-3
(10)
Troubleshooting E-7
Cause Remedy

between L12 (female) (1) Repair or
and L58 (female) (5) or replace
and L65 (female) (5).
Defective transmission Replace

cut-off switch
Defective neutralizer relay Replace

Replace
safety relay
Defective contact or disconn-
ection in wiring harness
between L58 (female) (3) and
FS2 (female) (8) or between Repair or
L58 (female) (2), CL1 (female) replace
(12) and chassis ground
Defective contact or disco-
2 YES nnection in wiring harness
Is voltage between CL1 (12) and chassis
YES L59 (female) (5) ground
1 and chassis ground
normal? Defective contact or disco-
Is resistance nnection in wiring harness Repair or
between L01 between L59 (female) (5) replace
(female) (3) and • 20 – 30 V NO
• Turn starting and FS2 (female) (7)
L59 (female) (1)
and (3) normal? switch ON.
• Max. 1 z • Disconnect L59. nnection in wiring harness Repair or
• Turn starting NO between L01 (female) (3) replace
switch OFF. and L59 (female) (1) and (3)
• Disconnect L01
and L59. Defective parking brake
switch Replace

nnection in wiring harness
Repair or
LR5 (3) and chassis ground
replace
WA700-3 20-491
(10)
Troubleshooting E-7
E-7 a) Related electrical circuit diagram
20-492 WA700-3
(10)
Troubleshooting E-7
b) No continuity in travel FORWARD solenoid circuit
2 YES
Is resistance bet-
YES ween T01 (female)
(A) and chassis
ground normal?
• Max. 1 z NO
1 • Turn starting
Is voltage between switch OFF.
T01 (female) (D) • Disconnect T01.
YES
and chassis
ground normal?
• 20 – 30 V
switch ON. Does condition 5
• Disconnect T01. become normal
• Release parking NO when relay is Is voltage between
brake (Turn switch YES L66 (female) (5)
replaced?
and chassis 6 YES
ON, then OFF).
• Replace forward ground normal?
• Set directional Is voltage between
relay (L66) with 4 • 20 – 30 V L04 (female) (1)
lever to FORWARD.
reverse relay (L67).
Is resistance bet- • Turn starting NO and chassis
• Start engine. switch ON. ground normal?
ween L66 (female)
• Release parking NO • Disconnect L66.
(6) and chassis • 20 – 30 V NO
brake. ground normal? • Set directional
• Set directional lever • Turn starting
lever to FORWARD.
to FORWARD. • Max. 1 z switch OFF.
• Turn starting • Disconnect L04.
switch OFF.
NO
• Disconnect L66.
20-494 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
Defective forward
Replace
solenoid

between T01 (female) (A), Repair or
TL1 (7), CL1 (12) and replace
chassis ground
Defective forward relay Replace
See E-7-a). —
Defective directional lever,

or defective contact or
(female) (5)
nnection in wiring harness Repair or
between L04 (female) (1), replace
FS2 (8) and fuse
CL1 (12) and chassis
ground
WA700-3 20-495
(10)
Troubleshooting E-7
c) No continuity in travel REVERSE solenoid circuit
2 YES
Is resistance bet-
YES ween T01 (female)
(A) and chassis
ground normal?
• Max. 1 z NO
1 • Turn starting
Is voltage between switch OFF.
T01 (female) (C) • Disconnect T01.
YES
and chassis
ground normal?
• 20 – 30 V
switch ON. Does condition 5
• Disconnect T01. become normal
• Release parking NO when relay is Is voltage between
brake (Turn switch YES L67 (female) (5)
replaced?
and chassis 6 YES
ON, then OFF).
• Replace reverse ground normal?
• Set directional Is voltage between
relay (L67) with 4 • 20 – 30 V L04 (female) (1)
lever to REVERSE.
forward relay (L66).
Is resistance bet- • Turn starting NO and chassis
• Start engine. switch ON. ground normal?
ween L67 (female)
• Release parking NO • Disconnect L67.
(6) and chassis • 20 – 30 V NO
brake. ground normal? • Set directional
• Set directional lever • Turn starting
lever to REVERSE.
to REVERSE. • Max. 1 z switch OFF.
• Turn starting • Disconnect L04.
switch OFF.
NO
• Disconnect L67.
E-7 c) Related electrical circuit diagram
20-496 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
Defective reverse
Replace
solenoid

between T01 (female) (A), Repair or
TL1 (7), CL1 (12) and replace
chassis ground
Defective reverse relay Replace
See E-7-a). —
Defective directional lever,

or defective contact or
harness between L04
replace
(female) (5)
FS2 (8) and fuse
ground
WA700-3 20-497
(10)
Troubleshooting E-7
d) Short circuit to chassis ground in directional solenoid circuit

1) Short circuit to chassis ground in travel FORWARD circuit
YES
6
Is resistance bet-
YES ween L04 (male)
(2) and chassis
5 ground normal?
Is resistance bet- • Min. 1 Mz
YES ween L04 (male) • Turn starting NO
(2) and (4), (5), (6), switch OFF.
(7), (8) normal? • Disconnect L04.
4
YES ween TL1 (male) • Turn starting
(5) and chassis switch OFF. NO
3
• Set directional lever
to N or F.
YES ween TL1 (female) • Turn starting
(5) and (1), (2), (3), switch OFF. NO
(4), (6), (7) normal? • Disconnect TL1,
2 L04 and L66.
YES ween T01 (female) • Turn starting
1 (D) and connector switch OFF. NO
Is resistance bet- body normal? • Disconnect T01
ween T01 (male) (D) and TL1.
and chassis ground • Min. 1 Mz
normal? • Turn starting
Is resistance NO
between (A), (B), (C), switch OFF.
(E), (F), (G), (H) and • Disconnect T01
chassis ground and TL1.
normal?
• Min. 1 Mz
NO
• Turn starting
switch OFF.
• Disconnect T01.
20-498 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
Short circuit between

7 YES
forward solenoid relay Replace
Is resistance bet- L66 (male) (1) and (2)
ween L04 (male)
ground normal? or ground wire in harness Repair or
• Min. 1 Mz NO between L04 (female) (2) replace
switch OFF.
• Disconnect L04 and L66. Defective transmission Replace
control switch

control switch
Short circuit with chassis or

ground wire in harness Repair or
between TL1 (male) (5) and
replace
L66 (male) (2)
Short circuit of harness
between TL1 (female) (5) and
T01 (female) (D) and harness Repair or
between TL1 (female) (1), (2), replace
(3), (4), (6), (7) and T01
(female) (A), (C), (E), (F), (G)
and (H) with each other
Defective insulation Repair or
between T01 (female) (D) replace
and connector body
Defective insulation between
T01 (male) (D) and connector
Repair or
body, or short circuit of
harness and chassis ground replace
with T01 (D) in control valve
and defective insulation
among pins of T01
WA700-3 20-499
(10)
Troubleshooting E-7
2) Short circuit to chassis ground in travel REVERSE circuit
YES
6
Is resistance bet-
YES ween L04 (male)
(4) and chassis
5 ground normal?
YES ween L04 (male) • Turn starting NO
(4) and (2), (5), (6), switch OFF.
(7), (8) normal? • Disconnect L04.
4
YES ween TL1 (male) • Turn starting
(6) and chassis switch OFF. NO
3
• Set directional lever
to N or F.
YES ween TL1 (female) • Turn starting
(6) and (1), (2), (3), switch OFF. NO
(4), (5), (7) normal? • Disconnect TL1,
2 L04 and L67.
YES ween T01 (female) • Turn starting
1 (C) and connector switch OFF. NO
Is resistance bet- body normal? • Disconnect T01
ween T01 (male) (c) and TL1.
and chassis ground • Min. 1 Mz
Is resistance NO
between (A), (B), (D), switch OFF.
(E), (F), (G), (H) and • Disconnect T01
chassis ground and TL1.
normal?
• Min. 1 Mz
NO
• Turn starting
switch OFF.
• Disconnect T01.
20-500 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
Short circuit between

7 YES
forward solenoid relay Replace
Is resistance bet- L67 (male) (1) and (2)
ween L04 (male)
ground normal? or ground wire in harness Repair or
• Min. 1 Mz NO between L04 (female) (4) replace
switch OFF.
• Disconnect L04 and L67. Defective transmission Replace
control switch

control switch
Short circuit with chassis or

ground wire in harness Repair or
between TL1 (male) (6) and
replace
L67 (male) (2)
Short circuit of harness
between TL1 (female) (6) and
T01 (female) (C) and harness Repair or
between TL1 (female) (1), (2), replace
(3), (4), (5), (7) and T01
(female) (A), (D), (E), (F), (G)
and (H) with each other
Defective insulation Repair or
between T01 (female) (C) replace
and connector body
Defective insulation between
T01 (male) (C) and connector
body, or short circuit of Repair or
harness and chassis ground replace
with T01 (C) in control valve
and defective insulation
among pins of T01
WA700-3 20-501
(10)
Troubleshooting E-7
E-7 d) Related electrical circuit diagram
20-502 WA700-3
(10)
Troubleshooting E-7
e) Abnormality in shift solenoid circuit
5 YES
Is voltage between
YES T01 (female) (H)
4 and chassis
ground normal?
Is voltage between
• 20 – 30 V NO
1st L04 (5) and chassis
ground normal?
• Disconnect T01.
• 20 – 30 V • Set gear shift lever to 1st.
switch ON.
• Connect T-adapter to L04.
• Set gear shift lever to 1st.
YES
7
Is voltage between
YES L76 (female) (3)
and chassis
ground normal?
6
• 20 – 30 V
Is voltage between • Turn starting
2nd L04 (6) and chassis switch ON.
Go to defective NO
• Set gear shift
transmission
• 20 – 30 V lever to 2nd.
YES range. • Turn starting
switch ON.
• Disconnect NO
T-adapter to L04.
• Set gear shift
lever to 2nd.
11 YES
Is voltage between
YES T01 (female) (F)
10 and chassis
ground normal?
Is voltage between
L04 (7) and chassis • 20 – 30 V NO
3rd
ground normal? • Turn starting switch ON.
3 • Disconnect T01.
• 20 – 30 V • Set gear shift lever to 3rd.
Is resistance bet-
YES ween T01 (female) • Turn starting NO
(B) and chassis switch ON.
ground normal? • Connect T-adapter
to L04.
• Max. 1 z • Set gear shift
13 YES
• Turn starting lever to 3rd. Is voltage between
switch OFF. YES T01 (female) (E)
• Disconnect T01. 12 and chassis
ground normal?
2 Is voltage between
L04 (8) and chassis • 20 – 30 V NO
Is voltage between 4th
YES L04 (female) (1) ground normal? • Turn starting switch ON.
and chassis • Disconnect T01.
ground normal? • 20 – 30 V • Set gear shift lever to 4th.
• 20 – 30 V switch ON.
• Turn starting • Connect T-adapter to L04.
1 switch ON. • Set gear shift lever to 4th.
Is resistance be- • Disconnect L04.
tween L04 (female) NO
(10) and chassis
ground normal?
• Max. 1 z
switch OFF.
• Disconnect L04.
NO
20-504 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
Defective 1st solenoid Replace

TL1 (1) and T01 (female) (H)
Defective gear shift lever

Replace
switch
8 YES Defective 2nd-1st selector

relay Replace
Does condition
become normal
when relay is
replaced? 9 YES Defective 2nd solenoid Replace
• Replace 2nd-1st Is voltage between
selector relay T01 (female) G and
(L76) with stop l NO chassis ground Defective contact or disco-
amp relay (L53). normal? nnection in wiring harness Repair or
• Start engine. between L76 (female) (6),
• 20 – 30 V replace
TL1 (2) and T01 (female) (G)
• Disconnect T01. Defective contact or discon-
• Set gear shift lever to 2nd. nection in wiring harness Repair or

switch Replace
Defective 3rd solenoid Replace

TL1 (3) and T01 (female) (F)

switch Replace
Defective 4th solenoid Replace

Repair or
replace
TL1 (4) and T01 (female) (E)

switch Replace

between T01 (female) (B),
Repair or
TL1 (7), CL1 (12) and chassis
ground replace

FS2 (8) and fuse I (9)
LR5 (3) and chassis ground
WA700-3 20-505
(10)
Troubleshooting E-7
E-7 e) Related electrical circuit diagram
20-506 WA700-3
(10)
Troubleshooting E-7
f) Short circuit to chassis ground in shift solenoid circuit

1) Short circuit to chassis ground in 1st solenoid circuit
Cause Remedy
YES
To A
4
Is resistance bet- Short circuit with harness
between following couples in
YES ween TL1 (male) harness between TL1 (male)
(1) and (2), (3), (4), (1) and L04 (female) (5); TL1
(5), (6), (7) normal? (male) (2) and L76 (female)
(6), TL1 (male) (3) and L04
3 • Min. 1 Mz (female) (7), TL1 (male) (4) Repair or
Is voltage between • Turn starting NO and L04 (female) (8), TL1 replace
YES TL1 (male) (1) and (male) (5) and L66 (female)
switch OFF. (2), TL1 (male) (6) and L67
chassis ground • Disconnect TL1, L04 (female) (2), TL1 (male) (7)
normal? and L76. and chassis ground
2 • 0 – 0.5V
Is resistance • Disconnect TL1, Repair or
between T01 L04 and L76.
YES NO bet-ween TL1 (male) (1), replace
(female) (H) and (A), • Turn starting
(B), (C), (D), (E), (F),
L04 (female) (5) and L76
(G) normal?
1
Is resistance • Min. 1 Mz Short circuit with harness
between T01 (male) • Turn starting between T01 (female) (H)
(H) and chassis switch OFF. and TL1 (female) (1) in
Is resistance • Disconnect T01 harness between T01 replace
NO (female) (A) – (G) and TL1
between (A), (B), (C), and TL1.
(D), (E), (F), (G) and (female) (2) – (7)
chassis ground
normal? Defective insulation
• Min. 1 Mz between T01 (male) (H) and
• Turn starting connector body, or short
circuit of harness and Repair or
switch OFF. replace
• Disconnect T01.
NO chassis ground with T01
(H) in control valve and
defective insulation among
pins of T01

Replace
Is resistance control switch
From A between L04 Short circuit with harness
(female) (5) and between following couples in
(2), (4), (6) normal? harness between L04 (female) Repair or
(5) and TL1 (male) (1); L04 replace
• Min. 1 Mz NO (female) (2) and L66 (female)
• Turn starting (5), L04 (female) (4) and L67
switch OFF. (female) (5), L04 (female) (6)
• Disconnect L04, and L76 (female) (3)
TL1 and L76.
WA700-3 20-507
(10)
Troubleshooting E-7
2) Short circuit to chassis ground in 2nd solenoid circuit
Cause Remedy
YES
To A
4
(5), TL1 (male) (3) and L04
2 • 0 – 0.5V Short circuit with power
Is resistance • Disconnect TL1 source in wiring harness Repair or
between T01 and L76. between TL1 (male) (2) and
YES NO replace
(female) (G) and (A), • Turn starting L76 (female) (6)
(B), (C), (D), (E), (F),
(H) normal?
switch ON.
1
Is resistance • Min. 1 Mz
Short circuit with harness
between T01 (male) • Turn starting
(G) and chassis between T01 (female) (G)
switch OFF. and TL1 (female) (2) in Repair or
ground normal?
Is resistance • Disconnect T01 harness between T01 replace
NO
between (A), (B), (C), and TL1. (female) (A) – (F), (H) and
(D), (E), (F), (H) and TL1 (female) (1), (3) – (7)
chassis ground
• Min. 1 Mz between T01 (male) (G) and
connector body, or short
• Turn starting Repair or
circuit of harness and
switch OFF. chassis ground with T01 replace
• Disconnect T01.
NO
(G) in control valve and
pins of T01

Replace
Is resistance control switch
From A between L04 Short circuit with harness
(female) (6) and between following couples in
(2), (4), (5) normal? harness between L04
Repair or
(female) (6) and L76 (female)
• Min. 1 Mz NO (3); L04 (female) (2) and L66 replace
• Turn starting (female) (5), L04 (female) (4)
switch OFF. and L67 (female) (5), L04 (fe-
male) (5) and TL1 (male) (1)
• Disconnect L04,
TL1 and L76.
20-508 WA700-3
(10)
Troubleshooting E-7
3) Short circuit to chassis ground in 3rd solenoid circuit
Cause Remedy
YES
To A
4
(5), TL1 (male) (2) and L76
2 • 0 – 0.5V Short circuit with power
Is resistance • Disconnect TL1, source in wiring harness Repair or
between T01 L04 and L76. between TL1 (male) (3) and
YES NO replace
(female) (F) and (A), • Turn starting L04 (female) (7)
(B), (C), (D), (E), (G),
(H) normal?
switch ON.
1 Short circuit with harness
Is resistance • Min. 1 Mz between T01 (female) (F)
between T01 (male) • Turn starting and TL1 (female) (3) in
(F) and chassis switch OFF. harness between T01
• Disconnect T01 (female) (A), (B), (C), (D),
Is resistance NO replace
between (A), (B), (C), and TL1. (E), (G), (H) and TL1
(D), (E), (G), (H) and (female) (1), (2), (4), (5), (6),
chassis ground (7)
normal?
• Min. 1 Mz Defective insulation
between T01 (male) (F) and
connector body, or short
switch OFF. circuit of harness and replace
• Disconnect T01.
NO
chassis ground with T01 (F)
in control valve and
pins of T01

Replace
Is resistance bet- control switch
ween L04 (female) Short circuit with harness
From A
(7) and (2), (4), (5), between following couples in
(6) normal? harness between L04 (female)
Repair or
(7) and TL1 (male) (3); L04
• Min. 1 Mz NO (female) (2) and L66 (female) replace
switch OFF. (female) (5), L04 (female) (5)
and TL1 (male) (1), L04
• Disconnect L04, (female) (6) and L76 (female)
TL1 and L76. (3)
WA700-3 20-509
(10)
Troubleshooting E-7
4) Short circuit to chassis ground in 4th solenoid circuit
Cause Remedy
YES
To A
4
(5), TL1 (male) (2) and L76
2 • 0 – 0.5V
Is resistance • Disconnect TL1, Repair or
between T01 L04 and L76.
YES NO between TL1 (male) (4) and replace
(female) (E) and (A), • Turn starting
(B), (C), (D), (F), (G),
L04 (female) (8)
(H) normal?
switch ON.
1 Short circuit with harness
Is resistance • Min. 1 Mz between T01 (female) (E)
between T01 (male) • Turn starting and TL1 (female) (4) in
(E) and chassis switch OFF. harness between T01
Is resistance • Disconnect T01 (female) (A), (B), (C), (D), replace
NO (F), (G), (H) and TL1 (fe-
between (A), (B), (C), and TL1.
(D), (F), (G), (H) and male) (1), (2), (3), (5), (6), (7)
chassis ground
• Min. 1 Mz between T01 (male) (E) and
• Turn starting connector body, or short
circuit of harness and Repair or
switch OFF.
NO chassis ground with T01 (E) replace
• Disconnect T01. in control valve and
pins of T01

Replace
Is resistance bet- control switch
ween L04 (female) Short circuit with harness
From A
(8) and (2), (4), between following couples in
(5),(6) normal? harness between L04 (female) Repair or
(8) and TL1 (male) (4); L04
• Min. 1 Mz NO (female) (2) and L66 (female) replace
(female) (5), L04 (female) (5)
switch OFF. and TL1 (male) (1), L04 (fe-
• Disconnect L04, male) (6) and L76 (male) (3)
TL1 and L76.
20-510 WA700-3
(10)
Troubleshooting E-7
E-7 f) Related electrical circuit diagram
WA700-3 20-511
(10)
Troubleshooting E-8
E-8 Kick-down switch does not work

(shift works correctly during normal gear shift operations F1 – F4)

YES
2 YES
Does condition
YES become normal
when kick-down
relay is replaced? YES
• Replace kick-down
relay (L68) with 3
Does condition
• Start engine. become normal
NO when forward
relay is replaced?
• Replace forward
relay (L66) with
• Start engine.
4
Does condition
become normal
when 2nd-1st
1 NO selector relay is
Is resistance replaced?
between L15 • Replace 2nd-1st
(male) (1) and (2) selector relay (L76) YES
normal? with stop lamp
• Max. 1 z relay (L53).
6
• Turn starting • Start engine.
Is resistance bet-
switch OFF. YES ween L15 (female)
• Press kick-down (2) and L68 (female)
switch (L15). (5) normal?
5
Is resistance bet- • Max. 1 z
ween L68 (female) • Turn starting
NO (6) and chassis switch OFF. NO
ground normal? • Disconnect L15
and L68.
• Max. 1 z
• Turn starting
switch OFF. NO
• Disconnect L68.
NO
11 YES
Is resistance bet-
From A ween L76 (female)
(5) and TL1 (male)
(1) normal?
• Max. 1 z NO
• Turn starting switch OFF.
• Disconnect L76 and TL1.
20-512 WA700-3
(10)
Troubleshooting E-8
Cause Remedy
Defective kick-down relay Replace
Defective forward relay Replace
Defective 2nd-1st selector

Replace
relay
10 YES
To A
Is resistance bet-
9 (4) and L76 (female)
Is voltage between (1) normal? Repair or
YES L68 (female) (3) • Max. 1 z NO between L68 (female)(4) replace
and chassis • Turn starting and L76 (female) (1)
8 ground normal? switch OFF.
Is voltage between
• 20 – 30V • Disconnect L66 and L76. Defective contact or disco- Repair or
YES L66 (female) (3) nnection in wiring harness
and chassis ground • Turn starting NO between FS2 (female) (8) replace
normal? switch ON. and L68 (female) (3)
7
• Disconnect L68.
Is resistance • 20 – 30V Defective contact or disco-
between L66 • Turn starting nnection in wiring harness Repair or
(female) (4) and L68 switch ON. NO between L76 (female) (3) replace
(female) (1) normal? • Disconnect L66. and L66 (female) (3)
• Set gear shift lever 2nd.
• Max. 1 z Defective contact or disco-
• Turn starting nnection in wiring harness Repair or
switch OFF. NO between L66 (female) (4) replace
• Disconnect L66 and L68 (female) (1)
and L68.

ground
Defective kick-down Replace

switch

between L76 (female) (2), Repair or
CL1 (12) and chassis replace
ground

and TL1 (male) (1)
WA700-3 20-513
(10)
Troubleshooting E-8
20-514 WA700-3
(10)
Troubleshooting E-9
E-9 Kick-down works only when kick-down switch is being turned ON

(kick-down switch does not carry out self-hold operation)

Cause Remedy
YES Defective kick-down relay

Replace
1
Does condition
become normal
when kick-down 2 YES nnection in wiring harness Repair or
relay is replaced? between L68 (female) (2) replace
Is resistance bet-
• Replace kick-down and (5)
ween L66 (female)
relay (L68) with NO (4) and L68 (female) Defective contact or disco-
reverse relay (L67). (1) normal?
• Start engine. • Max. 1 z between L66 (female) (4) replace
NO
switch OFF.
WA700-3 20-515
(10)
Troubleshooting E-10
E-10 Kick-down always works

a Before carrying out troubleshooting, check that all related connectors are properly inserted.
Cause Remedy
YES Defective 2nd-1st selector

Replace
relay
1
Does condition
2 YES
Kick-down is not Defective forward relay Replace
become normal reset when directio- Does condition
when 2nd-1st YES nal lever is returned become normal
selector relay is from FORWARD to when forward relay
eplaced? NEUTRAL or Short circuit in harness
is replaced? Repair or
• Replace 2nd-1st REVERSE. between L66 (female) (3)
• Replace forward NO replace
selector relay (L76) and (4)
with stop lamp Go to defective relay (L66) with
relay (L53). NO part. reverse relay (L67).
• Start engine. • Start engine. 3 YES
Defective kick-down relay Replace
Kick-down is not Does condition
reset when gear become normal
shift lever is set
NO from 2nd to another when replacing
speed. kick-down relay?
To A
• Replace kick-down NO
relay (L68) with
reverse relay (L67). Short circuit with harness
5 YES • Start engine. and L66 (female) (4) in har- Repair or
Is resistance ness between L68 (female) replace
YES between L68 (4) and L76 (female) (1)
4 (female) (1) and (2) Short circuit with harness
normal? between L68 (female) (1) Repair or
Is resistance and L66 (female) (4) in har-
From A between L68 • Min. 1 Mz NO replace
ness between L68 (female)
(female) (3) and (4) • Turn starting (2) and L68 (female) (5)
normal? switch OFF. Short circuit with harness
• Min. 1 z • Disconnect L68. between L68 (female) (3) Repair or
• Turn starting and FS2 (female) (8) in har- replace
NO
ness between L68 (female)
switch OFF. (4) and L76 (female) (1)
• Disconnect L68.
20-516 WA700-3
(10)
WA700-3 20-517
(10)
E-11 Kick-down swich works even when traveling forward in 2nd

Cause Remedy
YES Defective 2nd-1st selector

Replace
3 relay
Does condition be-
YES come normal when
2nd-1st selector 4 YES
relay is replaced? To A
Is resistance
2
• Replace 2nd-1st between L15 Short circuit with harness
Is resistance
selector relay NO (female) (1) and (2) between L15 (female) (1)
YES between L68 (male) (L76) with stop normal? and L66 (female) (4) in
(1) and (2) and Repair or
between (3) and (4) lamp relay (L53). • Min. 1 Mz NO harness between L15 replace
1 normal? • Start engine. (female) (2) and L68
• Turn starting
• Min. 1 Mz (female) (5)
Is resistance switch OFF.
between L15
• Turn starting • Disconnect L15. Repair or
(female) (1) and (2) switch OFF. Defective kick-down relay
NO replace
• Min. 1 Mz
• Turn starting Defective kick-down
switch OFF. Replace
NO switch
• Disconnect L15.
• Do not press kick-down Short circuit with harness
switch. between L68 (female) (3)
5 YES Repair or
and FS2 (female) (8) in har-
Is resistance ness between L68 (female) replace
between L68 (4) and L76 (female) (1)
From A
(female) (1) and (2)
Short circuit with harness
normal? between L68 (female) (1) Repair or
• Min. 1 Mz NO and L15 (female) (1) in har- replace
• Turn starting ness between L68 (female)
(2) and L15 (female) (2)
switch OFF.
• Disconnect L68.
20-518 WA700-3
(10)
WA700-3 20-519
(10)
E-12 Boom Kick-out does not work
a Check that fuse (10) is not blown.
YES
YES
6
Is voltage between
YES F06 (female) (2)
1 and chassis
5 ground normal?
Does condition
become normal Is voltage between • 20 – 30 V
when boom relay YES F06 (female) (1) • Turn starting
with another relay is
NO
and chassis
replaced? switch ON.
4 ground normal?
• Disconnect F06.
• Replace boom relay • 20 – 30 V
Is resistance bet-
(L49) with bucket YES ween F06 (female) • Turn starting
relay (L48). (3) and chassis switch ON. NO
3 ground normal?
Is resistance • Max. 1 z
YES between L16 • Turn starting
(male) (1) and (2) switch OFF. NO
normal? • Disconnect F06.
2
Is voltage between • 19 – 23 z
each two pins of • Disconnect L16.
NO F06 conformed to NO
Table 1?
• See Table 1.
• Turn starting
switch ON. NO
Table 1)
When screw driver is When screw driver is not
approached to proxity switch approached to proxity switch
Between (1) and (2) 20 – 30 V below 3 V
Between (1) and (3) 20 – 30 V 0 – 30 V
Between (2) and (3) below 3 V 20 – 30 V
20-520 WA700-3
(10)
Cause Remedy
Defective boom relay Replace

7 YES nnection in wiring harness Repair or
Is resistance bet-
ween L16 (female)
(2) and chassis Defective contact or discon-
between L16 (female) (2), CL1
• Max. 1 z NO (12) and chassis ground
replace
• Turn starting
switch OFF. Defective contact or discon-
• Disconnect L16. nection in wiring harness
between F06 (female) (2), FR2 Repair or
(2), LR2 (2) and L49 (female) replace
(2)
between FS2 (female) (10), Repair or
LR2 (1), FR2 (1) and F06 replace
(female) (1)

between F06 (female) (3) replace
and chassis ground
Defective boom kick-out

solenoid Replace
Defective boom
proximity switch Replace
WA700-3 20-521
(10)
E-13 Defective bucket positioner
YES
YES
6
Is voltage between
YES F05 (female) (2)
1 and chassis
5 ground normal?
Does condition
become normal Is voltage between • 20 – 30 V
when bucket relay YES F05 (female) (1) • Disconnect F05.
with another relay is
NO
and chassis
replaced? • Turn starting
4 ground normal?
switch ON.
• Replace bucket relay • 20 – 30 V
Is resistance bet-
(L48) with boom YES ween F05 (female) • Turn starting
relay (L49). (3) and chassis switch ON. NO
3 ground normal?
Is resistance • Max. 1 z
YES between L17 • Turn starting
(male) (1) and (2) switch OFF. NO
normal? • Disconnect F05.
2
Is voltage between • 19 – 23 z
each two pins of • Disconnect L17.
NO F05 conformed to NO
Table 1?
• See Table 1.
• Turn starting
switch ON. NO
Table 1)
When screw driver is When screw driver is not
approached to proxity switch approached to proxity switch
Between (1) and (2) 20 – 30 V below 3 V
Between (1) and (3) 20 – 30 V 0 – 30 V
Between (2) and (3) below 3 V 20 – 30 V
20-522 WA700-3
(10)
Cause Remedy
Defective bucket relay Replace

7 YES nnection in wiring harness Repair or
Is resistance bet-
ween L17 (female)
(2) and chassis Defective contact or discon-
between L17 (female) (2), CL1
• Max. 1 z NO (12) and chassis ground
replace
• Turn starting
switch OFF. Defective contact or discon-
• Disconnect L17. between F05 (female) (2), FR2 Repair or
(3), LR2 (3) and L48 (female) replace
(2)
between FS2 (female) (10), Repair or
LR2 (1), FR2 (1) and F05 replace
(female) (1)

between F05 (female) (3)
replace
and chassis ground
Defective bucket
positioner solenoid Replace
Defective bucket
proximity switch Replace
WA700-3 20-523
(10)
E-14 Power window does not work

a) Window does not go up

(This troubleshooting flowchart shows the troubleshooting procedure for the left power window)
Cause Remedy
4 YES
Defective relay (L75) Replace
Is resistance
YES between L75 Defective contact or
3 (female) (6) and disconnection in wiring
Is resistance chassis normal? harness between L75 Repair or
YES between PWL2 • Max. 1 z NO (female) (6) – CL1 (12) – replace
(female) and L75 • Turn starting chassis ground
(female) (3) normal? switch OFF.
• Disconnect PWL2 Defective contact or
and L75. disconnection in wiring
• Max. 1 z Repair or
2 harness between PWL2
• Turn starting NO (female) – CL4 (2) – L75 replace
Is voltage switch OFF.
YES between PWL1 (female) (3)
• Disconnect PWL2
and chassis and L75. 6 YES
normal? Defective relay (L70) Replace
Does condition
• 20 – 30 V YES become normal
• Turn starting 5 when relay is
1
switch ON. replaced?
Is resistance
Is there continuity • Left power • Replace L70 (left UP NO Go to A
between PWL1
between PWL1 window switch: (male) and L70 relay) with L80
(female) and PWL2 UP NO (right UP relay).
(female) (3) normal? • Turn starting switch ON. Defective contact or
(male)? • Left power window disconnection in wiring
• Max. 1 z switch: UP harness between PWL1
Repair or
• Turn starting replace
• Turn starting NO (male) – CL4 (1) – L70
switch OFF.
switch OFF. (female) (3)
• Disconnect PWL1
• Disconnect PWL1
and PWL2.
and L70. Defective power window
Replace
NO motor
YES harness between L70 Repair or
(female) (2) – CL1 (12) – replace
chassis ground
Is voltage harness between L41 replace
Is voltage (female) (5) and L70 (female)
From A between L70 YES between L70
(1)
(female) (1) and 9 (female) (5) and
chassis normal? Defective contact or
chassis normal? Is voltage disconnection in wiring Repair or
YES between L41 • 20 – 30 V NO harness between FS8 (male) replace
• 20 – 30 V
(female) (1) and • Disconnect L70. (1) and L70 (female) (5)
• Disconnect L70. 8 chassis normal? • Turn starting
• Turn starting Defective contact or
Is resistance switch ON. disconnection in wiring
switch ON. • 20 – 30 V Repair or
between L41 harness between L41
• Left power • Disconnect L41. NO replace
(male) (1) and (5)
window switch: NO • Turn starting (female) (1) and FS8 (male)
normal? (1)
UP switch ON.
• Max. 1 z
• Turn starting Defective switch (L41) Replace
switch OFF.
NO
• Disconnect L41.
• Left power
window switch:
UP
20-524 WA700-3
(10)

b) Window does not go down

(This troubleshooting flowchart shows the troubleshooting procedure for the left power window)
Cause Remedy
4 YES
Defective relay (L70) Replace
Is resistance
YES between L75 Defective contact or
3 (female) (6) and disconnection in wiring
chassis normal? harness between L70
(female) (6) – CL1 (12) –
YES between PWL1 • Max. 1 z NO chassis ground replace
(male) and L70 • Turn starting
(female) (3) switch OFF.
• Disconnect L70 Defective contact or
and L75. disconnection in wiring
• Max. 1 z harness between PWL1 Repair or
2
• Turn starting NO (male) – CL4 (1) – L70 replace
Is voltage switch OFF. (female) (3)
YES between PWL2 • Disconnect PWL1
and chassis and L70. 6 YES
normal? Defective relay (L75) Replace
Does condition
• 20 – 30 V YES become normal
• Turn starting 5 when relay is
1
switch ON. replaced?
Is resistance
Is there continuity • Left power • Replace L75 (left Go to A
between PWL2 NO
between PWL1 window switch: (male) and L75 DOWN relay) with
(female) and PWL2 DOWN NO L77 (right DOWN relay).
(female) (3) normal? • Turn starting switch ON. Defective contact or
(male)? • Left power window disconnection in wiring
• Max. 1 z switch: DOWN harness between PWL2
Repair or
• Turn starting replace
• Turn starting NO (female) – CL4 (2) – L75
switch OFF.
• Disconnect PWL1
• Disconnect PWL2
and PWL2.
and L75. Defective power window
Replace
NO motor
YES harness between L75 Repair or
(female) (2) – CL1 (12) – replace
chassis ground
Is voltage harness between L41 replace
Is voltage (female) (6) and L75 (female)
From A between L75 YES between L75
(1)
(female) (1) and 9 (female) (5) and
chassis normal? Defective contact or
chassis normal? Is voltage disconnection in wiring Repair or
YES between L41 • 20 – 30 V NO harness between FS8 (male) replace
• 20 – 30 V
(female) (1) and • Disconnect L75. (1) and L75 (female) (5)
• Disconnect L75. 8 chassis normal? • Turn starting
Is resistance switch ON. disconnection in wiring
switch ON. • 20 – 30 V Repair or
between L41 harness between L41
• Left power • Disconnect L41. NO replace
(male) (1) and (6)
window switch: NO • Turn starting (female) (1) and FS8 (male)
normal? (1)
DOWN switch ON.
• Max. 1 z
• Turn starting Defective switch (L41) Replace
switch OFF.
NO
• Disconnect L41.
• Left power
window switch:
DOWN
WA700-3 20-525
(10)
E14 Related electrical circuit diagram
20-526 WA700-3
(10)
Troubleshooting E-15, E-16, E-17, E-18, E-19
E-15 Abnormality in front working lamp
a Go to Troubleshooting M-8.
E-16 Abnormality in rear working lamp
E-17 Abnormality in transmission cut-off
E-18 Abnormality in parking brake dragging warning
a Go to Troubleshooting M-11, M-12.
E-19 Abnormality in buzzer
WA700-3 20-527
(10)
Troubleshooting of electric engine throttle
controller & APS controller system system
(G mode)
Serial No.: 50001 – 51000
Judgement table for engine controller and engine related parts ................................................................. 20-552
Action taken by controller and condition of machine when abnormality occurs .......................................... 20-554
Action taken by controller and conditions for resetting when abnormality occurs....................................... 20-560
Points to remember when carrying out troubleshooting of engine controller system.................................. 20-561
Judgement table for engine controller......................................................................................................... 20-563
G-1 [90] [OFF or 10] Abnormality in power source system ...................................................................... 20-564
G-2 [90] [11] Abnormality in controller system.......................................................................................... 20-564
G-3 [90] [21] Mistaken connection of connector ....................................................................................... 20-565
G-4 [90] [56] Abnormality in controller solenoid power source system..................................................... 20-565
G-5 [90] [58] Abnormality in back-up power source system ..................................................................... 20-566
G-6 [90] [59] Abnormality in switch power source system........................................................................ 20-567
G-7 [91] [14] Abnormality in governor solenoid system............................................................................ 20-568
G-8 [91] [16] Abnormality in governor cut relay system ........................................................................... 20-569
G-9 [91] [19] Abnormality in governor servo system ................................................................................ 20-570
G-10 [91] [1d] Abnormality in pre-stroke solenoid system ......................................................................... 20-571
G-11 [92] [12] Abnormality in rack sensor system...................................................................................... 20-572
G-12 [92] [18] Abnormality in rack sensor power source system ............................................................... 20-573
G-13 [93] [1b] Abnormality in engine speed sensor A system ................................................................... 20-574
G-14 [94] [1c] Abnormality in engine speed sensor B system ................................................................... 20-575
G-15 [93,94] [1b, 1c] Abnormality in engine speed sensor A, B system .................................................... 20-576
G-16 [95] [40] Abnormality in water temperature sensor system ............................................................... 20-576
G-17 [97] [31] Abnormality in accelerator sensor system .......................................................................... 20-577
G-18 [99] [22] Engine overrun.................................................................................................................... 20-579
G-19 Engine does not start (controller related only) ................................................................................... 20-579
G-20 Engine does not start ......................................................................................................................... 20-580
G-21 Engine does not stop ......................................................................................................................... 20-583
G-22 Defective actuation of APS ................................................................................................................ 20-584
a) Preheating lamp switch does not light up when APS switch is ON
(all APS controller LEDs are also OFF) ........................................................................................ 20-584
b) Preheating pilot lamp flashes when water temperature is below 20ºC when
APS switch is ON (controller LEDs all give normal display) ......................................................... 20-586
Preheating pilot lamp lights up when water temperature is above 20ºC when
APS switch is ON (controller LEDs all give normal display) ......................................................... 20-586
c) Nozzle does not inject fuel when starting switch is turned to START after completion
of preheating when APS switch is ON (controller LEDs all give normal display).......................... 20-586
d) APS controller LED 1 (short circuit in glow plug 1 system) gives abnormal display .................... 20-587
e) APS controller LED 2 (disconnection in glow plug 1 system) gives abnormal display................. 20-587
f) APS controller LED 3 (short circuit in glow plug 2 system) gives abnormal display ..................... 20-588
g) APS controller LED 4 (disconnection in glow plug 2 system) gives abnormal display................. 20-588
h) APS controller LED 5 (short circuit with ground in nozzle) gives abnormal display..................... 20-589
i) APS controller LED 6 (disconnection in nozzle) gives abnormal display ...................................... 20-589
WA700-3 20-551
(10)
Troubleshooting Judgement table for engine controller and engine related parts
Judgement table for engine controller and engine related parts
Error code
Controller solenoid power source system
Controller back-up power source system
Controller switch power source system

Controller power source system
Connector connection system

Controller system
Failure code displayed
90 90 90 90 90 90
by monitor
Failure code 10
LED built into controller 11 21 56 58 59
(OFF)
Engine does not start q q q q q
Exhaust smoke comes out but engine does not start,
(1)
Difficulty in starting engine difficult to start
(2) No exhaust smoke comes out q q q q
Engine stopped during operation
Engine lacks power, acceleration is poor
Engine speed stays at low (1) Exhaust gas is normal (operator’s judgement)
idling, does not change when
accelerator pedal is
depressed (2) Exhaust smoke is abnormally black
Engine accelerates to high (1) Accelerated at same time as abnormality display

idling (2) NAccelerated while abnormality display was showing
Change in low idling speed does not match operation
(1) Exhaust gas is normal (operator’s judgement)
High fuel consumption
(2) Exhaust smoke is abnormally black
Engine speed does not (1) Does not reach high idling
change to high idling (2) Reaches high idling but returns to low idling
Defective automatic warming-up operation
(1) Engine continues to run at high speed
Engine does not stop Engine continues to run at low idling even when start-
(2)
ing switch is turned OFF
(1) Engine rotation is unstable at low idling
There is hunting of engine
(2) Engine rotation is unstable at high idling
High oil consumption, or exhaust smoke is blue
Oil becomes dirty quickly
Oil in cooling water
Oil pressure lamp lights up
Oil level rises
Water temperature rises too high (overheating)
Abnormal noise is generated
Excessive vibration
Troubleshooting code when abnormality display is given G-1 G-2 G-3 G-4 G-5 G-6
q: Check the error code display. If there is no display, go to the right side; if there is a display, go to the bottom.
20-552 WA700-3
(10)
Troubleshooting Judgement table for engine controller and engine related parts
Rack sensor power source system
Water temperature sensor system

Engine speed sensor A, B system
Engine speed sensor A system
Engine speed sensor B system

Pre-stroke solenoid system
Accelerator sensor system

Governor cut relay system
Governor solenoid system
Governor servo system
Eangine does not start

Troubleshooting code if no
Rack sensor system
abnormality display is given
Engine overrun
93
91 91 91 91 92 92 93 94 95 97 99
94
1b
14 16 19 1d 12 18 1b 1c 40 31 22
1c
q q q q q q See engine shop manual
q q q q q
See engine shop manual
q q q See engine shop manual

q q q q q See engine shop manual
G-17
q q See engine shop manual
q q –
q G-17

q See engine shop manual
q q q q q G-13, G-14, G-17
q –
q –
G-21

q
G-7 G-8 G-9 G-10 G-11 G-12 G-13 G-14 G-15 G-16 G-17 G-18 G-19
WA700-3 20-553
(10)
Troubleshooting Action taken by controller and condition of machine when abnormality occurs
Action taken by controller and condition of machine when

abnormality occurs
Main Engine
System with
monitor controller Nature of abnormality
abnormality
error code error code
Abnormality in 1) Occurs at same time as 58 and 59.

90 10 power source
system
Abnormality in 1) Defective engine controller

90 11
controller system
1) Disconnection in wiring harness between controller EC5A (1) – GND

Mistaken
(chassis ground)
90 21 connection of
2) Defective engine controller
connector
1) Defective contact or disconnection inside governor cut relay

Abnormality in 2) Defective contact or disconnection in wiring harness between starting
controller solenoid switch ACC terminal – governor cut relay
90 56
power source 3) Short circuit with ground, defective contact or disconnection in wiring
system harness between governor cut relay – controller EC2 (1)
1) Back–up power voltage has dropped more than 5V from switch power
voltage.
Abnormality in
2) Short circuit with ground, defective contact or disconnection in wiring
controller back-up
90 58 harness between fuse box – controller EC1 (7)
power source
3) Defective contact or disconnection in wiring harness between controller
system
EC1 (16) – chassis ground
1) Switch power voltage has dropped more than 5V from back–up power
voltage.
Abnormality in
controller switch
90 59 harness between fuse box – controller EC1 (9)(17)
power source
system
EC1 (8)(16) – chassis ground
1) Short circuit, short circuit with ground, defective contact or disconnection

inside governor control solenoid
2) Short circuit with ground, short circuit with power source, defective
contact or disconnection in wiring harness between controller EC2 (7)
governor control solenoid CNE12 (2) (No. 1 (+) end)
Abnormality in contact or disconnection in wiring harness between controller EC2 (4) –
91 14 governor solenoid governor control solenoid CNE15 (2) (No. 2 (+) end)
system 4) Short circuit with ground, short circuit with power source, defective
contact or disconnection in wiring harness between controller EC2 (17) –
governor control solenoid CNE12 (1) (No. 1 (–) end)
contact or disconnection in wiring harness between controller EC2 (15) –
governor control solenoid CNE15 (1) (No. 2 (–) end)
20-554 WA700-3
(10)
Condition when
Action by controller when Problem that appears on machine
normal (voltage,
abnormality is detected when there is abnormality
current, resistance)
• Same as 58 and 59. 1) Stops engine. 1) Engine stops during operation.

2) Engine cannot be started.
1) Stops engine. 1) Engine stops during operation.

• Voltage between 1) Normal control (when 1) When traveling: same condition is maintained.
EC5A (1) – chassis: operating). 2) When starting: engine cannot be started.
Less than 0.5V 2) Stops engine (when engine is
started).
• Voltage between EC2 1) Engine stops. 1) Engine stops during operation.

(1) – chassis: 20 – 30V 2) Engine cannot be started.
a If the abnormality is restored
by the vibration of the
machine, it resets
automatically.
• Voltage between EC1 1) Operates under normal

(7) – (16): 20 – 30V control.

machine, it resets
automatically.
• Voltage between EC1 1) Operates under normal

(9)(17) – (8)(16): 20 – control.
30V
machine, it resets
automatically.
• Solenoid resistance 1) Sets output to governor 1) Engine stops during operation.

value: 10 – 21 z control solenoid to 0 (stops 2) Engine cannot be started.
engine).
WA700-3 20-555
(10)
Main Engine
System with
abnormality
1) Defective contact or disconnection inside governor cut relay

harness between starting switch ACC terminal – governor cut relay
Abnormality in 3) Short circuit with ground, defective contact or disconnection in wiring
91 16 governor cut relay harness between controller EC1 (4) – governor cut relay
system 4) Short circuit inside governor cut relay
5) Short circuit with power source in wiring harness between controller EC1
(4) – governor cut relay
1) Defective governor control solenoid system or rack sensor system

Abnormality in (governor command value and rack sensor signal do not match)
91 19 governor servo 2) Abnormality in solenoid power source system
system 3) Defective engine controller
4) Defective part related to fuel injection pump
1) Short circuit, short circuit with ground, defective contact or disconnection

inside pre–stroke control solenoid
EC2 (9) – pre–stroke control solenoid CNE18 (2) ((+) pin)
Abnormality in pre-
EC2 (19) – pre–stroke control solenoid CNE18 (1) ((–) pin)
91 1d stroke solenoid
4) Short circuit with ground, short circuit with power source in wiring
system
harness between controller EC2 (9) – pre– stroke control solenoid
CNE18 (1) ((+) pin)
5) Short circuit with power source in wiring harness between controller EC2
(19) – pre–stroke control solenoid CNE18 (2) ((–) pin)
6) Defective controller
1) Defect inside rack sensor

Abnormality in rack harness between controller EC3A (7) – rack sensor CNE14 (3) ((+) pin)
92 12
sensor system 3) Short circuit with ground, defective contact or disconnection in wiring
harness between controller EC3A (17) – rack sensor CNE14 (4) ((–) pin)
1) Defect inside rack sensor

Abnormality in rack
harness between controller EC2 (16) – rack sensor CNE14 (1)
92 18 sensor power
3) Defective contact or disconnection in wiring harness between rack
source system
sensor CNE14 (2) – chassis ground
20-556 WA700-3
(10)
Condition when
normal (voltage,
• Solenoid resistance 1) Operates under normal 1) Engine stops during operation.

value: 200 – 900 z control. 2) Engine cannot be started.
1) Engine stops. 1) Engine stops during operation.

• Solenoid resistance 1) Sets output to prestroke 1) Feels that there is lack of power during operation.
value: 10 – 21 z control solenoid to 0. 2) Engine does not pick up smoothly.
2) Operates with restricted 3) Amount of black smoke increases.
output 4) Starting performance is poor.
• Voltage between 1) Operates under open control. 1) Feels that there is lack of power during operation.
EC3A (7) – (17): 0.1 – (limits output) 2) Engine does not pick up smoothly.
4.5V 3) Starting performance is poor.
• Voltage between EC2 1) Operates under open control. 1) Feels that there is lack of power during operation.
(16) – chassis: 4.6 – (limits output) 2) Engine does not pick up smoothly.
5.4V 3) Starting performance is poor.
WA700-3 20-557
(10)
Main Engine
System with
abnormality
1) Defect inside engine speed sensor A or defective adjustment

Abnormality in harness between controller EC3A (2) – engine speed sensor A – CNE13
93 1b engine speed (1)
sensor A system 3) Defective contact or disconnection in wiring harness between engine
speed sensor A – CNE13 (2) – chassis ground
1) Defect inside engine speed sensor B or defective adjustment

Abnormality in harness between controller EC3A (3) – engine speed sensor B – CNE10
94 1c engine speed (1)
sensor B system 3) Defective contact or disconnection in wiring harness between engine
speed sensor B – CNE10 (2) – chassis ground
Abnormality in 1) 1b and 1c occur at same time

93 1b engine speed
94 1c sensor A, B
system
1) Short circuit, defective contact or disconnection inside water

temperature sensor
Abnormality in
harness between controller EC3B (9) – water temperature sensor
engine water
95 40 CNE11 (1) (signal end)
temperature
sensor system
harness between controller EC3A (16) – water temperature sensor
CNE11 (2) (GND end)
1) Short circuit, defective contact or disconnection inside accelerator

sensor
harness between controller EC3A (6) – accelerator sensor CNL13 (3)
((+) end)
Abnormality in
97 31 accelerator sensor
harness between controller EC3A (16) – accelerator sensor CNL13 (2)
system
((–) end)
harness between controller EC3B (11) – accelerator sensor CNL13 (1)
(signal end)
1) Engine speed exceeded operating range.
99 22 Engine overrun
20-558 WA700-3
(10)
Condition when
normal (voltage,
• Sensor resistance 1) Operates with restricted 1)Feels that there is lack of power during operation.
value: 500 – 1000 z output. 2)Engine does not pick up smoothly.
3) Engine stops during operation and cannot be started
again.
• Sensor resistance 1) Operates with restricted 1)Feels that there is lack of power during operation.
value: 500 – 1000 z output. 2)Engine does not pick up smoothly.
3)Engine stops during operation and cannot be started
again.
• Same as 1b and 1c. 1) Stops engine. 1)Engine stops during operation.

2)Engine cannot be started.
• Resistance value 1) Operates under normal 1)Does not carry out warming-up operation.
between EC3B (9) – control. 2)Does not stop warming-up operation.
EC3A (16): Below
several z or infinity is a If the abnormality is restored
abnormal by the vibration of the
machine, it resets
automatically.
• Voltage between 1) Low idling operation

EC3A (6) – (16) (power
source):4.6 – 5.4V a If the abnormality is restored
• Voltage between by the vibration of the
EC3B (11) – EC3A machine, it resets
(16) (signal): 0.5 – automatically.
4.4V
1) Sets fuel injection amount to

0.
a ßIf the abnormality is restored

machine, it resets
automatically.
WA700-3 20-559
(10)
Troubleshooting Action taken by controller and conditions for resetting when abnormality occurs
Action taken by controller and conditions for resetting when

abnormality occurs
Failure code
Action by controller when Conditions for
Monitor Engine System with abnormality
abnormality is detected resetting
panel controller
Abnormality in power source Stops engine Power source in
10
system normal range
Abnormality in controller Stops engine Turn on power
11
system again
Mistaken connection of When traveling: same condition is Turn on power
21 connector maintained; when stopped: engine again
90 cannot be started
Abnormality in solenoid power Engine stops Turn on power
56
source system again
Abnormality in back-up power Normal operation Power source in
58
source system normal range
Abnormality in switch power Normal operation Power source in
59
source system normal range
Abnormality in governor Engine stops Turn on power
14
solenoid system again
Abnormality in governor cut Normal operation Turn on power
16
relay system again
91
Abnormality in governor servo Engine stops Turn on power
19
system again
Abnormality in pre-stroke Pre-stroke OFF + 20% reduction in fuel Turn on power
1d
solenoid system again
Abnormality in rack sensor Open loop control Turn on power
12
system again
92
Abnormality in rack sensor Open loop control Turn on power
18
power source system again
Abnormality in engine speed Output restricted 50% Turn on power
93 1b
sensor A system again
Abnormality in engine speed Output restricted 50% Turn on power
94 1c
sensor B system again
Abnormality in engine speed Stops engine Input rotation
93, 94 1b, 1c
sensor A, B system
Abnormality in engine water Normal operation Power source in
95 40
temperature sensor system normal range
Abnormality in accelerator Low idling Power source in
97 31
sensor system normal range
99 22 Engine overrun No injection Below 1500 rpm
00 Normal
20-560 WA700-3
(10)
Troubleshooting Points to remember when carrying out troubleshooting of engine controller system
Points to remember when carrying out troubleshooting of

engine controller system
1. Points to remember if abnormality returns to normal by itself:
If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and the con-
nector is returned to its original position when carrying out troubleshooting of the failure, and the error code
is no longer displayed, or if the monitor display returns to normal, the abnormality has probably returned to
normal.
However, there is a high probability that the same problem will occur again, so it is desirable to follow up
this problem carefully.
2. Handling error code:

1) For details of the abnormality, in addition to the main monitor display, it is necessary to check the LED
display built into the engine controller before carrying out troubleshooting. (The main monitor error code
shows a large system category, so it is necessary to check the code on the LED display built into the
engine controller to check the detailed category.)
2) The engine controller error code stores the errors that have occurred in the past, so pay careful
attention to the display pattern below when proceeding with the troubleshooting operation.
3) After completing troubleshooting, erase all the error codes from the engine controller memory.
3. Details of LED display built into engine controller:

1) Display schedule
After controller is turned ON
[88] o Checks LED
o [XX] o [XX] o [XX] o [XX] Displays content of controller
o [– –] o
o [XX] o ... o [XX] Displays errors in memory
o [E ] o [XX] o [E ] o [XX] Displays existing errors
o [0 0] Display when normal
Checks LED: Displays [88] when checking LED

Displays content of controller: Displays content of engine controller program (displays codes for
program) [XX] o [XX] o [XX] o [XX] 2 digits * 4
Displays errors in memory: Displays error codes in controller memory for errors that occurred in past
[XX] o ... o [XX] errors in memory are displayed
Displays existing errors: Displays errors that are occurring now [E ] o [XX] displays [E ] in front of
the error code, displays number of occurrences
Error display continues for 5 minutes even after condition causing error
has been removed
If the condition is normal, [00] is displayed.
WA700-3 20-561
(10)
Troubleshooting Points to remember when carrying out troubleshooting of engine controller system
4. Controller
1. Case Outline
2. Self-diagnostic display window • This receives the signals from the accelerator
3. Printboard sensor, low idling selector switch, and other sen-
sors and switches mounted on the machine. It
then outputs the signals to control the fuel injec-
tion pump for the engine.
The controller has a self-diagnostic function. If
there is any abnormality, it sends the ON/OFF
signal to the main monitor and displays charac-
ters on the built-in segments.
20-562 WA700-3
(10)
Troubleshooting Judgement table for engine controller
Judgement table for engine controller

Display code for monitor panel Display code for LED built into controller
G-1 [90] Displays abnormality in controller [10] Abnormality in power source system
system and power source system
G-2 [11] Abnormality in controller system
G-3 [21] Mistaken connection of connector
G-4 [56] Abnormality in solenoid power source system
G-5 [58] Abnormality in back-up power source system
G-6 [59] Abnormality in switch power source system
G-7 [91] Displays abnormality in governor and [14] Abnormality in governor solenoid system
pre-stroke control system
G-8 [16] Abnormality in governor cut relay syst
G-9 [19] Abnormality in governor servo system
G-10 [1d] Abnormality in pre-stroke solenoid system
G-11 [92] Displays abnormality in rack sensor [12] Abnormality in rack sensor system
system
G-12 [18] Abnormality in rack sensor power source system
G-13 [93] Displays abnormality in engine speed [1b] Abnormality in engine speed sensor A system
sensor A system
G-14 [94] Displays abnormality in engine speed [1c] Abnormality in engine speed sensor B system
sensor B system
G-15 [93,94] Displays abnormality in engine speed [1b,1c] Abnormality in engine speed sensor A, B system
sensor A, B system
G-16 [95] Displays abnormality in engine water [40] Abnormality in engine water temperature sensor
temperature sensor system system
G-17 [97] Displays abnormality in accelerator [31] Abnormality in accelerator sensor signal system
sensor system
G-18 [99] Displays engine overrun [22] Engine overrun
G-19 Engine does not start

20
G-21 Engine does not stop
WA700-3 20-563
(10)
Troubleshooting G-1, G-2
G-1 [90] Abnormality in power source system

[OFF or 10]
a If this abnormality occurs, carry out troubleshooting G-5 and G-6.
G-2 [90] Abnormality in controller system

[11]
a When the battery is normal.

