SM Wa1200 3

SEBM018206
WA1200-3
MACHINE MODEL SERIAL NO.
WA1200-3 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.
• WA1200-3 mount the Cummins QSK60 engine.
© 2001 1
All Rights Reserved
00-1
Printed in Japan 03-01(01) 6
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 WA1200-3
5
LIST OF REVISED PAGES
The affected pages are indicated by the use of the

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

or made additions.
LIST OF REVISED PAGE
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
‡ 00- 1 6 10-18 10-46 10-74

00- 2 5 10-19 10-47 10-75
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‡ 00- 2-4 6 01- 4 10-23 10-51 10-79
‡ 00- 2-5 6 01- 5 10-24 10-52 10-80
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00- 6 10-29 10-57 10-85
00- 7 10-30 10-58 10-86
00- 8 10- 1 3 10-31 10-59 10-87
00- 9 10- 2 10-32 10-60 10-88
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00-20 10-15 10-43 10-71 10-100
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00-22 10-17 10-45 10-73 10-102
WA1200-3 00-2-1
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10-103 10-144 10-185 10-225 20- 1 2

10-104 10-145 10-186 10-226 20- 2 5
10-105 10-146 10-187 10-227 20- 3 1
10-106 10-147 10-188 10-228 20- 4 1
10-107 10-148 10-189 10-229 20- 5 2
10-108 10-149 10-190 10-230 20- 6 1
10-109 10-150 10-191 10-231 20- 7 1
10-110 10-151 10-192 10-232 20- 8 1
10-112 10-152 10-193 10-233 20- 9 2
10-113 10-153 10-194 10-234 20-10 2
10-114 10-154 10-195 10-235 20-11 2
10-115 10-155 10-196 10-236 20-12 2
10-116 10-156 10-197 10-237 20-13 2
10-117 10-157 10-198 10-238 20-14 2
10-118 10-158 10-199 10-239 2 20-15 2
10-119 10-159 10-200 10-240 2 20-16 2
10-120 10-160 10-201 10-241 2 20-17 2
10-121 10-161 10-202 10-242 20-18 2
10-122 10-162 10-203 10-243 20-19 1
10-123 10-163 10-204 10-244 20-20 2
10-124 10-164 10-205 10-245 20-21 2
10-125 10-165 10-206 10-246 20-22 2
10-126 10-166 10-207 10-247 20-23 1
10-127 10-168 10-208 10-248 20-24 1
10-128 10-169 10-209 10-249 20-25 1
10-129 10-170 10-210 10-250 20-26 1
10-130 10-171 10-211 10-251 20-27 1
10-131 10-172 10-212 10-252 20-28 2
10-132 10-173 10-213 10-253 20-29 1
10-133 10-174 10-214 10-254 20-30 2
10-134 10-175 10-215 10-255
10-135 10-176 10-216 10-256 ‡ 20-101 6
10-136 10-177 10-217 10-257 20-102 4
10-137 10-178 10-218 10-258 20-102-1 4
10-138 10-179 10-219 10-259 20-103 1
10-139 10-180 10-220 10-260 20-104 1
10-140 10-181 10-221 10-261 20-105 1
10-141 10-182 10-222 10-262 20-106 1
10-142 10-183 10-223 10-263 3 20-107 1
10-143 10-184 10-224 10-264 3 20-108 1
00-2-2 WA1200-3
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20-109 1 20-146 1 20-233 2 20-301 2 20-435 2

20-110 1 20-147 1 20-234 2 20-302 2 20-436 2
20-111 5 20-148 1 20-235 2 20-303 2 20-437 2
20-112 1 20-149 1 20-236 2 20-304 2 20-438 2
20-113 1 20-150 4 20-237 2 20-305 2 20-439 2
20-114 1 20-151 4 20-238 2 20-306 2 20-440 2
20-115 1 20-152 4 20-239 2 20-441 2
20-116 1 20-153 4 20-240 2 20-401 2 20-442 2
20-117 1 20-241 2 20-402 2 20-443 2
20-118 4 20-201 2 20-242 2 20-404 2 20-444 2
20-119 4 20-202 2 20-243 2 20-405 2 20-445 2
20-119-1 4 20-203 2 20-244 2 20-406 2 20-446 2
20-120 1 20-204 2 20-245 2 20-407 2 20-447 2
20-121 1 20-205 2 20-246 2 20-408 2 20-448 2
20-122 1 20-206 2 20-247 2 20-409 2 20-449 2
20-123 1 20-207 2 20-248 2 20-410 2 20-450 2
20-124 1 20-208 2 20-249 2 20-411 2 20-451 2
20-125 1 20-209 2 20-250 2 20-412 2 20-452 2
20-126 1 20-210 2 20-251 2 20-413 2 20-453 2
20-127 4 20-211 2 20-252 2 20-414 2 20-454 2
20-128 4 20-212 2 20-253 2 20-415 2 20-455 2
20-129 1 20-213 2 20-254 2 20-416 2
20-130 1 20-214 2 20-255 2 20-417 2 20-501 2
20-131 1 20-215 2 20-256 2 20-418 2 20-502 2
20-132 1 20-216 2 20-257 2 20-419 2 20-503 2
20-133 1 20-217 2 20-258 2 20-420 2 20-504 2
20-134 1 20-218 2 20-259 2 20-421 2 20-505 2
20-135 1 20-220 2 20-260 2 20-422 2 20-506 2
20-136 1 20-221 2 20-261 2 20-423 2 20-507 2
20-137 1 20-222 2 20-262 2 20-424 2 20-508 2
20-138 1 20-223 2 20-263 2 20-425 2 20-509 2
20-139 1 20-224 2 20-264 2 20-426 2 20-510 2
20-140 1 20-225 2 20-265 2 20-427 2 20-511 2
20-141 1 20-226 2 20-266 2 20-428 2 20-512 2
20-142 1 20-227 2 20-267 2 20-429 2 20-513 2
‡ 20-143 6 20-228 2 20-268 2 20-430 2 20-514 2
‡ 20-144 6 20-229 2 20-269 2 20-431 2 20-515 2
fi 20-144-1 6 20-230 2 20-270 2 20-432 2 20-516 2
fi 20-144-2 6 20-231 2 20-271 2 20-433 2 20-517 2
20-145 1 20-232 2 20-434 2 20-518 2
WA1200-3 00-2-3
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20-519 2 20-620 2 20-721 2 20-825 2 20-865 2

20-520 2 20-722 2 20-826 2 20-866 2
20-521 2 20-651 2 20-723 2 20-827 2 20-867 2
20-522 2 20-652 2 20-724 2 20-828 2 20-868 2
20-523 2 20-654 2 20-725 2 20-829 2 20-869 2
20-524 2 20-655 2 20-726 2 20-830 2 20-870 2
20-525 2 20-656 2 20-727 2 20-831 2 20-871 2
20-526 2 20-657 2 20-728 2 20-832 2 20-872 2
20-527 2 20-658 2 20-729 2 20-833 2 20-873 2
20-528 2 20-659 2 20-730 2 20-834 2 20-874 2
20-529 2 20-660 2 20-731 2 20-835 2 20-875 2
20-530 2 20-661 2 20-732 2 20-836 2 20-876 2
20-531 2 20-662 2 20-733 2 20-837 2 20-877 2
20-532 2 20-663 2 20-734 2 20-838 2 20-878 2
20-533 2 20-664 2 20-735 2 20-839 2 20-879 2
20-534 2 20-665 2 20-840 2 20-880 2
20-535 2 20-666 2 20-801 2 20-841 2 20-881 2
20-536 2 20-667 2 20-802 2 20-842 2 20-882 2
20-537 2 20-668 2 20-803 2 20-843 2 20-883 2
20-538 2 20-804 2 20-844 2 20-884 2
20-539 2 20-701 2 20-805 2 20-845 2 20-885 2
20-702 2 20-806 2 20-846 2 20-886 2
20-601 2 20-703 2 20-807 2 20-847 2 20-887 2
20-602 2 20-704 2 20-808 2 20-848 2 20-888 2
20-604 2 20-705 2 20-809 2 20-849 2 20-889 2
20-605 2 20-706 2 20-810 2 20-850 2 20-890 2
20-606 2 20-707 2 20-811 2 20-851 2 20-891 2
20-607 2 20-708 2 20-812 2 20-852 2 20-892 2
20-608 2 20-709 2 20-813 2 20-853 2 20-893 2
20-609 2 20-710 2 20-814 2 20-854 2 20-894 2
20-610 2 20-711 2 20-815 2 20-855 2 20-896 2
20-611 2 20-712 2 20-816 2 20-856 2 20-897 2
20-612 2 20-713 2 20-817 2 20-857 2 20-898 2
20-613 2 20-714 2 20-818 2 20-858 2 20-899 2
20-614 2 20-715 2 20-819 2 20-859 2 20-900 2
20-615 2 20-716 2 20-820 2 20-860 2 20-901 2
20-616 2 20-717 2 20-821 2 20-861 2 20-902 2
20-617 2 20-718 2 20-822 2 20-862 2 20-903 2
20-618 2 20-719 2 20-823 2 20-863 2 20-904 2
20-619 2 20-720 2 20-824 2 20-864 2 20-905 2
00-2-4 WA1200-3
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20-906 2 20-1015 2 30-033 5 30-069 5 30-084 5

20-907 2 20-1016 2 30-034 5 30-070 5 30-085 5
20-908 2 20-1017 2 30-035 5 30-070-1 5 30-086 5
20-909 2 20-1018 2 30-036 5 30-071 5 30-087 5
20-910 2 20-1019 2 30-037 5 30-072 5 30-088 5
20-911 2 20-1020 2 30-038 5 30-073 5 30-088-1 5
20-912 2 30-039 5 30-074 5 30-089 5
20-913 2 30-040 5 30-075 5 30-090 5
20-914 2 ‡ 30-001 6 30-041 5 30-076 5 30-090-1 5
20-915 2 30-002 5 30-042 5 30-076-1 5 30-091 5
20-916 2 30-003 5 30-043 5 30-076-2 5 30-092 5
20-917 2 ‡ 30-004 6 30-044 5 30-076-3 5 30-093 5
20-918 2 ‡ 30-005 6 30-045 5 30-076-4 5 30-094 5
20-919 2 30-006 5 30-046 5 30-076-5 5 30-095 5
20-920 2 30-007 5 30-047 5 30-076-6 5 30-095-1 5
20-921 2 30-008 5 30-048 5 30-076-7 5 30-095-2 5
20-922 2 30-009 5 30-049 5 30-076-8 5 30-095-3 5
20-923 2 30-010 5 30-049-1 5 30-076-9 5 30-095-4 5
20-924 2 30-011 5 30-049-2 5 30-076-10 5 30-096 5
20-925 2 30-012 5 30-049-3 5 30-077 5 30-097 5
20-926 2 30-013 5 30-049-4 5 30-078 5 30-098 5
20-927 2 30-014 5 30-050 5 30-079 5 30-099 5
20-928 2 30-015 5 30-051 5 30-079-1 5 30-099-1 5
20-929 2 30-016 5 30-052 5 30-079-2 5 30-099-2 5
20-930 2 30-017 5 30-053 5 30-079-3 5 30-099-3 5
30-018 5 30-054 5 30-079-4 5 30-099-4 5
20-1001 2 30-019 5 30-055 5 30-079-5 5 30-100 5
20-1002 2 30-020 5 30-056 5 30-079-6 5 30-101 5
20-1003 2 30-021 5 30-057 5 30-079-7 5 30-102 5
20-1004 2 30-022 5 30-058 5 30-079-8 5 30-103 5
20-1005 2 30-023 5 30-059 5 30-079-9 5 30-104 5
20-1006 2 30-024 5 30-060 5 30-079-10 5 30-105 5
20-1007 2 30-025 5 30-061 5 30-079-11 5 30-106 5
20-1008 2 30-026 5 30-062 5 30-079-12 5 30-107 5
20-1009 2 30-027 5 30-063 5 30-079-13 5 30-108 5
20-1010 2 30-028 5 30-064 5 30-079-14 5 30-109 5
20-1011 2 30-029 5 30-065 5 30-080 5 30-110 5
20-1012 2 30-030 5 30-066 5 30-081 5 30-111 5
20-1013 2 30-031 5 ‡ 30-067 6 30-082 5 30-112 5
20-1014 2 30-032 5 30-068 5 30-083 5 30-113 5
WA1200-3 00-2-5
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30-114 5 40-12 40-54

30-115 5 40-13 40-55
30-116 5 40-14 40-56
30-117 5 40-16 40-57
30-118 5 40-17 40-58
30-119 5 40-18 40-59
30-120 5 40-19 40-60
30-121 5 40-20 40-61
30-122 5 40-21 40-62
30-123 5 40-22 40-63
30-124 5 40-23 40-64
30-125 5 40-24 40-65
30-126 5 40-25 40-66
30-127 5 40-26
30-128 5 40-27 90- 1
30-129 5 40-28 ‡ 90- 2 6
fi 30-131 6 40-29 ‡ 90- 3 6
fi 30-132 6 40-30 ‡ 90- 4 6
fi 30-133 6 40-32 ‡ 90- 5 6
fi 30-134 6 40-33 90- 7
fi 30-135 6 40-34 90- 9
fi 30-136 6 40-35 90-11
fi 30-137 6 40-36 90-13
fi 30-138 6 40-37 90-15
fi 30-139 6 40-38 90-17 4
fi 30-140 6 40-39 90-19
fi 30-141 6 40-40 90-21
fi 30-142 6 40-41 90-23
40-42
40-43
40- 1 40-44
40- 2 40-45
40- 4 40-46
40- 5 40-47
40- 6 40-48
40- 7 40-49
40- 8 40-50
40- 9 40-51
40-10 40-52
40-11 40-53
00-2-6 WA1200-3
6
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 A is used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

keep tools and removed parts. Always keep
Mistakes in operation are extremely dangerous. the tools and parts in their correct places.
Read the Operation and Maintenance Manual Always keep the work area clean and make
carefully BEFORE operating the machine. sure that there is no dirt or oil on the floor.
1. Before carrying out any greasing or repairs, Smoke only in the areas provided for smok-
read all the precautions given on the decals ing. Never smoke while working.
which are fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK

wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs,
missing. park the machine on hard, level ground, and
. Always wear safety glasses when hitting block the wheels or tracks to prevent the
parts with a hammer. machine from moving.
. Always wear safety glasses when grind-
8. Before starting work, lower blade, ripper,
ing parts with a grinder, etc.
bucket or any other work equipment to the
3. If welding repairs are needed, always have a ground. If this is not possible, insert the
trained, experienced welder carry out the safety pin or use blocks to prevent the work
work. When carrying out welding work, al- equipment from falling. In addition, be sure
ways wear welding gloves, apron, hand to lock all the control levers and hang warn-
shield, cap and other clothes suited for welding signs on them.
ing work.
9. When disassembling or assembling, support
4. When carrying out any operation with two the machine with blocks, jacks or stands
or more workers, always agree on the oper- before starting work.
ating procedure before starting. Always in-
IO. Remove all mud and oil from the steps or
form your fellow workers before starting any
other places used to get on and off the ma-
step of the operation. Before starting work,
chine. Always use the handrails, ladders or
hang UNDER REPAIR signs on the controls
steps when getting on or off the machine.
in the operator’s compartment.
Never jump on or off the machine. If it is
5. Keep all tools in good condition and learn impossible to use the handrails, ladders or
the correct way to use them. steps, use a stand to provide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21 When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-1 terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has that the measuring tool is correctly assem-
ample capacity. bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any When removing the track, the track sepa-
part still raised by the hoist or crane. rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, 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 mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

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

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

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@@I@....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume: Each issued as one

volume to cover all REVISIONS
Attachments volume:
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach- SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the

page. File the pages in correct order.
2. Following examples show how to read the
Symbal Remarks
Special safety precautions are
page number.
Example 1 (Chassis volume):
AI Safety necessary when performing
the work.
Special technical precautions