Cause Remedy
1 YES
Defective controller Replace
Is voltage
between EC1 (9)
– (8), EC1 (17) – Check wiring harness.
(16) normal? For details, see section —
• 20 – 30 V NO on abnormality in power
• Turn starting source.
switch ON.
G-2 Related electrical circuit diagram
20-564 WA700-3
(10)
G-3 [90] Mistaken connection of connector

[21]
Cause Remedy
1 YES
Is voltage
between EC5A (1)
and GND less Defective contact or
than 0.5 V? Repair or
replace wiring
• Turn starting NO harness between EC5A
harness
switch ON. (female) (1) and GND
• Disconnect
CN5A.
• Check that CN3A
(1) is OPEN
(wiring harness is
not connected).
G-4 [90] Abnormality in controller solenoid power source system

[56]
a If this abnormality occurs, carry out troubleshooting G-7 and G-10.
WA700-3 20-565
(10)
Troubleshooting G-5
G-5 [90] Abnormality in back-up power source system

[58]
a Check that the fuse is not blown.

a If it is blown, check for a short circuit with the ground inside the controller and in the wiring harness between
the fuse and the controller.
Cause Remedy
YES
1
Is voltage disconnection in wiring
between EC1 (7) YES harness between CNFS2 Repair or
and EC1 (16) (female) (11) – EC1 (female)
(7) or EC1 (female) (16) – replace
normal? 2
battery terminal (– )
• 20 – 30 V Is voltage Defective contact or
• Turn starting between CNFS2 YES disconnection in wiring
Repair or
switch ON. NO (female) (11) and harness between CNFS2
3 (male) (11) and CNFS3 replace
chassis normal?
Is voltage (female) (6)
• 20 – 30 V Defective contact or
between CNFS3
• Turn starting
NO (male) (6) and 4 YES disconnection in wiring Repair or
switch ON. harness between CNLR5
chassis normal? Is voltage (male) (1) and battery replace
• 20 – 30 V between CNLR5 terminal (+)
• Turn starting NO (male) (1) and Defective contact or
switch ON. chassis normal? disconnection in wiring Repair or
• 20 – 30 V NO harness between EC1 replace
• Turn starting (female) (16) and battery
switch ON. terminal (– )
20-566 WA700-3
(10)
Troubleshooting G-6
G-6 [90] Abnormality in switch power source system

[59]

Cause Remedy
YES
1
Is voltage
between EC1 (9) harness between CNFS7
YES Repair or
– (8), EC1 (17) – (female) (1) – EC1 (female)
(16) normal? 2 (9), (17) or EC1 (female) (8), replace
s voltage (16) – battery terminal (– )
• 20 – 30 V between CNFS7 Defective contact or
• Turn starting disconnection in wiring
switch ON. NO (female) (1) and 3 YES
harness between CNFS7 Repair or
chassis normal?
Is voltage (male) (1) and CNL09 replace
• 20 – 30 V between CNL09 (female) (5)
• Turn starting NO (male) (5) and Defective contact or
switch ON. chassis normal? disconnection in wiring
harness between CNL09 Replace
• 20 – 30 V NO (male) (5) – starting switch –
• Turn starting battery terminal (+)
switch ON.
WA700-3 20-567
(10)
Troubleshooting G-7
G-7 [91] Abnormality in governor solenoid system

[14]
Cause Remedy
YES
3
Is resistance Short circuit with chassis
between EC2 ground in wiring harness
YES (female) (4), (7) –
chassis and EC2 between EC2 (female) (4), (7)
4 YES – CNE15 (female) (2), CNE12 Repair or
(female) (15), (17) –
chassis normal? Is resistance replace
between CNE12 (female) (2) or EC2 (female)
2 • Min. 1 Mz (male) (1) – chassis (15), (17) – CNE15 (female)
(1), CNE12 (female) (1)
Is resistance • Turn starting NO and CNE12 (male)
(2) – chassis
YES between EC2 switch OFF. normal? Defective governor
Replace
(female) (4), (7) – • Disconnect EC2. • Min. 1 Mz NO solenoid
• Turn starting switch OFF. Defective governor solenoid
(15), (17) normal? • Disconnect CNE12 and Defective contact or
CNE15. disconnection in wiring
• 10 – 21 z harness between EC2
1 5 YES
• Turn starting (female) (4), (7) – CNE15 Repair or
switch OFF. Is resistance (female) (2), CNE12 (female) replace
Is voltage between (2) or EC2 (female) (15), (17) –
EC1 (4) – chassis, • Disconnect EC2. between CNE12 CNE15 (female) (1), CNE12
between EC2 (1) NO (male) (1) and (2) (female) (1)
and chassis normal? normal?
Defective governor
• 10 – 21 z NO solenoid Replace
• 20 – 30 V
• Turn starting • Turn starting
switch ON. switch OFF.
• Disconnect CNE15 and CNE12.
Go to G-8 —
NO
Between EC2 (female) (4), (7) – chassis

Min. 1 Mz
Between EC2 (female) (15), (17) – chassis
Engine controller
Between CNE2 (female) – chassis
Min. 1 Mz
Between CNE2 (female) (2) – chassis
20-568 WA700-3
(10)
Troubleshooting G-8
G-8 [91] Abnormality in governor cut relay system

[16]

Cause Remedy
YES Defective controller Replace

2
Is voltage
YES between EC1 (4) Defective contact or
and chassis 3 YES Repair or
harness between EC1
normal? Is resistance replace
(female) (4) – relay –
• 20 – 30 V between (1) and CNFS7 – power source
1
Is voltage
• Turn starting NO (2) inside relay
switch ON. normal? Defective governor cut
between EC2 (1) Replace
• 200 – 900 z NO relay
and chassis
normal? • Turn starting switch OFF.
• Disconnect relay. Defective contact or
• 20 – 30 V disconnection in wiring
4 YES Repair or
• Turn starting harness between EC2
Is resistance replace
switch ON. (female) (1) – relay –
between (3) and CNFS7 – power source
NO (6) inside relay
normal?
Defective governor cut Replace
• MAX. 1 z NO relay
• Turn starting
switch OFF.
• Disconnect relay.
WA700-3 20-569
(10)
Troubleshooting G-9
G-9 [91] Abnormality in governor servo system

[19]
Cause Remedy
2 YES Defective fuel injection

pump related part (see
Is voltage Engine Shop Manual)
YES
between EC3A (7) Defective contact or
1 and (17) normal? disconnection in wiring Repair or
Is voltage harness between EC3A replace wiring
between EC2 (1) • 0.1 - 4.5 V NO (female) (7), (17) – CNE14 harness
and chassis • Turn starting (female) (3), (4)
normal? switch ON.
Defective contact or Repair or
• 20 – 30 V disconnection in wiring replace wiring
• Turn starting NO harness between EC2 harness
switch ON. (female) (1) – governor
cut relay
20-570 WA700-3
(10)
Troubleshooting G-10
G-10 [91] Abnormality in pre-stroke solenoid system

[1d]
Cause Remedy
YES Defective controller Replace

2
Is resistance
YES between EC2 Short circuit in wiring
harness between EC2
(female) (9) and 3 YES Repair or
(female) (9) – CNE16
chassis normal? Is resistance replace
(female) (2), (1) – EC2
• Max. 1 Mz between CNE16 (female) (19)
1
Is resistance
• Turn starting NO (male) (2) and
switch OFF. chassis normal? Defective pre-stroke
between EC2 Replace
• Disconnect EC2. • Max. 1 Mz NO solenoid
(female) (9) and
(19) normal? • Turn starting switch OFF. Defective contact or
• Disconnect CNE16. disconnection in wiring
• 10 – 21 z 4 YES harness between EC2 Repair or
• Turn starting
Is resistance (female) (9) – CNE16 replace
switch OFF.
between CNE16 (female) (2), (1) – EC2
• Disconnect EC2.
NO (male) (1) and (2) (female) (19)
normal?
Defective pre-stroke Replace
• 10 – 21 z NO solenoid
• Turn starting
switch OFF.
• Disconnect
CNE16.
WA700-3 20-571
(10)
G-11 [92] Abnormality in rack sensor system

[12]
Cause Remedy
YES
2 Defective contact or
YES Is voltage harness between EC3A
between EC3A (7) YES Repair or
and (17) normal? (female) (7) – CNE14
3 replace
(female) (3) or between
Is voltage EC3A (female) (17) –
• 0.1 – 4.5 V
between CNE14 CNE14 (female) (4)
1 • Turn starting
NO (3) and (4) 4 YES Replace
switch ON. Defective rack sensor
Is voltage normal? Is resistance
between EC2 (16) between CNE14 Short circuit with chassis
• 0.1 – 4.5 V
and EC3A (14) ground in wiring harness
• Turn starting NO (female) (2) – (3),
normal? (2) – (4) normal? between EC3A (female)
switch ON. Repair or
• 4.6 – 5.4 V (7) – CNE14 (female) (3)
• Disconnect EC3A. • 50 kz – 1 Mz NO or between EC3A replace
• Turn starting • Turn starting switch OFF.
switch ON. • Disconnect CNE14 (female) (17) – CNE14
and EC3A. (female) (4)
Go to G-12 —
NO
20-572 WA700-3
(10)
G-12 [92] Abnormality in rack sensor power source system

[18]
Cause Remedy
3 YES
Defective rack sensor Replace
Is voltage
YES between CNE14
2 (female) (1) and Defective wiring harness
(2) normal? between EC2 (female)
Is voltage Repair or
(16) – CNE14 (female) (1)
YES between EC2 • 4.6 – 5.4 V NO replace
or EC3A (female) (14) –
(male) (16) and • Turn starting
CNE14 (female) (2)
GND normal? switch ON.
1
• 4.6 – 5.4 V Defective controller Replace
Is resistance
between EC2
(female) (16) and switch ON. Defective wiring harness
EC3A (female) (14) • Disconnect EC2 and connect T-adapter to between EC2 (female)
normal? male end only. 4 YES (16) – CNE14 (female) (1) Repair or
• Min. 500 kz Is resistance and between EC1 replace
• Turn starting between CNE14 (female) (8) – CNE14
NO (male) (1) and (2)
• Disconnect EC2 normal?
and EC3A. Defective rack sensor Replace
• Min. 500 kz NO
• Turn starting
switch OFF.
• Disconnect
CNE14.
WA700-3 20-573
(10)
G-13 [93] Abnormality in engine speed sensor A system

[1b]
Cause Remedy
3 YES Defective adjustment of

—
Does condition speed sensor A
YES become normal
when speed sensor
2 A is adjusted?
Is resistance See TESTING NO
YES between EC3A AND ADJUSTING.
(female) (2) and
ground in wiring harness
chassis normal? 4 YES Repair or
between EC3A (female)
• Min. 1 Mz Is resistance (2) – CNE13 (female) (1), replace
1 • Turn starting between CNE13 (2) – EC3A (female) (14)
switch OFF.
Is resistance NO (male) (1) and
between EC3A • Disconnect chassis normal?
(female) (2) and EC3A. Defective speed sensor A Replace
• Min. 1 Mz NO
(14) normal? • Turn starting switch OFF. Defective contact or
• 500 – 1000 z • Disconnect CNE13. disconnection in wiring
• Turn starting 5 YES harness between EC3A Repair or
switch OFF. Is resistance (female) (2) – CNE13 replace
• Disconnect EC3A. between CNE13 (female) (1), (2) – EC3A
NO (male) (1) and (2) (female) (14)
normal?
Defective speed sensor A Replace
• 500 – 1000 z NO
• Turn starting
switch OFF.
• Disconnect
CNE13.
20-574 WA700-3
(10)
G-14 [94] Abnormality in engine speed sensor B system

[1c]
Cause Remedy
3 YES Defective adjustment of

—
Does condition speed sensor B
YES become normal
when speed sensor
2 B is adjusted?
Is resistance See TESTING NO
YES between EC3A AND ADJUSTING.
(female) (3) and
chassis normal? 4 YES Repair or
• Min. 1 Mz Is resistance (3) – CNE10 (female) (1), replace
1 • Turn starting between CNE10 (2) – EC3A (female) (14)
switch OFF.
Is resistance NO (male) (1) and
between EC3A • Disconnect chassis normal?
(female) (3) and EC3A. Defective speed sensor B Replace
• Min. 1 Mz NO
(14) normal? • Turn starting switch OFF.
• 500 – 1000 z • Disconnect CNE10. Defective wiring harness
• Turn starting 5 YES between EC3A (female) Repair or
switch OFF. Is resistance (3) – CNE10 (female) (1), replace
• Disconnect EC3A. between CNE10 (2) – EC3A (female) (14)
NO (male) (1) and (2)
normal?
Defective speed sensor B Replace
• 500 – 1000 z NO
• Turn starting
switch OFF.
• Disconnect
CNE10.
WA700-3 20-575
(10)
G-15 [93,94] Abnormality in engine speed sensor A, B system

[1b, 1c]
a If this abnormality occurs, carry out troubleshooting G- 13 and G-14.
G-16 [95] Abnormality in water temperature sensor system

[40]
Cause Remedy
YES
1
Is resistance Short circuit,
between EC3B disconnection between
(female) (9) and EC3B (female) (9) –
2 YES Repair or
EC3A (female) (16)
CNE11 (female) (1) or replace
normal? Is resistance
• Abnormal if between CNE11
(16) – CNE11 (female) (2)
resistance is NO (male) (1) and (2)
below several z normal? Defective water
or infinity. Replace
• Abnormal if NO temperature sensor
• Turn starting resistance is
switch OFF. below several z
• Disconnect EC3A or infinity.
and EC3B. • Turn starting
switch OFF.
• Disconnect
CNE11.
20-576 WA700-3
(10)
G-17 [97] Abnormality in accelerator sensor system

[31]
Cause Remedy
YES
2
Does voltage
between EC3B (11)
YES and EC3A (16) change
according to angle of 3 YES Adjust (see
accelerator pedal as Defective adjustment of
shown in Fig. 1? In Item 2, does TESTING AND
accelerator sensor
voltage change ADJUSTING)
• Turn starting
1
switch ON. NO but is outside
Is voltage • Operate specified value?
between EC3A (6) accelerator Go to A
NO
and EC3A (16) pedal.
normal?
• 4.6 – 5.4 V YES
• Turn starting Defective controller Replace
8
switch ON. Is resistance Short circuit in wiring
between EC3A harness between EC3A
(female) (6) – (16), (female) (6) – CNL13
NO (6) – chassis 9 YES Repair or
(female) (3) (5V), CNL13 (1)
normal? Is resistance between replace
accelerator sensor (male) (GND) – EC3A (female)
• Between (6) – (16): (5V) and (GND) and (16), contact with other
4.6 – 5.4 kz resistance between wiring harness
NO accelerator sensor (male)
Between (6) – (5V) and chassis normal? Defective accelerator Replace
chassis: Min. 1 Mz • Between (5V) – NO sensor
• Turn starting (GND): 4.6 – 5.4 kz
switch OFF. Between (5V) –
• Disconnect EC3A. chassis: Min. 1 Mz
• Turn starting
switch OFF.
• Disconnect sensor.
YES harness between EC3B Repair or
(female) (11) and CNL13 replace
(female) (Sig)
Does voltage between
accelerator sensor (Sig) 7 YES disconnection in wiring Repair or
YES and (GND) change Does resistance between harness between EC3B
according to angle of replace
accelerator sensor (Sig) (female) (11) and CNL13
accelerator pedal as YES and (GND) change (female) (Sig)
shown in Fig. 1? according to angle of
6
• Turn starting accelerator pedal as Disconnected accelerator
4 Is resistance shown in Fig. 2? Repair or
switch ON. sensor linkage or replace
between accelerator • Turn starting NO defective sensor
Is voltage between • Operate
From A accelerator sensor sensor (5V) – (GND) switch OFF.
accelerator NO
normal? • Disconnect
(5V) – (GND) pedal.
normal? • 4.6 – 5.4 kz sensor Defective accelerator
Replace
• 4.6 – 5.4 V • Turn starting NO sensor
switch ON. • Disconnect
sensor. harness between EC3A Repair or
NO (female) (6) – CNL13 replace
(female) (3) (5V), CNL13 (1)
(GND) – EC3A (female) (16)
WA700-3 20-577
(10)
20-578 WA700-3
(10)
G-18 [99] Engine overrun

[22]
Cause Remedy
Carry out
Problem probably caused troubleshooting
1 YES
by abnormality that of abnormality
Did any other occurred at same time that occurred at
abnormality same time
occur at same Problem probably caused
time? by external abnormality Look for other
NO and not by electric cause
engine throttle controller
G-19 Engine does not start (controller related only)
a When starting motor cranks but engine does not start.

Cause Remedy
Carry out
Problem probably
YES troubleshooting
caused by abnormality of displayed
1 that is displayed abnormality
Is there any
abnormality
2 YES See Engine
display? See Engine shop manual
Is resistance shop manual
between EC5B (4) Defective fuel cut switch Repair or
NO and EC1 (16) or APS assister or relay replace
normal? Short circuit in wiring Repair or
• Min. 1 Mz NO harness between EC5B replace
• Turn starting (4) – relay – APS assister
switch ON. – fuel cut switch
WA700-3 20-579
(10)
G-20 Engine does not start
a Check that the fuse is not blown. (If it is blown, check for a short circuit with the ground in the circuit related
to the fuse.)
a Check that the wiring harness between battery relay terminal B – battery (+) – battery (–) – chassis is
connected securely.
4 YES
Is voltage between
YES starting motor
terminal B and
chassis ground
normal?
switch ON.
3 • 20 – 30 V
Is there sound of YES
YES 6
starting motor
pinion engaging? Is voltage between
YES starting motor
• Turn starting terminal R and
7 YES
chassis ground
switch ON io
normal? Is voltage between
START alternator terminal
5 • Turn starting
switch ON. R and chassis
Is voltage between NO
ground normal?
starting motor • Max. 1 V
terminal C and • Disconnect wiring. NO
NO chassis ground • Turn starting switch
2 normal? ON.
• Max. 1 V
Is sound of • Turn starting 8 YES
YES actuation heard switch to START. Is resistance
from battery • 20 – 30 V between starting
relay? switch terminal B
NO and terminal C
• Turn starting normal?
switch OFF io • Turn starting NO
ON switch to START.
• Disconnect CNL09.
• Max. 1 z
10 YES
Is resistance
YES between battery
relay terminal E and
chassis ground
1 9 normal?
Is voltage between • Turn starting NO
Are voltage and battery relay switch OFF.
specific gravity of terminal BR and • Max. 1 z
battery normal? NO chassis ground YES
normal?
11
• Turn starting • Turn starting
Is voltage between
switch OFF. switch ON. starting switch
• Voltage: Min. 24V • 20 – 30 V terminal BR and
• Specific gravity: NO chassis ground
12 YES
Min. 1.26 normal? Is resistance
between starting
• Turn starting
switch terminal B
switch ON. NO and terminal BR
• 20 – 30 V normal?
switch to START.
• Max. 1 z
NO
20-580 WA700-3
(10)
Cause Remedy
Defective starting motor Replace
harness between starting Repair or
motor terminal B and replace
battery relay terminal
Defective starting motor Replace

between starting motor
terminal C – CNE22 – 25 Repair or
(female) (2), or short replace
circuit in diode CNE22 –
25
Defective alternator Replace
switch terminal C and replace
starting motor terminal C
relay terminal E and chassis replace
ground
switch terminal BR and replace
battery relay terminal BR
switch terminal B and
battery relay terminal B
Charge or
Lack of battery capacity replace
WA700-3 20-581
(10)
20-582 WA700-3
(10)
G-21 Engine does not stop
Cause Remedy
Defective fuel injection See Engine

YES pump Shop Manual
1 or defective engine Replace
controller
Is voltage
between EC1 Short circuit in wiring
(9)(17) and 2 YES harness between EC1 (9) Repair or
chassis normal? Is resistance (17) – starting switch replace
between starting ACC terminal
• Max. 1 V
switch terminal B
• Turn starting NO and ACC terminal
switch OFF. normal?
• Min. 1 Mz NO
• Turn starting
switch OFF.
• Disconnect
connector
connecting to
controller.
WA700-3 20-583
(10)
G-22 Defective actuation of APS
a) Preheating lamp switch does not light up when APS switch is ON (all APS controller LEDs are also
OFF)
a Carry out troubleshooting of the power system.
a Check that the engine can be cranked (if the engine cannot be cranked, carry out troubleshooting G-19 and
G-20 first).
a Check that the fuse is normal. (If it is blown, check for a short circuit with the ground in the related circuits
for the fuse).
a Carry out troubleshooting with the APS switch ON.
2 YES
Is resistance
YES between CNL71
(female) (1) and
chassis ground
normal?
switch OFF.
1 • Disconnect
Is voltage CNL71. YES
between CNL72 • Max. 1 z
(1) and chassis
ground normal?
• Turn starting YES
switch ON. 6
• 20 – 30 V Is voltage
3
When No-injection YES between CNL82
cranking (CNL82) is (3) and chassis 7 YES
interchanged with ground normal?
other relay, does 5 Is there continuity
NO voltage in Item 1 • Turn starting between starting
become normal? Is there continuity
YES between CNL82 switch ON. NO switch terminals B
• Turn starting • 20 – 30 V and ACC?
switch ON. (female) (2) and
• 20 – 30 V chassis ground? • Turn starting NO
switch OFF.
• Turn starting
4 switch OFF.
• Disconnect
Is voltage NO
CNL82.
between CNL82
NO (1) and chassis
ground normal?
9 YES
• Turn starting
switch ON. Is there continuity
YES
• 20 – 30 V between CNL09
8 (male) (3) and (4)?
Is voltage between
CNL09 (female) (3) • Turn starting NO
NO and chassis switch OFF.
ground normal? • Disconnect CNL09.
• Turn starting . Turn heater switch ON.
switch ON. NO
• 20 – 30 V
20-584 WA700-3
(10)
Cause Remedy
harness between CNL71 Repair or
(female) (1) and chassis replace
ground
Defective No-injection
cranking relay for APS Replace
controller
Defective contact,
disconnection, or short
circuit with chassis ground in Repair or
CNL82 (female) (6) and
CNEC5B (female) (4)
Defective contact,
disconnection, or short Repair or
circuit with chassis ground in
wiring harness between
replace
starting switch terminal ACC
and CNL82 (female) (3)
harness between CNL82 Repair or
(female) (2) and chassis replace
ground
harness between CNL09 replace
(female) (2) – CNL82
(female) (2)
Defective heater switch Replace
harness between fuse replace
and CNL09 (female) (3)
WA700-3 20-585
(10)
b) Preheating pilot lamp flashes when water temperature is below 20ºC when APS switch is ON (con-
troller LEDs all give normal display)
Preheating pilot lamp lights up when water temperature is above 20ºC when APS switch is ON (con-
troller LEDs all give normal display)
a Carry out troubleshooting of the APS water temperature sensor system.
a Check the engine water temperature.
Cause Remedy
2 YES
Is resistance
YES between CNL71 Defective contact,
(female) (2) and disconnection, or short
1 chassis ground
circuit with chassis
Is resistance normal? Repair or
between CNE08 • Turn starting NO replace
(male) and chassis between CNL71 (female)
switch OFF.
ground normal? (2) and CNE08 (female)
• Turn starting • Same as Item 1. Defective APS water
Replace
switch OFF. NO temperature senso
• Disconnect
CNE08.
• Water temperature
below 20 C:
Max. 1z
• Water temperature
above 20 C:
Min. 1 Mz
c) Nozzle does not inject fuel when starting switch is turned to START after completion of preheating
when APS switch is ON (controller LEDs all give normal display)
a Carry out troubleshooting of the starting motor signal (terminal C) system.
a Check that the injection nozzle stop valve is open.
Cause Remedy
YES
1 Defective APS controller Replace
Is voltage
between CNL71
(3) and chassis 2 YES Repair or
harness between CNL71
ground normal? Is voltage between replace
starting switch
(female) (3) and starting
• Turn starting terminal C and switch terminal C
switch to NO chassis ground
START. normal?
• 20 – 30 V • Turn starting NO
switch ON.
• 20 – 30 V
20-586 WA700-3
(10)
d) APS controller LED 1 (short circuit in glow plug 1 system) gives abnormal display
Cause Remedy
2 YES
Is resistance
YES between CNL72
1 chassis ground
Is resistance
normal? between CNL72 (female) Repair or
between glow plug
• Turn starting NO (2) and glow plug 1 replace
1 terminal and
chassis ground switch OFF. terminal
normal? • Disconnect CNL72.
• Turn starting • 0.8 – 1.3 z
switch OFF. NO
• Disconnect plug
terminal.
• 0.8 – 1.3 z
e) APS controller LED 2 (disconnection in glow plug 1 system) gives abnormal display
Cause Remedy
2 YES
Is resistance
YES between CNL72
(female) (2) and Defective contact or
1 chassis ground
Is resistance
normal? harness between CNL72 Repair or
between glow plug
• Turn starting NO (female) (2) and glow replace
1 terminal and
chassis ground switch OFF. plug 1 terminal
switch OFF. NO
• Disconnect plug
terminal.
• 0.8 – 1.3 z
WA700-3 20-587
(10)
f) APS controller LED 3 (short circuit in glow plug 2 system) gives abnormal display
Cause Remedy
2 YES
Is resistance
YES between CNL72
1 chassis ground
Is resistance
normal? between CNL72 (female) Repair or
between glow plug
• Turn starting NO (3) and glow plug 2 replace
2 terminal and
chassis ground switch OFF. terminal
switch OFF. NO
• Disconnect plug
terminal.
• 0.8 – 1.3 z
g) APS controller LED 4 (disconnection in glow plug 2 system) gives abnormal display
Cause Remedy
2 YES
Is resistance
YES between CNL72
1 chassis ground
Is resistance
normal? harness between CNL72 Repair or
between glow plug
• Turn starting NO (female) (3) and glow replace
2 terminal and
chassis ground switch OFF. plug 2
switch OFF. NO
• Disconnect plug
terminal.
• 0.8 – 1.3 z
20-588 WA700-3
(10)
h) APS controller LED 5 (short circuit with ground in nozzle) gives abnormal display
Cause Remedy
2 YES
Is resistance
YES between CNL72
(female) (4) and
1 chassis ground Short circuit with chassis
Is resistance normal? ground in wiring harness Repair or
between each • Turn starting NO between CNL72 (female) replace
nozzle and chassis switch OFF. (4) and each nozzle
• Turn starting • 1.5 – 2.5 z Defective nozzle (nozzle
Replace
switch OFF. NO with defective resistance)
• Disconnect
nozzle terminal.
•3– 5z
i) APS controller LED 6 (disconnection in nozzle) gives abnormal display
Cause Remedy
2 YES
Is resistance
YES between CNL72
1 chassis ground
Is resistance normal? Repair or
harness between CNL72
between each • Turn starting NO replace
(female) (4) and each
nozzle and chassis switch OFF. nozzle
• Turn starting • 1.5 – 2.5 z Defective nozzle (nozzle
Replace
switch OFF. NO with defective resistance)
• Disconnect
nozzle terminal.
•3– 5z
WA700-3 20-589
(10)
20-590 WA700-3
(10)
Troubleshooting of hydraulic and
mechanical system (H mode)
Method of using matrix troubleshooting tables............................................................................................ 20-604
H-1 Machine does not start ....................................................................................................................... 20-606
H-2 Machine lacks power or speed when traveling (all speed ranges) ..................................................... 20-607
H-3 Time lag is excessive when starting or shifting gear .......................................................................... 20-608
H-4 Torque converter oil temperature is high ............................................................................................ 20-609
H-5 Steering does not turn ........................................................................................................................ 20-610
Steering wheel specification
H-6 Steering does not turn ........................................................................................................................ 20- 611
Steering wheel and joystick steering specification
H-7 Steering does not turn ........................................................................................................................ 20-612
AJSS (Advanced Joystick steering system) specification
H-8 Turning, response of steering is poor ................................................................................................. 20-613
H-9 Turning, response of steering is poor ................................................................................................. 20-614
H-10 Turning, response of steering is poor................................................................................................. 20-616
H-11 Steering is heavy ................................................................................................................................ 20-617
H-12 Joystick lever is heavy ....................................................................................................................... 20-617
H-13 Joystick lever is heavy ....................................................................................................................... 20-618
H-14 Steering wheel shakes or jerks .......................................................................................................... 20-619
H-15 Steering shakes or there is excessive shock ..................................................................................... 20-620
H-16 Steering wheel shakes or jerks .......................................................................................................... 20-621
H-17 Minimum turning radii to right and left are different ............................................................................ 20-622
Steering wheel specification, Steerig wheel and joystick steering specification
H-18 Minimum turning radii to right and left are different ............................................................................ 20-622
H-19 Wheel brakes do not work or braking effect is poor ........................................................................... 20-624
H-20 Wheel brakes are not released or brakes drag .................................................................................. 20-626
H-21 Parking brake does not work or braking effect is poor ....................................................................... 20-627
H-22 Parking brake is not released or brake drags .................................................................................... 20-628
WA700-3 20-601
(10)
H-23 Neither boom nor bucket move .......................................................................................................... 20-629
H-24 Both boom and bucket are slow or lack power................................................................................... 20-630
H-25 Boom does not move ......................................................................................................................... 20-631
H-26 Boom is slow or boom lacks power .................................................................................................... 20-632
H-27 Boom cannot be set to FLOAT or cannot be released from FLOAT................................................... 20-633
H-28 Boom drops momentarily when control lever is operated from HOLD to RAISE................................ 20-633
H-29 Excessive hydraulic drift of boom ....................................................................................................... 20-634
H-30 Bucket does not move........................................................................................................................ 20-635
H-31 Bucket is slow or lacks power ............................................................................................................ 20-636
H-32 Excessive hydraulic drift of bucket ..................................................................................................... 20-637
20-602 WA700-3
(10)
Troubleshooting Method of using matrix troubleshooting tables
Method of using matrix troubleshooting tables

The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the
causes of failures in the machine. The troubleshooting tables are divided broadly into categories for the main
components, such as the steering system and work equipment hydraulic system. Follow the procedure given
below and carry out troubleshooting to locate the problems accurately and swiftly.
Step 1. Questioning the operator 1. Steering does not work i Symptom [Example]
The questions to ask the operator are given
Ask the operator about the following points.
below the failure symptom. If the answers to the
• Did the steering suddenly stop working o
questions match the information given, follow Breakage in steering equipment
the arrow to reach the probable cause of the fail- • Had the steering gradually been becoming heavy?
ure. o Internal wear of steering equipment, defective
Consider the contents of the questions and con- seal
sult the table while proceeding to Steps 2 and 3
to grasp the true cause.
Checks before starting [Example]
Step 2. Checks before troubleshooting • Is the oil level in the hydraulic tank correct?
Before starting the main troubleshooting and • Is the type of oil correct?
measuring the hydraulic pressure, first check • Is there any leakage of oil from the steering valve
the Checks before Starting items, and check for or Orbit-roll?
oil leakage and loose bolts. These checks may • Has the safety bar been removed from the frame?
avoid time wasted on unnecessary trouble-
shooting.
The items given under Checks before Starting
[Example 1]
are items which must be considered particularly
for that symptom before starting troubleshoot- Remedy
No. Problems
ing.
1 Steering does not work to the left or right.
Step 3. Using cross-reference table Same as item 1, but abnormality in actuation of
1) Operate the machine to carry out the checks 2 work equipment
in the troubleshooting item column.
3 Steering can only be operated to one side.
Mark the items where the results match the
symptom. 4 Steering wheel is heavy and cannot be turned.
a It is not necessary to follow the
troubleshooting checks in order; follow
an order which is easiest to carry out
troubleshooting.
[Example 2]
2) Find the appropriate cause from the cause
column. If the symptom appears, the Q
marks on that line indicate the possible
ses
causes. (For item No. 2 in the table on the

Cau
right, the possible causes are c or e.) a b c d e

If there is only one Q: Remedy
Carry out the other troubleshooting items C A
Problems
(where the same cause is marked with Q),
check if the symptom appears, then repair. 1
If there are two Q: 2
Go on to Step 3) to narrow down the possi- 3
ble causes. 4
5
20-604 WA700-3
(10)
Troubleshooting Method of using matrix troubleshooting tables
3) Operate the machine and check the

troubleshooting items other than those in 1).
Operate the machine and check the items in
the same way as in 1), and if the symptom
ses
appears, mark that item. (In the chart on the
Cau
right, the symptom appears again for item a b c d e
5). Remedy
C A
Problems
4) Find the appropriate cause from the cause
1
column. In the same way as in Step 2), if the
symptom appears, the Q marks on that line 2
indicate the possible causes. (For item No. 3
5 in the table on the right, the possible 4
causes are b or e.) 5
Applicable troubleshooting item located in Step 3).
5) Narrow down the possible causes.
Applicable troubleshooting item located in Step 1).
There is one common cause among the
causes located in Steps 2) and 4). (One
cause marked Q appears on the line for Ignore these causes
ses
both items.) This cause is common to both
Cau
the symptoms in troubleshooting Steps 1)
and 3). a b c d e Common causes
a The causes which are not common to Remedy
both troubleshooting items (items which C A
Problems
are not marked Q for both symptoms) 1
are unlikely causes, so ignore them. 2
(In the example given on the right, the
3
causes for Troubleshooting Item 2 are c
or e, and the cause for Troubleshooting 4
Item 5 are b or e, so cause e is common 5
to both.)
6) Repeat the operations in Steps 3), 4) and 5)

ses
unti l one cause (one common cause)

Cau
remains.
a b c d e
a If the causes cannot be narrowed down
to one cause, narrow the causes down Remedy Action to take
C A
as far as possible. Problems
1
7) Remedy 2
If the causes are narrowed down to one 3
common cause, take the aciton given in the
4
remedy column.
5
The symbols given in the remedy column
indicate the following:
X: Replace, E: Repair, A; Adjust, C: Clean
WA700-3 20-605
(10)
Troubleshooting H-1
Power train
H-1 Machine does not start
Ask the operator the following questions
• Did the problem suddenly happen?
Yes = Internal seizure, damage
• When this happened, was there any abnormal
noise?
ring
Yes = Broken part
e sp
roov ng valv
valv alve
ss)
uit
it
• Is the oil level in the transmission case correct?
ircu
circ
htne
i
• Is the monitor display correct?
duc
utch n of pil pool
ch c
lief
e
h
• Is the drive shaft broken?
il tig
ot re
lutc
n re
clut
,s
g, g
alve
o
ed c
lief
mai
ses
issio ) speed
e
ump
l rin
v
g re
ng v
spe
t i
of m ulating
Cau
alve
lve
e
a
latin
of p
tio
(def
e
3rd)
i
rd
t
id va
s
a
oid v
pera
sion
n
l
n (3
odu
u
side
tch
(
od
ch
leno
n
f mo
n
ve o
ng i
m
mis
n cl
u
clut
e
g
ion
nsm
l
c
n
of so
n of
s
on o
al ri
al ri
rans
issio
eed
ecti
suct
sion
f
ion
ctive side tra

ratio
ation
ation
ft se
ft se
f
) sp
de t
i
e
nsm
erat
erat
mis
mp
n, d
n at
ope
(3rd
a
sha
i
oper
oper
e pu
s
e op
e op
e tra
rans
e sh
atio
ed i
e in
e in
e
e
ctive
ctiv
ctiv
suck
ctiv
ctiv
rior
ctiv
ctiv
ctiv
ed t
ctiv
kag
kag
Defe
Defe
Defe
Defe
Dete
Defe
Defe
Defe
Defe
Brea
Brea
Defe
Defe
Seiz
Air
Tank – Torque
Pump Transmission converter
a b c d e f g h i j k l m n o
Remedy A
No.
Problems
1 Abnormal noise comes from between pump and filter
2 Machine does not start in any speed range (Item 1 normal)
3 Machine starts normally in certain speed range
4 When torque converter oil temperature rises, machine stops moving
5 Transmission relief pressure is low
6 Low at every speed range
Transmission
7 modulation Becomes lower at certain speed range
8 pressure is low Indicator is unstable and fluctuates excesively
9 Lack of pilot pressure (Items 5 – 8 are normal)
10 Torque converter relief valve pressure is low (Items 5 – 9 are normal)
11 Torque converter outlet port pressure is low (Items 5 – 9 are normal)
Note 1: Cause m is when the solenoid valve and

oil pressure are normal but the valve spool
does not move.
Note 2: If the transmission clutch pressure is low
but the cause cannot be found in the table
above, there may be a crack in the valve
or transmission.
20-606 WA700-3
(10)
Troubleshooting H-2
H-2 Machine lacks power or speed when traveling (all speed ranges)
ug)
• Is there any external oil leakage from the piping
ring
e pl
or valve joints?
d sp
loos
• Is there any dragging of the parking brake or
rate
ng,
ng
service brake?
erio
al ri
spri
e riv lve, det

n)
e se
alve
lve
Checking for abnormalities
roke
g va
v
ve v
ecti
• Engine high idling speed
et b
a
n
ief v
relie
f
• Torque converter stall speed
e
t
dula
er (d
r re l
• Machine travel speed
ain
rbin
f mo
vert
erte
• Transmission clutch (both high pressure and
ses
nm
p
r (tu
pum
con
o
onv
low pressure)
Cau
ssio
ion
erte
rque
• Pump outlet port pressure
tran e
ue c
f
erat
smi
o
in
lve
onv
side
e to
torq
n
g va
e op
of e
ue c
ion
d
n
v
n of
n of
s i
i
nce
i
c
torq
t
suct
e in
efec
edu
o
o
rma
i
i
akag
t
erat
mp
side
lot r
pera
n, d
n at
erfo
e pu
e op
e
atio
ed i
e pi
e in
o
ve l
p
e
ctiv
ctiv
suck
ctiv
rior
ctiv
kag
p in
essi
Defe
Defe
Defe
Dete
Defe
Brea
Dro
Exc
Air
Tank – En- Torque
Pump gine converter
a b c d e f g h i
Remedy A
No.
Problems
2 Torque converter stall speed is low
3 Torque converter stall speed is high
4 Transmission main relief valve pressure is low
5 Transmission Low at every speed range (Item 2 abnormal)
modulation
6 pressure is low Indicator is unstable and fluctuate excessively
7 Pressure in pilot reducing pressure circuit is low (Items 4 – 6 are normal)
8 Torque converter relief valve pressure is low (Items 4 – 7 are normal)
9 Torque converter outlet port pressure is low (Items 4 – 7 are normal)
10 Pieces of iron and aluminium stuck to strainer os transmission case
11 When oil temperature rises, modulating pressure drops
WA700-3 20-607
(10)
Troubleshooting H-3
H-3 Time lag is excessive when starting or shifting gear

• Is there any external oil leakage from the piping
or valve joints?
ng
spri
lve
g va
latin
ve
l
uit
s)
o o
groo
nes
circ
e sp
odu
ve
ight
utch
valv
l
ng,
of m
a
ses
v
ump
oil t
al ri
n
d cl
n
Cau
etur
tion
r
of p
tive
retu
e
pee
s
ick r
pera
utch
efec
in s
side
c k
u
i
o
u
in q
n cl
h (d
ring
q
e
ion
ctiv
f
ssio
on o
lutc
ole
suct
eal
defe
tle h
smi
c
i
aft s
erat
mp
eed
n at
ion,
tran
t
e pu
thro
e op
e sh
e sp
ed i
a t
e
rior
ctiv
ctiv
suck
ctiv
ctiv
ctiv
ked
Dete
Defe
Defe
Defe
Defe
Defe
Bloc
Air
Tank –
pump Transmission
a b c d e f g h
Remedy
No.
Problems
2 There is time lag when transmission is placed in any speed range
3 Machine starts normally in certain speed range
4 Transmission modulating pressure is low ehn placed in any speed range
5 In Item 4, indicator is unstable and fluctuates excessively
6 Torque converter oil temperature goes above operating range
20-608 WA700-3
(10)
Troubleshooting H-4
H-4 Torque converter oil temperature is high

Ask the operator the following questions
)
• Does oil temperature go up when torque convert-
bine
er is stalled and go down when torque converter
r
in tu
is not stalled?
crack
Yes = Normal (incorrect selection of speed
mp (
range)
g, pu
lu
ose p
alve
• Is oil level in transmission case correct?
g), lo
ief v
• Is filter clogged?
a l ri n
r rel
ve se
erte
ses
ump
a If oil temperature is normal but oil temperature
fecti
onv
Cau
of p
gauge on machine goes above operating range -
r (de
ue c
> defective oil temperature gauge
verte
ide
torq
s
e con
ion
n of
suct
orqu
ratio
p
ide t
n at
pum
ope
e ins
ed i
e
e
ctiv
suck
akag
ctiv
Defe
Defe
Oil le
Air
Tank – Trans-
pump mission
a b c d
Remedy
No.
Problems
1 Pump makes abnormal noise when oil temperature is low
2 High idling and low idling speeds are low
3 Transmission modulating pressure is low
4 Torque converter inlet port oil pressure is low
5 Torque converter outlet port oil pressure is low
WA700-3 20-609
(10)
Troubleshooting H-5
H-5 Steering does not turn

Ask the operator the following questions.

• Did the problem suddenly start?
Yes o Related equipment broken
Was there any abnormal noise when this hap-
pened? Where did the noise come from?

• Is the oil level in the hydraulic tank correct? Is the
type of oil correct?
• Is the steering shaft broken?
• Is the stop valve stopper properly adjusted?
• Has the safety bar been removed from the
ses
l
ool
frame?
mp
p oo
Cau
g sp
h pu
nd s
e
erin
v
witc
ema
a l
e
on v
f ste
v
nd s
of d
v va
ucti
o
seal
mp
lve
ng a
ion
relie
ion
ll
ty-s
t-ro
C pu
ston
op v
tuat
tuat
eeri
PPC
safe
Defe ve orbi
e PP
e ac
e ac
e st
e pi
e st
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC Orbit- Stop
Hydraulic relief Steering Cylin-
pump valve roll valve valve der
a b c d e f g h i
Remedy
No.
Problems
1 Steering wheel does not turn in both directions (left and right)
2 Steering wheel turns 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
Oil pressure is low or zero in both directions
8 When steering (left and right)
relief pressure
is measured Oil pressure is low or zero in one direction
9
(left or right)
10 Measured Orbit-roll output pressure is low or zero
11 When PPC valve (Orbit-roll) Oil pressure is low
12 basic pressure is measured Oil pressure is zero
a There is close connection between the steering circuit and the work equipment circuit, so if any abnormality
is felt in the steering, check the operation of the work equipment, also.
20-610 WA700-3
(10)
Troubleshooting H-6


Yes = Related equipment broken
• Was there any abnormal noise when this hap-

e
valv
• Is the stop valve stopper properly adjusted?
oid
ses
mp
l
ool
poo
frame?
olen
Cau
f pu
g sp
e
• Is the operation of the steering and the steering
s
valv
ck s
alve
d
alve
nd o
man
erin
mode switch correct?
ysti
ston trictor v
top
on v
l ve
f ste
on e
f de
of jo
of s
f va
ucti
o
o
ucti
seal
p
pum
s
ion
n
n
tion
oll
relie
y re
atio
atio
ty-s
at s
bit-r
tuat
Defe e actua
Defe e 2-wa
suck TO
PPC
actu
actu
safe
C
r
d in
filte
e PP
e Or
e ac
e pi
eP
e
e
e
e
e
ctiv
ged
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Clog
Defe
Defe
Defe
Defe
Defe
Air
Hydraulic PPC Orbit- Stop Steering Cylin-

pump relief Joystick Valve
valve roll valve valve der
a b c d e f g h i j k l m
Remedy C
No.
Problems
1 When steering Steering does not move (steering wheel mode only)
2 mode switch Steering does not move (joystick mode only)
3 is switched Steering does not move in either mode
5 Steering wheel turns only in one direction (left or right)
7 Steering wheel is heavy in one direction (left or right)
Oil pressure is low, or there is no pressure
12 When steering in both directions (left and right)
relief pressure
is measured Oil pressure is low, or there is no pressure
13
in one direction (left or right)
When Orbit-roll output pressure is measured, oil pressure

14
is found to be low or there is no oil pressure
When joystick solenoid valve output pressure is measured,
15
oil pressure is found to be low or there is no oil pressure
16 When PPC valve (Orbit-roll) Oil pressure is low
17 basic pressure is measured There is no oil pressure
a 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.
WA700-3 20-611
(10)
Troubleshooting H-7

Ask the operator the following points


• Is the oil level in the hydraulic tank correct?
• Is the type of oil correct?
frame?
l
ol
poo
p
• Is steering valve open?
ses
spo
pum
nd s
Cau
ing
e
itch
valv
ema
teer
d sw
tio n
of d
of s
e
n
seal
valv
mp
-suc
ng a
ion
ion
C pu
ston
tuat
tuat
ary
fety
eeri
t
e PP
e ac
e ac
e sa
e ro
e pi
e st
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Hydraulic Rotary Cylin-
pump valve Steering valve der
a b c d e f g
Remedy
No. Problems
2 Steering wheel turns only in one direction (left or right)
3 Joystick lever is heavy in both directions (left and right)
Oil pressure is low or there is no pressure in

8 both directions (left and right)
When steering
relief pressure
is measured Oil pressure is low or there is no pressure in
9 one direction (left or right)
10 When rotary valve output pressure is measured, oil pressure

is found to be low or there is no oil pressure
11 When PPC valve (rotary Oil pressure is low

12 valve) There is no oil pressure
20-612 WA700-3
(10)
Troubleshooting H-8
H-8 Turning, response of steering is poor


• Was there any symptom of difficulty in steering?
Yes o Wear of related equipment, defective seal

ses
mp
ol
poo
spo
Cau
f pu
e
nd s
valv
ring
nd o
lve
ema
stop
n va
e
e
stee
valv
valv
on e
mp
of d
ump
ctio
n of
n of
u
i
seal
liefe
p
lief
suct
ng p
pum
ion
y-su
ll
ch p
atio
atio
n re
t-ro
C re
ston
tuat
n at
eeri
Defe e safet
suck TO
u
PPC
actu
swit
orbi
mai
t
e PP
e ac
e ac
e pi
ed i
e st
eP
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
PPC Orbit- Stop Cylin-

Hydraulic pump relief
valve roll valve Steering valve der
a b c d e f g h i j k l m
Remedy
No.
Problems
1 Turning, response of steering is poor in both directions(left and right)
2 Turning, response of steering is poor in one direction (left or right)
5 Work equipment moves normally
6 Work equipment speed is low
8 Abnormal noise comes from around steering pump or hydraulic tank
9 Abnormal noise comes from around switch pump or hydraulic tank
relief pressure
11 (left or right)
12 Measured Orbit-roll output pressure is low
13 Measured PPC valve (Orbit-roll) basic pressure is low
is felt in the steering, check the operation of the work equipment, also.
WA700-3 20-613
(10)
Troubleshooting H-9


• Was there previously any symptom, such as dif-
ficulty in steering?
Yes = Wear of related equipment, defective seal
e
valv
oid
ses
l
poo
olen
pum
Cau
lve
s
ck s
d of
and
p va
ysti
dem
lve
n en
f sto
mp
valv
of jo
f va
ump
o
n of
g pu
o
i
p
suct
relie
lief
pum
ion
n
l
ch p
atio
atio
it-ro
n
C re
tuat
n at
eeri
ain
suck TO
PPC
actu
swit
actu
ilter
Orb
e PP
e ac
em
ed i
e st
eP
f
e
e
e
e
ged
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Clog
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
PPC Orbit- Stop Steering

Hydraulic pump relief
roll
Joystick valve
valve
valve
a b c d e f g h i j k l
Remedy C
No.
Problems
1 When steering Abnormality only in steering wheel mode
2 mode switch is Abnormality only in joystick mode
3 switched Abnormality in both modes
4 Turning, response of steering is poor in both directions (left and right)
13 When steering Oil pressure is low in both directions (left and right)
relief pressure
14 is measured Oil pressure is low in one direction (left or right)
15 When Orbit-roll output pressure is measured, oil pressure is found to be low
When joystick solenoid valve output pressure is measured,
16 oil pressure is found to be low
When PPC valve (Orbit-roll) basic pressure is measured,
17 oil pressure is found to be low
20-614 WA700-3
(10)
valve
Defe
m n
ctiv
Steering
e ac
Defe tuat
WA700-3
ctiv ion
Valve
Defe e sa of s
fety teer
o p
ctiv - ing
der
e suct spo
Cylin-
Defe 2-w i on ol
ay r valv
ctiv
e pi estr
icto e
ston
Troubleshooting
r va
seal lve
(10)
20-615
H-9
Troubleshooting H-10


• Was there previously any symptom, such as dif-
ficulty in steering?
Yes = Wear of related equipments, defective
seal

Is the type of oil correct?
ses
ool
ol
ump
spo
d sp
Cau
of p
ing
e
man
valv
end
teer
alve
f de
mp
tion
of s
tion
ump
e ac relief v
e
u
o
valv
seal
mp
ng p
-suc
ion
ion
c
t su
ch p
C pu
tuat
tuat
ston
tary
fety
eeri
ain
a
O
swit
d in
e PP
e PT
e ac
e ro
e sa
e St
e pi
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
suck
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
Hydraulic pump Rotary Steering valve Cylin-

valve der
a b c d e f g h i j k
Remedy
No. Problems
1 Turning, response of steering is poor in both directions (left and right)
3 Joystick lever is heavy in both directions
4 Joystick lever is heavy in one direction (left or right)
6 Work equipment also speed is slow
10 When steering both directions (left and right)
relief pressure
11 one direction (left or right)
When rotary valve output pressure is measured, oil pressure is

12
found to be low
When PPC valve (rotary valve) basic pressure is measured, oil

13
pressure is found to be low
20-616 WA700-3
(10)
Troubleshooting H-11, H-12
H-11 Steering is heavy


• Is the steering difficult to turn?
Yes o Go to H-8
• Measure the operating effort and turning speed,
and check the STANDARD VALUE TABLE to
see if they are normal.

ha f t
• Was there previously any symptom, such as
gs
erin
heavy steering?
ses
whe spool
Yes o Wear of related equipment, defective seal
r ste
Cau
lve
el o
ring
p va
stee
f sto
ring
n of
o
ion
stee
roll
• Is the tire inflation pressure correct?
atio
tuat
Defe e Orbit-
e of
actu
e ac
enc
e
ctiv
ctiv
ctiv
rfer
Defe
Defe
Inte
Orbit- Stop Stee-
ring Others
roll valve valve
a b c d
Remedy
No.
Problems
1 Steering is heavy in both directions (left and right)
2 Steering is heavy in one direction (left or right)
Steering is heavy even when joint between steering shaft and
3
Orbit-roll is disconnected
relief pressure
6 Measured Orbit-roll output pressure is low
H-12 Joystick lever is heavy

Causes and Remedy

• Abnormality of joystick lever (x)
(The joystick lever is an electrically operated lever, so if the operating effort is large, the abnormality is in the
joystick lever.)
WA700-3 20-617
(10)
H-13 Joystick lever is heavy


Yes = Go to H-10
• Measure the operating effort and turning speed,
and check the STANDARD VALUE TABLE to
see if they are abnormal.

• Was there previously any symptom, such as
haft
heavy steering?
ng s
Yes = Wear of related equipment, defective seal
ri
ol
stee
ses
spo
r or
Cau
ing
leve
teer
of s
tick
e
valv
joys
ion
tuat
tary
e of
e ac
e ro
enc
ctiv
ctiv
rfer
Defe
Defe
Inte
Rotary Steering
valve valve Others
a b c
Remedy
No. Problems
1 Joystick lever is heavy when turned in both directions (left and right)
2 Joystick lever is heavy when turned in one direction (left or right)
Joystick lever is heavy even when joint between steering

3
shaft and rotary valve is disconnected
relief pressure
When rotary valve output pressure is measured, oil pressure

6
is found to be low
20-618 WA700-3
(10)
H-14 Steering wheel shakes or jerks


Yes = Go to H-8
• Is there any abnormal noise from around the
steering equipment?

• Is the steering wheel play correct?
• Is there any abnormality in the connection be-
tween the steering shaft and the Orbit-roll?
ses
ool
poo
Cau
g sp
e
nd s
valv
lve
erin
ema
stop
n va
e
e
valv
e
valv
t
of d
of s
ctio
n of
seal
lief
lief
ion
ion
oll
y-su
atio
n re
C re
bit-r
ston
tuat
tuat
Defe e safet
actu
mai
e PP
e Or
e ac
e ac
e pi
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC Orbit- Stop Cylin-
relief
roll valve Steering valve der
valve
a b c d e f g h
Remedy
No.
Problems
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
3
wheel shakes or jerks in both directions (left and right)

4
wheel shakes or jerks in one direction (left or right)
Steering wheel jerks or there is excessive shock when steering

5
is operated to end of its stroke
6 Work equipment also jerks
Oil pressure is unstable in both directions
relief pressure
is measured Oil pressure is unstable in one direction
8 (left or right)
Oil pressure is unstable in both directions

9 When Orbit-roll (left and right)
output pressure
10 (left or right)
When PPC value (Orbit-roll) basic pressure is measured,

11
oil pressure is found to be unstable
WA700-3 20-619
(10)
H-15 Steering shakes or there is excessive shock


Yes = Go to H-9
steering equipment?

• Is any failure code for the electrical system dis-
played on the main monitor?
• Is the steering wheel play correct?
e
valv
tween the steering shaft and the Orbit-roll?
noid
ses
l
poo
on v g spoo
sole
Cau
e
s
valv
lve
d
tick
alve
man
a
i
v
r
joys
top
e
stee
e
r
valv
f de
icto
valv
of s
n of
n of
ucti
o
r
seal
lief
rest
lief
ion
n
oll
atio
atio
s
atio
n re
-
C re
bit-r
ston
tuat
fety
way
actu
actu
actu
mai
e PP
e Or
e sa
e ac
e 2-
e pi
e
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC Orbit- Joy- Stop Cylin-
relief
stick valve
Steering valve Valve
der
valve roll
a b c d e f g h i j
Remedy
No.
Problems
1 When steering Abnormality only in steering wheel mode
2 mode switch is Abnormality only in joystick mode
3 switched Abnormality in both modes
5 Steering wheel shakes or jerks in one direction (left or right)
6
wheel shakes or jerks in both directions (left and right)

7
wheel shakes or jerks in one direction (left or right)
Steering wheel jerks or there is excessive shock when steering

8
is operated to end of its stroke
9 Confirm recent repair
10 When steering Oil pressure is unstable in both directions (left and right)
relief pressure
11 is measured Oil pressure is unstable in one direction (left or right)
12 When Orbit-roll Oil pressure is unstable in both directions (left and right)
output pressure
14 When joystick solenoid Oil pressure is unstable in both directions (left and right)
valve output pressure
When PPC valve (Orbit-roll) basic pressure is measured,
16
oil pressure is found to be unstable
20-620 WA700-3
(10)
H-16 Steering wheel shakes or jerks


Yes = Go to H-10
steering equipment?

• Is the joystick lever play correct?
tween the steering shaft and the steering pilot
valve?
l
p oo
poo
ses
nd s
ng s
Cau
e
valv
ema
eeri
lve
t
tion
of d
f va
f s
e
on o
valv
seal
relie
-suc
ion
i
tuat
tuat
ston
tary
fety
ain
e ac
e ac
e ro
e sa
em
e pi
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Rotary Steering valve Cylin-
valve der
a b c d e f
Remedy
No. Problems
2 Steering wheel shakes or jerks in one directions (left or right)
During operations or when traveling (when steering is neutral),

3
steering wheel shakes or jerks in both directions (left and right)
During operations or when traveling (when steering is neutral),

4
steering wheel shakes or jerks in one direction (left or right)
5 Steering wheel jerks or there is excessive shock when

steering is operated to end of its stroke
6 Work equipment also jerks
7 Oil pressure is unstable in both directions

When steering (left and right)
relief pressure
8
(left or right)
9 Oil pressure is unstable in both directions

When rotary
valve output (left and right)
pressure
10 is measured Oil pressure is unstable in one direction
(left or right)
11 When PPC valve (rotary valve) basic pressure is measured, oil

pressure is found to be unstable
WA700-3 20-621
(10)
H-17 Minimum turning radii to right and left are different

Steering wheel specification,
Steerig wheel and joystick steering specification
Cause and remedy

E)
• Defective adjustment of stop valve (E
H-18 Minimum turning radii to right and left are different

Cause and remedy

E)
• Defective adjustment of steering stopper bolt (E
20-622 WA700-3
(10)
H-19 Wheel brakes do not work or braking effect is poor

• Measure the actual brake performance, and
check if there is actually an abnormality or wheth-
er it is just the feeling of the operator. For details,
a t or
see TESTING AND ADJUSTING, "Measuring
mul
brake performance"
a ccu
rom
as f
of g
ding
ses
blee
p
• Did the problem gradually appear?
lve
pum
Cau
ton
tive
Yes o Wear of related parts, defective seal
e va
brak ake pis

d of
efec
harg
al
n en
e
or d
v
alve
n se
br
l
c
r
a
e
r
ke v
o
e
just
n of
o
ke v
o
i
eal
p
suct
t
a
pum
s
l
t bra
k ad
i
umu
on s
atio
ke p
a
side
ft br
n at
• Is the brake pedal play correct?
suck TO
PPC
actu
c
righ
pist
c
a
e sla
e ac
e br
e in
ed i
e le
• Is there any leakage of oil from the brake tube? eP
e
ctiv
ctiv
ctiv
kag
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Is there any deformation of the tube? Defe
Defe
Defe
Brea
Defe
Defe
Defe
Defe
Defe
Defe
• Are the tire inflation pressure and tread pattern
Air
correct? PPC pump Charge Accu- Brake

valve
Slack
adjuster
Wheel brake
valve mulator
a b c d e f g h i j k
Remedy
No.
Problems
1 Brake has no effect only when left brake pedal is depressed
2 Left brake pedal is light when it is depressed
3 Right brake pedal is light when it is depressed
4 Left brake pedal is heavy when it is depressed
5 Right brake pedal is heavy when it is depressed
6 Abnormally large operating force is needed to obtain specified braking force
7 Abnormal noise is heard from brake when brake is applied
8 Work equipment and steering do not work either
9 Movement of work equipment and steering is slow
11 Abnormal noise comes from around hydraulic tank or PPC pump
12 Many metal particles are found in oil drained from axle case
13 Measured accumulator charge pressure is low
14 Braking effect is lost immediately after engine is stopped
15 There is time lag before brake takes effect
16 Measured brake oil pressure is low
17 Measured drop in brake piston pressure is excessive
18 Measured wear of brake disc is excessive
19 When air is bled from brake line, air comes out
a The PPC pump is used for the wheel brake actuation pressure in the same way as for the work equipment
circuit and steering circuit, so if any abnormality is felt in the wheel brake, check the condition of actuation of
the work equipment and steering, too (the circuit set pressure is different).
20-624 WA700-3
(10)
sc
uit
il
e di
le o
circ
brak
e ax
rake
ctiv
r of
in b
Defe
Wea
Air
Wheel
brake
Others
l m n
WA700-3 20-625
(10)
H-20 Wheel brakes are not released or brakes drag

o Related equipment broken

• Does the brake pedal come back fully?
• Is the parking brake still applied?
ses
er
ton
Cau
just
, pla ake pis
k ad
e
slac
valv
ve
br
te
e rig ake val
n of
n of
rake
atio
atio
disc
ht b
ft br
actu
Seiz ve actu
rake
e le
ed b
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe
Defe
Brake Slack Wheel

valve adjuster brake
a b c d e
Remedy
No.
Problems
1 Machine cannot travel at all
2 Machine can travel a small amount
When remaining pressure is released from brake accumulator
3
circuit with left brake pedal only, break is released
When remaining pressure is released from brake accumulator

4
circuit with right brake pedal only, break is released
When air bleed plug in wheel portion is loosened, oil flows
5
out and brake is released
6 When air bleed plug is loosened, a large amount of oil flows out
When wear of brake disc is measured and brake pedal is
7
released, piston returns
When wear of brake disc is measured and brake pedal is

8
released, piston does not return
20-626 WA700-3
(10)
H-21 Parking brake does not work or braking effect is poor

ston
e
e pi
ses
valv
brak
Cau
o i d
ing
olen
park
s
ake
ad
g
n of
n
or p
g br
r i
e sp
atio
rkin
disc
actu
brak
e pa
eak
e
e
ctiv
ctiv
n br
ctiv
Defe
Defe
Defe
Wor
SOL Parking brake
a b c d
Remedy
No.
Problems
1 Parking brake does not work when engine is stopped
Measured parking brake disc thickness is less than specified
2
value
There is no oil pressure when parking

When parking brake brake switch is ON (normal)
3 inlet port pressure
is measured There is oil pressure when parking
brake switch is ON
When parking brake There is no oil pressure when parking

solenoid valve brake switch is ON (normal)
4
output pressure is There is oil pressure when parking
measured brake switch is ON
WA700-3 20-627
(10)
H-22 Parking brake is not released or brake drags

Checking before troubleshooting
• Is the brake circuit pressure in the specified
range? [If it is below 3.6 ± 0.5MPa {37 ± 5kg/
cm2}, the parking brake solenoid valve operates
)
seat
d)
automatically to apply the parking brake.]
t pa
alve
ugh
e (V
a
nt
valv
eal)
c
tme
and
s
noid
djus
ton
aked
(Pis
ng a
sole
( F l
der
wro
ake
ake
ses
cylin
g br
g br
, or
Cau
age
n
rkin
ring
i
park
link
f pa
f sp
s of
o
rake
ts o
arts
part
r
ng b
a
al p
p
rnal
rnal
arki
tern
inte
inte
of p
e in
e
e
ctiv
age
ctiv
ctiv
Defe
Defe
Dam
Defe
a b c d
Remedy C
No.
Problems
When parking brake switch is OFF, oil leaks from spring
1 cylinder or cylinder rod does not return to end
2 When parking brake switch is OFF, parking brake is not released
Spring cylinder operates normally, and rod and lever return,
3
but brake drags
20-628 WA700-3
(10)
H-23 Neither boom nor bucket move

o Related equipment broken

ses
p
pum
Cau
d of
n en
lve
alve
f va
o
v
i
p
suct
relie
f
pum
relie
n at
ain
suck TO
PPC
Defe ve PPC
em
ed i
eP
e
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe
Air
Hydraulic PPC Cont-

relief rol
pump valve valve
a b c d e
Remedy
No.
Problems
1 Steering also does not work
3 Abnormal noise comes from around hydraulic tank or PPC pump
4 Measured PPC valve output pressure is normal
5 Measured PPC valve (Orbit-roll) basic pressure is low or zero
is felt in the work equipment, check the operation of the steering, also.
WA700-3 20-629
(10)
H-24 Both boom and bucket are slow or lack power

ses
l
poo
pum
Cau
mp
nd s
d of
t pu
ema
n en
e
men
alve
valv
of d
ump
o
ief v
p
i
p
lief
suct
i
pum
ion
equ
ch p
n re
l
C re
tuat
n at
ork
suck TO
PPC
swit
mai
e PP
e ac
ed i
ew
eP
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
PPC Cont- Steer-

Hydraulic pump relief rol ing
valve valve valve
a b c d e f g h
Remedy
No.
Problems
1 Boom and bucket movement takes approx. 1.5 times standard value
2 Boom and bucket movement takes approx. 3 times standard value
3 Steering works normally
4 Response of steering is also poor
6 Abnormal noise comes from around hydraulic tank or hydraulic pump
7 Measured PPC valve output pressure is normal
8 Measured PPC valve (Orbit-roll) basic pressure is low
is felt in the work equipment, check the operation of the steering, also.
20-630 WA700-3
(10)
H-25 Boom does not move

alve
ses
ck v
Cau
ol
spo
che
ge
om
nka
load
f bo
er li
e
e
al
valv
n of
v
o
r se
l
l lev
lve
a
n
ad v
atio
atio
ion
nde
C va
ntro
o
actu
actu
suct
i
l
l
e PP
e un
e cy
e co
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC
valve Control valve Boom Others
a b c d e f g
Remedy
No. A
Problems
1 Does not move in both directions (RAISE and LOWER)
2 Does not move in one direction (RAISE or LOWER)
3 When boom (RAISE and LOWER)
relief pressure
4
(RAISE or LOWER)
5 Measured PPC valve output pressure is low or zero
6 Measured operating effort of boom control lever is heavy
7 Measured travel of boom control lever is short
WA700-3 20-631
(10)
H-26 Boom is slow or boom lacks power

alve
ses
ck v
Cau
ol
spo
che
ge
om
nka
load
f bo
er li
e
e
al
valv
n of
v
o
r se
l
l lev
lve
a
n
v
atio
atio
ion
nde
C va
oad
ntro
actu
actu
suct
i
l
l
e PP
e un
e cy
e co
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC Cylin-
valve Control valve der
Others
a b c d e f g
Remedy
No. A
Problems
1 Does not move normally in both directions (RAISE and LOWER)
2 Does not move normally in one direction (RAISE or LOWER)
3 When boom Oil pressure is low in both directions (RAISE and LOWER)
relief pressure
4 is measured Oil pressure is low in one direction (RAISE or LOWER)
5 Measured PPC valve output pressure is low
6 Measured hydraulic drift of boom is excessive
7 Measured operating effort of boom control lever is heavy
20-632 WA700-3
(10)
H-27 Boom cannot be set to FLOAT or cannot be released from FLOAT


• Can other operations of boom (RAISE, HOLD,
LOWER) be carried out normally?
alve
ses
or v
alve
Cau
lect
ad v
ge
t se
nka
unlo
floa
er li
n of
n of
l lev
lve
atio
atio
C va
ntro
a ctu
actu
e PP
e co
e
e
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
PPC Defe Control Others

valve valve
a b c d
Remedy
No. A
Problems
1 When PPC valve output pressure is measured Oil pressure is normal
2 (boom control lever at FLOAT position) Oil pressure is low
3 When PPC valve output pressure is measured Oil pressure is normal
4 (boom control lever at LOWER position) Oil pressure is low
H-28 Boom drops momentarily when control lever is operated from HOLD to RAISE

• With the engine running at low idling, if the boom
control lever is gradually moved from HOLD to
RAISE, the boom moves down momentarily un-
der its own weight.
• If the control lever is operated fully to the RAISE
position, the condition becomes normal.
Causes and Remedy

• Defective throttling for control valve boom spool
(C)
WA700-3 20-633
(10)
H-29 Excessive hydraulic drift of boom

Yes = Wear of related parts, defective seal
ses
ol
spo
Cau
om
f bo
ss o
seal
htne
ston
l tig
e oi
e pi
ctiv
ctiv
Defe
Defe
Cont- Cylin-
rol
valve der
a b
Remedy
No.
Problems
1 When boom control lever is operated in Hydraulic drift increases
RAISE direction from boom maximum
2 raise with engine stopped (See Note) No change in hydraulic drift
NOTE: Before starting troubleshooting, the PPC accmulator must be charged, so run the engine at low idling
for 5 – 10 secound, the stop the engine.
20-634 WA700-3
(10)
H-30 Bucket does not move

• Was there any abnormal noise when this happened? Where did
the noise come from?
alve
ses
ol
ck v
Cau
spo
che
ge
e
cket
valv
nka
load
f bu
er li
ion
seal
n of
o
l lev
c
lve
n
u
atio
der
atio
ty-s
C va
ntro
cylin
actu
actu
f e
e PP
e co
e sa
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
PPC Cylin-
valve Control valve der Others
a b c d e f
Remedy
No. A
Problems
1 Does not move in both directions (TILT and DUMP)
2 Does not move in one direction (TILT or DUMP)
3 When bucket both directions (TILT and DUMP)
relief pressure
4
one direction (TILT or DUMP)
When PPC valve output pressure is measured, oil pressure is

5
found to be low or there is no pressure
When operating effort of bucket control lever is measured,

6
lever is found to be heavy
When travel of bucket control lever is measured, it is found to
7
be short
WA700-3 20-635
(10)
H-31 Bucket is slow or lacks power

lve
ses
k va
ol
Cau
spo
hec
ge
e
ket
valv
ad c
nka
buc
er li
of lo
ion
seal
n of
l lev
c
lve
ion
u
atio
der
ty-s
C va
ntro
tuat
cylin
actu
f e
e PP
e co
e sa
e ac
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
PPC
Defe
valve
Cylin-
Control valve der Others
a b c d e f
Remedy
No. A
Problems
1 Does not move in both directions (TILT and DUMP)
2 Does not move in one direction (TILT or DUMP)
3 When bucket Oil pressure is low in both directions (TILT and DUMP)
relief pressure
4 is measured Oil pressure is low in one direction (TILT or DUMP)
When PPC valve output pressure is measured, oil pressure is
5 found to be low
6 When hydraulic drift of bucket is measured, it is found to be excessive
When operating effort of bucket control lever is measured,
7 lever is found to be heavy
8 When travel of bucket control lever is measured, it is found to be short
20-636 WA700-3
(10)
H-32 Excessive hydraulic drift of bucket

ses
ol
spo
Cau
cket
f bu
ss o
seal
htne
ston
l tig
e oi
e pi
ctiv
ctiv
Defe
Defe
Cont- Cylin-
rol
valve der
a b
Remedy
No.
Problems
1 When bucket control lever is Hydraulic drift increases
operated in DUMP direction with
2 engine stopped (See Note) No change in hydraulic drift
NOTE: Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idling
for 5 – 10 seconds, then stop the engine.
WA700-3 20-637
(10)
Troubleshooting of transmission
control system
(T mode)
Judgement table for transmission controller system related parts .............................................................. 20-654
Action taken by controller when abnormality occurs and problems on machine......................................... 20-658
Electrical circuit diagram for transmission control system........................................................................... 20-668
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source
in backup lamp relay) is displayed...................................................................................................... 20-672
in F solenoid) is displayed................................................................................................................... 20-673
in R solenoid) is displayed .................................................................................................................. 20-674
in 1st solenoid) is displayed ................................................................................................................ 20-675
in 2nd solenoid) is displayed............................................................................................................... 20-676
in 3rd solenoid) is displayed................................................................................................................ 20-677
in 4th solenoid) is displayed................................................................................................................ 20-678
T-8 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed...... 20-679
T-9 Failure code [20] (Short circuit, disconnection in directional switch system) is displayed................... 20-680
Steering wheel specification, Steering wheel and joystick steering specification
T-10 Failure code [20] (Short circuit or disconnection in joystick directional switch system) is displayed .. 20-683
T-11 Failure code [21] (Short circuit, disconnection in range switch system) is displayed.......................... 20-684
T-12 Failure code [21] (Short circuit or disconnection in joystick shift-up/shift-down
switch system) is displayed................................................................................................................. 20-688
T-13 Failure code [22] (Disconnection in travel speed sensor system) is displayed................................... 20-690
T-14 Failure code [22] (Disconnection in travel speed sensor system) is displayed................................... 20-691
T-15 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is displayed ............ 20-692
T-16 Kickdown switch signal system and hold switch signal system .......................................................... 20-696
Steering wheel specification, AJSS (Advanced Joystick Steering System) specification
T-17 Shift-down switch signal system and shift-up switch signal system.................................................... 20-697
WA700-3 20-651
(10)
T-18 Transmission cut-off signal system ..................................................................................................... 20-698
T-19 Neutralizer relay signal system ........................................................................................................... 20-699
T-20 Neutralizer relay signal system ........................................................................................................... 20-700
T-21 Buzzer signal system .......................................................................................................................... 20-702
T-22 Network system .................................................................................................................................. 20-703
T-23 Transmission controller power source system .................................................................................... 20-704
T-24 Transmission controller power source system .................................................................................... 20-705
T-25 Short circuit in travel speed sensor system ........................................................................................ 20-706
T-26 Short circuit in travel speed sensor system ........................................................................................ 20-707
20-652 WA700-3
(10)
Troubleshooting Judgement table for transmission controller system related parts
Judgement table for transmission controller system related

parts
Steering wheel specification, steering wheel and joystick steering specification
Self-diagnostic display Self-diagnostic display

(abnormality display) (abnormality display)
Short circuit, disconnection in joystick directional switch system

Location of failure
Short circuit, disconnection in engine speed sensor system

Short circuit, disconnection in directional switch system
Abnormality in network signal system or main monitor

Short circuit, disconnection in range switch system
Abnormality in transmission cut-off signal system

Short circuit, disconnection in backup lamp relay
Abnormality in kickdown switch signal system

Disconnection in travel speed sensor system
Short circuit, disconnection in 2nd solenoid
Short circuit, disconnection in 3rd solenoid
Abnormality in alarm buzzer signal system

Short circuit, disconnection in 4th solenoid
Short circuit, disconnection in 1st solenoid
Short circuit, disconnection in R solenoid
Short circuit, disconnection in F solenoid
Abnormality in hold switch signal system
Abnormality in neutralizer signal system
Abnormality in network signal system

Failure
code
Transmission
Transmission controller error
controller error
Failure mode
10 12 13 14 15 16 17 19 20 21 22 23 – – – – – – –
1 Travel is impossible Q Q Q Q Q Q E E E
2 Auto-shifting is not carried out Q
3 Directional lever and direction of travel are different Q
4 Machine travels forward when directional lever is not at F Q Q
5 Machine travels in reverse when directional lever is not at R Q Q
6 Shifts down regardless of travel speed Q
7 Shifts up regardless of travel speed Q
8 Speed range is not same as position of lever Q
9 There is excessive gearshifting shock Q Q
10 There is shift hunting when traveling Q
11 There is shift hunting when shifting gear Q
12 Speed range cannot be controlled with speed lever Q
13 Backup lamp and buzzer do not work Q
14 Shift cannot be held Q
15 Kickdown does not work Q
16 When kickdown is actuated, there is no scooping power Q
17 Transmission is not cut off with left brake Q
18 It is possible to travel even when parking brake is applied Q
If F-R lever is operated when traveling at high speed, alarm
19 Q
buzzer does not sound
20 Alarm buzzer continues to sound Q
Main monitor does not display transmission controller infor-
21 Q
mation (alarm buzzer, failure code, etc.)
22 Gearshifting speed is abnormal (tire compensation) Q
T- T- T- T- T- T- T- T- T- T- T- T-
Troubleshooting code when no error code is displayed – – – – – – –
1 2 3 4 5 6 7 8 9 11 13 15
20-654 WA700-3
(10)
Troubleshooting code when no abnormality display is given
H-1
T-16
T-16, T-17, E-8
T-18
T-19, H-15, E-3
T-21
T-21, J-1
T-22
WA700-3 20-655
(10)
Self-diagnostic display Self-diagnostic display

(abnormality display) (abnormality display)
Short circuit, disconnection in joystick directional switch system

Short circuit, disconnection in Joystick forward-reverse switch
Location of failure
Short circuit, disconnection in engine speed sensor system
Abnormality in network signal system or main monitor

Abnormality in transmission cut-off signal system
Short circuit, disconnection in backup lamp relay
Abnormality in kickdown switch signal system

Disconnection in travel speed sensor system
Short circuit, disconnection in 2nd solenoid
Short circuit, disconnection in 3rd solenoid
Abnormality in alarm buzzer signal system

Short circuit, disconnection in 4th solenoid
Short circuit, disconnection in 1st solenoid
Short circuit, disconnection in R solenoid
Short circuit, disconnection in F solenoid
Abnormality in hold switch signal system
Abnormality in neutralizer signal system
Abnormality in network signal system

Failure
code
Transmission
Transmission controller error
controller error
Failure mode
10 12 13 14 15 16 17 19 21 22 23 – – – – – – –
1 Travel is impossible Q Q Q Q Q Q E E
2 Auto-shifting is not carried out Q
3 Directional lever and direction of travel are different
4 Machine travels forward when directional lever is not at F Q
5 Machine travels in reverse when directional lever is not at R Q
6 Shifts down regardless of travel speed Q
7 Shifts up regardless of travel speed Q
8 Speed range is not same as position of lever Q
9 There is excessive gearshifting shock Q Q
10 There is shift hunting when traveling Q
11 There is shift hunting when shifting gear Q
12 Speed range cannot be controlled with speed lever Q
13 Backup lamp and buzzer do not work Q
14 Shift cannot be held Q
15 Kickdown does not work Q
16 When kickdown is actuated, there is no scooping power Q
17 Transmission is not cut off with left brake Q
18 It is possible to travel even when parking brake is applied Q
If F-R lever is operated when traveling at high speed, alarm
19 Q
buzzer does not sound
20 Alarm buzzer continues to sound Q
Main monitor does not display transmission controller infor-
21 Q
mation (alarm buzzer, failure code, etc.)
22 Gearshifting speed is abnormal (tire compensation) Q
T- T- T- T- T- T- T- T- T- T- T-
Troubleshooting code when no error code is displayed – – – – – – –
1 2 3 4 5 6 7 10 12 14 15
20-656 WA700-3
(10)
Troubleshooting code when no abnormality display is given
H-1
T-16
T-16, E-8
T-18
T-20, H-15, E-3
T-21
T-21, J-1
T-22
WA700-3 20-657
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
Action taken by controller when abnormality occurs and

problems on machine
Failure
Abnormal system Nature of abnormality
code
1) Defective backup lamp relay

2) Short circuit with power source, short circuit with ground, defective contact,
disconnection in wiring harness between transmission & joystick controller
C1 (female) (8) and L76 (1)
Short circuit, disconnection 3) Defective contact or disconnection in wiring harness between backup lamp
10
in back lamp relay relay L76 (female) (2) – CL1 (12) – chassis ground
4) Defective transmission & joystick controller
1) Defective F solenoid
Short circuit, disconnection C1 (female) (2) – TL1 (5) – T01 (D)
12
in F solenoid system 3) Short circuit with ground, defective contact, disconnection in wiring harness
between T01 (A) – TL1 (7) – CL1 (12) – chassis ground
1) Defective R solenoid
Short circuit, disconnection C1 (female) (9) – TL1 (6) – T01 (C)
13
in R solenoid system 3) Short circuit with ground, defective contact, disconnection in wiring harness
between T01 (A) – TL1 (7) – CL1 (12) – chassis ground
1) Defective 1st solenoid

Short circuit, disconnection C1 (female) (3) – TL1 (1) – T01 (H)
14
in 1st solenoid system 3) Short circuit with ground, defective contact, disconnection in wiring harness
between T01 (B) – TL1 (7) – CL1 (12) – chassis ground
1) Defective 2nd solenoid

Short circuit, disconnection C1 (female) (10) – TL1 (2) – T01 (G)
15
in 2nd solenoid system 3) Short circuit with ground, defective contact, disconnection in wiring harness
1) Defective 3rd solenoid

Short circuit, disconnection C1 (female) (5) – TL1 (3) – T01 (F)
16
in 3rd solenoid system 3) Short circuit with ground, defective contact, disconnection in wiring harness
20-658 WA700-3
(10)
Problem that appears on Trouble-

Condition when normal Action by controller when
machine when there is shooting
(voltage, current, resistance) abnormality is detected
abnormality code
1) Resistance of relay coil: 200 – 400 z Neutral Backup lamp is not

2) Voltage between transmission & joystick control- (F, R, 1st, 2nd, 3rd, 4th actuated when driving in
ler C1 (8) and chassis ground at neutral: Less solenoid outputs: OFF). reverse
than 1 V
3) Resistance in wiring harness between transmis-
T-1
sion & joystick controller C1 (female) (8) and L76
(female) (1): Max. 1 z
4) Resistance in wiring harness between backup
lamp relay L76 (female) (2) – CL1 (12) – chassis
ground: Max. 1z
1) Resistance between transmission & joystick con- Neutral Travel impossible

troller C1 (female) (2) and chassis ground: 5 – (F, R, 1st, 2nd, 3rd, 4th
15 z solenoid outputs: OFF).
2) Voltage between transmission & joystick control- T-2
ler C1 (2) and chassis ground at neutral: Less
than 1 V
1) Resistance between transmission & joystick Neutral Travel impossible

controller C1 (female) (9) and chassis ground: 5 (F, R, 1st, 2nd, 3rd, 4th
– 15 z solenoid outputs: OFF).
2) Voltage between transmission & joystick T-3
controller C1 (9) and chassis ground at neutral:
Less than 1 V

Less than 1 V

Less than 1 V

Less than 1 V
WA700-3 20-659
(10)
Failure
code
1) Defective 4th solenoid

Short circuit, disconnection C1 (female) (11) – TL1 (4) – T01 (E)
17
in 4th solenoid system 3) Defective contact, disconnection in wiring harness between T01 (B) – TL1
(7) – CL1 (12) – chassis ground
1) Defective joystick directional lever F, N, R switch

2) Disconnection between joystick directional lever connector (8) and chassis
ground
When chassis wiring harness is in any of the following conditions with the
switch not pressed
3) Defective contact or disconnection in wiring harness between transmission
& joystick controller C5 (female) (8) – JL2 (2) – joystick lever connector (2)
Short circuit or
or short circuit with ground in wiring harness between C5 (female) (16) –
disconnection in joystick
19 JL2 (3) – joystick lever connector (3)
forward-reverse switch
signal system
JL2 (5) – joystick lever connector (5)
JL2 (7) – joystick lever connector (7)
1) Defective directional lever

2) Defective combination switch power source
Short circuit with power source, short circuit with ground, defective contact,
disconnection in the following wiring harnesses
Short circuit or 3) Wiring harness between transmission & joystick controller C3B (female) (5)
20 disconnection in directional and L04 (2)
switch signal system 4) Wiring harness between transmission & joystick controller C3B (female)
(13) and L04 (3)
5) Wiring harness between transmission & joystick controller C3B (female) (6)
and L04 (4)
1) Defective speed lever

2) Defective combination switch power source
Short circuit with power source, short circuit with ground, defective contact,
disconnection in the following wiring harnesses
Short circuit or and L04 (5)
21 disconnection in speed 4) Wiring harness between transmission & joystick controller C3B (female)
switch signal system (15) and L04 (6)
and L04 (7)
6) Wiring harness between transmission & joystick controller C3B (female)
(16) and L04 (8)
1) Defective travel speed sensor

2) Defective adjustment of travel speed sensor mount
Disconnection in travel & joystick controller C5 (female) (2) – TL1 (11) – T05 (1)
22
speed sensor 4) Defective contact or disconnection in wiring harness between transmission
& joystick controller C5 (female) (10) – TL1 (12) – T05 (2)
20-660 WA700-3
(10)

abnormality code
1) Resistance between transmission & joystick con- Neutral Travel impossible

15 z solenoid outputs: OFF).
than 1 V
1) Resistance between joystick directional lever Neutral Cannot travel in joystick

connector (8) and chassis ground: Less than 1 z (F, R, 1st, 2nd, 3rd, 4th mode (possible in steering
The following conditions are when the switch is not solenoid outputs: OFF). wheel mode)
pressed
2) Resistance between transmission & joystick con-
troller C5 (female) (8) and chassis ground: Less
than 1 z and resistance between C5 (female)
(16) and chassis ground: Min. 1 Mz
3) Resistance between transmission & joystick con- T-8
4) Resistance between transmission & joystick con-
1) Voltage between combination switch L04 (1) and • Shifts to neutral imme- Travel impossible
chassis ground: 20 – 30 V diately when short cir-
2) Voltage for only 1 system in accordance with cuit with power source
position of directional lever: 20 – 30 V is detected
(Others: Less than 1 V) • When there is no signal
F: Between transmission & joystick controller (disconnection), holds T-9
C3B (5) – chassis ground previous signal condi-
N: Between transmission & joystick controller tion for 2 seconds
C3B (13) – chassis ground
R: Between transmission & joystick controller
1) Voltage between combination switch L04 (1) and • If 2 signals are input, it 1) Auto–shift limit is
chassis ground: 20 – 30 V judges speed range different from range
2) Voltage for only 1 system in accordance with position in order of pri- position selected by
position of speed lever: 20 – 30 V ority 4 i 3 i 2 i 1 operator
(Others: Less than 1 V) • When there is no signal 2) Impossible to shift gear
1st: Between transmission & joystick controller (disconnection), holds in manual mode
C3B (7) – chassis ground previous signal condi- T-11
2nd: Between transmission & joystick controller tion (speed range posi-
C3B (15) – chassis ground tion
3rd: Between transmission & joystick controller
4th: Between transmission & joystick controller
1) Resistance between speed sensor T05 (1) and 1) Switches to manual 1) Does not carry out
(2): 500 – 1000 z mode auto–shift
2) Voltage between transmission & joystick 2) Shifts gear according to 2) Switches to manual
controller C5 (female) (2) and (10): Min. 0.5 V operation of speed shift T-13
(AC range) lever
WA700-3 20-661
(10)
Failure
code
1) Defective engine speed sensor

2) Defective adjustment of engine speed sensor mount
Short circuit, disconnection 3) Short circuit with ground, defective contact, disconnection in wiring harness
23 in engine speed sensor between transmission & joystick controller C4 (female) (2) and EC3A (5)
system 4) Defective contact or disconnection in wiring harness between transmission
& joystick controller C4 (female) (9) – LR5 (3) – chassis ground
20-662 WA700-3
(10)

abnormality code
1) Resistance between engine speed sensor E10, 1) It is possible to travel There is gearshifting shock
E13 (1) and (2): 100 – 500 z with engine speed
2) Voltage between transmission & joystick control- taken as 2100 rpm
ler C4 (female) (2) and (9): Min. 0.5 V T-15
WA700-3 20-663
(10)
Failure
code
1) Defective back lamp relay

2) Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission & joystick
controller C1 (female) (8) and L76 (1)
Short circuit, disconnection 3) Defective contact or disconnection in wiring harness between back lamp
10
in back lamp relay relay L76 (female) (2) and chassis ground
1) Defective F solenoid
Short circuit, disconnection controller C1 (female) (2) – TL1 (5) – T01 (D)
12
in F solenoid system 3) Short circuit with chassis ground, defective contact, disconnection in wiring
harness between chassis – TL1 (7) – T01 (A)
1) Defective R solenoid
Short circuit, disconnection controller C1 (female) (9) – TL1 (6) – T01 (C)
13
in R solenoid system 3) Short circuit with chassis ground, defective contact, disconnection in wiring
1) Defective 1st solenoid

Short circuit, disconnection controller C1 (female) (3) – TL1 (1) – T01 (H)
14
in 1st solenoid system 3) Short circuit with chassis ground, defective contact, disconnection in wiring
1) Defective 2nd solenoid

Short circuit, disconnection controller C1 (female) (10) – TL1 (2) – T01 (G)
15
in 2nd solenoid system 3) Short circuit with chassis ground, defective contact, disconnection in wiring
harness between chassis–TL1 (7)–T01 (A)
1) Defective 3rd solenoid

Short circuit, disconnection controller C1 (female) (5) – TL1 (3) – T01 (F)
16
in 3rd solenoid system 3) Short circuit with chassis ground, defective contact, disconnection in wiring
4) Defective transmission controller
20-664 WA700-3
(10)

abnormality code
1) Resistance of relay coil: 200 – 400 z Neutral Back lamp is not actuated
2) Voltage between transmission & joystick control- (F, R, 1st, 2nd, 3rd, 4th when driving in reverse
ler C1 (8) and chassis ground at neutral: Less solenoid output: off)
than 1 V
3) Resistance in wiring harness between transmis-
T-1
sion & joystick controller C1 (female) (8) and L76
(female) (1): Max. 1 z
4) Resistance in wiring harness between back lamp
relay L76 (female) (2) and chassis ground: Max.
1z
1) Resistance between transmission & joystick con- Neutral It is impossible to travel

15 z solenoid output: off)
than 1 V

than 1 V

than 1 V

than 1 V

than 1 V
WA700-3 20-665
(10)
Failure
code
1) Defective 4th solenoid

Short circuit, disconnection controller C1 (female) (11) – TL1 (4) – T01 (E)
17
in 4th solenoid system 3) Short circuit with chassis ground, defective contact, disconnection in wiring
4) Defective transmission controller
1) Defective joystick forward-reverse switch

2) Disconnection or defective contact in wiring harness between fuse – JL2 (1)
– JS1 (female) (1)
3) Disconnection, defective contact, short circuit with chassis ground, or short
circuit in wiring harness between transmission & joystick controller C3B
(female) (5) – JL2 (2) – JS1 (female) (2)
Short circuit or circuit in wiring harness between transmission & joystick controller C3B
disconnection in joystick (female) (13) – JL2 (3) – JS1 (female) (3)
20
forward-reverse switch 5) Disconnection, defective contact, short circuit with chassis ground, or short
signal system circuit in wiring harness between transmission & joystick controller C3B
1) Defective joystick shift-up/down switch

2) Disconnection or defective contact in wiring harness between fuse – JL2 (1)
– JS1 (female) (1)
Short circuit or 5) Disconnection, defective contact, short circuit with chassis ground, or short
disconnection in joystick circuit in wiring harness between transmission & joystick controller C3B
21
shift-up/down switch signal (female) (15) – JL2 (7) – JS1 (female) (7)
system 6) Disconnection, defective contact, short circuit with chassis ground, or short
1) Defective speed sensor

2) Defective adjustment of speed sensor mount
Disconnection in speed & joystick controller C5 (female) (2) – TL1 (11) – X05 (1)
22
sensor system 4) Defective contact or disconnection in wiring harness between transmission
& joystick controller C5 (female) (1) – TL1 (12) – X05 (2)
1) Defective engine speed sensor

2) Defective adjustment of engine speed sensor mount
Short circuit, disconnection 3) Defective contact or disconnection in wiring harness between transmission
23 in engine speed sensor & joystick controller C4 (female) (2) – LR3 (7) – ER1 (12) – E13 (2)
system 4) Defective contact or disconnection in wiring harness between transmission
& joystick controller C4 (female) (9) – LR3 (8) – ER1 (11) – E13 (1)
20-666 WA700-3
(10)

abnormality code

than 1 V
1) Voltage between transmission & joystick control- 1) When N signal is input: 1) When in F: Stops.
ler C3B (5) and chassis ground Shifts to N immediately. 2) When in N or R: Starts
When joystick forward-reverse switch is in "F": 2) When F/R signal is moving forward
17 – 30 V input: Shifts to N suddenly.
When joystick forward-reverse switch is not in immediately. 3) When in N: N signal is
"F": Max. 1 V 3) When there is no not output.
2) Voltage between transmission & joystick control- signal: Holds previous 4) When in F or R: Sets to
ler C3B (13) and chassis ground signal condition for 2 neutral suddenly.
When joystick forward-reverse switch is in "N": seconds, then shifts to 5) When in R: Stops.
T-10
17 – 30 V N. 6) When in N or F: Starts
When joystick forward-reverse switch is not in moving in reverse
"N": Max. 1 V suddenly.
3) Voltage between transmission & joystick control-
ler C3B (6) and chassis ground
When joystick forward-reverse switch is in "R":
17 – 30 V
When joystick forward-reverse switch is not in
"R": Max. 1 V
1) Voltage between transmission & joystick 1) Holds current gear 1) Cannot shift gear up.
controller C3B (7) and chassis ground (Shift-up speed. 2) Cannot shift gear
NO) down.
When joystick shift-up switch is ON: Max. 1 V
When joystick shift-up switch is OFF: 17 – 30 V
2) Voltage between transmission & joystick
controller C3B (8) and chassis ground (Shift-
down NO)
When joystick shift-down switch is ON: Max. 1 V
When joystick shift-down switch is OFF: 17 – 30
V
T-12
controller C3B (15) and chassis ground (Shift-up
NC)
When joystick shift-up switch is ON: 17 – 30 V
When joystick shift-up switch is OFF: Max. 1 V
controller C3B (16) and chassis ground (Shift-
down NC)
When joystick shift-down switch is ON: 17 – 30 V
When joystick shift-down switch is OFF: Max. 1
V
1) Resistance between travel speed sensor X05 (1) 1) Switches to manual 1) Does not carry out
and (2): 500 – 1,000 z mode (OP) auto-shift (OP)
controller C5 (female) (2) and (1): Min. 0.5 V operation of range shift T-14
lever
1) Resistance between engine speed sensor E13 1) Switches to manual 1) Does not carry out
(1) and (2): 100 – 500 z mode (OP) auto-shift (OP)
controller C4 (female) (2) and (9) operation of range shift T-15
lever
WA700-3 20-667
(10)
Troubleshooting Electrical circuit diagram for transmission control system
Electrical circuit diagram for transmission control system

20-668 WA700-3
(10)
a This circuit diagram is made by extracting the part of the transmission & joystick steering controller system
from the general circuit diagram.
WA700-3 20-669
(10)
20-670 WA700-3
(10)
a This circuit diagram is made by extracting the part of the transmission & joystick steering controller system
from the general circuit diagram.
WA700-3 20-671
(10)
Troubleshooting T-1
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in
backup lamp relay) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
Cause Remedy
4 YES
Go to A
Is resistance bet-
Is resistance between ground normal? ground in wiring harness Repair or
YES C1 (female) (8) and • Min. 1 Mz NO between C1 (female) (8) replace
chassis normal when
2 L76 (female) (1) is
grounded to chassis? OFF. Disconnection in wiring
Is resistance bet- • Disconnect C1 and L76
YES ween L76 (female) • Max. 1 z harness between C1 Repair or
(2) and chassis • Turn starting switch NO (female) (8) and L76 replace
ground normal? OFF. (female) (1)
1 • Disconnect C1 and L76
Is troubleshooting • Max. 1 z Disconnection in wiring
code 10 displayed • Turn starting switch harness between L76 Repair or
when the relay is inter- NO (female) (2) – LR5 (2) – replace
changed with other
OFF.
relay of same type? • Disconnect L76. chassis ground
OFF. Defective backup lamp
Replace
• Interchange with NO relay
other relay of same type.
• Directional lever: R Defective transmission &
5 YES
joystick steering Replace
Is voltage between controller
From A C1 (female) (8) and
chassis normal? Short circuit with power
Replace
• Turn starting switch NO between C1 (female) (8)
OFF. and L76 (female) (1)
• Disconnect C1 and L76.
• Less than 0.1 V
T-1 Related electrical circuit diagram
20-672 WA700-3
(10)
Troubleshooting T-2
F solenoid) is displayed
Cause Remedy
Defective transmission &

3 YES
YES
between C1 (2) –
(6), (12) normal? Short circuit with power
source in wiring harness Repair or
2 • Directional lever: N NO between C1 (female) (2) – replace
• Turn starting TL1 (5) – T01 (female) (D)
Is resistance switch ON. Defective contact or
YES between C1 • Max. 1 V 5 YES disconnection in wiring Repair or
(female) (2) and harness between C1
chassis normal? (female) (2) – TL1 (5) – T01
YES between T01
(female) (D)
• 5 – 15 z 4
(female) (A) and
chassis ground Defective contact or
1 • Turn starting disconnection in wiring
switch OFF. Is resistance between normal? Repair or
Is resistance harness between T01
• Disconnect C1.
C1 (female) (2) – T01 • Max. 1 z NO (female) (A) – TL1 (7) – LR5 replace
between T01 NO (female) (D) – chassis • Turn starting
ground normal? (2) – chassis ground
(male) (D) and (A) switch OFF.
normal? Short circuit with chassis
• Min. 1 Mz • Disconnect T01. Repair or
• 5 – 15 z • Turn starting NO between C1 (female) (2) – replace
• Turn starting switch OFF. TL1 (5) – T01 (female) (D)
switch OFF. • Disconnect C1
• Disconnect T01. and T01.
Defective F solenoid Replace
NO
WA700-3 20-673
(10)
Troubleshooting T-3
R solenoid) is displayed
Cause Remedy

3 YES
YES
between C1 (9) –
• Turn starting TL1 (6) – T01 (female) (C)
YES between T01
(female) (C)
• 5 – 15 z 4
(female) (A) and
• Disconnect C1.
C1 (female) (9) – T01 • Max. 1 z NO (female) (A) – TL1 (7) – LR5 replace
between T01 NO (female) (C) – chassis • Turn starting
(male) (C) and (A) switch OFF.
• Min. 1 Mz • Disconnect T01. Repair or
• Turn starting switch OFF. TL1 (6) – T01 (female) (C)
Defective R solenoid Replace
NO
20-674 WA700-3
(10)
Troubleshooting T-4
1st solenoid) is displayed
Cause Remedy

3 YES
YES
between C1 (3) –
• Turn starting TL1 (1) – T01 (female) (H)
YES between T01
(female) (H)
• 5 – 15 z 4
(female) (B) and
Is resistance C1 (female) (3) – T01 harness between T01
• Disconnect C1. • Max. 1z NO (female) (B) – TL1 (7) – LR5 replace
between T01 NO (female) (H) – chassis • Turn starting
(male) (H) and (B) switch OFF.
• Min. 1 Mz • Disconnect T01. ground in wiring harness Repair or
• Turn starting switch OFF. TL1 (1) – T01 (female) (H)
Defective 1st solenoid Replace
NO
WA700-3 20-675
(10)
Troubleshooting T-5
2nd solenoid) is displayed
Cause Remedy

3 YES
YES
between C1 (10) –
• Turn starting TL1 (2) – T01 (female) (G)
YES between T01
(female) (G)
• 5 – 15 z 4
(female) (B) and
Is resistance C1 (female) (10) – T01 harness between T01
• Disconnect C1. • Max. 1z NO (female) (B) – TL1 (7) – LR5 replace
between T01 NO (female) (G) – chassis • Turn starting
(male) (G) and (B) switch OFF.
• Turn starting switch OFF. TL1 (2) – T01 (female) (G)
Defective 2nd solenoid Replace
NO
20-676 WA700-3
(10)
Troubleshooting T-6
3rd solenoid) is displayed
Cause Remedy

3 YES
YES
between C1 (5) –
• Turn starting TL1 (3) – T01 (female) (F)
YES between T01
(female) (F)
• 5 – 15 z 4
(female) (B) and
• Disconnect C1.
C1 (female) (5) – T01 • Max. 1 z NO (female) (B) – TL1 (7) – LR5 replace
between T01 NO (female) (F) – chassis • Turn starting
(male) (F) and (B) switch OFF.
• Turn starting switch OFF. TL1 (3) – T01 (female) (F)
Defective 3rd solenoid Replace
NO
WA700-3 20-677
(10)
Troubleshooting T-7
4th solenoid) is displayed
Cause Remedy

3 YES
YES
between C1 (11) –
• Turn starting TL1 (4) – T01 (female) (E)
YES between T01
(female) (E)
• 5 – 15 z 4
(female) (B) and
• Disconnect C1.
C1 (female) (11) – • Max. 1 z NO (female) (B) – TL1 (7) – LR5 replace
between T01 NO T01 (female) (E) – • Turn starting
chassis ground (2) – chassis ground
(male) (E) and (B) switch OFF.
• Turn starting switch OFF. TL1 (4) – T01 (female) (E)
Defective 4th solenoid Replace
NO
20-678 WA700-3
(10)
Troubleshooting T-8
T-8 Failure code [19] (Short circuit, disconnection in joystick directional switch sys-
tem) is displayed
a Before carrying out troubleshooting, check that all the related
Cause Remedy
connectors are properly inserted.
a Always connect any disconnected connectors before going on to
the next step.
4 YES joystick steering
Replace
Is voltage between controller
YES C5 (female) (7), (8), Short circuit, short circuit
(9), (15), (16), (17) and
chassis as shown in with chassis ground, defec-
3 tive contact, or disconnec-
Table 1? Repair or
Is resistance tion in wiring harness bet-
• Turn starting switch NO ween JL2 (female) (2), (3),
replace
YES between JL2
(female) (8) and ON. (4), (5), (6), (7) – C5 (female)
(7), (8), (9), (15), (16), (17)
2 chassis normal?
Is voltage between • Min. 1 Mz nection in wiring harness Repair or
YES • Turn starting between JL2 (female) (8) – replace
JL2 (1) and NO
chassis normal? switch OFF. LR5 (3) – chassis
1 • Disconnect JL2. Short circuit, short circuit
Is voltage between • 20 – 30 V with chassis ground, defec-
JL2 (8) and terminals tive contact, or disconnec- Repair or
(2), (3), (4), (5), (6), tion in wiring harness bet- replace
and (7) as shown in ON. NO
ween C3A (male) (6) - JL2
Table 1? (1) - LR5 (3) - chassis
ON. Defective joystick lever Replace
NO
Table 1 Voltage of each direction position of joystick lever
When directional
switch is pressed F N R
Terminal
JL2 (male) (8) – (2) Between C5 (8) and chassis 20 – 30 V Max. 1 V Max. 1 V
JL2 (male) (8) – (3) Between C5 (16) and chassis Max. 1 V 20 – 30 V 20 – 30 V
JL2 (male) (8) – (4) Between C5 (7) and chassis Max. 1 V 20 – 30 V Max. 1 V
JL2 (male) (8) – (5) Between C5 (15) and chassis 20 – 30 V Max. 1 V 20 – 30 V
JL2 (male) (8) – (6) Between C5 (9) and chassis Max. 1 V Max. 1 V 20 – 30 V
JL2 (male) (8) – (7) Between C5 (17) and chassis 20 – 30 V 20 – 30 V Max. 1 V
WA700-3 20-679
(10)
Troubleshooting T-9
T-9 Failure code [20] (Short circuit, disconnection in directional switch system) is
displayed
YES
2 5 YES
Is voltage between Is there continuity
C3B (female) (5), (6), between L04 (female) (2)
YES YES – C3B (female) (5), L04
(13) – chassis (female) (4) – C3B
ground as shown in 4 (female) (6), L04
Table 1? Is resistance (female) (3) – C3B
• Turn starting YES between C3B • Turn starting NO
(female) (5), (6), (13)
switch OFF. switch OFF.
1 • Disconnect C3B. normal? • Disconnect C3B and L04.
• Turn starting Is voltage between • Max. 1z
Is voltage C3B (female) (5), • Turn starting
between L04 switch ON. switch OFF. NO
(female) (1) and
NO (6), (13) – chassis
ground normal? • Disconnect C3B
(10) normal? and L04.
• Turn starting • Min. 1 Mz
switch OFF. • Disconnect C3B NO
• Disconnect L04. and L04.
• Turn starting • Turn starting switch ON.
switch ON. • Max. 1 V
• 20 – 30 V
NO
Table 1
Terminal
F N R
Directional position
C3B (female) (5) – chassis ground 20 – 30 V Max. 1 V Max. 1 V
C3B (female) (13) – chassis ground Max. 1 V 20 – 30 V Max. 1 V
C3B (female) (6) – chassis ground Max. 1 V Max. 1 V 20 – 30 V
20-680 WA700-3
(10)
Troubleshooting T-9
Cause Remedy

controller
lever Replace
harness between L04
(female) (2) – C3B (female)
(5), L04 (female) (4) – C3B Repair or
(female) (6), L04 (female) (3) replace
– C3B (female) (13)
C3B (female) (5), L04 (female) Repair or
(4) – C3B (female) (6), L04 replace
(13)
C3B (female) (5), L04 (female) replace
(4) – C3B (female) (6), L04
(13)
Defective contact,
disconnection, or short Repair or
circuit with chassis ground in replace
wiring harness between L04
(female) (1) and FS2 (8),
blown fuse
WA700-3 20-681
(10)
Troubleshooting T-9
20-682 WA700-3
(10)
Troubleshooting T-10
T-10 Failure code [20] (Short circuit or disconnection in joystick directional switch
system) is displayed
a Check that fuse is normal.
Cause Remedy
Defective transmission
3 YES
and joystick steering Replace
Is voltage between
controller
YES C3B (5), (13), (6) and
chassis ground as Disconnection, defective
2 shown in Table 1? contact, short circuit with
Is voltage chassis ground, or short Repair or
YES between JS1 (1) circuit in wiring harness replace
• Turn starting NO between JS1 (female) (2), (3),
and chassis switch ON. (4) – C3B (female) (5), (13), (6)
1 ground normal?
Is voltage between • 20 – 30 V Disconnection or defective
JS1 (2), (3), (4) and contact in wiring harness Repair or
chassis ground as between fuse – JS1
shown in Table 1? switch ON.
(female) (1)
• Turn starting
switch ON. Defective joystick
Replace
NO directional switch
Table 1 Voltage measured with joystick directional switch at each position
Position of FNR switch

F N R
Terminals
JS1 (male) (1) – (2) C3B (5) – Chassis ground 20 – 30 V Max. 1 V Max. 1 V
JS1 (male) (1) – (3) C3B (13) – Chassis ground Max. 1 V 20 – 30 V Max. 1 V
JS1 (male) (1) – (4) C3B (6) – Chassis ground Max. 1 V Max. 1 V 20 – 30 V
WA700-3 20-683
(10)
T-11 Failure code [21] (Short circuit, disconnection in range switch system) is dis-
played
YES
2 5 YES
Is voltage between Is there continuity between
C3B (female) (7), L04 (female) (5) – C3B
YES YES (female) (7), L04 (female) (6) –
(15), (8), (16) – C3B (female) (15), L04
chassis ground as 4
shown in Table 1? Is resistance (8), L04 (female) (8) – C3B
• Turn starting YES between C3B • Turn starting NO
(female) (7), (15),
switch OFF. switch OFF.
3 (8), (16) and chassis
1 • Disconnect C3B. ground normal? • Disconnect C3B and L04.
Is voltage between
Is voltage • Turn starting C3B (female) (7), • Turn starting • Max. 1z
between L04 switch ON. (15), (8), (16) – switch OFF. NO
(female) (1) and
NO chassis ground • Disconnect C3B
(10) normal? normal?
and L04.
• Turn starting • Min. 1 Mz
switch OFF. • Disconnect C3B NO
• Disconnect L04. and L04.
• Turn starting • Turn starting switch ON.
switch ON. • Max. 1 V
• 20 – 30 V
NO
Table 1
Terminal
1st 2nd 3rd 4th
Directional position
C3B (female) (7) – chassis ground 20 – 30 V Max. 1 V Max. 1 V Max. 1 V
C3B (female) (15) – chassis ground Max. 1 V 20 – 30 V Max. 1 V Max. 1 V
C3B (female) (8) – chassis ground Max. 1 V Max. 1 V 20 – 30 V Max. 1 V
C3B (female) (16) – chassis ground Max. 1 V Max. 1 V Max. 1 V 20 – 30 V
20-684 WA700-3
(10)
Cause Remedy

controller
lever Replace
harness between L04 (female)
(5) – C3B (female) (7), L04
(female) (6) – C3B (female) Repair or
(15), L04 (female) (7) – C3B
(female) (8), L04 (female) (8) – replace
C3B (female) (16)
between L04 (female) (5) – C3B Repair or
(female) (7), L04 (female) (6) –
C3B (female) (15), L04 (female) replace
(7) – C3B (female) (8), L04
(female) (8) – C3B (female) (16)
between L04 (female) (5) – C3B Repair or
(female) (7), L04 (female) (6) – replace
C3B (female) (15), L04 (female)
(7) – C3B (female) (8), L04
(female) (8) – C3B (female) (16)
Defective contact,
disconnection, or short circuit Repair or
with chassis ground in wiring replace
harness between L04 (female)
(1) and FS2 (8), blown fuse
WA700-3 20-685
(10)
20-686 WA700-3
(10)
T-12 Failure code [21] (Short circuit or disconnection in joystick shift-up/shift-down

switch system) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
Cause Remedy
Defective transmission
3 YES
and joystick steering Replace
Is voltage between
controller
YES C3B (16), (8), (15), Disconnection, defective
(7) and chassis
2 ground as shown in
contact, short circuit with
chassis ground, or short
Is voltage Table 1? circuit in wiring harness Repair or
YES between JS1 (1) • Turn starting NO between JS1 (female) (5), (6), replace
and chassis (7), (8) – C3B (female) (16),
1 switch ON. (8), (15), (7)
ground normal?
Is voltage between
Disconnection or defective
JS1 (5), (6), (7), (8) • 20 – 30 V Repair or
and chassis ground contact in wiring harness
as shown in Table between fuse – JS1
switch ON.
1? (female) (1)
• Turn starting
Defective joystick shift-
switch ON. Replace
NO up/shift-down switch
Table 1 Voltage measured with joystick shift-up/shift-down switch at each position
When shift-up/shift-down switch

Shift-up Shift-down
is pressed
switch ON switch ON
Terminals
JS1 (5) – Chassis ground C5 (16) – Chassis ground 20 – 30 V Max. 1 V
JS1 (6) – Chassis ground C5 (8) – Chassis ground Max. 1 V 20 – 30 V
JS1 (7) – Chassis ground C5 (15) – Chassis ground Max. 1 V 20 – 30 V
JS1 (8) – Chassis ground C5 (7) – Chassis ground 20 – 30 V Max. 1 V
20-688 WA700-3
(10)
WA700-3 20-689
(10)
T-13 Failure code [22] (Disconnection in travel speed sensor system) is displayed
Cause Remedy

3 YES joystick steering Replace
Is resistance between
C5 (female) (10) and
controller
YES
chassis normal when Defective contact or
2 T05 (female) (2) is disconnection in wiring
Is resistance between grounded to chassis?
harness between C5 Repair or
YES C5 (female) (2) and • Max. 1 z NO (female) (10) – TL1 (12) – replace
chassis normal when
• Disconnect C5, T05 (female) (2)
1 T05 (female) (1) is
T05, and L07.
Is resistance grounded to chassis? Defective contact or
between T05 (male) • Max. 1z disconnection in wiring Repair or
(1) and (2), and • Disconnect T05, NO harness between C5 replace
between (1), (2) and C5, and L07. (female) (2) – TL1 (11) –
chassis normal? • Turn starting T05 (female) (1)
• Between (1) and switch OFF.
(2): 500 – 1000 z NO Defective speed sensor Replace
• Between (1), (2)
and chassis:
Min. 1 Mz
• Disconnect T05.
• Turn starting
switch OFF.
20-690 WA700-3
(10)
T-14 Failure code [22] (Disconnection in travel speed sensor system) is displayed
has been removed.
3 YES Defective transmission &

Is resistance controller
YES between C5 (female)
(1) and T05 (female) Defective contact or
2
(2) normal? disconnection in wiring
Is resistance harness between C5 Repair or
YES between C5 • Max. 1 z NO (female) (1) and T05 replace
(female) (2) and T05 • Disconnect C5, T05 and (female) (2)
1 (female) (1) normal?
L07.
Is resistance between Defective contact or
• Max. 1 z • Turn starting switch OFF. Repair or
T05 (male) (1) and (2) disconnection in wiring
and between (1), (2) • Disconnect T05, NO harness between C5 replace
and chassis ground C5 and L07. (female) (2) and T05
normal? • Turn starting (female) (1)
• Between (1) and switch OFF.
Defective speed sensor Replace
(2): 500 – 1000 z NO
• Disconnect T05.
• Turn starting
switch OFF.
WA700-3 20-691
(10)
T-15 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is
displayed
Serial No.: 50001 – 51000
a) Transmission controller system
2 YES
Is resistance
YES between C4
1 (female) (9) and
Is resistance chassis normal?
between C4 • Max. 1 z NO
(male) (2) and • Disconnect C4.
chassis normal? • Turn starting
• Min. 1 Mz switch OFF.
• Disconnect C4, NO
EC3A, and L07.
• Turn starting
switch OFF. 6 YES
Is resistance
YES between EC3A
5 (female) (2), (3) –
b) Electric engine throttle controller system (14)?
Is resistance
YES between EC3A • Min. 1 Mz NO
(female) (14) and • Disconnect EC3A,
4 chassis normal? E10, and E13.
Is resistance between • Turn starting switch
YES EC3A (female) (14) • Min. 1 Mz OFF.
and chassis normal • Disconnect EC3A, NO
when E10, E13
(female) (2) are E10, and E13.
3 grounded to chassis? • Turn starting
Is resistance • Max. 1 z switch OFF.
YES between EC3A • Disconnect EC3A,
(female) (2), (3) – E10, and E13. NO
2 chassis normal? • Turn starting
Is resistance between switch OFF.
EC3A (female) (2), (3) • Min. 1 Mz
YES – chassis normal • Disconnect EC3A,
when E10, E13 E10, and E13. NO
(female) (1) are
1 grounded to chassis? • Turn starting
Is resistance • Max. 1 z switch OFF.
between E10, E13 • Disconnect EC3A,
(male) (1) and (2) E10, and E13. NO
• 100 – 500 z switch OFF.
• Disconnect E10
and E13. NO
• Turn starting
switch OFF.
a Normally, the engine speed is detected from E13 Engine speed sensor A. When an abnormality occurs in
sensor A, it switches to E10 Engine speed sensor B.
20-692 WA700-3
(10)
Cause Remedy

controller
chassis ground
ground in wiring harness Repair or
between C4 (female) (2) – replace
EC3A (female) (5) or L07
(female) (3)
Defective electric engine
Replace
throttle controller
Short circuit in wiring harness
between EC3A (female) (2), (3)
– LR8 (5), (3) – ER3 (5), (3) –
E10, E13 (female) (1) and Repair or
wiring harness between EC3A
(female) (14) – LR8 (4), (6) – replace
ER3 (4), (6) – E10, E13 (female)
(2)
between EC3A (female) (14) –
LR8 (4), (6) – ER3 (4), (6) – replace
E10, E13 (female) (2)
harness between EC3A Repair or
(female) (14) and LR8 (4), (6) replace
– ER3 (4), (6) – E10, E13
(female) (2)
between EC3A (female) (2),
(3) – LR8 (5), (3) – ER3 (5), (3) replace
– E10, E13 (female) (1)
harness between EC3A Repair or
(female) (2), (3) – LR8 (5), (3) replace
– ER3 (5), (3) – E10, E13
(female) (1)
Defective engine speed

sensor A, B Replace
WA700-3 20-693
(10)
20-694 WA700-3
(10)
Serial No. : 51001 and up
position, if the failure code is no longer displayed on the monitor display, the problem has been removed.
Cause Remedy
4 YES
Go to A
Is resistance
YES between C4 Defective contact or
3 (female) (9) and E13 disconnection in wiring
(female) (2) normal?
YES between C4 (female) • Max. 1 z NO (female) (9) and E13 replace
2
(2) and chassis • Disconnect C4 and E13. (female) (2)
ground normal? • Turn starting switch
Is resistance
• Min. 1 Mz OFF. ground in harness Repair or
YES between C4
(female) (2) and E13 • Disconnect C4, NO between C4 (female) (2) replace
(female) (1) normal? E13 and L07. and E13 (female) (1)
1
Is resistance • Max. 1 z switch OFF. disconnection in wiring Repair or
between E13 • Disconnect C4,
NO harness between C4 replace
(male) (1) and (2) E13 and L07. (female) (2) and E13
normal? • Turn starting (female) (1)
• 100 – 500 z switch OFF.
• Disconnect E13. Defective engine speed Replace
• Turn starting NO sensor
switch OFF.
YES between C4 Short circuit of harness
5 (female) (2) and between C4 (female) (2)
(9) normal? and E03 (female) (1) and Repair or
Is resistance harness between C4
between C4 (female) • Min. 1 Mz NO replace
From A (female) (9) and E13
(9) and chassis • Disconnect C4, (female) (2) with each
ground normal? E13 and L07. other
• Turn starting switch OFF. Short circuit with chassis Repair or
• Min. 1 Mz
• Disconnect C4 NO ground in harness replace
and E13. between C4 (female) (9)
• Turn starting and E13 (female) (2)
switch OFF.
WA700-3 20-695
(10)
T-16 Kickdown switch signal system and hold switch signal system
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).
Cause Remedy
Kickdown switch

YES joystick steering Replace
1 controller
between C5 ground, defective
(female) (5) and 2 YES contact, or disconnection Repair or
chassis normal?
Is resistance in wiring harness replace
• Disconnect C5. between L15 between C5 (female) (5)
• Kick-down (male) (1) and (2) and L15 (female) (1)
NO normal?
switch Defective kick-down
ON: Max. 1 z • Disconnect L15. NO switch
Replace
OFF: Min. 1 Mz • Kick-down switch
ON: Max. 1 z
OFF: Min. 1 Mz
Hold switch
Cause Remedy
a Hold switch is applied to only the auto-shift specification

YES
1 controller
Is resistance
between C5 Short circuit with chassis
(female) (13) and ground, defective
2 YES Repair or
chassis normal? contact, or disconnection
• Hold switch (male) (3) and (4) and L15 (female) (3)
NO normal?
ON: Max. 1 z
OFF: Min. 1 Mz Defective hold switch Replace
• Hold switch
ON: Max. 1 z
OFF: Min. 1 Mz
20-696 WA700-3
(10)
T-17 Shift-down switch signal system and shift-up switch signal system
socket).
Cause Remedy
Shift-down switch

1 controller
between C5 ground, defective
(female) (5) and 2 YES contact, or disconnection Repair or
chassis normal?
• Shift-down (male) (1) and (2) and L15 (female) (1)
NO normal?
switch Defective shift-down
ON: Max. 1 z • Disconnect L15. NO switch
Replace
OFF: Min. 1 Mz • Shift-down switch
ON: Max. 1 z
OFF: Min. 1 Mz
Cause Remedy
Shift-up switch

YES
1 controller
Is resistance
between C5 Short circuit with chassis
(female) (13) and ground, defective
2 YES Repair or
chassis normal? contact, or disconnection
• Shift-up switch NO (male) (3) and (4) and L15 (female) (3)
ON: Max. 1 z normal?
OFF: Min. 1 Mz Defective Shift-up switch Replace
• Shift-up switch
ON: Max. 1 z
OFF: Min. 1 Mz
WA700-3 20-697
(10)
T-18 Transmission cut-off signal system
socket).
Cause Remedy