10 -3 or other precautions for pre-
TT * Caution serving standards are neces-
Item number (IO. Structure sary when performing the
work.
~~~~~~~~age number for
Weight of parts of systems.
each item. Caution necessan/ when se-
lecting hoisting wire, or when
Example 2 (Engine volume): working posture is important,
etc.
Places that require special at-

Unit number (I. Engine) tention for the tightening
Item number (2. Testing and torque during assembly.
Adjusting) Places to be coated with ad-
Consecutive page number for hesives and lubricants, etc.
each item.
Places where oil, water or fuel
must be added, and the ca-
3. Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-1 and number after the Places where oil or water
page number. File as in the example. - : Drain must be drained, and quan-
Example: tity to be drained.
IO-4 12-203
10-4-I -
> Added pages -c~~:~~~~:
1 O-4-2
1 o-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
I) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAW0479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
A Slinging with one rope may cause

turning of the load during hoisting,
WIRE ROPES untwisting of the rope, or slipping of
the rope from its original winding
I) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
Wire ropes 4) Do not sling a heavy load with ropes form-

(Standard “Z” or “S” twist ropes ing a wide hanging angle from the hook.
without galvanizing) When hoisting a load with two or more
ropes, the force subjected to each rope
Rope diameter T Allowable load will increase with the hanging angles. The
table below shows the variation of allow-
mm kN tons
able load kN {kg) when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 kN (1000 kg1 vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 kN (2000 kg) of total weight can be
16 27.5 2.8 suspended. This weight becomes 9.8 kN
18 35.3 3.6 11000 kg) when two ropes make a 120”
20 43.1 4.4 hanging angle. On the other hand, two

ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 kN 14000 kg) if they sling
30 98.1 10.0
a 19.6 kN 12000 kg) load at a lifting angle
40 176.5 18.0 of 150”.
50 274.6 28.0
60 392.2 40.0
-k The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
I I I I I I
2) Sling wire ropes from the middle portion 30 60 90 120 150
of the hook. Lifting mole (decree) SAD00480
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

+ There are 2 types of push-pull type coupler. The method of disassembling and connecting is differ-
ent, so see the table below when disassembling and connecting the coupler.
Type 1 Me 2
1) Hold the mouthpiece of the tightening por- 1) Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (1) contacts contact sur- ing prevention ring (I) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end. end.
CWP06391 CWP06392
2) Hold in the condition in Step I), and push 2) Hold in the condition in Step 11, and turn
until cover (3) contacts contact surface a of lever (4) to the right (clockwise).
the hexagonal portion at the male end.
>
?,
E
s 4
1
.E
c3
CWP06393 CWP06394
3) Hold in the condition in Steps 1 I and 21, and 3) Hold in the condition in Steps I) and 21, and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
CWPO6395 CWP06396
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 1 Type 2
l Hold the mouthpiece of the tightening por- l Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (1) contacts contact sur- ing prevention ring (I) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end to connect it. end to connect it.
CWPO6392
00-9
F O R EW OR D COATING MATERIALS
COATING MATERIALS
fl The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
fl 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. Used for plas-
790–129–9050 20 g Polyethylene
LT–1B tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
• Features: Resistance to heat and chemi-

Polyethylene cals
LT–2 09940–00030 50 g
container • Used for anti-loosening and sealant pur-
pose for bolts and plugs.
790–129–9060 Adhesive: • Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT–3 sive and Hardening Can
hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT–4 790–129–9040 250 g
container
Holtz • Used as heat-resisting sealant for repair-
790–126–9120 75 g Tube
MH 705 ing 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, rub-
bers, plastics and woods.

• Quick cure type (max. strength after 30 min-
Aron-alpha Polyethylene
790–129–9130 2g utes)
201 container
• Used mainly for adhesion of rubbers, plas-
tics and metals.
• Features: Resistance to heat, chemicals

Loctite Polyethylene • Used at joint portions subject to high tem-
648-50 79A–129–9110 50 cc
container peratures.
• 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

Polyethylene joints, flanges.
LG-5 790–129–9080 1 kg
container • Used as sealant for tapered plugs, elbows,
Gasket nipples of hydraulic piping.
sealant
• 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 case,
etc.
00-10
F O R EW OR D COATING MATERIALS
• Features: Silicon based, quick hardening

type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing, in-
Gasket take manifold, oil an, thermostat housing,
sealant etc.
Three bond • Used as heat-resisting sealant for repairing

790–129–9090 100 g Tube engine.
1211
• Used as lubricant for sliding portion (to pre-

Molybde- LM-G 09940-00051 60 g Can vent from squeaking).
num
disulphide • Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
• 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
• Used for normal temperature, light load

SYG2-400CA bearing at places in contact with water or
Grease SYG2-350CA steam.
G2-CA SYG2-400CA-A Various Various
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

* In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque
given in the table below.
Thread diameter Width

of bolt across flats
mm I mm I Nm I bm
6 10 13.2f 1.4 1.35f0.15
8 13 31+3 3.2 + 0.3
10 17 66+7 6.7 IL0.7
12 19 113+10 11.5+ 1
14 22 177f 19 18+2
16 24 279 f 30 28.5f3
18 27 382 f 39 39+4
20 30 549 f 59 56+6
22 32 745+83 76f8.5
24 36 927+ 103 94.5+ 10.5
27 41 1320+ 140 135+ 15
30 46 1720f 190 175+20
33 50 2210+240 225 k 25
36 55 2750 f 290 280 + 30
39 60 3290 f 340 335 f 35
Thread diameter Width

of bolt across flats
mm mm Nm km
6 10 7.85f 1.95 0.8 f 0.2
8 13 18.6f 4.9 1.9+0.5
10 14 40.2 f 5.9 4.1 f 0.6
12 27 82.35+ 7.85 8.4f 0.8
,Sealingsurface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

* In the case of flared nuts for which there is no special
instruction, tighten to the torque given in the table below.
SAD00483
Thread diameter Width across flat T Tighteni I torque
mm mm Nm kgm
14 19 24.5+ 4.9 2.5f0.5
18 24 49k19.6 5+2
22 27 78.5f 19.6 8f2
24 32 137.3k29.4 14+3
30 36 176.51k29.4 18f3
33 41 196.1+49 20f5
36 46 245.2+49 25+5
42 55 294.2f 49 30+5
00-l 2
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

* In the case of split flange bolts for which there is no special instruction, tighten to the torque
Thread diameter 1 Width across flat 1 Tiahtenina toraue
mm mm Nm kgm
10 14 65.7f6.8 6.7kO.7
12 17 112f9.8 11.5fl
16 22 279+29 28.5f3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

* Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque

Nominal No.
mm mm Nm kgm
02 14 34.3f4.9 3.5zko.5
03,04 20 Varies depending on 93.1 I!I9.8 9.5f 1
05,06 type of connector. 142.lf 19.6 14.5?2
10.12 f: 421.4k58.8 43f6
14 42 877.1k132.3 89.5f 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Ir Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Nominal No. / Threayzmeter Width across flat Tightening torque

mm Nm kgm
08 8 14 7.35f 1.47 0.75Iko.15
10 10 17 11.27f 1.47 1.15f0.15
12 12 19 17.64k1.96 1.8f0.2
14 14 22 22.54k1.96 2.3f0.2
16 16 24 29.4+ 4.9 3f0.5
18 18 27 39.2f 4.9 4f0.5
20 20 30 49+ 4.9 5kO.5
24 24 32 68.6k9.8 7fl
30 30 32 107.8f 14.7 11+1.5
33 33 - 127.4k19.6 13f2
36 36 36 151.9k24.5 15.5k2.5
42 42 - 210.7k29.4 21.5+3
52 52 - 323.4f 44.1 33f 4.5
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (BOLT AND NUTS)

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque

mm Nm kom
6 10 f 2 1.02 f 0.20
8 24 f 4 2.45 + 0.41
10 43 f 6 4.38 + 0.61
12 77 zk 12 7.85 f 1.22
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (EYE JOINTS)

Use these torques for eye joints (unit: mm) of Cummins Engine.

mm Nm kgm
: 10
8f2
f2 0.81
1.02 k
* 0.20
10 12 f2 1.22 f 0.20
12 24 + 4 2.45 f 0.41
14 36 + 5 3.67 + 0.51
TIGHTENING TORQUE FOR 102 ENGINE SERIIES (TAPERED SCREWS)

Use these torques for tapered screws (unit: inch) of Cummins Engine.

inch Nm kgm
l/l6 3fl 0.31 f 0.10
l/8 8f2 0.81 f 0.20
l/4 12 +2 1.22 f 0.20
318 15k2 1.53 _+0.41
l/2 24 z!z4 2.45 f 0.41
314 36 f 5 3.67 f 0.51
1 60 f 9 6.12 f 0.92
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
~ Cal;kzjD. Currerkrating
Applicable circuit
I I
2.4 12 Starting, lighting, signal etc.
3.1 20 Lighting, signal etc.
5 1 65 1 0.32 1 5.23 4.6 I 37 I Charging and signal

15 84 0.45 13.36
40 85 0.80 42.73
60 127 0.80 63.84
100 217 0.80 109.1 17.6 I 230 I Starting
CLASSIFICATION BY COLOR AND CODE
Prior-
ity
6
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.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @I, then draw a perpendicular line
down from @I.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches 1 mm = 0.03937 in
2 3 4 8 9
0 0.039 0.079 0.118 0.157 0.197i 0.236 0.276 0.315 0.354

0.394 0.433 0.472 0.512 0.551 0.591; 0.630 0.669 0.709 0.748
0.787 0.827 0.866 0.906 0.945 0.984; 1.024 1.063 1.102 1.142
1.181 1.220 1.260 1.299 1.339 1.378 i 1.417 1.457 1.496 1.536
1.575 1.614 1.654 1.693 1.732 1.772; 1.811 1.850 1.890 1.929
1.969 .. .2.008 2.205 2.244 2.283 2.323

50
@ ....... .. . .. . . . . ,.............
60
70
2.362
2.756
I
. . . . . . .. . . .. .2.047
2.402
2.795
. . .. . . . .. . ... 2.087
2.441
2.835 2.874
2.480
2.913
2.126 F%iJ
. .. . . . .. . . ,.............
2.520
2.953
2.598
2.992
2.638
3.032
2.677
3.071
2.717
3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
FOREWORD CONVERSIONTABLE
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
-7
0 1 2 3 4 5 6 7 8 9
0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
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

It = 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

I! = 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 I'
005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 077.7
11
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1 150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1.
222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1.
294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1:
367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1 439.4
00-l 9
kg/cm* to lb/in*
1kg/cm2 = 14.2233 lb/in*
1
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 59'7.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
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
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
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 46 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

-22.2 -6 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 71.1 166 320.0
-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 IO 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-2 1
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with lnternatinal System of units W.
As for reference, conventionally used Gravitational System of units are indicated in parentheses { I.
Example:
N {kg}
Nm {kgml
MPa {kg/cm*)
kPa {mm Hz01
kPa ImmHgI
kw/rpm W/rpm~
gikwh Ig/HPhI
00-22
01 GENERAL
General assembly drawing . .. . . . .. . . . . . . .. . . . . . . . .. . . 01-2

Specifications . . .. . .. . . . . . .. . . . . .. .. . . . .. . .. .. . . . . . . .. . . . . .. . . .. 01-3
Weight table . . . . . . .. . . . .. . . . . . .. . . . . . . .. .. . . . . . . . . . .. . . . . . .. . . 01-6
List of lubricant and water .. . . . . . . .. .. . . . . . . .. . . .. . . 01-8
WA1 200-3 01-l

GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING

Dimensions in ( 1 are for vehicles equipped
with 65/65-57-62PR tires.
Dimensions marked with % are for vehicles
for handling rocks and those marked with
*X are for vehicles for handling lime.
SJWO4720
01-2 WA1 200-3

GENERAL SPECIFICATIONS
Machine model WA1 200-3
Serial No. 50001 and up
Operating weight kg 205,200 [210,4001
Distribution (front) kg 122,220 [ 124,840l
Distribution (rear) kg 82,950 I85,5601
Bucket capacity (piled) m3 20.0
Rated load kg 36,000
Travel speed FORWARD 1st km/h 6.3 i6.51
FORWARD 2nd km/h 11.5 [Il.91
FORWARD 3rd km/h 19.8 120.41
REVERSE 1st km/h 7.4 17.71
REVERSE 2nd km/h 13.4 113.91
REVERSE 3rd km/h 22.6 i23.21
Max. rimpull kN {kg) 1,127 {115,000~ [1,088 ~lll,OOO~l
Gradeability deg 25
I
Center of outside wheel mm 12,000
Min. turning
radius Outside portion of chassis mm 14,300
Overall length mm 18,210
Overall width (chassis) mm 5,7 10 [5,9701
Bucket width mm 6,400 (Cutting edge)

6,550 (Tire guard)
Overall height (top of ROPS cab) mm 6,865 !6,9301
(Bucket raised) mm 11,865 [I I,9301
Wheelbase mm 7,100
Tread mm 4,300
Min. ground clearance mm 650 [7151
Height of bucket hinge pin mm 8,830 [8,8951
Dumping clearance (tip of edge) mm 6,735 [6,8001
Dumping reach (tip of edge) mm 2,665
Bucket dump angle deg 49.5 (Max. height)
Bucket tilt angle (SAE carrying position) deg 50
Digging depth (IO” dump) (tip of edge) mm 590 [5251
I I: with 65/65-57-62PR tires
WA1 200-3 01-3

Model Cummins QSK60
Type 4-cycle, water-cooled, V type,

16-cylinder direct injection, with
turbocharger, after-cooler
No. of cylinders - bore x stroke mm 16-159x190
Piston displacement e {cc) 60 (60,360)
Wrpm IHP/rpml 1,I 60/l ,900 {I ,558/l ,900)
lmlrpm Ikgmlrpml 7,830/l ,500 {798/l ,500)
Fuel consumption ratio g/kW-h {g/HP-h} 214 {ISO} (at rated output, gross)
i High idling speed wm 2,050
Low idling speed wm 650
Starting motor 24 V 9.0 kW x 2
Alternator 24V140A
Battery 12 V 200 Ah x 6
Torque converter 3-element, l-stage, single-phase

(TCA51-3)
Transmission Planetary gear, multiple-disc, hy-

lraulically actuated, modulation type
Reduction gear Spiral bevel gear
Differential Straight bevel gear
Final drive Planetary gear, 2 reduction,

oil bath
Drive type Front/rear-wheel drive
Front axle Fixed-frame, full-floating
Rear axle Center pin support type, full-floating
Tire 55.5/80-57-68PR(L-5)
[65/65-57-62PR(L-511
Wheel rim 44.00 x 57i6.0 [52.00 x 57i6.01
Inflation pressure kPa {kg/cm21 588 (6.01
-
Main brake Front/rear wheel braking, separate
front/rear wheel, wet disc,
1 hydraulically actuated
?
a Parking brake Drive shaft (Transmission output
shaft) braking, multiple wet disc,
hydraulically release spring apply
r I: ’with 65/65-57-62PR tires

01-4 WA1 200-3
Type Articulated type
Structure Fully hydraulically power steering
Torque converter, Umin 817

transmission pump (Gear type: SAR(4)200+SAR(4)200)
Steering pump Umin 630

(Fixed capacity piston pump:
HPF160+160)
Switch pump Umin 630

Variable + fixed capacity piston pump:
HPV160+HPF160)
Hydraulic
PPC pump 4Ymin 95
pump
(Gear type: SAR(2)50)
Delivery
Brake pump Urnin 54

(Gear type: SAR(2)28)
Work equipment pump (I) Urnin 630

(Variable capacity piston pump:
HPV160+160)
Work equipment pump (2) l?/min 383

(Variable capacity piston pump:
H PV95+95)
Transmission valve MPa {kg/cm? 2.65 127)

(Spool type, electric control)
Steering valve VlPa {kg/cm21 31.4 {320}

Control
valve (Spool type)
Set PPC valve VlPa {kg/cm? 3.7 08)
pressure
(2-lever type)
Main control valve VlPa {kg/cm’) 31.4 (320)

(2-spool type)
Steering cylinder Reciprocating piston

No. - bore x stroke mm 2 - 225 x 660
3oom cylinder Reciprocating piston

Cylinder
No. - bore x stroke mm 2-360x 1,835
3ucket cylinder Reciprocating piston

No. - bore x stroke mm 2-300x 1,025
-ink type Double Z bar link
3ucket edge type Spade nose bucket with teeth
WA1 200-3 01-5

GENERAL WEIGHT TABLE
WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model I WA1 200-3
Engine 7,250
Radiator (including hydraulic oil cooler) 2,750
Torque converter I 1,404
Torque converter oil cooler I 285
Fuel cooler 338
Transmission 3,690
Damper I 359
Upper drive shaft 112
Center drive shaft 184
Front drive shaft 209
Rear drive shaft 215
Center support I 154
Front axle I 16,500
Rear axle 16,500
Front differential assembly 1,570
Rear differential assembly 1,800
Planetary carrier assembly (each) 880
Planetary hub assembly (each) I 710
Axle pivot (Rear axle) (front/rear) 6251960
Wheel (55.5 tire/65 tire) (each) 1,913/2,051
Tire (55.5 tire/65 tire) (each) 5,930/7,150
Steering valve 68
Steering cylinder (each) I 589
Hydraulic tank (tank unit) 1,366 ( 1,230)
Work equipment pump (No.VNo.2) 193/I 66
Torque converter charging + PPC pump 70.3
Switch pump 189
Steering pump 191
Fender (one side) I 140
PPC valve 4
01-6 WA1 200-3

GENERAL WEIGHT TABLE
Unit: kg
Main control valve (each) 95
Boom cylinder (each) 2,943
Bucket cylinder 1,380
Radiator guard 905
Front frame I 15,160
Rear frame
Bucket link (including bushing) (each) 646
Bellcrank (including bushing) (each) 2,440
Boom (including bushing) r 18,430
Bucket (with teeth) I 23,840
Rear bumper (including fuel tank) I 6,470
Fuel tank (side x 2, center x 1) side: 520 x 2, center: 609
Battery (each) 59
Cab assembly 539
Air conditioner unit I 55
Operator’s seat
Floor plate
ROPS support assembly I 3,238
WA1 200-3 01-7

GENERAL LIST OF LUBRICANT AND WATER
LIST OF LUBRICANT AND WATER

AMBIENT TEMPERATURE CAPACITY
<IND OF
RESERVOIR -40 -22 -4 14 32 50 88 88 104 122°F
FLUID -40 -30 -20 -10 0 10 20 30 40 50°C Specified Refill
Engine oil pan 260 Q
Transmission case 380 k! 350 Q

Engine
oil
Hydraulic system 1,200 e
Brake Brake 60 Q 45 Q
tank Cooling 280 Q 270 Q
Axle
(Front and rear) See Note 1 670 Q 670 Q
(each)
Auto-grease Grease
Work equipment pir Gear oil
Fuel tank Gear 5,100 Q

-
Cooling system Water Add antifreeze 510 Q
% ASTM 0975 No.1

Note 1:
For axle oil, use only recommended oil as follows. * In cold areas when the hydraulic oil
SHELL: DONAX TT or TD temperature is low, if the steering wheel is
CALTEX: RPM TRACTOR HYDRAULIC FLUID turned and the machine is stopped in that
CHEVRON: TRACTOR HYDRAULIC FLUID position, there may be a time lag before
TEXACO: TDH OIL the machine turns and stops.
MOBIL: MOBILAND SUPER UNIVERSAL If this happens, turn the steering wheel
It is possible to substitute engine oil CLASS-CD slowly to the left and right (repeat for about
SAE30 for axle oil. 10 minutes) and the oil inside the steering
If noise comes from the brake, it is no problem of valve will be warmed up.
durability. [xl]: When working in particularly severe
conditions, use a multi-purpose grease
containing 3 - 5% molybdenum.
b+21: For machines equipped with an auto-
grease system, if the machine is operated
in temperatures below -2O”C, use lithium-
based grease No. 0 for the grease.
01-8 WA1 200-3

GENERAL LIST OF LUBRICANT AND WATER
REMARK
When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic mainte-
nance 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% l/2 of regular interval

I
Above 1.0% l/4 of regular interval
When starting the engine in an atmospheric tem-

perature of lower than O”C, be sure to use en-
gine oil of SAEIOW, SAEIOW-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 (SAEIOW-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 sys-
tem during normal inspection and maintenance.
ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute
WA1 200-3 01-9

10 STRUCTURE AND FUNCTION
Outline ......................................................... IO- 2 Brake.. .......................................................... IO-109

Radiator and hydraulic oil cooler.. ........... IO- 4 Parking brake .............................................. IO-I 10
Damper.. ...................................................... lo- 5 Arrangement of hydraulic equipment ...... IO-I 12
Torque converter and Work equipment lever linkage.. ................ IO-I 14
transmission piping ............................. IO- 6 Hydraulic tank ............................................. IO-I 15
Torque converter.. ...................................... IO- 8 Work equipment pump No. 1 ................... IO-I 18
Main relief valve and torque converter Work equipment pump No. 2.. ................. IO-131
relief valve ............................................ IO- 17 PPC valve .................................................... IO-148
Torque converter regulator valve.. ........... IO- 20 PPC relief valve .......................................... IO-I 52
ECMV ........................................................... IO- 22 Accumulator (for PPC valve) ..................... IO-153
Transmission .............................................. IO- 28 Main control valve ..................................... IO-154
Transmission control valve ....................... IO- 38 Work equipment linkage ........................... IO-168
Lubricating oil relief valve.. ....................... IO- 49 Operation of proximity switch .................. IO-170
Transfer ....................................................... IO- 50 Air conditioner.. .......................................... IO-172
Torque converter oil cooler ...................... IO- 52 Machine monitor system ........................... IO-175
Center support.. .......................................... IO- 53 Main monitor.. ............................................ IO-177
Axle .............................................................. IO- 54 CGC monitor ............................................... IO-181
Final drive ................................................... IO- 59 All-range electronic control automatic
Axle mount ................................................. IO- 60 transmission (ATM) system.. .............. IO-218
Center hinge pin.. ....................................... IO- 62 Modulated clutch (MOD/C)
Arrangement of steering equipment ........ IO- 63 control system ..................................... IO-233
AJSS (Advanced Joystick Steering Work equipment and joystick steering
System) ................................................. IO- 64 control system ..................................... 1O-237
Steering pump.. .......................................... IO- 65 Work equipment and joystick steering
Switch pump .............................................. lo- 68 controller .............................................. IO-243
Servo valve ................................................. IO- 71 Engine starting circuit.. .............................. IO-244
Steering demand valve ............................. IO- 75 Engine stopping circuit.. ............................ IO-248
Rotary valve ................................................ IO- 86 Ether injection circuit ................................. 1o-249
EPC valve .................................................... IO- 89 Electric parking brake control ................... IO-250
Diverter valve ............................................. IO- 90 Parking brake solenoid valve .. .................. IO-260
Arrangement of brake equipment.. .......... IO- 94 Emergency parking brake
Brake valve ................................................. IO- 96 reset solenoid valve ............................ IO-261
Charge valve ............................................... IO-101 Kick-down switch and auto shift/
Accumulator (for brake) ............................ IO-105 manual shift selector switch.. ............. IO-262
Slack adjuster ............................................. IO-106 VHMS Integrated Tool Soft.. ..................... IO-263
WA1 200-3 10-l

0
STRUCTURE AND FUNCTION OUTLINE
OUTLINE
SWWO4721
OUTLINE 1. Front differential

The power of engine (16) is transmitted 2. Front brake
through the engine flywheel to damper (15). 3. Front final drive
The damper output shaft is connected to 4. Front tire
modulated clutch (13) through upper drive 5. Front axle
shaft (14). The output of the modulated clutch 6. Front drive shaft
is connected to the pump of torque con- 7. Center drive shaft
verter (11). The turbine of the torque con- 8. Emergency steering pump
verter is connected to input shaft of trans- 9. Transfer (Output)
mission (IO). 10. Transmission
The transmission has five hydraulically op- 11. Torque converter
erated clutches and generates three gear 12. Transfer (Input)
speeds each in forward and reverse direc- 13. Modulated clutch
tions which are selected with an electric con- 14. Upper drive shaft
trol switch. 15. Damper
The transmission output shaft is connected 16. Engine
to the gear of transfer (91, then the power is 17. Work equipment pump No. 1
transmitted to the transfer output shaft. Then, 18. Work equipment pump No. 2
the power is transmitted from the transfer 19. Switching pump
output shaft through center drive shaft (71, 20. Steering pump
center support (321, front drive shaft (61, and 21. Control pump
rear drive shaft (31) to front axle (5) and rear 22. PPC pump
axle (281, then transmitted through the
wheels to the tires.
1 o-2 WA1 200-3

STRUCTURE AND FUNCTION OUTLINE
SWW04722
23. Torque converter, transmission pump
24. Brake cooling pump
25. Brake pump
26. Rear final drive
27. Rear tire
28. Rear axle
29. Rear differential
30. Rear brake
31. Rear drive shaft
32. Center support
33. Parking brake
WA1 200-3 1o-3

STRUCTURE AND FUNCTION RADIATOR AND HYDRAULIC OIL COOLER
RADIATOR AND HYDRAULIC OIL COOLER
,______-----
I
Y
SJW04723
1. Fan guard Specification

2. Water level sensor
3. Radiator cap LTC HTC 1
4. Sub-tank Core type Modular core Modular core
5. Upper tank Total heat
6. Hydraulic oil cooler m* 211.6 414.8
dissipating area I I
7. Radiator (LTC)
Cross-sectional
8. Radiator (HTC)
area of water tubes /cm ‘1 59,042 1 88,690 /
9. Lower tank I I I I I
1o-4 WA1 200-3

STRUCTURE AND FUNCTION DAMPER
DAMPER
3 4 5 6
SJW04724
1. Shaft FUNCTION
2. Breather . The damper reduces the torsional vibration
3. Rubber cushion caused by changes in the engine torque, and
4. Inner body acts to protect the units of the power train
5. Rubber cushion beyond the engine from the effects of tor-
6. Outer body sional vibration.
OPERATION
. The power of the engine is transmitted from
the flywheel to outer body (6). The torsional
vibration of the engine is absorbed by rub-
ber cushions (3) and (51, passes through in-
ner body (4) and shaft (I), and is transmitted
to the upper drive shaft between the torque
converter.
WA1 200-3 1o-5

STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING
TORQUE CONVERTER AND TRANSMISSION PIPING
SWW04725
1. Transmission
2. Transmission control valve
3. Transfer (input)
4. Torque converter oil cooler
5. Torque converter charging pump
6. Torque converter
7. Torque converter oil filter
8. Transmission oil level gauge
9. Transfer (output)
10-6 WA1 200-3

STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
(INPUT TRANSFER, PTO, MODULATED CLUTCH, TORQUE CONVERTER)
lZ
W
7
9JA00061
1O-8 WA1 200-3

G ! H
.\...
F
J
IO
9JBOOO62
A: Torque converter outlet port 1. Mounting port for steering pump, control
B: Outlet oil pressure pick-up port of torque pump, and PPC pump
converter 2. Mounting port for switch pump
c: Torque converter inlet port 3. Mounting port for transmission charging
D: Lubrication port for PTO, input transfer, pump, torque converter charging pump,
and modulated clutch brake cooling pump, and brake pump
E: Interconnection port 4. Regulator valve of torque converter outlet
F: Torque converter inlet port 5. Mounting port for work equipment pump
G: Inlet oil pressure pick-up port of torque 6. Mounting port for work equipment pump
converter 7. Output rotation sensor of modulated clutch
H: Main oil pressure pick-up port 8. ECMV for modulated clutch
J: Torque converter relief port 9. Torque converter valve
K: Drain port 10. Input rotation sensor of input transfer
WA1 200-3 1o-9

14
A-A
9JB00063
10-10 WA1 200-3

9JBOOO64
11. Coupling 21. Torque converter input shaft

12. Drive gear (Number of teeth: 74) 22. Drive case
13. PTO gear (Number of teeth: 68) 23. Turbine
14. PTO gear (Number of teeth: 68) 24. Stator
15. Idler gear (Number of teeth: 68) 25. Pump
16. Modulated clutch output shaft 26. Torque converter case
17. Modulated clutch piston 27. Transmission input shaft
18. Modulated clutch outer drum 28. Driven gear (Number of teeth: 58)
19. Modulated clutch inner drum 29. Modulated clutch disc
20. Coupling 30. Modulated clutch plate
WA1 200-3 10-11

Specifications
Model: 42C-13-11002
Type: 3-elemet, single stage, single phase
Stall torque ratio: 2.23 (T3/Tl)
2.84 (T3/T2)
T3
10-12 WA1 200-3

Operation
Power transmission route
9JBOOO66
l The torque converter is installed between The power transmitted to modulated clutch
the damper and transmission. outer drum (18) is further transmitted
The power from the damper is transmitted through modulated clutch output shaft (16)
through the upper drive shaft to coupling and coupling (20) to torque converter input
(II). shaft (21).
The speed of the rotation is heightened with Since torque converter input shaft (211, drive
drive gear (121, idler gear (151, and driven case (22). and pump (25) are secured with
gear (28) of the input transfer, then trans- bolts, they are rotated with the power from
mitted to modulated clutch inner drum (19). the modulated clutch.
If oil pressure is applied to the back of modu- The power of pump (25) rotates turbine (23)
lated clutch piston (171, modulated clutch to drive transmission input shaft (271, using
piston (171 presses modulated clutch disc the oil as medium.
(29) against modulated clutch plate (30) to l The power of coupling (11) is used to drive
transfer the power to modulated clutch outer the pump, too, through drive gear (121, PTO
drum (18). gear (131, or idler gear (15).
10-14 WA1 200-3

0
Flow of oil
9JBOOO67
l The oil flows through the main relief valve The oil from turbine (23) flows to stator (24)
and its pressure is regulated below the set and flows in pump (25) again. At this time, a
pressure by the torque converter relief valve, part of the oil flows through stator (24) and
then it flows in inlet port A and merges with outlet port B to the torque converter outlet
the oil sent from the torque converter charg- regulator valve.
ing pump through torque converter case (26), The oil that flows in the torque converter
then the merged oil flows in pump (25). outlet regulator valve flows further through
Set pressure: 1.05 MPa (IO.7 kg/cm*} the oil cooler to cool itself, then it is used to
The oil is given centrifugal force by pump lubricate the transmission.
(251, then it flows in turbine (23) and gives
its energy to turbine (23).
WA1 200-3 10-M

Outline
l The modulated clutch is installed between
the input transfer and torque converter.
l The clutch can be engaged or slipped by
adjusting the clutch oil pressure with ECMV.
l The power transmitted to the torque con-
verter can be reduced by slipping the clutch.
Operation
When clutch is engaged

l The oil sent from ECMV (1) for the modu-
lated clutch flows through the oil passage of
modulated clutch case (2) to piston (3) and
moves piston (3) to the right.
If piston (3) moves and the clutch oil pres-
sure rises, the pressure of piston (3) increases
and presses disc (4) against plate (5) to en-
gage inner drum (6) with outer drum (7).
Accordingly, all of the power transmitted
from inner drum (6) is transmitted to outer
drum (7).
When clutch is slipped

. If the controller outputs the signal to lower
the clutch oil pressure, ECMV (I) for the
modulated clutch lowers the clutch oil pres-
sure.
If the clutch oil pressure lowers, the pres-
sure of piston (3) lowers and disc (4) slips
on plate (51, then outer drum (7) rotates
slower than inner drum (6).
9JBOOO68
As a result, the transmitted power is reduced.
l The transmitted power depends on the slip

ratio of the clutch and the speed ratio of the
torque converter.
Slip ratio =
(I - Output rpm/lnput rpm) x 100 (%)
10-16 WA1 200-3

STRUCTURE AND FUNCTION MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
I E 23
D 7
A-A
P4 A4
\
Pi
9JB00069
A: From pump 1. Valve body

B: To torque converter 2. Valve spring (Small)
C: To transmission lubricating circuit 3. Valve spring (Large)
D: Drain 4. Main relief valve spool
E: Drain 5. Piston spring
F: Drain 6. Piston
G: Drain 7. Valve spring
PI: Inlet oil pressure pick-up port of torque 8. Torque converter relief valve spool
converter 9. Piston spring
P4: Main oil pressure pick-up port IO. Piston
Outline
. Main relief valve to the torque converter inlet circuit, and it
The main relief valve keeps the transmis- keeps the oil pressure at the torque con-
sion oil pressure at the set level. verter inlet circuit below the set pressure to
Set pressure: 2.65 MPa (27 kg/cm21 protect the torque converter from abnormally
(At the rated engine speed) high pressure.
l Torque converter relief valve Set pressure: 1.05 MPa 110.7 kg/cm*)
The torque converter relief valve is installed (Cracking pressure)
WA1 200-3 10-17

Operation
Operation of main relief valve

From Pump
l The oil from the torque converter charging
pump flows through the filter into port A of
spool (41, then flows through orifice a into
port B.
If the circuit is filled with the oil from the
pump, the oil pressure starts rising.
To torque To transmission
converter lubrication
SXW04736
l As the oil pressure in the circuit rises, the oil

in chamber B presses piston (6) and its reac-
tion force compresses springs (2) and (3) to
move spool (4) to the left to open ports A
and C.
Then, the oil from the pump flows through
port A and port C into the torque converter.
At this time, the oil pressure at port A is 2.65
MPa 127 kg/cm21 (at the rated engine speed).
To torque To transmission
sxwo4737
lo-18 WA 1200-3
STRUCTURE AND FUNCTION MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
Operation of torque converter relief valve

l The oil from the main relief valve flows
through port C into the torque converter. It
also flows through orifice b of spool (8) into
chamber D.
If the torque converter is filled with the oil,
the oil pressure starts rising.
l As the oil pressure in the torque converter
rises, the oil in chamber D presses piston
(10) and its reaction force compresses valve
spring (7) to move spool (8) to the right to
open ports C and E.
Then, the oil in port C flows through port E
into the transmission lubricating circuit.
At this time, the oil pressure at port C is 1.05
MPa 110.7 kg/cm? (cracking pressure).
To toraue To transmission
sxwo473a
WA1 200-3 10-19

STRUCTURE AND FUNCTION TORQUE CONVERTER REGULATOR VALVE
TORQUE CONVERTER REGULATOR VALVE
9JBOOO73
A: From torque converter Outline

B: To oil cooler l The torque converter regulator valve is in-
stalled to the torque converter outlet circuit
1. Valve body to extract the full performance of the torque
2. Valve spring (Small) converter by keeping the oil pressure in the
3. Valve spring (Large) torque converter at the set level.
4. Spool Set pressure: 0.88 2 0.10 MPa 19 -c 1 kg/cm?
5. Piston spring
6. Piston
1O-20 WA1 200-3

0
STRUCTURE AND FUNCTION TORQUE CONVERTER REGULATOR VALVE
Operation
l The oil from the torque converter flows
through port A and orifice a into chamber B.
Since the oil pressure in chamber B is lower
than the tension of valve springs (2) and (31,
spool (4) does not move.
8
From torque
converter
sxwo4739
. If oil pressure in chamber B rises above the

tension of valve springs (2) and (31, the oil in
chamber B presses piston (6) and its reac-
tion force compresses valve springs (2) and
(3) to move spool (4) to the left to open
ports A and C.
/ ii
A From torque
converter
sxwo4740
WA1 200-3 1o-21

STRUCTURE AND FUNCTION ECMV
ECMV
(For modulated clutch)
9JBOOO76
A: To clutch 1. Connector
B: Drain 2. Spring
C: From pump 3. Flow sensor valve spool
P: Clutch oil pressure pick-up port 4. Spring
5. Fill switch
6. Proportional solenoid
7. Pressure control valve spool
8. Load piston
9. Spring
1o-22 WA1 200-3

Outline
Outline of ECMV
l ECMV (Electronic Control Modulated Valve) A , E , D
consists of one pressure control valve and
one flow sensor valve.
. Pressure control valve
This valve receives the current sent from the
controller with a proportional solenoid, then
converts it into oil pressure.
l Flow sensor valve

This valve operates according to the trigger 0’ ’ w3ec
MPa!_ to/cm’)
_ _ I I Time
signals sent from the pressure control valve
and has the following functions. t
1) Keeps open untilthe clutch is filled with
oil to shorten the time to fill the clutch .-c al /-
with oil (filling time). zz
.-al
2) Closes and outputs a signal (a filling sig-
nal) to the controller to notify that filling
is completed when the clutch is filled *Set
‘,;I ; ) 1 Time
with oil.
3) Keeps outputting signals (filling signals)
to the controller to notify that oil pres-
t-l
sure is applied or not while oil pressure o 1 OFF 1 ON
*Set
is applied to the clutch. Time
Range A:
Before shifting gear (when draining) sxwo474 1
Range B: Fill starts (during trigger)
Range C: Fill completed
Range D: Pressure adjustment
Range E: During filling Characteristics of ProPortional
solenoid current-propulsion force
ECMV and proportional solenoid N (ka)
. For each ECMV, one proportional solenoid
is installed.
The proportional solenoid generates propul-
sion force according to the command cur-
rent from the controller as shown in the fig-
ure at right.
The propulsion force generated by the pro- 0 ’ (A)
portional solenoid is applied to the pressure - Current
control valve spool to generate the oil pres- Characteristics of proportional

sure shown in the figure at right. Accord- solenoid propulsion-oil Pressure
MPa( kg/cm’)
ingly, the propulsion force is changed by
controlling the command current to operate
the pressure control valve to control the flow
and pressure of the oil.
ECMV and fill switch

l For each ECMV, one fill switch is installed.
If the clutch is filled, the flow sensor valve
N(kel
turns on the fill switch. When this signal is - Propulsion force
output, oil pressure starts building up.
SXW04742
WA1 200-3
1 O-23
Operation
Operation of ECMV
l ECMV is controlled with the command cur-
rent sent from the controller to the propor-
tional solenoid and the fill switch output sig-
nal.
The relationship among the proportional so-
lenoid command current of ECMV, clutch in-
put pressure, and fill switch output signal is
shown at right.
Set
Range A: L
Before shifting gear (when draining)
Range E: During filling
i;; 4 Time
,Sec
t-l
1 OFF 1 ON
esec
Time
sxwo474 1
1. Before shifting gear (when draining) (Range

A in chart)
While any current is not flowing in propor-
tional solenoid (6). proportional solenoid (6)
is pushed back by the reaction force of pres-
sure control valve spring (9) through pres-
sure control valve spool (7). Accordingly,
pressure control valve spool (7) drains the
oil from clutch port C through drain port E.
At this time, since any oil pressure is not
applied to flow sensor valve spool (3), flow
sensor valve spool (3) is separated from fill
switch (5) by the reaction force of fill switch
spring (4) and stopped at a position where
fill switch spring (4) is balanced with flow
sensor valve return spring (2).
9JEOOO77
1O-24 WA1 200-3

2. When fill starts (During trigger)

(Range B in chart)
1) If a trigger current (the maximum cur-
rent) is given to proportional solenoid
(6) while there is not oil in the clutch,
proportional solenoid (6) moves through
its stroke and pressure control valve
spool (7) moves to the left. As a result,
pump port A and pressure control valve
output port B open, then the oil starts
flowing into the clutch through orifice a
of flow sensor valve spool (3).
9JBOOO78
2) At this time, differential pressure is gen-

erated between the upstream side and
downstream side of orifice a of flow sen-
sor valve spool (3).
Because of this differential pressure, flow
sensor valve spool (3) compresses flow
sensor valve return spring (2) and moves
to the left.
Then, flow sensor valve spool (3) opens
pump port D and oil flows through ori-
fice a into clutch port C.
9JBOOO79
WA1 200-3 1o-25

3. When fill is completed (When pressure con-

trol valve is set to initial pressure)
(Range C in chart)
I) If pump port D of the flow sensor valve

opens and oil starts flowing, differential
pressure is generated between the up-
stream side and downstream side of ori-
fice a of flow sensor valve spool (31, and
this pressure keeps pressing flow sen-
sor valve spool (3) to the left.
At this time, if the current flowing in pro-
portional solenoid (61 is lowered to the
initial pressure level for a moment, al-
most all the pump pressure is applied to
load piston (8) and pressure control valve
spool (7) is pushed back to the right,
then a little oil flows from pressure con-
trol valve output port B to drain port E.
Since the quantity of this oil is not much,
almost all the oil from the pump flows
into the clutch and flow sensor valve
spool (3) is kept pressed to the left.
9JBOOO80
2) If the clutch is filled with oil, the oil from

pressure control valve port B does not
flow into clutch port C. The pressure re-
ceiving area of the left side of flow sen-
sor valve spool (3) is larger than that of
the right side. Accordingly, if the same
oil pressure is applied to both sides, flow
sensor valve spool (3) is moved by the
oil pressure to the right. As a result,
pump port D and clutch port C are closed.
At this time, flow sensor valve spool (3)
is pushed to the right further by the dif-
ferential area between both sides and
the tension of flow sensor valve return
spring (21, and it compresses fill switch
spring (4). Then, flow sensor valve spool
(3) touches fill switch (5) and notifies the
controller of completion of filling. At this
time, a current of the initial pressure level
flows in proportional solenoid (6) and
pressure control valve (71 is set to the
initial pressure.
9JROOORl
1O-26 WA1 200-3

4. Pressure adjustment (Range D in chart)

If a current flows in proportional solenoid
(61, the solenoid generates a propulsion force
in proportion to the current. This propulsion
force of the solenoid is balanced with the
sum of the propulsion force of load piston
(8) generated by the oil pressure in clutch
port C and the reaction force of pressure
control valve spring (91, then the pressure is
settled.
Flow sensor valve spool (3) is pressed to the
right by the differential oil pressure between
both sides of itself and it continues
outputting the fill signal to the controller.
9JBOOO82
WA1 200-3 lo-27

STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
(Transmission, transfer, and parking brake)
9JB00083
1. Transmission valve 7. Parking brake

2. Transmission input shaft 8. Output coupling (Rear side)
3. Transmission 9. Travel speed sensor adapter
4. Transfer 10. Oil filler adapter
5. Output coupling (Front side) 11. Strainer
6. Drain plug
1O-28 WA1 200-3

STRUCTURE AND FUNCTK)N TRANSMISSION
9JBOO 004
A: From oil filter K: From torque converter case

B: From oil cooler L: To modulated clutch (Lubrication) and
c: Lubricating oil pressure pick-up port input transfer (Lubrication)
D: To parking brake valve M: To parking brake piston
E: To modulated clutch ECMV N: To transmission lubricating circuit
F: To main relief valve and torque converter P: To transmission lubricating circuit
relief valve Q: To 1st speed clutch
G: Drain port R: To 2nd speed clutch
H: From torque converter case S: To 3rd speed clutch
J: To transmission charging pump and torque T: To forward clutch
converter charging pump U: To reverse clutch
WA1 200-3 1O-29

44 6
x-x +
SJBOOOB5
1O-30 WA1 200-3

’I. Transmission inout shaft

2. Pinion shaft ’
3. Clutch disc
+ 4. Clutch plate
5. Planetary pinion No. 1 (for reverse)
(Number of teeth: 31)
6. Clutch No. 1 housing (for reverse)
7. Ring gear No. 1 (for reverse)
8. Clutch No. 2 housing (for forward)
9. Ring gear No. 2 (for forward)
(Number of teeth: 165, 94)
10. Planetary pinion No. 2 (for forward)
11. Pinion shaft
12. Planetary pinion No. 3 (for 3rd speed)
13. Ring gear No. 3 (for 3rd speed)
14. Clutch No. 3 housing (for 3rd speed)
15. Pinion shaft
16. Planetary pinion No. 4 (for 2nd speed)
17. Clutch No. 4 housing (for 2nd speed)
18. Ring gear No. 4 (for 2nd speed)
(Number of teeth 165, 94)
19. Piston No. 5 return spring (for 1st speed)
20. Clutch No. 5 piston (for 1st speed)
21. Rear housing
22. Transmission output shaft
23. Clutch No. 5 housing (for 1st speed)
24. Carrier No. 4 (for 2nd speed)
Clutch No. 5 drum (for 1st speed)
25. Clutch No. 5 hub (for 1st speed)
26. Sun gear No. 4 (for 2nd speed) (Number of
teeth: 50)
27. Clutch No. 4 piston (for 2nd speed)
.28. Piston No.4 return spring (for 2nd speed)
29. Sun gear No. 3 (for 3rd speed)
30. Clutch No. 3 piston (for 3rd speed)
Piston No. 3 return spring (for 3rd speed)
3”:: Carrier No. 2, 3 (for forward, 3rd speed)
33. Clutch No. 2 piston (for forward)
34. Sun gear No. 2 (for forward)
35. Piston No. 2 return spring (for forward)
36. Clutch No. 1 piston (for reverse)
37. Sun gear No. 1 (for reverse)
38. Ring gear No. 1 (for reverse)
39. Carrier No. 1 (for reverse)
9JROOO86
40. Piston No. 1 return spring (for reverse)
41. Pin
42. Washer spring
43. Tie bolt
44. Front housing
WA1 200-3 1o-31

Outline
l The transmission system consists of a for-
ward 3-gear speed and reverse 3-gear speed+
transmission consisting of planetary gear
mechanisms and disc clutches, transfer, park-
ing brake, and transmission control valve.
l Among the five sets of a planetary gear
mechanism and a disc clutch, 2 clutches are
operated with a control valve and fixed hy-
draulically to select one rotation direction
and one rpm.
l Clutch No. 1 is fixed for reverse travel, clutch
No. 2 for forward travel, clutch No. 3 for
travel at 3rd speed, clutch No. 4 for travel at
2nd speed, and clutch No. 5 for travel at 1st
speed.
Gear speeds and operated clutches
Gear speed Operated (Engaged) clutch
Forward 1st speed No.2 - No.5

Forward 2nd speed No.2 . No.4
Forward 3rd speed No.2 . No.3
Reverse 1st speed No.1 . No.5
Reverse 2nd speed No.1 . No.4
Reverse 3rd speed No.1 . No.3
Number of plates and discs used
Clutch No. Number of plates Number of discs
Clutch No. 1 7 8
Clutch No. 2 8 9
Clutch No. 3 4 5
Clutch No. 4 3 4
Clutch No. 5 8 9
lo-32 WA1 200-3

Operation
Operation of clutch
l The clutch consists of piston (361, plate (41,
disc (3), pin (411, piston return spring (401,
washer spring (421, etc. to secure ring gear
(38).
l The inside teeth of disc (3) are engaged with
the outside teeth of ring gear (38).
l The cut part of the outside of plate (4) is
engaged with pin (41) fixed to clutch hous-
ing (6).
9J800087
Clutch “ON” (Fixed)

l The oil sent from the transmission valve
flows through the oil passage in the trans-
mission to the back side of piston (36) to
move piston (36) to the left.
l Piston (36) presses plate (4) against disc (3)
to stop rotation of disc (3) with friction force
and fixes ring gear (38) engaged with the
inside teeth.
9J800088
Clutch ‘OFF” (Released)

. If the oil sent from the transmission valve is
shut off, piston (36) is returned by piston
return spring (401, then the friction force be-
tween plate (4) and disc (3) is released and
ring gear (38) is set in neutral.
l Washer spring (42) installed between plates
(4) at the pin section returns piston (36)
quickly and separates plate (4) from disc (3)
sharply to prevent drag turning when the
clutch is disengaged.
95800089
WA1 200-3 1o-33

Power train
Forward 1st speed
9J 800090
l When the transmission is set in the forward l At this time, rotation of carriers No. 2 and
1st speed, clutches No. 2 and No. 5 are con- No. 3 (32) is transmitted as rotary power in
nected and ring gear No. 2 (9) is fixed and the rotation direction of sun gear No. 2 (34).
clutch No. 5 hub (25) is directly coupled with l Since clutch No. 5 is engaged, ring gear No.
output shaft (22) to output the power. 3 (13), carrier No. 4, clutch No. 5 drum (24),
l The power from the torque converter is trans- and clutch No. 5 hub (25) are fixed as one
mitted to input shaft (I), then transmitted unit.
through sun gear No. 2 (34) to planetary l Since carriers No. 2 and No. 3 (32) rotate
pinion No. 2 (10). under this condition, the whole unit of ring
Since ring gear No. 2 (9) is fixed, planetary gear No. 3 (13), carrier No. 4, clutch No. 5
pinion No. 2 (10) rotates and revolves along drum (24), and clutch No. 5 hub (25) rotates,
ring gear No. 2 (9) around sun gear No. 2 and the rotary power is output through out-
(34) simultaneously. put shaft (22) in the rotation direction of sun
gear No. (2) (34).
1o-34 WA1 200-3

Forward 2nd speed
9JB00091
When the transmission is set in the forward l Since clutch No. 4 is engaged, ring gear No.
2nd speed, clutches No. 2 and No. 4 are 4 (18) is fixed.
connected and ring gears (9) and (18) are . Since carriers No. 2 and No. 3 (32) rotate
fixed to output the power. under this condition, the power is transmit-
The power from the torque converter is trans- ted from ring gear No. 3 (13) through carrier
mitted to input shaft (I), then transmitted No. 5 to clutch No. 5 drum (24). Planetary
through sun gear No. 2 (34) to planetary pinion No. 4 (16) rotates and revolves along
pinion No. 2 (IO). ring gear No. 4 (18) around sun gear No. 4
Since ring gear No. 2 (9) is fixed, planetary (261, and its rotary power is output to output
pinion No. 2 (IO) rotates and revolves along shaft (22) in the rotation direction of sun
ring gear No. 2 (9) around sun gear No. 2 gear No. 2 (34).
(34) simultaneously.
At this time, rotation of carriers No. 2 and
No. 3 (32) is transmitted as rotary power in
the rotation direction of sun gear No. 2 (34).
WA1 200-3 1o-35

Forward 3rd speed
QJBOOO!32
l When the transmission is set in the forward . At this time, rotation of carriers No. 2 and
3rd speed, clutches No. 2 and No. 3 are con- No. 3 (32) is transmitted as rotary power in
nected and ring gears No. 2 (9) and No. 3 the rotation direction of sun gear No. 2 (34).
(13) are fixed to output the power. l Since ring gear No. 3 (13) is fixed, as carri-
l The power from the torque converter is trans- ers No. 2 and No. 3 (32) rotate, planetary
mitted to input shaft (I), then transmitted pinion No. 3 (12) rotates along ring gear No.
through sun gear No. 2 (34) to planetary 3 (13) and revolves around sun gear No. 3
pinion No. 2 (IO). (291.
l Since ring gear No. 2 (9) is fixed, planetary l Under this condition, the rotary power of
pinion No. 2 (10) rotates and revolves along carriers No. 2 and No. 3 (32) rotates sun
ring gear No. 2 (9) around sun gear No. 2 gear No. 3 (29) and is output to output shaft
(34) simultaneously. (22) in the rotation direction of sun gear No.
2 (34).
1O-36 WA1 200-3

Reverse 1st speed
9JEOOO93
l When the transmission is set in the reverse l At this time, since clutch No. 1 fixes carrier
1st speed, clutches No. 1 and No. 5 are con- No. 1 (391, the rotary power of planetary
nected and ring gear No. 1 (38) is fixed and pinion No. 1 (5) is transmitted to carriers
clutch No. 5 hub (25) is directly coupled with No. 2 and No. 3 (32) to rotate ring gear No. 1
output shaft (22) to output the power. (7) in the opposite direction to sun gear No.
l The power from the torque converter is trans- 1 (36).
mitted to input shaft (I), then transmitted . As a result, the power in the reverse direc-
through sun gear No. 1 (36) and planetary tion is transmitted to output shaft (22). The
pinion No. 1 (5) to ring gear No. 1 (7). power train after this point in the reverse
l Since ring gear No. 1 (38) is fixed, planetary lst, 2nd, or 3rd speed is similar to that in
pinion No. 1 (5) rotates and revolves around the forward Ist, 2nd, or 3rd speed described
sun gear No. 1 (36) simultaneously. before.
WA1 200-3 1o-37

STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
9JBOOO94
1O-38 WA1 200-3

A: Reverse clutch oil pressure pick-up port

B: Forward clutch oil pressure pick-up port
c: 3rd speed clutch oil pressure pick-up port
D: 2nd speed clutch oil pressure pick-up port
E: Lubricating oil pressure pick-up port
F: 1st speed clutch oil pressure pick-up port
G: To parking brake valve
H: To modulated clutch ECMV
1. By-pass fill valve and by-pass drain valve

(for reverse clutch)
2. ECMV (for reverse clutch)
3. By-pass fill valve (for forward clutch)
4. ECMV (for forward clutch)
5. Lubricating oil relief valve
6. By-pass fill valve (for 1st speed clutch)
7. ECMV (for 1st speed clutch)
8. ECMV (for 2nd speed clutch)
9. ECMV (for 3rd speed clutch)
10. Pilot filter
ECMV operations table
% When the transmission is set in neutral in

the manual operation mode, the clutch of
the gear speed in which the gear shift lever
is set is turned “ON”.
WA1 200-3 1o-39

By-pass fill valve
Outline
When the piston volume of a clutch is large,
if only ECMV is used, it takes long time to
fill the clutch, that is, the fill time is length-
ened and the operator feels time lag in gear
shifting operation.
To solve this problem, by-pass valves are
installed, which are operated simultaneously
with ECMV to fill the large-piston volume
clutches with oil quickly.
The by-pass fill valves are installed to the

reverse clutch, forward clutch, and 1st speed
clutch circuits.
Relationship between by-pass fill valve and

ECMV F
l Each bv-oass
, . fill valve is controlled with the
command current from the transmission con-
troller. The relationship between ECMV and
operation of this valve is shown at right.
Range A: Before shifting gear

Time Set)
(when draining)
Range B: Fill starts
(both by-pass fill valve and ECMV
are opened simultaneously and oil
is filled at large flow rate)
Range C: During filling
(only ECMV is opened and oil is
filled at medium flow rate)
Range D: Fill completed
(only ECMV is opened and filling
is completed at low flow rate)
Range E: Pressure adjustment by ECMV
Range F: During filling
1O-40 WA1 200-3

Operation
When solenoid valve is “Da-energized”

l Since spool (2) in solenoid valve (11 is
pressed to the right by return spring (31,
chamber A and port T are opened and no oil
pressure is applied to chamber A.
Accordingly, spool (4) of the by-pass fill valve
is pressed to the right by return spring (5)
and ports P and C are closed.
5 C4PA T32 I
9JEIOOO96
When solenoid valve is “Energized”

. If a current flows in solenoid valve (I), spool
(2) is pressed to the left and port P and I ECMV
chamber A are opened and pressurized oil
is supplied to chamber A.
Accordingly, spool (4) is moved to the left
by the pressurized oil to open ports P and C,
then the oil is supplied to the clutch.
9JB00097
WA1 200-3 10-41

By-pass drain valve
Outline
l When a clutch is “disengaged”, the oil in
the clutch piston is drained through ECMV
into the transmission case.
When the piston volume of the clutch is
large, if only ECMV is operated as past, it
takes long time to discharge the oil. If the
next gear shifting operation starts before the
all oil is discharged, a shock may be gener-
ated.
To prevent this, a by-pass drain valve is in-
stalled to discharge the oil quickly from a
large-piston volume clutch without through
ECMV.
% The by-pass drain valve is installed to the

reverse clutch circuit.
Operation
When solenoid valve is “De-energized”

(When normal)
l Since spool (2) in solenoid valve (1) is
pressed to the right by return spring (3),
chamber A and port T are opened and no oil
pressure is applied to chamber A.
Accordingly, spool (4) of the by-pass fill valve
is pressed to the right by return spring (5)
and ports C and T are closed.
9JBOOO98
When solenoid valve is “Energized”

(When clutch oil is discharged)
. If a current flows in solenoid valve (I), spool
(2) is pressed to the left and port P and
chamber A are opened and pressurized oil
is supplied to chamber A.
Accordingly, spool (4) is moved to the left
by the pressurized oil to open ports C and T,
then the oil from the clutch is drained.
c!r A P2 1
Z This valve is operated for a set time just 9JBOOO99
after the clutch is “disengaged”. Accordingly,
it does not operate under the normal condi-
tion (while the clutch oil pressure is being
adjusted or the clutch is being filled with oil
or after a set time has passed after the clutch
is “disengaged”).
1o-42 WA1 200-3

ECMV
(For transmission)
SJBOOlOO
A: To clutch 1. Connector
B: Drain 2. Spring
C: From pump 3. Flow sensor valve spool
P: Clutch oil pressure pick-up port 4. Spring
5. Fill switch
6. Proportional solenoid
7. Pressure control valve spool
8. Load piston
9. Spring
WA1 200-3 1o-43

Outline
Outline of ECMV
l ECMV (Electronic Control Modulated Valve)
consists of one pressure control valve and
one flow sensor valve.
. Pressure control valve
This valve receives the current sent from the -L
transmission controller with a proportional !k=i
solenoid, then converts it into oil pressure. z-a
LC
. Flow sensor valve zg
This valve operates according to the trigger z 5s:
a. u-
sinnals sent from the pressure control valve
and has the following functions.
I) Closes and outputs a signal (a filling sig-
nal) to the controller to notify that filling
is completed when the clutch is filled
with oil.
2) Keeps outputting signals (filling signals)
to the controller to notify that oil pres-
sure is applied or not while oil pressure
is applied to the clutch.
Range A:
Range C: Fill completed Time (Set)

ECMV and proportional solenoid

Characteristics of proportional
l For each ECMV, one proportional solenoid solenoid current-propulsion force
is installed. N (ke)
The proportional solenoid generates propul-
sion force according to the command cur-
rent from the transmission controller as
shown in the figure at right.
The propulsion force generated by the pro-

portional solenoid is applied to the pressure
control valve spool to generate the oil pres- 0' (A)
sure shown in the figure at right. Accord- - Current
ingly, the propulsion force is changed by
Characteristics of proportional
controlling the command current to operate solenoid propulsion-oil pressure
MPa ( ks/cm’l
the pressure control valve to control the flow
and pressure of the oil.
ECMV and fill switch

. For each ECMV, one fill switch is installed.
If the clutch is filled, the flow sensor valve
turns on the fill switch. When this signal is
output, oil pressure starts building up.
Niksl
__c Propulsion force
sxwo4742
1o-44 WA1 200-3

Operation
Operation of ECMV
. ECMV is controlled with the command cur-
rent sent from the transmission controller to
the proportional solenoid and the fill switch
output signal.
The relationship among the proportional so-
lenoid command current of ECMV, clutch in-
put pressure, and fill switch output signal is
shown at right.
Range A:
Tine (Sec)
1. Before shifting gear (when draining)

(Range A in chart)
While any current is not flowing in propor-
tional solenoid (61, proportional solenoid (6)
is pushed back by the reaction force of pres-
sure control valve spring (9) through pres-
sure control valve spool (7). Accordingly,
pressure control valve spool (7) drains the
oil from clutch port C through drain port E.
At this time, since any oil pressure is not
applied to flow sensor valve spool (31, flow
sensor valve spool (3) is separated from fill
switch (5) by the reaction force of fill switch
spring (4) and stopped at a position where
fill switch spring (4) is balanced with flow
sensor valve return spring (2).
9JBOOlOl
WA1 200-3 1o-45

2. When fill starts (During trigger)

(Range B in chart) a
If a trigger current (the maximum current) is
given to proportional solenoid (6) while there
is not oil in the clutch, proportional solenoid
(6) moves through its stroke and pressure
control valve spool (7) moves to the left. As
a result, pump port A and pressure control
valve output port B open, then the oil starts
flowing into the clutch through orifice a of
flow sensor valve spool (3).
0 A 7
9JBOOlO2
1O-46 WA1 200-3

3. When fill is completed (When pressure con-

C
trol valve is set to initial pressure)
(Range C in chart)
1) After the set time, the current in propor-
tional solenoid (6) is lowered to the ini-
tial pressure level to move pressure con-
trol valve spool (7) to the right to throt-
tle the passage between pump port A
and pressure control valve output port
B. As a result, the oil flow rate into the
clutch is lowered. By this operation, gen-
eration of peak pressure in clutch port C
at the end of oil filling process is pre-
vented and the gear speed is changed
smoothly.
9JBOO103
2) If the clutch is filled with oil, the oil from

pressure control valve port B does not
flow into clutch port C. The pressure re-
ceiving area of the left side of flow sen-
sor valve spool (3) is larger than that of
the right side. Accordingly, if the same
oil pressure is applied to both sides, flow
sensor valve spool (3) is moved by the
oil pressure to the right. At this time,
flow sensor valve spool (3) is pushed to
the right further by the differential area
between both sides and the tension of
flow sensor valve return spring (21, and
it compresses fill switch spring (4). Then,
flow sensor valve spool (3) touches fill
switch (5) and notifies the controller of
completion of filling. At this time, a cur-
rent of the initial pressure level flows in
proportional solenoid (6) and pressure
control valve (7) is set to the initial pres-
sure.
95800104
WA1 200-3 1o-47

4. Pressure adjustment (Range D in chart)

If a current flows in proportional solenoid
(61, the solenoid generates a propulsion force
in proportion to the current. This propulsion
force of the solenoid is balanced with the
sum of the propulsion force of load piston
(8) generated by the oil pressure in clutch
port C and the reaction force of pressure
control valve spring (91, then the pressure is
settled.
Flow sensor valve spool (3) is pressed to the
right by the differential oil pressure between
both sides of itself and it continues
outputting the fill signal to the controller.
9JB00105
lo-48 WA1 200-3

STRUCTURE AND FUNCTION LUBRICATING OIL RELIEF VALVE
LUBRICATING OIL RELIEF VALVE
A-A
9JBOO106
P: Lubricating oil pressure pick-up port
1. Spool
2. Valve body
Function
l This valve is installed to the transmission
valve and prevents the pressure of the trans-
mission lubricating oil from rising abnor-
mally.
Set pressure: 0.26 MPa 12.7 kg/cm*)
(Cracking pressure)
WA1 200-3 1o-49

STRUCTURE AND FUNCTION TRANSFER
TRANSFER
9JBOO107
1. Transmission output shaft

2. Transfer input shaft (Number of teeth: 38)
3. Transfer idler gear (Number of teeth: 57)
4. Transfer output gear (Number of teeth: 40)
5. Output shaft
6. Front coupling
7. Rear coupling
8. Parking brake
Outline
l The transfer is installed on the output side
of the transmission and secured to the trans-
mission case with bolts.
1O-50 WA1 200-3

STRUCTURE AND FUNCTION TRANSFER
Operation
Power train
l Since transmission output shaft (I) and trans-
fer input gear (2) are fixed with the spline,
the power is transmitted through transfer
idler gear (3) to transfer output gear (41, then
transmitted to output shaft (5). One part of
the power transmitted to output shaft (5) is
further transmitted through the center drive
shaft and front drive shaft to the front axle.
The other part of the power is transmitted
through the rear drive shaft to the rear axle.
9JEIOOlO8
WA1 200-3 10-51

STRUCTURE AND FUNCTION TORQUE CONVERTER OIL COOLER
TORQUE CONVERTER OIL COOLER
1. Torque converter oil cooler OUTLINE

. The oil which comes out from the torque
A. Oil inlet port converter outlet port is at a high tempera-
(From torque converter regulator valve) ture because of the energy used in transmit-
B. Oil outlet port (To transmission lubricating) ting the motive force. This torque converter
C. Water inlet port (From water pump) oil passes through oil cooler port A and en-
D. Water outlet port (To engine block) ters the oil cooler. Here it is cooled by the
engine cooling water. The oil then flows out
from oil outlet port B, lubricates the trans-
mission and returns to the transfer case.
1O-52 WA1 200-3

STRUCTURE AND FUNCTION CENTER SUPPORT
CENTER SUPPORT
FUNCTION
1. Front coupling
l The center support is installed to the front
2. Case
frame between the center drive shaft and
3. Grease nipple
the front drive shaft.
4. Rear coupling
l With the articulating frame, this part is con-
stantly twisting from side to side, so there is
liable to be large stress on the drive shaft.
Therefore, the center support is used to
transmit the power smoothly, to reduce the
stress on the drive shafts, and in this way
improve the durability of the drive shafts.
WA1 200-3 1o-53

STRUCTURE AND FUNCTION AXLE
AXLE
FRONT AXLE
SJW04727
1. Front axle
2. Final drive
3. Brake
4. Front differential
5. Drain plug
1o-54 WA1 200-3

AXLE
FRONT DIFFERENTIAL
SJWO4728
1. Housing 5. Shaft
2. Bevel gear (Teeth 39) 6. Bevel pinion (Teeth IO)
3. Differential side gear (Teeth 28) 7. Coupling
4. Differential pinion gear (Teeth 22)
WA1 200-3 1o-55

REAR AXLE
lZ
\ b---=-t
5
SJWO4729
1. Rear axle
2. Rear differential
3. Brake
4. Final drive
5. Drain plug
lo-56 WA1 200-3

REAR DIFFERENTIAL
SJWO4730
1. Bevel pinion (Teeth IO)

2. Bevel gear (Teeth 39)
3. Shaft
4. Differential pinion gear (Teeth 22)
5. Differential side gear (Teeth 28)
6. Differential housing
7. Coupling
WA1 200-3 1o-57

Outline
The power of the engine is transmitted
through the damper, upper drive shaft,
modulated clutch, torque converter, trans-
mission, and drive shaft to the front and
rear axles.
In the axle, the rotation is transmitted from
pinion gear (I) to bevel gear (5) and its di-
rection is changed by 90 degrees and its
speed is reduced, then it is transmitted
through differential (4) to axle shaft (2).
The rotation speed of the axle shaft is fur-
ther reduced by the final drive of planetary
gear type, then transmitted to the wheels.
sEwooo77
When driving straight forward

l When the machine is driven straight forward,
the rotating speed of the left and right wheels
is the same, so pinion gear (4) inside carrier
(6) is sent through pinion gear (4) and side
gear (3) and is transmitted equally to the left
and right axle shafts (2).
SEW00078
When turning
l When turning, the rotating speed of the left
and right wheels is different, so pinion gear
(4) and side gear (3) inside the differential
assembly rotate in accordance with the dif-
ference between the rotating speed of the
left and right wheels. The motive force of
carrier (6) is then transmitted to axle shafts
(2).
lo-58 WA1 200-3

STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
SJW04731
1. Axle shaft Outline

2. Brake l The final drive reduces the rotation speed to
3. Ring gear (Number of teeth: 81) obtain a large drive force by using a plan-
4. Ring gear (Number of teeth: 76) etary gear mechanism and transmits the
5. Sun gear (Number of teeth: 21) obtained drive force to the tires.
6. Sun gear (Number of teeth: 28) l The power is transmitted from the differen-
7. Drain plug tial through axle shaft (I) to sun gear (5) of
8. Planetary gear (Number of teeth: 23) the first stage, then transmitted to planetary
9. Planetary gear (Number of teeth: 29) gear (9). The planetary gear rotates inside
10. Housing fixed ring gear (3) to transmit the power to
11. Wheel sun gear (6) of the second stage. Then, the
reduced rotation is transmitted to the plan-
etary carrier as in the first stage, then fur-
ther transmitted to wheels (II) installed to
the carrier.
WA1 200-3 1o-59

STRUCTURE AND FUNCTION AXLE MOUNT
AXlE MOUNT
I 2
Z
c
A-A B-B
SJWO4732
1O-60 WA1 200-3

STRUCTURE AND FUNCTION AXLE MOUNT
SJWO4733
1. Front frame Front axle

2. Rear frame . Front axle (4) receives the force directly dur-
3. Rear axle ing operations, so it is fixed directly to front
4. Front axle frame (I) by axle mounting bolts.
5. ROPS support
Rear axle
. Rear axle (3) has a structure which allows
the center of the rear axle to float, so that all
tires can be in contact with the ground when
traveling over soft ground.
WA1 200-3 lo-61

STRUCTURE AND FUNCTION CENTER HINGE PIN
CENTER HINGE PIN
A-A B-0 SJW04734
1. Front frame OUTLINE

2. Rear frame l The front frame and rear frame are joined
3. Rear axle by the center hinge pin through a bearing.
4. Front axle The steering cylinders adjust the angle of
5. Upper hinge pin curvature to the left and right of the front
6. Lower hinge pin and rear frame (in other words, they adjust
the turning radius).
1O-62 WA1 200-3

STRUCTURE AND FUNCTION ARRANGEMENT OF STEERING EQUIPMENT
ARRANGEMENT OF STEERING EQUIPMENT
3
\
1. Steering demand valve

2. Rotary valve
3. Hydraulic tank
4. Steering pump
5. EPC valve
6. Steering cylinder
WA1 200-3 1O-63

STRUCTURE AND FUNCTION AJSS (ADVANCED JOYSTICK STEERING SYSTEM)
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)
1. Steering lever 7. Rotary valve

2. Potentiometer (Lever operating angle) 8. Potentiometer (Frame angle)
3. Joint 9. Front frame
4. Joint 10. Bracket
5. Joint 11. Joint
6. Joint 12. Lever
1O-64 WA1 200-3

STRUCTURE AND FUNCTION STEERING PUMP
STEERING PUMP
Model: HPV160+ 160
l This pump consists of 2 fixed-displacement For the operation of this pump, see the sec-
swash plate piston pumps, 2 gear pumps tion of work equipment pump.
and 1 impeller pump between them.
PS PGSl PGSP
PD12 PA1 PA2 PD22 PAD1 PAD2
9JYOO227
PAI: Front pump discharge port PGSI : Gear pump suction Port
PA2: Rear pump discharge port PGSS: Gear pump suction Port
PADI: Gear pump discharge port PS: Pump suction port
PAD2: Gear pump discharge port
PDII: Drain port 1. Front pump
PD12: Drain port 2. Rear pump
PD21: Drain port 3. Gear pump
PD22: Drain port 4. Gear pump
WA1 200-3 1O-65

STEERING PUMP
c-c
2 3 4
B-0
I!
9JYOO228
1O-66 WA1 200-3

1. Front shaft 8. Front end cap 15. Rocker cam

2. Front cradle 9. Impeller 16. Rear case
3. Front case 10. Coupling 17. Rear cradle
4. Rocker cam 11. Rear end cap 18. Rear shaft
5. Piston 12. Valve plate 19. Servo piston
6. Cylinder block 13. Cylinder block
7. Valve plate 14. Piston
WA1 200-3 lo-67

STRUCTURE AND FUNCTION SWITCH PUMP
SWITCH PUMP
Model HPV160+ HPF160
l This pump consists of 1 variable-displace- pump and rear pump.

ment swash plate piston pump, 1 fixed-dis- For the operation of this pump, see the sec-
placement swash plate piston pump, and 1 tion of work equipment pump.
impeller pump built in between the front
PIN
PDl 1 PSV PD21
PD12 PA1 PA2 PD22
9JYOO229
PAI: Front pump discharge port PS: Pump suction port

PA2: Rear pump discharge port PSV: Servo main pressure supply port
PDll: Drain port
PD12: Drain port 1. Front pump
PD21: Drain port 2. Front servo valve
PD22: Drain port 3. Front CO + NC valves
PIN: Main pump pressure input port 4. Rear pump
1O-68 WA1 200-3

SWITCH PUMP
PSVl B PSI’1 PSVlA PSVPA PSVP PSV2B
X Y
9JYOO230
PSVI : Servo valve main pressure port PSVP: Servo valve main pressure port
PSVIA: Servo valve output port PSV2A: Servo valve output port
PSVlB: Servo valve output port PSVSB: Servo valve output port
WA1 200-3
1O-69
SWITCH PUMP
A-A
Cd
18
c-c
9JYOO231

2. Front cradle 9. Coupling 16. Rear case
3. Front case 10. Impeller 17. Rear cradle
1O-70 WA1 200-3

STRUCTURE AND FUNCTION SERVO VALVE
SERVO VALVE
1. Servo valve assembly (For front of switch)
PA ,c2 ‘AC1
Pl
P2
\
PECN
9JYOO232
PI: Main pump pressure IN pot-t PIN: Main pump pressure input port
P2: Main pump pressure IN port PPO: Servo main pressure IN port
PACl: Servo actuator port
PACS: Servo actuator port 1. CO + NC valves
PDR: Servo drain OUT port 2. Servo valve
PECN: CO + NC valves output pressure OUT port 3. Plate
WA1 200-3 1o-71

2. Servo valve (For front of switch)
Pl I P2 I
CN
A-A
D-D E-E F-F G-G H-H J-J K-K
9JYOO233
Pll: Main pump pressure IN port PDR: CO + NC valves drain IN pot-t

PlO: Main pump pressure OUT port PPO: Servo main pressure OUT port
P21: Main pump pressure IN port PECN: CO + NC valves output pressure IN port
P20: Main pump pressure OUT port
lo-72 WA1 200-3

CO + NC valves (For front of switch)
PECN
PPO
PDR
P2
Pl
9JYOO234
Pl: Main pump pressure front IN port PPO: Servo main pressure IN port
P2: Main pump pressure rear IN port PECN: CO + NC valves output pressure OUT port
PDR: CO + NC valves drain OUT port
WA1 200-3 1o-73

PEO
,PDR
A-A
SJYOO235
PI: Main pump pressure rear OUT port CO valve NC valve

P2: Main pump pressure rear OUT port 1. Cover 8. Cover
PDR: TVC valve drain IN port 2. Sleeve 9. Sleeve
PEO: Servo main pressure IN port 3. Piston 10. Piston
PPO: Servo main pressure OUT port 4. Spool 11. Spool
5. Spring 12. Spring
6. Seat 13. Cover
7. Plug
1o-74 WA1 200-3

STRUCTURE AND FUNCTION STEERING DEMAND VALVE
STEERING DEMAND VALVE
PB PI
PI
1. Overload relief valve

2. Surge cut relief valve
3. Steering spool
4. Demand spool
5. Main relief valve
A. To steering cylinder
6. To steering cylinder
PI. From steering pump
P2. From switch pump
PB. To main control valve
T. To hydraulic tank
(through hydraulic oil cooler)
5’ i
A-A
SEW01395
WA1 2003 1o-75

OVERLOAD RELIEF VALVE
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