1 controller
• Short circuit with chassis
s resistance ground, defective contact,
between C5 or disconnection in wiring
(female) (6) and YES harness between C5 (female) Repair or
chassis normal? 2 (6) and L12 (female) (1) replace
Is resistance • Short circuit with chassis
• Disconnect C5. ground in wiring harness
between L12
• Transmission between C5 (female) (6) and
cut-off switch NO (male) (1) and (2) L06 (female) (3)
normal?
ON: Max. 1 z Defective transmission
• Disconnect L12. Replace
OFF: Min. 1 Mz NO cut-off switch
• Transmission
cut-off switch
ON: Max. 1 z
OFF: Min. 1 Mz
20-698 WA700-3
(10)
T-19 Neutralizer relay signal system

a Check that the parking brake works normally.
socket).
Cause Remedy

YES
controller
1 4 YES Defective neutralizer

Replace
Is resistance bet- relay
Is voltage YES ween C3A (female)
between C3A (19) 3 Defective contact or discon-
(6) and C3A (female)
and (6) normal? nection in wiring harness
Is voltage between (19) normal? Repair or
between C3A (female) (6) –
• Insert T-adapter. YES L58 (female) (1) • Disconnect C3A, NO L58 (female) (5), L58 (female) replace
2 and chassis and L58. (3) – C3A (female) (19)
• Turn starting switch • Short circuit L58
ON. normal? Short circuit with chassis
Is resistance (female) (3) and (5).
• Parking brake switch: between L58 • Disconnect L58. • Max. 1z ground, defective contact, Repair or
ON o OFF • Turn starting switch or disconnection in wiring
NO (female) (2) and NO harness between L58 (female) replace
• 20 – 30 V chassis normal? ON.
• Parking brake switch: (1) and L01 (female) (2)
• Disconnect L58. ON o OFF Defective contact or
• Max. 1z • 20 – 30 V disconnection in wiring Repair or
NO harness between L58 replace
(female) (2) and chassis
WA700-3 20-699
(10)
T-20 Neutralizer relay signal system

a Check that the parking brake works normally.
socket).
Cause Remedy

YES
controller
1 4 YES Defective neutralizer

Replace
Is voltage Is resistance bet- relay
between C3A (6) YES ween C3A (female)
and C3B (14) (6) and C3B (female) nection in wiring harness
normal? Is voltage between (14) normal? between C3B (female) (14) Repair or
• Insert T-adapter. YES L58 (female) (1) • Disconnect C3A, C3B NO – L58 (female) (5), L58 replace
and chassis and L58. (female) (3) – C3A (female)
• Turn starting switch 2 (19)
normal? • Short circuit L58
ON. Is resistance (female) (3) and (5). Short circuit with chassis
• Parking brake switch: between L58 • Disconnect L58. • Max. 1z ground, defective contact, Repair or
ON o OFF NO (female) (2) and • Turn starting switch
NO or disconnection in wiring replace
• 20 – 30 V chassis normal? ON. harness between L58 (female)
• Parking brake switch: (1) and L01 (female) (C)
• Disconnect L58. ON o OFF
• Max. 1z • 20 – 30 V Defective contact or
Repair or
NO harness between L58 replace
(female) (2) and chassis
20-700 WA700-3
(10)
WA700-3 20-701
(10)
T-21 Buzzer signal system
a Check that the main monitor and alarm buzzer work normally.
socket).
Cause Remedy

2 YES
YES between C2
1 (female) (10) and Defective contact or
chassis normal? disconnection in wiring
between C2 • Disconnect C2 NO (female) (10) and L08 replace
(female) (10) and and L08. (female) (6)
chassis normal? • Short circuit between L08 (female) (6) and chassis.
• Max. 1 z Short circuit with chassis
• Disconnect C2 ground in wiring harness Repair or
and L08. NO between C2 (female) (10) replace
• Min. 1 Mz and L08 (female) (6)
20-702 WA700-3
(10)
T-22 Network system
socket).
Cause Remedy

Is resistance bet- controller
YES ween C3B (female)
(4), (12) and Defective contact or
1 chassis normal? disconnection in wiring
harness between C3B Repair or
Is resistance bet-
• Max. 1 z NO (female) (4), (12) and L08 replace
ween C3B (female)
(4), (12) and (female) (1), (3)
• Disconnect C3B and L08.
chassis normal? • Make short circuit between
L08 (female) (1), (3) and chassis. Short circuit with chassis
• Min. 1 Mz
NO between C3B (female) (4), replace
OFF.
(12) and L08 (female) (1),
• Disconnect C3B,
(3)
and L08.
WA700-3 20-703
(10)
T-23 Transmission controller power source system

socket).
Cause Remedy

1 controller
Is voltage between
Short circuit with ground,
C1 (7), (13), C2 (1),
defective contact or discon-
(12) – C1 (6), (12), C2 2 YES nection in wiring harness Repair or
(11), (21) normal? between C1 (female) (7),
between C1 (female) (13) and C2 (female) (1),
• 20 – 30 V (12) – FS11 (female) (1)
(6), (12) and C2
• Turn starting NO (female) (11), (21) – Defective contact or discon-
switch ON. chassis normal? nection in wiring harness Repair or
• Max. 1 z NO between C1 (female) (6), (12) replace
• Turn starting switch and C2 (female) (11), (21) –
LR5 (female) (3) – chassis
OFF.
• Disconnect C1 and C2.
20-704 WA700-3
(10)
T-24 Transmission controller power source system

socket).
Cause Remedy

1 controller
Is voltage between
Short circuit with ground,
C1 (7), (13), C2 (1),
defective contact or discon-
(12) – C1 (6), (12), C2 2 YES nection in wiring harness Repair or
(11), (21) normal? between C1 (female) (7),
between C1 (female) (13) and C2 (female) (1),
• 20 – 30 V (12) – FOP5 (female) (1)
(6), (12) and C2
• Turn starting NO (female) (11), (21) – Defective contact or discon-
switch ON. chassis normal? nection in wiring harness Repair or
• Max. 1 z NO between C1 (female) (6), (12) replace
• Turn starting switch and C2 (female) (11), (21) –
LR5 (female) (3) – chassis
OFF.
• Disconnect C1 and C2.
WA700-3 20-705
(10)
T-25 Short circuit in travel speed sensor system

Cause Remedy

controller Replace
Is resistance
YES between C5 Short circuit in wiring
harness between C5 (female)
1 (female) (2) and (2) – L07 (female) (1) – TL1
Is resistance (10) normal? (11) – T05 (male) (1) and Repair or
wiring harness between C5
between C5 • Min. 1 Mz NO (female) (10) – L07 (female) replace
(female) (2) and • Turn starting (2) – TL1 (12) – T05 (female)
chassis normal? switch OFF. (2)
• Disconnect C5, T05, and L07. Short circuit with chassis
• Min. 1 Mz ground in wiring harness
Repair or
• Turn starting NO between C5 (female) (2) – TL1 replace
switch OFF. (11) – T05 (male) (1), and
between C5 (female) (2) and
• Disconnect C5, L07 (female) (1)
T05, and L07.
20-706 WA700-3
(10)
T-26 Short circuit in travel speed sensor system

Cause Remedy

controller Replace
Is resistance
harness between C5 (female)
1 (female) (2) and (2) – L07 (female) (1) – TL1
Is resistance (1) normal? (11) – T05 (male) (1) and Repair or
wiring harness between C5
between C5 • Min. 1 Mz NO (female) (10) – L07 (female) replace
(female) (2) and • Turn starting (2) – TL1 (12) – T05 (female)
chassis normal? switch OFF. (2)
• Disconnect C5, T05, and L07. Short circuit with chassis
• Min. 1 Mz ground in wiring harness
Repair or
• Turn starting NO between C5 (female) (2) – TL1 replace
switch OFF. (11) – T05 (male) (1), and
between C5 (female) (2) and
• Disconnect C5, L07 (female) (1)
T05, and L07.
WA700-3 20-707
(10)
Troubleshooting of joystick steering controller
system (J mode)
Judgement table for joystick controller system related parts ...................................................................... 20-752
Action taken by controller when abnormality occurs and problems on machine......................................... 20-754
Electrical circuit diagram for joystick steering system ................................................................................. 20-758
J-1 Failure code [56] (Short circuit, disconnection in caution relay output) is displayed ........................... 20-759
J-2 Failure code [57] (Short circuit in steering right solenoid (detected when output)) is displayed.......... 20-760
J-3 Failure code [58] (Short circuit in steering left solenoid (detected when output)) is displayed............ 20-761
J-4 Failure code [59] (Short circuit in steering right solenoid (HOT end)) is displayed ............................. 20-762
J-5 Failure code [60] (Short circuit in steering left solenoid (HOT end)) is displayed................................ 20-763
J-6 Failure code [61] (Short circuit, disconnection in steering solenoid cut relay output) is displayed...... 20-764
J-7 Failure code [62] (Short circuit, disconnection in joystick steering neutral signal) is displayed........... 20-765
J-8 Failure code [63] (Short circuit, disconnection in joystick steering lever potentiometer system)
is displayed.......................................................................................................................................... 20-766
J-9 Abnormality in power source, voltage ................................................................................................. 20-767
J-10 Abnormality in joystick steering ON-OFF signal system ..................................................................... 20-768
J-11 Disconnection in steering right solenoid.............................................................................................. 20-769
J-12 Disconnection in steering left solenoid................................................................................................ 20-770
WA700-3 20-751
(10)
Troubleshooting Judgement table for joystick controller system related parts
Judgement table for joystick controller system related parts
Self-diagnostic display (abnormality display)
Location of failure
Short circuit, disconnection in steering solenoid cut relay output

Short circuit in steering right solenoid (detected when output)
Short circuit, disconnection in joystick steering neutral switch

Troubleshooting code when
Short circuit in steering left solenoid (detected when output)
Short circuit, disconnection in joystick caution relay output
no abnormality display is
given
Short circuit, disconnection in joystick potentiometer

Short circuit in steering right solenoid (HOT end)
Short circuit in steering left solenoid (HOT end)
Abnormality in joystick ON-OFF signal system

Abnormality in power source, voltage
Failure
code
Transmission & joystick
Failure mode
steering controller
56 57 58 59 60 61 62 63 – –
1 Alarm buzzer does not stop Q T-17
2 Steering does not turn to left Q Q Q Q H-6,H-8,H-9,H-11,J-9,J-11
3 Steering does not turn to right Q Q Q Q H-6,H-8,H-9,H-11,J-9,J-12
4 Steering can be turned fully to left Q Q Q
5 Steering canlbe turned fully to right Q Q Q
6 Both steering and transmission do not work at all Q Q J-9,J-10
Troubleshooting code when error code is displayed J-1 J-2 J-3 J-4 J-5 J-6 J-7 J-8 – –
20-752 WA700-3
(10)
Action taken by controller when abnormality occurs and

problems on machine
Joystick control system
Failure code Abnormal system Nature of abnormality
1) Defective caution relay

2) Short circuit with ground, defective contact, or disconnection in
wiring harness between joystick steering controller C2 (female)
(9) and L66 (1) (female)
56 Joystick caution relay system
(19) and L66 (2) (female)
4) Defective joystick steering controller
1) Defective R SOL
2) Defective steering solenoid cut relay
3) Short circuit in wiring harness between joystick steering control-
ler C2 (female) (2) and (13)
Short circuit with ground, defective contact, or disconnection in
the following wiring harnesses
Steering (R) (right) Sol. system
57 4) Wiring harness between joystick steering controller C2 (female)
(short circuit, disconnection)
(2) and L84 (2)
5) Wiring harness between joystick steering controller C2 (female)
(13) and L67 (3)
6) Wiring harness between steering solenoid cut relay L67 (5) and
L84 (1)
1) Defective L SOL
2) Defective steering solenoid cut relay
3) Short circuit in wiring harness between joystick steering control-
ler C2 (female) (3) and (14)
Short circuit with ground, defective contact, or disconnection in
the following wiring harnesses
Steering (L) (left) Sol. system
58 4) Wiring harness between joystick steering controller C2 (female)
(short circuit, disconnection)
(3) and L83 (2)
5) Wiring harness between joystick steering controller C2 (female)
(14) and L67 (3)
6) Wiring harness between steering solenoid cut relay L67 (5) and
L83 (1)
1) Defective R SOL
2) Short circuit with power source in wiring harness between joy-
Steering R (right) Sol. system stick steering controller C2 (female) (2) and L84 (2)
59
(short circuit with power source) 3) Defective joystick steering controller
1) Defective L SOL
2) Short circuit with power source in wiring harness between joy-
Steering L (left) Sol. system stick steering controller C2 (female) (3) and L83 (2)
60
(short circuit with power source) 3) Defective joystick steering controller
20-754 WA700-3
(10)
Action by controller Problem that appears on Trouble-

Condition when normal when abnormality is machine when there is shooting
(voltage, current, resistance) detected abnormality code
1) Joystick caution relay: (voltage between C2 (9) and

C2 (19): 20 – 30 V)
2) Resistance of relay coil between joystick steering
controller C2 (female) (9) and C2 (female) (19): 200
– 400 z Joystick caution
Caution output: OFF J-1
3) Resistance between joystick steering controller C2 actuated
(female) (9) and chassis ground: Min. 1 Mz
4) Resistance between joystick steering controller C2
(female) (19) and chassis ground:
Min. 1 Mz
1) Steering solenoid cut relay: ON (voltage between

L67 (1) and (2): 20 – 30 V)
2) Resistance of steering R solenoid: 10 – 20 z
Steering R, L solenoid
(female) (2), (13) and chassis ground: Min. 1 Mz
output: OFF Impossible to use
Resistance of the following wiring harnesses: Less
and steering solenoid joystick
than 1 z J-2
cut relay output: OFF and joystick caution
4) Wiring harness between joystick steering controller
and caution relay output: actuated
C2 (female) (2) and L84 (female) (2)
OFF
6) Wiring harness between steering solenoid cut relay
L67 (female) (5) and L84 (female) (1)
1) Steering solenoid cut relay: ON (voltage between

L67 (1) and (2): 20 – 30 V)
2) Resistance of steering L solenoid: 10 – 20 z
(female) (3), (14) and chassis ground: Min. 1 Mz
Resistance of the following wiring harnesses: Less
than 1 z J-3
OFF
6) Wiring harness between steering solenoid cut relay
L67 (female) (5) and L83 (female) (1)
1) Joystick lever at neutral
Voltage between joystick steering controller C2 J-4
(female) (2) and chassis ground: Less than 1 V
OFF
1) Joystick lever at neutral
Voltage between joystick steering controller C2 J-5
(female) (3) and chassis ground: Less than 1 V
OFF
WA700-3 20-755
(10)
Failure code Abnormal system Nature of abnormality
1) Defective steering SOL cut relay

61 Steering Sol. cut relay system
(1) and L67 (1)
1) Defective joystick neutral switch

62 Joystick neutral switch system (11) and JL1 (6)
3) Defective contact or disconnection in wiring harness between
JL1 (7) and chassis ground
1) Defective joystick potentiometer

2) Short circuit with power source, short circuit with ground,
defective contact, or disconnection in wiring harness between
joystick steering controller C3A (female) (3) and JL1 (3)
3) Short circuit with power source, defective contact, or
63 Joystick potentiometer system disconnection in wiring harness between joystick steering
controller C3A (female) (7) and JL1 (4)
4) Short circuit with power source, short circuit with ground,
defective contact, or disconnection in wiring harness between
joystick steering controller C3A (female) (17) and JL1 (5)
20-756 WA700-3
(10)
Action by controller Problem that appears on Trouble-

Condition when normal when abnormality is machine when there is shooting
(voltage, current, resistance) detected abnormality code
1) Resistance between joystick steering controller C1 and steering solenoid joystick
J-6
(female) (1) and chassis ground: 200 – 400 z cut relay output: OFF and joystick caution
OFF
(female) (11) and chassis ground:
Min. 1 Mz (when joystick is at neutral) J-7
Less than 1 z (joystick at angle of ± 5 – 15º from
neutral)
OFF
1) Voltage between joystick steering controller C3A
(female) (3) and C3A (17): 0.5 – 4.5 V (voltage J-8
when joystick is at neutral: Approx. 2.5 V)
OFF
WA700-3 20-757
(10)
Troubleshooting Electrical circuit diagram for joystick steering system
Electrical circuit diagram for joystick steering system
20-758 WA700-3
(10)
Troubleshooting J-1
J-1 Failure code [56] (Short circuit, disconnection in caution relay output)
is displayed
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
a Always turn the starting switch OFF before disconnecting any connector.
Cause Remedy

4 YES
YES between C2
3 (female) (19) and Short circuit with chassis
Is resistance chassis normal? ground in wiring harness Repair or
YES between C2 • Disconnect C2. NO between C2 (female) (19) replace
(female) (9) and • Min. 1 Mz and L66 (female) (2)
chassis normal? • Turn starting Short circuit with chassis
2
• Disconnect C2. switch OFF. ground in wiring harness Repair or
Is resistance
• Min. 1 Mz NO between C2 (female) (9) replace
YES between C2 (male)
(9) and C2 (female) • Turn starting and L66 (female) (1)
(19) normal? switch OFF.
Disconnection in wiring
5 YES harness between C2 Repair or
1 • Disconnect C2.
Is failure code • 200 – 400 z Is resistance
displayed when L66 • Turn starting between C2 (female) (2)
is replaced with switch OFF. NO Disconnection in wiring
other relay of same (female) (1) normal?
type? replace
• Disconnect C2 NO (female) (9) and L66
• Turn starting and L66. (female) (1)
switch OFF. • Max. 1 z
• Interchange L66 • Turn starting switch OFF.
with other relay Defective joystick caution
Replace
of same type. NO relay
• Turn starting
switch ON.
J-1 Related electrical circuit diagram
WA700-3 20-759
(10)
Troubleshooting J-2
J-2 Failure code [57] (Short circuit in steering right solenoid (detected when output))
is displayed
selector switch ON.
Cause Remedy
4 YES Defective joystick

controller Replace
Is resistance
3 (female) (2) and harness between C2
(13) normal? (female) (2) and L84
(female) (2) and between
YES between C2 • Min. 1 Mz NO replace
C2 (female) (13) and L67
(female) (13) and • Turn starting (female) (3)
2 chassis normal? switch OFF. Short circuit with chassis
Is resistance • Disconnect C2.
YES between C2 • Min. 1 Mz ground in wiring harness Repair or
(female) (2) and • Turn starting NO between C2 (female) (13) replace
chassis normal? switch OFF. and L67 (female) (3)
1
Is failure code
• Disconnect C2 Short circuit with chassis
displayed when L67 ground in wiring harness Repair or
• Turn starting
is replaced with between C2 (female) (2) replace
switch OFF. NO
other relay of same and L84 (female) (2)
type? • Disconnect C2
• Turn starting and L84.
switch OFF. Defective steering
Replace
• Interchange with NO solenoid cut relay
other relay of
same type.
• Turn starting
switch ON.
20-760 WA700-3
(10)
Troubleshooting J-3
J-3 Failure code [58] (Short circuit in steering left solenoid (detected when output))
is displayed
selector switch ON.
Cause Remedy

controller Replace
Is resistance
(14) normal? (female) (3) and L83
(female) (2) and between
C2 (female) (14) and L67
(female) (13) and • Turn starting (female) (3)
Is resistance • Disconnect C2.
(female) (3) and • Turn starting NO between C2 (female) (14) replace
chassis normal? switch OFF. and L67 (female) (3)
1
Is failure code
• Disconnect C2 Short circuit with chassis
displayed when L67 ground in wiring harness Repair or
• Turn starting
is replaced with between C2 (female) (3) replace
switch OFF. NO
other relay of same and L83 (female) (2)
• Turn starting and L83.
Replace
other relay of
same type.
• Turn starting
switch ON.
WA700-3 20-761
(10)
Troubleshooting J-4
J-4 Failure code [59] (Short circuit in steering right solenoid (HOT end)) is displayed
selector switch ON.
Cause Remedy

Replace
Is voltage steering controller
between C2
(female) (2) and Short circuit with power
chassis normal? source in wiring harness Repair or
• Max. 1 V NO between C2 (female) (2) replace
switch ON.
20-762 WA700-3
(10)
Troubleshooting J-5
J-5 Failure code [60] (Short circuit in steering left solenoid (HOT end)) is displayed
selector switch ON.
a Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket
adapter).
Cause Remedy

Replace
Is voltage steering controller
between C2
(female) (3) and Short circuit with power
chassis normal? source in wiring harness Repair or
• Max. 1 V NO between C2 (female) (3) replace
switch ON.
WA700-3 20-763
(10)
Troubleshooting J-6
J-6 Failure code [61] (Short circuit, disconnection in steering solenoid cut relay
output) is displayed
selector switch ON.
Cause Remedy

controller Replace
Is resistance
YES between L67
3 (female) (2) and
Is resistance chassis normal? Repair or
harness between L67
(female) (2) – LR5 (2) –
(female) (1) and • Turn starting chassis ground
Is resistance • Disconnect L67.
(female) (1) and L67 • Turn starting NO between C1 (female) (1) replace
(female) (1) normal? switch OFF. and L67 (female) (1)
1
Is failure code
• Disconnect C1 Defective contact or
displayed when L67
• Turn starting disconnection in wiring Repair or
is replaced with harness between C1 replace
switch OFF. NO
other relay of same (female) (1) and L67
and L67. (female) (1)
• Turn starting
Replace
other relay of
same type.
• Turn starting
switch ON.
20-764 WA700-3
(10)
Troubleshooting J-7
J-7 Failure code [62] (Short circuit, disconnection in joystick steering neutral signal)
is displayed
selector switch ON.
Cause Remedy
Defective joystick
YES controller or defective
joystick potentiometer Replace
mount
2
Is resistance
YES between C5 4 YES disconnection in wiring Repair or
harness between JL1
(female) (11) and Is resistance replace
(male) (6) and C5 (female)
chassis normal? YES between JL1 (11)
3 (male) (7) and
• Disconnect C5. Defective contact or
chassis normal? Repair or
• Operate joystick Is resistance disconnection in wiring
1 lever fully to left between JL1 • Disconnect JL1. NO harness between JL1 replace
Is resistance or right. NO (female) (6) and • Max. 1 z (male) (7) – LR5 (3)
between C5 • Max. 1 z (7) normal? chassis ground
(female) (11) and • Disconnect JL1.
chassis normal? Defective neutral switch Replace
• Operate joystick NO
• Disconnect C5. lever fully to left or right.
• Min. 1 Mz • Max. 1 z Short circuit with chassis
5 YES ground in wiring harness Repair or
Is resistance between JL1 (male) (6) replace
between JL1 (male) and C5 (female) (11)
NO (6) and chassis
ground normal?
Defective neutral switch Replace
• Disconnect JL1 NO
and C5.
• Min. 1 Mz
WA700-3 20-765
(10)
Troubleshooting J-8
J-8 Failure code [63] (Short circuit, disconnection in joystick steering lever
potentiometer system) is displayed
selector switch ON.
a After connecting the T-adapter, turn the starting switch ON.
Cause Remedy
Defective joystick Replace, adjust

YES
potentiometer, neutral neutral
2 position misaligned position again
Does voltage Short circuit with power
YES source, short circuit with
between C3A (3)
and (17) change? 3 YES ground, defective contact, or Repair or
Does resistance 3 replace
1 harness between C3A
• Operate joystick between JL1 (female) (3) and JL1 (male)
Is voltage lever to left or NO (female) (3) and (3)
between C3A (7) right (0.5 – 4.5 V). (5) change? Defective joystick
Replace
and (17) normal? • Operate joystick NO potentiometer
lever to left or
• 4.9 – 5.1 V right (0.2 – 5 kz)
Defective joystick
steering controller Replace
NO
20-766 WA700-3
(10)
Troubleshooting J-9
J-9 Abnormality in power source, voltage
selector switch ON.
Cause Remedy

Is voltage steering controller Replace
between C2
(female) (1), (12) Defective contact or
and chassis disconnection in wiring
normal? Repair or
harness between C2
• 20 – 30 V NO replace
(female) (1), (12) – FS11
• Turn starting (10) – fuse
switch ON.
WA700-3 20-767
(10)
Troubleshooting J-10
J-10 Abnormality in joystick steering ON-OFF signal system
selector switch ON.
Cause Remedy
YES Defective joystick

Replace
steering controller
1
Is voltage
3 YES Defective system cut-off
between C3B Replace
Is voltage switch
(female) (14) and
chassis normal? YES between JL1
2 (male) (1) and Defective contact or
• 20 – 30 V Is resistance between chassis normal? Repair or
• Turn starting C3B (female) (14) and replace
• 20 – 30 V NO harness between fuse –
switch ON. chassis normal when
• Turn starting FS2 (10) – JL1 (male) (1)
NO JL1 (male) (2) is
grounded to chassis? switch ON. Defective contact or
disconnection in wiring Replace
• Turn starting switch,
harness between C3B
switch OFF. NO or repair or
(female) (14) – L82 (1), (2) –
• Disconnect JL1 JL1 (male) (2), or defective replace
and C3B. joystick ON-OFF switch
• Max. 1 z
20-768 WA700-3
(10)
J-11 Disconnection in steering right solenoid
selector switch ON.
Cause Remedy

Is resistance between steering controller Replace
YES L67 (female) (5) and
chassis normal when
grounded to chassis? harness between L67 Repair or
YES C2 (female) (13) and • Max. 1 z NO
chassis normal when (female) (1)
L67 (female) (3) is • Turn starting
Is resistance between grounded to chassis? switch OFF.
• Disconnect L67. disconnection in wiring
YES C2 (female) (2) and • Max. 1 z harness between C2 Repair or
chassis normal when • Turn starting NO replace
L84 (female) (2) is
1 grounded to chassis?
• Disconnect C2
• Max. 1 z and L67.
Is resistance disconnection in wiring Repair or
• Turn starting
between L84 (1) NO harness between C2 replace
switch OFF.
and (2) normal? (female) (2) and L84
• Disconnect C2.
(female) (2)
• 10 – 20 z
Defective joystick
• Turn starting Replace
steering right solenoid
switch OFF. NO
valve
• Disconnect L84.
WA700-3 20-769
(10)
J-12 Disconnection in steering left solenoid
selector switch ON.
Cause Remedy

Is resistance between steering controller Replace
YES L67 (female) (5) and
chassis normal when
grounded to chassis? harness between L67 Repair or
YES C2 (female) (14) and • Max. 1 z NO
chassis normal when (female) (1)
L67 (female) (3) is • Turn starting
Is resistance between grounded to chassis? switch OFF.
• Disconnect L67. disconnection in wiring
YES C2 (female) (3) and • Max. 1 z harness between C2 Repair or
chassis normal when • Turn starting NO replace
L83 (female) (2) is
1 grounded to chassis?
• Disconnect C2
Is resistance • Max. 1 z and L67.
between L83 • Turn starting disconnection in wiring Repair or
(male) (1) and (2) switch OFF. NO harness between C2 replace
normal? • Disconnect C2.
(female) (2)
• 10 – 20 z
Defective joystick
• Turn starting Replace
steering left solenoid
switch OFF. NO
valve
• Disconnect L83.
20-770 WA700-3
(10)
Troubleshooting of
AJSS (advanced joystick steering system)
control system
(A mode)
AJSS (advanced joystick steering system) specification
Judgement table for AJSS (advanced joystick steering system) control system ........................................ 20-802
Operations of controller against abnormality and conditions of machine caused by abnormality............... 20-804
Electric circuit diagram related to AJSS (Advanced Joystick Steering System) control.............................. 20-808
A-1 Error code [56] (Disconnection or short circuit with chassis ground in
caution buzzer relay system) is displayed ...................................................................................... 20-810
steering lever angle sensor system) is displayed ........................................................................... 20- 811
A-3 Error code [58] (Deviation of steering lever angle sensor and frame
angle sensor signals) is displayed .................................................................................................. 20-812
frame angle sensor system) is displayed........................................................................................ 20-813
steering lever lock pressure switch system) is displayed ............................................................... 20-814
steering neutral interlock relay system) is displayed ...................................................................... 20-815
A-7 Error code [63] (Disconnection, short circuit with chassis ground, or
short circuit with power source in steering main pressure control EPC
solenoid system) is displayed ......................................................................................................... 20-816
A-8 Steering speeds in both directions are different.................................................................................. 20-817
A-9 Abnormality in console switch (adjustment of steering lever angle sensor
and frame angle sensor is impossible) ........................................................................................... 20-818
A-10 Abnormality in power source and voltage........................................................................................... 20-819
WA700-3 20-801
(10)
Judgement table for AJSS (advanced joystick steering
Troubleshooting system) control system
Judgement table for AJSS (advanced joystick steering system)

control system
Self-diagnosis display (Display of abnormality)
Disconnection, short circuit with chassis ground, or short circuit with power source in steering main pres-
Location of failure
Disconnection or short circuit with chassis ground in steering lever lock pressure switch system
Disconnection or short circuit with chassis ground in steering neutral interlock relay system
Disconnection or short circuit with chassis ground in steering lever angle sensor system
Deviation of steering lever angle sensor and frame angle sensor potentiometer signals
Disconnection or short circuit with chassis ground in caution buzzer relay system
Disconnection or short circuit with chassis ground in frame angle sensor system
Diagnosis code when failure code is not displayed

sure control EPC solenoid system
Failure
code
Failure mode
56 57 58 59 60 62 63
1 Engine cannot be started Q E-1
2 Steering speed is heightened Q —
3 Steering speed is lowered Q H-7, H-10, H-13, H16
4 Response of steering system is heightened Q —
5 Response of steering system is lowered Q H-7, H-10, H-13, H16
6 Steering speeds in both directions are different Q Q Q —
7 Machine is steered suddenly after engine is started Q —
8 Engine can be started while machine is steered Q —
9 Caution buzzer does not sound or keeps sounding Q M-22
Diagnosis code when failure code is displayed J-1 J-2 J-3 J-4 J-5 J-6 J-7
20-802 WA700-3
(10)
Operations of controller against abnormality and
Troubleshooting conditions of machine caused by abnormality
Operations of controller against abnormality and conditions of

machine caused by abnormality
Failure code Abnormal system Contents of abnormality
1) Defective caution buzzer relay

2) Disconnection, defective contact, or short circuit with chassis ground
in wiring harness between T/M and J/S controller C2 (female) (9) –
Disconnection or short L66 (female) (1)
circuit with chassis ground 3) Disconnection or defective contact in wiring harness between T/M and
56
in caution buzzer relay J/S controller C2 (female) (19) – L66 (female) (2)
system 4) Defective T/M and J/S controller
1) Improper installation (Misalignment) of steering lever angle sensor

2) Defective steering lever angle sensor
Disconnection or short 3) Disconnection, defective contact, or short circuit with chassis ground
circuit with chassis ground in wiring harness between T/M and J/S controller C3A (female) (3) –
57 in steering lever angle JS2 (female) (1)
sensor (potentiometer) 4) Defective T/M and J/S controller
system
1) Improper installation (Misalignment) of steering lever angle sensor

2) Defective steering lever angle sensor
3) Improper installation (Misalignment) of frame angle sensor
4) Defective frame angle sensor
Deviation of steering lever 5) Disconnection, defective contact, or short circuit with chassis ground
58 angle sensor and frame in wiring harness between T/M and J/S controller C3A (female) (3) –
angle sensor signals JS2 (female) (1)
in wiring harness between T/M and J/S controller C3A (female) (13) –
L84 (female) (A)
7) Defective T/M and J/S controller
1) Improper installation (Misalignment) of frame angle sensor

2) Defective frame angle sensor
Disconnection or short 3) Disconnection, defective contact, or short circuit with chassis ground
circuit with chassis ground in wiring harness between T/M and J/S controller C3A (female) (13) –
59 L84 (female) (A)
in frame angle sensor
(potentiometer) system 4) Defective T/M and J/S controller
20-804 WA700-3
(10)
Normal condition Operation of controller Condition of machine Diagnosis

(Voltage, current, resistance) against abnormality caused by abnormality code
1) Voltage between relay L66 (1) – chassis Does not operate at all. Caution buzzer does not
ground when caution buzzer is turned on: 20 – sound or keeps sounding.
30 V
2) Resistance between T/M and J/S controller C2
(female) (9) – (19), caution buzzer relay: 200 –
A-1
400 z
(female) (9) – L66 (female) (1): Max. 1 z
(female) (19) – L66 (female) (2): Max. 1 z
1) Voltage between T/M and J/S controller C3A 1) Turns off steering Steering speeds in both
(7) – (16): 0.5 – 4.5 V main pressure control directions are different.
2) Resistance between steering lever angle sen- EPC solenoid output.
sor JS2 (male) (1) – (2): 0 – 5 kz 2) Controls steering lever
angle sensor signal A-2
voltage as input
voltage.
1) Voltage between T/M and J/S controller C3A Turns off steering main Steering speeds in both
(7) – (16): 0.5 – 4.5 V pressure control EPC directions are different.
2) Voltage between T/M and J/S controller C3A solenoid output.
(3) – (16): 0.5 – 4.5 V
3) Resistance between steering lever angle
sensor JS2 (male) (1) – (2): 0 – 5 kz A-3
4) Resistance between frame angle sensor L84
(male) (1) – (2): 0 – 5 kz
1) Voltage between T/M and J/S controller C3A 1) Turns off steering Steering speeds in both
(7) – (16): 0.5 – 4.5 V main pressure control directions are different.
2) Resistance between frame angle sensor L84 EPC solenoid output.
(male) (1) – (2): 0 – 5 kz 2) Controls frame angle
sensor signal voltage A-4
as input voltage.
WA700-3 20-805
(10)
Failure code Abnormal system Contents of abnormality
1) Defective steering lock pressure switch

in wiring harness between T/M and J/S controller C3B (female) (9) –
L83 (female) (1)
3) Disconnection or defective contact in wiring harness between T/M and
J/S controller L83 (female) (2) – chassis ground
Disconnection or short
circuit with chassis ground
60
in steering lever lock
pressure switch system
1) Defective steering neutral interlock relay

in wiring harness between T/M and J/S controller C2 (female) (8) –
Disconnection or short
L86 (female) (1)
circuit with chassis ground
62 3) Disconnection or defective contact in wiring harness between L86
in steering neutral interlock
(female) (2) – chassis ground
relay system
1) Defective steering main pressure control EPC solenoid system

Disconnection, short circuit 2) Disconnection, defective contact, short circuit with chassis ground,
with chassis ground, or short circuit, or short circuit with power source in wiring harness
short circuit with power between T/M and J/S controller C2 (female) (7) – L82 (female) (2)
63 3) Short circuit with chassis ground in wiring harness between T/M and
source in steering main
pressure control EPC J/S controller C2 (female) (17) – L82 (female) (1)
solenoid system 4) Defective T/M and J/S controller
20-806 WA700-3
(10)
Normal condition Operation of controller Condition of machine Diagnosis

(Voltage, current, resistance) against abnormality caused by abnormality code
Voltage between T/M and J/S controller C3B (9) – Turns on caution buzzer. (In case of disconnection)
chassis ground: 1) Transmission is kept
• When steering lock lever is in LOCK: 20 – 30 V in N.
• When steering lock lever is in FREE: Max. 1 V 2) Steering system is
operable normally.
(In case of short circuit

with chassis ground) A-5
1) Machine can travel
although steering
system is locked.
2) Gear is shifted in F or
R.
3) Gear is shifted in F or
R.
Voltage between T/M and J/S controller C2 (8) – Does not operate at all. 1) Engine can be started
chassis ground: while machine is
• When steering lock lever is in NEUTRAL: steered.
Max. 1 V 2) Machine is steered
suddenly after engine A-6
is started
3) Engine cannot be
started.
Current flowing between T/M and J/S controller C2 Turns off steering main 1) Response of steering
(7) – (17): 600 ± 80 mA pressure control EPC system is lowered.
solenoid output. 2) Steering speed is
lowered.
3) Response of steering A-7
system is heightened
4) Steering speed is
heightened
WA700-3 20-807
(10)
Electric circuit diagram related to AJSS (Advanced
Troubleshooting Joystick Steering System) control
Electric circuit diagram related to AJSS (Advanced Joystick

Steering System) control
20-808 WA700-3
(10)
Electric circuit diagram related to AJSS (Advanced
Troubleshooting Joystick Steering System) control
a This circuit diagram is made by extracting the part of the transmission & joystick steering controller from the
general circuit diagram.
WA700-3 20-809
(10)
Troubleshooting A-1
A-1 Error code [56] (Disconnection or short circuit with chassis ground in caution
buzzer relay system) is displayed
has been removed.
a When the joystick steering lever is not being used, leave it at the neutral position.
Cause Remedy
4 YES Defective T/M and J/S

Replace
YES between C2
(female) (9) and Short circuit or short circuit
3 chassis ground with chassis ground in
Is resistance normal? wiring harness between C2 Repair or
YES between C2 NO (female) (9) – L66 (female) replace
• Min. 1 Mz
(female) (9) and L66 • Turn starting (1)
2 (female) (1) normal? switch OFF. Disconnection or defective
Is resistance
• Disconnect C2 and L66.
YES between L66 • Max. 1 z contact in wiring harness Repair or
(female) (2) and • Turn starting NO between C2 (female) (9) – replace
chassis ground switch OFF. L66 (female) (1)
1 normal?
• Disconnect C2 Disconnection or defective
Is resistance • Max. 1 z and L66. contact in wiring harness Repair or
between L66 • Turn starting
(male) (1) and (2) NO between C2 (female) (19) – replace
switch OFF. L66 (female) (2)
• 200 – 400 z
• Turn starting Defective caution buzzer
relay Replace
switch OFF. NO
• Disconnect L66.
A-1 Related electrical circuit diagram
20-810 WA700-3
(10)
Troubleshooting A-2
A-2 Error code [57] (Disconnection or short circuit with chassis ground in steering
lever angle sensor system) is displayed
has been removed.
Cause Remedy
Improper installation of Replace or

YES steering lever angle adjust neutral
2 sensor (Deviation of position
neutral position)
Does voltage Disconnection, defective
YES
between C3A (3) contact, short circuit with
and (16) change?
3 YES chassis ground, or short circuit Repair or
Does resistance with power source in wiring replace
1
• Lean steering between JS2 harness between C3A (female)
lever to right or NO (male) (1) and (3) (3) – JS2 (female) (1)
Is voltage
between C3A (7) left change? Defective steerintg lever
• 0.5 – 4.5 V Replace
and (16) normal? • Lean steering NO angle sensor
• Starting switch lever to right or
• 4.9 – 5.1 V ON. left
• Starting switch
• 0.2 – 5 kz Defective T/M and J/S
ON. Replace
NO • Starting switch OFF. controller
• Disconnect JS2.
WA700-3 20-811
(10)
Troubleshooting A-3
A-3 Error code [58] (Deviation of steering lever angle sensor and frame angle sensor
signals) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if
the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related
connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the Cause Remedy
neutral position.
a Always connect any disconnected connectors before going on to
the next step. Improper installation of
Replace or
YES steering lever angle
adjust neutral
sensor (Deviation of
position
neutral position)
2
Improper installation of
4 YES frame angle sensor Replace or
YES Does voltage adjust neutral
between C3A (3) (Deviation of neutral
and (16) change? Does voltage position
YES position)
between C3A (13)
3 and (16) change?
• Lean steering
1 Does resistance
lever to right or Go to A.
between JS2 • Change frame NO
Is voltage left
• 0.5 – 4.5 V NO (male) (1) and (3) angle
between C3A (7) change?
• Starting switch • 0.5 – 4.5 V
and (16) normal?
ON. • Lean steering • Start engine. Defective steerintg lever
Replace
• 4.9 – 5.1 V lever to right or NO angle sensor
• Starting switch left
ON. • 0.2 – 5 kz
• Starting switch OFF. Defective T/M and J/S Replace
NO • Disconnect JS2. controller
Disconnection, defective
contact, short circuit with
chassis ground, or short circuit Repair or
6 YES replace
with power source in wiring
Is harness between C3A
harness between C3A (female)
(female) (3) and JS2
YES (female) (1) normal (no (13) – L84 (female) (A)
5 disconnection and short
circuit with chassis
Disconnection, defective
Does resistance ground or power source)? contact, short circuit with
chassis ground, or short circuit Repair or
between L84 • Disconnect C3A, NO with power source in wiring replace
From A
(male) (A) and (C) JS2. harness between C3A (female)
change? (3) – JS2 (female) (1)
• Change frame Defective frame angle

Replace
angle NO sensor
• 0.2 – 5 kz
• Start engine.
• Disconnect L84.
20-812 WA700-3
(10)
Troubleshooting A-4
A-4 Error code [59] (Disconnection or short circuit with chassis ground in frame
angle sensor system) is displayed
has been removed.
Cause Remedy
Improper installation of Replace or

YES frame angle sensor adjust neutral
2 (Deviation of neutral position
position)
YES Does voltage Disconnection, defective
between C3A (13) contact, short circuit with
3 YES Repair or
and (16) change? chassis ground, or short circuit
Does resistance with power source in wiring replace
1
• Change frame between L84 harness between C3A (female)
(13) – L84 (female) (A)
Is voltage angle NO (male) (A) and (C)
between C3A (7) • 0.5 – 4.5 V change? Defective frame angle
and (16) normal? • Start engine. Replace
• Change frame NO sensor
angle
• 4.9 – 5.1 V
• 0.2 – 5 kz
• Start engine. Defective T/M and J/S
ON. Replace
NO • Disconnect L84. controller
WA700-3 20-813
(10)
Troubleshooting A-5
lever lock pressure switch system) is displayed
has been removed.
a When the steering lock lever is in the LOCK position, the steering lock pressure switch is opened (since the
oil pressure is not heightened).
Cause Remedy

Replace
YES between L83
(female) (2) and
3 chassis ground Disconnection or defective
Is resistance normal? contact in wiring harness Repair or
between C3B replace
YES
(female) (9) and • Max. 1 z NO between L83 (female) (2) –
chassis ground
2 chassis ground • Turn starting
normal? switch OFF. Disconnection or defective
Is voltage • Disconnect L83. contact in wiring harness Repair or
YES between C3B (9) • Min. 1 Mz
• Turn starting between C3B (female) (9) – replace
and chassis NO
1 ground normal?
• Disconnect C3B Short circuit with chassis
Is resistance •0– 2V and L83. ground in wiring harness Repair or
between L83 • Start engine.
between C3B (female) (9) replace
(male) (1) and (2) • When steering NO
normal? – L83 (female) (1)
lock lever is in
• Max. 1 z FREE.
• Disconnect L83. Defective steering lock
Replace
• Start engine. NO pressure switch
When steering
lock lever is in FREE:
Max. 1z
When steering
lock lever is in LOCK:
Min. 1 Mz
20-814 WA700-3
(10)
Troubleshooting A-6
neutral interlock relay system) is displayed
has been removed.
Cause Remedy
YES Defective steering neutral

relay Replace
1 4 YES Defective T/M and J/S

Is resistance controller Replace
If L86 relay is YES between L86
replaced, is (female) (2) and
3 chassis ground
Disconnection or defective
system normal? Is resistance contact in wiring harness Repair or
normal?
between C2 between L86 (female) (2) – replace
YES • Min. 1 z NO chassis ground
• Replace L127 (female) (8) and
with normal chassis ground
• Turn starting
2 switch OFF.
relay. normal? Short circuit with chassis
Is resistance
Min. 1 Mz • Disconnect L86. ground in wiring harness Repair or
between C2 between C2 (female) (8) –
NO (female) (8) and L86
(female) (1) normal?
• Disconnect C2 Disconnection or
• Max. 1 z and L86. defective contact in
NO wiring harness between replace
switch OFF. C2 (female) (8) – L86
• Disconnect C2 (female) (1)
and L86.
WA700-3 20-815
(10)
Troubleshooting A-7
A-7 Error code [63] (Disconnection, short circuit with chassis ground, or short cir-
cuit with power source in steering main pressure control EPC solenoid system)
is displayed
has been removed.
Cause Remedy
4 YES
Go to A.
Is resistance
YES between C2 Short circuit of wiring
Is resistance (17) normal? (female) (7) – L82 (female) Repair or
(2) with wiring harness replace
YES between C2 • Min. 1 Mz NO between C2 (female) (17)
(female) (17) and
chassis ground • Turn starting and L82 (female) (1)
2
normal? switch OFF.
• Disconnect C2 and L82. Repair or
YES between C2 • Min. 1 Mz ground in wiring harness
(female) (7) and • Turn starting NO between C2 (female) (17) – replace
chassis ground switch OFF. L82 (female) (1)
1 normal?
If L82 is replaced • Disconnect C2 Short circuit with chassis
with other same • Min. 1 Mz and L82. Repair or
EPC solenoid, • Turn starting between C2 (female) (7) – replace
does failure code switch OFF. NO
L82 (female) (2)
appear? • Disconnect C2
• Turn starting and L82. Defective steering main
switch OFF. pressure control EPC Replace
• Replace with NO solenoid
other same EPC
solenoid.
• Turn starting 5 YES Defective T/M and J/S
switch ON. Is resistance controller Replace
between C2
From A (female) (7) and
chassis ground Short circuit with power
normal? source in wiring harness Repair or
• Max. 1 V NO between C2 (female) (7) – replace
• Disconnect C2 L82 (female) (2)
and L82.
• Turn starting
switch ON.
20-816 WA700-3
(10)
Troubleshooting A-8
A-8 Steering speeds in both directions are different
a If an error code is displayed, check the parts corresponding to it.
Cause Remedy
Deviation of steering
lever angle sensor or Repair or
frame angle sensor replace
potentiometer
WA700-3 20-817
(10)
Troubleshooting A-9
A-9 Abnormality in console switch (adjustment of steering lever angle sensor and
frame angle sensor is impossible)
Cause Remedy

controller Replace
Is voltage between
YES C3A (female) (19)
normal? Repair or
Is resistance source in wiring harness
YES between C3A • Max. 1 V NO between C3A (female) (19) replace
(female) (6) and JS3 • Turn starting switch – JS4 (male) (1)
2 (female) (1) normal? ON.
Is resistance • Disconnect C3A and JS4. Disconnection or defective
• Max. 1 z • Turn starting switch ON contact in wiring harness Repair or
YES between C3A
(female) (19) and • Turn starting NO between C3A (female) (6) – replace
JS4 (male) (1) switch OFF. JS3 (female) (1)
1
normal? • Disconnect C3A
Is resistance Disconnection or defective
between console • Max. 1 z and JS3. contact in wiring harness
switch JS3 (male) • Turn starting Replace
between C3A (female) (19)
(1) and JS4 (female) switch OFF. NO
– JS4 (male) (1)
(1) normal? • Disconnect C3A
• When left armrest is and JS4.
at rearmost position Defective console switch Replace
(switch is ON): NO
Max. 1 z
• When left armrest is not at rearmost
position (switch is OFF): Min. 1 Mz
• Disconnect JS3 and JS4.
20-818 WA700-3
(10)
Troubleshooting A-10
A-10 Abnormality in power source and voltage
Cause Remedy
YES Defective T/M and J/S Replace

1 controller
Is voltage between Short circuit with chassis
C1 (7), (13), C2 (1), ground, disconnection, or
(12) and C1 (6),
(12), C2 (11), (21)
2 YES defective contact in wiring
Repair or
Is resistance harness between C1
normal?
between C1
replace
(female) (7), (13), C2
• 20 – 30 V (female) (6), (12), C2 (female) (1), (12) – fuse
• Turn starting (female) (11), (21)
NO and chassis ground Disconnection or defective
switch ON. normal?
contact in wiring harness Repair or
• Max. 1 z NO between C1 (female) (6), replace
• Turn starting (12), C2 (female) (1), (12) –
switch OFF. chassis ground
• Disconnect C1
and C2.
WA700-3 20-819
(10)
Troubleshooting of engine control system
(EA mode)
Serial No.: 51001 an up
Method of error code display ...................................................................................................................... 20-853
Action taken by controller and condition of machine when error code is displayed .................................... 20-856
Electrical circuit diagram for engine control system .................................................................................... 20-864
EA-1 Error code [111] (Abnormality in controller memory) ........................................................................ 20-866
EA-2 Error code [112] (Abnormality in timing rail actuator) ....................................................................... 20-866
EA-3 Error code [113] (Abnormality with electric current in timing rail actuator system)........................... 20-867
EA-4 Error code [115] (Abnormality in engine speed sensor 2 system).................................................... 20-868
EA-5 Error code [116] (Abnormality [high level] in timing rail pressure sensor system)............................ 20-870
EA-6 Error code [117] (Abnormality [low level] in timing rail pressure sensor system) ............................. 20-871
EA-7 Error code [118] (Abnormality [high level] in fuel pump pressure sensor system) ........................... 20-872
EA-8 Error code [119] (Abnormality [low level] in fuel pump pressure sensor system)............................. 20-873
EA-9 Error code [121] (Abnormality in engine speed sensor 1 system).................................................... 20-874
EA-10 Error code [122] (Abnormality [high level] in boost pressure sensor system) .................................. 20-875
EA-11 Error code [123] (Abnormality [low level] in boost pressure sensor system).................................... 20-876
EA-12 Error code [131] (Abnormality [high level] in accelerator sensor system) ........................................ 20-877
EA-13 Error code [132] (Abnormality [low level] in accelerator sensor system) ......................................... 20-878
EA-14 Error code [135] (Abnormality [high level] in oil pressure sensor system) ....................................... 20-879
EA-15 Error code [141] (Abnormality [low level] in oil pressure sensor system)......................................... 20-880
EA-16 Error code [143] (Abnormal drop in oil pressure (level 1)) ............................................................... 20-881
EA-17 Error code [144] (Abnormality [high level] in water temperature sensor system)............................. 20-882
EA-18 Error code [145] (Abnormality [low level] in water temperature sensor system) .............................. 20-883
EA-19 Error code [151] (Abnormal rise in water temperature).................................................................... 20-883
EA-20 Error code [153] (Abnormality [high level] in intake air temperature sensor system)....................... 20-884
EA-21 Error code [154] (Abnormality [low level] in intake air temperature sensor system) ........................ 20-884
EA-22 Error code [221] (Abnormality [high level] in atmospheric pressure sensor system) ....................... 20-885
EA-23 Error code [222] (Abnormality [low level] in atmospheric pressure sensor system)......................... 20-886
EA-24 Error code [234] (Overspeed) .......................................................................................................... 20-888
EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage) ............................................... 20-889
EA-26 Error code [259] (Abnormality in fuel shut-off valve) ........................................................................ 20-890
EA-27 Error code [261] (Abnormal rise in fuel temperature)....................................................................... 20-890
EA-28 Error code [263] (Abnormality [high level] in fuel temperature sensor system)................................ 20-891
EA-29 Error code [265] (Abnormality [low level] in fuel temperature sensor system) ................................. 20-891
EA-30 Error code [316] (Abnormality in fuel pump actuator system current).............................................. 20-892
EA-31 Error code [318] (Abnormality in fuel pump actuator) ...................................................................... 20-893
EA-32 Error code [343] (Abnormality in controller internal communication) ............................................... 20-893
EA-33 Error code [346] (Abnormality in controller power down) ................................................................. 20-894
WA700-3 20-851
(10)
EA-34 Error code [384] (Abnormality in preheating heater control system)................................................ 20-895
EA-35 Error code [415] (Abnormal drop in oil pressure (level 2)) ............................................................... 20-896
EA-36 Error code [423] (Abnormality [in range] in timing rail pressure sensor system).............................. 20-896
EA-37 Error code [431] (Abnormality [1] in idling validation switch system) ............................................... 20-898
EA-38 Error code [432] (Idling validation process error) ............................................................................. 20-900
EA-39 Error code [441] (Abnormality [low level] in battery voltage) ............................................................ 20-902
EA-40 Error code [442] (Abnormality [high level] in battery voltage) .......................................................... 20-902
EA-41 Error code [451] (Abnormality [high level] in fuel rail pressure sensor system) ............................... 20-903
EA-42 Error code [452] (Abnormality [low level] in fuel rail pressure sensor system)................................. 20-904
EA-43 Error code [455] (Abnormality in fuel rail actuator system current) .................................................. 20-905
EA-44 Error code [467] (Abnormality in timing rail actuator control) ........................................................... 20-906
EA-45 Error code [468] (Abnormality in fuel rail actuator control)............................................................... 20-906
EA-46 Error code [514] (Abnormality in fuel rail actuator)........................................................................... 20-906
EA-47 Error code [527] (Abnormality in dual output solenoid A system) .................................................... 20-907
EA-48 Error code [551] (Abnormality [2] in idling validation switch system) ............................................... 20-907
EA-49 Error code [554] (Abnormality [in range] in fuel rail pressure sensor) .............................................. 20-908
a This section gives an outline of the troubleshooting procedures for the electrical systems related to the
engine proper and the engine controller (for construction equipment).
When carrying out troubleshooting of the electrical system with the engine mounted on the machine, use this
section and the shop manual for the machine.
20-852 WA700-3
(10)
Troubleshooting Method of error code display
Method of error code display

• Error code display
1. An error code display device with tricolor lamps
is installed at the foot of the operator’s seat.
2. The error code display device is composed of
three lamps of different colors, e.g. orange (1),
yellow (2) and red (3), selector switch (4) and
diagnosis switch (5).
3. Checking blown lamps
1) When turning the engine starting switch ON:
When starting the engine starting switch
ON, the three lamps light up for about two
seconds to show if there is any blown lamp
and then go off, if there is none. At that time,
Example of display:
keep diagnosis switch (5) at the OFF posi-
When displaying error code [253]
tion.
2) Manual check:
It can be checked whether a lamp is blown
or not by turning diagnosis switch (5) ON,
after the engine starting switch has been
turned ON and if there is no engine trouble
occurred. If each of the three lamps lights
up, it is normal. A lamp which does not light
up may well be replaced, as it is all likely
b lo wn . I f t h ere i s a ny en gi ne t r ou bl e
occurred at that time, an error code is dis-
played.
4. Always keep diagnosis switch (5) at the OFF
position (normal position), except when seeing
an error code.
• An engine controller displays the engine con-

ditions in the following two modes.
1. Display of engine trouble
If any of the three color lamps lights up while the
engine is running, or when the engine starting
switch is in the ON position, it indicates that an
engine trouble has occurred and also the nature
and extent of such a trouble.
2. Display of error code
By calling an error code in the display after the
engine starting switch is turned ON but when the
engine is not run, a three-digit error code may
be confirmed through times that the lamp
flashes.
• Display of nature and extent of engine trouble

1. When the orange lamp lights up:
This indicates that the engine controller has
recorded some abnormality in the engine. The
device automatically regulates the engine output
depending upon nature of such abnormality.
2. When the yellow lamp lights up:
This indicates that some abnormality has
occurred in the engine, but that such abnormal-
ity is still light enough to tolerate the engine to
keep running.
WA700-3 20-853
(10)
Troubleshooting Method of error code display
3. When the red lamp lights up:

This indicates that some serious abnormality
has occurred in the engine, and that the engine
must be stopped immediately.
• Display of error code (Method for confirming

three-digit error code)
1. Turn the engine starting switch ON and turn
diagnosis switch (5) ON.
2. In this condition, the lamps light up and then go
off, if there is no blown lamp. (A function of
checking a blown lamp) If there is an engine
trouble occurred, meanwhile, an error code for
the trouble is displayed by the time that the red
lamp flashes. At that time, the orange (white)
lamp remains lit, while the error code is dis-
played.
3. Counting error code (Example: Case of Error
Code 253)
1) At first the yellow lamp flashes once.
(Starting display of error code)
2) All the lamps go off for about one second.
3) The red lamp repeats flashing so many
times as the third digit number of the error
code. (Example: 2 times)
times as the second digit number of the
error code. (Example: 5 times)
times as the first digit number of the error
code. (Example: 3 times)
9) The yellow lamp flashes once. (The end of
that error code number)
10) The processes of 2) through 9) are
repeated.
4. When plural troubles have occurred:
If it is suspected that more than two engine trou-
bles have occurred at a time, push up selector
switch (4) for about two seconds, then the dis-
play advances to the next error code number. In
case only one trouble has occurred, on the other
hand, the display shows the same error code
number. Continue to advance the display until
the same error code number is shown to read
out all the error codes. Push down selector
switch (4) to return to the immediately preceding
error code.
5. Turning off diagnosis switch
Turn diagnosis switch (5) OFF. (Return to nor-
mal condition)
6. An error code is deleted, once the engine trou-
ble is removed and the engine starting switch is
turned OFF.
20-854 WA700-3
(10)
Action taken by controller and condition of machine
Troubleshooting when error code is displayed
Action taken by controller and condition of machine when error

code is displayed
User System with
Nature of abnormality Condition when normal
code abnormality
Failure of memory hardware inside controller
Abnormality in controller
111 or communications failure in internal —
memory
processor
• Abnormality in timing rail Excessive
difference between timing rail command
fuel value and actual timing fuel Judgment
Abnormality in timing rail
112 value (reference): —
actuator
Difference more than 400 mm3/st or less
than –750 mm3/st (when coolant
temperature is 0ºC or above)
• Abnormality has occurred in timing rail • Resistance of timing rail actuator
actuator circuit Between TIMG (A) and (C): 7 – 9 z
Abnormality with electric
Between ECMA (1) and (20) (reference
113 current in timing rail
value):
actuator system
Detected outside range of 0.40 ± 0.35A
(engine stopped)
• No signal is input from engine speed sensor • Resistance of engine speed sensor
Abnormality in engine circuit system 2 Between SP2 (A) and (B) (signal 1):1 – 2 kz
115
speed sensor 2 system ECMA (27), (28): Signal 1 Between SP1 (A) and (B) (signal 2):1 – 2 kz
ECMA (37), (38): Signal 2
• Abnormality has occurred in timing rail • Voltage of timing rail pressure sensor
pressure sensor circuit Between ECMA (5) and (18) (power source):
ECMA (33): 4.78 V or more detected 4.75 – 5.25 V
116 pressure sensor system
Between ECMA (33) and (18) (signal):
high level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in timing rail • Voltage of timing rail pressure sensor
ECMA (33): 0.30 V or less detected 4.75 – 5.25 V
low level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in fuel pump • Voltage of timing rail pressure sensor
Abnormality in fuel pump
high level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in fuel pump • Voltage of timing rail pressure sensor
Abnormality in fuel pump
low level
0.42 – 0.58 V
(engine stopped)
• 15. No signal is input from engine speed • Resistance of engine speed sensor
Abnormality in engine sensor circuit system 2 to one of following Between SP2 (A) and (B) (signal 1): 1 – 2 kz
121
speed sensor 1 system ECMA (27), (28): Signal 1 Between SP1 (A) and (B) (signal 2): 1 – 2 kz
ECMA (37), (38): Signal 2
• Abnormality has occurred in boost pressure • Voltage of boost pressure sensor
sensor circuit Between ECMA (6) and (17) (power source):
Abnormality in boost
high level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in boost pressure • Voltage of boost pressure sensor
sensor circuit Between ECMA (6) and (17) (power source):
Abnormality in boost
low level
0.42 – 0.58 V
(engine stopped)
20-856 WA700-3
(10)
Problem that appears

Action by controller Probable cause
on machine
• Red lamp lights up • Engine cannot be started • Defective engine controller
• Red lamp lights up • Engine speed goes down • Excessive negative pressure at inlet port of
• Limits engine speed to 1500 rpm fuel pump
• Defective timing rail actuator or clogged
screen
• Broken injector O-ring
• Defective engine controller
• Yellow lamp lights up • Engine output goes down • Defective timing rail actuator
• Engine emits white smoke • Defective wiring harness and connector of
timing rail actuator circuit
• Red lamp lights up • Engine stops • Defective engine speed sensor

• Outputs speed signal 0 rpm • Defective wiring harness and connector of
engine speed sensor circuit
• Red lamp lights up • Engine makes abnormal • Defective timing rail pressure sensor
• Carries out open control of timing rail explosion sound or emits white • Defective wiring harness and connector of
• Limits engine speed to 1500 rpm smoke, then engine speed timing rail pressure sensor circuit
becomes 1500 rpm • Defective engine controller
• Red lamp lights up • Engine makes abnormal • Defective timing rail pressure sensor
• Carries out open control of timing rail explosion sound or emits white • Defective wiring harness and connector of
• Limits engine speed to 1500 rpm smoke, then engine speed timing rail pressure sensor circuit
becomes 1500 rpm • Defective engine controller
• Yellow lamp lights up • Defective fuel pump pressure sensor

• Carries out open control of fuel pump • Defective wiring harness and connector of fuel
pump pressure sensor circuit
—
• Yellow lamp lights up • Defective fuel pump pressure sensor

• Carries out open control of fuel pump • Defective wiring harness and connector of fuel
pump pressure sensor circuit
—
• Yellow lamp lights up • Defective engine speed sensor

• Defective wiring harness and connector of
—
engine speed sensor circuit
• No lamps light up • Exhaust gas color is poor when • Defective boost pressure sensor
accelerating • Defective wiring harness and connector of
• Engine output increases boost pressure sensor circuit
• No lamps light up • Engine output goes down • Defective boost pressure sensor
boost pressure sensor circuit
WA700-3 20-857
(10)
User System with

code abnormality
• Abnormality has occurred in throttle sensor • Resistance of throttle sensor
Abnormality in throttle circuit Between L13 (3) – (2) (power source):
131
sensor system high level ECMB (29): 4.80 V or more detected 2,000 – 3,000 z
Between L13 (1) – (2) (signal): 200 – 3,000 z
• Abnormality has occurred in throttle sensor • Resistance of throttle sensor
Abnormality in throttle circuit Between L13 (3) – (2) (power source):
132
sensor system low level ECMB (29): 0.30 V or less detected 2,000 – 3,000 z
Between L13 (1) – (2) (signal): 200 – 3,000 z
• Abnormality has occurred in oil pressure • Voltage of oil pressure sensor
sensor circuit Between ECMA (6) – (17) (power source):
Abnormality in oil
ECMB (24): 4.88 V or more detected 4.75 – 5.25 V
Between ECMA (24) – (17) (signal):
high level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in oil pressure • 14. Voltage of oil pressure sensor
sensor circuit Between ECMA (6) – (17) (power source):
Abnormality in oil
low level
0.42 – 0.58 V
(engine stopped)
• Oil pressure sensor detected pressure
lower than set oil pressure (level 1)
Level 1 judgment value (reference)
Abnormal drop in oil At 600 rpm Max. 0.05 MPa { 0.5 kg/cm2}
143 —
pressure (level 1) At 1000 rpm Max. 0.09 MPa { 0.9 kg/cm2}
At 1500 rpm Max. 0.15 MPa { 1.5 kg/cm2}
At 1800 rpm Max. 0.18 MPa {1.85 kg/cm2}
At 2000 rpm Max. 0.21 MPa { 2.1 kg/cm2}
Abnormality in water • Abnormality has occurred in water • Resistance of water temperature sensor
temperature sensor temperature sensor circuit Between CLTP (A) – (B): 600 – 36 kz
144
system high level ECMA (22): 4.95 V or more detected
Abnormality in water • Abnormality has occurred in water • Resistance of water temperature sensor
temperature sensor temperature sensor circuit Between CLTP (A) – (B): 600 – 36 kz
145
system low level ECMA (22): 0.21 V or less detected
• Water temperature sensor has detected

Abnormal rise in water
151 temperature higher than set temperature
temperature
Judgment value (reference): Min. 105ºC
Abnormality in intake air • Abnormality has occurred in intake air • Resistance of intake air temperature sensor
153 temperature sensor temperature sensor circuit Between IMTP (A) – (B): 36 – 600 z
system high level ECMA (23): 4.88 V or more detected
Abnormality in intake air • Abnormality has occurred in intake air • Resistance of intake air temperature sensor
154 temperature sensor temperature sensor circuit Between IMTS (A) – (B): 36 – 600 z
system low level ECMA (23): 0.08 V or less detected
• Abnormality has occurred in atmospheric • Voltage of atmospheric temperature sensor
pressure sensor circuit Between ECMA (6) – (17) (power source):
Abnormality in
221 atmospheric pressure
sensor system high level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in atmospheric • Voltage of atmospheric temperature sensor
Abnormality in
222 atmospheric pressure
sensor system low level
0.42 – 0.58 V
(engine stopped)
• Engine speed sensor has detected speed
higher than set speed
Judgment value (reference):
234 Overspeed D375A: 2,400 rpm or more —
WA700: 2,500 rpm or more
PC1100: 2,400 rpm or more
Morita: 2,550 rpm or more
20-858 WA700-3
(10)

on machine
• Red lamp lights up • Engine output and speed • Defective throttle sensor
• Holds engine at constant speed suddenly go down • Defective wiring harness and connector of
throttle sensor circuit
• Red lamp lights up • Engine output and speed • Defective throttle sensor
• Holds engine at constant speed suddenly go up • Defective wiring harness and connector of
throttle sensor circuit
• Yellow lamp lights up • Defective oil pressure sensor
• Defective wiring harness and connector of oil
pressure sensor circuit
—
• Yellow lamp lights up • Defective oil pressure sensor

• Defective wiring harness and connector of oil
pressure sensor circuit
—
• Orange lamp lights up • Defective engine

• After 10 seconds limits injection amount to • Defective oil pressure sensor
50%
—
• Yellow lamp lights up • Defective water temperature sensor

—
water temperature sensor circuit
• Yellow lamp lights up • Defective water temperature sensor
—
water temperature sensor circuit
• After 10 seconds limits injection amount to — • Defective water temperature sensor
50%
• Yellow lamp lights up • Defective intake air temperature sensor
—
intake air temperature sensor circuit
• Yellow lamp lights up • Defective intake air temperature sensor
—
intake air temperature sensor circuit
• Yellow lamp lights up • Defective atmospheric pressure sensor
— atmospheric pressure sensor circuit
• Yellow lamp lights up • Defective atmospheric pressure sensor

atmospheric pressure sensor circuit
—
• Red lamp lights up • Defective engine

• Shut off common rail actuator (fuel cut-off). • Defective engine speed sensor
• Defect on machine
—
WA700-3 20-859
(10)
User System with

code abnormality
• Abnormality has occurred in fuel shut-off • Resistance of fuel shut-off valve
Abnormality in fuel valve circuit Between FSO (+) – (–): 23 – 40 z
254 shut-off valve system Between ECMA (30) – (8):
voltage Voltage of 6.0 V or less or resistance of
20 z or less detected
• Fuel shut-off valve remains open and does
Abnormality in fuel
259 not close (even when electric power is —
shut-off valve
turned off, engine does not stop)
• Fuel temperature sensor has detected
Abnormal rise in fuel
261 temperature higher than set temperature —
temperature
Judgment value (reference): 76ºC or more
• Abnormality has occurred in fuel • Resistance of fuel temperature sensor
Abnormality in fuel
temperature sensor circuit Between FLTP (A) – (B): 600 – 36 kz
ECMA (26): 4.95 V or more detected
system high level
• Abnormality has occurred in fuel • Resistance of fuel temperature sensor

Abnormality in fuel
temperature sensor circuit Between FLTP (A) – (B): 600 – 36 kz
ECMA (26): 0.21 V or less detected
system low level
• Abnormality has occurred in fuel pump • Resistance of fuel pump actuator

actuator circuit Between PUMP (A) – (C): 7 – 9 z
Abnormality in fuel pump Between ECMA (11) – (40) (reference
316
actuator system current value):
Detected value outside range of 0.40 ±
0.35A (engine stopped)
• Excessive difference between fuel pump
command pressure value and actual
pressure
Abnormality in fuel pump Judgment value (reference):
318 —
actuator Difference more than ± 2.11 MPa {2.1 kg/
cm2}
(when coolant temperature is 38ºC or
above)
Abnormality in controller • Microprocessor error inside controller
343 —
internal communication
• Error in data recorded in power-down
internal memory of controller
Abnormality in controller
346 —
power down
• Abnormality has occurred in preheating • Resistance of heater relay

heater control circuit Between relay coils: 200 – 400 z
Abnormality in preheating
384 ECMB (2):
heater control system
Circuit open or short circuit in circuit
detected
• Oil pressure sensor detected pressure
lower than set oil pressure (level 2)
Level 1 judgment value (reference)
Abnormal drop in oil At 600 rpm Max. 0.04 MPa {0.4 kg/cm2}
415 —
pressure (level 2) At 1,000 rpm Max. 0.08 MPa {0.8 kg/cm2}
At 1,500 rpm Max. 0.13 MPa {1.3 kg/cm2}
• Timing rail pressure sensor detected
Abnormality in timing rail abnormal pressure
423 pressure sensor system Judgment value (reference) —
in range When starting switch is ON:
2.42 MPa {24.65 kg/cm2} or more
• Simultaneous detection of voltage from • Resistance of idling switch
both ON signal and OFF signal of idling Between L14(1) – (2):
Abnormality 1 in idling
431 validation switch Max. 125 z (pedal released)
validation switch system
ECMB (12): Idling OFF signal Between L14(1) – (3):
ECMB (13): Idling ON signal Max. 125 z (pedal depressed)
20-860 WA700-3
(10)

on machine
• No lamps light up • Engine stops • Defective fuel shut-off valve
• Shuts off power supply to fuel shut-off valve • Defective wiring harness and connector of fuel
shut-off valve circuit
• Red lamp lights up • Engine cannot stop • Defective fuel shut-off valve
• Shuts off power supply to fuel shut-off valve • Defective injector
• After 30 seconds limits engine speed to 800 — • Defective fuel temperature sensor
rpm • Defect on machine
• Yellow lamp lights up • Defective fuel temperature sensor
• Defective wiring harness and connector of fuel
—
temperature sensor circuit
• Yellow lamp lights up • Defective fuel temperature sensor
—
temperature sensor circuit
• Yellow lamp lights up • Defective fuel pump actuator
pump actuator circuit
—
• Yellow lamp lights up • Engine speed becomes • Defective fuel pump actuator
unstable • Excessive negative pressure at inlet port of
fuel pump
• Defective fuel temperature sensor
• Defective injector
• Yellow lamp lights up • Defective controller

—
• Yellow lamp lights up • Loss of power-down data • Defective battery

• (maintenance data, present • Blown fuse
controller data, engine • Defective wiring harness and connector of
operating time, etc.) controller power source circuit
• Yellow lamp lights up • Defective heater relay
— heater relay circuit

• After 10 seconds limits injection amount to • Defective oil pressure sensor
50%
—
• Yellow lamp lights up • Defective timing rail pressure sensor

• Limits high idling speed to 1,500 rpm • Defective wiring harness and connector of
— timing rail pressure sensor circuit
• Excessive suction resistance of fuel filter
• Red lamp lights up • Defective idling validation switch
— idling validation switch
WA700-3 20-861
(10)
User System with

code abnormality
• Throttle sensor signal and idling validation • Resistance of idling switch
ON signal, OFF signal do not match Between L14(1) – (2):
Idling validation process
432 ECMB (12): Idling OFF signal Max. 125 z (pedal released)
error
ECMB (13): Idling ON signal Between L14(1) – (3):
Max. 125 z (pedal depressed)
• Abnormality has occurred in controller • Voltage of controller power source
power source circuit Between ECMB (3)(4)(5) – ECMA (7)(8):
Abnormality in battery
441 ECMB (3)(4)(5): 12 V or less detected 17.3 – 34.7 V
voltage low level
(When starting switch is OFF)
• Abnormality has occurred in controller • Voltage of controller power source

power source circuit Between ECMB (3)(4)(5) – ECMA (7)(8):
Abnormality in battery
442 ECMB (3)(4)(5): 38 V or less detected 17.3 – 34.7 V
voltage high level
(When starting switch is OFF)
• Abnormality has occurred in fuel rail • Voltage of fuel rail pressure sensor
Abnormality in fuel rail
high level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in fuel rail • Voltage of fuel rail pressure sensor
low level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in fuel rail • Resistance of fuel rail actuator
Abnormality in fuel rail actuator circuit Between RAIL (A) – (C): 7 – 9 z
455
actuator system current Between ECMA (1) – (20) (reference
value): 0.40 ± 0.35 A (engine stopped)
• Excessive difference between timing rail
command fuel value and actual timing fuel,
467 does not reach target value —
actuator control
• Excessive difference between fuel rail

command injection amount value and
468 actual injection amount, does not reach —
actuator control
target value
• Excessive difference between fuel rail

command injection amount value and
actual injection amount
514 Fuel rail judgment value (reference): —
actuator
Difference ±600 mm3/st or more for ±50
msec or difference ±250 mm3/st or more
for ± 200 msec
• Abnormality has occurred in dual output • Resistance of dual output solenoid A
Abnormality in dual solenoid A circuit Between R17(female)(A) – chassis: 28 – 32 z
527
output solenoid A system ECMB (1):
Circuit open or short circuit detected
• Abnormality has occurred in dual output • Resistance of dual output solenoid B
Abnormality in dual solenoid B circuit Between solenoid pins: 28 – 32 z
529
output solenoid B system ECMB (9):
Circuit open or short circuit detected
• Simultaneous detection of no voltage from • Resistance of idling switch
both ON signal and OFF signal of idling Between IVS (A) – (B):
Abnormality 2 in idling
511 validation switch Max. 125 z (pedal released)
validation switch system
ECMB (12): Idling OFF signal Between IVS (A) – (C):
ECMB (13): Idling ON signal Max. 125 z (pedal depressed)
• Fuel rail pressure sensor detected
abnormal pressure
554 Judgment value (reference): —
pressure sensor in range
When starting switch is ON:
0.17 MPa {1.76 kg/cm2} or more
20-862 WA700-3
(10)

on machine
• Recognizes throttle signal as 0% • Defective wiring harness and connector of
— idling validation switch
• Defective battery
• Blown fuse
— — • Defective wiring harness and connector of
controller power source circuit
• Defective battery
• Blown fuse
— — • Defective wiring harness and connector of
controller power source circuit
• Red lamp lights up • Defective fuel rail pressure sensor
• Carries out open control of fuel rail • Defective wiring harness and connector of fuel
rail pressure sensor circuit
—
• Red lamp lights up • Defective fuel rail pressure sensor

• Carries out open control of fuel rail • Defective wiring harness and connector of fuel
rail pressure sensor circuit
—
• Red lamp lights up • Defective fuel rail actuator

• Sets current to fuel rail actuator to 0 A • Defective wiring harness and connector of fuel
—
rail actuator circuit
• Yellow lamp lights up • Excessive negative pressure at inlet port of
• Limits engine speed to 1500 rpm fuel pump
— • Defective fuel rail actuator or clogged screen
• Limits maximum injection amount to 217 fuel pump
mm3/st — • Defective fuel rail actuator or clogged screen
• Limits maximum injection amount to 217 fuel pump
mm3/st • Defective fuel rail actuator or clogged screen
— • Broken injector O-ring
• Yellow lamp lights up • Defective dual output solenoid A

—
dual output solenoid A circuit
• Yellow lamp lights up • Defective dual output solenoid B
—
dual output solenoid B circuit
• Recognizes throttle signal as 0% • Defective wiring harness and connector of
— idling validation switch circuit
• Yellow lamp lights up • Defective fuel rail pressure sensor

• Limits maximum injection amount to 270 • Defective wiring harness and connector of fuel
mm3/st — rail pressure sensor circuit
• Excessive suction resistance of fuel filter
WA700-3 20-863
(10)
Troubleshooting Electrical circuit diagram for engine control system
Electrical circuit diagram for engine control system
20-864 WA700-3
(10)
Troubleshooting Electrical circuit diagram for engine control system
WA700-3 20-865
(10)
Troubleshooting EA-1, EA-2
EA-1 Error code [111] (Abnormality in controller memory)
Cause Remedy
1
• Turn starting switch OFF
and wait for 5 minutes. Is error code [111] re-enacted?
NO
• Run engine at low idling.
YES
Defective engine controller Replace
2
Has error code [111] already It has probably been reset, so
NO operate for a short time and watch —
been generated 3 or more
times? for any change in symptoms
YES
EA-2 Error code [112] (Abnormality in timing rail actuator)
Cause Remedy
1
Is another error code displayed NO
• Turn starting switch ON. at same time?
Go to trouble-
YES shooting for
— service code
displayed
2
When engine is run at rated
speed, does output go up or NO
• Start engine
down, or does exhaust
temperature go up?
YES
Defective timing rail actuator Replace
3
Is there clogging, looseness,
breakage, or leakage from fuel NO
filter, piping?
YES
Clogging, looseness, breakage, or Repair or
leakage from fuel filter, piping replace
4
Is screen of timing rail actuator NO
clogged with dirt?
YES
Clogged timing rail actuator screen Clean or
replace
5
Is engine oil diluted with fuel? NO Defective timing rail actuator or de- Replace
fective engine controller
YES
Broken injector O-ring Replace
20-866 WA700-3
(10)
Troubleshooting EA-3
EA-3 Error code [113] (Abnormality with electric current in timing rail actuator system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between TIMG NO Replace
Defective timing rail actuator
• Disconnect TIMG. (male) (A) and (C) 7 – 9 z?
YES
2
Is resistance between TIMG NO
• Turn starting switch OFF. Defective timing rail actuator
(male) (A)(C) and ground more Replace
• Disconnect TIMG.
than 100 kz?
YES
3
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (1) and TIMG (female) Repair or
(A), and between ECMA (female) NO short circuit in wiring harness
• Disconnect ECMA and replace
(1) and surrounding wiring between ECMA (female) (1) and
TIMG.
harnesses as shown in Table 1? TIMG (female) (A)
YES
4
• Turn starting switch OFF. (female) (20) and TIMG (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and (C), and between ECMA (female)
(20) and surrounding wiring between ECMA (female) (20) and replace
TIMG.
harnesses as shown in Table 2? TIMG (female) (C)
YES
Table 1 Table 2
ECMA (female), TIMG (female) Resistance value ECMA (female), TIMG (female) Resistance value
Between ECMA (1) and TIMG (A) Max. 10 z Between ECMA (20) and TIMG (C) Max. 10 z
Between ECMA (1) and Between ECMA (20) and
Min. 1 Mz Min. 1 Mz
surrounding wiring harnesses surrounding wiring harnesses
EA-3 Related electrical circuit diagram
WA700-3 20-867
(10)
EA-4 Error code [115] (Abnormality in engine speed sensor 2 system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between SP1
NO Defective engine speed sensor Replace
• Disconnect SP1 and SP2. (male) (A) and (B), and between
SP2 (male) (A) and (B) 1k – 2kz?
YES
2
Is resistance between SP1
• Turn starting switch OFF. (male) (A) and ground, and NO
Defective engine speed sensor Replace
• Disconnect SP1 and SP2. between SP2 (male) (A) and
ground more than 10 Mz?
YES
3
Is resistance between SP1 (male)
• Turn starting switch OFF. (A) and SP2 (male) (A), and NO Replace
between SP1 (male) (B) and SP2 Defective engine speed sensor
• isconnect SP1 and SP2.
(male) (B) less than 10 z?
YES
4
• Remove engine speed Is engine speed sensor NO Defective engine speed sensor Replace
sensor. damaged?
YES
5
• Turn starting switch OFF. (female) (37) and SP2 (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and SP1. (A), and between ECMA (female)
harnesses as shown in Table 1? SP2 (female) (A)
YES
6
• Disconnect ECMA and SP1. (B), and between ECMA (female) between ECMA (female) (38) and replace
(38) and surrounding wiring
harnesses as shown in Table 2? SP2 (female) (B)
YES
7
(A), and between ECMA (female)
• Disconnect ECMA and SP2. (27) and surrounding wiring between ECMA (female) (27) and replace
harnesses as shown in Table 3? SP1 (female) (A)
YES
8
(female) (28) and SP1 (female) Repair or
• Turn starting switch OFF. (B), and between ECMA (female) NO short circuit in wiring harness
between ECMA (female) (28) and replace
• Disconnect ECMA and SP2. (28) and surrounding wiring
harnesses as shown in Table 4? SP1 (female) (B)
YES
20-868 WA700-3
(10)
Table 1 Table 2
ECMA (female), SP2 (female) Resistance value ECMA (female), SP2 (female) Resistance value
Between ECMA (37) and SP2 (A) Max. 10 z Between ECMA (38) and SP2 (B) Max. 10 z
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
Table 3 Table 4
ECMA (female), SP1 (female) Resistance value ECMA (female), SP1 (female) Resistance value
Between ECMA (27) and SP1 (A) Max. 10 z Between ECMA (28) and SP1 (B) Max. 10 z
WA700-3 20-869
(10)
EA-5 Error code [116] (Abnormality [high level] in timing rail pressure sensor system)
Cause Remedy
1
• Disconnect TPR. When TPR is disconnected, NO
• Turn starting switch ON. does error code [116] go out?
YES
Defective timing rail pressure Replace
2
Is resistance between ECMA
(female) (5) and TPR (female) (A), Defective contact, disconnection, or
•Turn starting switch OFF.
• Disconnect ECMA and TPR. and between ECMA (female) (5) NO short circuit in wiring harness Repair or
and surrounding wiring between ECMA (female) (5) and TPR replace
harnesses as shown in Table 1? (female) (A)
YES
3
• Turn starting switch OFF. (female) (18) and TPR (female)
(B), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and TPR. between ECMA (female) (18) and
(18) and surrounding wiring replace
harnesses as shown in Table 2? TPR (female) (B)
YES
4
(female) (33) and TPR (female) NO short circuit in wiring harness Repair or
• Turn starting switch OFF. (C), and between ECMA (female)
• Disconnect ECMA and TPR. between ECMA (female) (33) and replace
(33) and surrounding wiring
harnesses as shown in Table 3? TPR (female) (C)
YES
Table 1 Table 2
ECMA (female), TPR (female) Resistance value ECMA (female), SP1 (female) Resistance value
Between ECMA (5) and TPR (A) Max. 10 z Between ECMA (18) and TPR (B) Max. 10 z
Table 3
ECMA (female), TPR (female) Resistance value

Between ECMA (33) and TPR (C) Max. 10 z
Between ECMA (33) and
surrounding wiring harnesses Min. 1 Mz
20-870 WA700-3
(10)
EA-6 Error code [117] (Abnormality [low level] in timing rail pressure sensor system)
Cause Remedy
1
Is voltage between TPR (A) and
• Insert T-adapter to TPR. NO Defective timing rail pressure Replace
(B), and between (C) and (B) as
shown in Table 1?
YES
2
(female) (5) and TPR (female) (A), NO
• Turn starting switch OFF. and between ECMA (female) (5) short circuit in wiring harness Repair or
• Disconnect ECMA and TPR. and surrounding wiring between ECMA (female) (5) and TPR replace
YES
3
Is resistance between ECMA E. Defective contact, disconnection,
• Turn starting switch OFF. (female) (18) and TPR (female)
(B), and between ECMA (female) NO or short circuit in wiring harness Repair or
• Disconnect ECMA and TPR. (18) and surrounding wiring between ECMA (female) (18) and replace
harnesses as shown in Table 3? TPR (female) (B)
YES
4
• Turn starting switch OFF. (female) (33) and TPR (female) NO short circuit in wiring harness Repair or
(C), and between ECMA (female)
YES
Table 1 Table 2
TPR Voltage ECMA (female), TPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (5) and TPR (A) Max. 10 z
Between (C) and (B) 0.42 – 0.58 V Between ECMA (5) and
Table 3 Table 4
ECMA (female), TPR (female) Resistance value ECMA (female), TPR (female) Resistance value
Between ECMA (18) and TPR (B) Max. 10 z Between ECMA (33) and TPR (C) Max. 10 z
WA700-3 20-871
(10)
EA-7 Error code [118] (Abnormality [high level] in fuel pump pressure sensor system)
Cause Remedy
1
• Disconnect PMPR. When PMPR is disconnected, NO
YES
Defective fuel pump pressure Replace
2
• Turn starting switch OFF. (female) (5) and PMPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (A), and between ECMA (female) NO short circuit in wiring harness Repair or
PMPR. (5) and surrounding wiring between ECMA (female) (5) and replace
harnesses as shown in Table 1? PMPR (female) (A)
YES
3
NO Repair or
• Disconnect ECMA and (B), and between ECMA (female) short circuit in wiring harness
PMPR. between ECMA (female) (18) and
harnesses as shown in Table 2? PMPR (female) (B)
YES
4
• Disconnect ECMA and (C), and between ECMA (female) NO short circuit in wiring harness Repair or
PMPR. (32) and surrounding wiring between ECMA (female) (32) and replace
harnesses as shown in Table 3? PMPR (female) (C)
YES
Table 1 Table 2
ECMA (female), PMPR (female) Resistance value ECMA (female), PMPR (female) Resistance value
Between ECMA (5) and PMPR (A) Max. 10 z Between ECMA (18) and PMPR (B) Max. 10 z
Table 3
ECMA (female), PMPR (female) Resistance value

Between ECMA (32) and PMPR (C) Max. 10 z
20-872 WA700-3
(10)
EA-8 Error code [119] (Abnormality [low level] in fuel pump pressure sensor system)
Cause Remedy
1
• Insert T-adapter to PMPR. Is voltage between PMPR (A)
NO
and (B), and between (C) and Defective fuel pump pressure sensor Replace
(B) as shown in Table 1?
YES
2
• Turn starting switch OFF. (female) (5) and PMPR (female)
(A), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and
PMPR.
harnesses as shown in Table 2? PMPR (female) (A)
YES
3
• Turn starting switch OFF. (female) (18) and PMPR (female)
NO short circuit in wiring harness Repair or
• Disconnect ECMA and (B), and between ECMA (female)
PMPR.
harnesses as shown in Table 3? PMPR (female) (B)
YES
4
• Turn starting switch OFF. (female) (32) and PMPR (female) NO short circuit in wiring harness Repair or
PMPR.
harnesses as shown in Table 4? PMPR (female) (C)
YES
Table 1 Table 2
PMPR Voltage ECMA (female), PMPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (5) and PMPR (A) Max. 10 z
Table 3 Table 4
ECMA (female), PMPR (female) Resistance value ECMA (female), PMPR (female) Resistance value
Between ECMA (18) and PMPR (B) Max. 10 z Between ECMA (32) and PMPR (C) Max. 10 z
WA700-3 20-873
(10)
EA-9 Error code [121] (Abnormality in engine speed sensor 1 system)
a Carry out troubleshooting for error code [115].
20-874 WA700-3
(10)
EA-10 Error code [122] (Abnormality [high level] in boost pressure sensor system)
Cause Remedy
1
• Disconnect IMPR. When IMPR is disconnected, NO
YES
Defective boost pressure sensor Replace
2
• Turn starting switch OFF. (female) (6) and IMPR (female) Defective contact, disconnection, or
IMPR. (6) and surrounding wiring between ECMA (female) (6) and replace
harnesses as shown in Table 1? IMPR (female) (A)
YES
3
• Disconnect ECMA and (B), and between ECMA (female) NO short circuit in wiring harness Repair or
harnesses as shown in Table 2? IMPR (female) (B)
YES
4
harnesses as shown in Table 3? IMPR (female) (C)
YES
Table 1 Table 2
ECMA (female), IMPR (female) Resistance value ECMA (female), IMPR (female) Resistance value
Between ECMA (6) and IMPR (A) Max. 10 z Between ECMA (17) and IMPR (B) Max. 10 z
Table 3
ECMA (female), IMPR (female) Resistance value

Between ECMA (35) and IMPR (C) Max. 10 z
WA700-3 20-875
(10)
EA-11 Error code [123] (Abnormality [low level] in boost pressure sensor system)
Cause Remedy
1
Is voltage between IMPR (A)
• Insert T-adapter to IMPR. NO Defective boost pressure sensor Replace
and (B), and between (C) and
YES
2
• Turn starting switch OFF. (female) (6) and IMPR (female)
IMPR.
harnesses as shown in Table 2? IMPR (female) (A)
YES
3
• Turn starting switch OFF. (female) (17) and IMPR (female)
IMPR.
harnesses as shown in Table 3? IMPR (female) (B)
YES
4
• Turn starting switch OFF. (female) (35) and IMPR (female) Repair or
NO short circuit in wiring harness
IMPR.
harnesses as shown in Table 4? IMPR (female) (C)
YES
Table 1 Table 2
IMPR Voltage ECMA (female), IMPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (6) and IMPR (A) Max. 10 z
Table 3 Table 4
ECMA (female), IMPR (female) Resistance value ECMA (female), IMPR (female) Resistance value
Between ECMA (17) and IMPR (B) Max. 10 z Between ECMA (35) and IMPR (C) Max. 10 z
20-876 WA700-3
(10)
EA-12 Error code [131] (Abnormality [high level] in accelerator sensor system)
Cause Remedy
1
Is resistance between L13 (male)
• Turn starting switch OFF. NO Defective accelerator sensor Replace
(3) and (2), and between L13 (1)
• Disconnect L13.
and L13(2) as shown in Table 1?
YES
2
Is resistance between ECMB Defective contact, disconnection, or
• Turn starting switch OFF. (female) (11) and L13 (female) (2), NO
and between ECMB (female) (11) short circuit in wiring harness Repair or
• Disconnect ECMB and L13. and surrounding wiring between ECMB (female) (11) and replace
harnesses as shown in Table 2? L13(female) (2)
YES
3
(female) (29) and L13 (female) (1),
• Turn starting switch OFF. and between ECMB (female) (29) NO short circuit in wiring harness Repair or
• Disconnect ECMB and L13. and surrounding wiring harnesses between ECMB (female) (29) and replace
as shown in Table 3? L13 (female) (1)
YES
4
• Turn starting switch OFF. (female) (26) and L13 (female) (3), NO short circuit in wiring harness Repair or
and between ECMB (female) (26)
• Disconnect ECMB and L13. and surrounding wiring between ECMB (female) (26) and replace
harnesses as shown in Table 4? L13 (female) (3)
YES
Table 1 Table 2
L13 (male) Resistance value ECMB (female), L13 (female) Resistance value
Between L13(3) and L13(2) 2,000 – 3,000 z Between ECMA (11) and L13(2) Max. 10 z
Between L13(1) and L13(2) 200 – 3,000 z Between ECMB (11) and
Table 3 Table 4
ECMB (female), L13 (female) Resistance value ECMB (female), L13 (female) Resistance value
Between ECMB (29) and L13(1) Max. 10 z Between ECMB (26) and L13(3) Max. 10 z
Between ECMB (29) and Between ECMB (26) and
WA700-3 20-877
(10)
EA-13 Error code [132] (Abnormality [low level] in accelerator sensor system)
20-878 WA700-3
(10)
EA-14 Error code [135] (Abnormality [high level] in oil pressure sensor system)
Cause Remedy
1
• Disconnect CLPR. When CLPR is disconnected, NO
YES
Defective oil pressure sensor Replace
2
• Turn starting switch OFF. (female) (6) and CLPR (female) Defective contact, disconnection, or
CLPR. (6) and surrounding wiring between ECMA (female) (6) and replace
harnesses as shown in Table 1? CLPR (female) (A)
YES
3
CLPR. (17) and surrounding wiring between ECMA (female) (17) and replace
harnesses as shown in Table 2? CLPR (female) (B)
YES
4
CLPR. harnesses as shown in Table 3? CLPR (female) (C)
YES
Table 1 Table 2
ECMA (female), CLPR (female) Resistance value ECMA (female), CLPR (female) Resistance value
Between ECMA (6) and CLPR (A) Max. 10 z Between ECMA (17) and CLPR (B) Max. 10 z
Table 3
ECMA (female), CLPR (female) Resistance value

Between ECMA (24) and CLPR (C) Max. 10 z
WA700-3 20-879
(10)
EA-15 Error code [141] (Abnormality [low level] in oil pressure sensor system)
Cause Remedy
1
Is voltage between CLPR (A)
• Insert T-adapter to CLPR. NO Defective oil pressure sensor Replace
and (B), and between (C) and
YES
2
• Turn starting switch OFF. (female) (6) and CLPR (female) NO
(A), and between ECMA (female) short circuit in wiring harness Repair or
• Disconnect ECMA and between ECMA (female) (6) and
CLPR. CLPR (female) (A)
harnesses as shown in Table 2?
YES
3
• Turn starting switch OFF. (female) (17) and CLPR (female)
CLPR.
harnesses as shown in Table 3? CLPR (female) (B)
YES
4
• Turn starting switch OFF. (female) (24) and CLPR (female) NO short circuit in wiring harness Repair or
CLPR.
harnesses as shown in Table 4? CLPR (female) (C)
YES
Table 1 Table 2
CLPR Voltage ECMA (female), CLPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (6) and CLPR (A) Max. 10 z
Table 3 Table 4
ECMA (female), CLPR (female) Resistance value ECMA (female), CLPR (female) Resistance value
Between ECMA (17) and CLPR (B) Max. 10 z Between ECMA (24) and CLPR (C) Max. 10 z
20-880 WA700-3
(10)
EA-16 Error code [143] (Abnormal drop in oil pressure (level 1))
Cause Remedy
1
at same time?
Go to trouble-
YES shooting for
— service code
displayed
2
When troubleshooting for error Investigate
codes [135] and [141] is carried NO Defective engine cause and
out, does any problem occur in repair damage
electrical system? to engine
YES Defective electrical system for oil Repair or
pressure sensorDefective electrical replace
WA700-3 20-881
(10)
EA-17 Error code [144] (Abnormality [high level] in water temperature sensor system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between CLTP NO Defective water temperature sensor Replace
• Disconnect CLTP. (male) (A) and (B) 600 – 36kz?
YES
2
Is resistance between ECMA (fe- Defective contact, disconnection, or
• Turn starting switch OFF. male) (22) and CLTP (female) (A),
• Disconnect ECMA and and between ECMA (female) (22) NO short circuit in wiring harness be- Repair or
and surrounding wiring harnes- tween ECMA (female) (22) and CLTP replace
CLTP.
ses as shown in Table 1? (female) (A)
YES
3
• Turn starting switch OFF. male) (17) and CLTP (female) (B), NO short circuit in wiring harness be- Repair or
• Disconnect ECMA and and between ECMA (female) (17) tween ECMA (female) (17) and CLTP replace
CLTP. and surrounding wiring harnes-
ses as shown in Table 2? (female) (B)
YES
Table 1 Table 2
ECMA (female), CLTP (female) Resistance value ECMA (female), CLTP (female) Resistance value
Between ECMA (22) and CLTP (A) Max. 10 z Between ECMA (17) and CLTP (B) Max. 10 z
Between ECMA (22) and Between ECMA (17) and sur-
surrounding wiring harnesses Min. 1 Mz rounding wiring harnesses Min. 1 Mz
20-882 WA700-3
(10)
EA-18 Error code [145] (Abnormality [low level] in water temperature sensor system)
EA-19 Error code [151] (Abnormal rise in water temperature)
Cause Remedy
1
at same time?
Go to trouble-
YES shooting for
— service code
displayed
2
codes [144] and [145] is carried NO Defective engine cause and re-
out, does any problem occur in pair damage
YES Defective electrical system for oil Repair or
pressure sensor replace
WA700-3 20-883
(10)
EA-20 Error code [153] (Abnormality [high level] in intake air temperature
sensor system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between IMTP NO Defective intake air temperature Replace
• Disconnect IMTP (male) (A) and (B) 600 – 36kz? sensor
YES
2
male) (23) and IMTP (female) (A),
• Turn starting switch OFF. and between ECMA (female) (23) NO short circuit in wiring harness be- Repair or
• Disconnect ECMA and IMTP. and surrounding wiring harnes- tween ECMA (female) (23) and IMTP replace
ses as shown in Table 1? (female) (A)
YES
3
s resistance between ECMA (fe- Defective contact, disconnection, or
• Turn starting switch OFF. male) (17) and IMTP (female) (B), NO short circuit in wiring harness Repair or
and between ECMA (female) (17) between ECMA (female) (17) and replace
• Disconnect ECMA and IMTP. and surrounding wiring harnes-
ses as shown in Table 2? IMTP (female) (B)
YES
Table 1 Table 2
ECMA (female), IMTP (female) Resistance value ECMA (female), IMTP (female) Resistance value
Between ECMA (23) and IMTP (A) Max. 10 z Between ECMA (17) and IMTP (B) Max. 10 z
EA-21 Error code [154] (Abnormality [low level] in intake air temperature
sensor system)
20-884 WA700-3
(10)
EA-22 Error code [221] (Abnormality [high level] in atmospheric pressure

sensor system)
Cause Remedy
1
• Disconnect AAPR. When AAPR is disconnected, NO
YES Defective atmospheric pressure

Replace
sensor
2
• Turn starting switch OFF. (female) (6) and AAPR (female) Defective contact, disconnection, or
AAPR. (6) and surrounding wiring between ECMA (female) (6) and replace
harnesses as shown in Table 1? AAPR (female) (A)
YES
3
AAPR. (17) and surrounding wiring between ECMA (female) (17) and replace
harnesses as shown in Table 2? AAPR (female) (B)
YES
4
(C), and between ECMA (female) NO short circuit in wiring harness Repair or
AAPR. harnesses as shown in Table 3? AAPR (female) (C)
YES
Table 1 Table 2
ECMA (female), AAPR (female) Resistance value ECMA (female), AAPR (female) Resistance value
Between ECMA (6) and AAPR (A) Max. 10 z Between ECMA (17) and AAPR (B) Max. 10 z
Table 3
ECMA (female), AAPR (female) Resistance value

Between ECMA (34) and AAPR (C) Max. 10 z
WA700-3 20-885
(10)
EA-23 Error code [222] (Abnormality [low level] in atmospheric pressure

sensor system)
Cause Remedy
1
Is voltage between AAPR (A) Defective atmospheric pressure
• Insert T-adapter to AAPR. NO Replace
and (B), and between (C) and sensor
YES
2
• Turn starting switch OFF. (female) (6) and AAPR (female)
AAPR.
harnesses as shown in Table 2? AAPR (female) (A)
YES
3
• Turn starting switch OFF. (female) (17) and AAPR (female)
AAPR.
harnesses as shown in Table 3? AAPR (female) (B)
YES
4
• Turn starting switch OFF. (female) (34) and AAPR (female) NO short circuit in wiring harness Repair or
AAPR.
harnesses as shown in Table 4? AAPR (female) (C)
YES
Table 1 Table 2
AAPR Voltage ECMA (female), AAPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (6) and AAPR (A) Max. 10 z
Table 3 Table 4
ECMA (female), AAPR (female) Resistance value ECMA (female), AAPR (female) Resistance value
Between ECMA (17) and AAPR (B) Max. 10 z Between ECMA (34) and AAPR (C) Max. 10 z
20-886 WA700-3
(10)
WA700-3 20-887
(10)
EA-24 Error code [234] (Overspeed)
Cause Remedy
1
at same time?
Go to
YES
troubleshooting
—
for service code
displayed
2
Has machine been used is way NO
which would cause overspeed?
Investigate
YES cause and
Defective engine repair damage
to engine
3 Investigate
Can engine speed be read NO cause and
• Turn starting switch ON. Defective engine repair damage
correctly?
to engine
YES Investigate
Defective engine cause and
repair damage
to engine
20-888 WA700-3
(10)
EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between FSO+ NO Defective fuel shut-off valve Replace
• Disconnect FSO+ and FSO-. and FSO- (valve end) 23 – 40 z?
YES
2
Is resistance between FSO+
• Turn starting switch OFF. NO
and FSO- (valve end) more Defective fuel shut-off valve Replace
• Disconnect FSO+ and FSO-.
than 100 kz?
YES
3
(female) (8) and FSO-, and
• Turn starting switch OFF. between ECMA (female) (8) and NO short circuit in wiring harness Repair or
• Disconnect ECMA and FSO-. surrounding wiring harnesses between ECMA (female) (8) and replace
as shown in Table 1? FSO-
YES
4
• Turn starting switch OFF. (female) (30) and FSO+, and NO short circuit in wiring harness Repair or
• Disconnect ECMA and between ECMA (female) (30)
and surrounding wiring between ECMA (female) (30) and replace
FSO+.
harnesses as shown in Table 2? FSO+
YES
Table 1 Table 2
ECMA (female), FSO- Resistance value ECMA (female), FSO+ Resistance value
Between ECMA (8) and FSO- Max. 10 z Between ECMA (30) and FSO+ Max. 10 z
WA700-3 20-889
(10)
EA-26 Error code [259] (Abnormality in fuel shut-off valve)
Cause Remedy
• Turn starting switch ON. Is another error code NO

displayed at same time?
Go to
YES troubleshooting
— for service code
displayed
2
Is there problem with internal NO
parts of fuel shut-off valve?
YES
Defective fuel shut-off valve Replace
3
NO
breakage, or leakage from fuel
filter, piping?
YES
Clogging, looseness, breakage, or Repair or
4
parts of injector?
YES
Defective injector Replace
EA-27 Error code [261] (Abnormal rise in fuel temperature)
Cause Remedy
1
at same time?
Go to trouble-
YES shooting for
— service code
displayed
2
codes [263] and [264] is carried NO Defective engine cause and
out, does any problem occur in repair damage
YES Defective electrical system for fuel Repair or
temperature sensor replace
20-890 WA700-3
(10)
EA-28 Error code [263] (Abnormality [high level] in fuel temperature sensor system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between FLTP NO Defective fuel temperature sensor Replace
• Disconnect FLTP. (male) (A) and (B) 600 – 36 kz?
YES
2
(female) (26) and FLTP (female)
•Turn starting switch OFF. (A), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and FLTP. (26) and surrounding wiring between ECMA (female) (26) and replace
harnesses as shown in Table 1? FLTP (female) (A)
YES
3
• Turn starting switch OFF. (female) (17) and FLTP (female) NO short circuit in wiring harness Repair or
(B), and between ECMA (female) between ECMA (female) (17) and replace
• Disconnect ECMA and FLTP. (17) and surrounding wiring
harnesses as shown in Table 2? FLTP (female) (B)
YES
Table 1 Table 2
ECMA (female), FLTP (female) Resistance value ECMA (female), FLTP (female) Resistance value
Between ECMA (26) and FLTP (A) Max. 10 z Between ECMA (17) and FLTP (B) Max. 10 z
EA-29Error code [265] (Abnormality [low level] in fuel temperature sensor system)
WA700-3 20-891
(10)
EA-30 Error code [316] (Abnormality in fuel pump actuator system current)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between PUMP NO Defective fuel pump actuator Replace
• Disconnect PUMP. (male) (A) and (C) 7 – 9 z?
YES
2
Is resistance between PUMP
(male) (A)(C) and ground more Defective fuel pump actuator Replace
• Disconnect PUMP.
than 100 kz?
YES
3
• Turn starting switch OFF. (female) (11) and PUMP (female) short circuit in wiring harness
(A), and between ECMA (female) NO Repair or
• Disconnect ECMA and between ECMA (female) (11) and replace
PUMP. (11) and surrounding wiring
harnesses as shown in Table 1? PUMP (female) (A)
YES
4
• Turn starting switch OFF. (female) (40) and PUMP (female) NO short circuit in wiring harness Repair or
PUMP.
harnesses as shown in Table 2? PUMP (female) (C)
YES
Table 1 Table 2
ECMA (female), PUMP (female) Resistance value ECMA (female), PUMP (female) Resistance value
Between ECMA (11) and PUMP (A) Max. 10 z Between ECMA (40) and PUMP (C) Max. 10 z
20-892 WA700-3
(10)
EA-31 Error code [318] (Abnormality in fuel pump actuator)
Cause Remedy
1
at same time?
Go to trouble-
YES shooting for
— service code
displayed
2
When engine is run at rated
• Start engine speed, does output go up or NO
down, or does exhaust
YES
Defective fuel pump actuator Replace
3
filter, piping?
YES Clogging, looseness, breakage, or Repair or
4
Is negative pressure at suction NO
• Start engine. side (tank side) of fuel filter
more than 27kPa{203mmHg}?
YES
Excessive suction resistance of fuel Repair or
filter replace
5
When troubleshooting for error
codes [118] and [119] is carried NO
out, does any problem occur in
electrical system?
YES Defective electrical system for fuel Repair or
pump pressure sensor replace
6
parts of injector?
YES
Defective injector Replace
EA-32 Error code [343] (Abnormality in controller internal communication)
Cause Remedy
1
Is error code [343] re-enacted?
NO
• Wait for 5 minutes, then
turn starting switch ON.
YES
• Turn starting switch OFF 2

and disconnect ECMA and
ECMB.
Is error code [343] re-enacted?
NO System has been reset —
• After 1 minute, connect
ECMA and ECMB.
• Turn starting switch ON. YES
WA700-3 20-893
(10)
EA-33 Error code [346] (Abnormality in controller power down)
Cause Remedy
1
Is battery terminal connected NO Defective connection of battery Repair
normally? terminal
YES
2
Is voltage of battery 17.3 – 34.7 V ?
NO Drop in battery voltage Charge or
• Disconnect battery terminal. replace
YES
3
Is slow blow fuse blown? NO
YES
Blown slow blow fuse Replace
4
• Turn starting switch OFF. Is resistance between slow
blow fuse inlet and battery (+), Defective contact, disconnection, or
• Disconnect slow blow fuse NO Repair or
and between slow blow fuse short circuit in wiring harness
inlet terminal and battery replace
(+) terminal. inlet and surrounding wiring between slow blow fuse inlet and
harnesses as shown in Table 1? battery (+)
YES
5
• Turn starting switch OFF. (female) (3)(4)(5) and slow blow fuse NO
• Disconnect ECMB and short circuit in wiring harness Repair or
outlet, and between ECMB (female)
slow blow fuse outlet (3)(4)(5) and surrounding wiring between ECMB (female) (3)(4)(5) replace
harnesses as shown in Table 2? and slow blow fuse outlet
YES
Table 1 Table 2
Slow blow fuse inlet, battery (+) Resistance value ECMB (female), C slow blow fuse outlet Resistance value
Between slow blow fuse inlet and Between ECMB (3)(4)(5) and
Max. 10 z Max. 10 z
battry (+) slow blow fuse outlet
Between slow blow fuse inlet Between ECMB (3)(4)(5) and
and surrounding wiring harness Min. 1 Mz surrounding wiring harness Min. 1 Mz
20-894 WA700-3
(10)
EA-34 Error code [384] (Abnormality in preheating heater control system)
Cause Remedy
1
Is resistance between L82 NO Defective heater relay Replace
• Disconnect preheating
(male) (1) and (2) 200 – 400 z?
relay L82.
YES
2
Is the wiring harness resistance Defective contact, disconnection
• Turn starting switch OFF. value between ECMA(female) NO short circuit wiring harness between Repair or
• Disconnect L82. (2) and L82 (female) (1) as ECMA (female) (2) – L82 (female) (1) replace
indicated in Table 1?
YES
3
Is the resistance value between There is ground fault or short-
• Turn starting switch OFF. the chassis and ECMA (female) NO circuiting in the wiring harness Repair or
• Disconnect ECMA, L82. (2) or L82 (female) (1) as between ECMA (female) (2) and L82 replace
indicated in Table 1? (female) (1).
YES
4
Is the resistance value in the There is a disconnection or
wiring harness between L82 NO connection fault in the wiring Repair or
(female) (2) and the chassis as harness between L82 (female) (2) replace
indicated in Table 1? and the chassis.
YES
Table 1
ECMA (female), preheating relay (L82) Resistance value

Between ECMA (2) and L82 (female) (2) Max. 10 z
Between ECMA (2) and L82 (female) (2) – chassis Min. 1 Mz
WA700-3 20-895
(10)
EA-35 Error code [415] (Abnormal drop in oil pressure (level 2))
EA-36 Error code [423] (Abnormality [in range] in timing rail pressure sensor system)
Cause Remedy
• Remove timing rail 1

pressure sensor and fuel Is voltage between TPR (C) and
rail pressure sensor. NO Defective timing rail pressure
Replace
(B) same as voltage between
• Insert T-adapter into TPR sensor
and RPR. RPR (C) and (B)?
2
• Turn starting switch OFF. (female) (5) and TPR (female) (A), NO short circuit in wiring harness Repair or
and between ECMA (female) (5)
• Disconnect ECMA and TPR. and surrounding wiring between ECMA (female) (5) and TPR replace
YES
3
(female) (18) and TPR (female) NO short circuit in wiring harness Repair or
• Turn starting switch OFF. (B), and between ECMA (female) between ECMA (female) (18) and replace
• Disconnect ECMA and TPR. (18) and surrounding wiring TPR (female) (B)
YES
4
(female) (33) and TPR (female)
• Turn starting switch OFF. (C), and between ECMA (female) NO short circuit in wiring harness Repair or
YES
5
Is negative pressure at suction
NO
• Start engine. side (tank side) of fuel filter Defective engine controller Replace
YES
filter replace
Table 1 Table 2
ECMA (female), TPR (female) Resistance value ECMA (female), TPR (female) Resistance value
Between ECMA (5) and TPR (A) Max. 10 z Between ECMA (18) and TPR (B) Max. 10 z
Table 3
Between ECMA (33) and TPR (C) Resistance value

Between ECMA (33) and TPR (C) Max. 10 z
20-896 WA700-3
(10)
WA700-3 20-897
(10)
EA-37 Error code [431] (Abnormality [1] in idling validation switch system)
Cause Remedy
1
Is resistance between L14
• Turn starting switch OFF. NO Defective idling validation switch Replace
(female) (1) – (2) and (1) – (3)
• Disconnect L14.
shown in Table 1?
YES
2
• Turn starting switch OFF. (female) (21) and L14 (male) (1), NO short circuit in wiring harness Repair or
• Disconnect ECMB and L14. and between ECMB (female)
(21) and surrounding wiring between ECMB (female) (21) and replace
harnesses as shown in Table 2? L14 (male) (1)
YES
3
and between ECMB (female) between ECMB (female) (13) and replace
• Disconnect ECMB and L14. (13) and surrounding wiring
YES
4
Is resistance between ECMB (fe- Defective contact, disconnection, or
• Turn starting switch OFF. male) (12) and L14 (male) (3), NO
and between ECMB (female) (12) short circuit in wiring harness Repair or
• Disconnect ECMB and L14. and surrounding wiring harnes- between ECMB (female) (12) and replace
ses as shown in Table 4? L14 (male) (3)
YES
Table 1 Table 2
L14 (male) Pedal Resistance value ECMB (female), L14 (male) Resistance value
Between (1) and (2) Released (idling ON) Max. 125 z Between ECMB (21) and L14 (1) Max. 10 z
Between (1) and (3) Depressed (idling OFF) Max. 125 z Between ECMB (21) and
Table 3 Table 4
ECMB (female), L14 (male) Resistance value ECMB (female), L14 (male) Resistance value
Between ECMB (13) and L14 (2) Max. 10 z Between ECMB (12) and L14 (3) Max. 10 z
20-898 WA700-3
(10)
WA700-3 20-899
(10)
EA-38 Error code [432] (Idling validation process error)
Cause Remedy
1
Is resistance between L14
• Turn starting switch OFF. NO Replace
(female) (1) and (3), and between Defective idling validation switch
• Disconnect L14. (2) and (3) as shown in Table 1?
YES
2
• Turn starting switch OFF. (female) (21) and L14 (male) (1), NO
and between ECMB (female) short circuit in wiring harness Repair or
• Disconnect ECMB and L14. (21) and surrounding wiring between ECMB (female) (21) and replace
YES
3
and between ECMB (female) between ECMB (female) (13) and replace
• Disconnect ECMB and L14. (13) and surrounding wiring
YES
4
and between ECMB (female)
• Disconnect ECMB and L14. (12) and surrounding wiring between ECMB (female) (12) and replace
YES
Table 1 Table 2
L14 (male) Pedal Resistance value ECMB (female), L14(male) Resistance value
Between (1) and (3) Released or depressed 2,000 – 3,000 z Between ECMB (21) and L14 (1) Max. 10 z
Released (idling ON) 1,500 – 3,000 z Between ECMB (21) and
Min. 1 Mz
Between (2) and (3) surrounding wiring harnesses
Depressed (idling OFF) 200 – 1,500 z
Table 3 Table 4
ECMB (female), L14 (male) Resistance value ECMB (female), L14 (male) Resistance value
Between ECMB (13) and L14 (2) Max. 10 z Between ECMB (12) and L14 (3) Max. 10 z
20-900 WA700-3
(10)
WA700-3 20-901
(10)
EA-39 Error code [441] (Abnormality [low level] in battery voltage)
EA-40 Error code [442] (Abnormality [high level] in battery voltage)
20-902 WA700-3
(10)
EA-41 Error code [451] (Abnormality [high level] in fuel rail pressure sensor system)
Cause Remedy
1
• Disconnect RPR. When RPR is disconnected, NO
YES
Defective fuel rail pressure sensor Replace
2
(female) (5) and RPR (female) (A), Defective contact, disconnection, or
and between ECMA (female) (5) NO short circuit in wiring harness Repair or
• Disconnect ECMA and RPR. and surrounding wiring between ECMA (female) (5) and RPR replace
YES
3
(female) (18) and RPR (female) Defective contact, disconnection, or
(B), and between ECMA (female) short circuit in wiring harness Repair or
• Disconnect ECMA and RPR. (18) and surrounding wiring between ECMA (female) (18) and replace
harnesses as shown in Table 2? RPR (female) (B)
YES
4
(female) (31) and RPR (female) Defective contact, disconnection, or
• Turn starting switch OFF. (C), and between ECMA (female) NO short circuit in wiring harness Repair or
RPR (female) (C)
YES
Table 1 Table 2
ECMA (female), RPR (female) Resistance value ECMA (female), RPR (female) Resistance value
Between ECMA (5) and RPR (A) Max. 10 z Between ECMA (18) and RPR (B) Max. 10 z
Table 3
ECMA (female), RPR (female) Resistance value
Between ECMA (31) and RPR (C) Max. 10 z
WA700-3 20-903
(10)
EA-42 Error code [452] (Abnormality [low level] in fuel rail pressure sensor system)
Cause Remedy
1
Is voltage between RPR (A) and
• Insert T-adapter to RPR. NO Replace
(B), and between (C) and (B) as Defective fuel rail pressure sensor
shown in Table 1?
YES
2
• Turn starting switch OFF. (female) (5) and RPR (female) NO
(A), and between ECMA (female) short circuit in wiring harness Repair or
• Disconnect ECMA and RPR. (5) and surrounding wiring between ECMA (female) (5) and RPR replace
YES
3
(female) (18) and RPR (female)
• Turn starting switch OFF. (B), and between ECMA (female) NO short circuit in wiring harness Repair or
harnesses as shown in Table 3? RPR (female) (B)
YES
4
• Turn starting switch OFF. (female) (31) and RPR (female) NO short circuit in wiring harness Repair or
(C), and between ECMA (female) replace
• Disconnect ECMA and RPR. (31) and surrounding wiring between ECMA (female) (31) and
harnesses as shown in Table 4? RPR (female) (C)
YES
Table 1 Table 2
RPR Voltage ECMA (female), RPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (5) and RPR (A) Max. 10 z
Table 3 Table 4
Between ECMA (18) and RPR (B) Max. 10 z Between ECMA (31) and RPR (C) Max. 10 z
20-904 WA700-3
(10)
EA-43 Error code [455] (Abnormality in fuel rail actuator system current)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between RAIL NO Replace
Defective fuel rail actuator
• Disconnect RAIL. (male) (A) and (C) 7 – 9 z?
YES
2
Is resistance between RAIL
• Turn starting switch OFF. (male) (A)(C) and ground more
NO
Defective fuel rail actuator Replace
• Disconnect RAIL. than 100 kz?
YES
3
• Turn starting switch OFF. (female) (3) and RAIL (female)
(A), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and RAIL. (3) and surrounding wiring between ECMA (female) (3) and replace
harnesses as shown in Table 1? RAIL (female) (A)
YES
4
• Turn starting switch OFF. (female) (10) and RAIL (female) Repair or
NO short circuit in wiring harness
• Disconnect ECMA and (B), and between ECMA (female) replace
RAIL.
harnesses as shown in Table 2? RAIL (female) (B)
YES
Table 1 Table 2
ECMA (female), RAIL (female) Resistance value ECMA (female), RAIL (female) Resistance value
Between ECMA (3) and RAIL (A) Max. 10 z Between ECMA (10) and RAIL Max. 10 z
WA700-3 20-905
(10)
Troubleshooting EA-44, EA-45, EA-46
EA-44 Error code [467] (Abnormality in timing rail actuator control)
EA-45 Error code [468] (Abnormality in fuel rail actuator control)
Cause Remedy
• Turn starting switch ON. Is another error code displayed NO

at same time?
Go to
YES troubleshooting
— for service code
displayed
2
When engine is run at rated speed, NO
• Start engine does output go up or down, or
does exhaust temperature go up?
YES
Defective fuel rail actuator Replace
3
filter, piping?
YES Repair or
Clogging, looseness, breakage, or
4
Is fuel rail actuator screen NO
clogged with dirt?
YES
Clogged fuel rail actuator screen Clean or
replace
5
NO Defective fuel rail actuator or Replace
Is engine oil diluted with fuel?
defective engine controller
YES
Broken injector O-ring Replace
EA-46 Error code [514] (Abnormality in fuel rail actuator)
20-906 WA700-3
(10)
EA-47 Error code [527] (Abnormality in dual output solenoid A system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance of relay L64 (male) NO Defective engine oil pressure relay Replace
• Disconnect L64. (1) and (2) 200 – 400 z?
YES
2
Is resistance between ECMB Defective contact or disconnection
• Turn starting switch OFF. NO in wiring harness between ECMB Repair or
• Disconnect ECMB and L64. (female) (1) and L64 (female) replace
(1) less than 1 z? (female) (1) and L64 (female) (1)
YES
3
There is a disconnection or
Is the resistance value between
• Turn starting switch OFF. NO connection fault in the wiring Repair or
L64(frmale) (2) and the chassis
• Disconnect L64. harness between L64 (female) (2) replace
less than 1 z?
and the chassis.
YES
4
Is resistance between ECMB
Short circuit in wiring harness
(female) (1) and surrounding NO Repair or
• Turn starting switch OFF. between ECMB (female) (1) and L64
wiring harnesses more than 100 replace
• Disconnect ECMB and L64. (female) (1)
kz?
YES
EA-48 Error code [551] (Abnormality [2] in idling validation switch system)
WA700-3 20-907
(10)
EA-49 Error code [554] (Abnormality [in range] in fuel rail pressure sensor)
Cause Remedy
• Remove timing rail 1

pressure sensor and fuel Is voltage between RPR (C) and
rail pressure sensor. NO Replace
(B) same as voltage between Defective fuel rail pressure sensor
• Insert T-adapter into RPR
and TPR. TPR (C) and (B)?
2
• Turn starting switch OFF. (female) (5) and RPR (female) NO short circuit in wiring harness Repair or
harnesses as shown in Table 1? RPR (female) (A)
YES
3
(female) (18) and RPR (female) NO short circuit in wiring harness Repair or
• Turn starting switch OFF. (B), and between ECMA (female) between ECMA (female) (18) and replace
• Disconnect ECMA and RPR. (18) and surrounding wiring RPR (female) (B)
YES
4
4. Is resistance between ECMA Defective contact, disconnection, or
(female) (31) and RPR (female) NO short circuit in wiring harness Repair or
• Turn starting switch OFF. (C), and between ECMA (female)
harnesses as shown in Table 3? RPR (female) (C)
YES
5
Is negative pressure at suction
NO Defective engine controller Replace
• Start engine. side (tank side) of fuel filter
YES
filter replace
Table 1 Table 2
Between ECMA (5) and RPR (A) Max. 10 z Between ECMA (18) and RPR (B) Max. 10 z
Table 3
ECMA (female), RPR (female) Resistance value