i i i ‘5 SDW01396
FUNCTION
l The overload relief valve is installed in the cylin-

der 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 break-
age 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

l 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 dl and d2. d
Checkvalve poppet (3) and relief valve pop-
pet (2) are securely seated.
SDW01397
l 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.
A
SDW0139S
1O-76 WA1 200-3

. When pilot poppet (4) opens, the pressure at

the rear of poppet (I) drops, poppet (1) moves
to the right, and it is seated with pilot poppet
(4).
A
SDW01399
. 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 pres-
sure.
A B
SDW01400
2. Operation of suction valve 3

Negative pressure is generated at port A, the
l
difference in the area of diameters d3 and d4

opens check valve poppet (31,and the oil flows
from port B to port A to prevent a vacuum
from forming in the circuit. d
A e
SDWO1401
WA1 200-3 1o-77

MAIN RELIEF VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
FUNCTION
l 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 oper-
ated. 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.
1 O-78 WA1 200-3

OPERATION OF STEERING RELIEF VALVE
To main
control valve
sxwo4904
l When the pressure in the circuit rises and l

When demand spool (4) moves, the oil from
reaches the pressure set by spring (2) and ad- the steering pump is drained and the oil from
justment screw (I), pilot poppet (3) opens and the switch pump is relieved to the main con-
drains the oil. trol valve, so the steering circuit pressure is
l When this happens, the balance of the pres- prevented from going above the set value.
sure in pressure receiving chamber (I) and
pressure receiving chamber (II) is lost, and
demand spool (4) moves to the left.
WA1 200-3 1o-79

OPERATION OF DEMAND VALVE

When steering spool is at neutral
From switch
sxwo4905
l The oil from the steering pump enters port A l When the pressure in pressure receiving cham-
and the oil from the switch pump enters port ber (I) reaches a certain value (set by spring
B. (3)), notch f opens and the oil from the steer-
* When steering spool (2) is at the neutral posi- ing pump goes to the drain circuit. Notch g is
tion, pressure receiving pressure chamber (II) closed, so the oil from the switch pump all
is connected to the drain circuit through ori- flows to the main control valve.
fice b, and notch c is closed.
. 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 (I) to
the left.
1 O-80 WA1 200-3

WHEN STEERING SPOOL IS OPERATED

Engine running at low speed
From switch
SXWO4906
. When the steering is operated, oil flows from l The merged oil passes through notches c and
the rotary valve to steering spool (2) and d, pushes load check valve (51, and flows to
pushes steering spool (2) to the right. The cir- the cylinder. The return oil from the cylinder
cuit between pressure receiving chamber (II) passes through notch e and flows to the drain
and the drain circuit is shut off, and at the same circuit.
time, notch c opens. . When this happens, the pressure before
As a result, the pressure in pressure receiving passing through notch c is sent to pressure
chamber (II) rises, and demand spool (I) receiving chamber (I) and the pressure after
moves to the right until notch h closes. passing through notch c is sent to pressure
The passage from port B to the main control receiving chamber (II). Demand spool (I) is
valve is shut off, so the oil from the switch actuated so that the difference in pressure
pump pushes up pump merge-divider check on both sides of notch c is kept constant.
valve (4) and merges with the oil from the Therefore, an oil flow corresponding to the
steering pump at port A. opening of notch c is supplied to the cylinder
port. These pressure differences (control pres-
sure) are set by spring (3).
WA1 200-3 lo-81

Engine running at high speed
To main
control valve
%
%
From steering
Porno
sxwo4907
There is no need for supply of extra oil from . The oil from the steering pump passes through
l
the switch pump, so the steering pump pres- notches c and d, pushes load check valve (51,
sure rises until notch g closes and shuts off and flows to the cylinder. The return oil from
the merge passage from port B. the cylinder passes through notch e and flows
l The pressure difference on both sides of notch to the drain circuit.
. Notch g is closed, so the oil from the switch
c is controlled only by notch f, and the excess
oil from the steering pump is drained from pump all flows from port B and is sent to the
notch f to the drain circuit. (At this point, notch main control valve.
g is completely closed.)
1O-82 WA1 200-3

OPERATION OF STEERING VALVE

Neutral
SXWO4908
l The steering wheel is not being operated, so l

When the pressure at ports A and B rises, de-
steering spool (2) does not move. mand spool (I) moves to the left, so the oil
l The oil from the steering pump enters port A. from the steering pump passes through port
The oil from the switch pump enters port B. C of the spool and is drained.
The oil from the switch pump passes through
port D and all flows to the main control valve.
WA1 200-3 lo-83

Turning to right
From ro
From steerin
sxwo4909
. If the steering lever is moved to the right, the side of the right cylinder to turn the machine
rotary valve operates and the steering spool to the right. The oil from both cylinders is
(2) moves to the left. drained through load check valve (5) of the
The oil from the steering pump flows in port steering spool. The oil from the switch pump
A, then flows through flow control spool (I) flows in port 6, then flows through flow con-
to steering spool (2) and pushes load check trol spool (I) to push check valve (4) open
valve (6) of the spool open to supply oil to and merges with the steering pump oil.
the bottom side of the left cylinder and rod
1O-84 WA1 200-3

Turning to left
From rotary
valve
control valve
sxw04910
. If the steering lever is moved to the left, the side of the right cylinder to turn the ma-
rotary valve operates and the steering spool chine to the left. The oil from both cylinders
(2) moves to the right. is drained through load check valve (6) of
The oil from the steering pump flows in port the steering spool. The oil from the switch
A, then flows through flow control spool (1) pump flows in port B, then flows through
to steering spool (2) and pushes load check flow control spool (I) to push check valve
valve (5) of the spool open to supply oil to (41 open and merges with the steering pump
the rod side of the left cylinder and bottom oil.
WA1 200-3 lo-85

STRUCTURE AND FUNCTION ROTARY VALVE
.b
swwa94
1. Neutral position spring a. To hydraulic tank

2. Valve body b. To port Pb of steering demand valve
3. Check valve c. To pot-t Pa of steering demand valve
4. Spool d. From PPC pump
5. Sleeve
6. Feedback spool
7. Feedback sleeve
8. Loose spring
9. Drive shaft
IO. Center pin
11. Body
1O-86 WA1 200-3

STRUCTURE AND FUNCTION ROTARYVALVE
Outline
l The steering lever is connected to the top of
the rotary valve. The direction of the oil sent
from the PPC pump through the EPC valve
to this valve is changed with the steering
lever to move the spool of the steering de-
mand valve. As a result, the steering cylin-
der is operated to set the steering direction
of the machine.
l The link installed to the front frame is con-
nected to the bottom of the rotary valve to
feed back the steering angle of the machine.
Accordingly, the position of the steering le-
ver is matched to the steering angle of the
machine.
Structure
l Spool (4) is connected through pin (IO) Steerina lever
(which is not in contact with the spool while t

the steering lever is in “neutral”) and neu-
tral position spring (II to sleeve (5).
l The top and bottom of drive shaft (9) are
engaged with pin (IO) and assembled into
one unit together with sleeve (5) and feed-
back sleeve (7).
. Feedback spool (6) is connected through pin
(IO) (which is not in contact with the spool
while the steering lever is in “neutral”) and
loose spring (8) to feedback sleeve (7).
l Valve body (2) has four ports, which are con-
nected to the pump circuit, tank circuit, and
pilot circuit of the steering demand valve
respectively.
4
Link
WA1 200-3 lo-87

STRUCTURE AND FUNCTION ROTARY VALVE
Operation
. If the steering lever is operated, spool (4)
rotates along sleeve (5), against neutral po-
sition spring (I).
By this rotation, the port of spool (4) is
matched to that of sleeve (5) to form an oil
passage, then the oil flows in the steering
demand valve.
If the steering lever is operated more than
the allowable displacement of neutral posi-
tion spring (I), loose spring (8) absorbs the
displacement through drive shaft (9).
. If the oil flows in the steering cylinder and
steering operation starts, the link installed
to the front frame turns sleeve (5) through
feedback spool (6) and drive shaft (9) so that
the deviation of sleeve (5) from spool (4)
will be offset.
If the machine is steered to the position
matched to the operating distance of the
steering lever, deviation of spool (4) from
sleeve (5) is eliminated and the oil passage
is closed.
1O-88 WA1 200-3

STRUCTURE AND FUNCTION EPC VALVE
EPC VALVE
e
r---------7
I ,_+_______A-
D
I 11 P2
_I L ( T
c
T i
Ii Pl
T
i:--_.____i
SJWO4896
1. Min. pressure assurance pressure reducing

valve
2. Electromagnetic proportional valve
Pl. From PPC pump

P2. From diverter valve
C. To rotary valve
D. TO hydraulic tank
Outline
l The EPC valve controls the oil flow to the l Even if the electromagnetic proportional
rotary valve with the electromagnetic pro- valve does not work because of a controller
portional valve controlled with the command trouble, the minimum pressure assurance
current from the work equipment and joy- pressure reducing valve supplies the mini-
stick controller. mum oil pressure to the rotary valve.
WA1 200-3 1O-89

STRUCTURE AND FUNCTION DIVERTER VALVE
DIVERTER VALVE
1. Check valve A. To emergency pump FUNCTION

2. Check valve 6. Sensor mounting port l The diverter valve is a selector valve which
3. Check valve C. To hydraulic oil tank senses the pilot pressure from the steering
4. Check valve D. To steering valve pump and if there is no abnormality in the
5. Spool E. From hydraulic tank steering circuit, it drains the oil from the
6. Valve body F. From steering circuit emergency pump to the tank. If no pilot pres-
sure from the steering pump reaches the
diverter valve, the oil from the emergency
pump is switched to the steering circuit and
flows to enable the machine to be steered.
1O-90 WA1 200-3

EMERGENCY STEERING RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
m Kzr SDW01420
FUNCTION
Compared to the steering valve relief pressure
of 31.4 MPa 1320 kg/cm*}, the rated pressure of
the emergency steering pump and diverter valve
are both 20.6 MPa (210 kg/cm*). Therefore, to
protect the emergency steering pump and
diverter valve, there is a relief valve in the pip-
ing from the diverter valve to the steering valve.
When the emergency steering is being oper-
ated, and the hydraulic pressure generated by
the steering exceeds 20.6 MPa (210 kg/cm*}, 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
(I) and fills port B. Pilot poppet (3) is in
contact with valve seat (2).
I
l When the pressure inside port A and B A I 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.
l When the pressure at port B drops, the ori-
fice of main valve (I) generates a difference
in pressure between port A and port B. Main
valve (I) is opened by the pressure at port A
and the oil at port A is relieved.
WA1 200-3 10-91

HYDRAULIC CIRCUIT SCHEMATICS FOR EMERGENCY STEERING
Pump, engine working normally To steering From steering

cylinder CY I inder
When the steering pump and engine are work-

ing normally, the main pump, 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 trans-
mission, 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.
1 O-92 WA1 200-3

l When pump or engine has trouble while machine is traveling
To steering From steering

cylinder CYI inder
6 6
If the pump or engine has a trouble while the

machine is traveling, the rotation of the tires is
transmitted through the transmission to the
emergency pump. n n
Since the steering pump is not rotating, any
pressure is not generated in port D. Accord-
ingly, spool (3) is pressed to the right by spring
(4).
The oil from the emergency pump flows through
port A and port 6 to the rotary valve, and the
machine can be steered.
Emergency
steering ourno
% The emergency pump can rotated in either
forward or reverse direction.
WA1 200-3 1o-93

STRUCTURE AND FUNCTION ARRANGEMENT OF BRAKE EQUIPMENT
ARRANGEMENT OF BRAKE EQUIPMENT
1. Front brake (right) 9. Parking brake (Built in transmission)

2. Brake valve (right) IO. Accumulators
3. Parking brake switch 11. Brake valve (left)
4. Rear brake (right) 12. Front brake (left)
5. Slack adjuster (rear) 13. Slack adjuster (front)
6. Torque converter + transmission, 14. Charge valve
brake cooling, brake pump 15. Strainer
7. Rear brake (left) 16. Parking brake solenoid valve
8. Brake oil tank
1o-94 WA1 200-3

STRUCTURE AND FUNCTION BRAKE VLAVE
BRAKE VALVE
BRAKE VALVE (RIGHT)
swwo4aa5
1. Brake pedal (left, right brake) 9. Spool (left brake)

2. Rod (right brake) 10. Cylinder (left brake)
3. Pilot piston (right brake)
4. Spool (right brake) A. Pilot port (right brake)
5. Upper cylinder (right brake) B. To rear brake (right brake)
6. Spool (right brake) C. To front brake (right brake)
7. Lower cylinder (right brake) D. Drain (left, right brake)
8. Rod (left brake) E. To pilot port (left brake)
1O-96 WA1 200-3

BRAKE VALVE (LEFT)
II\_J U
SDWOO108
Outline
l There are two brake valves installed in par- In addition, the left brake pedal operates the
allel under the front of the operator’s cab, transmission cut-off switch to actuate the
and these are actuated by depressing the transmission solenoid valve electrically and
pedal. set the transmission to neutral.
l When the right pedal is depressed, oil is
sent to the brake cylinder to apply the brakes.
l 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 de-
pressed.
WA1 200-3 1o-97

Operation
Brake applied (right brake valve)
Upper portion
l When brake pedal (1) is depressed, the op-
erating force is transmitted to spool (3)
through rod (2) and spring (4). When spool
(3) goes down, drain port a is closed, and
the oil from the pump and accumulator flows
from port A to port C and actuates the rear
brake cylinders.
Lower portion
l When brake pedal (1) is depressed, the op-
erating force is transmitted ‘to spool (3)
through rod (2) and spring (4). When spool
(3) goes down, spool (5) is also pushed down
by plunger (6). When this happens, drain
port b is closed, and the oil from the pump
and accumulator flows from port B to port D
and actuates the front brake cylinders.
Brake applied (left brake pedal)

l When pedal (7) is depressed, spool (10) is
pushed up by rod (8) and spring (9), and
drain port c is closed. The oil from the pump
and the accumulator flows from port E to Left brake valv
port F.
. Port F of the left brake valve and port PP of
the right brake valve are connected by a
hose, so the oil flowing to port F flows to
pilot port PP of the right brake valve.
l The oil entering pilot port PP enters port G
from orifice d, and pushes piston (11). The
spring pushes spool (3) down, so the opera-
tion is the same as when the right brake
valve is depressed.
To front brake
1O-98 WA1 200-3

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 mechani-
cally when pedal (I) is depressed, and the
lower portion is actuated normally.
The upper brake is not actuated.
Applying brake when lower valve fails (right
brake valve)
l Even if there is leakage of oil in the lower
piping, the upper portion is actuated nor-
mally.
When actuation is balanced From pump M

Upper portion
l When oil fills the rear brake cylinder and the
pressure between port A and port C becomes From pump -&
high, the oil entering port H from orifice e of
spool (3) pushes against spring (4). It pushes
up spool (3) and shuts off the circuit be-
tween port A and port C. When this hap-
pens, drain port a stays closed, so the oil
entering the brake cylinder is held and the
brake remains applied.
Lower portion
l 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 cylin-
der 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 the
brake is applied.
l The pressure in the space in the upper por-
tion is balanced with the operating force of From pump
the pedal, and the pressure in the space in
To front brake
the lower portion is balanced with the pres-
sure in the space in the upper portion. When
From pump
spools (3) and (5) move to the end of their
stroke, the circuits between ports A and C
and between ports B and D are fully opened,
so the pressure in the space in the upper
and lower portions and the pressure in the
left and right brake cylinders is the same as
the pressure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of
the brake can be adjusted by the amount
that the pedal is depressed.
WA1 200-3 1o-99

Brake released (right brake valve)

Upper portion
l When pedal (I) is released and the operat-
ing force is removed from the top of the
spool, the back pressure from the brake cyl-
inder 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
l When the pedal is released, spool (3) in the
upper portion moves up. At tlie same time,
the back pressure from the brake cylinder
From pump From rear brake
and the force of the spool return spring move
spool (5) up. Drain port b is opened and the
oil from the brake cylinder flows to the hy-
From pump rom front brake
draulic tank return circuit to release the front
brake. SEW00113
10-100 WA1 200-3

STRUCTURE AND FUNCTION CHARGE VALVE
CHARGE VALVE
PP
ACC
_-_-_~-_---_--‘--_-,
I
I
ACC
PP
i_ -__--__________~I
T
SXWO4764
ACC. Plug Function

PP. To brake valve l The charge valve is actuated to maintain the
P. From pump oil pressure from the pump at the specified
T. To brake oil tank pressure and to store it in the accumulator.
l 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.
WA1 200-3 10-101

A-A
1. Main relief valve (R3)

2. Valve body
3. Relief valve (RI)
4. Relief valve (HI)
5. Filter
6. Filter
10-102 WA1 200-3

Operation
1. When no oil is being supplied to accumula-
tor (cut-out condition)
l The pressure at port B is higher than the set

pressure of the relief valve (RI), so piston
(8) is forcibly pushed up by the oil pressure
at port B. Poppet (6) is opened, so port C Front accumulator
pi lot ~rasaura
and port T are short circuited.
l The spring chamber at the right end of spool
(15) is connected to port C of the relief valve
(RI), so the pressure becomes the brake 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).
It also passes through orifices (171, (181, and
(16), and flows to the brake oil tank.
2. When oil is supplied to accumulator
I) Cut-in condition
l When the pressure at port B is lower than
the set pressure of the relief valve (RI), pis-
ton (8) is pushed back down by spring (5).
Valve seat (7) and poppet (6) are brought
rant accumulator
into tight contact, and port C and port T are i lot oresaura
shut off.
l The spring chamber at the right end of spool
(15) is also shut off from port T, so the pres-
sure rises, and the pressure at port P also
rises in the same way.
l 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 pres-
sure difference (equivalent to the load on
spring (14)) generated on both sides of the
orifice. A fixed amount is supplied regard-
less of the engine speed.
WA1 200-3 10403

STRUCTURE AND FUNCTION CHARGEVALVE
2) When cut-out pressure is reached

When the pressure at port B (accumulator
pressure) reaches the set pressure of the
relief valve (RI), 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 dif-
ference is generated above and below pis- rant accumulator
ilot ~reawre
ton (8), so piston 18) moves up, poppet (6) is
forcibly opened, and 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
(Rl), 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 6 is
stopped.
3. Main 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 cir-
cuit and protects the circuit.
10-104 WA1 200-3

STRUCTURE AND FUNCTION ACCUMULATOR (FOR BRAKE)
ACCUMULATOR (FOR BRAKE)
1. Valve
2. Top cover
3. Cylinder
4. Piston
sxwo4770
Function Specifications
l The accumulator is installed between the Gas used: Nitrogen gas
charge valve and the brake valve. It is Charge amount: 20 e
charged with nitrogen gas between cylinder Charging pressure: 11.8 f 0.49 MPa
(3) and free piston (41, and uses the 020 * 5 kg/cm21
compressibility of the gas to absorb the pulse
of the hydraulic pump or to maintain the
braking force and to make it possible to op-
erate the machine if the engine should stop.
WA1 200-3 10-105

STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
sxwo4771
1. Bleeder SPECIFICATIONS
2. Cylinder Piston operating oil pressure:
3. Check valve O.O1’~oo’MPa {O.l’~“’ kg/cm*)
4. Piston Check valve cracking pressure:
5. Spring 17.4 r 0.05 MPa (17.8 -c 0.5 kg/cm*})
Check valve closing pressure:
A. Inlet port 1.09 + 0.05 MPa (11.1 + 0.5 kg/cm9
B. Outlet port
FUNCTION
l The slack adjuster is installed in the brake
oil line from the brake valve 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.
10-106 WA1 200-3

OPERATION
1. When brake pedal is depressed
. Before the brake is depressed, piston (4) is
returned by the distance of stoke S (full Right brake
stroke). When the brake pedal is depressed,
the oil discharged from the brake valve flows c
from port P of the slack adjuster and is di- To

bra
vided to left and right cylinders (21, where it
moves piston (4) by stroke S to the left and
right. From brake valve SEW00122
l When this is done, brake piston (7) moves

by a distance of stroke S. In this condition,
the closer the clearance between the brake
piston and disc is to 0, the greater the brak-
ing force becomes.
From brake valve SEW00123
. If the brake pedal is depressed further, and

the oil pressure discharged from the brake
valve goes above the set pressure, check Right brake
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.
From brake valve SEW00124
WA1 200-3 10407

2. When brake pedal is released 4 0 7

. When the brake is released, piston (4) is re-
turned by brake return spring (8) by an
amount equivalent to the oil for stroke S,
and the brake is released. I)
In other words, return stroke T of brake pis- Fro
lef
ton (7) is determined by the amount of oil bra
for stroke S of the slack adjuster. The time
lag of the brake is always kept constant re-
gardless of the wear of the brake disc. SEW00125
lo-108 WA 1200-3
STRUCTURE AND FUNCTION BRAKE
BRAKE
I 2 3
VT) ;:7,
I ’ _~_____________ ---_s;
JJ.-J ----
II i \:- I / \-
9 1
SXW04772
1. Guide pin Operation

2. Brake piston l When the brake pedal is depressed, moves
3. Return spring brake piston (2) to the right, and presses
4. Floating seal disc (5) and plate (6) together to hold them
5. Disc in position. Disc (5) is rotating together with
6. Plate the wheel, so when it is held in position, the
rotation stops, the brake is actuated, and the
machine is stopped. When the brake pedal
is released, the pressure at the rear face of
FUNCTION
piston (2) is released, and the piston is
l The brakes are wet-type multiple disc brakes,
moved to the left by the force of return spring
and are fitted to all four wheels.
(3) to release the brake.
WA1 200-3 10409

STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
9JEIOO109
A: Piston chamber Outline

l The parking brake is a multiple-wet disc
1. Rear coupling brake, which is operated mechanically with
2. Output shaft spring (3) to brake output shaft (2).
3. Spring l The tension of spring (3) presses discs (5)
4. Piston and plates (6) with piston (4) to lock output
5. Disc shaft (2).
6. Plate l This brake is released by supplying pressu-
7. Front coupling rized oil to piston chamber A to move piston
(4) against the tension of spring (3) to set
discs (5) and plates (6) free.
10-l10 WA1 200-3

STRUCTURE AND FUNCTION ARRANGEMENT OF HYDRAULICEQUIPMENT
ARRANGEMENT OF HYDRAULIC EQUIPMENT
--
/
swwo4773
10-l 12 WA1 200-3

STRUCTURE AND FUNCTION ARRANGEMENT OF HYDRAULIC EQUIPMENT
1. Bucket cylinder l The work equipment system consists of the

2. PPC valve hydraulic circuit and steering circuit. The
3. Main pump hydraulic circuit controls the operation of
3A. No.1 main pump the bucket and attachment.
3B. No.2 main pump l The oil from hydraulic tank is sent from main
4. Switch pump pumps (3A) and (381, and switch pump (4)
5. Accumulator through the steering valve to two main con-
6. Hydraulic oil cooler trol valves (IO). If the bucket and boom
7. 4th gear pump spools of the main control valve are both in
(Torque converter + transmission neutral, the oil passes through the drain cir-
+ brake cooling + brake) cuit of the main control valve, is filtered by
8. Transmission the filter inside the hydraulic tank, and re-
9. Boom cylinder turns to the tank.
10. Main control valve (x 3) l The bucket or boom spool in PPC valve is
activated by operating the work equipment
control lever, causing each spool in the work
equipment valve to be hydraulically acti-
vated. Thereby, the oil is allowed to flow
from the work equipment valve to boom cyl-
inder (9) or bucket cylinder (I), thus operating
the boom or the bucket.
l The maximum pressure of the hydraulic cir-
cuit is regulated by the relief valve inside
the main control valve. There are two safety
valves (with suction valve) and an unloader
valve in the bucket cylinder circuit to protect
the circuit.
l Even when engine is at rest, the boom can
be lowered to the ground because accumu-
lator (5) is provided in the circuit.
. Hydraulic tank is a pressurized, sealed type
and has a breather with a relief valve. This
acts to pressurize the tank and at the same
time prevents negative pressure. This pro-
tects the pump from cavitation.
. A port is made on the hydraulic tank to pres-
surize the hydraulic tank with air to bleed air
from the piston pump after removing and
installing the piston pump and its piping.
WA1 200-3 10-113

STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
A-A
SJWO4782
1. Strainer OUTLINE
2. Oil filler l Oil is sent from the hydraulic tank through
3. Oil filler strainer the work equipment valve to each cylinder.
4. Filter bypass valve Then, it merges with the oil from various
5. Filter parts in the return circuit, and a part of it is
6. Breather cooled by the oil cooler and filtrated by the
7. Drain valve oil filter, then returned to the hydraulic tank.
l The oil filter filtrates the all oil in the return
A. Steering return port circuit from the work equipment valve. If this
B. Loader return port filter is clogged, the bypass valve operates
C. Emergency steering return port to let the oil return to the tank directly for
D. Main suction port prevention of breakage of the filter. The by-
E. Emergency steering suction port pass valve also operates when negative pres-
F. PPC, control suction port sure is generated in the circuit.
l Strainer (I 1 is installed to the suction port of
the hydraulic tank.
WA1 200-3 10-l 15

OPERATION OF OIL FILTER BYPASS

VALVE
When the filter is clogged.

Bypass valve (1) opens and the oil returns directly
to the tank without passing through the filter.
Bypass valve set pressure: 125 kPa (1.27 kg/cm21
From main control
To hvdrailic tank SDW02312
When negative pressure is formed in the return

circuit.
Valve (2) moves up and acts a check valve.
Check valve set pressure: 25.5 kPa IO.26 kg/cm21
To main control
@
From hydraulic tank SDW02313
10-116 WA1 200-3

BREATHER
1. Body
2. Filter element
3. Poppet
4. Sleeve
SEW00141
FUNCTION
Preventing negative pressure inside the tank

The tank is pressurized, sealed type, so negative
pressure is formed inside the hydraulic tank
when the oil level drops during operations.
When this happens, the difference in pressure
between the tank and the outside atmospheric
pressure opens poppet (31, and air from the
outside is let into the tank to prevent negative
pressure.
Preventing rise in pressure inside the tank

When the hydraulic cylinder are being used, the
oil level in the hydraulic circuit changes and the
temperature rises. If the hydraulic pressure rises
above the set pressure, sleeve (4) is actuated to
release the hydraulic pressure inside the tank.
WA1 200-3 10417

STRUCTURE AND FUNCTION WORK EQUIPMENT PUMP No. 1
WORK EQUIPMENT PUMP No. 1

Model: HPV160+ 160
PA1 PA2
PDl 1 PESl PSV PESP PD21
PS ? ?
CZ
9JYOO236
P: Main pump pressure IN port 1. Front pump

PAI: Front pump discharge port 2. Front servo valve
PA2: Rear pump discharge port 3. Rear servo valve
PDII: Drain port 4. Rear CO + NC valves
PD21: Drain port 5. Rear pump
PESI: ES valve output pressure IN port
PESS: ES valve output pressure IN port
PS: Pump suction port
PSV: Servo main pressure supply port
lo-118 WA1 200-3

Work equipment pump No. 1
f
A
PSVlA PSVl PSVlB PSVPB PSVP PSVPA
X Y
9JYOO237
PSVI: Servo valve main pressure port PSV2: Servo valve main pressure port
PSVIA: Servo valve output port PSVPA: Servo valve output port
PSVIB: Servo valve output port PSVPB: Servo valve output port
WA1 200-3 10419

c-l A-A
I8
c-c
9JYOO238

2. Front cradle 9. Coupling 16. Rear case
3. Front case 10. Impeller 17. Rear cradle
10-120 WA1 200-3

Servo valve
1. Servo valve (For front No. 1)
PACl PPO P2 PACP
PDR
A-A
D-D E-E F-F G-G H-H
9JYOO239
P2: Main pump pressure IN port 1. Servo valve

PACI: Servo actuator port
PAC2: Servo actuator port
PDR: Servo valve drain OUT port
PESI: ES valve output pressure IN port
PPO: Servo valve main pressure IN port
WA1 200-3 10421

2. Servo valve assembly (For rear No. 1)
PPO
PAC 1
PES PEbN
p: Main pump pressure IN port 1. CO + NC valves

PACI: Servo actuator port 2. Servo valve
PAC2: Servo actuator port 3. Plate
PDF?: Servo valve drain OUT port
PECN: CO + NC valves output pressure OUT port
PES: ES valve output pressure pick-up pot-t
PESP: ES valve output pressure IN port
PPO: Servo main pressure IN port
10422 WA1 200-3

3. Servo valve (For rear No. I)
D-D
E-E F-F G-G H-H J-J K-K
9JYOO241
PII: Main pump pressure IN port PDR: CO + NC valves drain IN port

PIO: Main pump pressure OUT port PPO: Servo main pressure OUT port
PZI: Main pump pressure IN port PECN: CO + NC valves output pressure IN port
WA1 200-3 lo-123

Structure
9JYOO242
7. Pin 13. Sleeve

1. Locknut
8. Piston 14. Piston
2. Cover
9. Locknut 15. Spring
3. Plug
IO. Plug 16. Plug
4. Spring
11. Locknut 17. Cover
5. Valve body
12. Cover 18. Locknut
6. Arm
(cc/rev1
Function
Discharge amounts Ql and 02 of main pumps a
Pl and P2 are controlled individually by the re- z=
spective servo valves. The relationship between E
pump discharge amount 0 and input signal
PECN to the servo valve is as shown in the
graph on the right. 0 varies in proportion to
PECN.
(MPa(kdcm’l)
CWNC valve output pressure PECN SWP06953
lo-124 WA1 200-3

1) Operation in direction of increase of pump discharge amount (max. angle)
SWPO6954
Operation
The control, pump pressure PPO is taken to l At the same time, port a is interconnected
port a. \ with port h, so the pressure oil flows through
Signal pressure PECN from the NC valve is port i to servo piston chamber j, pushes
taken from port b to chamber c. servo piston (19) to the right, increases the
When signal pressure PECN rises, piston (8) swash plate angle in the main piston pump
is pushed to the right by the pressure in and increases the pump discharge amount.
chamber c, and stops at a point where it l When servo piston (19) moves, arm (6) ro-
balances the pressure of springs (4) and (4A). tates counterclockwise with its center at pin
At the same time, arm (6) uses servo piston (7) and moves guide spool (13) to the left.
(19) as a fulcrum and sways to the right in Port a, port d and port h close, so the dis-
the same way as piston (8). This moves guide charge increases by an amount that matches
spool (13) to the right. signal pressure PECN.
When guide spool (13) moves, port a and
port d are closed and port d is connected to
drain chamber e. As a result, servo piston
chamber f is also interconnected with drain
chamber e through port g and port d.
WA1 200-3 10-125

21 Operation in direction of decrease of pump discharge amount (min. angle)
1 NCvalve 1
TVC valve
SWPO6955
Operation
l When signal pressure PECN goes down, pis- . At the same time, port a is interconnected
ton (8) moves to the left and stops at a point with port d, so the oil flows through port g
where the pressure in chamber c balances to servo piston chamber f, pushes servo pis-
the pressure of springs (4) and (4A). ton (19) to the left, decreases the swash plate
l At the same time, arm (6) uses servo piston angle in the main piston pump and decreases
(19) as a fulcrum and sways to the left in the the pump discharge amount.
same way as piston (81. This moves guide l When servo piston (19) moves, arm (6) ro-
spool (13) to the left. tates clockwise with its center at pin (7).
l When guide spool (13) moves, port a and Guide spool (13) is moved to the right and
port h are closed and port h is connected to closes port a, port d and port h, so the dis-
drain chamber e. As a result, servo piston charge decreases by an amount that matches
chamber j is also interconnected with drain signal pressure PECN.
chamber e through port i and port h.
10-126 WA1 200-3

CO + NC valves (For rear No. 1)
PECti
PDR
P2
9JYOO243
P2: Main pump pressure IN port

PDR: CO + NC valves drain OUT port
PECN: CO + NC valves output pressure OUT port
WA1 200-3 lo-127

9JYOO244
CO valve NC valve
1. Cover 8. Cover
2. Sleeve 9. Sleeve
3. Piston 10. Piston
4. Spool 11. Spool
6. Seat 13. Cover
7. Plug
lo-128 WA1 200-3

1. CO valve
Function
l When the load becomes large during opera- The CO valve is controlled by balancing the
tions and the main pump discharge pres- spring with the total of main pump discharge
sure rises to a point close to relief pressure, pressure P and CO valve output pressure
the cut-off function of the CO valve acts to PEC.
reduce the pump discharge in order to re-
duce relief loss.
I) When main pump discharge pressure is lower than relief pressure
w Servo
Sma I I
Piston
r) Large
Operation
. Spool (4) is being pushed down fully by
spring (3). As a result, port a and port b are
fully open and TVC valve output pressure
PE and CO valve output pressure PEC are
equal. In this way, CO valve output pressure
PEC becomes the maximum and the main
pump discharge amount also becomes the
maximum.
WA1 200-3 1O-l 29

2) When main pump discharge pressure becomes close to relief pressure
Servo valve
Servo Piston
Smal I+ Large
@
sxwo4747
Operation
. If the load increases and main pump dis- l As a result, the flow of oil from port a to
charge pressure P comes close to the relief port b is throttled by the notch in the spool,
pressure, main pump discharge pressure P and the area of the opening at port b and
pushes piston (5). At the same time, CO valve port c (drain port) becomes larger. In this
output pressure PEC pushes piston (51, and way, CO valve output pressure PEC goes
spool (4) moves up. down, and the pump discharge amount be-
comes the minimum.
10-130 WA1 200-3


Model: HPV95 + 95
J L PA2 PA1
I
Pyl 1 PE,S I PL)21
PS’V
PS
\
PSG
9JYOO247
P: Main pump input pressure IN port 1. Front pump

PI: Orifice upstream pressure IN port 2. Rear pump
P2: Orifice downstream pressure IN port 3. Fan driving gear pump
PAl: Front pump discharge port 4. Rear servo valve
PA2: Rear pump discharge port 5. Plate
PAG: Gear pump discharge port 6. ES valve (Engine sensing)
PDII: Drain port 7. CO + NC valves
PD21: Drain port 8. Plate
PESI: ES valve output pressure IN port 9. Servo valve
PESO: ES valve output pressure OUT port
PS: Pump suction port
PSG: Gear pump suction port
PSV: Servo main pressure supply port
WA1 200-3 10431

Work equipment pump No. 2
PSVlB PSVl PSVlA PSVPA PSVP PSVPB
9JYOO248
PSVI: Servo valve main pressure port PSV2: Servo valve main pressure port
PSVIA: Servo valve output port PSV2A: Servo valve output port
PSVIB: Servo valve output port PSVSB: Servo valve output port
1O-l 32 WA1 200-3

A-A
9JYO0’249
1. Front shaft 8. Front end cap 15. Rear case

2. Front cradle 9. Coupling 16. Rocker cam
3. Front case IO. Impeller 17. Rear cradle
WA1 200-3 m-133

Servo valve
1. Servo valve assembly (For front No. 21
PEiN
PDR
P2
PPO
PACl
PAC2
Z
9JYOO250
P: Main pump pressure IN port 1. CO + NC valves

PACI: Servo actuator port 3. Plate
PECN: CO + NC valve output pressure OUT port
PES: ES valve output pressure IN port
10-134 WA1 200-3

2. Servo valve (For front No. 21
PECN PDR pDP2

R
@
isiik!
0
0
H
QO
CZ
A-A
k-E
D-D E-E F-F G-G H-H
9JYOO251

PDR: CO + NC valve drain IN port
PECN: CO + NC valve output pressure IN port
WA1 200-3 10-135

3. Servo valve assembly (For rear No. 2)
POkl PCiRP
PES
PECN’
PDR P2
Pl
PACl
PPO PAC2
9JYOO252
Pl: Main pump pressure IN port 1. ES valve

PACI: Servo actuator port 3. Plate
PES: ES valve output pressure OUT port
PECN: CO + NC valve output pressure IN port
PORI: Orifice upstream pressure IN port
POR2: Orifice downstream pressure IN port
lo-136 WA1 200-3

4. Servo valve (For rear No. 2)
H4 I--D
M-0
+
Y
D-D E-E
F-F G-G H-H J-J K-K
9JYOO253
PI: Main pump pressure OUT port PPO: Servo main pressure OUT port
P2: Main pump pressure OUT port PECN: CO + NC valve output pressure IN port
PDR: ES valve drain IN port
WA1 200-3 10-137

Structure (For rear No. 21
9JYOO254
1. Locknut 7. Pin 13. Sleeve

2. Cover 8. Piston 14. Piston
3. Plug 9. Locknut 15. Spring
4. Spring 10. Plug 16. Plug
5. Valve body 11. Locknut 17. Cover
6. Arm 12. Cover 18. Locknut
Function
Discharge amounts Ql and Q2 of main pumps
PI and P2 are controlled individually by the re-
spective servo valves. The relationship between
pump discharge amount 0 and input signal
PECN to the servo valve is as shown in the
graph on the right. Q varies in proportion to
PECN.
(MPa{ktdcm'l)
CO+NC valve output oressure PECN SUP06953
10438 WA1 200-3

I) Operation to increase pump discharge (increase swash plate angle)
Control Main Pump

pump
SXWO4748
Operation
Signal pressure PI acts on chamber E of the l Consequently, arm (4) turns counterclockwise
control piston through port D. Control pump around pin (13) to move guide spool (12) to
pressure PC is led in port B. the left. Since ports B, A, and C are closed,
If PI rises, the oil pressure applied to cham- the discharge is increased by the quantity
ber E rises and control piston (9) moves to corresponding to signal pressure PI.
the right until the oil pressure force in cham-
ber E is balanced with the force of spring
(IO).
At the same time, arm (4) rocks to the right,
using servo piston (11) as a fulcrum, and
moves guide spool (12) to the right.
As guide spool (12) moves, port B is con-
nected to port A, then control pump pres-
sure PC is applied to chamber F of servo
piston (I 1) to push servo piston (II) to the
right. As a result, the swash plate angle of
the main piston is increased to increase the
discharge.
WA1 200-3 10-139

2) Operation to decrease pump discharge (reduce swash plate angle)
From rear
servo @
valve
PI-
Control Main Pump

Pump
sxwo4749
Operation
. If PI lowers, piston (9) moves to the left until . At this time, port B is connected to port C
the oil pressure force in chamber E is bal- and the pressurized oil flows in servo piston
anced with the force of spring (IO). chamber H and pushes servo piston (11) to
l At the same time, arm (4) rocks to the left, the left, together with the force of spring
similarly to piston (9) and using servo pis- (14). As a result, the swash plate angle of
ton (I I) as a fulcrum, and moves guide spool the main pump is reduced to decrease the
(12) to the left. pump discharge.
l As guide spool (12) moves, port B is discon- l As servo piston (11) moves, arm (4) turns
nected from port A, the port A is connected clockwise around pin (13) to move guide
to drain chamber T. Accordingly, servo pis- spool (12) to the right. Since ports B, C, and
ton chamber F is connected through port A A are closed, the discharge is decreased by
to drain chamber T. the quantity corresponding to signal pres-
sure PI.
10-140 WA1 200-3

CO + NC valves (For front No. 2)
0/
0
l--A
9JYOO257
P: Main pump pressure IN port

PDR: CO + NC valve drain OUT port
PECN: CO + NC valve output pressure OUT port
WA1 200-3 10-141

A-A
9JYOO258
CO valve NC valve
1. Cover 8. Cover
2. Sleeve 9. Sleeve
3. Piston IO. Piston
4. Spool 11. Spool
6. Seat 13. Cover
7. Plug
lo-142 WA1 200-3

1. CO valve
Function
l When the load becomes large during opera- * The CO valve is controlled by balancing the
tions and the main pump discharge pres- spring with the total of main pump discharge
sure rises to a point close to relief pressure, pressure P and CO valve output pressure
the cut-off function of the CO valve acts to PEC.
reduce the pump discharge in order to re-
duce relief loss.
1) When main pump discharge pressure is lower than relief pressure
Servo piston
Operation
l Spool (4) is being pushed down fully by
spring (3). As a result, port a and port b are
fully open and TVC valve output pressure
PE and CO valve output pressure PEC are
equal. In this way, CO valve output pressure
PEC becomes the maximum and the main
pump discharge amount also becomes the
maximum.
WA1 200-3 10-143

2) When main pump discharge pressure becomes close to relief pressure
Servo Piston
-
,I ’ f ’ , ,,‘,,,‘/ I I I I , YI I, , , , , , , , , , , ,‘
1 ‘“I fl IPPoy
sxwo4751
Operation
. If the load increases and main pump dis- l As a result, the flow of oil from port a to
charge pressure P comes close to the relief port b is throttled by the notch in the spool,
pressure, main pump discharge pressure P and the area of the opening at port b and
pushes piston (5). At the same time, CO valve port c (drain port) becomes larger. In this
output pressure PEC pushes piston (51, and way, CO valve output pressure PEC goes
spool (4) moves up. down, and the pump discharge amount be-
comes the minimum.
10-144 WA1 200-3

ES valve (For rear No. 2)
PES
PPO
POR
9JYOO261
PDR: ES valve drain OUT port PES: ES valve output pressure OUT port
PE: NC valve output pressure front-rear PPO: Servo main pressure IN port
connecting port
WA1 200-3 10-145

1,1
0
7
G
f G
D-D E-E F-F G-G H-H
9JYOO262
1. Cover 7. Cover
2. Plug 8. Sleeve
3. Rod 9. Piston
4. Plug 10. Spool
5. Nut 11. Cover
6. Screw
lo-146 WA 1200-3
FUNCTION
l A variable displacement piston pump is used
for the hydraulic pump to save energy by
reducing the consumption of hydraulic pres-
sure when the engine is running at low
speed. At the same time, it is also used to
increase the engine acceleration from low
speed. ;
a o.l4*oD1 O-37*0.02
Pilot pressure
For this reason, a pressure difference valve {IA4*0.11 (3.8*0.21difference
is used to detect the engine speed by using
a pressure difference system. The delivery
(delivery per rotation) is then adjusted to Approx.800 A~~t0~.1100
match the engine speed. Ensine speed(rpm) sxwo4752
OPERATION When the pilot pressure difference is below point a

Oil from the PPC pump passes through pres-
sure difference valve (I) and is sent to the
PPC valve. Pilot pressure from the inlet and
outlet ports (ports A and B) of the pressure
differential valve is supplied to the ES valve
(2).
The difference in pilot pressure becomes
larger as the flow from the PPC pump in-
creases (in other words, as the engine speed
increases).
When the pilot pressure difference reaches
point a (0.14 MPa 11.44 kg/cm*}), the ES valve
starts to operate, and actuates the servo
valve and servo cylinder to change the swash
plate angle of the pump. SDW01720
When the swash plate angle is changed, the
piston stroke also changes to change the
delivery of the pump (delivery per rotation). When the pilot pressure difference is above point b
Until the difference in pilot pressure reaches
0.37 MPa (3.8 kg/cm*}, the pump delivery
(delivery per rotation) increases in propor-
tion with the increase in the difference in
pilot pressure (in other words, the increase
in the engine speed).
When the difference in pressure reaches 0.37
MPa (3.8 kg/cm*}, the pump delivery (deliv-
ery per rotation) reaches the maximum.
SDW01721
WA1 200-3 10-147

STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE (Proportional Pressure Valve)
C A
P2 P4
P : From pump
T : To tank (drain)
PI : To boom cylinder (Raise)
P2 : To bucket cylinder (Dump)
P3 P3 : To boom cylinder (Lower)
P4 : To bucket cylinder (Tilt)
SEW01483
lo-148 WA1 200-3

A-A
D-D
1. Bolt
2. Piston c-c SWWO3476
3. Plate
4. Collar
5. Retainer
6. Center spring
7. Metering spring
8. Valve
9. Body
WA1 200-3 10-149

OPERATION
1. Control lever at “neutral” (Fig. 1):

Ports PA,, P2, Pe, 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
(21, retainer (7) is pushed. Valve (IO) 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 pres-
sure chamber PP, and the pilot pressure of
the control valve is sent through fine control
hole (f) to port P2 and PA,. 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.
Valve (10) moves up and down until the force

of spring (9) is balanced with the pressure
of port P2.
The position of valve (IO) and body (11)
(when fine control hole (f) is midway be-
tween drain chamber D and pump pressure
chamber PP) does not change until the head
of valve (IO) 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 PA, (same as
pressure at port P2) and the force of the
return spring of the control valve are bal-
anced.
PA1 (Fig. 2) PBl SDW01466
10-150 WA1 200-3

3. Control lever moved back from slightly op-

erated position to neutral (Fine control)
(Fig. 3):
When plate (2) starts to be pushed back,
piston (4) is pushed up by a force corre-
sponding to the force of centering spring (8)
and the pressure at port P2.
At the same time, fine control hole (f) of
valve (IO) is connected to drain chamber D,
so the oil at port P2 escapes.
If the pressure at port P2 drops too far, valve
(IO) is pushed down by spring (9). Fine con-
trol hole (f) is shut off from drain chamber
D, and at almost the same time it is con-
nected to pump pressure chamber PP. The
pump pressure is supplied until the pres-
sure at port P2 return to a pressure equiva-
lent 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 PB,.
4. Control lever operated to end of travel

(Fig. 4):
Plate (2) pushes piston (4) down, and piston
(4) forcibly pushes in valve (IO).
Fine control hole (f) is shut off from drain
chamber D, and is connected to pump pres-
sure chamber PP.
Therefore, pressure oil from the charging
pump passes through fine control hole (f),
and flows from port P2 to chamber PA, to
push the spool of the control valve.
The oil returning from chamber A2 flows
from port Pe, through fine control hole (f’) to
drain chamber D.
PA1 (Fig. 4) PBl SDWOl 488
WA1 200-3
PPC RELIEF VALVE
PPC RELIEF VALVE

Pump control circuit relief valve
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
Set pressure:
For PPC: 3.73 MPa 138.0 kg/cm*}
For pump control circuit:
9JYOO264 2.94 MPa (30.0 kg/cm*)
Function
1. PPC relief valve 2. Pump control circuit relief valve
l The PPC relief valve is installed between the l The pump control circuit relief valve is in-
PPC pump and PPC valve. While the PPC stalled between the main pump control
valve is not operating or when abnormally pump and main pump. The oil sent from the
high pressure is generated, this valve re- control pump is relieved through this valve
lieves oil sent from the pump to prevent to keep the pressure in the main pump con-
breakage of the pump and circuit. (It sets trol circuit constant.
the maximum pressure in the circuit.)
Operation
. Ports A and C are connected to the pump
circuit and drain circuit respectively. The oil
is filled in port B through the orifice of main
valve (I). Pilot poppet (3) is in contact with
valve seat (2).
9JYOO265
. If the pressure in ports A and B reaches the

set pressure of the poppet spring, pilot pop-
pet (3) opens to let the oil flow from port B
through port D to port C, then pressure in
port B lowers.
9JYOO266
I
. If the pressure in port B lowers, discharge
pressure is generated between ports A and
B because of the orifice of main valve (I),
then main valve (I) is opened by the pres-
sure of port A and the oil flows out of port
A.
9JYOO267
lo-152 WA1 200-3

STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR (FOR PPC VALVE)
1. Cap 4. Bladder
2. Nut 5. Oil port
3. Body 6. Nut
Specifications
Type of gas: Nitrogen gas
Gas amount: 3,000 cc
Max. actuation pressure: 2.9 MPa (30 kg/cm*)
Min. actuation pressure: 1.6 MPa (16 kg/cm*)
FUNCTION
l The accumulator is installed between the
hydraulic pump and PPC valve. An inflatable
‘4 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.
SEW0
OPERATION Before operation After operation

l After the engine stops, when the PPC valve
is a NEUTRAL, chamber A (volume of nitro-
gen gas: 3000 cc) inside the bladder is com-
pressed by chamber B.
l When the PPC valve is operated, the pres-

sure in chamber B drops below 2.9 MPa (30
kg/cm*) and the pressure of the nitrogen gas
in chamber A makes the bladder expand.
The actuating pressure is 1.6 to 2.9 MPa (16
to 30 kg/cm*}.
t +
From PPC pump To PPC valve
SEW0 1494 SE
WA1 200-3 10-153

STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE
Pl
PA2 .PB2
PA1
‘PBl
Al P 61
9JYOO268
1. Main relief valve PA1 : From PA1 of PPC valve

2. Bucket spool return spring PA2 : From PA2 of PPC valve
3. Boom spool return spring PBI : From PBI of PPC valve
4. Boom spool PB2 : From PB2 of PPC valve
5. Bucket spool Al : To bucket cylinder bottom side
6. Body A2 : To boom cylinder bottom side
7. Suction valve Bl : To bucket cylinder rod side
8. Unloader valve 82 : To boom cylinder rod side
9. Float selector valve P : Pump port
10. Safety valve (with suction) PI : From PA2 of PPC valve
T : Drain port (to hydraulic tank)
1o-1 54 WA1 200-3

A-A
D-D E-E
B-B
9JYOO269
FUNCTION
l The three main control valves control the l There are two safety valves (with suction
actuation of the attachments and the bucket valves) (IO) to protect the circuit if abnormal
in the hydraulic system. It has a tandem cir- pressure is generated in the bucket circuit. If
cuit which gives priority to the bucket cir- one of the two safety valves is acting as a
cuit. relief valve, the other valve acts as a suction
l The oil from the pump enters port P. The valve to make up any lack of oil.
maximum pressure is set by main relief valve
(I). The oil passes through the bypass cir-
cuit of bucket spool (5) and boom spool (4).
It then flows from port T to the drain circuit,
passes through the filter and returns to the
tank. If the bucket and boom spools are ac-
tuated, the oil flows to the bucket and boom
cylinders.
However, the circuit gives priority to the
bucket, so when the bucket spool is being
operated, even if the boom spool is operated,
the boom will not move.
WA1 200-3 10-155

RELIEF VALVE
I 2 3 45 6
1. Main valve
2. Valve seat
3. Pilot poppet
4. Pilot poppet spring
5. Adjustment screw
6. Lock nut
Set pressure: 31.4 MPa 1320 kg/cm21
FUNCTION
l 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 maxi-
mum pressure in the hydraulic circuit and
protects the circuit.
OPERATION
Port A is connected to the pump circuit, and
port C is connected to the drain circuit. The
oil passes through the orifice of main valve
(I) 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 (41, pilot pop-
pet (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 ori-
fice effect of main valve (I) generates a dif-
ference 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 SDW01500
flows to the drain circuit to release the ab-
normal pressure.
SDWOlSOl
10456 WA1 200-3

SAFETY-SUCTION VALVE
1. Suction valve
2. Main valve
3. Piston
4. Piston spring
5. Poppet
6. Poppet spring
7. Suction valve spring
8. Sleeve
9. Adjustment screw
10. Locknut
9JYOO270
Set pressure: 36.8 MPa 1375 kg/cm21
FUNCTION
. If any impact is applied to the cylinder and
abnormally high pressure is generated, that
pressure is relieved through the safety-suc-
tion valve to protect the cylinder and other
hydraulic devices.
. If any negative pressure is generated in the
cylinder circuit, the safety-suction valve func-
tions as a suction valve.
Operation as safety valve

. Ports A and B are connected to the cylinder
circuit and drain circuit respectively. The oil
pressure in port A is led through the hole of
piston (3) into port C. Main valve (2) is in
contact with the left side since d2 < d3. The
diameters (sectional areas) are set as fol-
lows; d5 > d4 > dl > d3 > d2
\
D
SJYOOP 71
. If abnormal pressure in port A reaches the a

set pressure of spring (61, poppet (5) opens
to drain the oil from chamber C through
chamber D and periphery a of suction valve
(1).
I f\ \\\
I C 5 60
9JYOO272
WA1 200-3 1o-1 57

l If poppet (5) opens, the pressure in chamber

C lowers and piston (3) moves to the right.
Piston (3) touches the end of poppet (51,
then the oil is drained from chamber D
through throttle b.
9JYOO2
l Since the pressure in chamber C is lower

than that in port A, main valve (2) moves to
the right and the oil flows from port A to
port B to prevent generation of abnormal
pressure.
l Even if abnormal pressure is generated, suc-

tion valve (1) having a larger diameter does
not operate, since dl < d4.
12 ‘6
9JYOO274
Operation as suction valve

. If any negative pressure is generated in the
cylinder circuit, the pressure in port A be- A E .B
comes negative, too, since port A is con-
nected to chamber C. Since the tank pres-
sure in port B is applied to port E, the oil
pressure on suction valve (I) is increased by
the degrees corresponding to the area dif-
ference between d5 and dl. Then, spring (6)
is compressed to move suction valve (I) to
the right. Accordingly, the oil flows from port
B to port A to prevent generation of nega-
tive pressure in port A. 9JYOO275
lo-158 WA1 200-3

FLOAT SELECTOR VALVE AND UNLOAD

VALVE
FUNCTION
l The float selector valve and unload valve
are inside the work equipment valve. If the
boom lever is set to the FLOAT position, the
float selector valve operates. As a result, the
unload valve operates to set the boom to
the floating position.
OPERATION
1. LOWER position
. In the figure at right, the boom lever is set
to the LOWER position.
8
From steering
valve
2. FLOAT position
. If the boom lever is pushed further from the
LOWER position, it is set to the FLOAT posi-
tion.
Boom spool (I) of the work equipment valve
is kept under the same condition as at the
LOWER position.
Since oil pressure in port A becomes higher
than that at the LOWER position, float selec-
tor valve (2) moves to the right and the back
pressure on unload valve (3) is released.
Accordingly, unload valve (3) opens and the
boom is floated.
From steering
va I ve
WA1 200-3
3. FLOAT position (Riding over)

. If the machine moves back and the boom is
raised, the pressure on the cylinder rod side
becomes higher. At this time, the oil is
drained through port B and unload valve (3).
Since the cylinder bottom side is evacuated,
oil flows in this side from port C.
Pump
8
From steering
valve
FLOAT position (Lowered by weight)

If the machine moves back and the boom is
lowered by its weight, the pressure on the
cylinder bottom side becomes higher. At this
time, the oil is drained through port C.
Since the cylinder rod side is evacuated, oil
flows in this side from port B.
8
From steering
va I ve
10-160 WA1 200-3

BOOM AND BUCKET SPOOLS IN NEUTRAL POSITION
I n I4 k
OPERATION
l Oil flows through the steering valve and work l The oil from the PPC pump flows through
equipment pumps 1 and 2 to port A, then its check valve (13) to port L of the PPC valve.
maximum pressure is regulated by relief Since the boom and bucket levers are in the
valve (11). neutral position, however, the oil returns
l Since bucket spool (I) is in the neutral posi- through PPC relief valve (12) to the hydrau-
tion, the bypass circuit is open and the oil in lit tank.
port A flows through the periphery of the
spool to port B. Since boom spool (2) is also
in the neutral position, the bypass circuit is
open and the oil in port B flows through the
periphery of the spool to port C of the drain
circuit, then it returns through the filter in
the hydraulic tank.
WA1 200-3 10-161

BOOM SPOOL IN “RAISE”
Hydraul
tank
OPERATION
l When boom lever (3) is pulled, the oil flows and flows to the bypass circuit of boom
from port L of the PPC valve to port N and spool (2). The bypass circuit is closed by the
port S. In addition, the oil at port T passes spool, so the oil pushes open check valve
through port M and flows to the drain cir- (IO). The oil flows from port H to port I, and
cuit. The oil pressure at port S pushes boom flows to the cylinder bottom.
spool (2) and moves it to the RAISE posi- . At the same time, the oil at the cylinder rod
tion. end enters drain port C from port K and
l The oil from the steering valve passes returns to the tank. Therefore, the boom
through the bypass circuit of the bucket spool rises.
10-162 WA1 200-3

BOOM SPOOL IN “LOWER”
tank
- r,
L1,,,,,,,,,,,,.,,,,........ SXW,-,A7Fiq
OPERATION
l When boom lever (3) is pushed, the oil flows (2). The bypass circuit is closed by the spool,
from port L of the PPC valve to port M and so the oil pushes open check valve (IO). The
port T. In addition, the oil at port S flows to oil flows from port J to port K, and flows to
the drain circuit. the cylinder rod end.
The oil pressure at port T pushes boom spool l At the same time, the oil at the cylinder
(2) and moves it to the LOWER position. bottom enters drain port C from port I and
l The oil from the steering valve passes returns to the tank. Therefore, the boom goes
through the bypass circuit of the bucket spool down.
and flows to the bypass circuit of boom spool
WA1 200-3 10-163

BOOM SPOOL IN “FLOAT”
HYdrauI ic ii!&_ 1
tank
SXWO4760
OPERATION
l When boom lever (3) is pushed to the FLOAT opens port Cl and port C, and connects to
position, the PPC valve spool moves beyond the drain circuit. When port Cl is connected
the LOWER position to the FLOAT position. to the drain circuit, unload valve (8) moves
The pressure oil at port L flows to port M, up and the oil from the pump flows to the
and at the same time, it also flows to port T drain circuit.
and port W. In addition, the pressurized oil l Therefore, the oil at the cylinder rod end
at port S flows to port N. passes from port K through unload valve (8)
l The pressurized oil at port T pushes boom and flows to the drain circuit. The oil at the
spool (2) to the LOWER position. cylinder bottom flows from port I to port C,
. If a difference in pressure greater than the and then flows to the drain circuit. There-
specified pressure is generated at port W fore, the boom is set to the FLOAT condi-
and port X, valve (7) moves to the right, tion.
10-164 WA1 200-3

BUCKET SPOOL IN “DUMP”
OPERATION
l When bucket lever (4) is pushed, the pres- valve (IO). The oil from checkvalve (IO) flows
sure oil at port L of the PPC valve flows from port F to port G, and then flows to the
from port Q to port V. In addition, the oil at cylinder rod end.
port R flows to the drain circuit. The pres- At the same time, the oil at the cylinder
sure oil at port V moves bucket spool (1) to bottom flows from port D to drain port C,
the DUMP position. and returns to the tank, so the bucket is
l The bypass circuit is closed by bucket spool dumped.
(I), so the oil from port A pushes open check
WA1 200-3 10-165

BUCKET SPOOL IN “TILT BACK”
w PPC valve lx
SXW04762
OPERATION
l When bucket lever (4) is pulled, the pressure (I 1, so the oil from port A pushes open check
oil at port L of the PPC valve flows from port valve (IO). The oil from check valve (IO) flows
P to port R. In addition, the oil at port V from port E to port D, and then flows to the
flows to the drain circuit. The pressure oil at cylinder bottom.
port R moves bucket spool (I) to the TILT l At the same time, the oil at the cylinder rod
position. end flows from port G to drain port C, and
l The bypass circuit is closed by bucket spool returns to the tank, so the bucket is tilted.
lo-166 WA1 200-3

STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
;; I,
Ii Ii
;--..--____.__._.____,--
i~~_~___-,____.,_-il
1. Bucket 5. Boom
2. Bucket link 6. Boom cylinder
3. Bellcrank 7. Tooth with tip
4. Bucket cylinder 8. Sweeper wing
lo-168 WA1 200-3

STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
B-B
D-D E-E F-F
G-G H-H
SJWO4764
WA1 200-3 lo-169

STRUCTURE AND FUNCTION OPERATION OF PROXIMITY SWITCH
OPERATION OF PROXIMITY SWITCH

BUCKET TILT Proximity switch for
l When the bucket is dumped beyond the set bucket positioner
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.
SVW03369
Cam
Bucket lever
\ Solenoid
Detector Proximity switch
SEW02327
. Proximity switch for

When the bucket lever is moved to the TILT bucket positioner
position, the bucket spool is held at the TILT -To battery
relay
position by the cam follower and cam on
the lever, and the bucket tilts. I
II Positioner relay
SVW03369
Bucket lever

+PPC valve
SEW02326
10-170 WA1 200-3

STRUCTURE AND FUNCTION OPERATION OF PROXIMITY SWITCH
l When the bucket tilts and reaches the set

Proximity switch for
position for the bucket leveler, in other bucket positioner
-To battery
words, the sensor (steel plate) separates from relay
the detection surface of the proximity switch,
I
electric current is sent to the solenoid by the
action of the proximity switch and relay cir-
cuit.
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.
Cam
Bucket lever
SEW02329
Action of proximity switch
When sensor is in position When sensor is separated

Position at detection surface of from detection surface of
proximity switch proximity switch
Proximity switch
Lights up Goes out
actuation display
Positioner relay Current flows Current is shut off

I
Solenoid (for bucket) Current is shut off Current flows

I I
WA1 200-3 10-171

STRUCTURE AND FUNCTlON AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
SWWO4785
1. Air vent
2. Air vent
3. Condenser (right)
4. Dry reservoir
5. Compressor
6. Condenser (left)
7. Air conditioner Unit
1o-172 WA1 200-3

STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER CONDENSER
1. Electric wiring SWWO4786

2. Fan
3. Refrigerant gas inlet port
4. Refrigerant gas outlet port
AIR CONDITIONER COMPRESSOR
1. Refrigerant outlet port

2. Refrigerant inlet port
3. Relief valve
4. Clutch
Specifications
Type: Piston pump type
Refrigerant used: R134a
4707
WA1 200-3 10-173

STRUCTURE AND FUNCTION AIR CONDITIONER
DRY RESERVOIR
1. Body
2. Drier
3. Filter
10-174 WA1 200-3

STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
Main monitor CGC monitor
(ggq$&-q
VHMS
controller
Work equipment
piiKiJ&l QUANTUM
circuit
ttt
Sensors
sxwo4915
OUTLINE
l The machine monitor system monitors the l The main monitor has a function to send
machine condition by means of the sensors and receive signals through the network cir-
installed to various parts of the machine and cuit to display the following items.
displays the result immediately on the moni- @ Shift indicator: 1st - 3rd gear speeds, N,
tor panel to notify the operator of the machine F, R
condition. @ Remedy code, failure code, time after fail-
l The machine monitor system consists of a ure (failure history mode)
main monitor, CGC monitor, various sen- l The CGC monitor consists of a display and
sors, switches, relays, an alarm buzzer, and touch switches. The monitor screen to dis-
a power supply unit. play the gauges, maintenance screen, fuel
. The displayed items are roughly classified consumption screen, positioner screen, load
into two groups; The items in one group are meter screen, etc. can be selected on the
various caution items displayed on the moni- display. If any trouble occurs, the CGC moni-
tor when any trouble occurs in the machine, tor receives signals from the VHMS control-
and those in the other group are the ma- ler and displays the warning screen.
chine conditions which are displayed con- . The VHMS controller monitors the data of
stantly by the gauges, speedometer, service the machine condition and maintenance con-
meter, pilot lamps, etc. dition, and saves them in itself.
l There are various switches inside the moni-
tor panel which are used to control the ma-
chine.
WA 1200-3 10-175
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
System configuration
I INPUT
I
1
Alternator R terminal voltage
D
Small lamp ON voltage
A
Boom cylinder bottom pressure
D
Boom proximity sensor
D
Sub total switch
D
Cancel switch
A
PPC relief pressure
Torque converter inlet oil pressure
A
Torque converter outlet oil pressure
Transmission main relief pressure
Transmission lubricating oil pressure
A
Transmission modulation oil pressure
A
Steering relief pressure
A
Work equipment relief pressure
Boom cylinder head pressure
OUTPUT
P: Pulse signal
A: Analog signal
D: ON-OFF signal
10476 WA1 200-3

STRUCTURE AND FUNCTION MAIN MONITOR
MAIN MONITOR
5C
5D
SE
4F 4E
SWWO4789
1. Check lamp OUTLINE

2. Caution lamp l The main monitor has functions to display
3. Caution item travel speed, etc. and switch functions to con-
3A. Operation of emergency steering system trol electrical equipment, controllers, etc.
4. Pilot items l The main monitor has one CPU (Central
4A.Turn signal lamp (Left) Processing Unit) in itself to process, display,
4B. Turn signal lamp (Right) and output the signals from the sensors, etc.
4C. Shift indicator . The main monitor uses LCD and LED to dis-
4D. Tachometer/Speedometer play various items. The switches are em-
4E. Parking brake bossed (convex) sheet switches.
4F. Remedy code
5. Switches
5A. Auto grease switch
5B. Tire slip control ON/OFF switch
5C. Working lamp (Front) switch
5D. Working lamp (Rear) switch
5E. Transmission cut-off switch
WA1 200-3 1o-177

DISPLAY FUNCTION OF MAIN MONITOR
Division
Symbol Indicated item Display range Display method
of display
When maintenance Flashing of displayed items

Check
0
CHECK Check monitor trouble is
displayed
(For details, see display functions
of maintenance monitor)
Operation of
emergency steeringI When system operates Flashing of displayed items
system
When parking brake is

applied while shift Flashing of displayed items and
lever is not in N sounding of buzzer
Caution
0
CAUTION Caution
When maintenance
Flashing of displayed items
(Buzzer may sound)
monitor trouble is (For details, see display functions
displayed of maintenance monitor)
Turn signal lamps

3 D When lamp is turned on Lighting of pilot lamp
(Right, Left)
Pilot Lighting of pilot lamp
c
$w p
Parking brake
When parking brake is
applied
If parking brake is applied while
shift lever is not in N, buzzer
sounds.
Tachometer/ x 100 rpm

Travel speed 0 - 99 km/h Digital display (Selection of
Speedo-
MPH tachometer/speedometer)
meter
Shift Digital display

Shift indicator l-3,N
indicator
If controller detects
failure and operator Digital display
Remedy must, take remedy, Sounding of buzzer
code Remedy code CALL is displayed, (For failure history mode, see
or CALL and E 0 0 failure history mode)
(Remedy code) are
displayed alternately.
Forward/Reverse
Shift (When joystick
LF/R dilrllr F, R Digital display
indicator steering system is
SDW02342
installed)
lo-178 WA1 200-3

STFWCTUREAND FUNCTION MAIN MONITOR
SWITCH FUNCTIONS OF MAIN MONITOR
Item Function Display Operation
When pilot lamp lights up,

Auto grease grease is supplied forcibly only
while switch is pressed. Auto grease controller has
Flashing (Quick)
trouble.
Auto grease controller is not

OFF
installed.
Tire slip control function is

ON
Tire slip control function is turned on
Tire slip control turned on and off each time
switch is pressed. Tire slip control function is
OFF
turned off.
While small lamp lights up, rear

Working lamps working lamp is turned on and
(Front) off each time switch is pressed.
head lamp, lamp in front of axle)
While small lamp lights up, ON Rear working lamp lights up.
Working lamp front working lamps are turned
(Rear) on and off each time switch is
pressed. OFF Rear working lamp goes off
Transmission cut-off function is ON Cut-off function is turned on.

Transmission
turned on and off each time
cut-off
switch is pressed.
OFF Cut-off function is turned off.
WA1 200-3 10-179

TROUBLE DATA DISPLAY MODE
Item Switch operation Actuation
Method of switching to With engine stopped and starting All switch displays (LEDs) go out, and
trouble data display switch turned ON, press 2nd switch failure code is displayed on speedometer
mode from top on left side of main display and time elapsed since failure is
monitor (switch below emergency displayed on failure action code display.
steering display) and working lamp (I) Failure code is a two-digit display
(front) switch simultaneously given in numbers or letters.
for at least 5 seconds. The display for the failure now
occurring flashes and the display for
past failures lights up.
If there is no failure, CC is displayed
(000 is displayed for time elapsed
since failure)
(2) The time elapsed since failure is
displayed as a three-digit number
to show how long ago the failure
occurred (the oldest failure time is
displayed. Any time greater than
999H is displayed as 999H).
(3) A maximum of 9 items are stored
in memory for the failure code.
Method of sending Press working lamp (front) switch Failure code and time elapsed since
failure code failure change to next item.
SDW01254
swwo479 1
Clearing failure code Press working lamp (rear) switch Failure code and time elapsed since
for at least 2 seconds failure being displayed are cleared.
Failure code for problem now occurring
(flashing display) cannot be cleared.
Resetting from travel Press 2nd switch from top on left Changes to normal display
data display mode side of main monitor (switch below
emergency steering display) and
working lamp (front) switch
simultaneously for at least
5 seconds, or start the engine.
lo-180 WA1 200-3

STRUCTURE AND FUNCTION CGC MONITOR
CGC MONITOR
X monitor
for user
After few second
MONITOR
I
Action of switch
I I 1~ I I
-
MAINTE- DATE/UNIT CALIB-
CCINSUMPT POSITIONER '"";;;""
NANCE SET - RATION
1
c
PRODUCT LOADMETER LOADTOTAL
HISTORY SUB . l
1 1
for SERVICE
SERVICE MENU SELECT

Action of switch
I
I I I I I I I
REAL MAINTE- SERIAL ID INPUT

FAILURE NO. SNAP-
TIME NANCE
HISTORY CL';:,, SET SHOT
MONITOR SET&DEF
MACHINE
SXWO4916
Outline
l On the CGC monitor, the monitor screen to . In addition to the screen for operator which
display gauges, maintenance screen, setting is normally displayed, the screen for serv-
screen, fuel consumption screen, etc. can be iceman is available to check and set the ma-
selected with the buttons on the screens chine data and clear the saved data. (A spe-
(touch switches). cial ID is required to open the screen for
. If any trouble occurs in the machine, the serviceman).
warning screen appears automatically.
WA1 200-3 lo-181

Monitor screen
1. Engine water temperature gauge

4 I 2. Torque converter oil temperature gauge
3. Fuel gauge
4. Clock
5 2 5. Tachometer
6. Brightness adjustment pop-up button
7. Maintenance screen button
II 3 8. Setting screen button
9. Fuel consumption screen button
IO. Positioner screen button
sxwo4195 11. Load meter screen button
After the initial screen disappears, the monitor screen appears automatically. This screen is composed
of the following gauges and buttons (touch switches).
l Engine water temperature gauge: The display range is 60 - 108°C. The red range is above
102°C. If the pointer enters the red range, its color changes
from green to red.
l Torque converter temperature gauge: The display range is 27 - 140°C. The red range is above
130°C. If the pointer enters the red range, its color changes
from green to red.
. Fuel gauge: The display range is 555 - 3700 e. The yellow range is
below 1250 e. If the pointer enters the yellow range, its
color changes from green to yellow.
l Clock: This clock indicates the present time. For setting method of
this clock, see the setting screen.
l Tachometer: This meter indicates the engine speed digitally.
. Brightness adjustment pop-up

button: This button is used to select the brightness and contrast
adjustment pop-up screen.
Brightness button: Used to adjust bright-
ness.
Contrast button: Used to adjust con-
trast.
EXIT button: Used to turn off the
pop-up screen and
display the monitor
screen.
10482 WA1 200-3

. Maintenance screen button: This button is used to select the maintenance screen. See the
maintenance screen. The color of this button changes to dis-
play the maintenance condition.
Yellow: One or more parts need to be maintained in 30 hours.

Red: One or more parts have passed the maintenance time.
. Setting screen button: This button is used to select the setting screen.
. Fuel consumption screen button: This button is used to select the fuel consumption screen.
. Positioner screen button: This button is used to select the positioner screen.
. Load meter screen button: This button is used to select the load meter screen.
WA1 200-3 1O-l 83

Maintenance screen
1. Display of maintenance items

(Maintenance item selector buttons)
2. Display of time before periodic maintenance
3. Page button
4. Monitor screen button
sxwo4797
If the maintenance screen button is pressed on the monitor screen, the maintenance screen appears.
. Display of maintenance items: Maintenance items are displayed.

The buttons to select maintenance items are formed
in this area. The color of each button changes to
display the maintenance condition.
YeIlow:The time before periodic maintenance is
shorter than 30 hours.
Red: The displayed part has passed the main-
tenance time (The time before periodic
maintenance is negative).
. Display of time before periodic maintenance: The time before the next periodic maintenance is
displayed. If the displayed part has passed the
planned maintenance time, a negative value is dis-
played.
. Page button: This button is used to turn over the displayed page.
. Monitor screen button: This button is used to select the monitor screen.
. Maintenance item selector button: If this button (one of displayed maintenance items)
is pressed, it flashes. If it is pressed again, the fol-
lowing pop-up screen appears. When maintenance
is executed, set the time before the next periodic
maintenance to the initial value on this screen.
YES button: Press this button if maintenance
has been executed, and the time MAINTENANCE MONITOR 250/500h
before the periodic maintenance

Really reset Transmission Oil Filter?
is set to the initial value.
NO button: Press this button if maintenance
has not been executed, and the
time before the periodic main-
tenance is kept as it is.
If the YES or NO button is pressed, the pop-

up screen disappears and the maintenance
sxw04790
screen appears.
lo-184 WA1 200-3

Maintenance items list
No. Interval Item
1 250H Change Corrosion Resistor
2 I 250H Change Fuel Filter
3 250H Change Engine Oil Filter
4 250H Change Engine Oil
5 250H Change Transmission Oil Filter
6 I 250H 1 Change Brake Oil Filter
7 1OOOH Change Transmission Oil
8 1OOOH Clean Transmission Breather
9 IOOOH Clean Transmission Strainer
10 I 1OOOH Change By-pass Engine Oil Filter
11 I 2000H Change Brake Oil
12 2000H Change Brake Oil Tank Breather
13 2000H Change Hyd. Tank Breather Element
14 2000H Clean Hyd. Tank Strainer
15 2000H Change Brake Line Strainer
16 I 2000H Clean Pilot Line Strainer
17 2000H Change Axle Oil
18 2000H Change Linkage Pin Lube Oil
19 2000H Change Hyd. Oil Filter
20 2000H Change Hyd. Oil
WA1 200-3 lo-185

Setting screen
I
5
2 1. DATE button
2. TIME button
3 3. UNIT button
4. USER ID button
4 5. SET button
6
sxwo4799
If the setting screen button on the monitor screen is pressed, the setting screen appears. Set the
present date and time, unit of the displayed data, and user ID on this screen.
. DATE button: Press this button to set the

present year, month, and day.
If this button is pressed, the pop-up
screen to select the year, month, or day
appears.
If the year, month, or day is selected
(pressed), the data inputting screen ap-
pears.
SXWO4800
SXWO4801
10-186 WA1 200-3

l TIME button: This button is used to set the

hour and minute.
screen to select the hour or minute ap-
pears.
If the hour or minute is selected (pressed),

the data inputting screen appears.
TIME SETTING
Exit
SXWO4803
. UNIT button: This button is used to set the

unit of the displayed data.
screen to select the unit appears.
The unit of METRIC, ENGLISH, or SI can
be selected.
. USER ID button: This button is used to set

the user ID No.
screen to input the user ID No. appears.
As the user ID No., any one of l-digit -
IO-digit values can be input.
Exit
WA1 200-3 1O-l 87

l SET button: If this button is pressed, the input date, time, unit, and user ID are saved.
If this button is not pressed, the input data are not saved, and the present
data not updated.
10-l 88 WA1 200-3

Fuel consumption screen
I
1. Display of data measurement period
2. Display of productivity in Ton/Hour
3. Fuel consumption ratio in Liter/Hour
4. Display of kind of material
2 5. Productivity history screen button
6’ \5 \
4
\
3
SXWO4806
If the fuel consumption screen button on the monitor screen is pressed, the fuel consumption
screen appears.
The fuel consumption is calculated from the data recorded on the load meter screen, then the data
measurement period, productivity in Ton/Hour, and fuel consumption ratio in Liter/Hour are dis-
played.
The displayed data are based on the kind or material (KIND) selected on the load meter screen. The
unit set on the setting screen is used for the displayed data.
. Productivity history screen button: This button is used to select the productivity history screen.
WA1 200-3 lo-189

Productivity history screen
1. Display of kind of load (Memory clear button)

2. Display of fuel consumption ratio
3. Display of productivity
4. Display of date when memory is cleared
5. Fuel consumption screen button
If the productivity history screen button on the productivity screen is pressed, the productivity history
screen appears.
The fuel consumption ratio in Liter/Hour and productivity data in Ton/Hour for each kind of load (KIND)
are calculated from the data recorded on the load meter screen, then displayed.
The unit set on the setting screen is used for the displayed data.
l Memory clear button: This button is used to clear the data of the selected kind of load (KIND).
screen to ask if your are really clearing
the data of the selected kind of load
(KIND) appears.
YES button: Press this button if you wish

to clear the data.
NO button: Press this button if you do
not wish to clear the data.
If the YES or NO button is pressed, the

sxw04808
pop-up screen disappears, and the pro-
ductivity history screen appears.
. Fuel consumption screen button: This button is used to select the fuel consumption screen.
10-190 WA1 200-3

Positioner screen
1. UPPER STOP selector button

2. UPPER STOP POSITION setting button
3. LOWER STOP selector button
4. LOWER STOP POSITION setting button
SXWO4809
If the positioner screen button on the monitor screen is pressed, the positioner screen appears.
This screen is used to set ON/OFF and stopping positions of the remote positioner function. (The set
condition is saved even if the starting switch is turned off.)
. UPPER STOP selector button: Each time this button is pressed, it lights up (green) and
goes off alternately. While this switch is lighting up, the
upper stopping function is effective.
. UPPER STOP POSITION setting button: After setting the upper stopping position according to the
given procedure, press this button to save the set data.
. LOWER STOP selector button: Each time this button is pressed, it lights up (green) and
goes off alternately. While this switch is lighting up, the
lower stopping function is effective.
. LOWER STOP POSITION setting button:After setting the lower stopping position according to the
given procedure, press this button to save the set data.
WA1 200-3 10-191

Load meter screen (integration mode)
1 1. Display of kind of load

2. Display of integrated load
3. Display of bucket load
4
6 4. Kind of load selector button
5. Subtraction mode button
2
6. Calibration screen button
3 7. Total load screen button
9. Gauge display button
SXWO4810
If the load meter screen button on the monitor screen is pressed, the load meter screen appears.
The load is measured each time, and the bucket load and integrated load are displayed.
The integrated load is added up and displayed for each of the seven kinds of load (KIND).
. Kind of load selector button: This button is used to select the kind of load (KIND).
If this button is pressed, the pop-up screen to select the kind of load
(KIND) appears. Select one of seven kinds A - G.
. Subtraction mode button: This button is used to select the load meter screen (subtraction mode).
10492 WA1 200-3

l Calibration screen button:This button is used to select the calibration screen.

l Total load screen button: This button is used to select the total load screen.
l Gauge display button: This button is used to display the gauges on the right side of the screen.
If this button is pressed, the engine water temperature gauge, torque
converter oil temperature gauge, and fuel gauge are displayed. If it is
pressed again, the displayed gauges disappear.
WA1 200-3 10493

Load meter screen (Subtraction mode)
I 1. Display of kind of load

2. Display of remaining load
4 3. Display of bucket load
7 4. Kind of load selector button
5 5. Subtraction standard value setting button
3 6. Integration mode button
2 7. Calibration screen button
8. Total load screen button
9 6 9 IO 10. Gauge display button
SXWO4813
If the subtraction mode button on the load meter screen (Integration mode) is pressed, this screen
appears.
The load measured each time is subtracted from the subtraction standard value which is set in
advance, and the bucket load and the remaining load are displayed.
. Kind of load selector button: This button is used to select the kind of load (KIND).
If this button is pressed, the pop-up screen to select the kind of load
(KIND) appears. Select one of seven kinds A - G.
10-194 WA1 200-3

l Subtraction standard value setting button: This button is used to set the subtraction standard
value.
If this button is pressed, the screen to input the sub-
traction standard value appears.
rminino data
SXWO4815
. Integration mode button: This button is used to select the load meter screen (Integration mode).
l Calibration screen but-ton:This button is used to select the calibration screen.
l Total load screen button: This button is used to select the total load screen.
. Gauge display button: This button is used to display the gauges on the right side of the screen.
If this button is pressed, the engine water temperature gauge, torque
converter oil temperature gauge, and fuel gauge are displayed. If it is
pressed again, the displayed gauges disappear.
SXWO4816
WA1 200-3 10-195

Calibration screen
2
CALIBRATION I/cw
1. Display of calibration method
2. Engine water temperature gauge
3. Torque converter oil temperature gauge
4. Fuel gauge
5. Load meter screen button
buctet at carrl mition.
2. Raise t
If the calibration screen button on the load meter screen in the integration mode or subtraction mode
is pressed, the calibration screen appears.
Operate the machine according to the displayed procedure for calibration, and the load meter is
calibrated automatically.
. Load meter screen button: This button is used to select the load meter screen again.
(For the engine water temperature gauge, torque converter oil temperature gauge, and fuel gauge, see
the monitor screen.)
10-196 WA1 200-3

Total load screen
1. Display of kind of load (Data clear button)

2. Display of number of loading times
3. Display of load
4. Display of date where data are cleared
5. Load meter screen button
GO BACK1
SXWO4818
If the total load screen button on the load meter screen in the integration mode or subtraction mode
is pressed, the total load screen appears.
On this screen, the total number of loading times, load, and date when the data are cleared are
displayed for each kind of load (KIND).
The unit set on the setting screen is used for the displayed data.
l Data clear button: This button is used to clear the data of each kind of load (KIND) or the data of
the total load.
If the display area of a kind of load (KIND) is
pressed, the pop-up screen to clear the data
appears.
YES button: Press this button if you wish to

clear the data and update the
display of the date when the
data are cleared.
NO button: Press this button if you do not
wish to clear the data.
. Load meter screen button: This button is used to select the load meter screen in the integration
mode or subtraction mode.
WA1 200-3 10-197

Warning screen
1. Display of warning item

neine oil level trouble 2. Display of warning message
3. Display of error code
Check oil level in themine
oil PM and additional oil.
4. Display of warning page
5. Cancel switch
camel
Error code :E 901 l/6
f \
5 3 4 swwo4820
If any trouble occurs, the CGC monitor displays the warning screen automatically, then displays the
screen used currently and the warning screen alternately.
l Display of warning item: Each warning item is displayed in yellow or red, depending on its type.
. Display of warning page: The position of the currently detected trouble is displayed.
(Example: l/5 means the first of five troubles.)
l Cancel switch: If the cancel switch is displayed on a warning screen, this screen can be
put out temporarily by pressing the cancel switch. (A warning screen
which does not have the cancel switch on it cannot be put out.)
If the trouble displayed on the warning screen is not repaired, it is
detected again and displayed on the warning screen when the starting
switch is turned on next time.
lo-198 WA1 200-3

Warning items list
Below 14.7 MPa
22 Engine trouble (3) Abnormal Yellow --- --- --- Displayed COO3
23 Engine trouble (4) Abnormal Red ___ ___ ___ Displayed COO2
24 Engine trouble (5) Abnormal Red ___ ___ ___ Displayed COO4
WA1 200-3 10-199

Service ID inputting screen
I---
&/2
1 DATE SETTING
1. Service ID inputting screen button (Upper)

2. Service ID inputting screen button (Lower)
SWWO4821
The service ID inputting screen buttons are hidden at the right bottom and right top of the setting
screen (They are not displayed on the screen).
Press the lower button, then press the upper button, and the following service ID inputting screen
appears.
I Please Input Service ID
B
1 231
,I
4 5 6
.”
Please Input Service ID
7 a 9 1. Display of message
2. Operator display screen button
0 clear enter
SWWO4822
Input the correct service ID through the keys and press the enter key, and the screen for serviceman
appears. If a wrong service ID is input, the message changes to “Please input the correct ID”.
l Operator display screen button: If this button is pressed, the serviceman display screen does not
appear, but the operator display screen appears again.
1o-zoo WA1 200-3

Service menu selection screen
I 2 1. Real-time monitor screen button

2. Maintenance time setting screen button
4 3 3. Failure history screen button
4. PM clinic screen button
5. Machine serial No. setting screen button
5
6. Snapshot operation screen button
7. Memory clear ID inputting screen button
7 6 8. Operator display screen button
SWWO4823
If the correct ID is input on the service ID inputting screen, the service menu selection screen appears.
If each screen button on this screen is pressed, the selected screen appears.
If the operator display screen button is pressed, the operator display screen appears.
WA1 200-3 10-201

Real-time monitor screen
2
SERVICE MENU SELECT
1. Engine system display button
pzzz7-j 2. Transmission system display button
I\ 3 3. Load meter system display button
Engine Transnission 4. Modulated clutch system display button
5. Remote positioner system display button
HOD/C Positioner AJSS
rAd \s 6. Joystick steering system display button

7. Service menu selection screen button
s WENU
I
7' 5 SWW04824
If the real-time monitor screen button on the service menu selection screen is pressed, the real-time
monitor screen appears.
On this screen, select the data of a desired controller.
If a display button is pressed, the data of the selected system are displayed.
If the service menu selection screen button is pressed, the service menu selection screen appears
again.
On the data display screen, the information of REAL TIME MONITOR(l/61

the selected controller is displayed in real time.
T/M CUTOFF SIGNAL m
Select the page to be displayed with the arrow
TRACTION CONT SIGNAL m V
keys.
SPEED CONT SIGNAL 1 V
If the MENU key is pressed, the real-time moni-
VEHICLE SPEED i Km/h
tor screen (for selection of a system) appears
SETTING VEHICLE SPEED m Km/h
again.
MENU A 7
SWW04825
1O-202 WA1 200-3

Real-time monitor display items
Engine
DISPLAYED
ON/OFF: LOGIC
PAGE
I I I I I
l/l 1 ENGINE SPEED 1 2s 1 1 rpm 1 VHMS 1 -
l/l 1 COOLANT TEMP. 1 2s 1 1°C 1 CENSE 1 - I
l/l 1 ENGINE OIL TEMP. 1 2s 1 1°C 1 CENSE 1 -

I
I O.OlMPa ’ CENSE ’ -
l/l FUEL RAIL PRESSURE 2s IO.1 kg/cm21
l/l ENGINE OIL LEVEL 2s (ON/OFF) CENSE k;g$__;; NG
Transmission
WA1 200-3 1 O-203

Load meter
DISPLAYED
NAME OF SIGNAL l”A-/;NGi UNIT l;;$E&E; 1 ON/OFF: LOGIC
PAGE
I
l/l 1 BOOM BOlTOM PRESSURE1 2s 1tn”f;::z, 1 VHMS -
O.OlMPa
VI MEASURED PRESSURE 2s {O.lkg/cm*}
VHMS I - 1
l/l CAL. PRESSURE 2s
O.OlMPa
{O.lkg/cmZ} VHMS I - I
l/l NO LOAD PRESSURE 2s -
l/l MEASURED LOAD 2s 1 TON VHMS -
Modulated clutch
I
DISPLAYED
PAGE
I NAME OF SIGNAL UNIT ON/OFF: LOGIC
TIRE SLIP SIGNAL ontrolled.

ach time switch is pressed)
ENGINE SPEED 2s 1 rpm VHMS -

ACCELERATOR SIGNAL 2s 0.1 v MOD -
CONTROLLEROUTPUT SIGNAL 2s 0.1 v MOD 0.1 V (Commandvalue of electronicgovernor)
LO IDLE SW SIGNAL 2s (ON/OFF) MOD Switch ON: ON (GND)
Switch OFF: OFF (OPEN)
1 O-204 WA1 200-3

Remote positioner
ON/OFF: LOGIC
Joystick steering
DISPLAYED
NAME OF SIGNAL lsA;;;NG~ UNIT I;;;;;;;,) ON/OFF: LOGIC
PAGE
112 J/S ON/OFF SIGNAL 2s (ON/OFF) J/S -
112 S/T NEUTRAL SW 2s (ON/OFF) J/S -
112 S/T LEVER POTENT10 2s 0.1 v J/S -
II2 ARTICULATE ANG. 2s 0.1 v J/S -
WA1 200-3 1O-205

Maintenance time setting screen
1. Display of maintenance items

(Maintenance item selector button)
2. Display of time before periodic maintenance
3. Display of maintenance period
(Maintenance period setting button)
4. Page button
If the maintenance time setting screen button on the service menu selection screen is pressed, this
screen appears.
l Display of maintenance items: The maintenance items are displayed.
The buttons to select maintenance items are formed
in this area.
The color of each button changes to display the
maintenance condition.
Yellow:The time before periodic maintenance is
shorter than 30 hours.
Red: The displayed part has passed the main-
tenance time (The time before periodic
maintenance is negative).
. Display of time before periodic maintenance: The time before the next periodic maintenance is
displayed. If the displayed part has passed the
planned maintenance time, a negative value is dis-
played.
. Display of maintenance period: The maintenance period set for each maintenance
item is displayed.
The buttons to set the maintenance period are
formed in this area.
l Service menu selection screen button: This button is used to select the service menu se-
lection screen.
. Maintenance item selector button: If this button is pressed, it flashes. If it is pressed
again, a pop-up screen appears, and the time be-
fore periodic maintenance is displayed again. (This
function is the same with the maintenance screen.)
1O-206 WA1 200-3

. Maintenance period setting button: If this button is pressed, the screen to set the maintenance
period appears.
If a new maintenance period is input and the enter button is
pressed, the maintenance period is updated.
Then, the time before the next periodic maintenance is calcu-
lated again on the basis of the new maintenance period.
Note) The input maintenance period must be shorter than the
set period. The set maintenance period cannot be length-
ened.
For the maintenance items and maintenance period, see the
maintenance screen.
MAINTENANCE MONITOR SET
Chance fuel filter
SWWO4827
WA1 200-3 1 O-207

Failure history screen
I
1. Display of number of detected failures
4A 2. Display of history No.
(History un-display button)
3. Display of error code
40
4. Display of failure occurrence time
4A. Time when detection was started
48. Time when detection was finished
5. Display item UP/DOWN button
6. Page button
6 5 6 SWWO4828
If the failure history screen button on the service menu selection screen is pressed, this screen
appears.
On this screen, the failures are displayed in the order of the time from the newest one.
If a trouble has not been repaired, the “time when detection was finished” is not displayed for that
trouble.
. History un-display button: If this button is pressed, the corresponding history is not
displayed. Once a history is set un-displayed, it cannot be
displayed on the CGC monitor any more. (The memory of
the VHMS controller is kept, however.)
If a history is set un-displayed, it is not counted in the
detected failures. (If one history is set un-displayed, the
number of the detected failures is reduced by one.)
. Display item UP/DOWN button: This button is used to move the displayed items up or
down one by one.
l Service menu selection screen button:This button is used to select the service menu selection
screen.
1 O-208 WA1 200-3

PM clinic screen
PM CLINIC MENU(1/4)- 2
I\_
-ENGINE SPEED 1. Display of items
COOLANT TEHP 1 dSl c -3 2. Display of page
T/C TEMP 1 dso C 3. Display of data
AMBIENT AIR TEHP 1 de0 C 4. Page button
BLOW-BY PRESSURE 151 lAu 5. Service menu selection screen button
ENGINE DIL PRESSURE 1 to/cm?
If the PM clinic screen button on the service menu selection screen is pressed, this screen appears.
On this screen, the data necessary to the PM clinic are displayed.
l Service menu selection screen button:This button is used to select the service menu selection
screen.
PM clinic items
WA1 200-3 1O-209

Machine serial No. setting screen
SERIAL NO.SETTING (MACHINE)

1. Machine model button
' WADHINE MODEL I[ 2. Variation code button
3. Type button
2w1tVariation Code
‘I 4. Machine serial No. button
Type 1 5. Component serial No. setting screen button
3J
, SERIAL No. 101
MENU COMPO
1 .
SWWO4830
If the machine serial No. setting screen button on the service menu selection screen is pressed, this
screen appears.
This screen is used to display and set the machine model, variation code, and serial No.
. Machine model, variation code, and type I SERIAL NO.SETTING (MACHINE)

buttons:
If these buttons are pressed, the pop-up
screen to set the machine model, varia-
tion code, or type appears.
Select proper ones displayed on the pop-
up screen.
. Machine serial No. button:

Serial No. SETTING
If this button is pressed, the serial No.
inputting screen appears. Pleae input Serial No.
If the serial No. is input and the enter
button is pressed, it is set and the ma-
chine serial No. setting screen appears
again.
If the Exit button is pressed, the machine
serial No. setting screen appears with-
out setting the input serial No.
As the serial No., a number up to 10 SWWO4832
digits can be input.
l Component serial No. setting screen button:

If this button is pressed, the component
serial No. setting screen appears.
l Service menu selection screen button:

This button is used to select the service
menu selection screen.
10-210 WA1 200-3

Component serial No. setting screen
SERIAL NO.SETTING (COMPONENTI
’ ENGINE MODEL I] 1. Engine model button

2. Engine serial No. button
2-q #I S/N
I 3. Transmission serial No. button
yjT/M SERIAL No. 101 4. Spare serial No. button
5. Machine serial No. setting screen button
I -0 6. Service menu selection screen button
/
MENU MACHINE
6 5 swwo4s33
If the component serial No. setting screen button on the machine serial No. setting screen is pressed,
this screen appears.
This screen is used to display and set the engine model and component serial No.
. Engine model button:

If this button is pressed, a pop-up screen sERiAL N~.SETTING (COMPONENT)
appears. Select proper ones displayed

on the pop-up screen.
. Engine serial No. button, transmission serial Serial No.SETTlNG

No. button, and spare serial No. button:
If these buttons are pressed, the serial Pleaeinputs1 S/N
No. inputting screen appears.
If the serial No. is input and the enter
button is pressed, it is set and the com-
ponent serial No. setting screen appears
again.
If the Exit button is pressed, the compo- 1Exit1
nent serial No. setting screen appears
without setting the input serial No. swwo4s35
As the serial No., a number up to 10

digits can be input.
. Machine serial No. setting screen button:

If this button is pressed, the machine
serial No. setting screen appears.
l Service menu selection screen button:

This button is used to select the service
menu selection screen.
WA1 200-3 10-211

Snapshot operation screen
1. Snapshot start button

2. Snapshot cancel button
3. Display of message
SWWO4836
If the snapshot operation screen button on the service menu selection screen is pressed, this screen
appears.
This screen is used to take in the snapshot data and save them manually.
(Normally, the snapshot data are taken in automatically by using an error as the trigger. See “Snap-
shot items”.)
l Snapshot start button:

If this button is pressed, the system gets
ready to take in the data.
If YES in the message area is pressed,

the snapshot data are taken in.
SWW04837
If take-in operation of the snapshot has SNAPSHOT TRIGGER

been started automatically, however, the
snapshot start button and cancel button
are not displayed. In this case, the data
cannot be taken in manually until the
automatic take-in operation is completed. /NIIIII:IIIYIII_I:
1
MENU
SWW04838
10-212 WA1 200-3

While the data are being taken in, the SNAPSHOT TRIGGER
snapshot start button is not displayed
and the message of “Executing . . .” is [Y&F-] ’
displayed.
If the snapshot cancel button is pressed,
the data take-in operation is canceled. 71
(In this case, the data taken in are not
effective.)
MENU
SWWO4839
If the data take-in operation is completed,

SNAPSHOT TRIGGER
the snapshot start button is displayed I
again and the message of “Snapshot fin-
ished” is displayed.
SWWO4840
l Snapshot cancel button: This button is used to cancel the data take-in operation.
The data that have been taken in so far are not effective
and not saved.
l Service menu selection screen button: This button is used to select the service menu selection
screen.
WA1 200-3 10-213

Snapshot items
If an error is made, the data in set time before and after that error (5 minutes 30 seconds before the
error and 2 minutes after the error) are saved.
The cause of the error can be found out easily by checking the data of the sensors concerned to the
error.
1) This system can be applied to an error which cannot be reproduced.
2) Troubleshooting can be executed by collecting the data freely with the manual trigger func-
tion.
Sampling period of data
Every 10 seconds in the period from 5 minutes 30 seconds to 30 seconds before the error
Every 1 second in the period from 30 seconds before the error to 2 minutes after the error
Items concerned to
Items concerned Items concerned Items concerned to
transmission/torque
to engine to modulated clutch hydraulic equipment
converter
Engine overrun Modulated clutch Double engagement High hydraulic oil

trouble of transmission clutch temperature
Abnormal blow-by Abnormal engine High torque converter

pressure rotation oil temperature
Trigger item
Abnormal exhaust
temperature
Overheatina of enaine
Manual trig !r (manually)
Engine rpm Slip ratio of Transmission fill Hydraulic oil

modulated clutch switch signal temperature
Blow-by pressure Modulated clutch Transmission ECMV

outlet rpm command value
Exhaust temperature Modulated clutch Torque converter
ECMV command value oil temperature
Saved data Engine oil temperature Modulated clutch Transmission filter

fill switch signal clogging signal
Engine water temperaturNe Accelerator pedal voltage
Fuel rail pressure Low idle switch signal

Atmospheric Electronic governor
temperature command voltage
(Number of saved errors: 9 errors max. 1 of them can be saved manually.)
Criteria (Threshold values) of trigger items
Trigner item Criterion
Engine overrun Engine rpm > 2200 rpm
Abnormal blow-by pressure 1 Blow-by pressure> 500 mmAq
1 Abnormal exhaust temoerature 1 Exhaust temperature > 800°C

Engine oil temperature > 120°C
Engine water temperature > 102°C
Different by 300 rpm or more from electronic governor command
Abnormal engine rpm
value (voltage). I
Slop ratio is different by 10% or more from clutch direct coupling
Abnormal modulated clutch I I
command current.
Double engagement of transmission clutch 1 Two or more fill switch signals are turned on simultaneously.
High torque converter oil temperature Torque converter oil temperature > 120°C
High hydraulic oil temperature Hydraulic oil temperature > 105°C
Manual triaaer As per switch input (start direction) signal of CGC.
lo-214 WA1 200-3

Memory clear ID inputting screen
I Please Input Wenorv Clear IO
2, 1
‘*L 4
231
5 6 II ,I 1. Display of message
Please Input Memory 2. ID inputting button
1 8 9 Clear ID
0 clear enter
MENU
SWWO484 1
If the memory clear screen button on the service menu selection screen is pressed, this screen
appears.
The memory clear screen appears only when the person of the input ID is proved to be qualified for
clearing the memory.
Input the memory clear ID with the ID inputting button, then press the enter button.
If a wrong ID is input, the message changes to “Please input the correct ID”.
If the correct ID is input, the memory clear screen appears.

If the service menu selection screen button is pressed, the service menu selection screen appears
again.
WA1 200-3 10-215

Memory clear screen
MEMORY CLEAR 1. Display of message

2A\ ID
“-Failure Hislorr Data Maintenance Data ‘l 2. Memory clear buttons
I- Trend Data Load Wau Data ,- 2A. Failure history data
2E
20/’ 28. Trend data
, Snap Shot Data
2C. Snapshot data
Select buttons.
2c .h
2D. Maintenance data
2E. Load map data
‘1
f’ MENU
3
SWWO4842
If the correct ID is input on the memory clear ID inputting screen, this screen appears.
This screen is used to clear various saved data.
MEMORY CLEAR
. Memory clear buttons:
Failure Histarr Data v
These buttons are used to select the data
to be cleared.
. Trend Data v
If a memory clear button is pressed, it Snap Shot Data
flashes and the confirmation message is Really Clear Failure Histarr?
displayed.
MENU
If the memory clear button is pressed

MEMORY CLEAR
again, the YES and NO buttons are dis-
Failure History Data Maintenance Data
played.
YES: Press this button if you wish to clear Snap Shot Data
the data. Reallr Clear Failure tlistorr?

NO: Press this button if you do not wish
to clear the data.
If the YES button is pressed, the mes-

sage of “Executing . . .“ is displayed and
the selected data are cleared.
Snap Shot Data
“*‘“1’....‘..1
SWWO4845
10-216 WA1 200-3

If the selected data are cleared, the mes-

sage that those data have been cleared
is displayed.
STATUS:aeaorr clear finished
MENU
SWWO4846
l Service menu selection screen button: This button is used to select the service menu selection
screen.
WA1 200-3 10-217

ALL-RANGE ELECTRONIC CONTROL AUTOMATIC
STRUCTURE AND FUNCTION TRANSMISSION (ATM) SYSTEM

TRANSMISSION (ATM) SYSTEM
OUTLINE OF SYSTEM
Auto gear shift

ECMV control of all gear speeds
Kickdown function
L Safety functions
Manual shift
Kickdown function
t Safety functions
Travel control function (Forward/Reverse travel, gear shift range)
Self-diagnosis function
Display of condition (Output, failure code)
t Troubleshooting (Detection of system trouble, wire breakage and short circuit in system)
Communicating function
l The electronically controlled full-automatic transmission system consists of a transmission control-

ler, FNR switch, shift-up and shift-down switches, engine rotation sensor, modulated clutch outlet
rotation sensor, speed sensor, transmission oil temperature sensor, and ECMV (transmission
clutch modulation valve) for the all gear speeds.
l The transmission controller selects the proper gear speed according to the operation signals of the
operator and travel speed. Modulation control is applied to the all-gear speed ECMV to reduce the
shocks made when the gear is shifted (when the clutch is engaged).
l This system prevents the machine from starting when the engine is started and protects the
transmission when the travel direction is changed at high travel speed and the gear is shifted
down (Priority shift control). With these functions, the transmission and clutch are protected and
their durability is heightened.
l The self-diagnosis system monitors the input and output conditions constantly and displays them
on the two “7-segment LED’s” of the transmission controller. If it detects any failure, it displays the
failure code, and displays the “remedy code” on the main monitor and turns on the alarm for
higher safety, depending on the degree of the failure.
. The transmission controller has a communicating function and transmits the gear speed informa-
tion (“F”, “N”, “R”,
“1 M - “3”) to the main monitor during travel, and the main monitor displays it.
1O-218 WA1 200-3

SYSTEM CONFIGURATION
Input signals Output signals

J/S N SW
1 D
b 1+ ECMV F
1 D
J/S F SW b
1 D
J/S R SW b
1 Dx2
J/S SHIFT UP SW ECMV 1
1 Dx2
1J/S SHIFT DOWN SW
Transmission cut-off SW
1 D 1
+ ECMV 3
KDS (Kick Down SW)

1 D
b
ID
Manual/Auto gear shift selector SW b
Engine speed
1 P
b
D
Modulated clutch outlet rotation signal

1 P
b
IP
Travel speed b
1 D <Display> Monitor
Neutralizer relay signal b ---_-.-.-.-_-_-_-_-_-_-_-,
s j I
Shift indicator I
I
(Actual gear speed) I
-1 D
I
Steering lever lock signal b I
s I+ I
Main monitor F.N.R
I I
I I
<Display> Monitor I
___________-_-_-_-_-_-_-_-_-_- Troubleindicatingbuzzeroutput i
I i S
i Tire correction l L_-_-_-_-_-_-_-_-_-_-_-__J
I
I I \
I
I
I I
I~__________________-_-_-_-_-_-A Auto gear
shift call
Memory clear signal
1 A
display
b
1 D
Fill SW F b
1 D
Fill SW R ä Fl output
J
D
Fill SW 1 b
R clutch drain valve
Fill SW 2
1 D
b
1 D S: S-NET signal
Fill SW 3 b D: Digital signal
I A A: Analog signal
Transmission oil temperature b P: Pulse signal
J/S: Joystick steering
WA1 200-3 10-219

FUNCTIONS
1. Auto gear shift function If the modulated clutch outlet speed
When the modulated clutch outlet speed is is below 1,450 rpm, however, ECMV
1,450 rpm or higher, shifting up and shifting is kept in the 3rd gear speed. (Coast-
down operations of the transmission are con- ing)
trolled with the signals of the travel direc- 4) When direction switch is in “R” position
tion, gear shift range, and travel sensor, ac- Similarly to the operation in the F posi-
cording to the “automatic gear shift change tion, the 2nd or 3rd gear speed (when
points table” (Table 1) stored in the trans- the gear shift range is 3) is selected au-
mission controller. tomatically according to the travel speed
See combination of gear speeds and when the modulated clutch outlet speed
output ECMV (Table 4), auto gear shift is 1,450 rpm or higher.
operation table (Table 21, and the sec- 5) Skip shift
tion of contents of control by transmis- If the accelerator pedal is pressed while
sion controller. the machine is coasting in the 3rd gear
1) Gear shift range (I - 3) speed at speed below 8 km/h (with the
The highest gear speed (gear shift range) auto gear shift function turned OFF), the
for the auto gear shift is limited. 2nd gear speed is selected immediately
Example: so that the machine can be accelerated
Gear shift range 3: Between 2nd and easily. If the travel speed is 8 km/h or
3rd gear speeds higher, however, the present gear speed
Gear shift lever 2: Only 2nd gear speed is maintained.
Gear shift lever 1: Only 1st gear speed 6) Period in which gear speed cannot be
2) When direction switch is in “N” position changed
If the direction switch is in the neutral A certain period to keep each gear speed
position, only the gear speed clutch of after gear shifting operation is set to pre-
the transmission is operated. vent gear shift hunting. This period de-
3) When direction switch is in “F” position pends on the gear shifting pattern. See
If the direction switch is set from the N “automatic gear shift change points ta-
position to F position, ECMV of F of the ble” (Table I).
transmission is turned on. If the gear
shift range is 2 or 3 at this time, the 2. Modulation control
machine starts with the 2nd gear. The modulation control system controls the
a) When the gear is shifted up (when clutch oil pressure (including the rising char-
gear shift range is 3) acteristics) matched to the condition of the
When the accelerator pedal is hydraulic circuit in the all gear speeds ac-
pressed to accelerate the machine cording to the engine speed, transmission
and the modulated clutch outlet oil temperature, gear shifting pattern, and
speed is 1,450 rpm or higher, if the data stored in the transmission controller to
travel speed reaches about 10.4 km/ reduce the shocks made when the gear
h, the 3rd gear speed of ECMV is speed is changed (when the clutch is en-
turned “ON” and the second gear gaged).
speed is turned “OFF”. (The trans- The modulation control system is also ap-
mission is set in the F3 position.) plied to ECMV to be turned off to prevent
b) When the gear is shifted down (when lowering of the torque.
gear shift range is 3)
If the accelerator pedal is released
and the travel speed lowers to about
9.8 km/h while traveling in the 3rd
gear speed, the second gear speed
of ECMV is turned “ON” and the 3rd
gear speed is turned “OFF”. (The
transmission is set in the F2 posi-
tion.)
1O-220 WA1 200-3

3. Kickdown function 2) Neutral safety

If the operation (the operation of turning When the engine is started, if the direc-
“ON” the kickdown switch) by the operator tion switch is not in the N position, the
satisfies the conditions (travel mode, gear transmission controller keeps itself in the
speed, and travel speed), the transmission neutral state and the machine cannot
is shifted down to the 1st gear forcibly. start (Prevention of abrupt start).
The transmission controller outputs the cut- This function is reset if the N signal is
off signal to the engine (electronic gover- input once after the engine is started.
nor) controller in the kickdown mode (while 3) Shift-down switch priority
the 1st gear signal is output). The transmission can be shifted imme-
See the section of contents of control by diately with the gear shift-down switch
transmission controller. and the engine can be used as a brake
1) Auto gear shift mode when the machine travels downhill.
The kickdown system becomes effective 4) Protective function of transmission
when the forward or reverse travel speed If the gear is shifted down or the travel
is below 13 km/h. It is also effective while direction is changed while the machine
the gear speed is held (while the auto is traveling in the 3rd or 2nd gear speed,
gear shift function is turned off). the gear speed and warning buzzer are
The resetting condition is either rise of controlled to protect the transmission.
the travel speed or change of the travel See the section of the protective func-
direction. If either condition is satisfied, tions of the transmission (gear speed
the transmission is set in the 2nd gear control table).
speed. 5) Manual gear shift mode
See the auto gear shift operation table If the travel speed data cannot be ob-
(Table 2) in the section of the protective tained because of a travel speed sensor
functions of the transmission (gear speed trouble, the manual gear shift mode is
control table). selected.
2) Manual gear shift mode
The kickdown system becomes effective Table 1 Automatic gear shift change Dints table
when the machine travels forward in the orward Reverse ‘eriod to keep
2nd gear speed. Solenoic (F) (8) ear speed af.
Applicable item ?r gear shift
signal Speed
The resetting condition is either opera- Speed lg operatior
(km/h) (km/h) XC)
tion of the shift up/down switch or
change of the travel direction. If either 1. 5.4 5.4 2
3asic gear shift
condition is satisfied, the transmission
:hange 10.4 10.4 2
is set in the 2nd gear speed.
3+2 9.8 9.8 2
4. Travel mode
2.
The auto or manual gear shift mode can be IModulated
selected with the travel mode selector switch. clutch outlet
speed signal 3+2 1.0 1.0 0
In the manual gear shift mode, the gear
OFF (Below
speed is changed with the shift up/down 1,450 rpm)
switch.
3.
Modulated
5. Safety functions clutch outlet
I) Transmission neutralizer function speed signal
OFF (Below 3-2 8.0 8.0
This function sets the transmission in the
1,450 rpm) +
neutral position when the steering lock ON (1,450 rpm
lever is operated (set in the LOCK posi- or higher)
tion) or when the machine is stopped
4.
and the engine has not been started. When direction +3 10.4 - 10.4 -
switch is
changed
F-+N+F +2 - 10.4 - 10.4

R-+N-+R
WA1 200-3 1o-22 1

Table 2 Auto gear shift operation table

Gear shift range
Period to keep
Remarks
1. Basic gear shift change Basic gear shift in auto

Modulated clutch outlet
speed is 1,450 rpm or
higher. Gear can be shifted to 1st
gear speed with shift-down
Operation of only switch or by KDS
accelerator pedal
@ 0
5.4
2. Modulated clutch outlet Basic gear shift when auto

1.0
speed is below 1,450 rpm. --@ mode is turned off
(During coasting or until

braked to stop)
3. Modulated clutch outlet Gear shift just after auto

speed is below 1,450 rpm mode is turned on
+ above 1,450 rpm.
Operation of only
accelerator pedal
(During coasting or
acceleration after braking)
4. Kickdown * Kickdown system

Only in moment after operates at any engine
operation of switch speed. Travel speed is
limited, however, to
prevent overrun.
* If accelerator pedal is
pressed and travel speed
rises, gear is shifted up in
auto mode.
5. When direction switch is -Whendirection is changed or

machine starts in neutral in
changed (Part 1)
another case than the left, gear
Lever is changed or
machine starts in neutral.
(F+)N+R, (R+)N-tF
o_ @
All range
protection of transmission.
6. When direction switch is

changed (Part 2)
Lever is returned to same
position.
F+N+F, R+N+R
Gear is shifted according
to travel speed at time
when lever is changed.
A” ra”se below s.3 All range below 9.3
1o-222 WA1 200-3

6. Self-diagnosis function
The transmission controller constantly moni-
tors the input and output signals of the travel
control system, and executes self-diagnosis
and displays the result with the LED of the
controller.
The transmission controller also transmits
the following data to the main monitor.
I) Normal display: The output gear speed
is displayed with the LED of the trans-
mission controller.
2) Display of failure code: If any trouble is
detected, its contents are displayed by
the code (See the table below).
Table 3 Failure codes table
WA1 200-3 1 O-223

7. Communicating function Power source of transmission controller

The transmission controller has a communi- When the starting switch is turned on and
cating function through S-NET, and it re- the source voltage is 20 V or higher and a
ceives the tire correction data from the main voltage of +20 V or higher is applied to the
monitor. transmission controller solenoid, drive of
If the transmission controller has a signal each solenoid valve can be controlled.
trouble in its control system, it displays the If the source voltage lowers below 19 V, all
remedy code on the main monitor to notify the outputs are turned off and control is not
the operator for higher safety, depending on executed. (The machine cannot travel.)
the degree of the trouble. If the source voltage rises to 20 V, the neu-
The failure code saved in the main monitor tral safety function works, and the machine
can be checked in the failure history mode can travel.
of the main monitor.
1O-224 WA1 200-3

INPUT SIGNALS
1. Steering lever lock signal are operated simultaneously, their operations
This signal is a GND/OPEN digital signal, are judged as follows.
which becomes OPEN when the steering le- . After either switch is turned ON, the turn-
ver is stopped (locked) and becomes GND on operation of the shift-up switch or
when the steering lever is operated (free). shift-down switch is not accepted for 0.2
If the steering lever is operated, the direc- seconds.
tion switch becomes effective. . If the shift-up and shift-down switches
are operated simultaneously (for 0.01
2. Neutralizer relay signal second), the operation of the shift-down
This signal is a +24V/OPEN digital signal. If switch is accepted.
the parking brake switch is turned off, +24 V
is input. 7. Fill switch
When this signal is OPEN, the transmission (F, R, 1st gear, 2nd gear, 3rd gear) signal
controller keeps itself in neutral state. (The This signal is a GND/OPEN digital signal,
machine cannot travel.) which becomes GND when each ECMV is
turned ON and becomes OPEN when each
3. Transmission cut-off switch signal ECMV is turned OFF.
This signal is a GND/OPEN digital signal,
which becomes OPEN when the left brake is 8. Engine rotation sensor signal
used (pressed) while the transmission cut- This signal is a pulse signal. The number of
off switch is effective, and becomes GND pulses sent from the electromagnetic pickup
when the left brake is released. sensor is converted into rpm and used for
If the left brake is used, the transmission control.
controller outputs the neutral signal. If the
transmission controller is reset, the gear 9. Modulated clutch outlet rotation sensor
speed matched to the current travel speed is signal
set. This signal is a pulse signal. The number of
pulses sent from the electromagnetic pickup
4. Manual/Auto gear shift selector switch sensor is converted into rpm and used for
signal control.
This signal is a GND/OPEN digital signal, The mode where the engine speed is 1,450
which becomes GND when the switch is rpm or higher is called the “auto-shift ON”
pressed and becomes OPEN when the switch mode, and the mode where the engine speed
is released. is below 1,450 rpm is called the “auto-shift
If this signal changes from OPEN to GND, OFF” mode.
the manual and auto travel modes are se-
lected alternately. 10. Travel speed sensor signal
This signal is a pulse signal. The number of
5. Direction switch (F, N, RI signal pulses sent from the electromagnetic pickup
This signal is a +24V/OPEN digital signal. sensor is converted into rpm and used for
When the machine is normal, one of the F control.
(Forward), N (Neutral), and R (Reverse) sig- When this signal is converted into the travel
nals is input (+24 V). speed, the tire correction data (sent from
the main monitor) are added to it.
6. Shift-up/Shift-down switch signal
This signal is a +24V/OPEN digital signal. If 11 Communication signal (S-NET)
the switch is pressed, its N.C side is opened The tire correction data set in the main moni-
and its N.0 side becomes +24 V. If the switch tor are received and used for control.
is released, its N.C side becomes +24 V and The accurate travel speed is obtained by
its N.0 side is opened. The operation of the adding the correction value (ranging from
switch is judged by these signals. 0.86 to 1.14) to the rpm data sent from the
If both shift-up switch and shift-down switch travel speed sensor.
WA1 200-3 1o-225

OUTPUT SIGNALS
1. Transmission modulation valve 4. Fl (Cut-off) signal
(ECMV) Command current This signal is a Lo side output, which be-
This signal is a current output (0 - 1 A). comes GND when the forward 1st gear (Fl)
There are five types of ECMV for directions is selected by the kickdown operation, etc.
of “R” and “F”, and for gear speeds of “Ist”,
“2nd”, and “3rd”. 5. Gear shift range display LED
This valve is a pressure control valve which I) This LED indicates the gear shift range
converts the current supplied to the sole- (range of auto gear shift operation) in
noid into the pressure. Accordingly, the oil the auto mode.
pressure on the clutch selected for each gear Gear shift range “1”:
speed is controlled to control the engage- LED 1 is turned on and only the 1st
ment of the clutches independently. gear speed is selected.
When the transmission is in neutral, only Gear shift range “2”:
the gear speed clutch is turned on. (The gear LED 2 is turned on and only the 2nd
speed is selected according to the gear shift gear speed is selected.
range and travel speed in the auto mode. In (If the gear is shifted down to the 1st
the manual mode, the gear speed before the gear speed by the kickdown opera-
transmission is set in neutral is maintained. tion, the 2nd gear speed is selected,
When the engine is started, the 2nd gear depending on the travel speed.)
speed is selected.) Gear shift range “3”:
LED 3 is turned on and the 2nd or
Table 4 Combination of gear speed and drive 3rd gear speed is selected automati-
ECMV (Holding state) cally.
2) This LED goes off in the manual mode.
6. Backup lamp relay signal

This signal is a digital (ON/OFF) output of
+24 V, which is turned ON when the direc-
tion switch is in the R position to turn on the
backup lamp and backup alarm.
7. Communication signal
(Data of disolav on main monitor)
I) Display of gear speed
1st gear speed output: “I”
2nd gear speed output: “2”
t R3 1 - 1 - 3rd gear speed output: “3”
0: ON In neutral: “N”
AZ One of 1 - 3 is turned on according to the condition. 2) Display of F and R
When travel direction is forward: “F”
When travel direction is reverse: “R”
2. Bypass valve (For F, R, and 1st gear speed) In neutral: Nothing is displayed.
+24 V, which is turned ON for the stored
period (data) when each ECMV is turned ON.
3. R clutch drain valve

+24 V, which is turned ON for the stored
period (data) when the R ECMV is turned
OFF.
1 O-226 WA1 200-3

STRUCTURE AND FUNCTION TRANSMISSION IATM) SYSTEM
LED DISPLAY
When the engine is started, the LED is set in 1. “Program part No. display mode”, then 2. “Output gear
speed display mode”.
If any trouble is detected, however, the LED is set in the “Troubleshooting display mode” immediately.
1. Program part No. display mode
When the power is turned on, the following are displayed in order at the interval of 1 second.
-0 -0 70 80 20 30 1, 9, A, 1, 0, 1, + To display mode 2
Al Al Al ti hl
w
2. Output gear speed display mode

LED display ‘X 0 Y 0’ (Dots of both are turned off.)
X: Drive condition of direction ECMV
Forward “F”: ‘F’, Reverse “R”: ‘A’, Neutral: ‘0
Y: Drive condition of gear speed ECMV
l-4
Example Display Contents
‘0 0 2 0’ Neutral, 2nd gear speed

‘F o 1 0’ Forward, 1st gear speed
‘A 0 2 0’ Reverse, 2nd gear speed
‘F o F 0’ Neutral safety state
+ If trouble is detected, Display mode 3 is selected.
I
N Gear shifting (Gear speed F2 is displayed continuously)
3. Troubleshooting display mode (Trouble currently detected)

“E - (2 set)” and “Code (2 set)” are repeated as one routine.
1) When there is only one trouble item
-+ Repeat
+=I=%
2) When there are two trouble items
E, -0 20 30 E, -0 1, 80 + Repeat
hl Ll Ll
ti
WA1 200-3 1O-227

CONTENTS OF CONTROL BY TRANSMISSION CONTROLLER
1. Devices used and display on monitor
Section Device Auto Manual Remarks
Steering Joystick steering lever 0 0
Manual/Auto shift selector switch 0 0
FNR seesaw switch (Joystick knob) 0 0
Transmission Shift-up switch (Joystick knob) 0 0
Shift-down switch (Joystick knob) 0 0
KDS 0 0
Display of setting of FNR 0 0 Main monitor
Display 1 Display of actual gear speed 1 0 1 0 1 Main monitor
Display of gear shift range (In AT) 0 OFF Displayed with LED (Only in auto shift mode)
2. Actual gear speed (II, gear shift range (III, and travel mode (Auto shift/Manual) (Ill)
I) Actual gear speed (1) and gear shift range (II) when manual shift and auto shift modes are
changed to each other
Manual/Auto shift
Before change After change
selector switch
@ Auto shift [Auto shift1 ä [Manuall
J (1)Actual gear speed b (1)Actual gear speed is the same as that in auto shift mode.
Manual
(II) Gear shift range --------------------b x (II)Gearshiftrangeisnotapplied,andisturnedoff.
@ Manual [Manual] b [Auto shift]

L (1) [In F or RI Actual gear speed is set according to travel speed.
Auto shift (1) Actual gear speedT’ IIn N12nd gear speed 6%)
--‘-+ (II) Gear shift range is the same as actual gear speed in manual mode
(~4):When gear shift range is [ll, 1st gear speed is selected.
2) Initial condition after power is turned on

(I) Actual gear speed [In manual mode] : Actual gear speed before key is turned to OFF
[In auto shift model : 2nd
(II) Gear shift range [Only in auto shift model: Gear shift range before key is turned to OFF
(III) Travel mode (Auto shift/Manual) : Travel mode before key is turned to OFF
3. Solenoid output when FNR signal is changed
The FNR signal is constantly monitored prior to the other controls.
Manual mode Auto shift mode
Joystick Solenoid output Joystick Solenoid output

knob knob
switch F R Gear speed before N is selected switch F R 2nd gear %
F 0 F 0
N 0 N 0
R 0 R 0
EWhen gear shift range is 111, 1st gear speed is selected.
1O-228 WA1 200-3

4. Gear shifting pattern

I) Manual mode
l The gear is shifted with the shift-up switch and
shift-down switch.
Actual gear speed

Gear shift
Gear shift operation Initial value (When power is turned on)
mode 1 2 I 3
Actual gear speed (Solenoid output)

.Gear speed before key is turned to OFF
Conditions for resetting kickdown function (Kickdown is effective only in F2)
Condition before Condition after

Resetting operation Remarks
resetting resetting
1 1Jovstick knob switch F + N 1 Fl I N2 I -1
2 Joystick knob switch F -+ R Fl R2
3 Shift-up switch Fl F2 Actual gear speed is shifted up only whenkickdown

is applied
4 Shift-down switch Fl Fl Gear speed is shifted down from 2 to 1, too.
5 Turn-off of power Fl -
2) Auto shift mode

l The shift-up switch and shift-down switch function as gear shift range selector
r Actual gear speed
Sear shifting
Gear shifting operation Initial value (When power is turned on)
mode 1 2 3
g I@Ei5q
g
1 Range 1 &
h
I ’’ II !I - Actual gear speed (Solenoid output) . .2nd (s)
E
r ’’ I II 3,: 1%) . . When gear shift range is [ll, 1st gear speed is selected.
”
4 0
*,
m 5 ’ i “an~2~’
- Gear shift range.. Gear shift range before power is turned o
1 $z$&
01
O 0
KICK DOWN SW ,AUtmlBflC
resetwhenLiirenion
i* changed between F and FL)
I
I b
Resetting condition Condition before resetting

Condition after resetting Remarks
(Operation) Kickdown in F 1Kickdown in R
1 Joystick knob switch F+ N Fl - N2
2 Joystick knob switch F -+ R Fl - R2
3 Joystick knob switch R + N - RI N2
I I I I
4 Joystick knob switch R + F - RI F2

5 Shift-up switch Fl Rl Shifting up to 2
6 Shift-down switch Fl RI
7 Turn-off of power Fl RI
8 Rise of travel speed Fl RI As per auto gear shift operation table
WA1 200-3 1 O-229

PROTECTIVE FUNCTIONS OF THE TRANSMISSION (GEAR SPEED CONTROL TABLE)
1. Protection functions in auto shift mode
I) Control of kickdown
Gear speed
Command from controller
before kickdown
3rd is held
Brd+lst 1st (Kickdown signal
is ignored).
2nd is held
2nd+lst 1st (Kickdown signal
is ignored).
\t
Travel speed o ’ ’ ’ ’ ’ ’ ’ ’ 9’ ’ ’ ’ 13
’ 15
’ ’ ’ ’ ’ 20’ ’ ’ ’
5
(km/h)
Period in which gear speed cannot be changed (5 set)
2) Control of shift-down operation
Operation of
shift-down Command from controller
switch 14
3rd-12nd 2nd 3rd &caution
When travel speed is

14 km/h or higher and
3rd+lst 2nd 4 3rd &caution shih-down switch is
accepted 2 times
2nd+lst 1st 2nd & caution
Travel speed o ’ ’ ’ ’ 5’ ’ ’ ’ 9’ ’ ’ ’ 1314

’ ’ ’ ’ ’ ’ 20’ ’ ’ ’
(km/h’
3) Control when direction is changed
Gear speed
Gear speed after change of direction
before change
(Command from controller)
of direction
3rd @ 2nd @ 3rd &caution
2nd @ 2nd @ 3rd &caution
When gear Restoration

shift range 1st 0 2nd @ 3rd &caution from
is 2nd, 3rd kickdown
When gear 1st is held

shift range 1st @I 1st @ E$$n @ 3rd &caution and direction
is 1st is changed.
\
Travel speed o ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’
5 9 14 20
(km/h’
Range 0: Gear speed is changed according to operation.

Range @J: Gear speed is controlled according to travel speed and caution signal is output.
1 O-230 WA1 200-3

4) Control after change of direction
When 9ear shift range

is 1 and travel speed
3rd+lst @I 3rd &caution
is 14 km/h or higher
j 1 / 1 1a&diiction is
Pnd-tlst @ IstI @ 2nd &caution
Travel speed
(km/h)

Range @: Gear speed is controlled according to travel speed and caution signal is output.
2. Protective functions in manual shift mode
1) Control of shift-down operation
Operation of
switch 14
3rd+2nd
3rd+lst
/ 1 1 accepted2 times
Znd+lst 0 1st @ 2nd &caution
Travel speed I I I I I I I I I I I I I I I I I I I I I I I I
(km/h)
0 5 9 1314 20

WA1 200-3 lo-231

2) Control when direction is changed
(The following control is also applied when the direction is changed to F or R while the machine is
coasting with the gear is in NJ
Gear speed after change of direction

(Command from controller)
3rd @ 2nd @ 3rd &caution
2nd @ 2nd @ 3rd &caution

I.
When range 1st is held

is judged to 1st @ 1st @ z2$!& @ 3rd &caution and direction
be 1st is changed.
\
Travel speed o ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ 20’ ’ ’ ’
5 9 14
(km/h)

3) Control after change of direction

I I I
Operation of
switch
Pnd-+lst 1Olst 1 @ 2nd &caution
I 1 ,
Travel speed i ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’
5 10 15 20
(km/h)

Control of gear speed when auto shift mode is in neutral
Gear speed selected when in neutral

kI:Tnge 1 (Co2myd from con_lerl 3rd
1 1st 2nd 3rd
Travel speed o ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’
5 9 14 20
(km/h)
lo-232 WA1 200-3

STRUCTURE AND FUNCTION MODULATED CLUTCH (MOD/C) CONTROL SYSTEM
MODULATED CLUTCH (MOD/C) CONTROL SYSTEM

Modulated clutch controller

-o ___________________________________.
g; Travel speed control

8:
‘0,
g:
oi
5’ Modulated clutch ECMV current
2i
Engine speed signal (output)
D
RPM set ON/OFF switch signal
D ?
SET/ACCEL switch signal E
Electronic governor voltage command
D 8
RESUME/DECEL switch signal
::
D S
2 A: Analog signal
D
Low idle switch signal
5 D: Digital signal
A e P: Pulse signal
S: S-NET signal
WA1 200-3 1O-233

Control function
Modulated clutch control
Travel speed control function
Drive force control function
I- Tire slip control function
RPM set control function
I Troubleshooting function
Modulated clutch control

The modulated clutch control system has the
following functions.
I) Travel speed control function 2) Drive force control function
Since the travel speed can be limited to the Since the drive force set with the drive force
maximum speed set with the travel speed control lever can be set at a properly low
control lever, the operator can keep the travel level, slip of the tires can be prevented on a
speed low without releasing the accelerator clayey ground (red clay), in mud, etc. Ac-
pedal when approaching a dump truck. As a cordingly, the operator can work without pay-
result, the operator can work easily. ing attention to the acceleration work.
This function can be applied with the travel The maximum drive force can be changed
speed control ON/OFF switch only when it is to 20% - 100% with the drive force control
required. lever.
<Operating conditions> <Operating condition>
l The travel speed control ON/OFF switch . The transmission is set in the Fl posi-
is turned ON. tion.
l The transmission is set in the Fl, F2, RI, (If the travel speed control function is
or R2 position. turned on, however, it is applied first.)
l The travel speed is 1.5 km/h or higher. 3) Tire slip control function
The maximum travel speed can be set as Even if the drive force is lowered with the
shown below according to the gear speed of drive force control function, the tires may
the transmission and the position of the still slip. If slip of the tires is detected in this
travel speed control lever. case, the drive force is further lowered to
minimize the slip.
<Operating conditions>
l The tire slip control switch is turned ON.
l The transmission is set in the Fl posi-
tion.
l The work equipment is not operated.
1 O-234 WA1 200-3

RPM SET CONTROL FUNCTION
Since the operator can set the idling speed of 2) How to lower set engine speed
the engine freely, unnecessary lowering of the i) Setting with accelerator pedal
engine speed can be prevented while the opera-
a) Press the right brake pedal, and the
tor is working with the accelerator, and the en-
memory of the engine speed is
gine is accelerated sharply and the cycle time is canceled temporarily and the engine
shortened. speed is lower to the low idling level.
Since the travel speed can be kept constant dur-
b) Press the accelerator pedal until the
ing load-and-carry operation, the operator is less
engine speed rises to the desired
fatigued and the machine consumes less fuel. level.
c) Press the SET/ACCEL switch to save
How to set engine speed
the new engine speed data.
1) Turn on the RPM set ON/OFF switch. Then, even if the accelerator pedal is
2) The RPM set pilot LED lights up. released, the engine runs at the
3) Press the accelerator pedal until the engine saved speed.
speed rises to the desired level. ii) Setting with switch
4) Press the SET/ACCEL switch to save the en-
a) Press and hold the RESUME/DECEL
gine speed data.
switch for more than 0.5 seconds,
Then, even if the accelerator pedal is re-
and the engine speed lowers.
leased, the engine runs at the saved speed.
b) When the engine speed lowers to the
desired level, release the RESUME/
How to change set engine speed
DECEL switch, and the new engine
Use the following method to change the save speed data is saved.
engine speed.
1) How to raise set engine speed How to cancel memory of engine speed
i) Setting with accelerator pedal temporarily
a) Press the accelerator pedal until the Press the right brake pedal, and the memory of
engine speed rises to the desired
the engine speed is canceled temporarily and
level. the engine speed lowers to the low idling level.
b) Press the SET/ACCEL switch to save
the new engine speed data. How to restore canceled engine speed
Then, even if the accelerator pedal is
Press the RESUME/DECEL switch, and the en-
released, the engine runs at the gine speed rises to the saved level again.
saved speed. (Note)
ii) Setting with switch If the engine starting switch or the RPM set
a) Press and hold the SET/ACCEL switch ON/OFF switch is turned OFF, the saved en-
for more than 0.5 seconds, and the gine speed is cleared, then the engine runs
engine speed rises. at the low idling speed. In this case, repeat
b) When the engine speed rises to the the above procedure to set the engine speed
desired level, release the SET/ACCEL again.
switch, and the new engine speed
data is saved.
WA1 200-3 lo-235

Troubleshooting function
The controller constantly monitors the electronic
devices such as the potentiometers to receive
input signals, solenoid valves to receive output
signals, etc. If any one of those devices has a
trouble, the controller detects it and displays is
as a “failure code” on the main monitor to no-
tify the operator.
1O-236 WA1 200-3

STRUCTURE AND FUNCTION WORK EQUIPMENT AND JOYSTICK STEERING CONTROL SYSTEM
WORK EQUIPMENT AND JOYSTICK STEERING CONTROL

SYSTEM
Work equipment and joystick steering controller
D +/ Boom lever kick-out SOL 1

Boom raising switch (Pressure switch)
Boom lowering switc

Remotepositionerswitch input checkbuzzeroutput
P
Engine rotation signal
Display of lower setting of remote positioner
S
Display of upper setting of remote positioner
-1 s
Lower setting switch of remote positioner
Upper setting switch of

Display of lower stop of remote positioner
Lower selection switch o

Pilot LED of upper stop of remote positioner
Upper selection switch of remote positioner

J s
Pilot LED of lower stop of remote positioner
1 Selection of remote positioner function
x:: j
Steering lever potentiometer
% Joystick main pressure control EPC SOL
Joystick caution buzzer relay
Joystick neutral caution buzzer relay

1
Steering potentiometer calibration reset switch
A: Analog signal
D: Digital signal
P: Pulse signal
S: S-NET signal
WA1 200-3 1o-237

COMPOSITION OF WORK EQUIPMENT (REMOTE POSITIONER) CONTROL CIRCUIT
Boom leve ‘r
:: kick-out
solenoid
I
Work equipment &
joystick steering I ,:’
controller
Boom RAISE switch
tp
: Boom LOWER switch
Bucket, inder
lo-238 WA1 200-3

COMPOSITION OF JOYSTICK STEERING CONTROL CIRCUIT
Steer ins
lever
Travel
Speed Steering lever
Potentiometer
Work eauipment h joystick

steerino controller
,_____-_____________-__-,
I I
:
I
I
I I
Steer in0 Rotary

I
I
I
lever lock I fI
valve II I
switch
______--__-___--I II
r I
Frame angle
I
Potentiometer 0 i I ! t
- I I
sxw0491.3
Control function
Remote positioner control

Boom “raising” and “lowering” position stop
Boom “raising” and “lowering” position setting
E Sensor adjustment function
Joystick steering control
Potentiometer calibrating function
t Neutral interlock function
Outline
l With the remote positioner control function, l With the joystick steering control function,
the operator can set the boom stopping (le- the flow gain in the steering hydraulic sys-
ver kick-out) position freely so that the boom tem is controlled according to the deviation
will stop smoothly. As a result, the operator of the frame angle from the operating angle
can operate the machine safely and easily of the joystick steering lever to improve the
when driving in reverse, digging the earth, narrow steering characteristics and response
or approaching a dump truck. to high-speed steering for higher
maneuverability.
WA1 200-3 1 O-239

0
REMOTE POSITIONER CONTROL
Functions of remote positioner (2) Each time the “LOWER” button is

1. Stopping boom at “raising” and pressed, it lights up and goes off al-
“lowering” oositions ternately. While it is lighting up, the
. The boom is decelerated and stopped at lowering stop function is effective.
the set raising and lowering positions. (The setting is maintained even if the
The controller constantly detects the op- starting switch is turned off.)
erating direction signal of the lever sent There is an indicator on the right con-
from the pressure switch installed to the sole, in addition to the “UPPER” and
PPC valve of the boom. It also detects “LOWER” buttons on the CGC moni-
the boom angle (position) signal sent tor screen, so that the operator can
from the boom angle potentiometer. see the setting condition.
I) Raising kick-out (When “UPPER” button
lights up)
If the boom lever is set to the “RAISE 2. Setting of “raising” stop position of
DETENT” position, the boom rises to the remote positioner
set position, then decelerates and stops. 1) Press the “UPPER” button to light it up.
The detent is reset at this position. When 21 Operate the boom lever to move the
the boom lever is not in the “RAISE boom to the stop position, then set it in
DETENT” position, the boom is raised neutral. (The boom must be higher than
as the operator operates. the level position.)
2) Stopping lowering boom (When 3) Press the raising stop position setting
“LOWER” button lights up) button.
If the boom lever is in the “FLOAT” or 4) The “UPPER” button flashes (for 2.5 sec-
“MAX. LOW” position, the boom lowers onds).
to the set position, then decelerates and 5) If the “UPPER” button lights up again,
stops. If the lever is held as it is, the the raising stop position is saved.
boom is fixed.
If the lever is returned to the neutral and 3. Setting of “lowering” stop position of
set to the “LOWER” position, the boom remote positioner
lowers again. 1) Press the “LOWER” button to light it up.
The operator can freely set the positions 2) Operate the boom lever to move the
at which the boom stops when it rises boom to the stop position, then set it in
and lowers. neutral. (The boom must be lower than
the level position.)
Setting range of stop position
3) Press the lowering stop position setting
(
button.
4) The “LOWER” button flashes (for 2.5
seconds).
5) If the “LOWER” button lights up again,
the lower stop position is saved.
(Angle is 0 degree when boom is hori- Sensor adjustment function

zontal.) l This function is used to offset the error
caused by installation of the potentiometer
Setting of the control can be changed as so that the correct position data of the work
explained below. equipment can be obtained.
Be sure to adjust the sensors with this func-
(1) Each time the “UPPER” button is tion after the controller, potentiometer, or
pressed, it lights up and goes off al- work equipment is replaced.
ternately. While it is lighting up, the (For the setting method, see TESTING AND
raising stop function is effective. ADJUSTING, “Initial setting procedure for
remote positioner”.)
1 O-240 WA1 200-3

0
JOYSTICK STEERING CONTROL
Potentiometer calibrating function

l This function is used to measure the difference between the steering lever angle and the frame
angle sensing potentiometer (offset angle), and correct it 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 articulate and the machine will not start abruptly when the engine is started.
If the difference between the operating angle of the steering lever and the frame angle is 6 degrees
or wider, the interlock operates so that the engine will not start. At this time, the buzzer sounds,
If the steering lever is set in neutral and the FNR switch is set to the “N” position, the interlock is
reset and the engine can start.
. If the FNR switch is not in the “N” position, the neutral safety function prevents the engine from
starting.
The controller constantly monitors the electronic devices such as the potentiometers to receive input
signals, solenoid valves to receive output signals, etc. If any one of those devices has a trouble, the
controller detects it and displays is as a “failure code” on the main monitor to notify the operator.
Failure codes table
Failure code on
58 frame angle sensor, and potentiometer signal - - EOl + CALL

from each other
59 Frame angle sensor 0 0 EOI + CALL
61 Steering lever lock switch 0 0 EOl + CALL
62 Joystick neutral interlock relay 0 0 EOO
63 Joystick main pressure control EPC SOL 0 0 EOI + CALL
E44 and E45 cannot be distinguished, and they are turned on simultaneously.
WA1 200-3 1O-241

0
POTENVOMETER
A-A
A4
SW04882
1. Connector 5. Bearing
2. Case 6. Contact
3. Shaft 7. Mold
4. Element
Potentiometer output
Potentiometer anole f1 sxwo4919
Function
The potentiometer senses the operating angle. the above signal in this area, it judges that the
In the potentiometer, the source voltage of 5 V potentiometer system has a trouble such as wire
is converted with a variable resistor into a sig- breakage, short circuit, etc. Since the correct po-
nal voltage according to the angle, then sent to sition cannot be sensed in this case, the control
the controller. output is turned off and the failure code is dis-
The hatched area in the above figure is the ab- played on the main monitor.
normality detection area. If the controller receives
1 O-242 WA1 200-3

STRUCTURE AND FUNCTION WORK EQUIPMENT AND JOYSTICK STEERING CONTROLLER
WORK EQUIPMENT AND JOYSTICK STEERING CONTROLLER
CN,l cy2 C.N3
Connector signal
CNI CN2 CN3

Pin Input/
Name of signal
Cl No. output
/ i 1Frameangle”““iometer / In: 1
- I - I 121 - I -1
1 3 1Boom PPC dumping SOL2 (+)I Output 1 - I - I
I41 - I - I - I - I 1 ,” ~:;,9:~;,s,p,e,e,“,s:gnal
(+) 1;;w;;1
5 Boom PPC dumping SOL1 (t) Output I 5 I Boom RAISE pressure switch Input I
6 J/S EPC SOL (+) output 6 Boom LOWER pressure switch Input 6 Remote positioner UPPERstop LED Output
I 7 I - I - I
1 8 I - I - I
I101 - I - I
I 11 I - I - I I I
12 S-NET (+) Input 12 - - 12 I Pulse input GND I Input
13 1Sensor power (+24V) ( output 13 - - I 13 I - I - I

14 Boom PPC dumping SOL2 H Output 14 Sir potentio CAL. reset switch Input 1 14 1 Remote positioner LOWERstop LED/ Output I
I 15
I 17
Boom PPC dumpmg
I SOL power input

SOL1 H Output
I Input I
15
16
17
-
-
-
-
I 15
16
I J/S caution
Buzzer output
buzzer output I Output
output
I
I 18 I Power input (+24V) I but I

1 19 1 GND I but I
I 20 I Boom lever kick-out output I Output I
I 21 I S/T neutral interlock relay I Output I
WA1 200-3 1O-243

STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT
tiler
Starting switch - xrv~ce meter
Main monitor
t
Slow blow
fuse 30A
Work equipment Battervl
Cummins engine
inject ion
solenoid
Voltage
Alternator Prelub
_-__- s regulator
r----r 1 ‘I I timer
rreluu 0 - Conventional
l___ -.- __-__
IE !I’
E:-___I
Pressure starter
,.
& swltcn
sxwo4920
Function Operation
l When the direction switch and the joystick . If the starting switch is turned to the ON
steering lever are in the N (Neutral) position, position, a current flows from the BR termi-
the neutral safety circuit prevents the engine nal of the starting switch to the battery relay,
from starting to secure the safety when the then the battery relay contacts are “closed”.
engine is started. The power is supplied to the machine by this
. If the starting switch is set to the START operation.
position, the engine oil is circulated first by . If the direction switch is set to the N (Neu-
the pre-lubricating function. After the oil pres- tral) position, a current flows in the neutral