Between ECMA (31) and RPR (C) Max. 10 z
20-908 WA700-3
(10)
WA700-3 20-909
(10)
Troubleshooting of VHMS controller system
(VHMS mode)
Electrical system diagram related VHMS controller .................................................................................. 20-1004
Information given in troubleshooting chart ................................................................................................ 20-1006
Phenomenon type code list....................................................................................................................... 20-1007
[DBB0KK] (or VHMS_LED indicates "n901") Abnormality in source voltage......................................... 20-1008
[DBB5KP] (or VHMS_LED indicates "n904") Abnormality in sensor power source (5 V) system.......... 20-1010
[DBB6KP] (or VHMS_LED indicates "n902") Abnormality in sensor power source (24 V) system........ 20-1012
[DBBRKR] (or VHMS_LED displays [n801]) Defective CAN communications: Defective
communications (KR) (between engine controller and VHMS controller)............................. 20-1014
[DGE1KB] (or VHMS_LED displays [n242]) Disconnection, short circuit with chassis ground
in engine oil temperature sensor system (KB) {30 min. (at 500 rpm or above) after
starting engine}..................................................................................................................... 20-1016
[DGE1KY] (or VHMS_LED displays [n242]) Short circuit with power source (hot short) in engine oil
temperature sensor system (KY) .......................................................................................... 20-1017
[DGE5KX] (or VHMS_LED displays [n401]) Failure in ambient temperature sensor system:
Input signal outside range (KX) ............................................................................................ 20-1018
[DGT4KA] (or VHMS_LED displays [n312]) Disconnection, short circuit with chassis ground
in No. 1, 2, 3 (front) exhaust temperature sensor system (KA) ............................................ 20-1020
[DGT4KB] (or VHMS_LED displays [n311]) Short circuit with power source (hot short)
in No. 1, 2, 3 (rear) exhaust temperature sensor system (KB) ............................................. 20-1022
[DGT5KA] (or VHMS_LED displays [n322]) Disconnection, short circuit with chassis ground
in No. 4, 5, 6 (front) exhaust temperature sensor system (KA) ............................................ 20-1024
in No. 4, 5, 6 (front) exhaust temperature sensor system (KB) ............................................ 20-1026
[DHE5KB] (or VHMS_LED displays [n332]) Disconnection, short circuit with chassis ground
in engine blow-by pressure sensor system (KA) .................................................................. 20-1028
[DHE5KY] (or VHMS_LED displays [n331]) Short circuit with power source (hot short) in engine
blow-by pressure sensor system (KY) .................................................................................. 20-1030
[DHT3KX] (or VHMS_LED displays [n614]) Trouble in transmission oil pressure sensor system:
Out of input signal range (KX) .............................................................................................. 20-1032
[DHP2KX] (or VHMS_LED displays [n531]) Trouble in main pump oil pressure sensor system:
[DHT8KX] (or VHMS_LED displays [n533]) Trouble in steering oil pressure sensor system:
[DGH2KX] (or VHMS_LED displays [n537]) Trouble in hydraulic oil temperature sensor system:
[DHU2KX] (or VHMS_LED displays [n711]) Trouble in front brake oil pressure sensor system:
WA700-3 20-1001
(11)
Troubleshooting
[DHU3KX] (or VHMS_LED displays [n712]) Trouble in rear brake oil pressure sensor system:
[DGR4KX] (or VHMS_LED displays [n717]) Trouble in front brake oil temperature sensor system:
[F@BBZL] (or VHMS_LED displays [n338]) Engine blow-by pressure is high: (ZL) .............................. 20-1045
[F@BYNR] (or VHMS_LED displays [n362]) No. 1, 2, 3 (rear) exhaust temperature is high (2): (NR) ... 20-1046
[F@BYNS] (or VHMS_LED displays [n361]) No. 1, 2, 3 (rear) exhaust temperature is high (1): (NS) ... 20-1047
[F@BZNR] (or VHMS_LED displays [n372]) No. 4, 5, 6 (front) exhaust temperature is high (2): (NR) .. 20-1048
[F@BZNS] (or VHMS_LED displays [n371]) No. 4, 5, 6 (front) exhaust temperature is high (1): (NS) .. 20-1049
VHMS-1 Abnormality in satellite data communication......................................................................... 20-1050
a) Satellite communication data are not transmitted............................................................. 20-1050
b) Abnormality in downloading into PC or setting of PC ....................................................... 20-1054
VHMS-2 Abnormality in saving data in VHMS controller (Data are not saved) ................................... 20-1056
VHMS-3 Engine blow-by pressure indicated by monitor is low (When blow-by pressure measured
with measuring instrument is normal) ................................................................................... 20-1058
20-1002 WA700-3
(11)
Troubleshooting Electrical system diagram related VHMS controller
Electrical system diagram related VHMS controller
20-1004 WA700-3
(11)
Troubleshooting Electrical system diagram related VHMS controller
WA700-3 20-1005
(11)
Troubleshooting Information given in troubleshooting chart
Information given in troubleshooting chart
a The following type of information is given in the troubleshooting charts and related circuit diagrams, so make
sure that you understand the content fully before starting troubleshooting.
Action code Failure code Controller code

Shown on panel Shown on panel Shown on panel Trouble Problem that appeared on machine
display display display
Contents of
Condition when monitor panel or controller detected failure.
trouble
Action of
Action taken to protect system or equipment when monitor panel or controller detected failure.
controller
Problem that
appears on Problem that appeared on machine when monitor panel or controller took above action.
machine
Related
Information related to troubleshooting or failure that occurred.
information
Cause Standard value in normal state/Remarks on troubleshooting

<Content of information>
• Standard value when condition is normal (used to judge status of
probable failure).
1 • Remarks used to judge status of probable failure.
<Problems with wiring harness>

• Disconnection
Defective connection of connector or disconnection in wiring harness.
• Ground fault
2 Wiring harness not connected to GND (ground) circuit is in contact
with GND circuit.
• Short circuit with power source (Hot short)
Wiring harness not connected to power source (24V) circuit is in con-
tact with power source circuit.
Probable cause • Short circuit
Probable cause of existing
and standard Wiring harnesses of independent circuits are in abnormal contact.
value when failure (the numbers are index
3
normal numbers and do not indicate
<Precautions when troubleshooting>
the order of priority)
1) Method of displaying connector No. and method of handling T-
adapter
If there are no special instructions, insert or connect the T-adapter
as follows.
• If there is no indication of (male) or (female) with the connector No.,
4 disconnect the connector and insert the T-adapter into both the
male and female sides.
• If (male) or (female) is indicated with the connector No., disconnect
the connector and insert the T-adapter into only the side indicated
(either male or female).
2) Order of listing pin No. and method of handling test lead
5 If there are no special instructions, connect the (+) lead and (–) lead
of the tester as follows.
• Connect the (+) lead to the pin No. or wiring harness given first.
• Connect the (–) lead to the pin No. or wiring harness given last.
20-1006 WA700-3
(11)
Troubleshooting Phenomenon type code list
Related electrical circuit diagram
This is the section of the circuit diagram that shows the parts related to the failure.
• Connector No.: (type – No. of pins) (color).
• Arrows ( ): Shows approximate mounting position on machine.
Phenomenon type code list
a For phenomenon type codes marked "See list", refer to this list.
Phenomenon Phenomenon
Contents Contents
code code
Fill signal for non-existent combination of clutches ON
KA Disconnection L0
simultaneously for 2 or more channels.
KB Short circuit L1 Fill signal ON when command current to ECMV is OFF.
KK Drop in power source voltage, input L2 Fuel pressure is higher than max. specified value.
KQ Mismatch in model selection signal L3 Target components cannot be controlled.
KR Defective communications L4 ON/OFF signals from 2 systems do not match.
Engine speed signal, C terminal signal, oil pressure
KT Abnormality inside controller L6 switch, coolant temperature sensor signals do not
match operating condition or stopped condition.
KX Input signal outside range L8 Analog signals of 2 systems do not match.
Short circuit with power source
KY LC Speed signals of 2 systems do not match.
(Hot short)
Switch remains pressed for length of time unthinkable
KZ Disconnection or short circuit LD
for normal operations .
Fill signal is turned OFF when command current to
MA Defective function LH
ECMV is ON.
MB Drop in function
MW Slippage
NS Overheat
ZG Drop in oil pressure
ZK Drop in level
WA700-3 20-1007
(11)
Troubleshooting [DBB0KK]
[DBB0KK] (or VHMS_LED indicates [n901]) Abnormality in source voltage

Trouble Abnormality source voltage
Not set DBB0KK Not set
Contents of
• The switch source voltage is below 9.5(± 2.5)V or above 42.4(± 6)V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • The system may not operate normally.
machine
Related
• VHMS controller LED indicates [n901].
information

• If the circuit breaker is turned OFF, the circuit probably has grounding
1 Defective circuit breaker
fault (See cause 3).
1) Turn starting switch OFF.
2) Disconnect connector CN-V01 and battery relay terminal CN-R12
(Terminal M).
Disconnection in wiring 3) Connect T-adapter.
2 harness (Disconnection or
Wiring harness between CN-V01 (female) (6),
defective contact) Resistance Max. 1 z
(7) – battery relay CN-R12 (Terminal M)
Resistance Max. 1 z
(12) – ER
Probable cause
and standard 1) Turn starting switch OFF.
value when 2) Disconnect connector CN-V01, battery relay terminal CN-R12
normal (Terminal M), and connectors related to them.
3 Ground fault in wiring harness Wiring harness between
CN-V01 (female) (6), (7) – Resistance between CN-V01
battery relay CN-R12 (female) (6), (7) – chassis Min. 1 Mz
(Terminal M) and wiring ground
harnesses related to it
2) Disconnect CN-V01.
4 Defective VHMS controller 3) Connect T-adapter.
4) Turn starting switch ON.
Between CN-V01 (6), (7) – chassis ground Voltage 20 – 30 V
20-1008 WA700-3
(11)
Troubleshooting [DBB0KK]
WA700-3 20-1009
(11)
Troubleshooting [DBB5KP]
[DBB5KP] (or VHMS_LED indicates [n904]) Abnormality in sensor power source (5 V)

system

Trouble Abnormality in sensor power source (5 V) system
Not set DBB5KP Not set
Contents of
• Sensor power source (5 V) voltage is out of the normal range (4.5 – 5.5 V).
trouble
Action of
controller
Problem that
machine
Related
information

2) Disconnect connectors CN-V01, CN-V32, CN-V27, CN-V26,
CN-V23 and CN-V22.
Wiring harness between Resistance between CN-V01
CN-V01 (female) (4) – (female) (4) or CN-V32 Min. 1 Mz
CN-V32 (female) (B) (female) (B) – chassis ground
1 Ground fault in wiring harness CN-V27 (female) (B) (female) (B) – chassis ground
CN-V27 (female) (B) (female) (B) c chassis ground
Probable cause
and standard
CN-V23, and CN-V22.
value when
normal
Wiring harness between Voltage between CN-V01
CN-V01 (female) (4) – (female) (4) or CN-V32 Max. 1 V
Short circuit with power CN-V01 (female) (5) – (female) (5) or CN-V27 Max. 1 V
2
source in wiring harness CN-V27 (female) (B) (female) (B) – chassis ground
2) Disconnect connector CN-V01.
Between CN-V01 (4), (5) – (11), (12) Voltage 4.5 – 5.5 V
20-1010 WA700-3
(11)
WA700-3 20-1011
(11)
[DBB6KP] (or VHMS_LED indicates [n902]) Abnormality in sensor power source

(24 V) system

Trouble Abnormality in sensor power source (24 V) system
Not set DBB6KP Not set
Contents of
• Sensor power source (24 V) voltage is out of the normal range (20 - 30V).
trouble
Action of
controller
Problem that
machine
Related
information

2) Disconnect connectors CN-V01, CN-V34, CN-V35 and CN-V28
CN-V34 (female) (A) (female) (A) – chassis ground
1 Ground fault in wiring harness
CN-V28 (female) (2) (female) (2) – chassis ground
Probable cause
2) Disconnect connectors CN-V01, CN-V34, CN-V35, and CN-V28.
and standard
value when
normal
Short circuit with power CN-V34 (female) (A) (female) (A) – chassis ground
2
Between CN-V01 (2) – (11), (12) Voltage 4.5 – 5.5 V
20-1012 WA700-3
(11)
WA700-3 20-1013
(11)
Troubleshooting [DBBRKR]
[DBBRKR] (or VHMS_LED displays [n801]) Defective CAN communications: Defective

communications (KR) (between engine controller and VHMS controller)
Action code Failure code Controller code Defective CAN communications: Defective communications
Trouble
Not set DBBRKR Not set (KR) (between engine controller and VHMS controller)
Contents of
• Communications (CAN) data from engine controller cannot be obtained.
trouble
Action of
• Maintains condition existing when abnormality occurred.
controller
Problem that
appears on • VHMS function for obtaining data from engine controller not working.
machine
• LED display is [n801]
Related
• If failure code [DASRKR] related to CAN communications is displayed, carry out troubleshooting first for
information
the applicable code.

1) Turn the starting switch OFF.
2) Disconnect connectors CN-V06 and CAN1.
1 harness (disconnection, Wiring harness between CN-V06 (female) (4) –
Resistance Max. 1 z
defective contact) CAN1 (female) (C)
Wiring harness between CN-V06 (female) (12)
Resistance Max. 1 z
– CAN1 (female) (D)
2) Disconnect connectors CN-V06 and CAN1.
2 Ground fault in wiring harness CN-V06 (female) (4) – (female) (4), CAN1 (female) Max. 1 z
CAN1 (female) (C) (C) – chassis ground
Probable cause CN-V06 (female) (12) – (female) (12), CAN1 (female) Max. 1 z
and standard CAN1 (female) (D) (D) – chassis ground
value when 1) Turn the starting switch OFF.
normal 2) Disconnect connector CN-V06.
Short circuit with power Wiring harness between Voltage between CN-V06
3
source in wiring harness CN-V06 (female) (4) – (female) (4), CAN1 (female) Max. 1 V
CAN1 (female) (C) (C) – chassis ground
CN-V06 (female) (12) – (female) (12), CAN1 (female) Max. 1 V
CAN1 (female) (D) (D) – chassis ground
2) Replace VHMS controller.
4 Defective VHMS controller Does not VHMS controller
Is communication communicate normally normal
normal when VHMS
controller is replaced? Communicates VHMS controller
normally defective
20-1014 WA700-3
(11)
Troubleshooting [DBBRKR]
WA700-3 20-1015
(11)
Troubleshooting [DGE1KB]
[DGE1KB] (or VHMS_LED displays [n242]) Disconnection, short circuit with chassis
ground in engine oil temperature sensor system (KB) {30 min. (at 500 rpm
or above) after starting engine}
Action code Failure code Controller code Disconnection, short circuit with chassis ground in engine
Trouble oil temperature sensor system (KB)
Not set DGE1KB Not set {30 min. (at 500 rpm or above) after starting engine}
Contents of
• Signal voltage of engine oil temperature sensor has dropped below 0.3V.
trouble
Action of
controller
Problem that
appears on • Engine oil temperature cannot be monitored with monitoring function.
machine
Related • Engine oil temperature can be checked with monitoring function (code: 42700).
information • LED display is [n242]

Defective engine oil 4) Connect connector.
1
temperature sensor 5) Turn starting switch ON.
Between CN-V33 25°C Resistance Approx. 35 – 50 kz
(male) (1) – (2) 100°C Resistance Approx. 3.3 – 4.3 kz
2) Disconnect connectors CN-V02 and CN-V33.
Probable cause Resistance Max. 1 z
defective contact) CN-V33 (female) (1)
and standard
value when Resistance Max. 1 z
normal – CN-V33 (female) (2)
2) Disconnect connector CN-V02 and CN-V33.
3 Ground fault in wiring harness Resistance between CN-V02
Wiring harness between
(female) (3), CN-V33
CN-V02 (female) (3) – Min. 1 Mz
(female) (1) – chassis
CN-V33 (female) (1)
ground
(female) (3) – (12) 100°C Resistance Approx. 3.3 – 4.3 kz
20-1016 WA700-3
(11)
Troubleshooting [DGE1KY]
[DGE1KY] (or VHMS_LED displays [n242]) Short circuit with power source (hot short)
in engine oil temperature sensor system (KY)
Action code Failure code Controller code Short circuit with power source (Hot short) in engine oil
Trouble
Not set DGE1KY Not set temperature sensor system (KY)
Contents of
• Signal voltage of engine oil temperature sensor has risen above 4.9V.
trouble
Action of
controller
Problem that
appears on • Engine oil temperature cannot be monitored with monitoring function.
machine
Related • Engine oil temperature can be checked with monitoring function (code: 42700).

Defective engine oil 4) Connect connector.
1
temperature sensor 5) Turn starting switch ON.
(male) (1) – (2) 100°C Resistance Approx. 3.3 – 4.3 kz
Probable cause
and standard
value when
Short circuit with power 3) Connect T-adapter.
normal 2
source in wiring harness Wiring harness between Voltage between CN-V02
CN-V02 (female) (3) – (female) (3), CN-V33 Max. 1 V
(female) (3) – (12) 100°C Resistance Approx. 3.3 – 4.3 kz
WA700-3 20-1017
(11)
Troubleshooting [DGE5KX]
[DGE5KX] (or VHMS_LED displays [n401]) Failure in ambient temperature sensor

system: Input signal outside range (KX)
Action code Failure code Controller code Failure in ambient temperature sensor system: Input signal
Trouble
Not set DGE5KX Not set outside range (KX)
Contents of
• Input signal voltage of ambient temperature sensor is more than 4.9V or less than 0.3V.
trouble
Action of
controller
Problem that
appears on • Ambient temperature cannot be monitored with monitoring function.
machine
Related • Ambient temperature can be checked with monitoring function (code: 37501).

1)Turn starting switch OFF.
2)Disconnect connector CN-V21.
3)Insert T-adapter.
Defective ambient 4)Connect connector.
1 5)Turn starting switch ON.
temperature sensor
0°C Resistance Approx. 10 – 15 kz
Between CN-V21
(male) (1) – (2)
Probable cause 2 harness (disconnection, Wiring harness between CN-V02 (female) (10)
Resistance Max. 1 z
and standard defective contact) – CN-V21 (female) (1)
value when Wiring harness between CN-V02 (female) (12)
normal Resistance Max. 1 z
– CN-V21 (female) (2)
CN-V02 (female) (10) – (female) (10), CN-V21 Min. 1 Mz
4 Defective VHMS controller
Between CN-V02
(female) (10) – (12)
20-1018 WA700-3
(11)
Troubleshooting [DGT4KA]
[DGT4KA] (or VHMS_LED displays [n312]) Disconnection, short circuit with chassis
ground in No. 1, 2, 3 (front) exhaust temperature sensor system (KA)
Action code Failure code Controller code Disconnection, short circuit with chassis ground in No. 1, 2,
Trouble
Not set DGT4KA Not set 3 (front) exhaust temperature sensor system (KA)
Contents of
• Signal voltage of less than 0.3V detected from No. 1, 2, 3 (front) exhaust temperature sensor.
trouble
Action of
controller
Problem that
appears on • No. 1, 2, 3 (front) exhaust temperature cannot be monitored with monitoring function.
machine
Related • No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600).
information • LED display is [n312].

2) Replace No. 1, 2, 3 (front) exhaust temperature sensor.
Defective No. 1, 2, 3 (front) Does not become normal when Exhaust temperature sensor
1
exhaust temperature sensor replaced normal
Exhaust temperature sensor
Becomes normal when replaced
defective
Defective No. 1, 2, 3 (front) 4) Connect connector.
2 exhaust temperature sensor 5) Start engine.
amp Between (A) – (C) Voltage 20 – 30 V
CN-V34 Between 20°C Voltage Approx. 0.9 – 1.2 V
(B) – (C) 500°C Voltage Approx. 2.6 – 3.5 V
Probable cause 2) Disconnect connectors CN-V01, CN-V02, CN-V34, CN-V36, and
CN-V38.
and standard
value when
normal Wiring harness between CN-V01 (female) (2) –
Disconnection in wiring Resistance Max. 1 z
CN-V34 (female) (A)
3 harness (disconnection,
Wiring harness between CN-V02 (female) (7) –
CN-V34 (female) (B)
Resistance Max. 1 z
CN-V38 (female) (1)
Resistance Max. 1 z
2) Disconnect connectors CN-V01, CN-V02, CN-V38, CN-V36, and
CN-V34.
20-1020 WA700-3
(11)

Probable cause 3) Insert T-adapter.
and standard 4) Connect connector.
value when 5 Defective VHMS controller 5) Start engine.
normal
Between CN-V01 (2) – CN-V02 (12) Voltage 20 – 30 V
Between CN-V02 20°C Voltage Approx. 0.9 – 1.2V
(7) – (12) 500°C Voltage Approx. 2.6 – 3.5 V
WA700-3 20-1021
(11)
Troubleshooting [DGT4KB]
in No. 1, 2, 3 (rear) exhaust temperature sensor system (KB)
Action code Failure code Controller code Short circuit with power source (Hot short) in No. 1, 2, 3
Trouble
Not set DGT4KB Not set (rear) exhaust temperature sensor system (KB)
Contents of
• Signal voltage of more than 4.9V detected from No. 1, 2, 3 (rear) exhaust temperature sensor.
trouble
Action of
controller
Problem that
appears on • No. 1, 2, 3 (rear) exhaust temperature cannot be monitored with monitoring function
machine
Related • No. 1, 2, 3 (rear) exhaust temperature can be checked with monitoring function (code: 42600).

2) Replace No. 1, 2, 3 (rear) exhaust temperature sensor
Defective No. 1, 2, 3 (rear) Does not become normal when Exhaust temperature sensor
1
defective
Defective No. 1, 2, 3 (rear) 4) Connect connector.
Probable cause 2) Disconnect connectors CN-V38 and CN-V36.
and standard 3 Ground fault in wiring harness
value when Wiring harness between Resistance between CN-V36
normal CN-V36 (female) (1) – (female) (1), CN-V38 Min. 1 Mz
Short circuit with power 4) Turn starting switch ON.
4
Wiring harness between CN- Resistance between CN-V02
V02 (female) (7) – CN-V34 (female) (7), CN-V34 Min. 1 Mz
(female) (B) (female) (B) – chassis ground
4) Connect connector.
5 Defective VHMS controller 5) Start engine.
Between CN-V01 (2) – CN-V02
Voltage 20 – 30 V
(12)
Between CN-V02 (7) – 20°C Voltage Approx. 0.9 – 1.2 V
(12) 500°C Voltage Approx. 2.6 – 3.5 V
20-1022 WA700-3
(11)
WA700-3 20-1023
(11)
[DGT5KA] (or VHMS_LED displays [n322]) Disconnection, short circuit with chassis
ground in No. 4, 5, 6 (front) exhaust temperature sensor system (KA)
Action code Failure code Controller code Disconnection, short circuit with chassis ground in No. 4, 5,
Trouble
Not set DGT5KA Not set 6 (front) exhaust temperature sensor system (KA)
Contents of
• Signal voltage of less than 0.3V detected from No. 4, 5, 6 (front) exhaust temperature sensor.
trouble
Action of
controller
Problem that
appears on • No. 4, 5, 6 (front) exhaust temperature cannot be monitored with monitoring function
machine

2) Replace No. 4, 5, 6 (front) exhaust temperature sensor
1
defective
Probable cause 2) Disconnect connectors CN-V01, CN-V02, CN-V39, CN-V37, and
CN-V35.
and standard
value when
normal Wiring harness between CN-V01 (female) (2) –
Disconnection in wiring Resistance Max. 1 z
CN-V35 (female) (A)
3 harness (disconnection,
CN-V35 (female) (B)
Resistance Max. 1 z
CN-V39 (female) (1)
Resistance Max. 1 z
2) Disconnect connectors CN-V01, CN-V02, CN-V39, CN-V37, and
CN-V35.
20-1024 WA700-3
(11)

Probable cause 3) Insert T-adapter.
and standard 4) Connect connector.
value when 5 Defective VHMS controller 5) Start engine.
normal Between CN-V01 (2) – CN-V02
Voltage 20 – 30 V
(12)
WA700-3 20-1025
(11)
in No. 4, 5, 6 (front) exhaust temperature sensor system (KB)
Action code Failure code Controller code Short circuit with power source (Hot short) in No. 4, 5, 6
Trouble
Not set DGT5KB Not set (front) exhaust temperature sensor system (KB)
Contents of
• Signal voltage of more than 4.9V detected from No. 4, 5, 6 (front) exhaust temperature sensor.
trouble
Action of
controller
Problem that
appears on • No. 4, 5, 6 (front) exhaust temperature cannot be monitored with monitoring function.
machine

2) Replace No. 4, 5, 6 (front) exhaust temperature sensor
1
defective
Probable cause 2) Disconnect connectors CN-V38 and CN-V39.
and standard 3 Ground fault in wiring harness
value when Wiring harness between Resistance between CN-V37
normal CN-V37 (female) (1) – (female) (1), CN-V39 Min. 1 Mz
Short circuit with power 4) Turn starting switch ON.
4
4) Connect connector.
Voltage 20 – 30 V
(12)
20-1026 WA700-3
(11)
WA700-3 20-1027
(11)
Troubleshooting [DHE5KB]
[DHE5KB] (or VHMS_LED displays [n332]) Disconnection, short circuit with chassis
ground in engine blow-by pressure sensor system (KA)
Action code Failure code Controller code Disconnection, short circuit with chassis ground in engine
Trouble
Not set DHE5KB Not set blow-by pressure sensor system (KA)
Contents of
• Signal voltage of blow-by pressure sensor has dropped below 0.1V.
trouble
Action of
controller
Problem that
appears on • Blow-by pressure cannot be monitored with monitoring function.
machine
Related • Blow-by pressure can be checked with monitoring function (code: 42800).

Defective engine blow-by 4) Connect connector.
1
pressure sensor 5) Turn starting switch ON.
Between CN-V32 (B) – (A) Voltage 4.5 – 5.5V
Between CN-V32 (C) – (A) Voltage 0.3 – 0.7V
2) Disconnect connectors CN-V01, CN-V02, and CN-V32.
Resistance Max. 1 z
defective contact) CN-V32 (female) (B)
– CN-V32 (female) (C)
and standard
value when 1) Turn starting switch OFF.
normal 2) Disconnect connectors CN-V01, CN-V02, and CN-V32.
3 Ground fault in wiring harness CN-V01 (female) (5) – (female) (5), CN-V32 Min. 1 Mz
CN-V32 (female) (C) (female) (C) - chassis ground
4 Defective VHMS controller 4) Connect connector.
5) Start engine.
Between CN-V01 (5) – CN-V02 (12) Voltage 4.5 – 5.5V
Between CN-V02 (18) – (12) Voltage 0.3 – 0.7V
20-1028 WA700-3
(11)
Troubleshooting [DHE5KB]
WA700-3 20-1029
(11)
Troubleshooting [DHE5KY]
[DHE5KY] (or VHMS_LED displays [n331]) Short circuit with power source (hot short)
in engine blow-by pressure sensor system (KY)
Action code Failure code Controller code Short circuit with power source (Hot short) in engine blow-
Trouble
Not set DHE5KY Not set by pressure sensor system (KY)
Contents of
• Signal voltage of blow-by pressure sensor has risen above 4.7V.
trouble
Action of
controller
Problem that
appears on • Blow-by pressure cannot be monitored with monitoring function.
machine
Related • Blow-by pressure can be checked with monitoring function (code: 42800).

Defective engine blow-by 4) Connect connector.
1
Between CN-V32 (B) – (A) Voltage 4.5 – 5.5 V
Between CN-V32 (C) – (A) Voltage 0.3 – 0.7 V
Probable cause 1) Turn starting switch OFF.
and standard 2) Disconnect connectors CN-V02 and CN-V32.
value when 3) Connect T-adapter.
normal 2 4) Turn starting switch ON.
Wiring harness between CN- Voltage between CN-V02
V02 (female) (18) – CN-V32 (female)(18), CN-V32 Max. 1 V
(female) (C) (female) (C) – chassis ground
Between CN-V01 (5) – CN-V02 (12) Voltage 4.5 – 5.5 V
Between CN-V02 (18) – (12) Voltage 0.3 – 0.7 V
20-1030 WA700-3
(11)
Troubleshooting [DHT3KX]
[DHT3KX] (or VHMS_LED displays [n614]) Trouble in transmission oil pressure

sensor system: Out of input signal range (KX)
Action code Failure code Controller code Transmission oil pressure sensor: Out of input signal range
Trouble
Not set DHT3KX Not set (KX)
Contents of
• The signal circuit voltage of the transmission oil pressure sensor is below 0.3 V or above 4.7 V.
trouble
Action of
controller
Problem that
appears on • The transmission oil pressure is not displayed and recorded normally.
machine
Related
• The LED indicates [n614].
information

Disconnection in wiring Wiring harness between CN-V01 (female) (2) –
Resistance Max. 1 z
1 harness (disconnection, CN-V28 (female) (2)
defective contact) Wiring harness between CN-V02 (female) (6) –
Resistance Max. 1 z
CN-V28 (female) (1)
Resistance Max. 1 z
CN-V28 (female) (1)
2 Ground fault in wiring harness CN-V01 (female) (2) – (female) (2) or CN-V28 Min. 1 Mz
Probable cause CN-V28 (female) (3) (female) (3) – chassis ground
value when 2) Disconnect connectors CN-V02 and CN-V28.
normal 3) Connect T-adapter.
3 4) Turn starting switch ON.
CN-V02 (female) (6) – (female)(6), CN-V28 (female) Max. 1 V
CN-V28 (female) (3) (3) – chassis ground
Defective transmission oil 4) Connect connector.
4
Between CN-V28 (3) and (1) Voltage 20 – 30 V
Between CN-V28 (2) and (1) Voltage 1.0 – 4.6 V
5 Defective VHMS controller 4) Connect connectors.
Between CN-V01 (2) and CN-V03 (9) Voltage 20 – 30 V
Between CN-V02 (6) and CN-V03 (9) Voltage 1.0 – 4.6 V
20-1032 WA700-3
(11)
WA700-3 20-1033
(11)
Troubleshooting [DHP2KX]
[DHP2KX] (or VHMS_LED displays [n531]) Trouble in main pump oil pressure sensor
system: Out of input signal range (KX)
Action code Failure code Controller code Main pump oil pressure sensor: Out of input signal range
Trouble
Not set DHP2KX Not set (KX)
Contents of
• The signal circuit voltage of the main pump oil pressure sensor is below 0.3 V or above 4.7 V.
trouble
Action of
controller
Problem that
appears on • The main pump oil pressure is not displayed and recorded normally.
machine
Related
information

Resistance Max. 1 z
1 harness (disconnection, CN-V27 (female) (B)
defective contact) Wiring harness between CN-V02 (female) (15)
Resistance Max. 1 z
Resistance Max. 1 z
CN-V28 (female) (A)
Probable cause CN-V27 (female) (C) (female) (C) – chassis ground
CN-V02 (female) (15) – (female)(15), CN-V27 Max. 1 V
CN-V27 (female) (C) (female) (C) – chassis ground
Defective main pump oil 4) Connect connector.
4
Between CN-V27 (B) and (A) Voltage 4–6V
Between CN-V27 (C) and (A) Voltage 1.0 – 4.6 V
Between CN-V01 (4) and CN-V03 (9) Voltage 4–6V
20-1034 WA700-3
(11)
Troubleshooting [DHP2KX]
WA700-3 20-1035
(11)
[DHT8KX] (or VHMS_LED displays [n533]) Trouble in steering oil pressure sensor

Trouble Steering oil pressure sensor: Out of input signal range (KX)
Not set DHT8KX Not set
Contents of
• The signal circuit voltage of the steering oil pressure sensor is below 0.3 V or above 4.7 V.
trouble
Action of
controller
Problem that
appears on • The steering oil pressure is not displayed and recorded normally.
machine
Related
information

Resistance Max. 1 z
1 harness (disconnection, CN-V26 (female) (B)
defective contact) Wiring harness between CN-V02 (female) (16)
Resistance Max. 1 z
Resistance Max. 1 z
CN-V26 (female) (A)
Probable cause CN-V26 (female) (C) (female) (C) – chassis ground
CN-V02 (female) (16) – (female)(16), CN-V26 Max. 1 V
CN-V26 (female) (C) (female) (C) – chassis ground
Defective steering oil 4) Connect connector.
4
Between CN-V26 (B) and (A) Voltage 4–6V
Between CN-V26 (C) and (A) Voltage 1.0 – 4.6 V
20-1036 WA700-3
(11)
WA700-3 20-1037
(11)
Troubleshooting [DGH2KX]
[DGH2KX] (or VHMS_LED displays [n537]) Trouble in hydraulic oil temperature

Action code Failure code Controller code Hydraulic oil temperature sensor: Out of input signal range
Trouble
Not set DGH2KX Not set (KX)
Contents of
• The input signal voltage of the hydraulic oil temperature sensor is above 4.9 V or below 0.3 V.
trouble
Action of
controller
Problem that
appears on • The hydraulic oil temperature cannot be monitored with the monitoring function.
machine
Related
information

Disconnection in wiring 3)Insert T-adapter.
1 harness (disconnection, 4)Turn starting switch ON.
defective contact) 25°C Resistance 38.2 – 47.8 kz
Between CN-V24
30°C Resistance 31.6 – 39.1 kz
(male) (1) and (2)
2 Wiring harness between CN-V02 (female) (11)
Probable cause harness Resistance Max. 1 z
– CN-V24 (1)
and standard
CN-V24 (2)
normal
Wiring harness between Wiring harness between
CN-V02 (female) (11) – CN-V03 (female) (9) – Max. 1 Mz
CN-V24 (2) CN-V24 (1)
2) Disconnect connector CN-V02, CN-V03, and CN-V24.
4 Defective VHMS controller
Between CN-V02 25°C Resistance 38.2 – 47.8 kz
(female) (11) and 30°C Resistance 31.6 – 39.1 kz
CN-V03 (9) 80°C Resistance 6.2 – 6.7 kz
20-1038 WA700-3
(11)
Troubleshooting [DHU2KX]
[DHU2KX] (or VHMS_LED displays [n711]) Trouble in front brake oil pressure sensor
Action code Failure code Controller code Front brake oil pressure sensor: Out of input signal range
Trouble
Not set DHU2KX Not set (KX)
Contents of
• The signal circuit voltage of the front brake oil pressure sensor is below 0.3 V or above 4.7 V.
trouble
Action of
controller
Problem that
appears on • The front brake oil pressure is not displayed and recorded normally.
machine
Related
information

Resistance Max. 1 z
Resistance Max. 1 z
CN-V22 (female) (3)
Resistance Max. 1 z
CN-V22 (female) (1)
CN-V22 (female) 3 (female) (3) – chassis ground
Defective front brake oil 4) Connect connector.
4
Between CN-V22 (3) and (1) Voltage 4–6V
20-1040 WA700-3
(11)
WA700-3 20-1041
(11)
[DHU3KX] (or VHMS_LED displays [n712]) Trouble in rear brake oil pressure sensor
Action code Failure code Controller code Rear brake oil pressure sensor: Out of input signal range
Trouble
Not set DHU3KX Not set (KX)
Contents of
• The signal circuit voltage of the rear brake oil pressure sensor is below 0.3 V or above 4.7 V.
trouble
Action of
controller
Problem that
appears on • The rear brake oil pressure is not displayed and recorded normally.
machine
Related
information

Resistance Max. 1 z
Resistance Max. 1 z
CN-V22 (female) (3)
Resistance Max. 1 z
CN-V23 (female) (1)
Defective rear brake oil 4) Connect connector.
4
Between CN-V23 (3) and (1) Voltage 4–6V
20-1042 WA700-3
(11)
WA700-3 20-1043
(11)
Troubleshooting [DGR4KX]
[DGR4KX] (or VHMS_LED displays [n717]) Trouble in front brake oil temperature
Action code Failure code Controller code Front brake oil temperature sensor: Out of input signal
Trouble
Not set DGR4KX Not set range (KX)
Contents of
• The input signal voltage of the front brake oil temperature sensor is above 4.9 V or below 0.3 V.
trouble
Action of
controller
Problem that
appears on • The front brake oil temperature cannot be monitored with the monitoring function.
machine
Related
information

Disconnection in wiring 3)Insert T-adapter.
1 harness (disconnection, 4)Turn starting switch ON.
defective contact) 25°C Resistance 38.2 – 47.8 kz
Between CN-V25
(male) (1) and (2)
2 Wiring harness between CN-V02 (female) (2) –
Probable cause harness Resistance Max. 1 z
CN-V25 (1)
and standard
normal CN-V25 (2)
Wiring harness between Wiring harness between
CN-V02 (female) (2) – CN-V03 (female) (9) – Max. 1 Mz
CN-V25 (2) CN-V25 (1)
2) Disconnect connector CN-V02 and CN-V03.
4 Defective VHMS controller 25°C Resistance 38.2 – 47.8 kz
Between CN-V02 (2)
and CN-V03 (9)
20-1044 WA700-3
(11)
Troubleshooting [F@BBZL]
[F@BBZL] (or VHMS_LED displays [n338]) Engine blow-by pressure is high: (ZL)

Trouble Engine blow-by pressure is high: (ZL)
Not set F@BBZL Not set
Contents of
• Blow-by threshold value exceeds 8.83 kPa {900 mmH2O}.
trouble
Action of
controller
Problem that
appears on • If machine continues to be used as it is, engine may be damaged.
machine
• Blow-by pressure can be checked with monitoring function (code: 42800).
Related • LED display is [n338].
information • If failure codes [DHE5KA] or [DHE5KY] are displayed, carry out troubleshooting first for the applicable
code.

Probable cause Abnormal rise in blow-by
1 Inspect engine and repair if any abnormality is found
and standard pressure
value when Defective orifice inside
normal 2 Inspect orifice inside breather and repair if any abnormality is found
breather
3 Defective VHMS controller If Items 1 and 2 are normal, defective VHMS controller
WA700-3 20-1045
(11)
Troubleshooting [F@BYNR]
[F@BYNR] (or VHMS_LED displays [n362]) No. 1, 2, 3 (rear) exhaust temperature is

high (2): (NR)

Trouble No. 1, 2, 3 (rear) exhaust temperature is high (2): (NR)
Not set F@BYNR Not set
• Signal circuit of No. 1, 2, 3 (rear) exhaust temperature sensors has detected more than exhaust temper-
Contents of
ature limit line 2 for more than 10 seconds. (Exhaust temperature limit line 2: Straight line between 750°C
trouble
at more than rated output speed and 800°C at less than max. torque speed)
Action of
controller
Problem that
machine
• No. 1, 2, 3 (rear) exhaust temperature can be checked with monitoring function (code: 42600).
information • If failure codes [DGT4KA] or [DGT4KB] are displayed, carry out troubleshooting first for the applicable
code.

Abnormal rise in exhaust
temperature for No. 1, 2, 3
(rear) (When system is
normal)
value when 3) Insert T-adapter.
normal 4) Connect connector.
Voltage 20 – 30 V
(12)
20-1046 WA700-3
(11)
Troubleshooting [F@BYNS]
[F@BYNS] (or VHMS_LED displays [n361]) No. 1, 2, 3 (rear) exhaust temperature is

high (1): (NS)

Trouble No. 1, 2, 3 (rear) exhaust temperature is high (1): (NS)
Not set F@BYNS Not set
• Signal circuit of No. 1, 2, 3 (rear) exhaust temperature sensors has detected more than exhaust temper-
Contents of
ature limit line 1 for more than 1 second. (Exhaust temperature limit line 1: Straight line between 700°C
trouble
Action of
controller
Problem that
machine
• No. 4, 5, 6 (rear) exhaust temperature can be checked with monitoring function (code: 42601).
code.

(rear) (When system is
normal)
Voltage 20 – 30 V
(12)
WA700-3 20-1047
(11)
Troubleshooting [F@BZNR]
[F@BZNR] (or VHMS_LED displays [n372]) No. 4, 5, 6 (front) exhaust temperature is

high (2): (NR)

Trouble No. 4, 5, 6 (front) exhaust temperature is high (2): (NR)
Not set F@BZNR Not set
• Signal circuit of No. 4, 5, 6 (front) exhaust temperature sensors has detected more than exhaust temper-
Contents of
ature limit line 2 for more than 10 seconds. (Exhaust temperature limit line 2: Straight line between 750°C
trouble
Action of
controller
Problem that
machine
• No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600).
code.

(front) (When system is
normal)
Voltage 20 – 30 V
(12)
20-1048 WA700-3
(11)
Troubleshooting [F@BZNS]
[F@BZNS] (or VHMS_LED displays [n371]) No. 4, 5, 6 (front) exhaust temperature is

high (1): (NS)

Trouble No. 4, 5, 6 (front) exhaust temperature is high (1): (NS)
Not set F@BZNS Not set
• Signal circuit of No. 4, 5, 6 (front) exhaust temperature sensors has detected more than exhaust temper-
Contents of
ature limit line 1 for more than 1 second. (Exhaust temperature limit line 1: Straight line between 700°C
trouble
Action of
controller
Problem that
machine
• No. 4, 5, 6 (front) exhaust temperature can be checked with monitoring function (code: 42601).
code.

(front) (When system is
normal)
Voltage 20 – 30 V
(12)
Between CN-V02 (5) – 20° C Voltage Approx. 0.9 – 1.2 V
WA700-3 20-1049
(11)
Troubleshooting VHMS-1
VHMS-1 Abnormality in satellite data communication
a) Satellite communication data are not transmitted
Action code Failure code Controller code Abnormality in satellite data communication
Trouble
Not set Not set Not set a) Satellite communication data are not transmitted
Contents of
• Satellite communication data are not transmitted.
trouble
Action of
controller
Problem that
appears on • Satellite communication data are not transmitted.
machine
Related
information

Machine is in tunnel or • Not defective.
1
building aMove the machine outdoors.
Machine is behind building or • Not defective.
2 mountain and only a part of aMove the machine to a place from where you can look out over the
heaven is seen from it heavens.
Abnormality in communication • Check communication antenna. If it is broken or removed, repair or
3
antenna replace it.
Entry of foreign matter in
4 communication antenna • Check inside of communication antenna and remove foreign matter.
connector
Abnormality in communication • Check communication antenna. If it is broken (or disconnected), re-
5
antenna cable pair or replace it.
Probable cause 2) Disconnect connectors CN-V01, CN-V02, CN-V04, CN-V07,
and standard CN-V08, and CN-V06.
value when
normal
Resistance Max. 1 z
CN-V07 (female) (4)
Resistance Max. 1 z
CN-V07 (female) (10)
6 harness (disconnection, Resistance Max. 1 z
CN-V07 (female) (3)
defective contact)
Resistance Max. 1 z
(8) – CN-V01 (female) (7)
Resistance Max. 1 z
CN-V01 (female) (5)
Resistance Max. 1 z
CN-V04 (female) (17)
Resistance Max. 1 z
(10), (11) – CN-V04 (female) (12)
20-1050 WA700-3
(11)

CN-V08, and CN-V06.
CN-V8 (female) (7), (8) – (female) (7), (8) or CN-V01 Min. 1 Mz
Resistance between CN-V08
Wiring harness between
(female) (5), (10), (11) or
CN-V8 (female) (5), (10), Min. 1 Mz
CN-V02 (female) (7) –
(11) – CN-V02 (female) (7)
chassis ground
Between CN-V06 (female) Resistance between CN-V06
Probable cause (1) – CN-V07 (4) wiring (female) (1) – CN-V07 (4)
and standard
Ground fault or short circuit in harness and CN-V06 wiring harness and CN-V06 Min. 1 Mz
value when 7 (female) (2) – CN-V07 (female) (2) – CN-V07
normal wiring harness
(female) (10) wiring harness (female) (10) wiring harness
(1) – CN-V07 (4) wiring (female) (1) – CN-V07 (4)
harness and CN-V06 wiring harness and CN-V06 Min. 1 Mz
(female) (3) – CN-V07 (female) (3) – CN-V07
(2) – CN-V07 (10) wiring (female) (2) – CN-V07 (10)
harness and CN-V06 wiring harness and CN-V06 Min. 1 Mz
(female) (3) – CN-V07 (female) (3) – CN-V07
(2) – CN-V02 (female) (17) (female) (2) – CN-V02
wiring harness and CN-V08 (female) (17) wiring harness
Min. 1 Mz
(female) (5), (10), (11) – and CN-V08 (female) (5),
CN-V02 (female) (12) wiring (10), (11) – CN-V02 (female)
harness (12) wiring harness
(6) – CN-V04 (female) (5) (female) (6) – CN-V04
wiring harness and CN-V08 (female) (5) wiring harness
Min. 1 Mz
(female) (5), (10), (11) – and CN-V08 (female) (5),
CN-V02 (female) (12) wiring (10), (11) – CN-V02 (female)
harness (12) wiring harness
(7), (8) – CN-V01 (female) (female) (7), (8) – CN-V01
(7) wiring harness and (female) (7) wiring harness
Min. 1 Mz
CN-V08 (female) (5), (10), and CN-V08 (female) (5),
(11) – CN-V02 (female) (10), (11) – CN-V02 (female)
(12) wiring harness (12) wiring harness
WA700-3 20-1051
(11)

2) Disconnect connectors CN-V01, CN-V02, CN-V04,
CN-V07, CN-V08, and CN-V06.
Max. 1 V
4) Connect connectors.
Short circuit with power CN-V07 (female) (4) (female) (4) – chassis ground
8
source in wiring harness Wiring harness between Voltage between CN-V06
Probable cause
and standard
value when
normal
About 3 minutes after the VHMS controller is turned ON, judge by
the state of the decimal point of the VHMS controller LED (7 seg-
ments on the right side).
• VHMS controller cannot communicate with
Decimal point goes off ORBCOMM controller (Abnormality in ORB-
COMM controller).
Defective ORBCOMM • Communication with VHMS is normal.
9
controller Decimal point lights up • ORBCOMM controller does not have data to
transmit.
• Communication with VHMS is normal.
Decimal point flashes
• ORBCOMM controller has data to transmit
quickly
and has captured satellite (is transmitting).
• Communication with VHMS is normal.
Decimal point flashes
• ORBCOMM controller has data to transmit
slowly
but has not captured satellite.
20-1052 WA700-3
(11)
WA700-3 20-1053
(11)
b) Abnormality in downloading into PC or setting of PC
Action code Failure code Controller code Abnormality in satellite data communication
Trouble
Not set Not set Not set b) Abnormality in downloading into PC or setting of PC
Contents of
• PC cannot download or cannot be set.
trouble
Action of
controller
Problem that
appears on • PC cannot download or cannot be set.
machine
Related
information

harness (disconnection, Wiring harness between CN-V06 (female) (9) –
Resistance Max. 1 z
1 defective contact) CN-V30 (female) (13)
aWiring harness for Wiring harness between CN-V06 (female) (10)
Resistance Max. 1 z
downloading in cab – CN-V30 (female) (14)
Resistance Max. 1 z
CN-V06 (female) (9) – (female) (9), CN-V30 (female) Min. 1 Mz
CN-V30 (female) (13) (13) – chassis ground
Probable cause Wiring harness between Resistance between CN-V06
and standard CN-V06 (female) (10) – (female) (10), CN-V30 Min. 1 Mz
value when CN-V30 (female) (14) (female) (14) – chassis ground
normal Wiring harness between Resistance between CN-V06
Ground fault or short circuit in
wiring harness Wiring harness between Resistance between CN-V06
2 CN-V06 (female) (9) – (female) (9) – CN-V30
aWiring harness for
downloading inside cab CN-V30 (female) (13) and (female) (13) and between Min. 1 Mz
between CN-V06 (female) CN-V06 (female) (10) –
(10) – CN-V30 (female) (14) CN-V30 (female) (14)
CN-V06 (female) (9) – (female) (9) – CN-V30
CN-V30 (female) (13) and (female) (13) and between Min. 1 Mz
CN-V06 (female) (10) – (female) (10) – CN-V30
CN-V30 (female) (14) and (female) (14) and between Min. 1 Mz
20-1054 WA700-3
(11)

2) Disconnect connectors CN-V30 and VDL.
harness (disconnection, Wiring harness between CN-V30 (male) (13) –
Resistance Max. 1 z
3 defective contact) VDL (female) (B)
aWiring harness for Wiring harness between CN-V30 (male) (14) –
downloading inside cab Resistance Max. 1 z
VDL (female) (C)
Wiring harness between CN-V30 (male) (15) –
Resistance Max. 1 z
VDL (female) (D)
2) Disconnect connectors CN-V30 and VDL.
CN-V30 (male) (13) – (male) (13) – VDL (female) Min. 1 Mz
VDL (female) (B) (B) – chassis ground
Probable cause Wiring harness between Resistance between CN-V30
and standard CN-V30 (male) (14) – (male) (14) – VDL (female) Min. 1 Mz
value when VDL (female) (C) (C) – chassis ground
normal Wiring harness between Resistance between CN-V30
CN-V30 (male) (15) – (male) (15) – VDL (female) Min. 1 Mz
VDL (female) (D) (D) – chassis ground
Ground fault or short circuit in
wiring harness Wiring harness between Resistance between CN-V30
4 CN-V30 (male) (13) – (male) (13) – VDL (female)
aWiring harness for
downloading outside cab VDL (female) (B) and (B) and between CN-V30 Min. 1 Mz
between CN-V30 (male) (male) (14) – VDL (female)
(14) – VDL (female) (C) (C)
Wiring harness between Resistance betweenCN-V30
CN-V30 (male) (13) – VDL (male) (13) – VDL (female)
(female) (B) and between (B) and between CN-V30 Min. 1 Mz
CN-V30 (female) (15) – (male) (15) – VDL (female)
VDL (male) (D) (D)
(female) (C) and between (C) and between CN-V30 Min. 1 Mz
(female) (D) (D)
WA700-3 20-1055
(11)
VHMS-2 Abnormality in saving data in VHMS controller (Data are not saved)
Action code Failure code Controller code Abnormality in saving data in VHMS controller
Trouble (Data are not saved)
Not set Not set Not set
aLED of VHMS counts up and operates normally
Contents of • Data are not saved in the VHMS controller.
trouble aPower is kept turned off.
Action of
controller
Problem that
appears on • None in particular.
machine
Related • If fuse box 1 (14) is broken, check the wiring harness between fuse and CN-V01 (6), (7) for grounding
information fault.