sure has risen, the engine is started. relay, then the contacts 5 and 3 of this relay
are connected to each other.
On the other hand, when the joystick steer-
ing lever is set to the N (Neutral) position,
contacts 6 and 3 of the steering neutral relay
are connected to each other, and the con-
tacts 6 and 3 of the alternator hold relay are
also connected to each other.
At this time, if the starting switch is set to
the START position, the current flows through
the following route.
1o-244 WA1 200-3

. Positive terminal of the battery + Terminal

B of the starting switch + Terminal C of the
starting switch + Terminals 5 - 3 of the
neutral relay + Terminals 6 - 3 of the steer-
ing neutral relay + Terminals 6 - 3 of the
alternator hold relay + Pre-lubrication hold
relay coil + Ground. As a result, contacts 1
and 2, and contacts 3 and 4 of the pre-lubri-
cation hold relay are connected to each other
respectively, and the following circuit is
formed and the current flows through it.
. Terminal BR of the starting switch + Termi-
nals 1 - 2 of the pre-lubrication hold relay +
Terminal 3 of the pre-lubrication timer.
As a result, the contacts of the pre-lubrica-
tion timer are “closed”. Then, the current
flows from the positive terminal of the bat-
tery through the battery relay to the pre-
lubrication starting motor to circulate the en-
gine oil.
At this time, the following circuit is formed,
too; Terminal BR of the starting switch +
Terminals 3 - 4 of the pre-lubrication hold
relay + Neutral relay + Steering neutral re-
lay + Alternator hold relay -_j Pre-lubrica-
tion hold relay coil + Ground. Accordingly,
the current flows in the coil of the pre-lubri-
cation hold relay continuously to hold the
circuit from the starting switch through the
pre-lubrication hold relay to the pre-lubrica-
tion timer.
Accordingly, even after the starting switch is
returned from the START position to the ON
position, the engine starting operation is
continued. That is, it is not necessary to keep
the starting switch at the START position
until the engine starts successfully. The star-t-
ing operation of the engine is stopped by
returning the starting switch to the OFF po-
sition.
If the oil is supplied all over the engine and
the oil pressure rises, the contacts of the
pre-lubrication oil pressure switch are
“opened”. Upon receiving the signal from
this oil pressure switch, the pre-lubrication
timer “opens” its own contacts.
As a result, the current flowing in the pre-
lubrication starting motor is turned off and
pre-lubrication is completed.
WA1 200-3 1 O-245

-VHMS controller
Start ine switch -Service meter
-Main monitor
Slow blow
fuse 30A
rPrelub
hold
relay
Battery
r
Alternator _
I
t
I , starter G
I
Pr club oil Conventional
i-.---c____-3 pr essure : starter
3 switch
sxwo4921
l Several seconds after pre-lubrication is com- . If the starting motor rotates slowly and
pleted, a current flows from terminal 5 of meshes with the gear of the engine, the con-
the pre-lubrication timer to terminal 1 of the tacts of the starting motor are “closed” by
safety relay to “close” the contacts of the the suction force of the pull-in coil, then the
safety relay, then the electric power is sup- starting motor starts quick rotation to start
plied to the pre-lubrication starting motor the engine.
and conventional starting motor. The current does not flow in the pull-in coil
l At this time, the current flows in both hold- any more, but the contacts of the starting
ing coil and pull-in coil of each starting mo- motor are kept “closed” by the current flow-
tor to “close” the contacts. Since the current ing in the holding coil.
also flows through the pull-in coil to the
motor, the starting motor starts slowly.
1 O-246 WA1 200-3

VHMS controller
Sta rtins switch Service meter
3 Main monitor
3
3
------I Slow blow
Battery
LLllrl
- I I
injection & 11 / I
Cummins engine
controller
Ether
injection
9
solenoid
:i
SafZ ’ c
relay T
+
Conventional
pressure = starter
8 switch
sxwo4922
. If the engine starts, the alternator starts gen- connection between terminals 6 and 3 of the
eration and outputs the power through ter- alternator hold relay, then the starting cir-
minal B. At this time, the same voltage is cuit is not held any more.
generated at terminals B and L, and a cur- The current from terminal L of the alternator
rent flows into terminal 2 of the safety relay is supplied as the signal that the engine is
to “open” the contacts of this relay to break rotating to the service meter, etc.
the power for the starting motor. . If the direction switch and/or the joystick
The current flows from terminal L of the steering lever is not in the N (Neutral) posi-
alternator through the alternator hold relay tion, the circuit is broken by the steering
coil to the ground, and the circuit to the pre- neutral relay and the engine does not start.
lubrication hold relay is broken to break the
WA1 200-3 lo-247

STRUCTURE AND FUNCTION ENGINE STOPPING CIRCUIT
ENGINE STOPPING CIRCUIT
VHMS controller
Starting switch
Service meter
Main monitor
Cummins engine
Voltage
Alternator
----__-__-_B reeulato r
-
+
Prelub oi Conventional
IE E: 111;
-__- Pressure starter
switch
sxwo4923
Operation
. If the starting switch is turned to the OFF nals B and L any more, and the signal that
position, the signal from terminal BR of the the engine is rotating is stopped.
starting switch to the CUMMINS electronic The power is not supplied from terminal BR
governor controller is turned off, and the of the starting switch to the battery relay
fuel supply to the engine is stopped to stop any more, and the contacts of the battery
the engine. relay are “opened” to turn off the power
If the engine speed lowers, the alternator supplied to the machine.
does not generate the voltage at its termi-
lo-248 WA1 200-3

STRUCTURE AND FUNCTION ETHER INJECTION CIRCUIT
ETHER INJECTION CIRCUIT
VHMS controller
Starting switch Service meter
Main monitor
Cummins engine
Ether
injection
solenoid
Voltage
Alternator regulator
-__-__-__--8
Prelub oil Conventional

Pressure = starter
8 switch
sxwo4924
Operation
l The ether injection system can operate only 3 and 5 of the ether start relay, and ether
while the starting switch is at the START injection solenoid to the ground is formed,
position. If the ether injection switch is turned then the ether is injected.
on while the starting switch is at the START . If the ether injection switch is turned to the
position, a current flows as follows. OFF position, the current flowing in the ether
l The current flows from terminal R2 of the start relay coil is broken to stop injection of
starting switch through ether injection switch ether. If the starting switch is not at the
and ether start relay coil to the ground, and START position, the current does not flow
terminals 3 and 5 of the ether start relay are from terminal R2 of the starting switch, and
closed. As a result, the circuit from terminal ether is not injected accordingly.
R2 of the starting switch through terminals
WA1 200-3 1 O-249

STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
ELECTRIC PARKING BRAKE CONTROL
Y
SWWO4852
OUTLINE
l The parking brake is a wet multi-disc brake 1. Parking brake switch
built in the transmission. If the current flows 2. Emergency parking brake reset switch
in the parking brake solenoid valve, the oil 3. Parking brake display switch
pressure from the transmission pump is ap- 4. Accumulator
plied to the parking brake cylinder to release 5. Emergency brake switch
the parking brake. If the current is broken, 6. Parking brake solenoid valve
the oil pressure from the transmission pump 7. Emergency parking brake reset solenoid valve
is shut off and the pressurized oil in the 8. Neutralizer relay
parking brake is drained through the park- 9. Parking safety relay
ing brake valve, then the parking brake is
operated with the spring force.
1O-250 WA1 200-3

FUNCTION
1. Applying and releasing parking brake 6. Parking brake emergency release solenoid
The parking brake is applied or released by valve
using the parking brake switch. If the supply of pressure oil from the trans-
mission pump should stop because of some
2. Automatic parking brake failure, it is possible to actuate the emer-
When the engine stops (when the starting gency relief solenoid valve with the parking
switch is OFF), the parking brake is auto- brake emergency release switch in the op-
matically applied to prevent the machine erator’s compartment. This sends the accu-
from running away when the operator is mulator charge pressure in the brake piping
away from his seat. to the parking brake cylinder to release the
parking brake.
3. Emergency brake
If the pressure in the oil pump should drop
because of damage to the hydraulic circuit
and the braking force can not be ensured,
the parking brake is applied automatically to
act as an emergency brake.
4. 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. Therefore, to ensure safety,
the system is designed so that the brake
cannot be released unless the starting switch
is turned ON and then the parking brake
switch is also turned ON.
5. 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 opera-
tion. In addition to this, when the parking
brake is applied, the transmission is forcibly
shifted to neutral to make it impossible to
drive the machine. However, the braking dis-
tance will become longer if the transmission
is shifted to neutral when the emergency
brake is applied. It may also 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.
WA1 200-3 10-251

OPERATION
1. Starting switch OFF
Parking brake switch

(manual)
OFF - - ON
(Applied) Parking brake Neutralizer
seftv relay relay
To transmission
controller
Start ins
switch Emergency brake switch
(installed to accumulator)
sxwo4925
l When the starting switch is turned OFF, the

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 park-
ing brake solenoid valve, regardless of
whether the parking brake switch is ON (ap-
plied) or OFF (released), so the parking brake
is actuated. (Automatic parking brake)
1o-252 WA1 200-3

2. When starting switch is turned ON
2-l.ln case where parking brake switch has been turned ON (operated) before starting switch is turned
ON

(manua I)
OFF - - ON
Battery (Applied) Parking brake Neutralizer
Battery seftu relay relay
Battery
Battery
_-
--!i%~~-~l
L---A L-_
t -
Starting
SXWO4926
l @ Since the current flows from the positive relay + Terminals 5 - 3 of the parking safety
(+I terminal of the battery through the start- relay + Terminals 1 - 2 of the parking safety
ing switch and battery relay coil to the relay + Ground. From this time on, the park-
ground, the battery relay is “closed”. Then, ing safety relay is kept in the circuit of @
@ the current flows from the positive (+) until the starting switch is turned to the OFF
terminal of the battery through the battery position.
. Under this condition, since the current does
relay, terminals 1 - 2 of the parking brake
switch, and terminals 1 - 2 of the parking not flow in the parking brake solenoid valve,
safety relay to the ground. As a result, the the parking brake is applied.
parking safety relay operates and its termi- . Under this condition, since the terminals 3
nals 3 and 5 are “closed”. and 5 of the neutralizer are “opened”, the
l Then, @the following circuit is formed; Posi- transmission is set in neutral by the trans-
tive (+) terminal of the battery + Battery mission controller.
WA1 200-3 lo-253

2-2.ln case where parking brake switch has been turned OFF (released) before starting switch is turned
ON

(manua I)
5 @ To t.an!mission
controller
Start ins
sxwo4927
l @ Since the current flows from the positive valve. Even if the starting switch is turned to
(+I terminal of the battery through the start- the ON position after the automatic parking
ing switch and battery relay coil to the brake is operated, the parking brake is not
ground, the battery relay is “closed”. Since released automatically.
the parking brake switch is turned off (re- l Since the current does not flow in the trans-
leased), however, the parking safety relay mission controller, the machine does not
does not operate. Accordingly, the current move.
does not flow in the parking brake solenoid
1O-254 WA1 200-3

3. When parking brake switch is turned OFF (released)

In case where parking brake switch is turned OFF after starting switch is turned ON

(manua I)
Battery (Applied) Parking brake Neutral izer

Battery relay seftu relay relay
Battery
Battery
y Alternator
R terminal L
@ To !ran!nission
controller
Start ine
SXWO4928
. If the parking brake switch is turned “OFF” @ The circuit of the emergency brake switch
(released), its terminals 2 and 3 are con- through the parking brake solenoid valve to
netted to each other. Since the parking brake the ground is formed, and the parking brake
safety relay is turned on at this time, @ the is released.
current flows from positive (+I terminal of @ The signal flows from terminal 3 of the neu-
the battery through the battery relay and tralizer to the transmission controller, and
parking brake safety relay to parking brake the machine can travel.
switch, then it flows as follows.
WA1 200-3 1o-255

4. When parking brake switch is turned ON (operated)

(manual)
Battery
Bat terv relay
y Alternator
n terminal L
@ To !ran!mission
controller
Start ina
SXWO4926
. If the parking brake switch is turned ON (op- l Since the neutralizer is reset at this time, the
erated) after operating the machine with the circuit of 3 and 5 is “opened” and the signal
parking brake switch turned “OFF”, the does not flow from terminal 3 of the neutral-
above circuit is formed. izer to the transmission controller, then the
l Since the current does not flow in the park- transmission is set in neutral. In this way,
ing brake solenoid valve, the pressurized oil the transmission is set in neutral while the
supplied to the parking brake cylinder is shut parking brake is operated to prevent the
off and the pressurized oil in the parking machine from traveling with the parking
brake cylinder is drained through the park- brake applied to seizure of the parking brake.
ing brake valve. As a result, the parking brake
is operated with the spring force.
1 O-256 WA1 200-3

5. When main brake oil pressure lowers (When emergency brake operates)

(manua I)
Neutralizer
Battery relay
Battery
Battery
controller
Starting
sxwo4930
Operation
. If the oil pressure in the main brake line l As a result, the signal flows to the transmis-
lowers, the emergency brake switch installed sion controller and the transmission clutch
to the accumulator is “opened”. can be engaged. By this operation, the en-
Accordingly, the current does not flow in gine can be used as a brake when the emer-
the parking brake solenoid valve and the gency brake is operated. Consequently, the
pressurized oil in the parking brake cylinder braking distance can be shortened. In addi-
is drained and the parking brake operates. tion, when the emergency brake operates
In this case, however, the current is still flow- but the machine needs to be moved (e.g.
ing in the neutralizer coil, unlike the case when the emergency brake operates while
where the parking brake is turned ON (oper- the machine is traveling through a railroad
ated). crossing), the machine can be moved by op-
erating the transmission switch.
WA1 200-3 lo-257

6. Parking brake emergency release
(Re I eased) Parking brake

ON emergency release
switch_-.-_ Main monitor
Battery
Battery
____ _-- l&Z -7-l 1
c
--@J+--0
t - OFF
I Battery --”
relay_ Buzzer
I I
III IOA
I
Parking brake
BR emergency release
8- solenoid valve
Start ins
switch sxwo4931
Operation
. If the machine should stop because of en- The oil pressure stored in the accumulator
gine trouble, the oil pressure form the trans- in the main brake line then flows to the park-
mission pump to the parking brake cylinder ing brake cylinder to release the parking
is shut off and the parking brake is applied. brake.
When this happens, the oil pressure in the l The emergency release switch should nor-
main brake line is stored in the accumulator. mally be kept at the OFF position and should
l When the emergency release switch is turned be returned to the OFF position after the
on (released), the buzzer sounds, and at the emergency release.
same time, electric current flows to the emer-
gency parking brake release solenoid valve.
lo-258 WA1 200-3

PARKING SAFETY RELAY

NEUTRALIZER RELAY
3
1
6 Relay connection chart
5 2 Relay actuation table
Terminal No. 1
I I
I I
EMERGENCY BRAKE SWITCH
0 0
0
:a @g--D
SWWO4860
PARKING BRAKE EMERGENCY RELEASE SWITCH
Connection table
OFF
4 2
If3
SEW00319
I
WA1 200-3 1O-259

STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
SWWO486I
1. Solenoid valve assembly Outline

2. Block . This solenoid valve is turned on and off ac-
cording to the ON-OFF operation of the park-
B. Outlet port ing brake switch to supply or stop the pres-
P. Inlet port (From transmission) surized oil from the transmission to the park-
T. Drain port ing brake spring cylinder to apply or release
the parking brake.
l When the parking brake solenoid valve is
turned on: Parking brake is released.
When the parking brake solenoid valve is
turned off: Parking brake is applied.
1O-260 WA1 200-3

STRUCTURE AND FUNCTION EMERGENCY PARKING BRAKE RESET SOLENOID VALVE
EMERGENCY PARKING BRAKE RESET SOLENOID VALVE
1. Valve assembly
2. Solenoid valve
A. To parking brake
B. From parking brake solenoid valve
C. From transmission
T. Drain
P. From brake (Accumulator circuit)
SWWO4862
Function
l The emergency parking brake reset solenoid
valve is installed between the transmission
and brake circuit. When the transmission
pump cannot supply oil pressure because of
an engine trouble, etc., the solenoid of the
parking brake reset switch on the operator’s
seat is turned on to apply the accumulator
charge pressure of the brake circuit to the To Parking From parking
brake brake solenoid
parking brake cylinder.
Operation
. If emergency parking brake reset switch @
is turned “ON”, solenoid valve @ operates.
As a result, the pressurized oil in accumula-
tor @ flows in port P to change the circuit
with the pilot pressure, then flows through
port A to the parking brake to reset the park-
ing brake.
WA1 200-3 1O-261

KICK-DOWN SWITCH AND AUTO SHIFT/MANUAL SHIFT
STRUCTURE AND FUNCTION SELECTOR SWITCH
KICK-DOWN SWITCH AND AUTO SHIFT/MANUAL SHIFT

SELECTOR SWITCH
1. Kick-down switch
2. Spring
3. Spring
4. Auto shift/Manual shift selector switch
5. Harness
Resetting
(In manual shift mode)
l When the direction switch is set to the “N”
or “R” position
l When the shift-up switch or shift-down
switch is pressed
SDW02101
(When the shift-down switch is pressed, the
gear is kept in the 1st gear speed.)
When the starting switch is turned off
;ln auto shift mode)
. When the direction switch is set to the “N”
position
l When F or R of the direction switch is
Kick-down switch changed to the opposite direction
. When the shift-up switch or shift-down
Operation switch is pressed
The kick-down switch is installed to the boom . When the travel speed rises
lever. While the conditions of the travel . When the starting switch is turned off
mode, gear speed, and travel speed are sat-
isfied, if this switch is turned ON (pressed), Auto shift/Manual shift selector switch
the gear is shifted down to the 1st gear
speed. Operation
In the manual shift mode, the kick-down l The auto shift/manual shift selector switch
switch is effective only when the transmis- is installed to the boom lever. Each time it is
sion is in the forward 2nd gear position. If it pressed, the travel mode (auto shift/manual
is pressed at this time, the gear is shifted shift) is changed.
down to the 1st gear speed. . In the auto shift mode, the indicator (one of
In the auto shift mode, if the kick-down the three) under the main monitor lights up.
switch is pressed when the machine is l When the starting switch is turned ON, the
traveling forward or in reverse at a speed travel mode (auto shift/manual shift) saved
below 13 km/h, the gear is shifted down to when the starting switch was turned off last
the 1st gear speed. time is selected.
1O-262 WA1 200-3

STRUCTURE AND FUNCTION VHMS INTEGRATED TOOL SOFT
VHMS INTEGRATED TOOL SOFT

l VHMS, which stands for Vehicle Health Monitoring System, is a registered trademark.
. “Overhaul recommendation” and “Life forecast” utilized the memorized data due to a trend
analysis are the future theme.
1. Specifications
The “VHMS Integrated Tool Soft” requires an IBM PC/AT compatible PC running Windows” 95/98.
1) Hardware
CPU: 100 MHz Pentium or higher
l
. Main memory: 16 MB or more

. Hard disk: 8 MB or more of available disk space
. I/O: One or more available serail ports
I/O: Floppy disk drive that is compatible with an IBM PC/AT
l
The use of a computer attached to a LAN is not recommended, as this connection may interfere
with operation.
2) Operating system
The software operates on systems running the following language versions of Windows@ 95 or
Windows@ 98.
However, all screens are displayed in English.
English Japanese Spanish German
3) User interface
User interface uses Windows@-based icons and pull-down menus.
4) Contents of VHMS Integrated Tool Software

@I Service Kit 799-608-3100
The service kit (depicted) consists of the dis-
kette set, installation manual, operation
manual and harness.
@ Diskette 799-608-3110
The diskette set includes VHMS Integrated
Tool Software on four floppy disks, an in-
stallation manual and an operation manual.
@ Harness 799-608-3220
This download cable connects a lap-top PC
to the machine.
Remarks
l To protect important information and prevent illegal copies, this software includes a program
which limits the installation of this product is limited to two times. In principle, this product should
be installed only on one personal computer.
l Error codes and descriptions for new machines must be updated using a reference chart.
l These items can be ordered through normal spare parts routes.
WA1 200-3 1 O-263

0
STRUCTURE AND FUNCTION VHMS INTEGRATED TOOL SOFT
2. Five Major Automatic Data Storage

Functions
1) Snapshot
Data is recorded for each category, creating
a snapshot of 7 minutes, 30 seconds when
the accident occured.
Pm-CLINIC also allows the user to take a
manual snapshot.
2) Trend
Maximum, average and minimum values are
recorded for each category for every 20 hours
of operation.
3) Map function
Engine load map:
This function records engine rpms and rack
position to estimate the position and fre-
quency of operation on the engine torque
curve. This judges severity.
4) Fault history
Electrical and mechanical system abnormali-
ties:
In addition to recording the time at which an
abnormality occurs and the accident code,
this function records the number of times
an abnormality recurs and the accident code
for each occurrence.
Accident codes are displayed with a mes-
sage.
5) Maintenance history
This function records a machine’s m.ainte-
nance history.
(Information is input from a monitor panel.)
1 O-264 WA1 200-3

0
20 TESTING AND ADJUSTING
Standard value table

Standard value table for engine ........................................................................................................ 20- 2
Standard value table for chassis ....................................................................................................... 20- 3
Standard value table for electrical parts .......................................................................................... 20- 9
Testing and adjusting ............................................................................................................................ .20-101
Troubleshooting ...................................................................................................................................... 20-201
Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
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.
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.
These standard values are not the standards used in dealing with claims.
a When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety
pins, and use blocks to prevent the machine from moving.
g When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
g When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
g Be careful not to get caught in the fan, fan belt or other rotating parts.
WA1 200-3 20-l

0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Machine model WA1200-3
I
Item 1 Measurement conditions / Unit ( f~~~~~r~~$‘~e ( Se~~~~mit
Low idling 650 + 50 650 f 75
Rotation speed High idling rpm 2,050 f 50 2,050 + 100
Rated rotation speed 1,900 -
Intake air pressure kPa 165.6 & 15 130

(Boost pressure) Torque converter stall ImmHgI 11,293 r 1131 11,000~
At sharp acceleration Max. 4.5 f 0.5 Max. 4.5 * 0.5

Bosch
Exhaust gas color
index
At high idling Max. 1.0 f 0.5 Max. 1.0 f 0.5
Blow-by pressure (Watertemperaturein operatingrange) 1.25 3.29

(15W-40 oil) Torque converter stall {I271 I3301
h-
(Watertemperaturein operatingrange)
Oil pressure
(I 5W-40 oil) {k;::? )
Oil temperature
All rotation range
(In oil pan) I "C
I 80 - 110 Min. 120
When new (~1 N {kg1 4,893 1498.951 4,893 1498.951

Tension of Measure belt tension with
fan belt belt tension gauge.
When re-tensed N (kg) 4,893 1498.951 4,893 (498.95)
t-i
Press intermediate point I I I

between drive pulley and
Tension of air conditioner
air conditioner compressor mm 9 - 12.5 9 - 12.5
compressor belt
pulley with force of about
98 N (IO kg}.
%: If new one is installed, be sure to readjust it after operating 24 hours.
20-2 WA1 200-3

0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

Standard value Ser$tdmit

/ Unit for new machine
13.7 f 2.0 13.7 + 2.0

(1.4 * 0.2) (1.4 * 0.2)
4.9 +:
(0 .5+q
0
;;:zrting wi l Stop engine. N{kgI
l Measure at center of lever knob. 6.9 + 1.0 6.9 f 1.0
(0.7 f 0.11 IO.7 f 0.11
HOLD+RAISE Max. 23.52 (2.41 Max. 35.28 (3.61
RAISE+HOLD Max. 15.68 Il.61 Max. 23.52 (2.41
HOLD-+LOWER Max. 24.5 (2.5) Max. 37.24 (3.81

E I
8
m
LOWER+HOLD - -
l Run engine at low idling.

l Hydraulic oil temperature: N{kgI Max. 34.3 13.5) Max. 51.94 (5.31
45 - 55°C
FLOAT-tHOLD Max. 14.7 (1.5) Max. 23.54 (2.31
HOLD+DUMP Max. 23.52 (2.4) Max. 35.28 (3.61
Max. 23.52 (2.41 Max. 35.28 I3.6)
Max. 14.7 (I.51 Max. 23.54 (2.31
HOLD-tRAISE 67_+ 15 67 ?I 30
I
t
8 HOLD+LOWER 53_+ 15 53 + 30
m
l Run engine at low idling.
HOLD-FLOAT l Hydraulic oil temperature: mm 672 15 67 ?I 30
45 - 55°C
HOLD-DUMP 60+_ 15 60 + 30
z
5
m3
HOLD-TILT 60f 15 60 + 30
WA1 200-3 20-3

0
Machine model
I
deg. Max. 8 Max. 10
On flat, level, straight, dry, 13.7 f 5.0

Operating effort
l
Wgl 23.5 (2.41
paved road. (I.4 f 0.51
l Run engine at high idling.

Operating angle l Left lock position - Right lock deg. 80 k 8 Max. 90
position.
I
Start engine.
l---i
l
Low idling
l Hydraulic oil temperature:
Operating 45 - 55°C
time l Left lock position - Right lock
High idling
position.
58.8 f 2.45
Pressing force NIkgl Max. 88.2 (9.0)
IS.0 + 0.25)
Neutral (a I) *See Fig. A.

Pressing l Run engine at low idling.
angle l Hydraulic oil temperature:
Max. (a 2) 45 - 55°C
*See Fig. B. 45 -
Pressing Run engine at low idling.
tTq--T-
l
angle l Hydraulic oil temperature:

45 - 55°C deg.
2
Play
Fitting condition of
wheel lock ring
A
*See Fig. C.
y--e+-+
mm Max. 4.0 -
B l Tire inflation pressure:
i= Specified pressure
Clearance of wheel c 2 - 10 -
rock ring
. Coolant: ln operating range 1,950 k 100 1,950 k 200

-0 Torque converter stall speed
8 l Torque converter oil tempera-
,P 1,990 + 200
rpm 1,990 * 100
z
.-
P
w Torque converter stall speed l Gear shift lever: F4 or R4
1,745 f 200 1,745 _+300
+ Hydraulic stall speed
20-4 WA1 200-3
0
Machine model
I WA1 200-3
Standard value Servf$imit

Item Measurement conditions
I 21
{27 C+ 0.2
2.8 I 2.8 21
(27 +f 0.2
2.8 + 0.2 2.8 + 0.2

l Torque converter oil tempera- 127 + 2) (27 f 2)
ture: 60 - 80°C
Torque converter relief l Run engine at high idling. 1.05 + 0.1 1.05 + 0.1
(inlet) pressure (IO.7 * 1.0) I10.7 + 1.0)
Torque converter outlet oil MPa 0.89 + 0.1 0.88 f 0.1

pressure @cm9 19+ 11 {9f 11
2.25 i 0.15 2.25 + 0.15

1st l Torque converter oil tempera-
ECMV output I23 f 1.51 (23 f 1.51
ture: 60 - 80°C
(clutch) oil l Run engine at high idling.
pressure 2nd, 3rd 2.45 + 0.15 2.45 + 0.15
l Turn ON manual switch.
MOD/C, F-R {25 + I.51 (25 f 1.51
l Torque converter oil tempera-

Lubricating oil (oil cooler 0.1 c 0.05 0.1 f 0.05
ture: 60 - 80°C
outlet) pressure 11.o c 0.5) 11.o * 0.5)
Steering relief pressure

45 - 55°C
Orbit roll output pressure
l When brake oil +I.47

17.6 %” 17.6 o
Charge cut-in pressure . Run engine {180+,6) 1180 +;“I
at low idling.
l Hydraulic oil MPa
temperature: :g/cm3
l When rising oil
45 - 55°C 20.6 ‘;.” 20.6 %”
Charge cut-out pressure pressure starts
I210 $5, (210 +o”,
I 6.3 f 0.3
I
6.3 + 0.3
Forward 2nd 11.5 + 0.6 11.5 f 0.6
3rd 19.8 + 1.0 19.8 k 1.0

Travel speed :m/h
7.4 f 0.4 7.4 * 0.4
WA1 200-3 20-5

0
Machine model I WA1200-3
Standard value Setvic&tmit

Item Measurement conditions Unit for new machine
- Hydraulic oil temperature:

Brake oil pressure
45 - 55°C
l Stop engine.
l Continue pressing brake pedal
Brake oil pressure drop to 4.9 MPa 150 kg/cm3 and
measure oil pressure drop
after 5 minutes.
l Tire inflation pressure:

Specified pressure
l On flat, level, straight, dry,
paved road.
l Set initial speed for braking to
Performance 20 km/h. Delay in pressing m Max. 6 Max. 6
must be 0.1 set max.
l Pressing force of brake pedal:
Specified pressing force
294 +- 29.4 N (30 f 3 kg}
l Measure braking distance.
*See Fig. D.
Wear of disc l Measure wear of disc by mm 0 7.0
measuring piston stroke.
High idling 2.65 + 0.2 2.65 + 0.2

IParkina 47 + 21 (27 rf 2)
I
l Torque converter oil tempera- MPa 2.94 It 0.29 2.94 * 0.29
I
ture: 80 - 80°C kdcm3 130 f 31 {30 + 31
2.65 f 0.2 2.65 f 0.2
Parking brake pilot pressure
(27 + 2) 07 + 2)
,
*See Fig. E.
l Tire inflation pressure:
Performance Specified pressure
l On flat, paved, dry road - stop stop
having gradient of l/5 (11’20’).
l Set machine in operating state.
Thickness of disc mm 3.2 + 0.1 2.77

I
PPC pump pressure 45 - 55°C

PPC valve main pressure 3.72 2” 3.72 + 0.2
45 - 55°C
Run engine at high idling. I38’,1 i38+21
l
MPa
:Qlcm3
Raising/Floating
of boom and l Hydraulic oil temperature: 3.72 T’ 3.72 f 0.2
PPC valve dumping/tilting 45 - 55°C 08’: 1 138 f 2)
3utput of bucket l Run engine at high idling.
Jressure l Operate work equipment
Lowering of control lever full stroke. 2.54 T!Z0.05 2.54 + 0.05
i boom (26 z!z0.51 126 + 0.51
20-6 WA1 200-3

0
Machine model WA1 ZOO-3
l Hydraulic oil temperature: MPa 31.36%: 3 1.36 %‘;;

Work equipment relief 45 - 55°C
pressure I’kg/cm3 -3 )
{320+” -13 )
f320”’
l Run engine at high idling. I I
12.5 f 0.5 Max. 14.0

I
set
I}I 5.0 f 0.5
I
Max. 7.0
When tilted through

I 3.7 * 0.3
I
Max. 5.0
2.3 + 0.3 Max. 3.4
*See Fig. H.
C Hydraulic drift of Hydraulic oil temperature: Max. 250
l Max. 250
g bucket hinge pin 45 - 55°C
l Stop engine and leave it for
mm
!-----I 15 min, then measure for I5
min. Max. 100 Max. 100
5 Hydraulic drift of (Excluding (Excluding
l Empty bucket and set boom
s bucket tooth edge hydraulic drift of hydraulic drift of
and bucket level.
bucket hinge pin) bucket hinge pin)
WA1 200-3 20-7

0
* Illustration of components related to standard values table
*Fie.A
face
*Fig. C *Fig. D
*Fig. E ) f Fio. F
*Fig.G *Fig. H
When fully
Work equipment
I Posture
Horizontal
rim A
I TWW0243 I
20-B WA1 200-3
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
T
Systen n
Name of
comioonent T
(Zonnector
No.
Judgement table
Measurement
conditions
Normal ranges are as follows. I) Turn starting
switch OFF.
2) Insert T-
SW power
supply
-1 20_30”
adapter.
3) Turn starting
switch ON.
1 Between C2(1), (12) -(II), (21) 1
Normal ranges are as follows. 1) Turn starting

switch OFF.
Between (6) - (17) 2) Inset-t T-
Sensor 20- 30 v adapter.
power C3A Between (6) - chassis 3) Ts;cpo;ng
supply
4) Turn parking
brake switch
OFF.

switch OFF.
S-NET 1 Between (4). (12) - chassis 1 4- 8V 2) Insert T-
adapter.
3) Turn starting
switch ON.

C3B switch OFF.
2) Insert T-
adapter.
Manual shift 3) Turn starting
switch switch ON.

switch OFF.
Transmis- 2) Insert T-
sion cut-off adapter.
switch 3) Turn starting
switch ON.
C3A
switch OFF.
Kickdown 2) Insert T-
switch adapter.
3) Turn starting
switch ON.

switch OFF.
Joystick 2) Insert T-
FNR button adapter.
switch “F” 3) Turn starting
switch ON.
C3B
Normal ranges are as follows. II Turn starting
switch OFF.
FNR button adapter.
switch “N” 3) Turn starting
switch ON.
WA1 200-3 20-9

Syste:m
T Name of
comDonent
Connect0
No.
Judgement table
Measurement
conditions

switch OFF.
gear shift C3B adapter.
switch R 3) Turn starting
switch ON.
L I I J

switch OFF.
Neutralizer 2) Insert T-
relay signal C3A adapter.
3) Turn starting
switch ON.

switch OFF.
shift-up adapter.
switch (N.0 3) Turn starting
switch ON.
c5
switch OFF.
shift-down adapter.
switch (N.0 3) Turn starting
switch ON.

switch OFF.
Joystick When joystick shift- Between 2) Insert T-
17 -30 v
shift-up up switch is “ON” adapter.
switch (N.CI When joystick shift- ,.i.$& 3) T~;c~ort$g
Max. 1 V
up switch is “OFF”
c5
switch OFF.
2) Insert T-
Joystick
adapter.
shift-down
3) Ts;c,staOrt$g
switch (N.C)

switch OFF.
2) Insert T-
Steering adapter.
lock signal C3B
3) Turn starting
switch ON.

switch OFF.
Transmis- 2) Disconnect
sion oil C3A connector.
temperature 3) Connect T-
adapter.
20-10 WA1 200-3
0
7
Syste!m
Name of
comeonent
I Connectc
No.
iOll
Od
Judgement
Measure in AC range.
table
Measurement
conditions
1) Turn starting
Engine :, switch OFF.
rotation 1 Between (1) - (9) Min. 0.5 V 2) Insert T-
sensor j adapter.
3) Start engine

switch OFF.
2) insert T-
adapter.
Backup lam 3) Turn starting
relay signal ~~ switch ON.

switch OFF.
2) Insert T-
> Sl adapter.
Buzzer
3) Turn starting
signal ON switch ON.
Normal ranges are as follows. II Turn starting

switch OFF.
I
2) Insert T-
‘1 signal adapter.
XJtput 3) Turn manual
shift switch
ON.
4) Start engine

switch OFF.
2) Insert T-
adapter.
Jut0 range 3) Turn starting
1st LED switch ON.
rignal I I) Set directional
t If shift-down switch is kept pressed, lever in F or FL
gear is shifted down to 1st. j) Turn manual
shift switch
OFF.

switch OFF.
!I Insert T-
* adapter.
kit0 range I) Turn starting
!nd LED switch ON.
#ignal 1) Set directional
lever in F or R.
* Do not operate shift-up switch or shift-
down switch when default mode is in 2nd i) Turn manual
shift switch
(Leave as set when engine was started).
OFF.
Normal ranges are as follows. ) Turn starting

switch OFF.
!I g”lsepsee;-
Uto range I) Turn st&ing
:rd LED switch ON.
ignal ,I Set directional
lever in F or R.
Ir If shift-up switch is kept pressed, gear is 1)Turn manual
shift switch
shifted up to 3rd.
OFF.
WA 1200-3 20-11
0
Name of Connect0r Measurement

Syste No.
Judgement table
conditions
component
switch OFF.
2) Disconnect
L15 connector.
Manual shift
switch (Male) 3) Connect T-
adapter.

1 When FORWARD 1 I 1
switch OFF.
2) Disconnect
connector.
F: T14 3) Connect T-
(Male) adapter.
4) Start engine.
I measuring point I 5) Turn transmis-
sion cut-off
switch OFF.
Normal ranges are as follows. 6) Turn parking
brake switch
OFF.
7) Press brake
R: Tl2 pedal to
(Male) ~~ prevent ma-
chine from
ECMV fill switch moving.

switch OFF.
2) Disconnect
connector.
1st: T4 3) Connect T-
(Male) adapter.
~~
2nd: T6 %)Start engine.
(Male) 5) Set directional
3rd: T8 lever in N.
(Male) * When default after starting of engine is 2nd, 6) Turn manual
if shift-down switch is kept pressed, gear is shift switch
shifted down to lst, and if shift-up switch is ON.
kept pressed, gear is shifted up to 3rd.

switch OFF.
2) Disconnect
Transmission L12 connector.
cut-off switch (Male) 3) Connect T-
adapter.

f switch OFF.
2) Disconnect
Kickdown switch L15 connector.
(Male) 3) Connect T-
adapter.

switch OFF.
Transmission oil 2) Disconnect
T19
temperature connector.
sensor (Male)
3) Connect T-
adapter.

switch OFF.
Speedometer T15 1 Between (1) - (2) I500-1,OOOR 1 2) Disconnect
sensor (Male) connector.
1 Between (11, (2) -chassis 1 Min. 1 MR 1 3) Connect T-
adapter.
20-12 WA1 200-3

0
Name of Connectc Measurement

System Judgement table
component No. conditions
1) Screw in speed sensor until it touches

Speedometer - ring gear, then return it by l/2 - 1 turn.
sensor 2) Speed sensor must operate normally af-
ter above adjustment.

switch OFF.
Engine rotation T17 Between (1) - (2) 500 - 1,000 R 2) Disconnect
Between (1). (2) - chassis Min. 1 MR 3) Connect T-
adapter.
1) Screw in engine rotation sensor until it

Engine rotation touches ring gear, then return it by l/2 -
sensor 1 turn.
2) Engine rotation sensor must operate nor-
mally after above adjustment.

switch OFF.
Modulated 2) Disconnect
clutch outlet T16 Between (1) - (2) 500 - 1,000 R
(Male) connector.
rotation sensor Between (11, (2) - chassis Min. 1 MR 3) Connect T-
adapter.
1) Screw in modulated clutch outlet rotation

Modulated sensor until it touches ring gear, then re-
clutch outlet - turn it by 314 - 1 turn. -
rotation sensor 2) Modulated clutch outlet rotation sensor
must operate normally after above
adiustment.

switch OFF.
2) Insert T-
Parking brake LO1 adapter.
switch
3) Turn starting
switch ON.

switch OFF.
F bypass T22 1 Between (1) - (2) 1 5-15R 1 2) Disconnect
solenoid (Male) connector.
adapter.

switch OFF.
R bypass T21 Between (1) - (2) 5-15n 2) Disconnect
Between (11, (2) - chassis Min. 1 MR 3) Connect T-
adapter.

switch OFF.
R drain solenoid T23 1 Between (1) - (2) I 5-15R I 2) Disconnect
(Male) connector.
1 Between (11, (2) - chassis I Min. 1 MB 1 3) Connect T-
adapter.

switch OFF.
1st bypass T20 Between (1) - (2) 5-15R 2) Disconnect
Between (11, (2) - chassis Min. 1 MQ 3) Connect T-
adapter.
WA1 200-3 20-13

0
Name of Zonnectc Measurement

Syste Judgement table
comoonent No. conditions
switch OFF.
FFFMV solenoid T13 Between (1) - 12) 5-15n 2) Disconnect
(Male) connector.
Between (I), (2) - chassis Min. 1 MfZ 3) Connect T-
adapter.

switch OFF.
ECMV solenoid Tll Between (1) - (2) 5-15R 2) Disconnect
(R) (Male) connector.
Between (l), (2) - chassis Min. 1 MR 3) Connect T-
adapter.

switch OFF.
ECMV solenoid Between (I) - (2) 5-15R 21 Disconnect
(1st) connector.
Between (11, (2) - chassis Min. 1 MR 3) Connect T-
adapter.

switch OFF.
ECMV solenoid Between (1) - (2) 5-I5R 2) Disconnect
(2nd) (Mze) connector.
Between (l), (2) - chassis Min. 1 MQ 3) ~;;anp~ T-

switch OFF.
ECMV solenoid Between (1) - (2) 5-15R 2) Disconnect
(3rd) (M;e) connector.
Between (l), (2) - chassis Min. 1 MR 3) Connect T-
adapter.

switch OFF.
SW power Between (8) - chassis 2) insert T-
supply 20 - 30 v adapter.
Between (18) - chassis 3) Turn starting
switch ON.

switch OFF.
Solenoid 2) Insert T-
power Between (17) - chassis 20 - 30 v
MO1 adapter.
supply 3) Turn starting
switch ON.

switch OFF.
Between (11, (12) - chassis 4-8V U Insert T-
S-NET adapter.
3) Turn starting
switch ON.

switch OFF.
!) Insert T-
adapter_
3) Start engine
PPC pres-
sure switch
(Raise M02A
boom)
f Operate lever just a little (to degree that

work equipment does not move) (for only
detection PPC pressure signal).
20-14 WA1 200-3
0
T
Systern
Name of
comDonent
-I-
T
(Ionnectoi
No.
Judgement table
Measurement
conditions
switch OFF.
I Work equipment I I I 2) Insert T-
adapter.
PPC pres-
3) Start engine
sure switch
&:)r
* Operate lever just a little (to degree that

switch OFF.
2) Insert T-
adapter.
PPC pres- 3) Start engine.
sure switch
(Tilt bucket)


switch OFF.
2) Insert T-
adapter.
3) Start engine
PPC pres-
sure switch
[Dump
bucket)
M02A + Operate lever just a little (to degree that

switch OFF.
Right brake 2) insert T-
pedal signal adapter.
11 3) Turn starting
switch ON.

switch OFF.
??a !I Insert T-
adapter.
-1 signal 24 s) Turn manual
input :% shift switch
H’
ON.
C) Start engine

Transmis- switch OFF.
sion cut-off !) Insert T-
switch adapter.
signal 1) Turn starting
switch ON.
Normal ranges are as follows. 1 Turn starting

switch OFF.
RPM set t) Insert T-
DLE-UP adapter.
signal 1) Turn starting
switch ON.
WA1 200-3 20-15

0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PAFfTS
I-
Systern
Name of
lmponent T
Connector
No.
Xl
d
Judgement table
Measurement
conditions
switch OFF.
2) Insert T-
RPM set
adapter.
IDLE-DOWN
3) Turn starting
signal
switch ON.

switch OFF.
When accelerator 1 1 2) Insert T-
Low idling adapter.
(Li) switch 3) Turn starting
signal switch ON.
M02A
switch OFF.
Between M02A(lO) - M02A(9) 14.75 - 5.25 V 2) Insert T-
Between M02Al19) - M02A(9) 1 0.5 - 4.75 V adapter.
3) Turn starting
switch ON.
Between M02A(19) - M02A(9)

Accelerator
pedal signal
* Above table shows standard value of
potentiometer voltage at which controller
can recognize dial range normally.
When potentiometer is readjusted, set
margin of error judging area.
y3100w,i$$rg, set voltage in range from
(Error jddging area is potentiometer volt-

age < 0.5 V or potentiometer voltage >
4.5 V.)

switch OFF.
Between M02AUO) - M02A(9) 14.75 - 5.25 ~1 2) Insert T-
adapter.
Between M02BU) - M02A(9) 0.5 - 4.75 v 3) Turn starting
Between M02BH) - M02A(9) switch ON.
0.5 - 1.6 V
IMAXI
Between M02BU) - M02A(9)
3.5 - 4.75 v
Drive force M02A (MINI
control dial M02B
rlr When potentiometer is readjusted, set
At MIN, set voltage in range from 1.3 to
1.6 V.
(Error judging area is potentiometer volt-
age c 0.3 V or potentiometer voltage >
4.7 V.)
20-16 WA1 200-3

0
TESTING AND ADJUSllNG STANDARD VALUE TABLE FOR ELECTRICAL PARTS
I
Syste m
Name of
comoonent
Connector
No.
Judgement table Measurement
conditions
switch OFF.
Between M02A(lO) - M02A(9) 2) insert T-
adapter.
Between M02BHO) - M02A(9)
3) Turn starting
switch ON.
Between M02B(lO) - M02A(9)

Travel 3.5 - 4.75 v
speed M02A (MINI
control dial M02B
f When potentiometer is readjusted, set
At MIN, set voltage in range from 1.3 to
1.6 V.
(Error judging area is potentiometer volt-
age c 0.3 V or potentiometer voltage >
4.7 V.)

RPM set switch OFF.
ON/OFF 2) Insert T-
switch adapter.
signal 31 Turn starting
switch ON.
Measure in AC range. 1) Turn starting

Engine switch OFF.
.otation M02B Between (5) - (12) Min. 0.5 V 2) Insert T-
iensor adapter.
3) Start engine.
Measure in AC range. 1) Turn starting

Engine switch OFF.
-0tation Between (14) - chassis Min. 0.5 V 2) Insert T-
signal adapter.
.output) 3) Start engine.

switch OFF.
!) Insert T-
adapter.
leutral-cut $1 Start engine.
~~ 1) Travel in F3 at
NC) 10 km/h or
solenoid
higher.
f Operate lever just a little (to degree that

MO1 work equipment does not move) (for only
Normal ranges are as follows.

Electronic
governor
voltage
:ommand
signal
WA1 200-3 20-17

0
-
Name of Conner% ion Measurement
Judgement table
comoonent No. od conditions
RPM set switch OFF.
:,
)
ON/OFF 2) insert T-
3 adapter.
switch 5
indicator . 3) Turn starting
switch ON.
MO1
Travel switch OFF.
speed 2) Insert T-
switch adapter.
indicator 3) Start engine.

Travel switch OFF.
speed set When travel speed 2) Insert T-
M02A set switch is “ON” Max. 1 V adapter.
switch Between
signal When travel speed (26) - (8) Min 2 6 v 3) Turn starting
set switch is “OFF” . . switch ON.

switch OFF.
1 When FORWARD 1 2) Disconnect
F: T14 connector.
(Male) 3) Connect T-
adapter.
4) Start engine.
5) Turn transmis-
sion cut-off
switch OFF.
Normal ranges are as follows. 6) Turn parking
brake switch
1 When REVERSE I OFF.
R: T12 7) Press brake.
(Male)
ECMV fill switch Normal ranges are as follows. 1) Turn starting

switch OFF.
1When set to measur- 1 I I 2) Disconnect
connector.
1st: T4 3) Connect T-
(Male) adapter.
2nd: T6 4) Start engine.
(Male) 5) Set directional
3rd: T8 lever in N.
(Male) * When default after starting of engine is 5) Turn manual
2nd. if shift-down switch is kept pressed, shift switch
gear is shifted down to lst, and if shift-up ON.
switch is kept pressed, gear is shifted up
to 3rd.

switch OFF.
!I Disconnect
connector.
M%C $1 Connect T-
(Male) ~~ adapter.
20-l 8 WA1 200-3

0
Name of Connect0 Measurement

Syster n Judgement table conditions
component No.
I) Screw in wheel rotation sensor (on left

Wheel rotation side of front wheels) until it touches
sensor (on left flange, and measure clearance between -
IF151 rotation sensor flange and housing.
side of front
wheels) 2) Adjust clearance to +{0.6 + 0.11 mm with
shims.

switch OFF.
Modulated T16 Between (I) - (2) 500 - 1,000 R 2) Disconnect
clutch outlet connector.
(Male)
rotation sensor Between (11, (2) - chassis Min. 1 MR 3) Connect T-
adapter.
1) Screw in modulated clutch outlet rotation

sensor until it touches ring gear, then re-
Modulated turn it by l/2 - 1 turn.
clutch outlet - -
2) Modulated clutch outlet rotation sensor
rotation sensor must operate normally after above
adjustment.

switch OFF.
T17 Between (I) - (2) 500 - 1,000 R 2) Disconnect
Engine rotation connector.
sensor (Male)
Between (I 1, (2) - chassis Min. 1 MQ 3) Connect T-
adapter.
I) Screw in engine rotation sensor until it

touches ring gear, then return it by l/2 -
Engine rotation - 1 turn. -
sensor 2) Engine rotation sensor must operate
normally after above adjustment.

switch OFF.
Speedometer T15 Between (1) - (2) 500 - 1,000 R 2) Disconnect
Between (I), (2) - chassis Min. 1 ML2 3) Connect T-
adapter.
I) Screw in speed sensor until it touches

Speedometer - ring gear, then return it by II2 - 1 turn.
sensor 2) Speed sensor must operate normally
after above adjustment.

switch OFF.
Between (1) - (2) 5-15R 2) Disconnect
connector.
Between (I), (2) - chassis Min. 1 MQ 3) Connect T-
adapter.
WA1 200-3 20-19

0
T
Syste m
Name of
)mponent -TConnector
NO.
m
d
Judgement table

Measurement
conditions
1) Turn starting
switch OFF.
SW power Between (8) - chassis 2) Insert T-
switch ON.

switch OFF.
Solenoid 2) Insert T-
power L26 Between (17) - chassis I 20 - 30 v I
adapter.
switch ON.

switch OFF.
Between (11, (12) - chassis 4-8V 2) Insert T-
S-NET adapter.
3) Turn starting
switch ON.

switch OFF.
Workequipment 2) Insert T-
adapter.
PPC
3) Start engine.
pressure
switch
(Raise I I I
boom)

switch OFF.
2) Insert T-
PPC adapter.
pressure 3) Start engine.
switch
I I I
!CZ%r
-work equipment does not move) (for only
L27 detection PPC pressure signal).

switch OFF.
Remote 2) Insert T-
positioner adapter.
function )I 3) Turn starting
switch switch ON.

switch OFF.
Steering 2) Insert T-
rock adapter.
pressure 3) Start engine.
switch

switch OFF.
potentiomete adapter.
calibration 3) Turn starting
reset switch switch ON.
20-20 WA1 200-3
0
T
System
m
Name of
‘mponent T
(Zonnector
No.
Judgement table
Measurement
conditions
switch OFF.
When boom angle 2) Insert T-
Boom angle is UPPER. 4.33 ?:0.33 V
Between adapter.
sensor When boom angle (19) - (9) o 66 + o 33 V 3) Start engine.
is LOWER.
L27
switch OFF.
lever angle adapter.
sensor 3) Start engine.

switch OFF.
Frame angle L28 2) Insert T-
sensor L27 adapter.
3) Start engine.

switch OFF.
2) Insert T-
Joystick adapter.
lever neutral 3) Turn starting
~~
interlock switch ON.
relay
* Set machine in straight travel position.

L26
1 When boom switch OFF.
2) insert T-
Boom
adapter.
raising
3) Start engine.
kick-out
solenoid
relay
used
* Use remote positioner function.
switch OFF.
When joystick 2) Insert T-
caution buzzer 17 - 30 v adapter.
relay is output Between 3) T~;cyort$g
Joystick When joystick (15) -
caution L28 chassis
caution buzzer Max. 1 V
buzzer relay relay is not output
+ Signals are output to joystick caution buzzer
relay when machine is set in straight travel
position and joystick steering lever is set in
position other than neutral.

switch OFF.
When boom 2) Insert T-
positioner function Min. 5 V adapter.
Boom is turned on Between 3) Start engine.
dumping L26 When boom (3) - (14)
solenoid (1) positioner function Max. 1 V
is not turned on
* Lower boom lever fully by lowering op-
eration of remote positioner.
WA1 200-3 20-21

0

Syster No.
Judgement table
conditions
bmponent
switch OFF.
When boom positioner 2) Insert T-
Boom function is turned on Min. 5 V
Between adapter.
dumping L26 When boom positioner (5) - (15) 3) Start engine.
solenoid (21 function is not turned on t Max. 1 V
L I
* Lower boom lever fully and hold it by

lowering operation of remote positioner.
Joystick Normal ranges are as follows. 1) Turn starting

CGC I , switch ON.
main pres- monitor
sure contra When joystick lever switch is 466k ,00 mA
screen in neutral
EPC

switch OFF.
2) Insert T-
adapter.
3) Start engine.
Boom angle
F04
sensor
switch OFF.
Between (1) - (2) o-5kQ 2) Disconnect
connector.
Between (3) - (2) 4-5kQ 3) Connect T-
adapter.

switch OFF.
2) Insert T-
adapter.
3) Start engine.
Steering lever
JS2
angle sensor
switch OFF.
1 Between (1) - (2) I o-5ks2 1 2) Disconnect
connector.
Between (3) - (2) 4-5kQ 3) Connect T-
adapter.

switch OFF.
2) Insert T-
adapter.
3) Start engine.
Frame angle
L30
sensor 1) Turn starting
switch OFF.
1 Between (1) - (2) I o-5kQ 2) Disconnect
connector.
Between (3) - (2) 3) Connect T-
adapter.

switch OFF.
Speedometer T15 1 Between (1) - (2) I 500 - 1,000 kQ 2) Disconnect
sensor connector.
(Male)
1 Between (11, (2) - chassis 1 Min. 1 MR ( 3) Connect T-
adapter.
1) Screw in speed sensor until it touches

Speedometer ring gear, then return it by l/2 - 1 turn.
sensor 2) Speed sensor must operate normally
after above adjustment.
20-22 WA1 200-3
0
Name of Eonnector Measurement

Systen Judgement table
comDonent No. n&hod conditions
Boom lever switch OFF.
kick-out Between (1) - (2) 19-23R 2) Disconnect
L16
solenoid connector.
3) Connect T-
adapter.
switch OFF.
Boom dumping Between (I) - (2) 15-25R 2) Disconnect
HR8 connector.
solenoid (I 1
3) Connect T-
adapter.
switch OFF.
Boom dumping Between (1) - (2) 15-250 2) Disconnect
HR9
solenoid (2) connector.
3) Connect T-
adapter.
switch OFF.
NSW power Between (6) - chassis 2) Insert T-
switch ON.
switch OFF.
SW power Between (8) - chassis 2) Insert T-
switch ON.
switch OFF.
Sensor
Between (2) - chassis 22 - 25 V 2) Insert T-
power VI
adapter.
switch ON.
Sensor switch OFF.
power Between (3) - chassis 11- 13v 2) Insert T-
=$PlY adapter.
3) Turn starting
switch ON.
Sensor switch OFF.
power Between (4) - chassis 2) Insert T-
&PPIY 4-6V adapter.
switch ON.
switch OFF.
S-NET V3A Between (8), (18) - chassis 4-8V 2) Insert T-
adapter.
3) Turn starting
switch ON.
Boom switch OFF.
bottom Between (1) - (12) 0.7 - 5.3 v 2) Insert T-
pressure adapter.
sensor (Reference) When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.
VI
Boom head switch OFF.
pressure Between (IO) - (12) 0.7 - 5.3 v 2) Insert T-
sensor adapter.
:3) Turn starting
(Reference) When open to atmosphere: 0.5 - 1.5 V
switch ON.
WA1 200-3 20-23

0
l-
Systern
Name of
comcronent T
IZonnector
No.
Judgement table
Measurement
conditions
Flashing switch OFF.
synchroniz- Whenflashingsynchro- 2) Insert T-
ing signal nizingsignalis ON Between Max. 1 V
(13) - adapter.
(For main Whenflashingsynchro- 3) Turn starting
monitor) chassis 20 - 30 v
nizingsignalis OFF switch ON.

switch OFF.
2) Insert T-
Check lamp adapter.
(For main 3) Turn starting
monitor) switch ON.
Vl
4) Satisfv condi-
Ir Disconnect connector of battery fluid level tion for turning
sensor to output low fluid level alarm. on check lamp.

switch OFF.
When buzzer is 2) Insert T-
turned on Between Max. 1 V
(16) - adapter.
Buzzer When buzzer is chassis 3) Turn starting
output stopped 20 - 30 v switch ON.
4) Satisfy condi-
* Disconnect connectors of coolant level tion for turning
sensor, brake fluid level sensor, etc. to on buzzer.
output low fluid level alarm.

switch OFF.
PPC relief 1 Between (1) - (12) I 0.7 - 5.3 v I 2) Insert T-
pressure adapter.
Ir When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.

switch OFF.
2) Insert T-
Alternator adapter.
terminal R
voltage
Ir If battery is deteriorated or in cold district,
voltage may not rise for a while after en-
gine is started.

Torque switch OFF.
converter 1 Between (5) - (3) 1 0.7 - 5.3 v 1 2) Insert T-
outlet oil V2A adapter.
pressure Ir When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.
Transmis- switch OFF.
sion main 1 Between (6) - (3) I 0.7 - 5.3 v 1 2) Insert T-
relief pres- adapter.
sure 1: When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.
switch OFF.
Brake Between (7) - (3) 0.7 - 5.3 v 2) Insert T-
pressure (F) adapter.
Ir When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.
switch OFF.
Brake Between (8) - (3) 0.7 - 5.3 v 2) Insert T-
pressure (R) adapter.
* When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.
20-24 WA1 200-3

0
T
Syster n
-
Name of
lmponent T
(lonnector
No.
Judgement table
Measurement
conditions
switch OFF.
Hydraulic oi 1oo”c 2) Disconnect
25°C 3. Insert T-
adapter.

Transmissior switch OFF.
lubricating 1 Between (14) - (12) I 0.2 - 4.8 v I 2) Insert T-
oil pressure adapter.
sensor Ir When open to atmosphere: 0.2 - 0.8 V 3) Turn starting
switch ON.

Transmissior switch OFF.
modulating 1 Between (15) - (12) 1 0.7 - 5.3 v 1 2) Insert T-
oil pressure V2A adapter.
switch ON.

F;;;;ing switch OFF.
Between (16) - (12) 0.7 - 5.3 v 2) Insert T-
pressure adapter.
switch ON.

Work
equipment switch OFF.
relief Between (18) - (12) 0.7 - 5.3 v 2) Insert T-
pressure adapter.
sensor * When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.

switch OFF.
Battery fluid Between (1) - chassis 5.5 - 6.5 V 2) Insert T-
level (1) adapter.
3) Turn starting
switch ON.
switch OFF.
level (2) adapter.
3) Turn starting
switch ON.
V2B
switch OFF.
level (3) adapter.
3) Turn starting
switch ON.
Torque Normal ranges are as follows. 1) Turn starting

converter switch OFF.
inlet oil Between (IO) - (9) 0.7 - 5.3 v 2) Insert T-
pressure adapter.
switch ON.

switch OFF.
Brake fluid 2) Insert T-
V3A
level (RI adapter.
3) Turn starting
switch ON.
WA1 200-3 20-25

0
Systenn
T Name
co mponent
of
Tc lonnector
No.
Kp.40
nethoc
Judgement table
Measurement
conditions

switch OFF.
2) Insert T-
adapter.
Coolant u 3) Turn starting
switch ON.
Ir When coolant level is low, sensor is
OPENED.

switch OFF.
Transmis- 2) Insert T-
sion oil filterr adapter.
differential V3A
3) Turn starting
pressure switch ON.
Klogging)
* When filter is clogged, sensor is
OPENED.

Boom switch OFF.
positioner
proximity E Bemeeni
Max.lV 1
2) Insert T-
adapter.
switch (For 3) Turn starting
:oad meter) receives rated load (16) - (17) 17 - 30 V switch ON.

switch OFF.
2) insert T-
adapter.
Just 3) Turn starting
ndicator ‘I switch ON.
li When air cleaner is clogged, dust indica-
tor 1 is CLOSED and dust indicator relay 1
is OPENED.

switch OFF.
2) Insert T-
adapter.
Dust 3) Start engine.
indicator 2
t When air cleaner is clogged, dust indica-
is OPENED.
V3B
switch OFF.
2) Insert T-
adapter.
Dust 3) Start engine.
indicator 3
t When air cleaner is clogged, dust indica-
is OPENED

switch OFF.
2) Insert T-
adapter.
3ust 3) Start engine.
ndicator 4
* When air cleaner is clogged, dust indica-
is OPENED.
L
20-26 WA1 200-3

0
Name of :onnectoi Measurement

switch OFF.
When brake fluid 21 InsertT-
V3B level is normal Between Max. 1 V
(5) - adapter.
When brake fluid chassis 3) Start engine.
level is low I7 - 30 V

switch OFF.
Boom bottom Between (3) - 111 0.7 - 5.3 V 21 Insert T-
pressure sensor FO6
adapter.
Ir When open to atmosphere: 0.5 - I.5 V 3) $;c~ort$g

switch OFF.
Boom head Between (3) - (I) 0.7 - 5.3 v ~ 2) Insert T-
pressure sensor F14
adapter.
* When open to atmosphere: 0.5 - 1.5 V 31 Turn starting
switch ON.
switch OFF.
PPC relief 1 Between (3) - (1) I 0.7 - 5.3 v ~ 2) Insert T-
pressure sensor HS4
adapter.
f When open to atmosphere: 0.5 - 1.5 V 31 T$;cFort$g

Transmission switch OFF.
main relief Between (3) - (1) 0.7 - 5.3 v 2) Insert T-
MT2
pressure sensor adapter.
switch ON.
Torque switch OFF.
converter outlet 1 Between (3) - (1) 1 0.7 - 5.3 v / 2) Insert T-
oil pressure MT3
adapter.
sensor * When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.
Torque switch OFF.
converter inlet 1 Between (3) - (1) I 0.7 - 5.3 v I 21 Insert T-
oil pressure MT4
adapter.
sensor t When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.
lubricating oil MT1 1 Between (3) - (1) 10.2 - 4.8 V 1 2) Insert T-
pressure sensor adapter.
t When open to atmosphere: 0.2 - 0.8 V 3) Turn starting
switch ON.
modulating oil MT5 Between (3) - (1) 0.7 - 5.3 v 2) insert T-
oressure sensor adapter.
f When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.
switch OFF.
Steering oil ) Between (3) - (I) I 0.7 - 5.3 v I 2) Insert T-
lressure sensor HS3
adapter.
switch ON.
Nork equipment switch OFF.
.elief pressure 1 Between (3l- (1) I 0.7 - 5.3 v I 2) Insert T-
HS2
sensor adapter.
f When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.
WA1 200-3 20-27

0
Name of Connector Measurement

Syster Judgement table
switch OFF.
Brake fluid level 2) Insert T-
HR6 adapter.
(R)
3) Turn starting
switch ON.
switch OFF.
Brake fluid level 2) Insert T-
(F) HRlO adapter.
3) Turn starting
switch ON.
switch OFF.
Brake pressure Between (3) - (1) 0.7 - 5.3 v 2) Insert T-
HR15 adapter.
sensor (F)
f- When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.
switch OFF.
Brake pressure 2) Insert T-
HR16 Between (3) - (1) 0.7 - 5.3 v
sensor (RI adaoter.
t When open to atmosphere: 0.5 - 1.5 V 3) Turn starting
switch ON.
switch OFF.
Atmospheric 2) Disconnect
temperature PHI connector.
sensor
3) Connect T-
adapter.

Hydraulic oil switch OFF.
temperature HSl 100°C Between Approx. 3.5 - 4 kQ 2) Disconnect
sensor connector.
25°C (‘1 - 12) Approx. 37 - 50 kQ 3) CZ;;;;e;t T-

Torque switch OFF.
converter oil T24 Normal (25°C) Approx.40 kQ 2) Disconnect
Between
sensor 130°C (1) - (2) Approx.1.7 161 3) Connect T-
adauter.
switch OFF.
FULL (100%) Approx.10R 2) Disconnect
connector.
Fuel level l/2 (50%) Approx.32 R 3) Set fuel level
sensor R05 Between
l/4 (25%) Approx.49.5R sensor as
(‘1 - (2)
shown at left.
EMPTY (0%) Approx.85 R 4) Connect T-
adaDter.
Normal ranges are as follows, 1) Turn starting
switch OFF.
Battery fluid Between RA7 - 2) Disconnect
level (1) RA7 5.6 - 6.5 V connector.
chassis ground
3) Cb;gt T-

switch OFF.
Battery fluid 2) Disconnect
RAB Between RA8 -
level (2) 5.6 - 6.5 V connector.
chassis ground
3) Cbmgrt T-

I switch OFF.
Battery fluid 2) Disconnect
RA9 Between RA9 -
level (3) 5.6 - 6.5 V connector.
chassis ground
I I 1 3) Insert T-
adapter.
WA1 200-3
Name of Zonnectoi Measurement

Syster Judgement table
component No. &ha conditions
switch OFF.
Power supply 2) Insert T-
adapter.
3) Turn starting
switch ON.

switch OFF.
2) Insert T-
LO5
adapter.
Charge
(Alternator)
* If battery is deteriorated or in cold dis-

trict, voltage may not rise for a while af-
ter engine is started.

switch OFF.
Starting switch LO9 2) Connect T-
terminal C (Male) adapter.

2w switch OFF.
2P 2) Insert T-
PRE-LUBE LO5 WZ adapter.
i:

switch OFF.
Starting switch 2) Insert T-
LO7
terminal BR adapter.
I I , 1

switch OFF.
Parking brake T18 2) Disconnect
indicator switch (Male) connector.
3) CXI;~~ T-

switch OFF.
2) Insert T-
FNR switch (N) LO5 adapter.
3) Turn starting
switch ON.

switch OFF.
When FNR switch !I Insert T-
FNR switch (F) is in “F” Between 20 - 80 V
adapter.
(7) - 3) Turn starting
When FNR switch chassis
is not in “F” Max. 1 V switch ON.
LO8
switch OFF.
3) Insert T-
FNR switch (R) adapter.
3) Turn starting
switch ON.
WA1 200-3 20-29

0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PAFiTS

conditions
comoonent No.
switch OFF.
Parking brake HR14 Between (I) - (2) IO-40R 2) Disconnect
solenoid connector.
Between (I), (2) - chassis Min. 1 MR 3) Connect T-
adapter.

Parking brake switch OFF.
HRl9 Between (2) - (I 1 20 - 60 R 2) Disconnect
emergency reset
connector.
solenoid
adapter.

switch OFF.
2) Insert T-
Parking brake adapter.
emergency reset . L89 3) Turn starting
switch ~1 switch ON.

switch OFF.
Bucket 2) Disconnect
positioner L17 Between (I) - (2) 19-23R
connector.
solenoid Between (I), (2) - chassis Min. 1 MD 3) Connect T-
adapter.

switch OFF.
When accumulator 2) Disconnect
pressure is 3.92 f connector.
0.49 MPa {40 f 5 Max. 1 R
3) Connect T-
HR17, kg/cm3 or higher adapter.
Emergency
HR18
brake switch ,,,&~~dk;opeda’ HT;y8:;[-
(Male)
lower accumulator Min 1 MR
pressure to below
3.63 + 0.49 MPa
(37 k 5 kg/cm%
20-30 WA1 200-3

0
ITEMS TO BE PREPARED
List of devices for troubleshooting ......................................................................................................................... 20-102
ITEMS RELATED TO ENGINE
Measuring engine speed .......................................................................................................................................... 20-103
Measuring exhaust gas color .................................................................................................................................. 20-106
Measuring blow-by pressure ................................................................................................................................... 20-107
Measuring engine oil pressure ............................................................................................................................... 20-108
Measuring exhaust temperature ............................................................................................................................. 20-109
Measuring intake air pressure (Boost pressure) ................................................................................................... 20-110
Testing and adjusting fan belt tension .................................................................................................................. 20-111
Testing and adjusting belt tension of air conditioner compressor ..................................................................... 20-111
Adjusting rotation sensor ........................................................................................................................................ 20-112
POWER TRAIN
Testing and adjusting torque converter and transmission oil pressure ............................................................ 20-114
Flushing procedure for hydraulic circuit of torque converter and transmission .............................................. 20-117
How to move machine when transmission valve is broken ............................................................................... 20-118
STEERING SYSTEM
Testing and adjusting steering oil pressure .......................................................................................................... 20-120
Testing and adjusting emergency steering oil pressure ...................................................................................... 20-121
Bleeding air from steering circuit ........................................................................................................................... 20-123
Adjusting steering stopper bolt .............................................................................................................................. 20-124
BRAKE SYSTEM
Testing drop of wheel brake oil pressure .............................................................................................................. 20-125
Testing wheel brake function .................................................................................................................................. 20-126
Measuring wear of wheel brake disc ..................................................................................................................... 20-127
Testing and adjusting charge cut-in and cut-out pressure of accumulator ....................................................... 20-128
Testing parking brake performance ........................................................................................................................ 20-129
Testing wear of parking brake disc ........................................................................................................................ 20-130
How to reset parking brake manually .................................................................................................................... 20-131
Measuring parking brake oil pressure .................................................................................................................... 20-132
HYDRAULIC EQUIPMENT
Testing and adjusting work equipment oil pressure ............................................................................................ 20-133
Testing and adjusting PPC oil pressure ................................................................................................................. 20-135
Adjusting PPC valve linkage .................................................................................................................................... 20-136
Bleeding air from each part ..................................................................................................................................... 20-137
Releasing residual pressure from hydraulic circuit .............................................................................................. 20-140
WORK EQUIPMENT SYSTEM
Adjusting work equipment lever linkage ............................................................................................................... 20-141
ELECTRICAL SYSTEM
Testing and adjusting bucket proximity switch .................................................................................................... 20-143
Testing and adjusting boom potentiometer .......................................................................................................... 20-144
Adjusting boom horizontal detection switch ...................................................................................................... 20-144-1
Procedure for setting initial value for remote boom positioner (Method of inputting base point) ............ 20-144-2
Checking proximity switch actuation pilot lamp ................................................................................................... 20-145
Initial learning method of transmission controller ............................................................................................... 20-146
Adjusting main monitor (Speedometer module) .................................................................................................. 20-147
Adjusting steering lever angle and frame angle sensors .................................................................................... 20-148
Procedure for checking diode ................................................................................................................................. 20-149
Method of adjusting auto-grease injector discharge amount ............................................................................. 20-150
Method of setting auto-grease timer ...................................................................................................................... 20-151
How to select JAPANESE/ENGLISH on VHMS ...................................................................................................... 20-153
How to set service meter of VHMS ........................................................................................................................ 20-153
WA1200-3 20-101
20-101
1
6
TESTING AND ADJUSTING ITEMS TO BE PREPARED
ITEMS TO BE PREPARED
LIST OF DEVICES FOR TROUBLESHOOTING
inspection/Adjustment item Symbol Part No. Part Name Remarks
Coolant/Oil/Exhaust temperature B 799-101-1502 Digital thermometer set -99.9 - 1,299”C
799-101-5002 Hydraulic tester Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
1 {25,60, 400, 600 kg/cm21
Oil pressure C
790-261-I 203 Digital hydraulic tester Pressure gauge: 68.6 MPa 1700kg/cm21
2 799-401-2320 Hydraulic gauge 1.0 MPa {lo kg/cm21
1 799-201-9000 Handy smoke checker Pollutiondegree:0 - 70%(Withstandardcolor)

Exhaust gas color G
2 Purchase Smoke meter (Pollution degree x l/10 4 Bosch index)
Pedal pressing angle H Purchase Angle gauge

793-520-1805 Brake test kit -
Brake oil pressure I
l 793-520-1851 Nipple -
1 79A-264-0020 0 - 294.2 N IO - 30 kg}

Operating effort J Push-Pull scale
2 79A-264-0090 0 - 490.3 N IO - 50 kg1
Stroke/Hydraulic drift K Purchase Rule
Work equipment speed L Purchase Stopwatch -
Measurement of wear of brake disc M 1 Purchase 1Slide calipers I -

792-415-1200 Fixed valve assembly
Note:
l 792-415-l 110 Cover This kit is for dump trucks, so
the following parts are
1 l 792-415-1120 Spacer
Movement of machine with included, but they are not used
N l 175-15-15540 Valve on the WA1200-3.
transmission valve broken I
792-415-1130
l 238-15-12930 Spring
(Soacer. with 3rd. H stamp)
l 792-415-1150 Wrench 792-415-1140 .
2 (Spacer, with 4th, L stamp)
l 792-415-1160 Adapter
Measurement of voltage/resistance 0 79A-264-0211 Tester -

-
1 799-60 I-7400 T-adapter assembly
799-601-7500 AMP070connectoradapterassembly
l 799-601-7510 For AMP07010
. 799-601-7520 For AMP07012

2
l 799-601-7530 Adapter For AMP07014
l 799-601-7540 For AMP07018
l 799-601-7550 For AMP07020

Check of sensors/harnesses P
799-601-7600 DTSeriesconnectoradapterassembly
l 799-601-7610 For DT Series P-pin
l 799-601-7620 For DT Series 3-pin
3 l 799-601-7630 For DT Series 4-pin

Adapter
l 799-601-7640 For DT Series 5-pin
l 799-60 I-7650 For DT Series B-pin
l 799-601-7660 For DTM Series 2-pin

-
20- 102 WA1 200-3
0
TESTING AND ADJUSTING ITEMS TO BE PREPARED
Inspection/Adjustment item I symbol 1 Part No. Part Name Remarks

-
Contact size #20
l 799-601-7710
(Usedfor both DT Series and HD31 Series)
Contact size #I 6
. 799-601-7720
(Used for both DT Series and HD31 Series)
Contact size #I2

Check of sensors/harnesses P 3 . 799-601-7730 Contact
Contact size #8
l 799-601-7740
(Used for bothDT Series and HD31 Series1
Contact size #4
. 799-601-7750
-
Flushing torque converter, Standard element part number
07063-41210 Ilement (for flushing)
transmission hydraulic circui t - I 07063-01210
WA1 200-3 20-102-l

0
TESTING AND ADJUSTING ITEMS RELATED TO ENGINE
ITEMS RELATED TO ENGINE

MEASURING ENGINE SPEED ', SERVICE MENU SELECT
Real Time Monitor Maintenance Monitor

A moving
Be careful not to touch any hot part when
or installing the measuring tools.
re-
PM-Clinic Failure History
A When measuring, confirm that there is nobody

around the machine. Serial No.set
A Put blocks under the wheels to prevent the ma-

chine from moving.
Memory Clear Snapshot Triseer
Ir Measure the engine speed under the following - I

condition. 9JFOO384
l Coolant temperature: Within operating range
. Hydraulic oil temperature: 45 - 55°C
. Power train oil temperature: 70 - 90°C
SERVICE MENU SELECT
Measuring low idling and high idling speeds
Real Time Monitor
1. Select the SERVICE MENU SELECT screen on

the CGC monitor.
2. Press Real Time Monitor button (I) to select the

“REAL TIME MONITOR” screen.
3. Select the screen of the system of the items

corresponding to “ENGINE SPEED” of the real 9JFOO385
time monitor list (See Preface of STRUCTURE
AND FUNCTION or TROUBLESHOOTING). (In
this example, select the screen of “Engine”,
“Transmission”, or “MOD/C”).
I REAL TIME MONITOR(1/6)
T/M CUTOFF SIGNAL
4. Display the items of “ENGINE SPEED”. TRACTION CONT SIGNAL V
SPEED CONT SIGNAL V

5. Start the engine and measure its low idling and
high idling speeds. PEDAL SIGNAL V
Sr Check that the engine speed is in the stand- I VEHICLE SPEED

ard range. If not, ask CUMMINS distributor SETTING VEHICLE SPEED I/ km/h
for adjustment.
MENU lAiv[
I 9JFOO461
WA1 200-3 20- 103

0
Measuring torque converter stall speed
1. Similarly to “Measuring low idling and high

idling speeds”, display the items of “ENGINE
SPEED” on the REAL TIME MONITOR screen.
2. Start the engine.
3. Turn transmission cut-off switch (2) OFF and

press the left brake pedal securely. (Check that
the transmission cut-off pilot lamp goes off.)
4. Turn the auto/manual shift selector switch “ON”

(Turn it to MANUAL position).
* At this time, the gear shift mode should be
in “2nd”.
5. Press the shift-up switch to shift up the gear to

“3rd”.
6. Set the directional (FNR) switch to “F” or “R”.
7. Reset the parking brake.
8. Run the engine at full speed and stall the torque

converter, and measure the engine speed at this
time.
L 9JFOO366
Measuring hydraulic stall speed
1. Similarly to “Measuring low idling and high

idling speeds”, display the items of “ENGINE
SPEED” on the REAL TIME MONITOR screen.
3. Run the engine at full speed and extract the

boom cylinder or bucket cylinder to relieve the
oil, and measure the engine speed at this time.
20-104 WA1 200-3

0
Measuring torque converter stall speed +

hydraulic stall speed
1. Similarly to “Measuring low idling and high idling

speeds”, display the items of “ENGINE SPEED”
on the REAL TIME MONITOR screen.
3. Turn transmission cut-off switch (2) OFF and press

the left brake pedal securely. (Check that the trans-
mission cut-off pilot lamp goes off.)
4. Turn the auto/manual shift selector switch “ON”

(Turn it to MANUAL position).
Sr At this time, the gear shift mode should be in
“2nd”.
5. Press the shift-up switch to shift up the gear to

“3rd”.
6. Set the directional (FNR) switch to “F” or “R”.
7. Reset the parking brake.

converter and extract the boom cylinder or bucket
cylinder to relieve the oil, and measure the en-
gine speed at this time.
9JFOO386
WA1 200-3 20-105

0
MEASURING EXHAUST GAS

COLOR
l When measuring the exhaust gas color in the
field without compressed air and power source,
use handy smoke checker Gl. When taking
records of official data, use smoke meter G2.
f Before measuring, heighten the coolant tempera-
ture to the operating range.
A Be careful not to touch any hot part when re-
moving or installing the measuring tools.
1. Measuring with handy smoke checker

1) Install filter paper to tool Gl.
2) Insert exhaust gas suction adapter in the
exhaust pipe. Heighten the engine speed
sharply and operate the handle of tool Gl
simultaneously to have the filter paper ab-
sorb the exhaust gas.
3) Remove the filter paper and compare it with
the attached scale.
2. Measuring with smoke meter G2

1) Insert probe in the outlet of exhaust pipe
and secure it to the exhaust pipe with the
clip.
2) Connect the probe hose, accelerator switch
outlet, and air hose to tool G2.
* Limit the applied air pressure to 1.5 MPa
115 kg/cm21.
3) Connect the power cable to an AC 100 V
outlet.
* When connecting the power cable, check
that the power switch of tool 62 is turned
Off.
4) Loosen the cap nut of the suction pump and
set the filter paper.
* Set the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of tool G2.
6) Heighten the engine speed sharply and press
the accelerator pedal of tool G2 simultane-
ously to have the filter paper absorb the
exhaust gas.
7) Remove the contaminated filter paper and
place it on clean filter paper (at least IO
sheets) in the filter paper holder and read
the indicated value. TLD00140
20- 106 WA1 200-3

co
MEASURING BLOW-BY
PRESSURE
SERVICE MENU SELECT
* Before measuring, heighten the coolant tempera- I, ( Real Time Monitor Maintenance Monitor
/)ryl 1 Failure History 1I/
the CGC monitor.
2. Press PM-Clinic screen button (I) to select the

“PM-CLINIC MENU” screen.
3. Display the items of “Blow-by pressure” (l/4 of 9JFOO387

PM-CLINIC MENU screen).
4. Run the engine at full speed and relief the oil

from the bucket cylinder, and measure the blow-
by pressure at this time.
A ing
Be careful not to touch any hot part or rotat-
part while measuring.
Precautions for measuring blow-by pressure
l The blow-by pressure may vary largely with

the engine condition. If the measured value
is judged abnormal, check for increase of oil 9JFOO388
consumption, bad exhaust gas color, dete-
rioration of oil, high deterioration speed of
oil, etc. which are related to the abnormal
blow-by pressure.
WA1 200-3 20-l 07

0
MEASURING ENGINE OIL

PRESSURE
1 SERVICE MENU SELECT
* Before measuring, heighten the coolant tempera-

the CGC monitor.

“PM-CLINIC MENU“ screen.
3. Display the items of “Engine oil pressure” (l/4 9JFOO387

of PM-CLINIC MENU screen).
4. Run the engine at high idling and measure the PM CLINIC MENU(1/4)
oil pressure. ENGINE SPEED
COOLANT TEMP
T/C TEMP
AMBIENT AIR TEMP
BLOW-BY PRESSURE
ENGINE OIL PRESSURE IO. kg/cm:
MENU A 7
9JFOO388
20- 108 WA1 200-3

0
MEASURING EXHAUST
TEMPERATURE I
SERVICE MENU SELECT

* Before measuring, heighten the coolant tempera- Real Time Monitor Maintenance Monitor

the CGC monitor.
2. Press PM-Clinic screen button (1) to select the

I- t
3. Display the items of “Exhaust temperature”
of PM-CLINIC MENU screen).
(2/4 9JFOO387
J
Measurement procedure
PM CLINIC MENU(l/4)
1. When measuring the maximum value for trou- ENGINE SPEED 17291 r pm
bleshooting COOLANT TEMP
Perform the actual work and measure the maxi-
T/C TEMP
mum value.
* Use the PEAK mode of the thermometer AMBIENT AIR TEMP
function (in which the maximum value can BLOW-BY PRESSURE 1-5 mmAq
be saved). ENGINE OIL PRESSURE v] kg/cm2
(Note)
The exhaust temperature varies largely with
the ambient temperature (temperature of air 9JFOO388
sucked in the engine). Accordingly, if an ab-
normal value is measured, correct it.
+ Corrected value = Measured value + 2 x (Con-
Tempera- Stable readine
verted ambient temperature - Ambient tem- ture t DOSSible
perature)
Exhaust temper-
* Set the converted ambient temperature to ature at torque
20°C. converter stal I
When measured only
with torque convert er
2. When measuring periodically for preventive
maintenance service
1) Heighten the exhaust temperature under the
full stall condition (with the torque converter FuI l;tal I wime
stalled and oil relieved from work equipment Torque con- )

pump). verter stall BKD00676
(Approx. 700% - . . . Standard value)
2) Reset the relief condition, but keep the torque
converter stalled. (The temperature should
start lowering. If it does not lower but rises,
heighten the set temperature at @ in the
figure at right.
3) After the temperature lowers and stabilizes,
record it.
* If only the torque converter is stalled, it
will overheat before the exhaust tem-
perature stabilizes.
WA1 200-3 20- 109

0
MEASURING INTAKE AIR

PRESSURE
(BOOST PRESSURE)
I
* Before measuring, heighten the coolant tempera-

the CGC monitor.

“PM-CLINIC MENU” screen. I
9JFOO387
3. Display the items of “Intake air pressure (Boost

pressure)” (l/4 of PM-CLINIC MENU screen).
PM CLINIC MENU(l/4)
converter, then read the pressure indicated by t ENGINE SPEED 1729 fom
the gauge. COOLANT TEMP 1-41 dea C
T/C TEMP
* Normally, the intake air pressure (boost pres-
AMBIENT AIR TEMP
sure) should be measured while the engine
BLOW-BY PRESSURE
is operated at the rated output. In the field,
however, an approximate value can be op- ENGINE OIL PRESSURE wl kg/cm2
erated by stalling the torque converter. MENU

I
9JFOO388 )
20-l 10 WA1 200-3

0

FAN BELT TENSION
Testing
. Using belt tension gauge (I), measure the ten-

sion of fan belt (2) at the intermediate point
between the pulleys.
Ir Standard belt tension: 4,893 N (498.95 kg}
Adjusting
1. Loosen 7 bolts (3) and adjust tension with rod

(4).
Sr Do not loosen the bolt marked with %.
-k If rod (2) is turned in the direction of the
arrow, the tension is heightened.

BELT TENSION OF AIR
CONDITIONER COMPRESSOR
Testing
. Press the intermediate point of the belt between

drive pulley (I) and air conditioner compressor
pulley (2) with the force of about 98 N {IO kg),
and measure deflection b of the belt.
* Deflection of belt (Standard value) b:
9 - 12.5 mm
Adjusting 9JFOO391
I
1. Loosen mounting bolts and nuts (31, (41, and (51,
and locknut (6).
2. Loosen locknut (8) of adjustment bolt (71, and

adjust the tension of air conditioner compressor
belt (9) with adjustment bolt (7).
3. After positioning air conditioner compressor,

tighten locknut (8) and mounting bolts and nuts
(31, (41, (51, and (6).
4. After adjusting the belt tension, check that it is

in the standard range according to the above
9JFOO392
procedure.
WA1 200-3 20-111

0
ADJUSTING ROTATION
SENSOR
Engine rotation sensor
1. Screw in rotation sensor (1) until its tip touches

gear (21, then return it by l/2 - 1 turn.
2. Tighten locknut (3).

m Locknut: 34.3 - 39.2 Nm 13.5 - 4.0 kgm}
* Handle the wires of the rotation sensor very
carefully so that an excessive force will not
applied to them.
* Take care that steel chips will not stick to
the tip of the rotation sensor and the latter
will not be scratched.
Transmission output shaft rotation sensor
1. Screw in transmission output shaft rotation sen-

sor (4) until its tip touches gear (51, then return
it by l/2 - 1 turn.

m Locknut: 49.0 - 68.6 Nm I5.0 - 7.0 kgm}
I 9JFOO444
WA1 200-3
Modulated clutch outlet rotation sensor
1. Screw in modulated clutch outlet rotation sen-

sor (7) until its tip touches gear (81, then return
it by l/2 - 1 turn.

w Locknut: 49.0 - 66.6 Nm 15.0 - 7.0 kgm1
9JFOO446
WA1 200-3 20413

0
TESTING AND ADJUSTING POWER TRAIN
POWER TRAIN
TORQUE CONVERTER AND
TRANSMISSION OIL
PRESSURE
Measuring
. Engine coolant: In operating range

l Torque converter oil temperature: 60 - 80°C
9JFOO387
A chine
Put blocks under the
from moving.
wheels to prevent the ma-
1. Main relief pressure

1) Select the SERVICE MENU SELECT screen
on the CGC monitor.
2) Press PM-Clinic screen button (I) to select
the “PM-CLINIC MENU” screen.
3) Display the items of “Transmission main re-
lief pressure” (l/4 of PM-CLINIC MENU
screen).
4) Start the engine and measure the oil pres-
sure when the engine speed is 1,900 rpm.
9JFOO388
2. Modulating oil pressure

I) Select the SERVICE MENU SELECT screen
on the CGC monitor.
3) Display the items of “Transmission modu-
lating oil pressure” (3/4 of PM-CLINIC MENU
screen).
4) Turn drive force control dial (2) and travel
speed control dial (3) to the “right end”.
5) Set the directional lever in “Neutral” and
run the engine at full speed, then measure
the oil pressure.
3. Torque converter inlet oil pressure

on the CGC monitor.
3) Display the items of “Torque converter inlet
oil pressure” (2/4 of PM-CLINIC MENU
screen).
sure while the engine is running at full speed.
20-l 14 WA1 200-3

0
4. Torque converter outlet oil pressure

on the CGC monitor.
3) Display the items of “Torque converter out-
let oil pressure” (2/4 of PM-CLINIC MENU
screen).
5. Lubricating valve oil pressure

on the CGC monitor.
3) Display the items of “Transmission lubricat-
ing valve oil pressure” (2/4 of PM-CLINIC
MENU screen).
6. ECMV clutch oil pressure

1) Remove the oil pressure pickup plug of the
clutch to be measured.
. Pickup plug for 1st gear speed clutch: (I)
. Pickup plug for 2nd gear speed clutch: (2)
. Pickup plug for 3rd gear speed clutch: (3)
. Pickup plug for reverse clutch: (4)
. Pickup plug for forward clutch: (5)
2) Install oil pressure gauge Cl i5.88 MPa (60
kg/cm2H.
3) Star-t the engine and measure the oil pres-
sure of the Ist, 2nd, and 3rd clutches under
the following condition.
11 Keep the FNR (Forward/Reverse) switch
in “N” (Neutral).
21 Set the auto shift/manual shift switch to
“ON” (Manual) position.
31 Select each gear speed with the shift-up/
-down switches
41 Measure while the engine is running at
full speed.
sure of the forward and reverse clutches
under the following condition.
11 Set the transmission cut-off switch to
“OFF” position (to turn the light off).
21 Set the parking brake switch to “OFF”
position.
31 Press the brake pedal.
WA1 200-3 20415

0
41Set the auto shift/manual shift switch to

“ON” (Manual) position, and set the shift-
up switch to “3rd”.
51 Keep pressing the brake pedal, set the
FNR (Forward/Reverse) switch to “F”
(Forward) or “R” (Reverse).
61 Measure while the engine is running at
full speed.
+ Heighten the engine speed gradually
to the maximum.
Adjusting
a Adjust the oil pressure

stopped.
while the engine is
* When the main relief pressure cannot be meas-

ured accurately, do not adjust it.
* If the main relief pressure is out of the standard
1.
range, adjust it according to the following pro-
cedure.
1. Adjusting transmission main relief pressure

1) Remove cover (1) and change the number
of shims (2) to adjust the oil pressure.
* Loosen the bolts of cover (I) gradually,
lowering the tension of springs (3) and 9JFOO447
(41.
li Standard thickness of shims: 2.0 mm
+ Pressure changed with 1 shim (t = 0.5
mm): 42.17 Pa (0.43 kg/cm*)
Ir The set pressure is heightened by in-
creasing the shims, and lowered by de-
creasing the shims.
20-116 WA1 200-3

0
FLUSHING PROCEDURE FOR HYDRAULIC CIRCUIT OF

TORQUE CONVERTER AND TRANSMISSION
* Metal chips, etc. in the hydraulic circuit of the torque converter and transmission shorten the lives
of the torque converter and transmission and can cause an internal breakage. Accordingly, flush
the hydraulic circuit to remove the metal chips, etc. from them.
1. Flush the circuit in the following cases.

1) When metal chips are sent to the circuit because of a damage of torque converter, transmis-
sion, or hydraulic equipment.
2) When torque converter or transmission is overhauled or repaired.
2. Install the flushing elements.

1) Drain the oil from the filters.
2) Remove the 2 transmission oil filters, then install 2 flushing elements.
* Clean the inside of the case and removed parts.
3. Refill transmission case with oil.

l Add new oil through the oil filler to the specified level. Run the engine to circulate the oil
through the system. Then, check the oil level again.
G Transmission case: Approx. 350 t
4. Flush the circuit according to the following procedure.

1) Start the engine, then run it at low idling without operating the gear shift lever or directional
lever for about 20 minutes.
-)r Heighten the engine speed to about 1,500 rpm at intervals.
Jr If the engine water temperature gauge does not rise to the green range because of low
ambient temperature, continue the warm-up operation further.
2) Perform actual work or travel for at least 20 minutes.
Sr Use the all gear speeds (Forward, reverse, and 1st - 3rd gears).
3) Run the engine at low idling for about 20 minutes similarly to 4-I) above.
5. Replace the flushing elements.

1) Replace the flushing elements with the standard elements similarly to 2-I) above.
A If the flushing elements are used for long hours, they are clogged. Accordingly,
replace them with the standard ones.
be sure to
2) Supply oil and check the oil level again.
6. Replace the transmission last-chance filter.

1) Turn part A of last-chance filter case (I) with a wrench to remove the case.
* If there is dirt in the filter case, clean it.
2) Remove element (2) and install a new element.
3) Fit new O-ring (3) to the rim of the case.
* Apply a little quantity of grease to the
periphery of the O-ring.
4) Install the case.
w Case mounting bolt:
58.8 - 73.55 Nm 16 - 7 kgm1
9JFOO458
WA1 200-3 20-117

0
HOW TO MOVE MACHINE

WHEN TRANSMISSION VALVE
IS BROKEN
* If the machine cannot be moved because of a
trouble of the transmission valve parts (electric
system, solenoid valve, spool, etc.), it can be
moved again by installing fixed valve assembly
(tool Nl).
AInstallation of fixed valve assembly (tool Nl) to
ECMV is a measure to move the machine from
a dangerous work site to a safety place when it
cannot be moved at any gear speed because of
a transmission valve trouble. Use this method
only when the transmission valve has a trouble.
AWhen moving the machine, observe the proce-
dure and take care of safety.
A Lower the work equipment to the ground, apply
the parking brake, and put blocks under the
wheels to prevent the machine from moving.
A When working, stop the engine.
A Take care not to get burned

perature is high.
when the oil tem-
1. Open the transmission top cover.
2. Remove the valve cover.

Ir Clean around ECMV thoroughly and remove
soil and dirt.
3. Disconnect wiring connectors (I) - (14) (CN-T3,

T4, T5, T6, T7, T8, Tll, T12, T13, T14, T20, T21,
T22, T23).
* For the precautions for removal of the wir-
ing connectors, see DISASSEMBLY AND AS-
SEMBLY, “Removing transmission control
valve assembly”.
20-118 WA1 200-3

0
4. Remove the following 2 ECMV solenoids (15)

according to the moving direction of the ma-
chine (Forward or reverse), then install fixed
valve assembly (tool Nl).
. When moving forward: Remove the F sole-
noid and 2nd solenoid.
. When moving in reverse: Remove the R so-
lenoid and 2nd solenoid.
* If a wrong solenoid is removed, the trans-
mission may be broken. Be careful.
* Install plate N with the projected side di-
rected to ECMV. Check that the O-ring is TWWO2612
fitted to the fitting face.

* Take care that soil and dirt will not enter the
removed solenoids and valves.
TWW02613
1) Assembly of fixed valve assembly (tool Nl)

i) Assemble spring (17) to cover (16).
ii) Assemble the following spacers (18) (792-
415-1120, stamped mark R, 1, 2)
Spacer (18) to use
TWW02614
Fixed valve assembly (tool Nl) includes

the following parts, but they are not used
on the WA1200-3.
792-415-1130 (Spacer, with 3rd, H stamp)
792-415-1140 (Spacer, with 4th, L stamp)
iii) Assemble valve (19).

iv) Assemble O-ring on ECMV matching sur-
face and proportional solenoid to the
fixed valve cover.
I i9 17
TWW02615
WA1 200-3
2) Using tool N2, install fixed valve assembly

(20) to the ECMV.
w Fixed valve assembly mounting bolt:
13.2 f 1.5 Nm Il.35 f 0.15 kgml
5. Press the left brake pedal securely.
6. Start the engine and release the parking brake.
7. Release the brake pedal gradually to start the

machine.
A Put blocks under the wheels to prevent the
machine from moving.
A If the engine is started, the transmission
engaged immediately and the machine starts.
is
Accordingly, when starting the engine, check

the travel direction and safety around the
machine, and be sure to press the brake
pedal.
20-119-l WA1 200-3

0
TESTING AND ADJUSTING STEERING SYSTEM
STEERING SYSTEM
TESTING AND ADJUSTING SERVICE MENU SELECT
1, [
STEERING OIL PRESSURE , Real Time Monitor Maintenance Monitor
PM-Clinic Failure History
Measuring
Serial No. set
Hydraulic oil temperature: 45 - 55°C Memory Clear Snapshot Trigger
a Lock the front frame and rear frame with the

safety bar.
A Loosen the oil filler cap to release the residual
pressure from the hydraulic tank.
9JFOO387

the CGC monitor. PM CLINIC MENU(1/4)
ENGINE SPEED 1729-J rDm
2. Press PM-Clinic screen button (I) to select the COOLANT TEMP
T/C TEMP
AMBIENT AIR TEMP

3. Display the items of “Steering oil pressure” (3/4
of PM-CLINIC MENU screen). BLOW-BY PRESSURE (1 mmAq
ENGINE OIL PRESSURE II kg/cm2

4. Run the engine and turn the joystick lever to the
MENU A 7
“left” or “right”, and measure the oil pressure
when the relief valve operates. 9JFOO388
Adjusting
Alf the relief pressure is not normal, adjust the

steering relief valve according to the following
procedure.
A When adjusting, stop the engine.
1. Loosen locknut (3) and turn adjustment screw

(4) to adjust the relief pressure.
Pressure changed with adjustment screw
Pressure changed by 1 turn:
Approx. 3.5 MPa {Approx. 35.7 kg/cm*] TKWOlI12
If the adjustment screw is tightened, the set

pressure is heightened. If the former is loos-
ened, the latter is lowered.
When the relief pressure cannot be meas-
zo- 120 WA1 200-3

0

EMERGENCY STEERING OIL
PRESSURE
Measuring
Hydraulic oil temperature: 45 - 55°C
a Lock the front frame and rear frame with the

safety bar.
ALoosen the oil filler cap to release the residual
pressure from the hydraulic tank. / I 9JFOO448
1. Disconnect drive shaft (I 1 between transmission

and center support from the transmission.
2. Disconnect drive shaft (2) between transmission

and rear axle from the transmission.
3. Disconnect diverter valve pilot hose (3). Replace

elbow (4) with an oil passage shut-off elbow
(See the next page), then install hose (3).
(By this work, the oil pressure applied to the
pilot port of the diverter valve is shut off and
the emergency steering system can operate.)
4. Remove oil pressure pickup plug (5) (PT l/8)

between the diverter valve and steering valve,
then install nipple C2 and oil pressure gauge Cl
(39.2 MPa (400 kg/cm21).
5. Start the engine and shift the gear to FORWARD

(or REVERSE) 3rd. Heighten the travel speed to
24 km/h and turn the steering wheel to the right
or left. Measure the oil pressure when the relief
valve operates.
WA1 200-3
Adjusting
A When adjusting, stop the engine.
1. Remove cap nut (6) of the relief valve.
2. Loosen locknut (7) and turn adjustment screw

(8) to adjust the pressure.
* Pressure changed with adjustment screw
Pressure changed by 1 turn:
Approx. 3.5 MPa {Approx. 35.7 kg/cm21
t If the adjustment screw is tightened, the set
pressure is heightened. If the former is loos-
ened, the latter is lowered.
* When the relief pressure cannot be meas-
* Preparation of oil pressure shut-off elbow

Prepare elbow (07236-10210) and drive a pin
having diameter of 5 mm into the drilled
hole and weld it to shut off the oil passage.
TKWOllt8
WeI
20-122 WA1 200-3

0
BLEEDING AIR FROM

STEERING CIRCUIT
Ir If the steering valve or the steering cylinder is
removed and installed, bleed air from its circuit
according to the following procedure.
1. Run the engine at low idling for about 5 min-

utes.
2. Running the engine at low speed, steer the ma-

chine to the right and left 4 - 5 times.
+ Stop the piston rod about 100 mm before 9JFOO396
each stroke end, and never relief the oil.
3. Running the engine at full speed, perform the

operation in 2 above.
4. Running the engine at low speed, move the pis-

ton rod to the stroke end to relief the oil.
WA1 200-3 20- 123

0
ADJUSTING STEERING
STOPPER BOLT
1. Running the engine at low speed, steer the ma-
chine and measure clearance a between frame
end stopper (2) of front frame (I 1 and rear frame
(3). If clearance a is out of the standard range,
adjust it according to the following procedure.
* Clearance a: 37 - 40 mm
1) Loosen locknut (4) and adjust clearance a to
the standard range with steering angle ad-
justment bolt (5).
ARun the engine at low speed and oper- 9JFOO397
ate the joystick steering lever slowly.
ATake care not to catch your body, arm,
etc. between the front frame and rear
frame. I I\
* Adjust the stopper bolts on both sides

by the above method.
2) Start the engine and check that the clear-

ance between frame end stopper (2) of front
frame (1) and rear frame (3) is normal when
the machine stops turning.
9JFOO399
20-124 WA1 200-3

0
TESTING AND ADJUSTING BRAKE SYSTEM
BRAKE SYSTEM
TESTING DROP OF WHEEL ? I!
BRAKE OIL PRESSURE
A the
Put blocks under the wheels
machine from moving.
securely to prevent
1. Testing wheel brake oil pressure

1) Remove bleeder screw (I), then install oil
pressure gauge 139.22 MPa I400 kg/cm211 of
tool I, joint, bleeder screw, and nipple.
2) Connect hose (2) to the bleeder screw to
bleed air from the brake circuit. For details,
see BLEEDING AIR FROM EACH PART.
3) Press the left brake pedal and measure the
brake oil pressure.
2. Measuring drop of brake piston pressure

1) Remove bleeder screw (I), then install oil
pressure gauge i39.22 MPa 1400 kg/cm211 of
tool I, joint, bleeder screw, and nipple.
2) Connect hose (2) to the bleeder screw to
bleed air from the brake circuit. For details,
see BLEEDING AIR FROM EACH PART.
3) Stop the engine, then press the left brake
pedal so that the brake oil pressure becomes
15.5 MPa 1158 kg/cm21 and leave it for 5
minutes. Then, measure the pressure drop.
* Take care not to move the brake pedal
for 5 minutes.
* After finishing the above work, bleed air
from the brake circuit again.
WA1 200-3 20- 125

0
TESTING WHEEL BRAKE FUNCTION

* Test the wheel brake function under following condition.
. Road surface: Flat, level, straight, paved, and dried road
l Speed: Initial braking speed of 20 km/h
.
Tire inflation pressure: Specified pressure (588 kPa (6 kg/cm211
.
Delay in pressing pedal: 0.1 set
1. Start the engine and drive the machine with the directional lever in F (Forward) and the gear shift
lever in 3rd.
2. Keep the travel speed at 20 km/h, then press the brake pedal with the specified force.
* Set the run-up path and the point to start measurement in advance. Keep the travel speed at 20
km/h on the run-up path and press the brake pedal when the machine passes the point to start
measurement.
* Perform this test with the transmission cut-off switch turned ON.
3. Measure the distance between the point to start measurement and the stopping point of the
machine.
Ir Perform the above measurement 3 times, then obtain the average.
+ --
Stoooino Point Point where braking Point where operator Put
effect started foot on brake Pedal
looeration Point1
I
Stoooine distance Run-up path
TWW02433
20- 126 WA1 200-3

0
MEASURING WEAR OF WHEEL

BRAKE DISC
a Stop the machine on a level place, and put blocks
under the wheels to prevent the machine from
moving.
* Brake oil pressure:

15.49 + 1.37 MPa {I58 f 14 kg/cm*)
1. Remove cap (I).
2. Press the brake pedal to the stroke end. 9JFOO405
9JFOO406
3. Using slide calipers M, measure depth a from

the end of shaft (2) to guide (3).
Ir Keep pressing the brake pedal during meas-
urement.
Wear limit: a = 7.0 mm
* After the disc has been worn to near the
wear limit, test it frequently, regardless of
the maintenance period.
I 9JFOO407
WA 1200-3 20-127
0

CHARGE CUT-IN AND
SERVICE MENU SELECT
CUT-OUT PRESSURE OF
I, 1 Real Time Monitor Maintenance Monitor
ACCUMULATOR
Failure History
Measuring
Serial No. set
Brake oil temperature: 45 - 55°C

a While the engine is stopped, press the brake
pedal at least 100 times to release the pressure
from the accumulator circuit.
9JFOO387
the CGC monitor.
“PM-CLINIC MENU” screen. I PM CLINIC MENU(l/4)
3. Display the items of “F brake” or “R brake” (3/4 ENGINE SPEED 11 rpm
of PM-CLINIC MENU screen). COOLANT TEMP
4. Measure the charge cut-in pressure of the accu-
T/C TEMP
mulator. Run the engine at low speed, check
AMBIENT AIR TEMP
that the oil pressure rises, then when the rise in
the oil pressure becomes slow, measure the oil BLOW-BY PRESSURE
pressure (read the front brake pressure or rear ENGINE OIL PRESSURE
brake pressure on the CGC monitor).
5. Measure the charge cut-out pressure of the ac-
cumulator. 9JFOO388
After the cut-in of the accumulator, the oil pres-

sure starts lowering. At this time, measure the
oil pressure.
Adjusting
Charge cut-out and cut-in pressure of accumulator

* If the charge cut-out pressure of the accumula-
tor is adjusted, the valve area ratio cut-in pres-
sure is changed. Accordingly, a cut-in pressure
adjustment screw is not installed.
1. Loosen locknut (5) of cut-out valve (4) and turn

adjustment screw (6) to adjust the cut-out pres- 9JFOO408
sure.
* If the adjustment screw is
. turned to the right, the pressure is height-
ened.
. turned to the left, the pressure is low-
ered.
* Pressure changed by 1 turn of adjustment
screw: 5.59 MPa (57 kg/cm*)
w Locknut: 9.8 - 11.8 Nm 11 - 1.2 kgm)
t After adjusting, check the cut-in and cut-out
pressure of the accumulator again accord-
ing to the above testing procedure.
20-128 WA1 200-3
0
TESTING PARKING BRAKE

PERFORMANCE
* Test the parking brake function under following
condition.
. Tire inflation pressure: Specified pressure

. Road surface: Flat, paved, dry road having gra-
dient of l/5 (11” 20’)
. Machine: Operating state
1. Start the engine and drive straight up a slope

having gradient of l/5. TWW02434
2. Press the brake pedal and set the directional

lever in neutral, then stop the engine.
3. Turn on the parking brake switch and release

the brake pedal gradually. At this time, the ma-
chine must stop.
j, Test the parking brake on an uphill road and
a downhill road.
TWW02435
WA1 200-3 20-129

0
TESTING WEAR OF PARKING

BRAKE DISC
* When the parking brake does not work suffi-
ciently, check the parking brake disc for wear
ALower the work equipment to the ground and
put blocks under the wheels to prevent the ma-
chine from moving.
AWhen checking the wear, stop the engine.
1. Drain oil from the transmission case.
& Transmission case: Approx. 350 e
2. Remove 1 of 2 plugs (I).
3. Measure depth a from end of cage (2) to the

piston with slide calipers M.
l Standard depth: a = 41.2 mm max. M
4. If depth a is larger than the standard value, re-

move parking brake (4) and measure disc thick-
ness W. For details, see DISASSEMBLY AND
ASSEMBLY, Removing parking brake disc.
l Standard thickness: W = 3.2 + 0.1 mm
5. If the thickness of the parking brake disc is be-

low the standard value, replace the disc.
20- 130 WA 1200-3

0
HOW TO RESET PARKING

BRAKE MANUALLY
* The parking brake is controlled hydraulically. If
it cannot be reset because of a trouble in the
transmission, emergency reset solenoid valve,
etc., it can be reset manually to move the ma-
chine.
A ure
Manual resetting of the parking brake is a meas-
to move the machine from a dangerous work
site to a safety place. Use this method only in
an emergency
A Lower the work equipment to the ground and
put blocks under the wheels to prevent the ma-
chine from moving.
A When resetting the parking brake, stop the en-
gine.
1. Drain oil from the transmission case.
& Transmission case: Approx. 350 I?
2. Remove 2 plugs (I).
3. Remove 2 cage mounting bolts (21, then screw

them in the slug holes alternatelv. 9JFOO452
* Remove 2 bolts (2) in the diagonal positions,
together with the washers.
* Tighten bolts (2) to pull piston (3) and reset
the parking brake.
* Tighten the 2 bolts evenly little by little.
* If the bolts are tightened about -(3 + l/4)
turns farther after they and washers touch
the seat, the brake is reset.
Refilling with oil

. Add oil through the oil filler to the specified
level. Run the engine to circulate the oil through
the system. Then, check the oil level again.
WA1 200-3 20431

0
MEASURING PARKING BRAKE

OIL PRESSURE
Measuring parking brake inlet pressure
* Torque converter oil temperature: 60 - 80°C

A Put blocks under the wheels to prevent the ma-
chine from moving.
1. Remove oil pressure pickup plug (PT l/8) (I),

and install oil pressure gauge Cl (5.88 MPa 160
kg/cm21).
2. Turn the parking brake switch OFF.
3. Run the engine at high idling and measure the

oil pressure.
A-A 9JFOO413
Measuring parking brake solenoid inlet

pressure
f Torque converter oil temperature: 60 - 80°C

A chine
Put blocks under the wheels to prevent the ma-
from moving.
A While the engine is stopped, press the brake
pedal at least 100 times to release the pressure
from the accumulator circuit.
1. Turn the starting switch to the “ON” position

and the parking brake switch to “OFF” position i 9JFOO414
to reset the brake.
2. Disconnect hose (21, and install the adapter and
oil pressure gauge Cl (5.88 MPa {SO kg/cm211 of
tool Cl.
3. Run the engine at high idling and measure the
oil pressure.
20-132 WA1 200-3

0
TESTING AND ADJUSTING HYDRAULIC EQUIPMENT
HYDRAULIC EQUIPMENT
WORK EQUIPMENT OIL
PRESSURE
Hydraulic oil temperature: 45 - 55°C
Loosen the oil filler cap of the hydraulic tank gradu-
ally to release the residual pressure from the hy-
draulic tank.
Measuring
at b
9JFOO415
1. Measuring work equipment relief pressure

1) Lower the bucket- so that its part b will be in
contact with the ground and its part a will be 30 1 SERVICE MENU SELECT
- 50 mm above the ground.
2) Stop the engine, then operate the work equip-
ment control lever to check that the bottom of 8I ,
the bucket (parts a and b) is in contact with the

Serial No. set
ground.
A After lowering the bucket to the ground, Memory Clear Snapshot Trigger
operate the work equipment control lever 2
- 3 times to release the pressure from the
piping.
3) Select the SERVICE MENU SELECT screen on 9JFOO387
the CGC monitor.
4) Press PM-Clinic screen button (1) to select the
I
5) Display the items of “Work equipment relief
pressure” (3/4 of PM-CLINIC MENU screen).
6) Start the engine and raise the boom, then run
the engine at full speed and dump the bucket.
When the relief valve operates, measure the oil
pressure.
A After measuring the oil pressure, release
the pressure from the circuit by the same
procedure for installation of the oil pres-
sure gauge, then remove the oil pressure
gauge. I 9JFOO388
WA1 200-3 20- 133

0
Adjusting
1. Adjusting work equipment relief valve

&hen adjusting the oil pressure, stop the
engine.
I) Loosen locknut (3) of work equipment relief
valve (21, then turn adjustment screw (4) to
adjust the oil pressure.
. turned to the right, the pressure is
heightened.
.
2
turned to the left, the pressure is low- .21
'004
QJF
ered.
* Pressure changed by 1 turn of adjust-
ment screw: 1.02 MPa (10.39 kg/cm21
* After adjusting, measure the work equip-
ment relief pressure again according the
procedure described above.
3 4
9JFOO417
20-134 WA1 200-3

0

PPC OIL PRESSURE r ,
SERVICE MENU SELECT
Hydraulic oil temperature: 45 - 55% Real Time Monitor Maintenance Monitor
Loosen the oil filler cap of the hydraulic tank
gradually to release the residual pressure from {vi _ Failure History _
the hydraulic tank.
A Operate the work equipment control lever 2 - 3
times to release the pressure from the PPC ac-
cumulator circuit.
Measuring
9JFOO387
1. Measuring PPC relief pressure
on the CGC monitor.
2) Press PM-Clinic screen button (I) to select PM CLINIC MENU (l/4)
the “PM-CLINIC MENU” screen. ENGINE SPEED r-5r-j
3) Display the items of “PPC relief pressure” COOLANT TEMP
(4/4 of PM-CLINIC MENU screen).
T/C TEMP
4) Run the engine at full speed and measure
the oil pressure. AMBIENT AIR TEMP
BLOW-BY PRESSURE
ENGINE OIL PRESSURE
9JFOO388
I
2. Measuring PPC valve output pressure

1) Remove the work equipment valve cover.
2) Remove oil pressure pickup plugs (PT l/8)
(I) - (4) from each circuit, then install nip-
ples C2 and oil pressure gauges Cl (5.9 MPa
(60 kg/cm*)).
* 1. For raising boom
2. For lowering boom
3. For dumping bucket
4. For digging with bucket
3) Start the engine and operate each circuit to
the stroke end, then run the engine at full
speed and operate each circuit. When the
relief valve operates, measure the oil pres-
sure.
9JFOO416
WA1 200-3 20- 135

a
Adjusting
1. Adjusting PPC relief valve
A When adjusting the oil pressure, stop the

engine.
A Loosen the oil filler cap of the hydraulic tank
gradually to release the residual pressure
from the hydraulic tank.
A Operate the work equipment control lever 2
- 3 times to release the pressure from the
PPC accumulator circuit. I 71 9JFOO418
1) Open the transmission top cover.

2) Loosen locknut (6) of PPC relief valve (5),
then turn adjustment screw (7) to adjust the
oil pressure.
. turned to the right, the pressure is
heightened.
. turned to the left, the pressure is low-
ered.
* Pressure changed by 1 turn of adjust-
ment screw: 1.02 MPa I10.39 kg/cm*}
9JFOO419
ADJUSTING PPC VALVE

LINKAGE
1. Remove the underside cover of the work equip-
ment control lever.
2. Adjust distance a from nut (I) of the PPC valve

linkage to the floor top.
l Distance a (Target value): 54 mm
3. Loosen nuts (2) and (31, then adjust the installed

height of trunnion (5) to eliminate the play of 9JFOO420
lever (4).
4. After adjusting, tighten nuts (2) and (3).
20- 136 WA1 200-3

0
BLEEDING AIR FROM EACH

PART
I\ i i !!! I!
Bleeding air from wheel brake circuit
Sr If any brake circuit hose is disconnected for re-

moval and installation of the brake valve, axle,
etc., bleed air from the circuit according to the
following procedure.
A~pply the parking brake put and blocks under
the wheels to prevent the machine from mov-
ing.
Awhile the engine is running, never bleed air
from the slack adjuster, since the drive shaft is
rotating.
1. Start the engine and heighten the pressure in

the accumulator. (The pressure is heightened in
about 30 set, if the engine runs at high idling.)
2. Start the engine. Insert one end of a vinyl hose

in bleeder (I), and put the other end in a con-
tainer.
3. Press the brake pedal and loosen the bleeder

screw to bleed the air. Tighten the bleeder screw,
then release the brake pedal slowly.
Sr This work shall be done by two persons.
One person shall press the brake pedal, and
the other shall bleed air through the bleeder
screw.
* Use the left brake pedal.
It Keep the brake oil tank full.
4. Repeat this operation until any bubble does not

come out any more through the vinyl hose. Then,
press the pedal fully and tighten the bleeder
screw while the oil is flowing out.
5. Similarly to the above procedure, bleed air from

the slack adjuster on the opposite side and
bleeder (3) of each wheel.
* If the pressure in the accumulator lowers,
start the engine to heighten it.
* After bleeding the air, run the engine at low
idling and check the oil level in the brake oil
tank, then supply oil, if necessary.
* After bleeding the air, perform “Testing
wheel brake performance”.
WA1 200-3 20- 137

0
Bleeding air from piston pump
* If the hydraulic oil is replaced or the piston pump

is replaced or the piston pump piping is re-
moved, bleed air to prevent seizure of the pump
6. Check that the hydraulic tank is filled with oil to

its top level.
7. Loosen plugs (I), (21, (3), and (4) of the suction

tubes of the piston pump.
8. Loosen the adapter on the block side of case

drain hose (5) of the piston pump.
9. Oil flows out of plugs (I), (21, (31, (41, and hose
(5) in order. After the all air is bled, tighten the
plugs and hose adapter.
* Since the oil level in the hydraulic tank is

higher than (I), (21, (31, (41, and (5) above, oil
can be bled easily.
20- 138 WA1 200-3

0
Bleeding air from work equipment circuit
* If the work equipment control valve or the work

equipment cylinder is removed and installed,
bleed air according to the following procedure.
1. Run the engine idle for about 5 minutes.
2. Running the engine at low speed, raise and lower

the boom 4 - 5 times repeatedly.
Ir Stop the piston rod about 100 mm before
each stroke end, and never relief the oil. 9JFOO425
3. Running the engine at full speed, perform the

operation of 2 above.
4. Running the engine at low speed, operate the

piston rod to the stroke end to relief the oil.
5. Repeat the operations of 2 and 3 above for the

bucket cylinder.
-
9JFOO426
WA1 200-3 20-139

0
RELEASING RESIDUAL
PRESSURE FROM HYDRAULIC
CIRCUIT
Releasing residual pressure from piping
between a hydraulic cylinder and control
valve
* When disconnecting the piping between a hy-

draulic cylinder and the control valve, release
the pressure from the circuit according to the
1. Stop the engine.
2. Loosen the oil filler cap gradually to release the

pressure from the tank.
3. Operate the control lever.

* After the control lever is operated 2 - 3 times,
the pressure in the accumulator is lost.
4. Run the engine at low idling for about 5 sec-

onds, then stop it and operate the control lever.
* Repeat the operations of 3) and 4) above 2 -
3 times to release the residual pressure com-
pletely.
Releasing residual pressure from brake

accumulator circuit
* When disconnecting the piping between the ac-

cumulator and accumulator check valve or be-
tween the accumulator and brake valve, release
the pressure from the circuit according to the
1. Stop the engine.
2. Press the brake pedal at least 100 times to re-

lease the pressure from the brake accumulator
circuit.
Releasing residual pressure from PPC

accumulator circuit
* When disconnecting the piping between the PPC

accumulator and PPC valve, release the pres-
sure from the circuit according to the following
procedure.
* Operate the control lever 2 - 3 times to release
the pressure from the circuit.
20- 140 WA1 200-3

a
TESTING AND ADJUSTING WORK EQUIPMENT SYSTEM
WORK EQUIPMENT SYSTEM

ADJUSTING WORK
EQUIPMENT LEVER LINKAGE
* If the operating effort or stroke of a work equip-
ment control lever is out of the standard range,
or if the work equipment control lever, PPC valve
assembly, or boom/bucket solenoid is removed,
adjust the operating effort and stroke of the con-
trol lever according to the following procedure.
A
f
When adjusting, stop the engine.
Check that the operating effort of the work equip-
ment control lever is in the standard range.
1. Remove the side cover of the work equipment

control levers.
2. Operate boom lever (I) and adjust the length of

rod (4) so that cam follower (2) for the boom
lever will be put in the detents on both ends of
cam (3) evenly and clearance a will be 0.2 - 1
Tm&stance b between pins of rod (4):

337 mm (Reference value) 1i? / 9JFOO427
I-
3. Operate bucket lever (5) and adjust the length of

rod (8) so that cam follower (6) for the bucket
lever will be put in the detents on both ends of
cam (7) evenly and clearance c will be 0.2 - 1
mm.
* Distance b between pins of rod (4):
337 mm (Reference value)
48 lr)l 9JFOO428
I 9JFOO429
WA1 200-3
20-141
0
TESTING AND ADJUSTING WORK EQUIPMENT SYSTEM
4. Perform the following procedure to set boom

kick-out solenoid (9) and bucket positioner sole-
noid (10) in the pull state (to turn them on) (See
the illustration on the previous page).
1) Remove relay (L45) (117 and (L48) (12) in the
operator’s cab.
+ L45: Boom kick-out relay
L48: Bucket positioner relay
2) Connect a T-adapter to short @ and @ of
relay 45 (Female) to each other, and short @
and @ of relay 48 (Female) to each other.
-k Check that each solenoid is in pull state m---9;FOO430
of 12 mm.
-
5. Move boom kick-out solenoid (9) so that clear-
ance d between boom lever cam (3) and cam
I
follower (2) will be 0 - 0.5 mm when the sole-
noid is in the pull state. 3 7
* When adjusting, keep the boom lever in neu- 00
tral. go 0
+
6. Move bucket positioner solenoid (IO) so that 2 e
d 6
clearance e between bucket lever cam (7) and
q %
cam follower (6) will be 0 - 0.5 mm when the
solenoid is in the pull state.
9JFOO431
7. If the boom lever canceling force and the bucket
lever canceling force are not 19.6 N (2 kg) and
9.8 N (1 kg) respectively, adjust them by chang-
ing installing holes d (at 4 places) of spring (13).
Ir When the machine is shipped, the spring is
installed to the second installing hole from
the top.
8. After adjusting, operate the bucket lever and

boom lever and check that they are held in TILT,
DUMP, and FLOAT positions.
I 9JFOO437
20-142 WA1 200-3
0
TESTING AND ADJUSTING ELECTRICAL EQUIPMENT
ELECTRICAL EQUIPMENT
BUCKET PROXIMITY SWITCH
Testing
1. Run the engine and operate the bucket to have

proximity switch (1) operate. Stop the engine
and measure clearance a between the proximity
switch and angle (2).
fl Standard clearance: a = 3 – 5 mm
2. Run the engine at medium speed (about 1500

rpm) and have the proximity switch operate and
lower the bucket to the ground. At this time,
check that the bucket angle is directed down by
0 – 1°.
Adjusting
1. If clearance a is not within the standard value,

adjust as follows.
2. Lower the bucket completely to the ground on a
horizontal ground surface.
3. Adjust proximity switch (1) so that clearance b
from the switch detection surface to the tip of
protector (3) is the standard value, then tighten
nut (4) to hold it in position.
• Standard clearance: b = 0.5 – 1.0 mm
3 Mounting nut:
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
4. Angle (2) moves to the side in relationship to
the switch detection surface, so adjust the clear-
ance so that it is a = 3 – 5 mm at all surfaces
that it passes.
5. Run the engine at a mid-range speed (1500 rpm),
and adjust mounting bracket (5) of the proxim-
ity switch so that the bucket angle is directed
down by 0 – 1 degrees when the bucket is low-
ered to the ground and the positioner is actu-
ated.
fl Set the nominal position of the bracket so
that c = 139 mm standard.
fl The relationship between the bucket angle
and the length of the cylinder when the
bucket is at the horizontal position above
the ground is 12 mm/1°.
6. The variation caused by the engine speed when
the bucket is actuated must be within 4° when
the bucket is just above the ground.
fl If it cannot be adjusted correctly, repeat Steps 1
to 4 again.
WA1200-3 20-143
20-143
1
6

BOOM POTENTIOMETER
fl After installing the boom, adjust the boom prox-
imity switch.
1. Remove bolts (1) and cover (2).
2. Raise the boom to the stroke end of the boom
cylinder, then stop the engine.
3. Loosen 2 screws (3).
4. Insert a T-adapter between the front harness
and potentiometer. Turn the starting switch to
the ON position and turn the potentiometer to
the “right” or “left” slowly so that the voltage
between terminals No. 2 and 3 of CN-F04 will
be 4.3 ± 0.1 V.
5. After adjusting the potentiometer, tighten screws
(3) temporarily and turn the starting switch to
OFF position, then turn it to the ON position
again.
6. Start the engine and lower the boom, then raise
it to the top. Check again that the voltage is in
the range of 4 above.
fl If the voltage is in the range of 4 above,
tighten screws (3) securely, then install cover
(2) and bolts (1).
fl If the voltage is out of the range of 4 above,
adjust it again according to 4.
20-144
20-144 WA1200-3
1
6
ADJUSTING BOOM HORIZON-

TAL DETECTION SWITCH
fl Adjusting in lateral direction
1. Lower the bucket completely to the ground on a

horizontal ground surface.
2. Adjust proximity switch (1) so that clearance d

from the switch detection surface to cover (2) is
the standard value, then tighten nut (3).
• Standard clearance: d = 3 – 5 mm
3 Mounting nut:
14.7 – 19.6 Nm {1.5 – 2.0 kgm}
3. Cover (2) moves in relationship to the switch

detection surface, so adjust the clearance so that
it is standard value d at all surfaces that it passes.
fl Adjusting boom in rotating direction
4. Set the boom to the horizontal position.
5. Loosen 2 lock bolts (5) of the switch mounting

bracket.
6. When the boom is horizontal, use the oblong

hole of bracket (4) to adjust the position so that
cover (2) covers half the detection surface of
proximity switch (1).
fl See Fig. Y.
7. After completing the adjustment, tighten lock

bolts (5).
WA1200-3 20-144-1
6
PROCEDURE FOR SETTING

INITIAL VALUE FOR REMOTE
BOOM POSITIONER (METHOD
OF INPUTTING BASE POINT)
fl Carry out this setting after adjusting the boom
potentiometer.
1. Operate the boom cylinder to the end of its stroke

to raise the boom to the maximum height.
2. Switch the CGC screen to the remote positioner

screen.
3. Check both the UPPER stop position set display

and LOWER stop position set display to make
sure that they are not at the stop condition.
fl Check that UPPER stop position set indica-
tor (5) and LOWER stop position set indica-
tor (6) are both OFF.
4. Press UPPER stop position set button (1) and

LOWER stop position set button (2) within 10
seconds at least two times each.
fl The buttons can be pressed in any order.
5. If the mounting position of the potentiometer is

correct, UPPER stop position set display (3),
LOWER stop position set display (4), UPPER stop
position set indicator (5), and LOWER stop posi-
tion set indicator (6) light up for 2.5 seconds
and the buzzer sounds.
20-144-2 WA1200-3
6
CHECKING PROXIMITY
SWITCH ACTUATION PILOT
LAMP
Proximitv switch actuation Dilot IamD (Red1
fctuation Pilot lamp
. nn I
The proximity switch has a pilot lamp to indi-
cate its operating condition. Use it for adjust-
ment.
* Condition of proximity switch actuation pilot

lamp TEWDOl66
. When the detector is at (near) the detecting face
of the proximity switch: Lamp is turned on.
. When the detector is apart from the detecting
face of the proximity switch: Lamp is turned off.
Proximity switch
actuation Lights UP Goes out
Pilot lamp
When detector is positioned at When detector has moved away from

Detector positior I
detectian surface of Proximity switch detection surface of Proximity switch
~--r--L_ I
__-_____-
_-______j j j
.-_-___A j II
j
Bucket I I +__-._-__-
positioner l-l_-__
Detector Proximiiu switch

=7=---T
Deteitor Proximiiv switch
Proximity switch
\ \
Reading of
load-meter
Detector
TWW02436
1
WA1 200-3 20- 145

0
INITIAL LEARNING METHOD

OF TRANSMISSION
CONTROLLER
Ir The transmission controller has a learning When performing the above opera-
function to correct itself so that the gear tion, run the engine at low idling and
shift feeling will be kept constant even if the turn the transmission cut-off switch
transmission clutch is worn. If the transmis- off, and turn the manual shift switch
sion controller is overhauled or transferred on.
to another machine, the control command Keep the gear at each gear speed for
values which the transmission controller the following time.
have learned from the former transmission Hold in “F3” for “5 seconds”, and in
are used. the other gear speeds for “3 sec-
As a result, gear shift shocks or abnormal onds”.
sounds may be made. As the machine is 2) Heighten the torque converter oil tem-
operated, the transmission controller learns perature to the second segment from the
the condition of the new transmission and bottom (Torque converter may be stalled
corrects the command values properly. for this purpose), then lower the engine
If you wish to reset the current data and speed to low idling.
have the transmission controller learns the * The target transmission oil tempera-
new data immediately, however, “reset the ture is 40 - 50°C. There will be no
collected control data” and “perform initial troubles even if the torque converter
learning” according to the following proce- oil temperature lowers to the first
dure. segment during the following gear
shifting operation.
1. How to reset collected control data 3) Perform following cycles @ and @ 2
* The all control data collected in the past times each; @ “N” + “Fl” + “F2” +
“F3”. @ “F3” ~ “F2” ~ “N” ~ “R,” ~
can be reset to the initial values by the
following procedure. “N”.
I) Check that the starting switch is at the * When performing the above opera-
OFF position. tion, run the engine at low idling and
2) Remove the right cover of the work turn the transmission cut-off switch
equipment control lever box. off, and turn the manual shift switch
3) Disconnect wiring connector (CN-CSB) on.
and connect a T-adapter P. * Keep the gear at each gear speed for
4) Turn the starting switch to the ON posi- the following time.
tion. . Hold in “F3” for “5 seconds”, and in
* Do not start the engine. the other gear speeds for “3 sec-
5) Short @ and @ of T-adapter P to each onds”.
other, then open them again. * If the engine is stopped before per-
forming the operations of 2) and 31,
2. How to perform initial learning start with I) again.
* When correcting the initial control data 4) Raise the engine speed to 1,000 rpm,
of each clutch in the controller to proper and repeat the operations of 2 and 3).
values, perform the following procedure 5) Raise the engine speed to 1,500 rpm,
after “resetting the collected control and repeat the operations of 2 and 3).
data” as explained above. (Reference)
* Start the engine and perform the follow- The above gear shifting operations can
ing gear shifting operation to stabilize be performed with the brake turned
the fill time of each clutch. “ON”, and it is not necessary to drive
1) Perform one cycle of the following gear the machine.
shifting operation; “N” + “Fl” + “F2”
~ “F3” ~ “F2” ~ UN” --) MR.,” --j “N”_
20-146 WA1 200-3

0
ADJUSTING MAIN MONITOR

(SPEEDOMETER MODULE)
Monitor Panel (rear)
l The speedometer of the main monitor is com-
mon to various models, and different models
input different travel speed signals. Accordingly,
the speedometer needs to be adjusted for each
model.
Ir The speedometer is normally used as the ta-
chometer.
Adjusting procedure
TWW01722
. Turn off the power and remove the main moni-
tor, then adjust the adjustment section of the
rear side of the speedometer.
1. Adjusting for each model

I) Remove the rubber caps of DIP switches 1, :I >dswitch
2, and 3 (SWI, SW2, and SW3) on the rear

side of the main monitor.
2) There are rotary switches under the rubber
caps. Adjust these rotary switches with a
flat-head screwdriver according to the fol-
lowing table.
Ir To change the tachometer to the speed-
ometer, set switch 3 to “0”. TWW01723
DIP SW 1.2.3
DIP SW 4
ON
piigq OFF
- -
Switch posisiton
TWW02437
3) Remove the cap of DIP switch 4 (SW41 on

the rear side of the main monitor, and set
the inside ON-OFF switches according to the
table at right.
4) After adjusting, fit the rubber caps securely,
then install the main monitor.
3 ON
(Reference) Correction ratio of switch (2) 4 ON
Position of switch 01234567
Correction ratio (%I +14 +I2 +lO +8 +6 +4 +2 0
WA1 200-3 20-147

a
ADJUSTING STEERING LEVER

ANGLE AND FRAME ANGLE
SENSORS
1. Set the machine body and lever (1) at a right
angle (measuring with eye).
2. Set steering lock lever (2) to the LOCK (lower)

position.
3. Run the engine at low idling.
9JFOO398
4. Slide the armrest to the auxiliary position (the
backmost position).
* If the armrest is set to this position, the con-
sole switch is turned “ON”.
5. Turn steering lock lever (2) to the FREE (upper)

position.
6. About 1 second after, pips come out and adjust-

ment is completed.
* Do not operate the steering lever during the
operations of 1) - 6).
* If the sensors do not operate normally, check
the installing direction of potentiometers (4)
Z 9JFOO437
and (5) again, then calibrate again. 1
. (4) Frame angle sensor (Potentiometer)

. (5) Lever angle sensor (Potentiometer)
9JFOO438
9JFOO439
20-l 48 WA1 200-3

0
PROCEDURE FOR CHECKING

DIODE
. Use the following procedure to check the diode
as individual part and the wiring harness includ-
ing the diode.
. Use a digital tester with a range for measuring
diodes.
1. Put the red (+) end of the test pin in contact with
the anode (PI of the diode, and the black (-1 end
in contact with the cathode (N).
* There is a mark showing the direction of TLPO0663
continuity on the surface of the diode.
* If a normal tester is switched to the diode
l---z--
Diode included in wiring harness
range, the voltage of the internal battery is
displayed.
The value indicates the following.
. No change: No continuity
l Changes: There is continuity (normal)
(Note)
l Value is 0 or near 0: Short circuit inside
diode
Note: In the case of silicon diodes, a value be-

tween 450 and 600 is displayed. TLP00664
BLPO1357
WA1 200-3 20-149

0
TESTING AND ADJUSTING GREASING SYSTEM
METHOD OF ADJUSTING
AUTO-GREASE INJECTOR
DISCHARGE AMOUNT
1. The injector is actuated by pressure from the
pump and sends the set amount of grease to
the bearing.
2. To check if the injector is working properly, ob-

serve the movement of indicator pin @ at the
head. If the operation is normal, the pin will first
be pulled in, and when the pump sto@s and the
pressure is removed, the pin will return to its
original position to complete the resetting for
the next greasing. K
3. To adjust the injector discharge amount, turn 0
adjustment screw @ at the head.
1) To reduce the discharge amount, loosen
locknut @ and turn adjustment screw @
clockwise to gradually decrease the dis-
charge amount. When the screw cannot be
tightened any further (the position where it
contacts the stopper), the discharge amount
is the minimum.
2) If the adjustment screw is turned counter- SJWOll33
clockwise 10 turns from the fully tightened
position (minimum discharge amount), the
setting will be maximum discharge amount.
Maximum discharge amount: 1.3 cc/ST
* After adjusting the injector discharge amount
as shown above, be sure to tighten locknut
@ again.
4. It is possible to overhaul or repair the injector,

but if the injector fails, it is better to replace the
injector with a new injector assembly.
. Loosen locknut @ and turn adjustment screw
@to adjust the amount of grease discharged
each time.
Discharge per time
Screwed in clockwise to
0.3 cc (minimum)
contact stopper
Loosened 10 turns counter-

1.30 cc (maximum
clockwise from above position
l One turn between the maximum and mini-

mum positions changes the discharge by
0.13 cc.
* After adjusting the screw, be sure to tighten
LlJWO1134
the locknut.
20- 150 WA1 200-3

0
METHOD OF SETTING
AUTO-GREASE TIMER
. The timer is installed to control the greasing
interval for the auto-greasing system.
. The timer is installed in box @ at the rear of the
operator’s seat.
. The timer can be adjusted to the desired greas-
ing interval according to the following table by
turning the blue dial.
Note that there is a tolerance of approx. +15%.
(Both the operation and rest periods)
Example: When timer is set to 11.25 minutes
11.25 minutes 11.25 minutes 11.25 minutes
stop stop stop

Operation
1. Adjustment of greasing interval

Timer box @ is in the position shown in the
diagram on the right.
. Power supply for timer

Even after the starting switch is turned off,
both the rest time and operating time are
stored in this circuit board by the capacitor
(Super Cap) for about five days, and the next
operation starts under the condition when
the power was turned off the previous time.
However, if the power is kept turned off for Dial (red)
more than five days, the data are deleted
from memory. /
2. Method of adjusting interval time (Blue dial)

Open the door at the bottom rear of the cab,
then open the lid of the timer box. Turn the dial
shown in the diagram on the right to adjust the
rest time and operating time.
To adjust the rest time, turn blue rotary switch
@ in the diagram on the right according to the
following table.
AW43740B
WA1 200-3
Position of switch 1 2 3 4 5 6 7 8 9
Greasing interval (min) 3.75 7.5 11.25 15 18.75 22.5 28.25 30 33.75
Position of switch A B C D E F
Greasing interval (min) 37.5 41.25 45 48.75 52.5 56.25
I) Set the blue dial to position 3 after the auto-

greasing system is installed.
3. Method of adjusting operating time (Red dial)

To adjust the operating time, turn red rotary
switch @ in the diagram on the right according
to the following table. (Normally, fix this dial to
position 2 (15 seconds).)
D i a I (b I ue)
AW437415
Position of switch 1 2 3 4 5 6 7 8 9
Operatingtime of pump(set) 7.5 15 22.5 30 37.5 45 58.5 60 67.5
Position of switch A B C D E F
Operatingtime of pumpkiec) 75 82.5 90 97.5 105 112.5
I) Set the red dial to position 2 (for normal

operation).
2) When greasing is finished and the greasing
pump is balanced, the greasing pump stops
even if within the specified operating time
(15 set).
20-152 WA1 200-3

0
HOW TO SELECT JAPANESE/

ENGLISH ON VHMS
1. When VHMS is replaced, remove rubber cap (I)
and set rotary switch (2) as shown below.
* 0: English
1: Japanese
I BVH00389
HOW TO SET SERVICE METER

OF VHMS
MEMORY CLEAR
1. Select the memory clear ID inputting screen.
Failure History Data Maintenance Data
2. Press button (I) at the right bottom of the screen. Trend Data Load Map Data
Snap Shot Data

3. Press “SET” switch (2).
4. Input hours (H) with keys (31, then press “enter”

key (4). MENU
* If “I,,, “o”, “o”,
“enter” are pressed in or-
der, “lOO.O”H is displayed in part (a). 9JFOO402
* If a value smaller than the currently saved

data is input, the saved data is maintained.
(For example, if the input value is “50” and
the currently saved value is “loo”, “100” is SERVICE METER SETTING
not changed but saved again.)
SET
9JFOO403
4 9JFOO404
WA1 200-3 20-l 53

0
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
A Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
A 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.
A the
If the radiator cap is removed when the engine is hot, hot water
engine to cool down before starting troubleshooting.
may spurt out and cause burns, so wait for
A Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first.
A When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 4) Check the stroke of the control valve spool.
to disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
. Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
. It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. + When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in items 2 - 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
I) Have any other problems occurred apart from * The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check the oil level
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
20-202 WA1 200-3

0
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
ber of machine
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary
toots. * Pinpoint locations of failure (carry out
* T-adapter
. Hydraulic pressure gauge kii, etc.
2) Look in the parts book and prepare the nec-
essary replacement parts. 1) Before starting troubleshooting, locate and
21 See the Troubleshooting Section of the shop

manual, select a troubleshooting flowchart
- Drive and operate the machine to confirm

the condition and judge if there is really a
Step 4
- Was there anything strange about the ma-

chine before the failure occurred?
- Did the failure occur suddenly?
Had any repairs been carried out before the
WA1 200-3 20-203

0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAlmNANCE
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 re-
pairs 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, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

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.
I TEwoo192
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
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
correction or breakage.
TEwGm93
20-204 WA1 200-3

0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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.
TEwOOl94
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 be short- I TEWOO196
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
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- TEWW196
tact restorer.
f When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
* If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
WA1 200-3 20-205

0
2) Removing, installing, and drying connectors and

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

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
* If the connector is twisted up and down
or to the left or right, the housing may
break.
0 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.
* If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 WA1 200-3

0
0 Connecting connectors
Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
* If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
* If there is any damage or breakage, re-
place the connector.
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.
Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion or the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
j, If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps.
WA1 200-3 20-207

0
l 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 wa-
ter or steam directly on the wiring harness.
If water gets directly on the connector, do as

follows.
6) Disconnect the connector and wipe off the
water with a dry cloth.
Ir If the connector is blown dry with com- TEWW196
pressed air, there is the risk that oil in

the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
Dry the inside of the connector with a dryer.

lf water gets inside the connector, use a dryer
to dry the connector.
+ 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 connec-
tor.
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.
* After completely drying the connector,
blow it with contact restorer and reas-
T-adapter
semble.
20-208 WA1 200-3

0
3) Handling control box

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.
Do not open the cover of the control box
unless necessary.
Do not place objects on top of the control

box.
Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
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)
Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
-
II TEWC0206
2. Points to remember when troubleshooting electric circuits

I) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
* If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
+ If there is any change, there is probably defective contact in that circuit.
WA1 200-3 20-209

0
TROUBLESHOOllNG POINTS TO REMEMBER WHEN CARRYING OUT MAIMENANCE
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

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

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

If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equipment.
I - TEWOO207
31 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 en-
tering. 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 leak-
ing oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4) Do not let any dirt or dust get in during refilling

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.
TEwOO209
20-210 WA1 200-3

0
51 Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as pos-
sible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the
new oil and will shorten the life of the hydraulic
oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or chanoing the oil, use flushing oil to
oil
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3~11particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
WA1 200-3 20-211

0
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

l-
Judgement
Item Remedy
standard
1. Check fuel level, type of fuel - Add fuel
2. Check for impurities in fuel - Clean, drain
3. Check hydraulic oil level - Add oil
4. Check hydraulic filter - Clean, drain

(Torque converte, Transmission hydraulic, hydraulic tank oil)
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
10. Check for looseness, corrosion of alternator terminal, wiring - Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, wiring - Tighten or replace
12. Check operation of instruments - Repair or replace
13. Check for abnormal noise, smell - Repair
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
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 - Disconnect
to water leaking on connectors or terminals) :onnector and dry
22. Check for blown, corroded fuses - Replace
23. Check alternator voltage (engine running at l/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 WA1 200-3

0
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

* The Address column in the table below shows the address in the connector arrangement drawing
(Bdimensional drawing).
WA1 200-3 20-2 13

0
Add-
Mounting location ress
El0 DTl 2 Compressor magnet clutch H-9

El1 DTl 2 Diode l-3
El2 DTl 2 Intermediate connector K-5
E13 Terminal 1 Engine ground K-5
El4 DTl 3 PRE-LUB starter l-2
El5 DTl 3 Safetv relav H-2
ERI 1DTI 1 6 1Intermediate connector 1 L-2 1 1 GO2 1M 1 2 1Riaht working lame I Kl
ER3 1 DTHD4l 1 I intermediate connector 1 K-l 1 1 GO3 I M 1 2 I Rioht workino lamp 1 J-9 I
ER4 I DTHD4l 1 1Intermediate connector 1 K-1 1 GO4 DTl 3 Stairway lamp switch K-4
ER5 DTHD4 1 Intermediate connector K-1 GO4 Plug 1 Left backup buzzer K-7
ER6 DT2 3 Intermediate connector L-2 GO5 Plug 1 Left backup buzzer K-7
ER7 DT2 4 Intermediate connector L-2 GO6 DTl 3 Backup buzzer relay K-7
ER8 DT2 3 Intermediate connector L-2 GO6 DTl 2 Coolant level sensor l-9
ETHl ;t&r 1 Ether injection solenoid l-9 GO7 M 2 Left working lame K-7
ETH2 DTl 2 Diode l-9 I ~08 IM 1 2 I Left working Iamp I K-6 I
ETH3 Imnnm,l
‘-pi” 1 I Ether iniection solenoid I I-9 I I GO9 I M I 6 I Left combination lamp 1 K-7 I
FOl 1DTl 1 6 I Intermediate connector I A-5 l l GlO l’-pi” l
mnntirir 1 I Right backup buzzer I K-8 I
l-pin
F02 DTl 6 Intermediate connector A-4 Gil conneuor 1 Right backup buzzer K-8
F04 DT2 3 Boom angle sensor A-6 G12 M 2 Left engine room lamp J-8
F05 DT2 3 Proximity switch for load meter A-5 G13 M 2 Right engine room lamp l-9
F06 I DT2 I 3 I Boom bottom Dresswe sensor I D-l I G14 M 2 Left rear side working lame K-8
F06 l X l 3 1 Drive force control dial I d-l I I G15 I M I 2 1Rioht rear side working iamo I H-9 I
F07 l X I 3 1Travel speed control dial 1 d-l I I G16 1M I 2 1Stairwav lame I K-8 I
F07 I 1 I Horn (350 Hz)
I Terminal I B-l I I GND I M I 1 I Right front combination Iamp I B-7 I
F08 1Terminal
I I I Horn (350 Hz) I B-l I I GND I M I 1 I Left front combination lamp1 C-l I
~1
FO9 Terminal 1 Horn (315 Hz) A-5
F10 Terminal 1 Horn (315 Hz) A-5
Fll - 2 Working lamp (Optional) B-l GRl DTlA 12 lntermedtate connector
F12 - 2 Working lamp (Optional) A-2
F13 DT2 3 Bucket positioner A-4
F14 DT2 3 Boom head oressure sensor A-3 HRl lDT2 1 2 I NC (Neutral) solenoid t G-9 l
F15 I DT2 1 3 1 Wheel rotation sensor I A-2 1 I HR2 I DT2 I 2 I Diode I G-l 1
F20 I Terminal
I 1 I Chassis ground I D-8 I I HR3 I DT2 I 2 I Bucket TILT switch I C-8 I
F21 I Terminal1 1 I Horn (add) I C-1 I HR4 DT2 2 Bucket DUMP switch C-8
F22 Terminal 1 Horn (add) C-l HR6 DTI 2 Rear brake level E-l
F23 TeninaI 1 Horn (add) A-5 HR8 DT2 2 Boom dump solenoid B-7
F24 Terminal 1 Horn (add) A-4 HR9 DT2 2 Boom dump solenoid B-7
FL1 HD-2608614 Intermediate connector A-9 HRlO DTI 2 Front brake level D-l
FL2 HD-25085 14 Intermediate connector B-9 HRll DT2 2 Boom lever detent switch C-8
FRl HD-86J8623 Intermediate connector B-9 I HR12 I DT2 I 2 I Boom RAISE switch 1 B-7 I
FR2 I HP4W82l21 I Intermediate connector I B-8 I I HR13 I DT2 I 2 I Boom LOWER switch I C-8 I
FSl lL I 2 I Fuse box I h-7 I I HR14 I DT2 I 2 I Parkina brake solenoid I F-l l
20-214
0
Con- No.
Add-
nectar Type of Mounting location ress
No. pins
JL9 DT2 6 Joint connector a-2
JLlO DT2B 8 Joint connector a-2
~ HR17 l DT2 l 2 l Ememencv brake switch 1 E-I 1 JLII DTI 6 Joint connector a-l
~ HR18 1DT2 l 2 l Ememencv brake switch / E-I 1 JL12 DT2 6 Joint connector a-l
HR19 1DT2 I brakeresetsolenoid1
2 I Emergencvoarking F-l 1 1 JL13 1DTI I 6 I Joint connector I a-1
1 HSl DT2 2 Hydraulicoil temperaturesensor A-6 JL14 DT2 6 Joint connector a-l
HS2 DT2 3 Workequipment oil pressure sensor A-7 JL15 DT2 6 Joint connector a-l
~ HS3 DT2 3 Steering oil pressure switch C-I JL16 DT2 6 Joint connector a-l
HS4 DT2 3 PPC oil pressure sensor G-9 JL17 DT2 6 Joint connector a-l
JBl DTl 8 Joint connector V-9 JL18 DT2 6 Joint connector a-l
JB2 DTl 6 Joint connector v-9 JLI9 DT2 6 Joint connector a-l
JEI 1DTl 1 6 1Joint connector I T-9 1 I JL20 l DT2 I 6 I Joint connector I a-l
JE2 DTl 6 Joint connector V-8 1 JL21 1DTIB I 8 l Joint connector I a-l
JE3 DTIB 8 Joint connector v-9 JL22 DT2B 8 Joint connector a-l
JE4 DTl 6 Joint connector v-9 JL23 DTPB 8 Joint connector a-l
JFl DTI 6 Joint connector O-I JL24 DT2 6 Joint connector c-l
JF2 DTl 6 Joint connector N-l JL25 DTI 6 Joint connector C-l
JF3 DT2 6 Joint connector M-4 JL26 DT2 6 Joint connector C-I
JF4 I DTZB I 8 1Joint connector 1M-4 I JM4 DTI 6 Joint connector Q-9
JF5 1DTlBl 8 / Joint connector I M-3 I I JRI i DTIB 1 8 1Joint connector 1W-6
JF6 DTI 6 Joint connector M-4 I JR2 I DTI I 6 I Joint connector I w-5
JGl DTlB 8 Joint connector w-7 JR3 DTI 6 Joint connector T-2
JG2 DTI 6 Joint connector w-7 JR4 DT2 6 Joint connector T-2
JG3 DTlB 8 Joint connector w-7 JR5 DT2 6 Joint connector T-l
JG4 DTI 6 Joint connector W-8 JR7 DTl 6 Joint connector u-2
JG7 DTIB 8 Joint connector W-8 JR8 DTlB 8 Joint connector Q-I
JG8 l DTI I 6 I Joint connector I W-8 I JR9 DT2 6 Joint connector R-I
JGN l DTl I 6 l Joint connector 1M-2 I I JR10 I DT2 I 6 I Joint connector l Q-I
JGN I DTl I 6 1Joint connector I M-6 I I JRII I DT2 I 6 l Joint connector l Q-9
JR12 DTI 6 Joint connector Q-9
JR13 DTlB 8 Joint connector O-8
JR14 DT2 6 Joint connector N-7
JR15 DTl 6 Joint connector O-8
JR16 DTl 6 Joint connector N-7
JLl1 DT2 1 6 1Joint connector I z-2 I JRA DT2 6 Joint connector T-9
JL2 I DT2 I 6 I Joint connector 1 Z-2 I I JSI I SWP 1 12 I Jovstick lever switch I i-7
JL3 1DT2Bl 8 \ Joint connector I z-2 I I JS2 I x I 3 I Potentiometer I i-5
l-pin
JL4 DTI 6 Joint connector z-4 JS3 COllWCt0r 1 Console switch i-6
l-pin
JL5 DTlB 8 Joint connector z-4 JS4 connector I Console switch i-5
JL6 DTZB 8 Joint connector z-4 JTI DT2 6 Joint connector w-5
JL7 DT2 6 Joint connector z-2 JT2 DT2 6 Joint connector w-6
JL8 DT2 6 Joint connector z-2 JT3 DT2B 8 Joint connector w-5
WA1 200-3 20-Z 15

0
?O-216 WA1 200-3

0
Con- No.
Add-
lector Type of Mounting location ress
No. pins
L127 1Reiavl 5 1Steerina neutral relav 1 n-8 1
L128 1DT2 1 2 1 Diode I r-9 I
L129 I - I 2 I Resistor I r-9 I
L130 &$&, 1 Travel speed “ON/OFF” indicator u-2 MT5 DT2 3 modulating
Transmission oilpressure
sensor ab-6
l-pin
L131 &$&), 1 Travel speed “ON/OFF” indicator t-2 OPl COtNECtOf 1 Fuse box v-7
L132 Relay 5 Dust indicator 1 relay m-9 QP2 l-pin
connector 1 Fuse box v-7
L133 Relav 5 Dust indicator 2 relav n-9 OP3 z-tn. 1 Fuse box v-7
L134 1Relavl 5 I Dust indicator 3 relav I n-9 I 0~4 I,2L,I I I Fuse box Iv-71
~135 I Relay1 5 I Dust indicator 4 relav I n-8 1 0~5 I,Z’L,,I I I Fuse box
L136 &F&r 1 Remote positioner RAlSEindicator n-8
L137 &$&, 1 Remotepositioner RAlSEindicator o-8
L138 g& 1 Remote positionerLOWER indicator n-7
L139 l-P’”
COlXECtO~ 1 RemotepositionerLOWERindicator o-8
L140 &:&tor 1 PRE-LUBE indicator r-9
L141 &!$&,, 1 PRE-LUBE indicator o-9
L142 I&&orl 1 Turn signal switch n-7 I 01 IHD-~w I 21 I Enaine controller I T-9
L143 I,i.2~l 1 I Turn sianal switch n-7 I ~2 lH5~ I 31 I Engine controller I T-9 I
~144 I&$!&,/ 1 ( Turn signal switch I n-7 I ROl I DT2 I 2 l Torqueconverteroil fiiterdoggingsensorI S-l I
L145 I&!$,,r/ 1 1DC converter (24 V/12 VI ) v-5 R02 ( DT2 1 2 1Torqueconverter
oil filtercloggingSensor1 S-l
._.
L146 mnnector
‘-p’” 1 DC converter (24 V/12 VI v-6 R03 DT2 2 Diode u-2
l-147 KES 2 DC converter (24 VI12 V) v-5 R04 DT2 2 Diode u-2
L150 I
KES
~- I
2-,-- Service meter
~~~ I
s-9 R05 DTl 2 Fuel level sensor v-9
L152 I Relavl 5 I Alternator sianal relav I n-9 R06 Terminal 1 Slow blow fuse W-8
L160 I;;{$;rl 1 Alternator indicator I q-9 I R07 ITerminalI I I Slow blow fuse IW-81
L161 l,Z~,,l 1 I Alternator indicator I o-9 I R08 \Terrninal
I I I Slow blow fuse IW-81
LRI 1~~95086131 I Intermediate connector I N-9
I R23 (DT2 I 2 1Diode I a-9 I