2) Disconnect connector CN-V01 and fuse box 1 (14).
and standard (7) – fuse box 1 (14)
value when 1 harness (disconnection, *1) After the starting switch is turned to the OFF position, the LED of
normal defective contact) the VHMS displays SH (Processing time of memory), and then the
all operation is finished (the power for the VHMS is turned OFF), if
the all system is normal.
*2) If the power for the VHMS is turned OFF immediately after the
starting switch is turned to the OFF position, the power is not
applied constantly.
20-1056 WA700-3
(11)
WA700-3 20-1057
(11)
VHMS-3 Engine blow-by pressure indicated by monitor is low (When blow-by

pressure measured with measuring instrument is normal)
Action code Failure code Controller code Engine blow-by pressure indicated by monitor is low
Trouble (When blow-by pressure measured with measuring
Not set Not set Not set
instrument is normal)
Contents of
• The engine blow-by pressure indicated by the monitor is low.
trouble
Action of
controller
Problem that
• The engine blow-by pressure indicated by the monitor is low.
appears on
(The blow-by pressure measured with a measuring instrument is normal.)
machine
Related • The blow-by pressure can be checked with the monitoring function (Code: 42800).
information • If failure code "DHE5KA" is indicated, carry out the troubleshooting for it.
Probable cause Cause Standard value in normal state/Remarks on troubleshooting

and standard 1 Defective orifice in breather Check the orifice in the breather and repair it, if abnormal.
value when
normal 2 Defective VHMS controller If the result of 1 above is normal, the VHMS controller is defective.
20-1058 WA700-3
(11)
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL ................... 30- 3 HYDRAULIC OIL COOLER, RADIATOR,

PRECAUTIONS WHEN CARRYING AFTERCOOLER, FUEL COOLER
OUT OPERATION ................................... 30- 5 Serial No.: 51001 and up
SPECIAL TOOLS LIST .................................. 30- 8 Removal ............................................... 30-36-1
SKETCHES OF SPECIAL TOOLS ................. 30-12 Installation ........................................... 30-36-3
STARTING MOTOR ENGINE, DAMPER
Removal & Installation ......................... 30-16 Removal .................................................. 30-37
ALTERNATOR Installation .............................................. 30-39
Serial No.: 50001 – 51000 DAMPER
Removal & Installation ......................... 30-17 Removal & Installation ......................... 30-40
ENGINE OIL COOLER Disassembly ........................................... 30-41
Removal & Installation ......................... 30-18 Assembly ................................................ 30-43
FUEL INJECTION PUMP PTO
Serial No.: 50001 – 51000 Disassembly ........................................... 30-47
Removal .................................................. 30-19 Assembly ................................................ 30-49
Installation .............................................. 30-20 TORQUE CONVERTER, TRANSMISSION
WATER PUMP Removal ................................................ 30- 52
Serial No.: 50001 – 51000 Installation ............................................ 30- 56
Removal & Installation ......................... 30-21 TORQUE CONVERTER
NOZZLE HOLDER Disassembly ......................................... 30- 57
Serial No.: 50001 – 51000 Assembly .............................................. 30- 61
Removal & Installation ......................... 30-22 TRANSMISSION
TURBOCHARGER Disassembly ......................................... 30- 66
Serial No.: 50001 – 51000 Assembly .............................................. 30- 80
Removal .................................................. 30-23 TRANSMISSION VALVE
Installation .............................................. 30-24 Removal & Installation ....................... 30- 95
REPLACEMENT OF ENGINE TRANSMISSION CONTROL VALVE
Serial No.: 50001 – 51000 Disassembly & Assembly ................... 30- 96
Front seal ................................................ 30-25 TRANSFER
Rear seal ................................................. 30-27 Disassembly ......................................... 30-101
CYLINDER HEAD Assembly .............................................. 30-108
Serial No.: 50001 – 51000 CENTER SUPPORT
Removal .................................................. 30-29 Removal ................................................ 30-117
Installation .............................................. 30-32 Installation ............................................ 30-118
THERMOSTAT Disassembly ......................................... 30-119
Serial No.: 50001 – 51000 Assembly .............................................. 30-121
Removal & Installation ......................... 30-34 DRIVE SHAFT
HYDRAULIC OIL COOLER, RADIATOR, Disassembly ......................................... 30-124
AFTERCOOLER Assembly .............................................. 30-126
Serial No.: 50001 – 51000 FRONT AXLE
Removal .................................................. 30-35 Removal ................................................ 30-128
Installation .............................................. 30-36 Installation ............................................ 30-129
WA700-3 30-1
3
7
FRONT DIFFERENTIAL WORK EQUIPMENT VALVE
Removal ................................................ 30-130 Removal ................................................ 30-197
Installation ............................................ 30-131 Installation ............................................ 30-198
REAR AXLE WORK EQUIPMENT CONTROL VALVE
Removal ................................................ 30-132 Disassembly ......................................... 30-199
Installation ............................................ 30-136 Assembly .............................................. 30-201
REAR DIFFERENTIAL DUMP CYLINDER
Removal ................................................ 30-137 Removal & Installation ....................... 30-203
Installation ............................................ 30-138 LIFT CYLINDER
Disassembly ......................................... 30-139 Removal ................................................ 30-204
Assembly .............................................. 30-143 Installation ............................................ 30-205
FINAL DRIVE STEERING, LIFT, DUMP CYLINDER
Disassembly ......................................... 30-152 Disassembly ......................................... 30-206
Assembly .............................................. 30-156 Assembly .............................................. 30-208
ORBIT ROLL CENTER HINGE PIN
Removal & Installation ....................... 30-160 Removal ................................................ 30-210
STEERING CYLINDER Installation ............................................ 30-216
Removal ................................................ 30-161 WORK EQUIPMENT
Installation ............................................ 30-163 Removal ................................................ 30-220
STEERING DEMAND VALVE Installation ............................................ 30-223
Removal ................................................ 30-164 BULKHEAD
Installation ............................................ 30-166 Removal ................................................ 30-225
BRAKE VALVE Installation ............................................ 30-226
Removal & Installation ....................... 30-166 FLOOR FRAME
BRAKE VALVE (RIGHT) Removal ................................................ 30-227
Disassembly ......................................... 30-167 Installation ............................................ 30-229
Assembly .............................................. 30-169 COUNTERWEIGHT
BRAKE VALVE (LEFT) Removal & Installation ....................... 30-230
Disassembly ......................................... 30-171 FUEL TANK
Assembly .............................................. 30-173 Removal ................................................ 30-231
SLACK ADJUSTER Installation ............................................ 30-232
Removal & Installation ....................... 30-175 CAB
BRAKE STOP VALVE
Removal ................................................ 30-178 Removal & Installation ....................... 30-236
Installation ............................................ 30-179 ACCUMULATOR CHARGE VALVE
Disassembly ......................................... 30-180 Removal & Installation ....................... 30-237
Assembly .............................................. 30-184 Disassembly ......................................... 30-238
HYDRAULIC PUMP Assembly .............................................. 30-239
Removal ................................................ 30-190 PARKING BRAKE SOLENOID VALVE,
Installation ............................................ 30-191 PRESSURE SWITCH
PISTON PUMP Removal & Installation ....................... 30-241
Disassembly ...................................... 30-191-1 DIVERTER VALVE
Assembly ........................................... 30-191-7 Removal & Installation ....................... 30-242
HYDRAULIC TANK Disassembly ......................................... 30-243
Removal ................................................ 30-192 Assembly .............................................. 30-244
Installation ............................................ 30-193 EMERGENCY STEERING PUMP
PPC VALVE Removal & Installation ....................... 30-246
Removal ................................................ 30-194 PARKING BRAKE
Installation ............................................ 30-195 Removal & Installation ....................... 30-247
Disassembly & Assembly ................... 30-196
30-2 WA700-3
3
7
PARKING BRAKE CALIPERS AIR CONDITIONER UNIT
PARKING BRAKE PAD MAIN MONITOR
Removal & Installation ....................... 30-252 Removal ................................................ 30-259
REAR TIRE Installation ............................................ 30-260
Removal & Installation ....................... 30-253 MAINTENANCE MONITOR
AIR CONDITIONER COMPRESSOR Removal & Installation ....................... 30-261
Removal & Installation ....................... 30-254 ENGINE, APS CONTROLLER
AIR CONDITIONER CONDENSER Serial No.: 50001 – 51000
Removal & Installation ....................... 30-255 Removal & Installation ....................... 30-262
RECEIVER TANK
Removal & Installation ....................... 30-256
WA700-3 30-2-1
7
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
fl After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and
installing any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equip-
ment piping, always bleed the air as follows after completion of installation.
1. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders
4 – 5 times without going to the end of this stroke. (Stop approx. 100 mm before the end of the
stroke.)
2. Operate the steering, bucket, and lift arm cylinders 3 – 4 times to the end of the stroke, then
stop the engine and bleed the air from the plugs at the top of the hydraulic tank filter.
3. Raise the engine speed and repeat Step 2. to bleed the air. Repeat this procedure until no more
air comes out from the plugs.
4. After completing bleeding the air, tighten the plugs.
3 Plug: 11.3 ± 1.5 Nm {1.15 ± 0.15 kgm}
fl If the engine is run at high speed from the start, or the cylinders are operated to the end of
this stroke, the air inside the cylinder will cause damage to the piston packing.
fl After repair or long storage, follow the same procedure.
WA700-3 30-7
3
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

fl Tools with part number 79T- - cannot be supplied (they are items to be locally manufactured).
fl Necessity: ■: ....... Cannot be substituted, should always be installed (used)
●: ...... Extremely useful if available, can be substituted with commercially available part
fl 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, used without any modification
fl Tools marked in the Sketch column are tools introduced in the sketches of the special tools (See
SKETCHES OF SPECIAL TOOLS).
Component Symbol Part No. Part Name Neces- Q’ty New/ Sketch Nature of work,
sity remodeled remarks
1 792-400-1110 Bracket ■ 1 Engine sling
795-902-1410 Sleeve ■ 1 Installation of front seal
01050-32235 Bolt ■ 3
2
795-902-1430 Push tool ■ 1
01050-32240 Bolt ■ 3
795-902-1420 Sleeve ■ 1 Installation of rear seal
795-902-1450 Bolt ■ 2
3 01582-02016 Nut ■ 2
795-902-1440 Push tool ■ 1
01050-32050 Bolt ■ 4
Disassembly,
assembly of A 4 790-331-1110 Wrench ■ 1 Tightening of cylinder head
engine assembly Removal, installation
5 795T-871-1110 Adapter ■ 2 of fuel injection pump
6 795-601-1110 Push tool ■ 1 Removal of water tube
795-799-5410 Adapter ■ 1 N Disassembly, assembly of

7 engine
795-799-5420 Remover ■ 1 N
798-621-1140 Push tool ■ 1 N Assembly of engine
8 795-902-1460 Bolt ■ 3
01582-02218 Nut ■ 3
795-621-1130 Push tool ■ 1 N Assembly of engine

9
01050-32280 Bolt ■ 5
10 Commercially
available Filler gauge ● 1 Assembly of engine
1 793-612-1110 Guide ■ 1 Press fitting of bearing
Assembly of 2 793-612-1120 Push tool ■ 1

B
damper assembly 3 790-201-2670 Plate ■ 1 Press fitting of oil seal
4 790-201-2320 Push tool ■ 1

Centering of parts between
1 790-413-1110 Centering tool 1 engine and torque converter
Disassembly, Unit repair ■ 1 Torque converter and PTO
assembly of torque 790-501-5000 stand (100V) repair stand
converter and PTO
2 or
assembly Unit repair ■ 1
790-501-5200 stand (110-120V
or 220-240V)
30-8 WA700-3
3
7
Neces- New/ Nature of work,

Component Symbol Part No. Part Name sity Q’ty remodeled Sketch remarks
790-901-4110 Bracket ■ 1 Torque converter and PTO
2 repair stand
790-901-4231 Plate ■ 1
Removal, installation of
3 790-102-1011 Nut wrench ■ 1 PTO gear bearing nut
Disassembly, Removal, installation of round
assembly of torque 4 792-201-7211 Wrench ■ 1 set nut of pump fixture bearing
converter and PTO C
790-101-5401 Push tool kit C ■ 1 Press fitting of retainer oil
assembly seal
· 790-101-5461 · Plate ■ 1
5
· 790-101-5421 · Grip ■ 1
· 01010-51240 · Bolt ■ 1
Check of operation of
1 799-301-1600 Oil leak tester kit ■ 1 clutch piston
Disassembly, Centering of transmission
assembly of 2 793-615-1200 Centering tool ■ 1 and center support
transmission D
793-615-1100 Wrench assembly ■ 1 Adjustment of pre-load
assembly 3 on transfer bearing
793-615-1130 Spline wrench ■ 1
793-673-1110 Push tool ■ 1 Press fitting of center

support oil seal
1 · 790-101-5421 · Grip ■ 1
· 01010-51240 Bolt ■ 1
793-673-1120 Push tool ■ 1 Press fitting of bearing

inner race
Disassembly, 2 · 790-101-5421 · Grip ■ 1
assembly of center H
support assembly · 01010-51240 · Bolt ■ 1
790-101-5401 Push tool kit C ■ 1 Press fitting of bearing

outer race and oil seal to
· 790-101-5491 · Plate ■ 1 housing
3
· 790-101-5421 · Grip ■ 1
· 01010-51240 · Bolt ■ 1
Unit repair ■ 1 Differential repair stand
790-501-5000 stand (100V)
or
Unit repair ■ 1
4 790-501-5200 stand (110-120V
or 220-240V)
790-901-5110 Bracket ■ 1
Disassembly, 793-623-1110 Plate ■ 1

assembly of Press fitting of bearing
H 5 790-201-2860 Spacer ■ 1 inner race
differential
assembly 793T-815-1120 Plate ■ 1 Press fitting of bearing
inner race
6 · 790-101-5421 · Grip ■ 1
· 01010-51240 · Bolt ■ 1
793T-622-1160 · Plate ■ 1 N Press fitting of cage oil

seal
7 · 790-101-5421 · Grip ■ 1
· 01010-51240 · Bolt ■ 1
WA700-3 30-9
3
7
Neces- New/ Nature of work,

Component Symbol Part No. Part Name sity Q’ty remodeled Sketch remarks
793T-622-1160 Plate ■ 1 Press fitting of cage dust
seal
793T-622-1170 Spacer ■ 1 N
8
· 790-101-5421 · Grip ■ 1
· 01010-51240 · Bolt ■ 1
Adjustment of pre-load
9 790-425-1660 Wrench ■ 1 on side bearing
Positioning of pinion
Disassembly, 10 793-623-1120 Plate ■ 1 gear of differential
assembly of Holding of brake assem-
H 11 793-623-1130 Fixture ■ 2 bly and wheel hub
differential
assembly 791-585-1510 Installer ■ 1 Installation of floating
12 seal
792-530-1700 Push tool ■ 1
793T-833-1110 Plate ■ 1 Press fitting of oil seal to

wheel hub
13 · 790-101-5421 · Grip ■ 1
· 01010-51240 · Bolt ■ 1
Check of brake oil for
14 793-520-1805 Brake tester ■ 1 leakage
790-101-2501 Push tool kit ■ 1 Installation of center
hinge bearing
· 790-101-2510 · Plate 1
· 790-101-2520 ·Screw 1
· 791-112-1180 · Nut 1
1 · 790-101-2540 · Washer 1
· 790-101-2610 · Leg 2
· 790-101-2570 · Plate 4
Installation of · 790-101-2560 · Nut 2
center hinge K
bearing · 790-101-2740 · Adapter 2
793-646-1110 Push tool ■ 1 Upper part

2
793-646-1120 Guide ■ 1
793-646-1130 Push tool ■ 1 Lower part
3
793-646-1140 Guide ■ 1
790-201-1310 Spacer ■ 1
4
790-101-2102 Puller (30 ton) ■ 1
5 790-101-1102 Hydraulic pump ■ 1

Cylinder Disassembly, assembly
1 790-502-1003 repair stand ● 1 of cylinder
Disassembly, Press fitting of wound
assembly of 790-201-1702 Push tool kit ■ bushing
hydraulic cylinder U
2 · 790-101-5021 · Grip 1 Applicable to all
assembly cylinders
· 01010-50816 · Bolt 1
30-10 WA700-3
3
7
· 790-201-1881 · Push tool 1 Boom cylinder
· 790-201-1940 · Push tool 1 Steering cylinder
2 790-201-1910 Push tool ■ 1
· 790-101-5421 · Grip ■ 1 Bucket cylinder
· 01010-51240 · Bolt ■ 1
790-201-1500 Push tool kit ■ 1 Press fitting of dust seal

· 790-201-1690 · Plate 1
· 790-101-5021 · Grip 1 Boom cylinder
· 01010-50816 · Bolt 1
790-201-1980 Plate ■ 1
Disassembly, 3
· 790-101-5021 · Grip ■ 1 Steering cylinder
assembly of
U
hydraulic cylinder · 01010-50816 · Bolt ■ 1
assembly
790-201-1920 Plate ■ 1
· 790-101-5421 · Grip ■ 1 Bucket cylinder

· 01010-51240 · Bolt ■ 1
4 790-720-1000 Expander ● 1 Installation of piston ring

(All cylinders)
796-720-1720 Ring ■ 1 Boom cylinder
07281-02429 Clamp ■ 1
796-720-1670 Ring ■ 1 Steering cylinder

5
07281-01279 Clamp ■ 1
796-720-1730 Ring ■ 1 Bucket cylinder
07281-02909 Clamp ■ 1
793T-870-1110 Sleeve ■ 1
793T-870-1120 Plate ■ 1
791-745-2110 Adapter ■ 1
790-438-1110 Screw ■ 1 Pulling out pin

Pulling out work connecting bucket and
equipment V 1 790-101-2540 Washer ■ 1 boom connecting and
connecting pins pulling out boom
02215-11622 Nut ■ 1 cylinder end pin
01010-81655 Bolt ■ 3
790-101-2102 Puller (30 ton) ■ 1
790-101-1102 Hydraulic pump ■ 1
799-703-1200 Service tool kit ■ 1 Charge of air conditioner

gas
799-703-1100 Vacuum ■ 1
pump (100 V)
Charge of air Vacuum
conditioner gas X 1 799-703-1110 pump (220 V) ■ 1
790-703-1120 Vacuum ■ 1
pump (240 V)
799-703-1401 Gas leak detector ■ 1
WA700-3 30-11
(10)
3
1 790-501-5000 Unit repair stand 1
2 790-901-2110 Bracket 1
Y
3 790-901-1330 Plate 1
4 790-345-1020 Plate 1
(for minimum swash

1 790-445-3400 Gauge 1 plate angle) HPV
(for maximum swash

Disassembly, Z 2 790-445-3300 Gauge 1 plate angle) HPV,
assembly of piston HPF090+090 common
pump assembly
3 790-445-3500 For front 1 (HPF076+071)
4 790-445-3600 For rear 1 (HPF076+071)
1 796-720-3520 Cap 1
AA 2 796-720-2220 Socket 1
3 796-730-2120 Screwdriver 1
1 795-630-1803 Torque wrench 1

BB
2 796-720-3800 wrench 1
30-11-1 WA700-3
4
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
A5 ADAPTER
H6 PLATE
30-12 WA700-3
3
H7, H8 PLATE
H8 SPACER
WA700-3 30-13
(10)
V1 PLATE
WA700-3 30-15
3
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Remove left side cover (1).
2. Open side cover (2).
3. Disconnect wiring connectors (3) (E03) and (4)

(E04).
4. Disconnect cable (5) between battery relay and

starting motor.
5. Remove mounting bolts to remove starting mo-

tor assembly (6).
4 Starting motor assembly: 18 kg × 2 pcs.
fl The mounting bolts of the upper and lower start-

ing motors are also used to install the ground
cable.
INSTALLATION OF STARTING
MOTOR
• Carry out installation in the reverse order to
removal.
30-16 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
Serial No.: 50001 – 51000
cle from moving.
1. Open left side cover (1).
2. Disconnect alternator wires (2) (E6), (3) (E7), and

(4) (E5).
3. Loosen drive belt adjustment nut (5). 1

fl Loosen the mounting bolt.
4. Remove drive belt (6).
5. Remove lock bolt (7) and press down adjust-

ment bolt (8). 2
6. Remove mounting bolt to remove alternator as-

sembly (9).
4 Alternator assembly: 12 kg
INSTALLATION OF
ALTERNATOR ASSEMBLY
Serial No.: 50001 – 51000
removal.
1
3 Lock bolt:
53.9 – 122.6 Nm {5.5 – 12.5 kgm}
2
fl Adjust the drive belt tension. For details,
see TESTING AND ADJUSTING, Testing and
adjusting alternator drive belt.
WA700-3 30-17
3
7
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
¤ Stop the machine on level ground and lower
the work equipment completely to the ground,
then put blocks under the wheels to prevent the
machine from moving.
1. Open engine right side cover.
2. Disconnect alternator terminals (1) (E15) and (2)

(E16) and (3) (E17).
3. Loosen locknuts (4).
4. Loosen adjustment rod (7) and mounting bolt

(5).
5. Remove lock bolt (6) and move adjustment rod

(7) outside.
6. Loosen alternator mounting bolt (8), then re-

move belt. 1
7. Remove mounting bolt (8), then remove alter-

nator (10).
4 Alternator: 12 kg
INSTALLATION OF
ALTERNATOR ASSEMBLY
removal.
1
fl Adjust the deflection of the belt to the speci-
fied value. For details, see TESTING AND
ADJUSTING ALTERNATOR BELT TENSION.
30-17-1 WA700-3
7
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER ASSEMBLY
Serial No.: 50001 – 51000
cle from moving.
1. Drain engine cooling water.
6 Cooling water: 190 ¬
fl Drain cooling water from the engine oil

cooler, too.
2. Disconnect alternator wire (1) and move har-
ness (2) toward the flywheel housing.
3. Disconnect tube (3) between transmission oil
cooler and engine oil cooler.
4. Disconnect tube (4) between water pump and
transmission oil cooler.
5. Remove muffler drain tube (5) by cutting its
clamp.
6. Remove tube (6) between engine block and wa-
ter pump.
7. Disconnect tube (7) between corrosion resistor
and oil cooler.
8. Disconnect 2 turbocharger drain tubes (8).
9. Remove turbocharger exhaust tube (9).
10. Disconnect turbocharger lubricating oil inlet hose
(10).
11. Disconnect turbocharger joint hoses (11) and
(12), and move them toward tubes.
12. Remove turbocharger assembly (13). 1
13. Using guide bolt a, remove oil cooler assembly
(14).
INSTALLATION OF ENGINE OIL

COOLER ASSEMBLY
Serial No.: 50001 – 51000
removal.
1
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
• Refilling with water

Add water through the water filler to the speci-
fied level. Run the engine to circulate the water
through the system. Then, check the water level
again.
30-18 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER ASSEMBLY
put blocks under the wheels to prevent the ve-
hicle from moving.
fl Drain cooling water from the engine oil

cooler, too.
2. Disconnect tube (1) between engine block and
transmission oil cooler.
3. Disconnect tube (2) between engine water pump
and transmission oil cooler.
4. Disconnect turbocharger lubrication oil drain
tube (3).
5. Disconnect turbocharger lubrication oil inlet tube
(4).
6. Remove oil cooler assembly (5), (6).
INSTALLATION OF ENGINE OIL

COOLER ASSEMBLY
removal.

again.
WA700-3 30-18-1
7
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
Serial No.: 50001 – 51000
cle from moving.
1. Open right side cover (1).
2. Disconnect hose (2) between hand priming pump

and fuel injection pump.
3. Disconnect hose (3) between fuel filter and fuel
injection pump.
4. Disconnect lubricating oil inlet tube (4). 1
5. Disconnect hose (5) between emergency engine
stop solenoid valve and fuel injection pump.
2
6. Disconnect emergency engine stop solenoid
valve wiring connector (6) (E20).
7. Disconnect electronic governor wiring connec-
tor (7).
fl Located at the rear of the oil filter (E12 =
Governor solenoid, E14 = Rack sensor, E15
= Governor solenoid, E16 = Pre-stroke sole-
noid)
8. Disconnect lubricating oil outlet tube (8). 3
9. Disconnect fuel return hose (9). 4

10. Disconnect 6 fuel injection tubes (10). 5
11. Remove safety cover (11).
12. Loosen coupling clamp bolt (12).

fl Take care not to lose the woodruff key of
the drive shaft.
WA700-3 30-19
3
7
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
13. Remove mounting bolt (13) to remove fuel in-

jection pump assembly (14). 6
fl Install tool A5 to the delivery valve holder,
then lift off the fuel injection pump assem-
bly.
4 Fuel injection pump assembly: 40 kg
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
Serial No.: 50001 – 51000
removal.
1
3 Eyebolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
2
3 Hose adapter:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3
3 Eyebolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
4
3 Eyebolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
5
3 Sleeve nut:
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
6
fl Adjust the fuel injection timing. For details,
see TESTING AND ADJUSTING, Testing and
adjusting fuel injection timing.
• Bleeding air
Bleed air from fuel circuit. For details, see TEST-
ING AND ADJUSTING, Bleeding air from each
part.
30-20 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
Serial No.: 50001 – 51000
cle from moving.
1. Drain cooling water.
2. Open left side cover (1).
3. Disconnect 3 alternator wires (2) and move har-

ness (3) toward engine oil cooler.
4. Disconnect cooling water outlet tube (4) of en-
gine oil cooler and cooling water inlet tube (5)
of water pump.
5. Disconnect cooling water bypass tube (6).
6. Loosen clamp and remove hoses (7) and (8) and

tubes (4) and (5) together.
7. Disconnect suction tube (9) between radiator bot-
tom and water pump assembly.
8. Remove bracket (10). 1

9. Remove mounting bolts (11) to remove water
pump assembly (12).
4 Water pump assembly: 20 kg
INSTALLATION OF WATER
PUMP ASSEMBLY
Serial No.: 50001 – 51000
removal.
1
fl Tighten the upper and lower mounting bolts
alternately and evenly.

again.
WA700-3 30-21
3
7
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
Serial No.: 50001 – 51000
cle from moving.
1. Remove handrail (1), then lift off engine hood

(2).
fl Keep both side covers open.
4 Engine hood assembly: 330 kg
2. Remove boot and disconnect fuel injection tube

(3).
3. Disconnect spill tube (4). 1
4. Remove head cover (5). 2
5. Remove flange (6), then remove nozzle holder

assembly (7). 3
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
Serial No.: 50001 – 51000
removal.
1
3 Spill tube:
13.8 – 17.7 Nm {1.4 – 1.8 kgm}
2
3 Head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
3
3 Flange mounting bolt:
24.5 – 29.4 Nm {2.5 – 3.0 kgm}
30-22 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLIES
Serial No.: 50001 – 51000
cle from moving.
A. Removal of upper turbocharger assembly

1. Remove handrail (1), then lift off engine hood
(2).
fl Keep both side covers open.
4 Engine hood assembly: 330 kg
2. Remove tube clamp (3).

3. Disconnect lubricating oil drain tube (4).
4. Loosen hose clamp (5) fully.
5. Remove heat insulation cover (6).
6. Remove lock plate (7) to disconnect hose (8).

7. Disconnect hose (9), then remove tube (10).
fl Move hoses (8) and (9) toward tube (10).
8. Remove lock plate (11) to disconnect hose (12).
9. Disconnect tube (13) from lower turbocharger.
10. Remove flange (14) and clamp (15), then re-
move joint (16).
fl Take care since the joint on the turbocharger
side and the gasket on the muffler side are
removed together.
11. Disconnect lubricating oil inlet hose (17).

12. Loosen clamp and move air cleaner joint hose
(18) toward air cleaner connector.
13. Remove mounting bolts to remove turbocharger
assembly (19). 1
4 Turbocharger assembly: 17 kg
WA700-3 30-23
3
7
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
B. Removal of lower turbocharger assembly

flExterior parts do not need to be removed.
1. Open left side cover.
2. Loosen clamp (1) fully and move joint hose (2)
toward air cleaner connector.
3. Remove heat insulation plate (3).
4. Loosen clamp (4) fully.
5. Remove heat insulation cover (5).

6. Loosen clamp (6).
7. Disconnect flange (7) from muffler.
8. Remove plate (8).
9. Remove exhaust connector (9).
fl Take care since the exhaust connector, gas-
ket, and joint are removed together.
10. Disconnect lubricating oil inlet hose (10).
11. Disconnect lubricating oil drain tube (11).

12. Remove mounting bolts to remove turbocharger
assembly (13). 1
fl Turn turbocharger assembly (13) outward
and remove it down to disconnect it from
hose (12).
4 Turbocharger assembly: 17 kg
INSTALLATION OF
TURBOCHARGER ASSEMBLY
Serial No.: 50001 – 51000
removal.
1
3 Turbocharger mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
30-24 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL OF ENGINE FRONT

SEAL
Serial No.: 50001 – 51000
1. Remove the radiator. For details, see REMOVAL

OF RADIATOR.
2. Removal of engine front seal

1) Loosen tension pulley (1), then remove fan
belt (2).
fl Remove the inside belt toward the en-
gine and remove the central and outside
belts toward the radiator.
2) Remove mounting bolts (3), then remove
crank pulley damper (4).
3) Remove engine front seal (5).
3. Installation of engine front seal
• Installation of standard seal

1) Press fit front seal (1) to the front cover or
trunnion (2) (if installed) with tool A2.
2 Fill the lip with lithium grease (G2-
LI) of about 5cc.
fl Tighten the 3 bolts evenly.
• Installation of front seal having sleeve (For re-

pair)
1) Press fit sleeve (3) to crankshaft (4) with tool
A2.
fl Press fit until tool A2 comes into contact
with the crankshaft end.
WA700-3 30-25
3
7
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
2) Press fit front seal (6) to front cover (3) with

tool A2.
fl Fit the lip with lithium grease (G2-LI) of
about 5cc.
4. Installation of crankshaft pulley and damper

Tighten the mounting bolts in the order given in
the diagram on the right.
2 Mounting bolt: Lubricant (LM-P)
2 Mounting bolt:
1st step: 53.9 – 93.1 Nm {7.5 ± 2.0 kgm}
2nd step: 225 – 265 Nm {25.0 ± 2.0 kgm}
3rd step: 617 – 657 Nm {65.0 ± 2.0 kgm}
5. Adjustment of fan belt

1) Loosen the stop bolt and install the 3 belts.
2) Tighten the stop bolt until it comes into con-
tact with the tension bracket.
3) After the stop bolt comes into contact with
the tension bracket, further tighten it by two
turns.
3 Locknut:
245.0 – 308.7 Nm {25.0 – 31.5 kgm)
30-26 WA700-3
3
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REPLACEMENT OF ENGINE
REAR SEAL
Serial No.: 50001 – 51000
1. Remove the damper. For details, see REMOVAL

OF DAMPER.
2. Removal of engine rear seal

1) Sling and remove flywheel (1).
4 Flywheel: 48 kg
2) Remove engine rear seal (2).
3. Installation of engine rear seal
• Installation of standard seal

fl Before installing the seal, check that the end
corners and lip sliding surfaces of the crank-
shaft and the housing are free from flaws,
burrs, rust, etc.
fl When installing the seal, apply grease to
seal lip very little, never fill grease in the
groove of seal. Wipe the all oil off the shaft.
1) Install seal (1) to crankshaft (2).
2) Tighten the 4 bolts with tool A3 until the
cover of seal (1) comes into contact with
end surface of flywheel housing (3).
2 Oil seal lip: Grease (G2-LI)
• Installation of rear seal having sleeve (For repair)

1) Press fit sleeve (4) to crankshaft (2) by using
A3.
fl Tighten the 2 nuts evenly.
fl Press fit the seal until tool A3 comes
into contact with the crankshaft end.
WA700-3 30-27
3
(9)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
2) Install seal (5) to sleeve (4).

3) Tighten 4 bolts until the cover of seal (5)
comes into contact with end surface of fly-
wheel housing (3).
3 Oil seal lip: Grease (G2-LI)
4. Installation of flywheel
1) Using bar 1, fix the flywheel.
2) For the tightening order, see the diagram on
the right.
2 Mounting bolt: Lubricant (LM-P)
3 Mounting bolt:
1st step: 98.0 ± 20.0 Nm {10.0 ± 2 .0 kgm}
2nd step: 294.0 ± 20.0 Nm {30.0 ± 2.0 kgm}
3rd step: 539.0 ± 20.0 Nm {65.0 ± 2.0 kgm}
3) Measure the radial runout and face runout
of the flywheel.
Radial runout: Max. 0.15 mm
Face runout: Max. 0.20 mm
30-28 WA700-3
3
(9)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

Serial No.: 50001 – 51000
cle from moving.
6 Engine cooling water: 190 ¬
2. Remove handrail (1).

3. Remove exhaust tube (2).
4. Lift off side cover (3) and engine hood (4).
5. Disconnect clamp (5) from engine.

6. Disconnect fuel return block (6) from engine.
7. Disconnect auto-priming fuel feed hose (7).
8. Disconnect fuel hose (8), then remove fuel filter
assembly (9) from engine.
9. Disconnect tube (10), then remove corrosion re-

sistor assembly (11).
10. Disconnect intake manifold inlet hose (12).
11. Disconnect cooling water outlet hose (13).
12. Disconnect joint hose (14) from aftercooler.
13. Disconnect komaclone valve (15) from muffler.
14. Disconnect komaclone hoses (16) and (17), then

remove tube (18).
15. Disconnect plate (19) and joint hose (20), then
remove air tube (21) and mounting bracket (22).
16. Remove komaclone tube (23).
17. Remove heat insulation plate (24).
WA700-3 30-29
3
7
18. Disconnect water temperature wiring connec-

tor (25) (E09, E11).
19. Disconnect water temperature wiring connec-
tor (26) (E08).
20. Disconnect cab heater hose (27).
21. Disconnect lower turbocharger joint tube (28).

22. Remove mounting bolts of muffler (29) to re-
move muffler.
fl When removing the muffler, take care not
to break the joint of the upper turbocharger.
23. Remove clamp, bracket, etc. to remove tube
(30) from aftercooler.
24. Remove hose (31) to remove tube (32).
25. Loosen clamp and disconnect hose (33) from
turbocharger.
26. Disconnect joint tube (33-1) from air cleaner.
27. Disconnect turbocharger lubrication hose (34).
fl Disconnect the hose of the upper turbo-
charger, too.
28. Disconnect turbocharger lubricating oil drain
tube (35).
29. Remove turbochargers (36) and (37).
30. Remove exhaust manifold (38). 1
31. Remove holders (39) and (40), then remove fuel

injection tubes (41) (No. 1 – 4) and (42) (No. 5,
6).
32. Lift off intake manifold assembly (43). 2
4 Intake manifold assembly: 50 kg
33. Disconnect spill tube (44).

34. Remove head cover (45). 3
30-30 WA700-3
3
35. Remove rocker arm (46). 4

fl Loosen the locknut and loosen adjustment
screw (47) by 2 – 3 turns so that the push
rod will not push up when the rocker arm is
installed.
36. Pull out push rod (48).

37. Remove cross head (49). 5
38. Remove mounting bolts (50) to remove injec-

tion nozzle assembly (51). 6
39. Remove snap ring (52), then pull out water tube
(53) with push tool A6.
WA700-3 30-31
3
40. Remove rocker arm housing (54).

41. Using hanging bolt 1, lift off cylinder head
assembly (55). 7
4 Cylinder head assembly: 40 kg
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
Serial No.: 50001 – 51000
removal.
1
2 Exhaust manifold mounting bolt:
Lubricant (LM-P)
3 Exhaust manifold mounting bolt:
98.1 – 122.6 Nm {10.0 – 12.5 kgm}
fl For tightening order, see the figure at right.
2
3 Intake manifold mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
3
3 Head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4
fl Check that the push rod is securely fitted in
the cam follower and adjustment screw ball.
3 Rocker arm mounting bolt:
93.1 – 102.9 Nm {9.5 – 10.5 kgm}
5
fl Adjust the cross head according to the fol-
lowing procedure.
i) Loosen the locknut and return the ad-
justment screw.
ii) Pressing the top of the cross head lightly,
tighten the adjustment screw.
iii) After the adjustment screw comes in
contact with the valve stem, tighten it
further by 20 degrees. Tighten the
locknut at this position.
3 Locknut:
33.3 – 45.1 Nm {3.4 – 4.6 kgm}
30-32 WA700-3
3
7
6
fl Assemble the nozzle holder with the match
marks directed toward the front side of the
engine.
3 Flange mounting bolt:
24.5 – 29.4 Nm {2.5 – 3.0 kgm}
7
fl Before setting the cylinder head gasket, check
that there is not dust or foreign matter on
the fitting face of the cylinder head and in
the cylinder.
fl When fitting the gasket, check that the grom-
met is installed normally.
3 Cylinder head mounting bolt:

First time: 88.3 – 107.9 Nm {9.0 – 11.0 kgm}
Second time:
181.4 – 191.2 Nm {18.5 – 19.5 kgm}
Third time: Tighten further by 60 degrees
fl Adjust the valve clearance. For details, see
TESTING AND ADJUSTING, Adjusting valve
clearance.
3 Rocker arm screw nut:
57.8 – 77.4 Nm {5.9 – 7.9 kgm}

again.
WA700-3 30-33
3
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
Serial No.: 50001 – 51000
hicle from moving.
1. Remove engine hood. For details, see REMOVAL

OF CYLINDER HEAD ASSEMBLY.
6 Engine cooling water: 190¬
3. Disconnect hose (1) between after cooler and

inlet manifold.
4. Disconnect hose (2) between radiator upper tank

and thermostat.
5. Disconnect aeration hose (3).
6. Disconnect muffler lock plate (4).
7. Disconnect tube (5) between corrosion resistor

and thermostat.
8. Remove 10 mounting bolts (6) to remove cover

(7).
9. Remove thermostat (8).
INSTALLATION OF
THERMOSTAT ASSEMBLY
Serial No.: 50001 – 51000
removal.

again.
30-34 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER
REMOVAL OF HYDRAULIC OIL

COOLER, RADIATOR,
AFTERCOOLER ASSEMBLY
Serial No.: 50001 – 51000
cle from moving.

5. Remove mounting bolts and lift off radiator mask

(5).
6. Disconnect working lamp wiring connector (6)
(GR1).
7. Remove 8 radiator guard mounting bolts (7).
8. Remove U-bolt (8) to remove bracket (9).

9. Open radiator check covers (10) on both sides.
10. Lift off radiator guard (11).
4 Radiator guard assembly: 230 kg
11. Disconnect hose between turbocharger and

aftercooler, then remove tube (12).
12. Disconnect hose between aftercooler and intake
manifold, then remove tube (13).
13. Disconnect radiator upper tube (14).
WA700-3 30-35
3
7
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER
15. Disconnect hydraulic oil cooler outlet/inlet tube

(16).
16. Remove hydraulic oil cooler lock bolts (on both
sides) (17).
17. Sling hydraulic oil cooler temporarily and re-
move mounting bolts (on both sides) (18).
18. Lift off hydraulic oil cooler assembly (19).
4 Hydraulic oil cooler assembly: 350 kg
19. Disconnect radiator lower hose (20).

20. Remove fan guard (21).
21. Remove supports (on both sides) (22).
22. Sling radiator and aftercooler assembly (24) tem-
porarily and remove both mounting bolts (23).
23. Lift off radiator and aftercooler assembly (24).
4 Radiator and aftercooler assembly:

644 kg
24. Lift off shroud (25) and aftercooler (27) from

radiator and aftercooler assembly (24).
4 Aftercooler assembly: 65 kg
INSTALLATION OF HYDRAULIC
OIL COOLER, RADIATOR,
AFTERCOOLER ASSEMBLY
Serial No.: 50001 – 51000
removal.

again.
30-36 WA700-3
3
7
HYDRAULIC OIL COOLER, RADIATOR,
DISASSEMBLY AND ASSEMBLY AFTERCOOLER, FUEL COOLER
REMOVAL OF HYDRAULIC OIL

COOLER, RADIATOR,
AFTERCOOLER, FUEL COOLER
ASSEMBLY
cle from moving.

5. Remove mounting bolts and lift off radiator mask

(5).
6. Disconnect working lamp wiring connector (6)
(GR1).
7. Remove 8 radiator guard mounting bolts (7).
8. Remove U-bolt (8) to remove bracket (9).

9. Open radiator check covers (10) on both sides.
10. Lift off radiator guard (11).
4 Radiator guard assembly: 230 kg
11. Disconnect hose between turbocharger and

aftercooler, then remove tube (12).
12. Disconnect hose between aftercooler and intake
manifold, then remove tube (13).
13. Disconnect radiator upper tube (14).
WA700-3 30-36-1
7
15. Disconnect hydraulic oil cooler outlet/inlet tube

(16).
16. Remove hydraulic oil cooler lock bolts (on both
sides) (17).
17. Sling hydraulic oil cooler temporarily and re-
move mounting bolts (on both sides) (18).
18. Lift off hydraulic oil cooler assembly (19).
4 Hydraulic oil cooler assembly: 350 kg
19. Disconnect radiator lower hose (20).

20. Remove fan guard (21).
21. Remove supports (on both sides) (22).
22. Disconnect fuel cooler hoses (23), (24).
23. Sling radiator, aftercooler and fuel cooler as-

sembly (25) temporarily and remove mounting
bolts (26).
24. Lift off radiator, aftercooler and fuel cooler as-
sembly (25).
4 Radiator, aftercooler and fuel cooler as-

sembly: 720 kg
25. Lift off shroud (27), aftercooler (28) and fuel

cooler (29) from radiator, aftercooler and fuel
cooler assembly (25).
4 Aftercooler assembly: 50 kg
Fuel cooler assembly: 12 kg
30-36-2 WA700-3
7
INSTALLATION OF HYDRAULIC
OIL COOLER, RADIATOR,
AFTERCOOLER, FUEL COOLER
ASSEMBLY
removal.

again.
WA700-3 30-36-3
7
DISASSEMBLY AND ASSEMBLY ENGINE, DAMPER
REMOVAL OF ENGINE,
DAMPER ASSEMBLY
Serial No.: 50001 – 51000
hicle from moving.
1. Remove bulkhead assembly. For details, see

REMOVAL OF BULKHEAD ASSEMBLY.
2. Remove hydraulic oil cooler, radiator, and

aftercooler assembly. For details, see REMOVAL
OF HYDRAULIC OIL COOLER, RADIATOR,
AFTERCOOLER ASSEMBLY.
3. Disconnect engine oil drain valve (1) from fuel

tank.
4. Disconnect starting motor cable (2).
5. Disconnect ground cable (3) between engine and
vehicle body.
6. Disconnect engine wiring connectors (4) (ER3),

(5) (ER4), (6) (ER1), and (7) (ER2).
7. Disconnect ground cable (8) (E02) from vehicle
body.
8. Disconnect slow-blow fuse wire (9) (E01).
9. Disconnect hoses (10) and (11) between engine

and torque converter.
10. Disconnect hoses (12) (return) and (13) (supply)

between air conditioner unit and engine.
fl (12): Located at suction opening of water
pump.
fl (13): Located near upper turbocharger.
WA700-3 30-37
3
7
11. Disconnect air conditioner compressor pipes (14)

and (15).
fl Take measures to prevent dust, water, etc.
from entering the pipes.
12. Disconnect fuel spill hose (16).
fl Located on the top of the fuel tank.
13. Disconnect hose (17) between engine oil full-

flow filter and bypass filter.
14. Disconnect hose (18) between engine and fuel
tank.
15. Disconnect hose (19) between engine oil bypass

filter and engine.
fl Oil flows out less if this hose is disconnected
on the bypass filter side.
16. Disconnect hose (20) between fuel strainer and
hand priming pump.
17. Disconnect drive shaft (21) between engine

and torque converter. 1
4 Drive shaft: 52 kg
30-38 WA700-3
3
18. Remove both front mounts (22) and both rear

mounts (23) of engine. 2
19. Using tool A1, lift off engine and damper as-
sembly (24).
fl Checking that the all hoses, harnesses, etc.
are disconnected, sling the assembly slowly.
4 Engine and damper assembly: 3,270 kg
INSTALLATION OF ENGINE,
DAMPER ASSEMBLY
Serial No.: 50001 – 51000
removal.
1
3 Mounting bolt:
156.9 – 196.1 Nm {16.0 – 20.0 kgm}
2
3 Mounting bolt:
824.0 – 1030.0 Nm {84.0 – 105.0 kgm}

again.
• Bleeding air
Bleed air from the fuel circuit. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
• Charging air conditioner with gas

Using tool X1, charge the air conditioner circuit
with new Freon gas (R134a).
WA700-3 30-39
3
7
REMOVAL OF ENGINE,
DAMPER ASSEMBLY
hicle from moving.

2. Remove hydraulic oil cooler, radiator, aftercooler

and fuel cooler assembly. For details, see RE-
MOVAL OF HYDRAULIC OIL COOLER, RADIA-
TOR, AFTERCOOLER, FUEL COOLER ASSEMBLY.
3. Disconnect engine oil drain valve (1) from fuel

tank.
4. Disconnect starting motor cable (2).
5. Disconnect ground cable (3) between engine and
vehicle body.
6. Disconnect engine wiring connectors (4) (ER3),

(5) (ER2) and (6) (ER1).
fl Remove the clips fixing the engine wiring
harness to the machine body.
7. Disconnect ground wire (7) (E02) from the ma-
chine body.
8. Disconnect wire (E01) from slow blow fuse (80A)
(8).
9. Disconnect wires (E10) and (E11) from slow blow
fuse (120A) (9).
10. Disconnect hoses (10) and (11) between engine

and torque converter.
11. Disconnect hoses (12) (return) and (13) (supply)

between air conditioner unit and engine.
30-39-1 WA700-3
7
12. Disconnect pipes (14) and (15) from the air

conditioner compressor.
fl Arrange the pipes so that dusts, dirt, water,
etc. do not enter the pipes.
13. Disconnect fuel filter inlet hose (16) and fuel

cooler hose (17).
14. Disconnect drive shaft (18) between engine

and torque converter. 1
15. Remove both front mounts (19) and both rear

mounts (20) of engine. 2
WA700-3 30-39-2
7
16. Using tool A1, lift off engine and damper as-
sembly (21).
fl Checking that the all hoses, harnesses, etc.
are disconnected, sling the assembly slowly.
4 Engine and damper assembly: 3,270 kg
DAMPER ASSEMBLY
removal.
1
3 Mounting bolt:
156.9 – 196.1 Nm {16.0 – 20.0 kgm}
2
3 Mounting bolt:
824.0 – 1030.0 Nm {84.0 – 105.0 kgm}

again.
• Bleeding air
Bleed air from the fuel circuit. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.

with new Freon gas (R134a).
30-39-3 WA700-3
7
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
cle from moving.

2. Remove covers (1) and (2) under air cleaner.
3. Sling drive shaft (3) temporarily and disconnect

mounting bolts. 1
4 Drive shaft assembly: 52 kg
4. Sling damper cover (4) temporarily and remove

mounting bolts, then remove damper cover,
pulling out output shaft. 2
4 Cover assembly: 113 kg
5. Using sling 1, sling damper assembly (5) tempo-

rarily and remove mounting bolts. 3
flSlowly lift off the damper assembly.
4 Damper assembly: 122 kg
INSTALLATION OF DAMPER
ASSEMBLY
removal.
1
Mounting bolt:
156.9 – 196.1 Nm {16.0 – 20.0 kgm}
2
flApply grease to the oil seal lip.
2 Shaft spline: Lubricant (LM-P)
3 Mounting bolt:
110.8 ± 11.8 Nm {11.3 ± 1.2 kgm}
3
3 Mounting bolt:
277.5 ± 31.4 Nm {28.3 ± 3.2 kgm}
30-40 WA700-3
3
DISASSEMBLY AND ASSEMBLY FRONT AXLE
3. Brake hose
1) Disconnect parking brake cylinder hose (3).
3
2) Disconnect both front brake hoses (4).
4
4. Front axle
1) Sling front axle assembly temporarily and
remove both mounting bolts (5). 5
2) Remove front axle assembly (6).
4 Front axle assembly: 5532 kg
INSTALLATION OF FRONT
AXLE ASSEMBLY
removal.
1
3 Hub nut:
823.8 ± 88.3 Nm {84.0 ± 9.0 kgm}
2
3 Drive shaft mounting bolt:
176.5 ± 19.6 Nm {18.0 ± 2.0 kgm}
34
fl Bleed air from the parking brake cylinder
and front brake. For details, see TESTING
AND ADJUSTING, Bleeding air from each
part.
5
3 Front axle mounting bolt:
3521.0 ± 353.0 Nm {350.0 ± 36.0 kgm}
WA700-3 30-129
3
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
REMOVAL OF FRONT
DIFFERENTIAL ASSEMBLY
Serial No.: 50001 – 50044
1. Remove front axle assembly. For details, see
REMOVAL OF FRONT AXLE ASSEMBLY.
2. Remove drain plugs (1) from both final drives to

drain oil.
6 Axle oil: 245 ¬ each
3. Remove mounting bolts (2) to remove cover (3).

fl Remove the cover with the top mark up.
1
4. Install bolt 1 to end of drive shaft (4) and pull

out drive shaft.
5. Lift off drive shaft (4).
6. Loosen locknut and remove tension bolt (5).

2
7. Remove parking brake disc cover (6).
8. Remove plate (7), then remove pad (8). 3
9. Remove caliper and spring cylinder assembly

(9).
10. Remove plate (10). 4
11. Remove mounting bolts to remove disc plate

(11). 5
30-130 WA700-3
3
7
12. Remove mounting bolts (12). 6
13. Sling front differential assembly (13) temporar-

ily and separate it from axle by using forcing
bolts 2.
14. Lift off front differential assembly (13).
4 Front differential assembly: 826 kg
Serial No.: 50001 – 50044
removal.
1
3 Cover mounting bolt:
98.0 – 123.0 Nm {10.0 – 12.5 kgm}
2
fl Adjustment of tension bolt
Press tension bolt (14) end against the back
of the gear, then return it by 1/2 turn.
3 Locknut:
343.0 – 441.0 Nm {35.0 – 45.0 kgm}
34
2 Plate mounting bolt: Adhesive (LT-2)
3 Plate mounting bolt:
824.0 – 1030.0 Nm {84.0 – 105.0 kgm}
5
2 Disc mounting bolt: Adhesive (LT-2)
3 Disc mounting bolt:
490.0 – 608.0 Nm {50.0 – 62.0 kgm}
6
3 Differential mounting bolt:
490.0 – 608.0 Nm {50.0 – 62.0 kgm}
WA700-3 30-131
3
7
REMOVAL OF FRONT
1. Remove front axle assembly. For details, see
REMOVAL OF FRONT AXLE ASSEMBLY.
2. Remove drain plugs (1) from both final drives to

drain oil.
6 Axle oil: 245 ¬ each
3. Remove mounting bolts (2) to remove cover (3).

fl Remove the cover with the top mark up.
1
4. Install bolt 1 to end of drive shaft (4) and pull

out drive shaft.
5. Lift off drive shaft (4).
6. Loosen locknut and remove tension bolt (5).

2
7. Remove parking brake disc cover (6).
8. Remove brackets (7), (8) with return spring.

3
9. Remove plate (9), then remove pad (10). 4
10. Remove caliper and spring cylinder assembly

(11).
12. Remove mounting bolts to remove disc plate

(13). 6
30-131-1 WA700-3
7
13. Remove mounting bolts (14). 7
14. Sling front differential assembly (15) temporar-

ily and separate it from axle by using forcing
bolts [2].
15. Lift off front differential assembly (15).
4 Front differential assembly: 826 kg
removal.
1
3 Cover mounting bolt:
98.0 – 123.0 Nm {10.0 – 12.5 kgm}
2
fl Adjustment of tension bolt
Press tension bolt (16) end against the back
of the gear, then return it by 1/2 turn.
3 Locknut:
343.0 – 441.0 Nm {35.0 – 45.0 kgm}
3
3 Bracket mounting bolt:
98 – 122 Nm {10 – 12.5 kgm}
45
2 Plate mounting bolt: Adhesive (LT-2)
3 Plate mounting bolt:
824.0 – 1030.0 Nm {84.0 – 105.0 kgm}
6
2 Disc mounting bolt: Adhesive (LT-2)
3 Disc mounting bolt:
490.0 – 608.0 Nm {50.0 – 62.0 kgm}
7
3 Differential mounting bolt:
490.0 – 608.0 Nm {50.0 – 62.0 kgm}
WA700-3 30-131-2
7
DISASSEMBLY AND ASSEMBLY REAR AXLE
REMOVAL OF REAR AXLE

ASSEMBLY
cle from moving.
¤ Release residual pressure from the hydraulic cir-
cuit. For details, see TESTING AND ADJUST-
ING, Releasing residual pressure from hydraulic
circuit.
1. Exterior parts and counterweight

1) Lift off grille (1).
2) Sling counterweight (2) temporarily and re-
move mounting bolts (3) and (4) on both
sides. 1
4 Counterweight assembly: 2510 kg
3) Lift off handrail, guard, and ladder (5).
2. Rear frame support

Jack up rear frame and place stand 5 under it.
4 Rear frame assembly: 27,000 kg
fl Put block 2 between the top of the rear axle

housing and rear frame (on each side).
fl Place a steel plate under the stand for safety.
fl Use the stand used for transportation. (When
making a new stand, see step 9.)
fl Tighten the mounting bolts of the rear frame
support stand securely.
3 Mounting bolt:
2451.8 – 3040.2 Nm {250.0 – 310.0 kgm}
3. Tire • wheel
Lift off tire • wheels (6) on both sides. 2
4 Tire • wheel assembly: 2490 kg
4. Drive shaft
Disconnect rear drive shaft (7). 3
4 Rear drive shaft assembly: 83 kg
fl Install a lever block to the upper drive shaft

and sling it temporarily to disconnect the
rear drive shaft.
30-132 WA700-3
3
DISASSEMBLY AND ASSEMBLY PISTON PUMP
DISASSEMBLY OF PISTON
(HPF90+90)
PUMP ASSEMBLY
HPV90+HPF90, HPF90+90
fl The disassembly procedure is the same for both

the front and rear pumps, so the procedure for
disassembly of the front pump is given below.
If there are any differences, the different part is
explained.
Preparatory work
Set pump assembly to tool Y1.
(HPV90+HPF90)
1. ES valve assembly, hoses (HPV90+HPF90 only)
1) Remove ES valve assembly (3).
2) Remove hoses (4) and (5).
2. Rear pump assembly

1) Sling rear pump assembly (7).
2) Remove 4 nuts at front pump end, then re-
move rear pump assembly (7).
fl It separates between the end caps.
fl Only the HPV90+HPF90 has a gear pump.
Disassembly of pump
fl The front pump is disassembled as it is, but for

rear pump assembly (7), install plate Y4 and
disassemble.
30-191-1 WA700-3
(9)
3. Impeller
1) Remove bolt (15), then remove plate (9) and
shim (17).
fl Check the number and thickness of the
shims, and keep in a safe place.
2) Remove impeller (8).
4. Servo valve assembly (HPV90+HPF90 only)

Remove servo assembly (12).
fl For the HPF pump, remove the cover.
5. End cap
1) Remove snap ring (13), then remove washer
(14).
2) Remove inner race (20) and bearing (21).

3) Remove end cap (23).
4) Remove valve plate.
fl It is stuck to the cylinder block, so be
careful not to scratch or damage it.
Note: If the cylinder block and valve plate are
to be used again, keep them in a safe
place as a set.
5) Remove outer race and bearing from end
cap.
WA700-3 30-191-2
(9)
6. Valve plate
Remove valve plate (45).
fl It is stuck to the cylinder block, so be careful
not to scratch or damage it.
7. Pump sub-assembly
Support cylinder block and shaft, and remove
pump sub-assembly (49).
8. Servo piston
1) Using forcing screw 1 (Thread dia.=10 mm,
Pitch=1.5 mm) and nut 2, remove cap (27)
and shim (28).
2) Remove spring (31).
fl The spring and forcing screw are for the
HPV090+090 only.
3) Screw in forcing screw and remove cap (29)

and shim (30).
4) Remove servo piston (32).
fl The servo pistons for the front and rear
pumps are different parts, so mark them
with a distinguishing mark.
fl With the HPF pump, there is a spacer on
the right side as seen from the rear of
the pump.
30-191-3 WA700-3
4
Disassembly of pump sub-assembly
9. Cylinder, shaft
1) Set pump sub-assembly (49) in vice.
fl Be careful not to damage the flange sur-
face of the cradle.
2) Remove slider (38) and cylinder block (35).
3) Screw in forcing screw and remove housing

(40) and shim.
fl Check the number and thickness of the
shims, and keep in a safe place.
fl The control pump is installed to the rear

pump. Therefore, collar (10) assembled to
the pilot pump must be removed.
(HPV90+HPF90 only)
fl Remove the cover of the HPF pump.
4) Knock out drive shaft assembly (41) from

piston end and remove.
10. Piston
Remove 4 screws (56), then remove retainer
bearing (57), shoe retainer (58), spacer (59), and
piston (60).
WA700-3 30-191-4
(9)
When using pump drive shaft and cylinder block

again
• Removal of bearing from pump drive shaft

1) Remove snap ring (55), then remove washer
(54), inner race A (53), and bearing (68).
2) Using bearing race puller 3, remove inner

race B (52).
• Disassembly of cylinder block

1) Remove snap ring (34).
30-191-5 WA700-3
4
2) Remove washer (36) and spring (37) from

cylinder block (35).
WA700-3 30-191-6
4
ASSEMBLY OF PISTON PUMP

ASSEMBLY
HPV90+HPF90, HPF90+90
Precautions when assembling
1) Clean all parts and remove all burrs.

2) Coat the rotating and sliding surfaces of all
parts with engine oil (EO-10CD) before as-
sembling.
fl Always use the following parts as a set.
i) Cradle and rocker cam
ii) Cylinder block and valve plate
fl The disassembly procedure is the same for
both the front and rear pumps, so the proce-
dure for disassembly of the front pump is
given below.
If there are any differences, the different part
is given.
1. Cradle, piston assembly

1) Fit dowel pin, then install rocker cam stop-
per (64) to cradle (65).
2 Stopper bolt:
(Loctite #262)
3 Stopper bolt:
13.24 ± 1.47 Nm {1.35 ± 0.15 kgm}
2) Fit dowel pin to cradle, set rocker cam (62)

in position, then install plate (63).
fl Set the side of the rocker cam with the
groove facing the oil hole in the cradle.
2 Plate bolt:
(Loctite #262)
3 Plate bolt:
30.89 ± 3.53 Nm {3.15 ± 0.35 kgm}
fl After tightening the bolts, check that the
rocker cam moves smoothly.
30-191-7 WA700-3
(9)
iii) Select shim of following thickness.

fl Shim thickness =
f – e = g + (0.05 to 0.15) mm
fl This will produce a clearance of 0.05
to 0.15 mm at portion h.
fl With the rear pump, install collar (66) to con-

trol pump (67), then measure dimension j of
collar. (HPV90+HPF90 only)
fl Measure the dimension of the collar portion
of the cover on the HPF pump.
3. Cylinder block
Align with drive shaft and piston, and install
cylinder block (35).
fl The valve plate forms a set with the cylinder
block, so always mark with a distinguishing
mark and keep as a set.
fl Install the spring and washer inside the cyl-
inder block after adjusting the bearing
preload.
30-191-11 WA700-3
(9)
fl The length from the center is different for the

side where the spring is fitted and the side where
no spring is fitted.
WA700-3 30-191-12
4
4. Servo piston (HPV90+HPF90 only)

1) Install pump case (33) to tool Y1.
2) Install servo piston (32).
fl The servo pistons for the front and rear
pumps are different parts, so be careful
not to mistake them when installing.
fl See the diagram on the next page.
3) Adjust servo piston stroke as follows.

i) Align groove k for servo valve arm of
servo piston with dowel pin, then set on
tool Z.
fl The right side as seen from the rear
(the side with the spring, the top
when mounted on the machine) is
the maximum angle side.
Note: Use the same tool and turn it
over for the rear pump.
ii) Measure dimension n between servo pis-

ton and case.
iii) Measure dimension p of cap (29).
iv) Calculate shim thickness from dimension
p of cap and dimension n of servo as
follows to give a clearance of ± 0.05 mm.
Shim thickness: p – n = q ± 0.05 mm
fl Keep the adjusted shim and the cap
as a set.
fl When adjusting the minimum angle side,

replace tool Z with the minimum angle tool,
and repeat the procedure in Steps i) – iv)
above.
Note that the direction of the case is the
opposite from the maximum angle.
30-191-13 WA700-3
(9)
6) Set dial gauge 2 to case, move shaft to

front and rear, and measure end play.
fl End play: 0.1 – 0.3 mm
fl If the end play is not within the standard
range, carry out the shim selection again.
7) After completion of measurement, remove
end cap.
fl Be careful not to drop the valve plate
when removing the end cap.
fl With the rear pump, after tightening the

bolts, for holding the cradle bearing in posi-
tion, install the control pump, set dial gauge
2 to the end cap, and measure.
fl HPV90+HPF90 only
7. End cap
1) Assemble spring (37) and washer (36) to cyl-
inder block (35), then install snap ring (34).
fl Be careful not to damage the contact
surface of the valve plate.
2) Install end cap.
fl For details, see Steps 6-1)-iii), iv), and 2).
3) Fit bearing (21), inner race (20), spacer (18),

boss (16), shim (15), and plate (14), and
tighten bolt (13).
2 Bolt: Thread tightener (LT-2)
3 Bolt: 68.65 ± 4.9 Nm {7 ± 0.5 kgm}
30-191-17 WA700-3
(9)
4) Install selected spacer (10) to rear pump.

5) Fit selected spacer (9) to front pump and
install impeller (8).
11. Rear pump assembly

1) Install each O-ring to front and rear end caps.
2) Raise rear pump assembly (7), then align
spline and install.
3 Mounting nut:
235.36 ± 19.61 Nm {24 ± 2 kgm}
3 Stud bolt:
132.39 ± 14.71 Nm {13.5 ± 1.5 kgm}
fl Only HPV90+HPF90 has a gear pump.
(HPV90+HPF90)
12. ES valve assembly, hoses (HPV090+090 only)
1) Fit O-ring and install ES valve assembly (3).
2) Install hoses (4) and (5).
(HPF90+90)
fl Checking quality after completion of assem-

bly
After completing assembly of the pump as-
sembly, use a test stand (A type or C type)
and check the quality.
fl For details of the procedure for checking the
quality, see the Testing Method.
WA700-3 30-191-20
(9)
DISASSEMBLY AND ASSEMBLY BULKHEAD
REMOVAL OF BULKHEAD
ASSEMBLY
Serial No.: 50001 – 51000
cle from moving.
4. Lift off both side covers (3) and (4) and engine
hood (5).
5. Remove both side covers (6).
6. Open bulkhead cover (7).
7. Remove transmission inspection cover (8).
8. Disconnect hose (9) between receiver tank and

air conditioner unit. 1
fl Using tool X1 on the air conditioner com-
pressor side, collect air conditioner refriger-
ant (R134a).
9. Disconnect hose (10) between air conditioner

compressor and condenser. 2
10. Disconnect window washer hose (11).

fl Collect window washer detergent liquid from
the tank.
11. Remove covers (12) and (13) from front of air

cleaner.
WA700-3 30-225
3
7
12. Disconnect high-temperature heater hose (14)

(Outlet on engine side).
13. Disconnect low-temperature heater hose (15) (Re-

turn).
fl When the cooling water is not drained, close
the valve and bend the hose at a point on
the way, then disconnect and plug it.
14. Disconnect wiring connector (16) (BR1).
15. Remove covers (17) and (18) inside bulkhead.
16. Disconnect dust indicator wiring connectors (19)

(B06, B07) and (20) (B08, B09).
17. Disconnect both supports (21) from bulkhead.
18. Remove mounting bolts, then lift off bulkhead

assembly (22).
4 Bulkhead assembly: 235 kg
INSTALLATION OF BULKHEAD
ASSEMBLY
Serial No.: 50001 – 51000
removal.
12
fl Do not twist the hoses.
fl Do not let dirt, dust, water, etc. in the hoses.
fl Using tool X1, charge the air conditioner
circuit with new refrigerant (R134a).

again.
30-226 WA700-3
3
7
REMOVAL OF BULKHEAD
ASSEMBLY
cle from moving.
4. Lift off both side covers (3) and (4) and engine
hood (5).
5. Remove both side covers (6).
6. Remove precleaner (7).
8. Remove transmission inspection cover (9).

air conditioner unit. 1
fl Using tool X1 on the air conditioner com-
pressor side, collect air conditioner refriger-
ant (R134a).
10. Disconnect hose (11) between air conditioner

compressor and condenser. 2
WA700-3 30-226-1
7
11. Disconnect window washer hose (12).

fl Collect window washer detergent liquid from
the tank.
12. Remove covers (13) and (14) from front of air

cleaner.
13. Disconnect high-temperature heater hose (15)

(Outlet on engine side).
14. Disconnect low-temperature heater hose (16) (Re-

turn).
fl When the cooling water is not drained, close
the valve and bend the hose at a point on
the way, then disconnect and plug it.
15. Disconnect wiring connector (17) (BR1).
16. Disconnect dust indicator hose (18).
30-226-2 WA700-3
7
17. Disconnect both supports (19) from bulkhead.
18. Remove mounting bolts, then lift off bulkhead

assembly (20).
4 Bulkhead assembly: 235 kg
INSTALLATION OF BULKHEAD
ASSEMBLY
removal.
12
fl Using tool X1, charge the air conditioner
circuit with new refrigerant (R134a).

again.
WA700-3 30-226-3
7
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
REMOVAL OF FLOOR FRAME

ASSEMBLY
 Stop the vehicle on level ground and lower the
cle from moving.
 Disconnect the cable from the negative (–) ter-
fl Collect air conditioner gas.