LR7 I DTI I 4 \ Intermediate connector 1M-9 1 R24 I KES I 2 I Rear windshield washer \ O-8 I
LR~ I DT2 I 3 I Intermediate connector I M-9 R25 DT2 2 Diode Q-9
LR9 I DT2 I 4 I Intermediate connector I M-9 R26 KES 2 Side windshield washer P-8
MO1 MIC 21 Modulated clutch controller v-5 R27 DT2 2 Diode Q-9
M02A 040 20 Modulated clutch controller v-5 R30 DTI 3 Left condenser P-9
M02B 040 16 Modulated clutch controller v-4 R31 DTl 3 Right condenser P-8
MC1 X 3 Modulated
clutchdirectcouplingswitch u-8 RAI DT2/DTl
_ 4 Intermediate connector I
u-9
MC2 - 2 Resistor n-8 RA2 M2/DTl 3 Intermediate connector 1 R-9
MC3 - 2 Diode s-9 RA3 DT2 6 Intermediate connector I x-3
MC4 I- I 2 I Diode I v-4 I RA4 I DTHDSI 1 I Intermediate connector I x-2 I
MT1 I DT2 I 3 I Tranunission
lubricating
oil preswre~nwj z-9 1 RA5 1DTI 1 4 I Intermediate connector 1x-2 1
WA1 200-3 20-217