= Cooling water: 190 ¬
2. Remove front, rear, right, and left side covers
(1) under cab.
3. Remove ROPS cab assembly (2). For details,

see REMOVAL OF ROPS CAB ASSEMBLY.
4 ROPS cab assembly: 1,100 kg
4. Disconnect left brake valve drain hose (3) and
right brake valve drain hose (4).
5. Disconnect hose (5) between steering valve and

right stop valve.

left stop valve.
7. Disconnect PPC valve drain hose (7).
8. Disconnect hose (8) connected to PPC pump.
9. Disconnect hoses (9) (Lower boom), (10) (Raise

boom), (11) (Tilt bucket), and (12) (Dump bucket)
connected to work equipment control valve.
10. Disconnect stop valve drain hose (13).

fl From the left stop valve to the block.
11. Disconnect hose (14) between right brake valve

and front brake and hose (15) between right
brake valve and rear brake.
WA700-3 30-227
(10)
12. Disconnect hose (16) between left brake valve

and accumulator.
13. Disconnect hoses (17) and (18) between right

brake valve and accumulator.
fl Before disconnecting these hoses, release
the pressure from the accumulator.
14. Disconnect steering valve drain hose (19).

PPC relief valve.
16. Disconnect heater hoses (21) and (22) connected

to air conditioner unit.
fl Plug the disconnected hoses.
fl Close the valves on the engine side.
17. Disconnect air conditioner hoses (23) and (24).

1
fl Since the hose adapters are brittle, be sure
to use double spanner to loosen them.
18. Disconnect 12 floor frame wiring connectors (25).

fl Connector No. LR1, 2, 3, 4, 5, 6, 7, 8
FR1, 2
LT1
GRE
19. Disconnect 2 window washer hoses (26).

fl These hoses have different colors. When
connecting them again, observe their colors.
30-228 WA700-3
(10)
20. Disconnect ground cable (27).
21. Disconnect 4 nuts of floor frame mount (28).

2
22. Lift off floor frame assembly (29).

fl Checking that the all hoses, wires, etc. are
disconnected, sling the assembly slowly.
4 Floor frame assembly: 350 kg
INSTALLATION OF FLOOR
FRAME ASSEMBLY
removal.
1
fl Install each hose so that it will not be twisted.
fl When installing the air conditioner hoses,
take care that dirt, dust, water, etc. will not
enter them.
fl When tightening each joint of the air condi-
tioner hose, check that O-ring is fitted to it.
fl Apply sufficient compressor oil for R134a
(DENSO: ND-OIL8, ZEXEL: ZXL100PG (appli-
cable to PAG46)) to each O-ring.
3 Tightening torque of air conditioner re-

frigerant piping:
Thread size Tightening torque
16 x 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 x 1.5 19.5 – 24.5 Nm {2.0 – 2.5 kgm}
24 x 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
2
3 Mounting nut:
245.0 – 308.7 Nm {25.0 – 31.5 kgm}

with air conditioner gas (R134a).

again.
WA700-3 30-229
(10)
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
Serial No.: 50001 – 51000
cle from moving.
1. Drain fuel.
6 Fuel: Approx. 1,060 ¬ when full
2. Remove handrail (1) on right side of engine.
3. Remove bolt securing step (2) and battery box.

fl Remove the bolt on the left side, too.
4. Remove ladder handrail (3).
5. Remove cover (4).
6. Lift of ladder (5).
7. Remove cover (6) at right top of fuel tank.
8. Disconnect engine oil drain valve (7) and cool-

ing water drain valve (8) from fuel tank.
9. Remove cover (9) at left top of fuel tank.
10. Disconnect tube (10) between fuel tank and valve.
11. Disconnect tube (11) between valve and strainer.
12. Remove valve (12).
13. Disconnect hose (13) between fuel injection

pump and fuel tank.
WA700-3 30-231
3
7
14. Disconnect fuel level gauge wiring connector (14)

(R05).
15. Disconnect hose clamp (15) from fuel tank.

fl Located at the left under the radiator.
16. Disconnect fuel spill hose (16).

fl Located under the engine oil bypass filter.
17. Set pallet 1 under fuel tank.
18. Sling fuel tank assembly (17) temporarily and

remove mounting bolts. 1
fl Check the place and quantity of the shims
on both sides of the fuel tank on the radiator
side.
19. Lower fuel tank assembly (17) slowly to pallet.
4 Fuel tank assembly: 650 kg
fl Lower the fuel tank straight, taking care of

the breather tube extended up.
INSTALLATION OF FUEL TANK

ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to re-
moval.
1
Adjust the shims so that the clearance between
the fuel tank and rear frame will be 0.5 mm
maximum.
3 Fuel tank mounting bolt:
1,520.1 – 1,912.4 Nm {155.0 – 195.0 kgm}
• Bleeding air
After installing the fuel tank, bleed air from the
fuel circuit. For details, see TESTING AND AD-
JUSTING, Bleeding air from each part.
30-232 WA700-3
3
7
REMOVAL OF FUEL TANK

ASSEMBLY
cle from moving.
1. Drain fuel.
6 Fuel: Approx. 1,060 ¬ when full
2. Remove handrail (1) on right side of engine.
3. Remove bolt securing step (2) and battery box.

fl Remove the bolt on the left side, too.
4. Remove ladder handrail (3).
6. Lift of ladder (5).
7. Remove cover (6) at right top of fuel tank.
8. Disconnect engine oil drain valve (7) and cool-

ing water drain valve (8) from fuel tank.
9. Remove cover (9) at left top of fuel tank.
10. Disconnect hose (10) between fuel tank and valve

(11).
11. Disconnect hose (12), valve (11) and strainer.
12. Remove valve (11).
13. Disconnect hose (13) between fuel tank and

breather.
14. Disconnect hose (14) between fuel cooler and

fuel tank.
WA700-3 30-232-1
7
15. Disconnect fuel level gauge wiring connector (15)

(R05).
16. Set pallet 1 under fuel tank.
17. Sling fuel tank assembly (16) temporarily and

remove mounting bolts. 1
fl Check the place and quantity of the shims
on both sides of the fuel tank on the radiator
side.
18. Lower fuel tank assembly (16) slowly to pallet.
4 Fuel tank assembly: 600 kg
fl Lower the fuel tank straight, taking care of

the breather tube extended up.
INSTALLATION OF FUEL TANK

ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
1
Adjust the shims so that the clearance between
the fuel tank and rear frame will be 0.5 mm
maximum.
3 Fuel tank mounting bolt:
1,520.1 – 1,912.4 Nm {155.0 – 195.0 kgm}
• Bleeding air
After installing the fuel tank, bleed air from the
fuel circuit. For details, see TESTING AND AD-
JUSTING, Bleeding air from each part.
30-232-2 WA700-3
7
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CALIPERS
5. Assemble adjuster (2) and secure with snap ring

(1).
WA700-3 30-251
3
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD
REMOVAL OF PARKING BRAKE

PAD
Serial No.: 50001 – 50044
put blocks under the wheels to prevent the ma-
chine from moving.
1. Remove disc plate cover (1).
2. Turn adjustment bolt (2) counterclockwise to in-

crease the clearance between the pad and disc.
1
3. Secure calipers (3) with wires.

fl Since 2 dowel pins are installed, raise the
calipers a little, then remove the plate.
5. Remove pad (5).
INSTALLATION OF PARKING
BRAKE PAD
Serial No.: 50001 – 50044
removal.
1
fl Adjust the parking brake pad. For details,
see TESTING AND ADJUSTING PARKING
BRAKE of TESTING AND ADJUSTING.
2
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
824.0 – 1030.0 Nm {84.0 – 105.0 kgm}
30-252 WA700-3
3
7
REMOVAL OF PARKING BRAKE

PAD
put blocks under the wheels to prevent the ma-
chine from moving.
1. Remove disc plate cover (1).
2. Turn adjustment bolt (2) counterclockwise to in-

crease the clearance between the pad and disc.
1
3. Secure calipers (3) with wires.
4. Remove brackets (4), (5) with return springs.

2

fl Since 2 dowel pins are installed, raise the
calipers a little, then remove the plate.
6. Remove pad (7).
WA700-3 30-252-1
7
INSTALLATION OF PARKING
BRAKE PAD
removal.
1
fl Adjust the parking brake pad. For details,
see TESTING AND ADJUSTING PARKING
BRAKE of TESTING AND ADJUSTING.
2
3 Mounting bolt:
98 – 122 Nm {10 – 125 kgm}
3
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
824.0 – 1030.0 Nm {84.0 – 105.0 kgm}
30-252-2 WA700-3
7
DISASSEMBLY AND ASSEMBLY REAR TIRE
REMOVAL OF REAR TIRE

ASSEMBLY
¤ Stop the vehicle on level ground and install the
safety bar to the frame and put blocks under the
wheels to prevent the vehicle from moving.
1. Set blocks 1 to both sides of rear axle.

fl These blocks are used to prevent the tire
from bouncing when it is removed.
3. Raise vehicle body with 2 jacks (50 ton) 2 and

set stand 3 under counterweight.
4. Sling tire assembly temporarily and remove hub

nuts (2). 1
5. Lift off tire assembly (3).

fl Secure the center of the tire with a noose of
the sling.
4 Tire assembly: 2,490 kg
INSTALLATION OF REAR TIRE

ASSEMBLY
removal.
1
3 Hub nut:
736.0 – 912.0 Nm {75.0 – 93.0 kgm}
fl Match the holes for the stud bolts by turn-
ing the tire on the opposite side.
WA700-3 30-253
3
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
Serial No.: 50001 – 51000
cle from moving.
1. Collect air conditioner gas (R134a).
2. Disconnect wiring connector (1) (E21).
3. Disconnect hose (2) between condenser and air

conditioner compressor and hose (3) between
air conditioner unit and air conditioner compres-
sor. 1
4. Loosen mounting bolt (4).
5. Remove adjustment bolt (5) and slant compres-

sor toward engine to remove drive belt (6).
6. Remove 4 mounting bolts (7) to remove air con-

ditioner compressor assembly (8).
30-254 WA700-3
(10)
INSTALLATION OF AIR
ASSEMBLY
Serial No.: 50001 – 51000
removal.
1

frigerant piping:
16 x 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 x 1.5 19.5 – 24.5 Nm {2.0 – 2.5 kgm}
24 x 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

WA700-3 30-254-1
(10)
REMOVAL OF AIR
ASSEMBLY
cle from moving.
2. Disconnect wiring connector (1) (E21).
3. Disconnect hose (2) between condenser and air
conditioner compressor and hose (3) between
air conditioner unit and air conditioner compres-
sor. 1
4. Loosen mounting bolt (4) of air conditioner com-
pressor bracket.
5. Remove adjustment bolt (5) and slant compres-
sor toward engine to remove drive belt (6).
6. Remove 2 mounting bolts (7) to remove cover (8).
7. Remove 2 mounting bolts (9) to remove air con-
ditioner compressor assembly (8).
INSTALLATION OF AIR
ASSEMBLY
removal.
1
• Compressor oil
(When using new compressor or refill com-
pressor oil.)
5 Compressor oil (DENSO: ND-OIL8, ZEXEL:
ZXL100PG (applicable to PAG46)) : 220 m¬
frigerant piping:
16 x 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 x 1.5 19.5 – 24.5 Nm {2.0 – 2.5 kgm}
24 x 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

30-254-2 WA700-3
(10)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLIES
cle from moving.

A. Removal of left air conditioner condenser as-

sembly
air conditioner condenser. 1
fl Since the hose adapter is brittle, be sure to
use double spanner to loosen it.
2. Disconnect hose (2) between right condenser
and left condenser.
3. Disconnect wiring connectors (3) (B10) and (4)
(B11).
4. Remove mounting bolts to remove air condi-
tioner condenser assembly (5).
B. Removal of right air conditioner condenser as-

sembly
1. Disconnect hose (1) between left condenser and
right condenser. 1
2. Disconnect hose (2) between air conditioner com-
pressor and right condenser.
3. Disconnect wiring connectors (3) (B12) and (4)
(B13).
4. Remove mounting bolts to remove air condi-
tioner condenser assembly (5).
WA700-3 30-255
(10)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
removal.
1

frigerant piping:
16 x 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 x 1.5 19.5 – 24.5 Nm {2.0 – 2.5 kgm}
24 x 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

30-255-1 WA700-3
(10)
DISASSEMBLY AND ASSEMBLY RECEIVER TANK
REMOVAL OF RECEIVER TANK

ASSEMBLY
cle from moving.
3. Disconnect hose (2) connected to air conditioner

unit.
4. Disconnect hose (3) connected to condenser.

1
5. Remove clamp (4) to remove receiver tank as-
sembly (5).
INSTALLATION OF RECEIVER
TANK ASSEMBLY
removal.
1

frigerant piping:
16 x 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 x 1.5 19.5 – 24.5 Nm {2.0 – 2.5 kgm}
24 x 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

30-256 WA700-3
(10)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR
CONDITIONER UNIT
ASSEMBLY
cle from moving.
= Cooling water: 190 ¬
3. Remove cab assembly. For details, see RE-

MOVAL OF CAB ASSEMBLY.
4. Disconnect operator’s seat suspension switch

wiring connector (1) (ASS).
fl Installed at the rear of the seat.
5. Remove operator’s seat assembly (2).
4 Operator’s seat assembly: 50 kg
6. Remove covers (3) and (4).
7. Remove console box (5).
8. Disconnect wiring connectors (6) (A5), (7) (A7),

and (8) (A6).
9. Disconnect wiring connectors (9) (A8B) and (10)

(A8A).
10. Disconnect expansion valve switch connector

(11) (A15).
11. Disconnect tube (12) connected to receiver tank.

1
12. Disconnect tube (13) connected to air conditioner

compressor. 1
fl Collect air conditioner refrigerant (R134a).
For details, see REMOVAL OF AIR CONDI-
TIONER COMPRESSOR ASSEMBLY.
fl Take measure to prevent dirt, water, etc. from
entering the system.
13. Disconnect heater hot water inlet hose (14).
14. Disconnect valve of heater hot water outlet hose.

fl Close the valve on the engine side.
fl Plug the disconnected hoses.
WA700-3 30-257
(10)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
15. Remove screws (16).
16. Remove mounting bolts (17) to remove air con-

ditioner unit (18).
fl Pull out the unit.
INSTALLATION OF AIR
CONDITIONER UNIT
ASSEMBLY
removal.
1

frigerant piping:
16 x 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 x 1.5 19.5 – 24.5 Nm {2.0 – 2.5 kgm}
24 x 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}

fl If the air conditioner is operated without charging

it with refrigerant, its compressor may be broken.
Take care.

again.
30-258 WA700-3
(10)
DISASSEMBLY AND ASSEMBLY MAINTENANCE MONITOR
REMOVAL OF MAINTENANCE
MONITOR ASSEMBLY
cle from moving.
1. Remove armrest (1).

fl Raise the cover and disconnect wiring con-
nector (L40, L41) of power window switchs
(3).
3. Remove mounting bolts to remove maintenance

monitor assembly (4).
fl Disconnect wiring connector of monitor as-
sembly (L18, L19, L21, L22).
INSTALLATION OF
MAINTENANCE MONITOR
ASSEMBLY
removal.
fl After installing the maintenance monitor, check

its operation.
WA700-3 30-261
3
DISASSEMBLY AND ASSEMBLY ENGINE, APS CONTROLLER
REMOVAL OF ENGINE, APS

CONTROLLER ASSEMBLY
Serial No.: 50001 – 51000
hicle from moving.
1. Open right door of cab and remove console box

side cover (1).
A. Removal of engine controller assembly

1) Disconnect engine controller wiring connec-
tors (2) (EC1), (3) (EC3A, B), (4) (EC2), and
(5) (EC5A, B).
2) Remove mounting bolts to remove engine
controller assembly (6).
B. Removal of APS controller assembly

1) Disconnect APS controller wiring connectors
(7) (L71) and (8) (L72).
2) Remove mounting bolts to remove APS con-
troller assembly (9).
APS CONTROLLER ASSEMBLY
Serial No.: 50001 – 51000
removal.
fl After installing the engine and APS controller

assembly, check its operation.
30-262 WA700-3
3
7
40 Maintenance standard
Engine and tansmission mount ......................40- 3

Damper ..........................................................40- 4
Torque converter and PTO .............................40- 6
Torque converter regulator valve....................40- 7
Transmission ..................................................40- 8
Transmission control valve.............................40- 12
Transfer ..........................................................40- 18
Drive shaft ......................................................40- 20
Center support ...............................................40- 21
Differential ......................................................40- 22
Final drive.......................................................40- 24
Axle mount .....................................................40- 26
Center hinge pin.............................................40- 28
Steering column .............................................40- 30
Steering demand valve...................................40- 32
Diverter valve .................................................40- 34
Steering cylinder mount..................................40- 35
Emergency steering pump .............................40- 36
Brake valve ....................................................40- 38
Slack adjuster.................................................40- 45
Brake..............................................................40- 46
Parking brake .................................................40- 50
Control pump..................................................40- 51
Steering and switch pump ..............................40- 52
Main piston pump...........................................40- 53
Main control valve ..........................................40- 54
PPC valve ......................................................40- 58
PPC relief valve..............................................40- 60
Hydraulic cylinder ...........................................40- 61
Work equipment linkage.................................40- 62
Bucket ............................................................40- 64
Bucket positioner and boom kick-out .............40- 65
WA700-3 40-1
(10)
Maintenance standard Engine and tansmission mount
Engine and tansmission mount
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

Clearance between trunnion size Shaft Hole clearance limit
1
and torque converter case
–0.100 +0.072 0.100 –
230
–0.172 0 0.244
Replace
Clearance between shaft and 0 +0.035 0.00 –
2 63
rubber cushion –0.030 0 0.065
Clearance between rubber +0.115 +0.054 –0.115 –
3 97
cushion and bracket +0.080 0 –0.026
Standard shim thickness: 1.0 mm (parallelism of coupling mating joint
4 Thickness of mount shim —
of transmission output shaft and center of center pin: Max. 0.10 mm)
WA700-3 40-3
(10)
Maintenance standard Damper
Damper
40-4 WA700-3
(10)
Maintenance standard Damper
Unit: mm

Clearance between bearing size Shaft Hole clearance limit
1
and shaft
+0.015 0 –0.035 –
85 0.025
+0.003 –0.020 –0.003
Clearance between bearing 0 –0.008 –0.033 –
2 150 0.018
and housing –0.018 –0.033 0.010
Clearance between inner –0.012 +0.110 0.042 –
3 85 0.25
body and shaft –0.034 +0.030 0.144 Replace
Standard size Tolerance Repair limit
Wear of surface in shaft and
4 0
oil seal 100 –0.133
–0.087
Wear of surface in sleeve and 0
5 120 –0.138
oil seal –0.087
6 Backlash of spline 0.068 – 0.262
WA700-3 40-5
(10)
Maintenance standard Torque converter and PTO
Torque converter and PTO
Unit: mm

Inside diameter of seal ring
1 +0.040 Repair chrome
surface of retainer 170 170.2
0 plating or
replace
Inside diameter of seal ring +0.030
2 75 75.2
surface of sleeve 0
0
Width and Width 4.45 3.9
–0.1
3 thickness of
seal ring Thickness 6.0 ±0.1 5.85 Replace
Backlash of PTO gear

4 0.20 – 0.52
(Drive gear)
40-6 WA700-3
(10)
Maintenance standard Torque converter regulator valve
Torque converter regulator valve

Unit: mm

Clearance between poppet size Shaft Hole clearance limit
1
and spool
–0.020 +0.021 0.020 –
28 0.080
–0.030 0 0.051
Clearance between spool and –0.035 +0.016 0.035 –
2 40 0.080
body –0.045 0 0.061
Standard size Repair limit Replace
Installation Installation Installation

Free length Free length
3 Poppet spring length load load
47 N 44.7 N
53 23 51.4
{4.8 kg} {4.6 kg}
341 N 324.0 N
4 Spool spring 157 84 152.3
{34.8 kg} {33.1 kg}
Pressure per 1 piece: (t=4.5) 0.034 MPa {0.348 kg/cm2}
5 Thickness of shim 9 Adjust
Pressure per 1 piece: (t=0.5) 0.004 MPa {0.039 kg/cm2}
WA700-3 40-7
(10)
Maintenance standard Transmission
Transmission (1/2)
Unit: mm
Standard size Repair limit

Reverse clutch springs Free length Free length
1 length load load
(12 pieces)
192 N 164 N
91 69.2 85.5
{19.6 kg} {16.7 kg}
Forward clutch springs 146 N 125 N
2 91 74.4 85.5
(12 pieces) {14.9 kg} {12.7 kg} Replace
101 N 86.3 N
3 4th clutch springs (12 pieces) 52 46 48.9
{10.3 kg} {8.8 kg}
84.3 N 71.6 N
4 3rd clutch springs (12 pieces) 52 47 48.9
{8.6 kg} {7.3 kg}
155 N 131 N
5 1st clutch springs (12 pieces) 52 42.8 48.9
{15.8 kg} {13.4 kg}
40-8 WA700-3
(10)
Unit: mm

Thickness of assembled 5 discs
6
and 4 plates for reverse clutch 50.2 — 48.2

7 61.4 — 59.0
and 5 plates for forward clutch
8 27.8 — 26.6
and 2 plates for 4th clutch
9 45.0 — 43.0
and 4 plates for 2nd clutch
10 27.8 — 26.6
and 2 plates for 3rd clutch
11 27.8 — 26.6
and 2 plates for 1st clutch
Forward, Reverse,
Thickness 1st, 3rd, 4th 5.4 — 5.0
12
of 1 disc
2nd 5.0 — 4.6
Forward, Reverse,
Thickness 1st, 3rd, 4th 5.8 — 5.2
13
of 1 plate
2nd 5.0 — 4.5
Outside diameter of input +0.018 +0.018 Replace
14 130
shaft –0.007 –0.007
Outside diameter of input +0.016 +0.016
15 110
shaft –0.006 –0.006
Outside diameter of output +0.018 +0.018
16 130
shaft –0.007 –0.007
Outside diameter of output +0.018 +0.018
17 140
shaft –0.007 –0.007
–0.01
Wear of seal ring Width 3.0 2.6
18 –0.03
for input shaft
Thickness 3.7 ±0.12 3.55
–0.01
19 –0.03
for output shaft
Thickness 5.2 ±0.12 5.05
–0.01
20 –0.03
for output shaft
Thickness 5.4 ±0.12 5.25
–0.01
21 –0.03
for 2nd clutch
Thickness 6.6 ±0.15 5.85
WA700-3 40-9
(10)
Transmission (2/2)
Unit: mm
Backlash between reverse

1 0.13 – 0.32
sun gear and planetary gear
Backlash between reverse
2 0.15 – 0.38
planetary gear and ring gear
Backlash between forward
3 0.13 – 0.36
sun gear and planetary gear
Backlash between forward
4 0.14 – 0.39
planetary gear and ring gear
Backlash between 4th plane-
5 0.14 – 0.39
tary gear and ring gear
Replace
Backlash between 4th sun
6 0.13 – 0.36
gear and planetary gear
Backlash between 3rd sun
7 0.13 – 0.36
Backlash between 3rd plane-
8 0.14 – 0.39
Backlash between 1st sun
9 0.13 – 0.36
Backlash between 1st plane-
10 0.14 – 0.39
40-10 WA700-3
(10)
Maintenance standard Transmission control valve
Transmission control valve

Upper valve
Relief valve
Serial No.: 50001 — 51000 Serial No.: 51001 and up
40-12 WA700-3
(10)
Unit: mm

Clearance between reducing size Shaft Hole clearance limit
1
valve and body
–0.035 +0.013 0.035 –
25 0.08
–0.045 0 0.058
Clearance between torque con- –0.035 +0.013 0.035 –
2 25 0.08
verter relief valve spool and body –0.045 0 0.058
Clearance between priority –0.020 +0.013 0.020 –
3 25 0.08
valve spool and body –0.041 0 0.054
Clearance between quick –0.035 +0.011 0.035 –
4 12 0.08
return valve spool and body –0.045 0 0.056
Clearance between modulation –0.035 +0.013 0.035 –
5 25 0.08
Clearance between main –0.035 +0.016 0.035 –
6 40 0.08
relief valve spool and body –0.045 0 0.061
Clearance between quick fill –0.035 +0.013 0.035 –
7 25 0.08
Installation Installation Installation Replace
8 Priority valve spring Free length Free length
length load load
217 N 206 N
62 37.74 60.1
{22.1 kg} {21.0 kg}
Torque converter relief valve 152 N 144 N
9 62 45 60.1
spring {15.5 kg} {14.7 kg}
300 N 285 N
10 Inner 159 135 154.2
Modulation valve {30.6 kg} {29.1 kg}
spring 328 N 311 N
11 Outer 161 135 156.2
{33.4 kg} {31.7 kg}
Serial No. Free Installation Installation Free Installation
length length load length load
Main relief valve 50001 – 995 N 945 N
12 124 101 120.3
spring 51000 {101.5 kg} {96.4 kg}
455.4 N 432.6 N
Inner 117 93.5 113.5
51001 {46.4 kg} {44.1 kg}
and up 1,124.7 N 1,068.5 N
Outer 117 93.5 113.5
{114.7 kg} {109.0 kg}
50001 407 N 386 N
13 Reducing valve spring 75 57 72.8
and up {41.5 kg} {39.4 kg}
Standard thickness of shim of 50001
14 3.5 mm (pressure per 1 piece: 0.06 MPa {0.65 kg/cm2}
reducing valve and up
modulation valve and up
priority valve and up
Adjust
torque converter relief valve and up
50001 –
2.0 mm (pressure per 1 piece: 0.045 MPa {0.46 kg/cm2}
18
main relief valve 50001
3.5 mm (pressure per 1 piece: 0.06 MPa {0.56 kg/cm2}
and up
quick fill valve and up
WA700-3 40-13
(10)
Lower valve
40-14 WA700-3
(10)
Unit: mm

Clearance between size clearance limit
Shaft Hole
1 FORWARD-REVERSE spool
and body –0.035 +0.013 0.035 –
22 0.08
–0.045 0 0.058
Clearance between 1st speed –0.035 +0.013 0.035 –
2 22 0.08
spool and body –0.045 0 0.058
Clearance between 2nd –0.035 +0.013 0.035 –
3 22 0.08
speed spool and body –0.045 0 0.058
Clearance between 3rd speed –0.035 +0.013 0.035 –
4 22 0.08
Clearance between 4th speed –0.035 +0.013 0.035 –
5 22 0.08
Clearance between pilot reducing –0.035 +0.013 0.035 – Replace
6 25 0.08
Clearance between lubrica- –0.035 +0.013 0.035 –
7 22 0.08
tion valve plunger and body –0.045 0 0.058
FORWARD-REVERSE, No. Installation Installation Installation
8 1, No. 2, No. 3, and No. 4 length load load
speed spring
107 N 102 N
78 47 75
{10.9 kg} {10.4 kg}
164 N 156 N
9 Pilot reducing valve spring 62 43.7 60.1
{16.7 kg} {15.9 kg}
60.8 N 57.9 N
10 Lubrication valve spring 39.4 37 38.2
{6.2 kg} {5.9 kg}
Thickness of shim for pilot
11 3 mm (pressure per 1 piece: 0.026 MPa {0.26 kg/cm2}) Adjust
reducing valve
WA700-3 40-15
(10)
Solenoid valve
40-16 WA700-3
(10)
Maintenance standard Transfer
Transfer
40-18 WA700-3
(10)
Maintenance standard Transfer
Unit: mm
No. Cehck item Criteria Remedy
Standard Tolerance Standard

Repair limit
Clearance between input size Shaft Hole clearance
1
shaft and bearing
+0.052 0 –0.077 – –0.077 –
140
+0.027 –0.025 –0.027 –0.027
Clearance between input 0 0 –0.046 – –0.046 –
2 210
shaft bearing and case –0.030 –0.046 0.030 0.030
Clearance between idler shaft +0.070 +0.025 –0.070 – –0.070 –
3 104.775
and bearing +0.048 0 –0.023 –0.023
Clearance between idler shaft +0.025 +0.025 –0.046 – –0.046 –
4 180.975
bearing and case 0 –0.021 0.025 0.025
Clearance between output +0.052 0 –0.077 – –0.077 –
5 130
shaft and bearing +0.027 –0.025 –0.027 –0.027 Replace
Clearance between output 0 0 –0.046 – –0.046 –
6 200
Clearance between output +0.045 0 –0.065 – –0.065 –
7 100
shaft and bearing +0.023 –0.020 –0.023 0.023
Clearance between output 0 –0.012 –0.057 – –0.057 –
8 180
Oil seal sliding surface of
9 0
output shaft coupling 130 129.9
–0.100
Oil seal sliding surface of 0
10 150 149.9
output shaft coupling –0.100
Standard clearance Adjust value of bearing preload
Clearance between bearing
11 0.49 – 0.98 Nm {0.05 – 0.1 kgm}
cage and case 2 (shims)
(Preload, gear as individual part)
Clearance between output Max. 0.49 Nm {Max. 0.05 kgm} Adjust
12 1 (shim)
cover and case (after inserting shim)
Clearance between idler 0.49 – 0.98 Nm {0.05 – 0.1 kgm}
13 2 (shims)
cover and case (Preload, gear as individual part)
Backlash between input gear
14 0.22 – 0.47
and idler gear
Backlash between idler gear
15 0.22 – 0.47 Replace
and idler gear
Backlash between output
16 0.22 – 0.47
gear and idler gear
WA700-3 40-19
(10)
Maintenance standard Drive shaft
Drive shaft
40-20 WA700-3
(10)
Maintenance standard Center support
Center support
Unit: mm

Clearance between case and size Shaft Hole clearance limit
1
bearing
0 –0.036 –0.061 –
160 0.008
–0.025 –0.061 –0.011
Clearance between case and 0 –0.036 –0.061 – Replace
2 160 0.008
bearing –0.025 –0.061 –0.011
Clearance between coupling +0.059 0 –0.079 –
3 90 –0.033
shaft and bearing +0.037 –0.020 –0.037
Clearance between coupling +0.059 0 –0.079 –
4 90 –0.033
shaft and bearing +0.037 –0.020 –0.037
5 Wear of oil seal surface 0 Repair chrome
110 –0.19
–0.087 plating or
replace
0
6 Wear of oil seal surface 130 –0.18
–0.010
7 End play of coupling shaft 0.05 – 0.15 Replace
WA700-3 40-21
(10)
Maintenance standard Differential
Differential
40-22 WA700-3
(10)
Maintenance standard Differential
Unit: mm

Clearance of side bearing outer size Shaft Hole clearance limit
1
race in differential gear assembly
0 +0.069 0.104 –
260 —
–0.035 +0.017 0.017
Clearance of side bearing inner +0.052 0 –0.027 –
2 170 —
race in differential gear assembly +0.027 –0.025 –0.077
Clearance of outer race of +0.025 +0.020 0.020 –
3 250.825 —
pinion shaft bearing 0 –0.027 –0.052
Clearance of inner race of +0.064 +0.025 –0.013 –
4 101.6 —
pinion shaft bearing +0.038 0 –0.064
Clearance of inner race of +0.050 +0.025 –0.003 –
5 101.6 —
pinion shaft bearing +0.028 0 –0.050
Clearance of outer race of 0 +0.039 –0.064 –
6 160 —
pilot bearing –0.025 +0.014 –0.014
Clearance of inner race of +0.061 0 –0.042 –
7 75 —
pilot bearing +0.042 –0.015 –0.076
Clearance between differen- –0.020 +0.052 0.112 –
8 310 —
tial carrier and cage –0.060 +0.010 0.030
Clearance between spider –0.155 +0.03 0.210 – Replace
9 50 0.35
and differential pinion bushing –0.180 –0.02 0.135
Thickness of side gear
10
washer 4.0 ±0.05 3.5
0
11 Wear of oil seal surface 160 —
–0.100
12 Backlash of bevel gear 0.46 – 0.66
13 Backlash of differential gear 0.25 – 0.33
14 End play of pinion gear 0 – 0.266
Free rotating torque of bevel

15 15.2 Nm {1.55 kgm}
gear
16 Preload of bevel gear 9.81 – 19.61 kN {1,000 – 2,000 kg}
Rear face runout of bevel

17 0.1
gear
WA700-3 40-23
(10)
Maintenance standard Final drive
Final drive
40-24 WA700-3
(10)
Maintenance standard Final drive
Unit: mm

Repair limit
Clearance between planetary size Shaft Hole clearance
1
shaft and bearing
+0.018 0 0–
90 —
0 –0.020 –0.038
Clearance between planet 0 –0.035 –0.010 –
2 155 —
gear and bearing –0.025 –0.075 –0.075
Clearance between ring gear +0.066 +0.025 –0.009 –
3 300.038 —
hub and bearing +0.034 0 –0.066
Clearance between wheel +0.051 –0.017 –0.017 –
4 422.275 —
hub and bearing 0 –0.080 –0.131
Clearance between case and –0.017 +0.025 0.074 –
5 266.7 —
bearing –0.049 0 0.017 Replace
Clearance between wheel +0.051 –0.016 –0.016 –
6 355.6 —
hub and bearing 0 –0.073 –0.124
Thickness of retainer at ring Standard size Tolerance Repair limit

7
gear hub mount 25 ±0.1 24.6
Standard clearance Clearance limit
Backlash between planetary
8
gear and sun gear 0.22 – 0.53 —
Backlash between planetary

9 0.26 – 0.72 —
gear and ring gear
Thickness of standard shim
10 2.1
for wheel hub
WA700-3 40-25
(10)
Maintenance standard Axle mount
Axle mount
40-26 WA700-3
(10)
Maintenance standard Axle mount
Unit: mm

Clearance of shaft and hole size clearance limit [Bushing is
Shaft Hole
1 (Front support side) stuck to
(Before press-fit bushing) +4.800 +0.155 housing]
470.2 — —
+0.800 0
Clearance of shaft and hole
–0.068 +0.555 0.068 –
2 (Front support side) 460.0 1.6 Replace
–0.165 0 0.720
(After press-fit bushing)
Clearance of shaft and hole [Bushing is
+4.800 +0.155
3 (Rear support side) 470.2 — — stuck to
+0.800 0
(Before press-fit bushing) housing]
Clearance of shaft and hole
–0.068 +0.555 0.068 –
4 (Rear support side) 460.0 1.6 Replace
–0.165 0 0.720
(After press-fit bushing)
5 Thickness of thrust washer
8 ±0.2 —
–0.21
6 Thickness of thrust plate 33 —
–0.35 Replace
7 Thickness of rear bushing 5 ±0.1 —
8 Thickness of front bushing 5 ±0.1 —
WA700-3 40-27
(10)
Maintenance standard Center hinge pin
Center hinge pin
40-28 WA700-3
(10)
Maintenance standard Center hinge pin
Unit: mm

Clearance between lower size Shaft Hole clearance limit
1
hinge pin and upper bushing
–0.043 +0.063 0.043 –
139.725 1.0
–0.068 0 0.131
Clearance between lower –0.043 0 0.018 –
2 139.725 —
hinge pin and bearing –0.068 –0.025 0.068
Clearance between lower –0.043 +0.063 0.043 –
3 139.725 1.0
hinge pin and lower bushing –0.068 0 0.131
Clearance between lower
–0.043 +0.063 0.043 –
4 bushing and frame (bottom) at 180.0 —
–0.106 0 0.169
lower hinge
Replace
Clearance between front frame 0 –0.074 –0.049 –
5 254.025 —
and lower hinge bearing –0.025 –0.126 –0.126
Clearance at press-fitted part +0.260 +0.072 –0.088 –
6 200 —
of seal of lower hinge pin +0.160 0 –0.260
Height of top bushing at lower
7
hinge 55 ±0.1 —
Height of lower bushing at

8 113.3 ±0.1 —
lower hinge
Thickness for lower hinge
9 32 ±0.8 —
retainer
Shim thickness for lower
10 3.65
hinge and retainer
Adjust
Shim thickness for lower
11 1.7
hinge and retainer

Clearance between upper size Shaft Hole clearance limit
12
hinge pin and rear frame
–0.018 +0.063 0.018 –
127 —
–0.043 0 0.106
Clearance between rear frame –0.043 +0.063 0.043 – Replace
13 170 —
and bushing at upper hinge –0.068 0 0.131
Clearance between front frame 0 –0.063 –0.109 –
14 215.925 —
and upper hinge bearing –0.025 –0.109 –0.038
Clearance at press-fitted part –0.043 +0.063 0.043 –
15 146.05 —
of seal of upper hinge pin –0.068 0 0.131
Shim thickness for upper
16 1.8 Adjust
hinge and retainer
WA700-3 40-29
(10)
Maintenance standard Steering column
Steering column
Unit: mm

Clearance between steering size Shaft Hole clearance limit
1 Replace
shaft and column bushing
0 +0.15
19 0.05 – 0.23 0.4
–0.08 –0.05
40-30 WA700-3
(10)
Maintenance standard Steering demand valve
Steering demand valve
40-32 WA700-3
(10)
Maintenance standard Steering demand valve
Unit: mm

Installation Installation
Free length Free length Load limit
1 Steering spool return spring length load
74.5 N 58.8 N
41.8 38.0 —
{7.6 kg} {6 kg}
8.8 N 7.0 N
2 Load check valve spring 20.9 13.2 —
{0.9 kg} {0.71 kg}
410 N 328 N
3 Demand spool return spring 90.8 83.0 —
{41.8 kg} {33.4 kg} Replace
182.4 N 145.1 N
4 Surge cut relief valve spring 24.0 22.19 —
{18.6 kg} {14.8 kg}
182.4 N 145.1 N
5 Main relief valve spring 24.0 22.19 —
{18.6 kg} {14.8 kg}
590 N 471 N
6 Overload relief valve spring 39.5 35.7 —
{60.2 kg} {40.8 kg}
8.8 N 7.0 N
7 Check valve return spring 20.9 13.2 —
{0.9 kg} {0.71 kg}
WA700-3 40-33
(10)
Maintenance standard Diverter valve
Diverter valve
Unit: mm

Clearance between body and size Shaft Hole clearance limit
1
spool
–0.013 +0.015 0.020 –
40 —
–0.015 +0.007 0.030
Free length Free length Replace
2 Spool return spring length load load
216.7 N 205.9 N
122.6 84 120.7
{22.1 kg} {21.0 kg}
5.6 N 5.3 N
3 Check valve spring 79.2 54.5 77.9
{0.57 kg} {0.54 kg}
4.9 N 4.6 N
4 Check valve spring 79.2 57.5 77.9
{0.50 kg} {0.47 kg}
40-34 WA700-3
(10)
Maintenance standard Steering cylinder mount
Steering cylinder mount
Unit: mm

Clearance between mounting pin size clearance limit
Shaft Hole
1 and bushing connection of
steering cylinder rod and frame –0.036 +0.207 0.156 –
110 1.0
–0.090 +0.120 0.297
Clearance between mounting pin
–0.036 +0.020 0.036 –
2 and bushing at connection of 110 1.0
–0.090 0 0.110
steering cylinder bottom and frame
Standard clearance
Width of boss Width of hinge Replace
Connection of steering (Clearance a + b)
3
cylinder and front frame 0 +1
88 –0.2 96 0 1.2 – 3.2
Connection of steering +0.8 After adjusting with

4 90 0 96 ± 1.5
cylinder rod and rear frame shim: Less than 1.0
5 Width of spacer
3.2 ±0.2 —
WA700-3 40-35
(10)
Maintenance standard Emergency steering pump
Emergency steering pump

(SAM3-125)
Unit: mm

1 Side clearance
0.10 – 0.15 019
Clarance between inside diameter

2 of plain bearing and outside 0.020 – 0.043 0.075 Replace
diameter of gear shaft

3 Insertion depth of pin 0
14
–0.5
4 Rotating torque of spline shaft 6.86 – 11.8 Nm {0.7 – 1.2 kgm}
Revolution Pressure Standard Repair limit

Discharge discharge discharge —
(rpm) (MPa {kg/cm2}) (l/min) (l/min)
– Oil: SAE10W
Temperature: 50 to 80°C
2,500 20.6 {210} 276 244
40-36 WA700-3
(10)
Maintenance standard Brake valve
Brake valve
(Left)
Serial No.: 50001 – 50055
40-38 WA700-3
(10)
Unit: mm

Repair limit
Clearance between pedal size Shaft Hole clearance
1
mount hole and bracket hole
–0.025 +0.1 0.175 –
10 0.25
–0.075 0 0.025
Clearance between roller and –0.025 +0.1 0.175 –
2 10 0.25
pin –0.075 0 0.025
3 Outside diameter of roller 0
30 29.2
–0.5
4 Control spring 50001 – 3.82 N Replace
34 33.5 33
50048 {0.39 kg}
50049 – 7.65 N
34 33 33
50055 {0.78 kg}
50001 – 11.8 N
46.3 46 45.3
50048 {1.2 kg}
5 Control spring
50049 – 18.6 N
46.7 46 45.7
50055 {1.9 kg}
50001 – 60.8 N
86.2 58 78
50048 {6.2 kg}
6 Return spring
50049 – 58.1 N
63.3 58 57
50055 {5.93 kg}
50001 – 16.7 N
7 Return spring 31.5 19.5 28
50055 {1.7 kg}
WA700-3 40-39
(10)
(Left)
Unit: mm

Clearance between pedal size Shaft Hole clearance limit
1
–0.025 +0.1 0.175 –
10 0.25
–0.075 0 0.025
2 10 0.25
pin –0.075 0 0.025
30 29.2
–0.5
Standard size Repair limit Replace
4 Control spring length load load
0N
28 28 27 —
{0 kg}
37.2 N
5 Control spring 47.2 46 46.2 —
{3.8 kg}
60.8 N
6 Return spring 86.2 58 78 —
{6.2 kg}
16.7 N
7 Return spring 31.5 19.5 28 —
{1.7 kg}
40-40 WA700-3
(10)
(Right)
Serial No.: 50001 – 50055
40-42 WA700-3
(10)
Unit: mm

Repair limit
Clearance between pedal size Shaft Hole clearance
1
–0.025 +0.1 0.175 –
10 0.25
–0.075 0 0.025
2 10 0.25
pin –0.075 0 0.025
30 29.2
–0.5
4 Control spring 50001 – 30.6 N
34 30 33
50048 {3.12 kg} Replace
50049 – 7.65 N
34 33 33
50055 {0.78 kg}
50001 – 0N
46 46 45
50048 {0 kg}
5 Control spring
50049 – 18.6 N
46.7 46 45.7
50055 {1.9 kg}
50001 – 60.8 N
86.2 58 78
50048 {6.2 kg}
6 Return spring
50049 – 58.1 N
63.3 58.1 57
50055 {5.93 kg}
50001 – 17.7 N
7 Spring 17 16.5 16.2
50055 {1.8 kg}
50001 – 16.7 N
50055 {1.7 kg}
WA700-3 40-43
(10)
(Right)
Unit: mm

Clearance between pedal size Shaft Hole clearance limit
1
–0.025 +0.1 0.175 –
10 0.25
–0.075 0 0.025
2 10 0.25
pin –0.075 0 0.025
30 29.2
–0.5
Installation Installation Installation Replace
4 Control spring length load load
0N
28 28 27
{0 kg}
37.2 N
5 Control spring 47.2 46 46.2
{3.8 kg}
60.8 N
6 Return spring 86.2 58 78
{6.2 kg}
17.7 N
7 Spring 17 16.5 16.2
{1.8 kg}
16.7 N
{1.7 kg}
40-44 WA700-3
(10)
Maintenance standard Slack adjuster
Slack adjuster
Unit: mm

Clearance between body and size Shaft Hole clearance limit
1
piston
–0.030 +0.074 0.030 –
80 0.250
–0.076 0 0.150
Replace
2 Spring length load load
118 N
230 88 — —
{12 kg}
66.7 N
3 Spring 45.4 38 — —
{6.8 kg}
WA700-3 40-45
(10)
Maintenance standard Brake
Brake
Serial No.: 50001 – 50045
40-46 WA700-3
(10)
Unit: mm

1 Return spring length load load
1010 N 924 N
114.8 95.0 113.1
{103 kg} {94.2 kg}
2 Thickness of plate
3.1 2.8
3 Thickness of disc 6.7 6.2
Total thickness of plate and

4 61.9 56.8
disc
Wear of contact surface of Replace
5 0
seal 580 —
–0.175
Wear of surface in contact +0.110
6 585 —
with piston seal 0
7 655 —
with piston seal 0
Standard Repair limit
Deformation of friction surface
8
of plate and disc Max. 0.4 0.70
Backlash between outer gear

9 0.211 – 0.638
and plate
Backlash between inner gear
10 0.222 – 0.662
and disc
WA700-3 40-47
(10)
40-48 WA700-3
(10)
Unit: mm

1 Return spring length load load
1010 N 924 N
114.8 95.0 113.1
{103 kg} {94.2 kg}
2 Thickness of plate
2.4 2.15
3 Thickness of disc 5.1 4.6
Total thickness of plate and

4 62.4 56.15
disc
Wear of contact surface of Replace
5 0
seal 580 —
–0.175
6 585 —
with piston seal 0
7 655 —
with piston seal 0
Standard Repair limit
Deformation of friction surface
8
of plate and disc Max. 0.45 0.70
Backlash between outer gear

9 0.211 – 0.638
and plate
Backlash between inner gear
10 0.222 – 0.662
and disc
WA700-3 40-49
(10)
Maintenance standard Parking brake
Parking brake
Unit: mm

Remaining thickness
Wear of 22.2 — 3.7
1 of friction material Replace
rod
Including backing
31.7 — 12.7
plate
2 Face runout of disc 0.6 — 1.2
–0.10
3 Wear of rod connecting pin 12.7 — Rebuild
–0.17
Thickness of plate
Wear of disc must be under 23 mm
4 25 ±0.7
(Thickness of disc plate)
Less than 23 mm Replace
Clearance between pad and disc
5 1.06 ±0.18 2.1
(Total of both sides)
Adjust
Clearance between brake
6 0.36 – 1.0
body and plate
40-50 WA700-3
(10)
Maintenance standard Control pump
Control pump
Model: BAR025
Unit: mm

1 Top clearance of gear
0.090 – 0.130 0.145
Replace
2 Side clearance of gear 0.055 – 0.075 0.105
Clearance between gear shaft and

3 0.045 – 0.076 0.13
bushing
Revolution Standard Repair limit

Discharge Pressure discharge discharge
(rpm) (l/min) (l/min)
– Oil: EO10-CD —
Temperature: 45 to 55°C 2.9 MPa
3,200 72 68
{30 kg/cm2}
Tightening torque for housing
– 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm} Tighten
case mounting bolt
WA700-3 40-51
(10)
Maintenance standard Steering and switch pump
Steering and switch pump

Serial No.: 50001 – 50056
Model: HPF90+90

Model: HPF95+95
40-52 WA700-3
(10)
Maintenance standard Main piston pump
Main piston pump

Serial No.: 50001 – 50056
Model: HPV90+HPF90

Model: HPV95+HPF95
WA700-3 40-53
(10)
Maintenance standard Main control valve
Main control valve

Serial No.: 50001 – 51000
40-54 WA700-3
(10)
Unit: mm

431.5 N 345.2 N
69.9 63.0 —
{44.0 kg} {35.2 kg}
0N
2 Spool return spring 77.0 77.0 — —
{0 kg}
61.6 N 49.0 N
3 Spool return spring 79.7 78.5 —
{6.28 kg} {5.0 kg}
Main valve spring of relief 86.3 N 69.0 N
4 52.4 38.0 —
valve {8.80 kg} {7.04 kg}
18.8 N 14.7 N Replace
5 Check valve spring 78.2 52.0 —
{1.92 kg} {1.5 kg}
Suction valve spring of safety 6.9 N 5.9 N
6 27.9 18.0 —
valve {0.70 kg} {0.6 kg}
6.9 N 5.9 N
7 Suction valve spring 27.9 18.0 —
{0.70 kg} {0.6 kg}
137.3 N 109.8 N
8 Float selector valve spring 53.0 42.1 —
{14.0 kg} {11.2 kg}
49.0 N 39.2 N
9 Unloader valve spring 82.7 47.0 —
{5.0 kg} {4.0 kg}
319.7 N 256.0 N
10 Pilot poppet spring of relief valve 30.7 26.9 —
{32.6 kg} {26.1 kg}
WA700-3 40-55
(10)
40-56 WA700-3
(10)
Unit: mm

431.5 N 345.2 N
69.9 63.0 —
{44.0 kg} {35.2 kg}
0N
2 Spool return spring 77.0 77.0 — —
{0 kg}
61.6 N 49.0 N
3 Spool return spring 79.7 78.5 —
{6.28 kg} {5.0 kg}
Main valve spring of relief 5.6 N 4.5 N
4 15.0 12.1 —
valve (Large) {0.57 kg} {0.46 kg}
18.8 N 14.7 N
5 Check valve spring 78.2 52.0 —
{1.92 kg} {1.5 kg} Replace
Suction valve spring of safety 6.9 N 5.9 N
6 27.9 18.0 —
valve {0.70 kg} {0.6 kg}
6.4 N 5.1 N
7 Suction valve spring 64.9 5.6
{0.65 kg} {0.52 kg}
137.3 N 109.8 N
8 Float selector valve spring 53.0 42.1
{14.0 kg} {11.2 kg}
49.0 N 39.2 N
9 Unloader valve spring 82.7 47.0
{5.0 kg} {4.0 kg}
319.7 N 256.0 N
10 Pilot poppet spring of relief valve 27.7 25.4
{32.6 kg} {26.1 kg}
Main valve spring of relief valve 2.3 N 1.9 N
11 10.45 6.3
(Small) {0.236 kg} {0.19 kg}
WA700-3 40-57
(10)
Maintenance standard PPC valve
PPC valve
40-58 WA700-3
(10)
Maintenance standard PPC valve
Unit: mm

Centering spring Free length Free length
1 length load load
(Bucket dump, boom raise)
5.4 N
39.9 34.5 — —
{0.55 kg} Replace
Centering spring 21.1 N if damaged or
2 56.7 34.5 — — deformed
(Bucket tilt, boom lower) {2.15 kg}
33.3 N
3 Metering spring 33.5 29.4 — —
{3.4 kg}
14.7 N
4 Return spring 28.2 17.5 — —
{1.5 kg}
WA700-3 40-59
(10)
Maintenance standard PPC relief valve
PPC relief valve
Unit: mm

1 Main valve spring length load load
20.6 N 15.7 N Replace
47 26 —
{2.1 kg} {1.6 kg}
73.5 N 47.1 N
2 Poppet spring 33.6 29.7 —
{7.5 kg} {4.8 kg}
40-60 WA700-3
(10)
Maintenance standard Hydraulic cylinder
Hydraulic cylinder
Unit: mm
Name of Standard Tolerance Standard Clearance

cylinder size Shaft Hole clearance limit
–0.036 +0.257 0.083 –

Steering 85 0.597
Clearance between piston rod –0.090 +0.047 0.347
1
and bushing
–0.043 +0.255 0.081 –
Bucket 170 0.661
–0.106 +0.038 0.361
–0.043 +0.256 0.082 –
Boom 140 0.662
–0.106 +0.039 0.362
+0.207
Steering 100 — — —
+0.120 Replace
bushing
Clearance between piston rod +0.395
2 Bucket 180 — — 1.0
mounting pin and bushing +0.295
+0.3
Boom 160 — — 1.0
+0.2
+0.020
Steering 100 — — —
0
Clearance between cylinder
+0.395
3 bottom mounting pin and Bucket 180 — — 1.0
+0.295
bushing
+0.395
Boom 160 — — 1.0
+0.295
Steering +0.15
130 —
0
4 Cylinder bore +0.2 Replace
Bucket 280 —
0
+0.2
Boom 225 —
0
WA700-3 40-61
(10)
Maintenance standard Work equipment linkage
Work equipment linkage
40-62 WA700-3
(10)
Maintenance standard Work equipment linkage
Unit: mm

Clearance between pin and size Shaft Hole clearance limit
1
bushing of bucket link
–0.043 +0.434 0.390 –
160 1.0
–0.106 +0.347 0.540
Clearance between pin and –0.043 +0.395 0.338 –
2 160 1.0
bushing of bucket link –0.106 +0.295 0.501
Clearance between pin and bushing –0.043 +0.434 0.390 –
3 160 1.0
at joint of boom and bucket –0.106 +0.347 0.540
4 200 1.0
at joint of boom and frame –0.122 +0.320 0.557 Replace also
Clearance between pin and if other parts
–0.043 +0.395 0.338 – are biting into
5 bushing at joint of bucket 180 1.0
cylinder bottom and frame –0.106 +0.295 0.501 pin
6 bushing at joint of bucket 180 1.0
cylinder rod and bellcrank –0.106 +0.295 0.501

7 200 1.0
at joint of bellcrank and boom –0.122 +0.320 0.557
8 bushing at joint of boom cylinder 160 1.0
bottom and frame –0.106 +0.295 0.501

9 bushing at joint of boom cylinder 160 1.0
rod and boom –0.106 +0.295 0.501
Width between Standard clearance

Width of hinge
Joint of bucket cylinder and bosses (Clearance a + b)
10
frame –0.8
213 ± 0.8 210 0 1.4 – 3.8
11 Joint of boom and frame 214 ± 0.8 210 ± 2.1 1.1 – 6.9
No. 10. 11 and
15 only:
+1.5 254 ± 4 Insert shims on
12 Joint of boom and bucket 259 0 1.0 – 10.5
(After installing flange) both sides so
+3 that clearance
+1.5 254 –5 on both left and
13 Joint of bucket link and bucket 259 0 2.0 – 11.5
(After installing flange) right is less than
1.5 mm.
Joint of bellcrank and bucket +1.5 +1
14 203 0 200 –3 2.0 – 7.5
link
Joint of boom cylinder and +0.8
No. 12 and 13
15 229 ± 0.8 225 0 2.4 – 4.8 only:
frame
Insert shims so
that clearance is
16 Joint of bellcrank and boom 358 ± 0.5 355 ± 0.5 2.0 – 4.0
1.5 mm on both
left and right.
Joint of bellcrank and bucket +1.5 +0.8
17 213 0 210 0 2.2 – 4.5
cylinder
Joint of boom cylinder and
18 184 ± 1.5 180 ± 2.1 0.4 – 7.6
boom
WA700-3 40-63
(10)
Maintenance standard Bucket
Bucket
Unit: mm

1 Wear of bucket tooth Replace
45 0
40-64 WA700-3
(10)
Maintenance standard Bucket positioner and boom kick-out
Bucket positioner and boom kick-out
Unit: mm
Clearance of bucket position

1 3–5
switch
Clearance of boom kick-out
2 3–5 Adjust
switch
Clearance between bucket
3 0.5 – 1
positioner protector and tip of switch
WA700-3 40-65
(10)
90 Others
Electric circuit diagram (1/5) (Serial No.: 50001 – 51000) ............................................................................90- 3

Electric circuit diagram (1/6) (Serial No.: 51001 and up) ..............................................................................90- 13
Electric circuit diagram (1/3) (with auto shift and joystick steering)
(Serial No.: 50001 – 51000) ...................................................................................................................90- 25
(Serial No.: 50001 – 51000) ...................................................................................................................90- 27
(Serial No.: 50001 – 51000) ...................................................................................................................90- 29
Electric circuit diagram (AJSS (Advanced joystick steering system) specification) (1/3)
(Serial No.: 51001 and up) .....................................................................................................................90- 31
(Serial No.: 51001 and up) .....................................................................................................................90- 33
(Serial No.: 51001 and up) .....................................................................................................................90- 35
WA700-3 90-1
(10)
Electric circuit diagram (1/5)
Serial No.: 50001 – 51000
WA700-3 90-3
(10)
Serial No.: 50001 – 51000
WA700-3 90-5
(10)
Serial No.: 50001 – 51000
WA700-3 90-7
(10)
Serial No.: 50001 – 51000
WA700-3 90-9
(10)
Serial No.: 50001 – 51000
WA700-3 90-11
(10)
WA700-3 90-13
(10)
WA700-3 90-15
(10)
WA700-3 90-17
(10)
WA700-3 90-19
(10)
WA700-3 90-21
(10)
WA700-3 90-23
(10)
with auto shift and joystick steering
Serial No.: 50001 – 51000
WA700-3 90-25
(10)
Serial No.: 50001 – 51000
WA700-3 90-27
(10)
Serial No.: 50001 – 51000
WA700-3 90-29
(10)
WA700-3 90-31
(10)
WA700-3 90-33
(10)
WA700-3 90-35
(10)

Wa700 3

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Wa700 3

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SEBM013312

Machine model Serial number

WA700-3 50001 and up

• WA700-3, WA700-3D mount the SAA6D170E-2 or SAA6D170E-3 engine.

10 Structure and function ...................................................................................... 10-1

20 Testing and adjusting ........................................................................................ 20-1

30 Disassembly and assembly .......................................................................... 30-1

40 Maintenance standard....................................................................................... 40-1

90 Others ............................................................................................................................. 90-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

List of revised pages

Time of Time of Time of Time of Time of

q 00-1 (12) 00-22 10-17 (10) 10-46 (10) 10-74 (10)

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

30-204 (3) 30-239 (3) 40-13 (10) 40-57 (10)

Important safety notice

16. When removing components, be careful not to

17. When removing piping, stop the fuel or oil from

18. As a general rule, do not use gasoline to wash

Structure and function

Testing and adjusting

Disassembly and assembly

How to read the shop manual Revised edition mark

3. Additional pages: Additional pages are indi-

• If a part cannot be smoothly removed from the

Method of disassembling, connecting push-pull type coupler

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rubber

Standard tightening torque

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

Table of tightening torques for flared nuts

Thread diameter Width across flats Tightening torque

Table of tightening torques for flared nuts

Thread diameter Width across flats Tightening torque

Table of tightening torques for o-ring boss piping joints

Thread diameter Width across flats Tightening torque (Nm {kgm})

Table of tightening torques for o-ring boss plugs

Thread diameter Width across flats Tightening torque (Nm {kgm})

Tightening torque for 102 and 114 engine series

(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 — —

(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 — —

Electric wire code

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