0
Con- No. Con- No.

Add- Add.
nectar Type of Mounting location nectar Type of Mounting location
ress ress
No. I
oins
,~
No. pins
RA6 DTHD3 1 intermediate connector u-9 T20 DT2 2 1st bypass solenoid X-8
RA7 DTl 2 Battery fluid level sensor W-3 T21 DT2 2 ‘R” (Reverse) bypasssolenoid ab-4
RA8 DTl 2 Battery fluid level sensor R-9 T22 DT2 2 “F” (Forward) bypasssolenoid aa-
RA9 1DTl 1 2 1Batten, fluid level sensor 1 R-9 1 T23 DT2 2 “R” (Reverse) drain solenoid ab-4
RAlO 1DTHD41 1 1Intermediate connector 1 R-9 1 T24 1DT2 1 2 1Torqueconverter oil temperaturesensor 1 v-8
RAll I Terminal
1 1 I Terminal I S-9 I
V2B IAMPO7OI12 I VHMS controller I r-l

RES3 I- I 2 I Resistor (150 Q f 1 %I I a-l I V3A I AMP070
I 18 I VHMS controller
RES4 I- I 2 I Resistor (120 Q) I m-5 I
WORK21M I 2 I Riaht headlamp I M-6

SMALLI M I 1 1 Left front combination lamp I P-l I WORK21M I 2 1Left headlamp I M-5
STL I DT2 2 I Steering lock switch I t-1 I WORK3 M 2 Right working lamp M-6
SVl I- I 4 1Solenoid 1 I S-9 I WORK3 M 2 Left working lamp M-5
sv2 I- I 4 I Solenoid 2 I s-9 I
T5 I DT2 1 2 l2nd solenoid I x-81

T6 1DTl 1 2 I2nd fill switch 1 x-8 I
Ti’ 1DT2 2 I3rd solenoid 1 v-8
T8 IDTl 2 I3rd fill switch I v-8
T9 DT2 2 Modulated clutch solenoid ab-5
TlO DTl 2 Modulated clutch fill switch ab-6
111 DT2 2 ‘R” (Reverse) solenoid aa-
T12 DTl 2 “R” (Reverse) fill switch ab-3
T13 1DT2 I 2 1“F” (Forward) solenoid
T14 I DTl I 2 I “F” (Forward) fill switch I z-2 I
T15 I DT2 2 I Speed sensor 1w-4 I
~16 I DT2 I 2 I Modulatedclutchrotationsensorlab- I
T17 I DT2 2 I Engine rotation sensor I z-9 I
T18 DT2 1 2 Parking brake indicator switch y-l
T19 DT2 1 2 Torque converter oil temperature sensor a b-5
20-218 WA1 200-Z

0
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
CONNECTOR ARRANGEMENT DIAGRAM
FL2 +
AR02
FL1. I AR01
I
. ..._” \
I I
Rl8 HR14
HRi9
F22
BwWOl5Ol +
20-220 WA1 200-3

0
--ilS 9 c2 807 G16 G13 ETH2
.E03
GRl
GR6
E05
\ E07
El3
GO4
E‘ll
\ ERl
El4 ER6
ER7
I ER8
16
AiOl
AL02
BWWO1502
WA1 200-3 20-221

0
LRl
RA9 RAlO +
LR2 I 11.. \ I._ I_._
JR1 1
1119
-..--
R30 JM4
R3! PHl \\\
R3-
WORK1
WORK2
WORK3
JHD
JGN
WORK3
WORK2
WORK1
JF6
JF3
/ / /
Rll JF2 JFl TURN’ SMAlLL Ri2
BWW01503 +
20-222 WA1 200-3

0
+ PRE SV2 JGR3 REl 01
JE4
R07
JG4
/
/JG7
,JG3
,JGl
bJG2
‘JR2
\
RA’
RA3
‘JGRP
RAS
RA4
RA12
\
R01
si2
RA13
R02
+
WA1 200-3 20-223

0
+-
c2
C3B I
CO6
co4
\ \
JLb
JL6
20-224 WA1 ZOO-3
0
FS6
FS6
I I / FS4
JS2
33
/ I I YY\M\\\ 'A10
1 1 \ \ ‘Al2 ‘A14
\ A\8B
A16 DLi
+ ’ A14 1542
BWWO
WA1 200-3 20-225

0
L6iil:4L73L;L91 17;;z3/:::
+
Lf 19
Ll14 L133
L69 & -1134 L39
L69
L92 I ‘~j;l?T I
L61
L99
L68
L67
L63
L62
L4i Li6 LiO6

W
RESP
RES4
LO6
L26
Li6
I I
L96 L97 ,
20-226 WA1 XXI-3

0
+
Ll03 L160 LO1 L128 Ll50
t en
I. OP2.OP3
OP6
WA1 200-3 20-227

0
\
Tl4
Ti2
T18
/
Tl
20-228 WA1 200-3

0
I8 I c21 c29 c20
!!
A17
Al6
Cl3
c12
!ll \ \\\ 1
Cl7
Cl4
Cl6
Cl8 C23
C27
C24
.C26
.
‘cne
WA1 200-3 20-229

0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

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

of
pins Male (female housing) Female (male housing)
1 3
EElI
2 4
TEwoozz5
20-230 WA1 200-3

0
No.
of
T SWP type connector
‘6
TFNc4l235
1 5
4 8
1 4
5 8
9 12
BLFWO34 BlPOKl35
1 4 8 11 11 8 4 1
14
3 i io ?14
TEwooz39 TEwoo240
4 1 4
1
5 8
16
9 2
WA1 200-3 20-231

0
No.
of
T M type connector
2
e7
1
BLFOCO38
TEwoo244
3 1
4
ElS
4 2
TEwca245 lEwoo246
1 4 4 1
6
cl
3’ ‘6
TEWOO247
8
Qzl 8’ ‘5
BLFWXO BLPOOO41
20-232 WA1 200-3

0
NO.
of
T S type connector
Ezl ‘8
TEwKQ49
1 6
\ /
10
(White
$3 5 10
Two0251
I 6
12
(White
i
5 12
BEL00113 BEL00114
16
(White
WA1 200-3
is- 0
i i6 BEL00115
16 7 BEL00116
20-233
0
TROUBLESHOOTING CONNECTlON TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T S type connector
10
(Blue
i 10
BEL00117
BELO
1 6
6 1
12
(Blue
5 12
ElFwx3
1 8 8 1
16
(Blue
El
0
16 7 TEwoozs6
20-234 WA1 200-3

0
No. MIC connector

of
13
8
13
H BLFOOO4B
9 9
Bl.Pooo50
00 0
17 17 10
17
BLPmo52
21
WA1 200-3 20-235

0
No.
of
T AMP040 type connector
a 4
6 12
8LFwos5
i i BLFUOOBB
a 16
16
20
ai 11 1
lEww234
20-236 WA1 200-3

0
No.
of
l- AMP070 type connector
10
EWWOl601 BWWO1602
12
i
5 12 BWW01603 5 NW01604
14
6 BWWO1605
aI EWWOl606
18
8 18 BWWO1607 18 8 8WWO1608
10 1
20
20 Y
EWWOl609 BWWOl6lO
WA1 ZOO-3 20-237

0
No.
of
T L type type connector
I I
ELI
a
2
m
20-238 WA1 200-3

0
No.
of
T Automobile (KESI 1 connector
WLOI 140
it3 2 3
BVLOI 141
BVLOl142
.
k BLFQWW
4 1
8
Em f?3 I
5
\
BU%QQ?2
8
WA1 200-3 20-239

0
T
Type HD30 series connector
Shell
size
code 1 Body (Plug) Body (Receptacle)
Pin (male terminal) Pin (female terminal)
EWWO1612
18-8
Pin (female terminal) Pin (male terminal)
(1)
NW01614
BWWO1616
18-14
(2)
BWWO1617
20-240 WA1 200-3

0
TYPE HD30 series connector

Shel
size
Body (Plug) Body (Receptacle)
code
BWWO1820
18-2C
(3)
BWWO1621 BWWO1622
fn\
0
'00
IlO
o
'2
::O
90
O
200
03 o 060'6
0405
,' 0 O'6
15
02'
,07
0'7
020
0'9
BWWO1623 BWWO1624
18-21
(4)
BWWO1625 BWWOl626
WA1 200-3 20-24 1

0
Type
Shell
T HD30 series connector
I size
code
Body (Plug)
Pin (male terminal)

Body (Receptacle)
Pin (female terminal)
oT
0
ova
0
OS
f\ oz 0”
owoy ox
BWWO1627 BWW01628
24-9
(5)
l-3 0
SOT ” lT
u
OS
ooopooV
/OR .Z
oy ox ow lwl l X y
BWWOI
629 BWW01830
BWWO1631 BWWO1632
24-16
(6)
BWWOl633 BWW01634
20-242 WA1 200-3

0
TROUBLESHOOTlNG CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

Shell
size
code i I Body (Plug) Body (Receptacle)
EWWO1636
24-21
(7)
BWWO1637 BWWOI 636
BWWO1639 BWWOl640
24-23
(8)
BWWO1642
WA1 200-3 20-243

0
T
Shell
size
code 1 Body (Plug)
Pin (male terminal)

Body (Receptacle)
Pin (female terminal)
BWWO1644
24-31
(9)
BWWO
I646
20-244 WA1 200-3

0
TROUBLESHOOTING CONNECTIONTABLE FOR CONNECTOR PIN NUMBERS
[Number is printed on each connector (Wire inserting end).]
No.
of
T DT series connector
pins Body Plug) Body (Receptacle)
2
2 fiE3
lzzil
I
BWWO1647
EWWO1649 6WWO1650
BWW01652
WA1 200-3 20-245

0
[Number is printed on each connector (Wire insetting end).]
No.
Of
T DT series connector
pins Body (Plug) Body (Receptacle)
BWWOl653 BWWO1654
a
@f!a!@
I
Em
08
4 BWWO1655 4 1 BWW01656
12
1 6
BWWO1657 I
BWWO1656
20-246 WA1 200-3

0
[Number is printed on each connector (Wire inserting end).]
No.
of
T DTM series connector
pins Body (Plug) Body (Receptacle)
2
2 B
ihdi
0 0
1 1 c3
m 2
BWWOl659 BWW01660
WA1 200-3 20-247

0
No.
of
T DTHD series connector
pins Body F’b) Body (Receptacle)
0Q 0
EWWO1661
0 4%
BWWO1662
20-248 WA1 200-3

0
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL

MECHANISM (For details, see section STRUCTURE AND FUNCTION)
TRANSMISSION CONTROL SYSTEM
(Input sianals) (Dutwt sionalsl
_I
ECMV 3rd
Shift-down c
0
ECHV R
Transmission
cut-off switch
:....r:,...-
Auto/Manual
I Backup lamp relay
Transmission
controller
psolenoid 1
Fill switch F IstLE

wq?- I
Fill switch R
*7-
Fill switch I
*7-
Fill switch 2
*F”----
Fill switch 3
Work ewipsent
-7-
Transmission oil
temPerature
1 TXW02438
WA1 200-3 20-249

0
MODULATED CONTROL SYSTEM
(Input sionals) Klutuut sisnats)
I
Drive force
control voltaoe $---_H
Travel speed
control voltaoe
Transmission cut-off selector snitch
NC solenoid valve outout
Sneed settins LE
VHMS controller (+12VI
Modulated clutch
(MOD/C) controller
Sneed set ON/OFF sional
a7
Modulated clutch ECMV fill signal
1
*7
Transmission F clutch sisnal
-7
Transmission R clutch signal
I
O?
Transmission 1st clutch sinnal
q
F
Transmission 2nd clutch sisnal
q
=7
Transmission 3rd clutch signal
q
TXW02439
20-250 WA1 200-3

0
WORK EQUIPMENT CONTROL SYSTEM
lnout signals Output sianals
(1) Boon lever kick-out solenoid

@ Boom anale ootentioaeter
@Boom RAISE witch
12) Boom PPC dumoino solenoid
+?!!I
A: Analog signal
B: Dioital sional
P: Pulse signal
S: S-NET sional
@Booa lever detent snitch (3) Remote Positioner snitch inout check
buzzer outout
Main monitor
R-IIxzI
@ nettino twitch (4) Diselar of lower settino
of remote positioner
Q) ~:y;;:,m:j;;ner raise
(5) Disolav of raise setting
@ Remote positioner raise Work eouionent
eta0 selector witch controller (6) Disolav of raise stop
@ Remote mritioner lower
tten selector switch (7) Disolar of lower stop
of remote Positioner
@Remote Positioner TMS controller

function selector
l :8) EPC solenoid for control
@Steerins potentiometer of steering main Pressure
calibration relet switcl Steerino lock velve
To steerino
@Steering lever anal1

rrn”?’
5i1iy
@Frame angle
Potentiometer
!y;;; caution buzzer ’ 1 F
@ Steer ino lever

lock switch
Startino lever u Neutral safetrl

relay
.I
I
Nban loratickknob tch is la N
WA1 200-3 20-251

0
TROUBLESHOOTlNG EXPLANATIONOF FUNCTIONS OF ELECTRICCONTROL MECHANISM
MAINMONITORSYSTEM
Network tire slip

control ON/OFF Auto grease
_ Modulated clutch Parkino brake indicator a
controller _[ sri tch I
1
, Network t c -
.Uodel shional
.Abnormalitr signal
[ .Neutcal sional
Transmission When jcrstick is used)

c
controller
Gear weed signal
Alarm buzzer
Rear uorkino lame

I t Transmitsion cut-off sritcb tinnal relay sional
Transmission cut-off aressure
A switch sidnal
I- ..A I Ensine weed signal I
Travel speed signal
;ygo;;f coolant temoerature
Main monitor
Alarm buzzer signal

w Service meter
I
I
Turn signal lame switch signal
Joystick FNR
+
lever INisht Iishtinr sisnaf imi
L switch
Emersencv steering operation
I VHYS
controller
I
Starting switch ON signal
WA1 200-3
VHMS CONTROL SYSTEM

Monitoring items for maintenance
Engine speed
I 1
Electromaonet ic
Fuel level
1
Toraue converter
oil temperature
.
a
Hydraulic oil
tenperature Brake fluid level
.
g
~ Ataos~~ temperature
Coolant level
Transmission oil filter
differential pressure I
~;pa~;a 4; air cleaner
1
%
F
Alternator terminal R
+24V
Brake differential
wemutt
+24V I +24V
I
Transmission lubricatino
oil preswr.2
+24vfTj+q Tranmission
oi I Prefmre
I
modulation
i24V
+24V +24V
I
Steering relief
outlet Pressure
nb
+24V- 1
-+24V
relief Dressure
I
7h I
I
I I
TXW02442
WA1 200-3 20-253

0
Functional items of load meter
INPUT +24\ OUTPUl

I
+24\
+24V
L
+*4”m!i
VHMS
controller
Subtotal switch
-7
Cancel switch
1 Mele;ase disDlav 1
TXW02443
20-254 WA1 200-3

0
TROUBLESHOOTING METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
METHOD OF DISPLAYING ACTION

CODE AND FAILURE CODE
1. Display on CGC
1) Outline
The VHMS controller transmits information of
various types through CAN (network) to the CGC
monitor, and the “Failure history information”
in that information is displayed on the SERVICE
MENU SELECT SCREEN of the CGC monitor.
2) Display of failure history

If failure history button (1) on the service menu
SERVICE MENU SELECT
is pressed, the “FAILURE HISTORY SCREEN”
appears. Real Time Monitor aintenance Monitor
,1
The “Code”, “Contents”, “Starting time of fail- PM-Clinic Failure History A’
ure detection start time”, and “Finishing time of
failure detection” of the failures are displayed in Serial No. set
the order of time from the oldest one. If the Memory Clear Snapshot Trigger
failure still exists, the “finishing time of failure
detection” is not displayed.
The number of the all past failures is displayed
in section (21, the failure No. in section (31, the BWWOl551
failure code and its contents in section (41, and
the time when the failure occurred in section 5.
31 Function of each button 2

i) Service Menu button (6): 3 4
. If this button is pressed, the “SERVICE
MENU SCREEN” appears.
ii) Page button (7): 5
l This button is used to turn over the page. 7
iii) UP/DOWN button (8):
- This button is used to move the dis-
played part up and down. 6
iv) Failure history No. button (3):
. If this button is pressed, the history cor-
BWWO 1552
responding to it is not displayed.
* Although the history is not displayed
in this case, the data in the control-
ler are saved.
WA1 200-3 20-255

0
TROUBLESHOOTlNG METHOD OF DISPLAYING ACTlON CODE AND FAILURE CODE
2. Display on main monitor
1) Outline
The speedometer display on the main monitor
is used to display the troubleshooting for each
control system. The nature of the troubleshoot-
ing is displayed as the failure action code, fail-
ure code, and the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the
network circuit. (Only the engine controller uses
a special parallel signal.)
2) Display of failure action code Examole: When action code CALL is displayed
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 (a): EOO,
I SPEED \
E01 + CALL (EOI and CALL are displayed alter-

nately), and CALL. If a failure occurs suddenly, a
one of these codes is shown on the speedom-
eter display.
31 Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible
I BWWO153
to tell from this code which system in which

controller has failed, so carry out troubleshoot-
ing for the applicable controller.
41 Saving failure code

The transmission controller writes the failure
codes to memory.
i) A total of 9 failure codes can be saved in
memory.
ii) The data that is saved to memory is as fol-
lows: (1) Failure code (b)
(2) Time elapsed since failure (c)
(up to 1000 hours) Example: When failure code “41” has
iii) The failures are saved in the order that they occurred 27 hours before
occur. If a failure code already exists in the b
memory, the repeat failure code is not saved.
iv) If there are already 9 items in memory, and / SPEED /\
a 10th failure occurs, the oldest item is de-
leted and the new item is saved.
c
* 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.
BWWOl532
20-256 WA1 200-3

0
TROUBLESHOOTING METHOD OF DISPLAYING ACTlON CODE AND FAILURE CODE
5) Switch operation procedure and actuation
Switch operation Actuation
Trouble data memory

mode display
i) Stop engine. The failure code is
ii) Turn starting displayed on the
switch ON. speedometer dis-
iii) Switch (I) (Second play and the time
switch from the elapsed since failure
left top) and head is displayed on the
lamp switch (2) action code display.
simultaneously ant If there is no failure,
keep pressed for at the speedometer dis-
least 5 seconds. play shows [CC] and
the action code dis-
play shows 100001.
Going to nest failure
code
iv) Press head lamp The failure code and
switch (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 ex-
ists, the display r
flashes; if the failure
has been restored,
the display lights up.
Clearing failure code

Y) Keep rear lamp The failure code and
switch (3) pressed elapsed time on the
for at least 2 display are cleared.
seconds. If the failure still ex-
ists, the failure code
is not cleared.
Wtting trouble data
memory display mode
4 Switch (I) and The display returns
head lamp switch to the normal dis-
(2) simultaneously play.
and keep pressed
for at least 5
seconds. Or start
the engine.
WA1 200-3 20-257

0
MONITORING ITEMS LIST (CGC)
Screen Component
Name of signal Unit Remarks
No. name
REAL TIME MONITOR
T/M UP SHIFT SW
114 T/M DOWN SHIFT SWITCH (ON/OFF) T/M
114 (ON/OFF)
274 ENGINE SPEED 1 rpm VHMS
2l4 FILL SIGNAL F (ON/OFF) T/M
2/4 FILL SIGNAL R (ON/OFF) T/M
2l4 FILL SIGNAL 1st (ON/OFF) TIM
I 2l4 FILL SIGNAL 2nd I (ON/OFF) ) T/M

FILL SIGNAL 3rd I (ON/OFF) I TIM
SOLENOID 2nd I 1 mA 1 T/M

SOLENOID 3rd I 1mA 1 TIM
ENGINE SPEED 1 rpm VHMS
AUTO SHIFT SIGNAL (ON/OFF) T/M Each time momentary

switch is turned ON,
state (AUTO/MANUAL)
is changed. Value
recognized by controller
is displayed.
Each time momentary

switch is turned ON,
state (AUTO/MANUAL)
is changed. Value
recognized by controller
is displayed.
20-258 WA1 200-3

0
(MOD/C OUTPUT
SPEEDJAENGINE SPEED
WA1 200-3 20-259

0
Screen Component
Name of signal Unit Remarks
No. name
I 516 I BUCKET TILT SIGNAL I (ON/OFF) MOD/C I
I 516 I FILL SIGNAL F I (ON/OFF) I T/M I ~~ ~~~

5/6 FILL SIGNAL 1st (ON/OFF) T/M
516 TIRE SLIP SIGNAL (ON/OFF) Main monitor
516 (ON/OFF)
I 616 I ENGINE SPEED I 1 rpm I VHMS I

I 6/S 1 R.H. BRAKE PROXIMITY SWITCH 1 (ON/OFF) I MOD/C I
I 6/S I ACCELERATOR SIGNAL I 0.1 v I MOD/C I
616 1 CONTROLLER OUTPUT SIGNAd 0.1 v I MOD/C I
6/S SET/ACCEL, DECEL (IDLE UP) --- ---
616 RESUMEIACCEL, DECEL (IDLE DOWN) - - - - - -
REMOlE POSITIONER CONTROLLER
l/l BOOM ANGLE SIGNAL 0.1 v Work equipment
I l/l I BOOM RAISE SIGNAL I (ON/OFF) Work equipment
l/7 BOOM LOWER SIGNAL (ON/OFF) Work equipment
l/l DETENT SIGNAL (ON/OFF) Work equipment
l/l UPPER SET SIGNAL (ON/OFF) VHMS Positioner screen switch

of CGC
111 LOWER SET SIGNAL (ON/OFF) VHMS Positioner screen switch

of CGC
LOAD METER
I I
l/l BOOM BOTTOM PRESSURE O.OlMPa 10.1 kg/cm? 1 VHMS 1 Di$?~;~?~~fafr;;~~
I I
l/l MEASURED PRESSURE O.OlMPa (0.1 kg/cm21 VHMS Measured trigger
pressure
I l/l I CAL. PRESSURE IO.OlMPa (0.1 kg/cm’!I I VHMS I Calibration pressure
I I
l/l NO LOAD PRESSURE O.OlMPa IO.1 kg/cm*] VHMS Default calibration
pressure
lb MEASURE LOAD 1 TON VHMS Measured trigger load
JOYSTICK STEERING
l/2 J/S ON/OFF SIGNAL _-- _--
l/2 S/T NEUTRAL SWITCH (ON/OFF) Work equipment
I 712 I S/T LEVER POTENT10 I 0.1 v I Work equipment
I l/2 I ARTICULATE ANGLE 0.1 v Work equipment
II2 J/S SOLENOID OUTPUT 1 mA Work equipment
l/2 STEERING LOCK (ON/OFF) Work equipment
20-260 WA1 200-3

0
Screen Name of signal Unit Component

No. name Remarks
2/2 T/M DIRECTION SIGNAL F (ON/OFF) T/M
1 2/2 1 T/M DIRECTION SIGNAL N 1 (ON/OFF) I T/M I I

1 Z/2 1 T/M DIRECTION SIGNAL R 1 (ON/OFFIj I T/M I I
l/2 S/l N SIGNAL OUTPUT (ON/OFF) Work equipment
PM CLINIC
114 ENGINE SPEED 1 rpm VHMS
114 COOLANT TEMP. 1°C CENSE
114 T/C TEMP. 1°C VHMS
I l/4 I AMBIENT TEMP. I 1°C j VHMS I I

I 114 I BLOW-BY PRESSURE I 1 mmAq 1 CENSE I I
I l/4 I ENGINE OIL PRESSURE 1O.OlMPa (0.1 kg/cm3 I CENSE I I
1 2/4 1 BOOST PRESSURE I O.OlMPa (0.1 kg/cm3 I CENSE I I
2i4 EXH. GAS TEMPERATURE 1% CENSE
2l4 T/C IN PRESSURE O.OlMPa IO.1 kg/cm3 VHMS
2l4 T/C OUT PRESSURE O.OlMPa IO.1 kg/cm3 VHMS
1 2/4 ( T/M MAIN PRESSURE 1O.OlMPa (0.1 kg/cm3 1 VHMS I I

1 Z/4 1 T/M LUB. PRESSURE I O.OlMPa 10.1 kg/cm3 I VHMS I I
I 314 I T/M MOD PRESSURE I O.OlMPa (0.1 kg/cm3 I VHMS I I
-I- S/T PUMP PRESSURE
314 I o.lMPa 11 kg/cm3 1 VHMS
314 F BRAKE OIL PRESSURE O.lMPa 11 kg/cm3 VHMS
314 R BRAKE OIL PRESSURE O.lMPa 11 kg/cm3 VHMS
314 HYD. OIL TEMP. 1°C VHMS
I 314 I HYD. OIL PRESSURE I O.lMPa 11 kg/cm3 I VHMS I I

414 PPC OIL PRESSURE O.lMPa (1 kg/cm3 VHMS
WA1 200-3 20-261

0
LIST OF ALARM ITEMS DISPLAYED ON CGC MONITOR

1. The check lamp output is driven with VHMS.
2. As the signal to synchronize flashing of the caution lamp output of the main monitor, the ON/OFF
output of VHMS is used. Permission of the alarm output is given by S-NET and is sent from VHMS
to main monitor.
3. The check lamp and caution lamp are set independently (When two failures occur, both flash).
Al arming condiion 1
Letactinc
Detecting condiion 1
m mdilkmi Resettingcondition 1
Failure
UO. Item Display range Detail of display range engine engine etectinf Resettingcondition
t-l- starts is runnin mekec
___
H: Normal -__
1 Engine oil level Below LOW level
lz Abnormal 0 2 When left is not satisfied
(Engine speed in rpm,
1
oil pressure in kPa)
Below followina linear
interpolation graph
Below specified
2 Engine oil pressure
pressure (0.0) 0 2 When left is not satisfied
(800, 138)
;;;3 $4r71
12200:345)
Above 102oC Above 102°C

but 1OEK alarm is not detected T-tx- 10 When left is not satisfied.
Above 105°C Above 105°C 0 0 10 When left is not satisfied

Belowspecifiedlevel Below 1 segment of gauge (11%) 0 __- 10 When left is not satisfied
Belowspecifiedlevel Below 1 segment of gauge (11%) *_-- 0 10 When leit is not satisfied.
Above 120°C
Above 12OOC
Above 130°C
Above 105oC
but 130°C alarm is not detected
Above 130°C
Above 10S°C
--I-O
0
0
0
10
10
10
When left is not satisfied.
Below 14.7 MPa Below 14.7 MPa (150 kg/cm3 __- ___
(150 kglcmq and within 60 set after engine starts 0 When left is not satisfied.
-i-
Below 14.7 MPa (150 kg/cm?
and atter 60 set after engine starts
---
l 0 5 When left is not satistied.
Below 14.7 MPa Below 14.7 MPa I150 kg/cm9 ___ ___
(150 kg/cm? and within 60 set after engine starts
0 When left is not satisfied.
Below 14.7 MPa f150 kg/cm3 -_-

and after 60 set after engine starts
0 5 When let?is not satisfied.
OPEN (Fluid level is low)

Batteryfluid level(1) Below LOW level
=6Vcellisbelow2V
t
17 1Batteryfluid level(21 Below LOW level 0 0 10 When leti is not satisfied.
-I--
= 6 V cell is below 2 V
Batteryfluid level (3) Below LOW level
-_-
= 6 V ceil is below 2 V
___
_-_
Belowspeciiiedlevel OPEN = 24 V (Fluid level is low) 0 10 When left is not satisfied.
0
___
Belowsoecifiedlevel OPEN = 24 V (Fluid level is low) 10 When left is not satisfied.
4
‘1 Coolant level Below LOW level
Below LOW level
Above specified
pressure
OPEN = 24 V (Coolant is insufficient)
OPEN = 24 V (Coolant is insufficient)
OPEN = 24 V (Clogging) and torque
converteroil temoeratureis above 50°C
=I=
--_
0
0
0
2
2
2
Above specified __-

negative pressure
OPEN = 24 V (When clogged) 0 2 When left is not satisfied.
Above specified __-

negative pressure
OPEN = 24 V (When clogged) 0 When left is not satisfied.
Above specified ___

OPEN = 24 V (When clogged) 0 When left is not satisfied.
negative pressure
above specified
negative pressure
OPEN = 24 V (When clogged) _-_ I 0 When left is not satistied.
Above 9.3 V (While engine is running)

,8 Voitageat alternator when charging is [Criterionwhile engine is running: ---
. terminal R sbnormal Voltage of terminal R is above 9.3 V
0 When let?is not satisfied.
or engine speed > 600 mm)
20-262 WA1 200-3

0
Alarm output
w
T,
ompent &ference) Clinic(Reference)
Abnormal Red Not installed - - - Flashing CENSE --- 0
I I , I
I 1 1
Abnormal Yellow Installed - - - Flashing Gauge 0
CENSE
Gauge 0
VHMS Gauge ---
-__ 1 966 ) X Gauge ---
Gauge 0
0 VHMS
Gauge 0
Abnormal Red Installed - - - Flashing VHMS --- 0
‘ressurizing Yellow Installed --- Flashing --- 0

VHMS
Abnormal 1 Red 1Not installed1 - -- 1Flashing ON 1913 1 0 ___ 0
‘ressurizing Yellow Installed --- Flashing ___

I 912 I X
VHMS .
-__ 0
Abnormal Red Not installed - - - Flashing ON 1915 1 0 ___ 0
Abnormal Yellow Installed Flashing - - - ---
Abnormal Yellow Installed Flashina - - - --- ___

VHSM
Abnormal Red Not installed - - - Flashing --- -__
Abnormal Yellow Installed Flashing - - -
Abnormal Red Not installed - - - Fiashina
Abnormal I Yellow I installed ( Flashing 1 ---
Abnormal I Yellow I installed I Flashing 1 - -- ___ 932 0
Abnormal Yellow Installed Flashing - -- ___ 933 0

VHMS
Abnormal Yellow Installed Flashing --- ___ 934 0
*
Abnormal I Yellow I Installed I Flashing 1 --- -__ 935 0
Abnormal 1 Yellow 1 Installed 1Flashing / i:y -__ 937 0 VHMS
+-
WA1 200-3 20-263

0
TROUBLESHOOTING FAILURE CODES LIST
FAILURE CODES LIST

* Failure codes related to VHMS are not displayed on the main monitor (They are displayed on only
CGC monitor).
* For display of cautions related to alarm, see the List of alarm items displayed on CGC monitor.
* In “Display of history”, EOOO + Contents of failure + Time when failure occurred + Time when
failure is rest are displayed.
39 E01 1Short circuit with chassis ground in 1st bypass solenoid signal system I 1 E039
70 1 Disconnection in boom RAISE/LOWER, bucket TILT/DUMP pressure switch system 1 E070
72 EOl + CALL Short circuit, disconnection, or short circuit with power source in accelerator pedal sensor system / E072
a4 1 Short circuit, disconnection, or short circuit with chassis ground in neutral cut solenoid system ( E084
a5 ( CALL I Short circuit. discunnsction,or short circuit with chassis gmund in modulated clutch ECMV solenoid system 1 E085
20-264 WA1 200-3

0
CGC monitor).
CGC monitor
)e,,ke Failure Action Failed system
code code Real-time Displayof
display history
43 Disconnection, short circuit, or short circuit with chassis ground in dumping solenoid E043
44 EOl + CALL Short circuit of hot side of dumoina solenoid with Dower source E044
45 CALL Short circuit of return side of dumping solenoid with power source E045
=g 49 Disconnectionor short circuitwith chassisground in boom lever kick-outsolenoidsystem E049
2
51 Disconnection in boom RAISE/LOWER pressure switch system E051
g
U 52 Disconnection,
short circuitwith chassisground or short circuitin boom angle sensorsystem E052
2 55 EOO Short circuit or disconnection in travel sDeed sensor svstem E055
: 56 shortcircuitwithchassisground or short circuit in joystick cautionbuzzerrelaysystem
Disconnection, E056
‘3
57 shortcircuitwithchassis ground or short circuit in steering lever angle sensor system
EOl t CALL Disconnection, EO57
B
Y 58 EOlt CALL Deviationof potentiometer signal in steering lever angle sensor/frsmeangle sensor system E058
z
59 EOl t CALL Disconnection,
short circuitwith chassisgroundor short circuitin frame angle sensorsystem E059
61 EOl t CALL Disconnection or short circuit with chassis ground in steering lever lock switch system E061
62 EOO Disconnection,
shortcirceitwithchassis
aroundor shortcinxitin iovstkkneutrelinterfcck
relevsystem E062
Disconnection, short circuit with chassis ground or short circuit in joystick main
63 EOl t CALL E063
pressure control EPC solenoid system
lE8ii I 1 Disconnection or short circuit with Dower source in NSW Dower sutmlv svstem 1 I E811 I
E812 1 1 Short circuit with chassis ground in 24-V system of sensor power supply 1 E812
E813 1 1Short circuit with chassis around in 12-V svstem of sensor Dower SUDDIY I 1 E813
E814) ) Short circuit with chassis ground in 5-V system of sensor power supply I 1 E814
E818 I I Wrong connection of connector I E818
I E821 l I Failure in controller (Failure in securino of memorv) I I E821 I
E824 1 1Failure in communication with CGC and engine controller ! 1 E824
Disconnection, short circuit with chassis ground or short circuit with power
E825 E825
source in S-NET (Between transmission controllers)
E826 E826
source in S-NET (Between modulated clutch controllers)
E827 E827
source in S-NET (Between work eauioment controllers1
lE4 I Disconnection, short circuit with chassis ground or short circuit with power
source in S-NET (Between main monitors) I I E828 I
IE8311 I Failure in controller (Handle error) I l E831 I
E841 1 Short circuit of buzzer output with power source 1 E841
E843 I 1Short circuit of check lamp with power source I E843
E844 Short circuit of flash synchronizing signal with power source E844
E861 Disconnection
or short circuitwith chassisground in boom bottompressuresensorsystem E861
E862 Disconnectionor short circuit with chassisaround in boom head oressure sensor svstem E862
E863 ) Disconnectionor short circuitwith chassisground in rear brake oil pressuresensor system 1 ) E863
E864 1 or shortcircuitwith chassisgroundin work equipment relief pressure sensor system 1
1Disconnection 1 E864
E865 Disconnection
or short circuitwith chassisground in front brakeoil pressuresensorsystem E865
E866 or shortcircuitwithchassisgmundin transmission main relief pressure senscrsystem
Disconnection E866
E867 Disconnectionor short circuitwith chassisaround in steerinarelief oressuresensorsystem E867
E8681 Disconnectionor short circuit with chassis
groundin torque converter outlet oil pressure sensor system 1 E866
E871 I 1Disconnectionor short circuit with chassis around in transmission modulation oil pressure sensor system 1 1 E871
lE8721
I Disconnection, short circuit with chassis ground or short circuit with power
source in transmission lubricating oil pressure sensor system
WA1 200-3 20-265

0
CGC monitor).
1 CGC monitor 1
Failed system 1 Real-time 1Displayof 1
1 display 1 history
E874 Short circuit with chassis ground in torque converter oil temperature sensor system E874
E875 Shortcircuit
withchassis
ground
or shortcircuit
withpowersource
in hydraulic
oiltemperature
senscr
system E875
ES77 E877
source in atmosoheric temoerature sensor svstem
1
E878 Disconnectionor short circuit with chassisground in PPC relief pressure sensor system ES78
5884 Diicnnectionor shortcircuitwithchassis
groundin torqueconverterinletoil pressuresecscrsystem E884
E901 Enaine oil level below LOW level DkhvofcautbnE901
E937 1 Charging trouble of alternator ~k$ayofratin( E937
* For display of failure codes related to engine controller, see “Troubleshooting for engine controller
system (G-mode)“.
20-266 WA1 200-3

0
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormal-
ity in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms
are then used to decide which troubleshooting table
(E-00, H-OO, etc.) matches the symptoms.
The judgement table is designed so that it is easy to determine from the self-diagnostic display which
troubleshooting table to go to.
* The abnormality display given by the monitor panel leads directly to troubleshooting of the monitor
system (M-00).
(See troubleshooting of the machine monitor system)
[Method of using judgement table1

l A 0 mark is put at the places where the failure mode and self-diagnostic display match, so check
if an error code is displayed on the graphic display portion of the monitor panel.
l If an error code is displayed:
Go to the troubleshooting code at the bottom of the judgement table (E-OO, etc.).
l If there is a problem but no error code is displayed:
Go to the troubleshooting code on the right of the judgement table (H-001.
l For failure modes where no 0 mark is given, go directly to the troubleshooting code on the
right of the judgement table.
WA1 200-3 20-267

0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTINGCHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. 1 Component
G-00 Troubleshooting of engine controller system
T-00 Troubleshooting of transmission controller system
MC-00 Troubleshooting of modulated clutch controller system
J-00 Troubleshooting of joystick steering controller system
w-00 1 Troubleshooting of work equipment controller system

M-00 1 Troubleshooting of main monitor system
v-00 Troubleshooting of VHMS controller system
H-00 Troubleshooting of hydraulic, mechanical system
2. Method of using troubleshooting table

Troubleshooting code number and problem
The top left of the troubleshooting chart gives the troubleshooting code number and the
problem with the machine.
General precautions
When using the troubleshooting chart, precautions that apply to all items are given at the top
of the page and marked with f.
The precautions marked * are not given in the I, but must always be followed when
carrying out the check inside the I.
Distinguishing conditions
Even with the same problem, the method of troubleshooting may differ according to the
model, component, 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.
Method of following troubleshooting chart
* Check or measure the item inside In, and according to the answer follow either the
YES line or the NO line to go to the next 0. (Note: The number written at the top right
corner of the I 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 I there are the methods for inspection or measurement, and the judgement
values. If the judgement values below the I are correct or the answer to the question
inside the I is YES, follow the YES line; if the judgement value is not correct, or the
answer to the question is NO, follow ttie NO line.
. Below the I 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 equip-
ment may be damaged. Therefore, before starting inspection or measurement, always read
the instructions carefully, and start the work in order from Item 1).
Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For de-
tails, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the con-
nector pin number and location for inspection and measurement of the wiring connector
number appearing in the troubleshooting flow chart.
20-268 WA1 200-3

0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example>
@ M-5 Turn signal display does not light up
0* Before carrying out troubleshooting, check that all the related connectors are properly
inserted.
* Always connect any disconnected connectors before going on to the next step.
* 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

0 a) Divided into sections a) and bl I
b) R.H. turn signal display does not light up
@ Flow chart a1 L.H. turn signal display does not light up
1 YES
IS voltage
between Lo6 (14)
and chassis DefBcdve cowact 0,
groundnormal? d&connection in wirina
hamessbetweenLO6” Repairor
. Repeats0 V and NO (female)(14) and L144
M-30V. (male)(1)
*Turn startingswitchON.
. Turn LH. turn signalON.
b) R.H. turn signal display does not light up

,
Repair or
replace
M-5 Related electrical circuit diagram
L.H. turn
signal
I alllo
- (25W)
WA1 200-3 20-269

0
TROUBLESHOOTING METHOD OF USING MAiRlX TROUBLESHOOTINGTABLES
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 t Symptom [Example]
-The questions to ask the operator are given
below the failure symptom. If the answers Ask the operator about the following points.
to the questions match the information given, Did the steering suddenly stop working +
follow the arrow to reach the probable cause
of the failure. Had the steering gradually been becoming
heavy? + Internal wear of steering equipment,
Consider the contents of the questions and
consult the table while proceeding to Steps
2 and 3 to grasp the true cause.
Step 2. Checks before troubleshooting Checks before starting [Example]

Before starting the main troubleshooting and
measuring the hydraulic pressure, first check l Is the oil level in the hydraulic tank correct?
the Checks before Starting items, and check Is the type of oil correct?
for oil leakage and loose bolts. These checks l Is there any leakage of oil from the steering
valve or Orbit-roll?
may avoid time wasted on unnecessary trou-
l Has the safety bar been removed from the
bleshooting.
frame?
The items given under Checks before Start-
ing are items which must be considered par-
ticularly for that symptom before starting
troubleshooting. [Example 1I
Step 3. Using cross-referencetable Remedy

1) Operate the machine to carry out the No- Problems
checks in the troubleshooting item col- 1
I
Steering does not work to the left or right.
umn. 3 Same as item 1, but abnormality in actuation of
Mark the items where the results match work equipment
the symptom. 3 Steering can only be operated to one side.
* It is not necessary to follow the trou-
4 Steering wheel is heavy and cannot be turned.
bleshooting checks in order; follow
an order which is easiest to carry
out troubleshooting.
2) Find the appropriate cause from the [Example 21

cause column. If the symptom appears,
the 0 marks on that line indicate the
possible causes. (For item No. 2 in the
table on the right, the possible causes
are c or e.)
lf there is only one 0:
Carry out the other troubleshooting items
(where the same cause is marked with
0), check if the symptom appears, then
repair.
If there are two 0:
Go on to Step 3) to narrow down the
possible causes.
-i--H
20-270 WA1 200-3

0
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES
3) Operate the machine and check the trouble-

shooting items other than those in 1).
Operate the machine and check the items in
the same way as in I), and if the symptom
appears, mark that item. (In the chart on the
right, the symptom appears again for item
5).
4) Find the appropriate cause from the cause

column. In the same way as in Step 21, if the
symptom appears, the 0 marks on that line
indicate the possible causes. (For item No. 5
in the table on the right, the possible causes
are b or e-1
5) Narrow down the possible causes.

L
LApplicable troubleshooting item located in Step 3).
Applicable troubleshooting item located in Step 1).
There is one common cause among’the

causes located in Steps 2) and 41. (One cause I ///‘I1 Janore these causes
marked 0 appears on the line for both items.)
This cause is common to both the symp-
toms in troubleshooting Steps 1) and 3). causes
Jr The causes which are not common to
both troubleshooting items (items which
are not marked 0 for both symptoms)
are unlikely causes, so ignore them.
(In the example given on the right, the
causes for Troubleshooting Item 2 are c
or e, and the cause for Troubleshooting
Item 5 are b or e, so cause e is common
to both.)
6) Repeat the operations in Steps 31, 4) and 5)

until one cause (one common cause) re-
mains.
J, If the causes cannot be narrowed down
to one cause, narrow the causes down
as far as possible. n to take
71 Remedy
If the causes are narrowed down to one com-
mon cause, take the aciton given in the rem-
edy column.
The symbols given in the remedy column 4 101 1 JOI i I
indicate the following: 5_--__I_+3c_I_
X: Replace, a: Repair, A; Adjust, C: Clean
WA1 200-3 20-271

0
TROUBLESHOOTING OF
ENGINE CONTROLLER SYSTEM
(G MODE)
Display method of CUMMINS engine controller failure codes and contents of display .............. 20-302
Failure codes and actions table .... ........ .................. ..... ..... ...... ...... ..... ........-.......................................... 20-303
WA1 200-3 20-301

0
DISPLAY METHOD OF CUMMINS ENGINE CONTROLLER
TROUBLESHOOTING FAILURE CODES AND CONTENTS OF DISPLAY
DISPLAY METHOD OF CUMMINS ENGINE CONTROLLER

FAILURE CODES AND CONTENTS OF DISPLAY
1. The failure codes from the CUMMINS engine controller are transmitted through communication
(CAN) line to the VHMS controller, where they are processed.
2. The failure codes and contents of the failures (displayed messages) are saved as failure history.
3. The failure codes are displayed on the alarm screens corresponding to the operator codes (for the
customer).
4. Operator codes [Oil - I041 and other five screens are set for the alarm screens (for the customer).
5. If a failure which is not shown in this list occurs, the alarm screen of occurrence of an un-
registered error appears.
20-302 WA1 200-3

0
TROUBLESHOOTING FAILURE CODES AND ACTIONS TABLE
FAILURE CODES AND ACTIONS TABLE
I Cl24 I 124 Abnormal LB suction Dressure Hi I 1 I SeeCummins Manual I
Short circuit in PTO circuit Lo

Cl35 135 Abnormal oil pressure sensor Hi 1 See CumminsManual
Cl36 136 Abnormal filter inlet pressure sensor Hi. 6 See CumminsManual
Cl37 137 Abnormal filter inlet pressure sensor Lo 6 See CumminsManual
Cl41 141 1Abnormal oil pressure sensor Lo 1 1See CumminsManual
Cl43 143 I Oil rxessure Lo 4 1See Cummins Manual
Cl51 151 Coolant Hi 3 1See CumminsManual

Cl53 I 153 1 Abnormal LBF air boost temDerature sensor Hi 1 1 1See CumminsManual
I Cl54 I 154 1Abnormal LBF air boost temoerature sensor Lo 1 1 I SeeCumminsManual
Cl55 155 LBF air boost temperature Hi 4 See CumminsManual
Cl56 156 Abnormal LBR air boost temperature sensor Hi 6 See CumminsManual
Cl57 157 Abnormal LBR air boost temperature sensor Lo 6 See CumminsManual
Cl56 156 LBR air boost temperature Hi 4 See CumminsManual
Cl59 159 Abnormal RBF air boost temperature sensor Hi 6 See CumminsManual
Cl61 161 Abnormal RBF air boost temDerature sensor Lo 6 See CumminsManual
Cl62 162 RBF air boost temperature Hi 4 See CumminsManual
Cl63 163 Abnormal RBR air boost temperature sensor Hi 6 See CumminsManual
Cl64 164 Abnormal RBR air boost temperature sensor Lo 6 See CumminsManual
Cl65 165 RBR air boost temperature Hi 4 See CumminsManual
c212 212 Abnormal oil temperatuer sensor Hi 6 See CumminsManual
C213 213 Abnormal oil temDerature sensor Lo 6 See CumminsManual
I C214 1 214 I Oil temoerature Hi I 3 I SeeCumminsManual I
c219 219 Remote oil level Lo 1 See CumminsManual
c221 221 Abnormal atmospheric temperature sensor Hi 6 See CumminsManual
c222 222 Abnormal atmospheric temperature sensor Lo 6 See CumminsManual
C223 223 Short circuit in CORS BV solenoid Lo 1 See CumminsManual
C225 225 Short circuit in CORS M valve Lo 1 See CumminsManual
WA1 200-3 20-303

0
Contents of failure
1 C452 452 Fuel rail pressure Lo 1 1See Cummins Manual
C527 I 527 A-double output Hi I 1 1See Cummins Manual

C528 528 1Abnormal aenerator 1 1See Cummins Manual
c529 528 B-double output Hi 1 See Cummins Manual
c55S 553 Fuel rail pressure Hi 4 See Cummins Manual
c554 554 Abnormal fuel rail pressure 2 See Cummins Manual
c555 555 Blow-by pressure Hi 4 See Cummins Manual
C611 611 Sudden stop of overheating 8 See Cummins Manual
20-304 WA1 200-3

0
Komatsu Cummins Cummins Action

Contents of failure (System)
failure code failure code operator code (Diagnosis code)
C612 612 Oil filter pressure Hi 2 See CumminsManual
C616 616 LBR turbocompressor suction temperature Hi 6 See CumminsManual
C621 621 #1 LB low pressure 1 See CumminsManual
C622 622 #2 LB low pressure 1 Sea CummincManll:
.” . .._.._.ij
C623 623 #3 LB low oressure 1 scva

___ fhnrnil
_I........is
Manual
c
t- 628 #8 LB low pressure 1 See CumminsManual
t C631 631 #1 RB over-outout 1 See
--- Cflmminc
__........._ Mant~al
,.,“..““.
#2 RB over-output 1 See CumminsManual

i #5 RB over-output 1 See CumminsManual
636 #6 RB over-output 1 See CumminsManual
$7 #7 RB over-output 1 See CumminsManual
I 638 #8 RB over-outout 1 See
-__ Cummins ..._..__.
_- .. ....._ Mniwal
C641 641 #l LB over-exhaust temperature 4 See CumminsManual
C642 642 #2 LB over-exhaust temperature 4 See CumminsManual
C643 643 #3 LB over-exhaust temperature 4 See CumminsManual
C644 644 1#4 LB over-exhaust temperature 4 1See CumminsManual 1
C645 645 1#5 LB over-exhaust temperature 4 / See CumminsManual 1
C646 I 646 1#6 LB over-exhaust temperature I 4 1See CumminsManual
C647 647 1#7 LB over-exhaust temoerature 4 I See Cummins Manual
LB over-exhaust temperature 4 See CumminsManual
#l RB over-exhaust temperature 4 See CumminsManual
#2
- RB over-exhaust temperature 4 See CumminsManual
/ #3 RB over-exhaust temperature 4 1See CumminsManual 1
-#4 RB over-exhaust temperature 4 1See CumminsManual 1
#5 RB over-exhaust temperature 4 1See CumminsManual
t C656 I 656 1#6 RB over-exhaust temoerature 4 I See Cummins Manual
C657 657 #7 RB over-exhaust temperature .4 See CumminsManual

C658 658 #8 RB over-exhaust temperature 4 See CumminsManual
C661 661 #I LB over-output 2 See CumminsManual
___-
i-x67 -_ i2
6f I #2 LB over-output 2 1See CumminsManual1
I
C663 663 I #3 LB over-output 2 ) See CumminsManual 1

1
c
C664 1 664 I #4 LB over-outout I 2 1SeeCumminsManual 1
C665 665 #5 LB over-output 2 See CumminsManual
C666 666 #6 LB over-output 2 Saa CumminsManual
C667 667 #7 LB over-output 2 See CumminsManual
C6fi8
---_ I
f%
__
1 C6:
WA1 200-3 20-305

0
Contents of Cummins operator codes and display of CGC [message)

* Operator codes [ll - [41 are displayed. Operator codes [51- I81 are not displayed, however, and they are
only saved as history. (Ill - 141 are saved as history, too.)
l Operator code 1:
Check and maintain when the work is finished or the operator is changed.
l Operator code 2:
Stop the machine on a safe place, then check and maintain immediately.
l Operator code 3:
Operate the machine with the engine speed and travel speed low.
l Operator code 4:
Stop the machine immediately on a safe place and stop the engine, then check and
maintain immediately.
l Operator codes 5 - 8:
They are only saved as history (not displayed).
l Failures other than above:
Contact your distributor.
20-306 WA1 200-3

0
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM
(T MODE)
Judgement table for transmission control system related parts ...................................................... 20-404
Operations of controller against abnormality and conditions of
machine caused by abnormality .......................................................................................................... 20-406
Electrical circuit diagram for transmission controller system ........................................................... 20-416
T- 1 Failure code [IO] (Short circuit, disconnection, short circuit with
power source in backup lamp relay) is displayed ................................................................. 20-418
T- 2 Error code [l II (Disconnection in modulated clutch outlet rotation signal
sensor system) is displayed ..................................................................................................... 20-419
T- 3 Error code 1121 (Short circuit, disconnection, or short circuit with
power source in F solenoid system) is displayed ................................................................. 20-420
power source in R solenoid system) is displayed ................................................................ .20-421
power source in 1st solenoid system) is displayed .............................................................. 20-422
T- 6 Error code II51 (Short circuit, disconnection, or short circuit with
power source in 2nd solenoid system) is displayed ............................................................. 20-423
T- 7 Error code [161 (Short circuit, disconnection, or short circuit with
power source in 3rd solenoid system) is displayed.. ........................................................... .20-424
power source in R clutch drain valve solenoid system) is displayed ................................ -20-425
T- 9 Error code 1201 (Short circuit or disconnection in
joystick FNR switch system) is displayed.. ............................................................................. 20-426
T-IO Error code 1211 (Short circuit or disconnection in
joystick shift-up/shift-down switch system) is displayed ...................................................... 20-427
T-II Error code [221 (Disconnection in travel speed sensor system) is displayed.. .................. 20-428
T-12 Error code 1231 (Short circuit or disconnection in
engine speed sensor system) is displayed.. ........................................................................... 20-429
T-13 Failure code 1241 (Short circuit, disconnection in EEP ROM) is displayed ........................ 20-430
T-14 Error code 1251 (Short circuit in transmission oil temperature sensor system)
is displayed ................................................................................................................................ 20-431
T-15 Error code 1261 (Short circuit in F ECMV fill switch system) is displayed ......................... 20-432
T-16 Error code 1271 (Short circuit in R ECMV fill switch system) is displayed.. ....................... 20-432
T-17 Error code I281 (Short circuit in 1st ECMV fill switch system) is displayed ...................... 20-433
T-18 Error code 1291 (Short circuit in 2nd ECMV fill switch system) is displayed.. ................... 20-433
T-19 Error code [301 (Short circuit in 3rd ECMV fill switch system) is displayed.. .................... 20-434
T-20 Error code [321 (Disconnection in F or R ECMV fill switch system) is displayed ............. 20-435
WA1 200-3 20-401

0
T-21 Error code [331 (Disconnection in lst, 2nd, or 3rd ECMV fill switch system)
is displayed ................................................ ................................................................................ 20-436
T-22 Error code 1341 (Disconnection or 3rd short circuit with power source in
F bypass solenoid system) is displayed ................................................................................. 20-437
T-23 Error code [351 (Short circuit in F bypass solenoid system) is displayed ......................... 20-438
T-24 Error code [361 (Disconnection or short circuit with power source in
R bypass solenoid system) is displayed ................................................................................. 20-439
T-25 Error code [371 (Short circuit in R bypass solenoid system) is displayed ......................... 20-440
T-26 Error code 1381 (Disconnection or short circuit with power source in
1st bypass solenoid system) is displayed .............................................................................. 20-441
T-27 Error code 1391 (Short circuit in 1st bypass solenoid system) is displayed ...................... 20-442
T-28 Auto/Manual selector switch system ...................................................................................... 20-443
T-29 Kickdown switch system .......................................................................................................... 20-443
T-30 Transmission cut-off switch signal system ............................................................................ 20-444
T-31 Steering lock switch signal system ......................................................................................... 20-445
T-32 Neutralizer relay signal system ............................................................................................... 20-446
T-33 Buzzer signal system ................................................................................................................ 20-447
T-34 Network system ......................................................................................................................... 20-448
T-35 Transmission controller power supply system ...................................................................... 20-449
T-36 Short circuit in travel speed sensor system ........................................................................... 20-450
T-37 Short circuit in modulated clutch outlet rotation sensor system ........................................ 20-451
T-38 Disconnection in transmission oil temperature sensor system ........................................... 20-452
T-39 Fl (Forward 1st gear) signal system ....................................................................................... 20-453
T-40 Abnormality in auto shift indicator lamp ............................................................................... 20-454
20-402 WA1 ZOO-3

0
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER
TROUBLESHOOTING SYSTEM RELATED PARTS
JUDGEMENT TABLE FOR TRANSMISSION CONTROL

SYSTEM RELATED PARTS
i Self-diaanosis disolav (Dis av of abnormality)
Location of failure
Failure mode
controlle
1 1Machine cannot travel

2 1Machine can travel even if steering lock lever is in ‘LOCK’ position
3 1Gear is not shiited automaticailv
4 FNR (Forward/Reverse) switch is not matched to travel direction
5 Machine travels forward even if FNR (Forward/Reverse) switch is not in ‘F’ position
6 Machine travels in reverse even if FNR (ForwardlReverse) switch is not in ‘R’ oosition
7 Gear is shifted down, regardless of travel speed
8 Gear is shifted up, regardless of travel speed
9 Large shocks are made when gear is shifted
10 Gear shift hunting occurs during travel
11 Gear shift huntina occurs when aear is shifted
12 Gear shift indicator does not follow up gear shift-up/down switch in auto mode
13 Gear speed cannot be controlled with gear shift-up/down switch in manual mode
14 Gear shifting operation and travel speed are abnormal in auto mode
15 Travel mode (Manual/Auto) cannot be changed.
16 Kickdown svstem does not work (Travel sot?4 must be below 13 km/h in auto mode)
17 1Scooping power is lost when kickdown system operates.
18 I Transmission is not cut off when left brake is aonlied
19 1Machine can travel while oarkina brake is aoolied
20 1Backup lamp and alarm buzzer do not operate
21 1F-R chanae alarm buzzer does not sound durina hiah-soeed travel
22 Alarm buzzer does not stop sounding
23 Main motor does not display transmission controller information (Alarm buzzer, failure code, etc.)
24 Modulated clutch controller does not function
25 Travel mode (and gear shift range)when key is turnedto OFF is not saveduntil engine is startedagain
26 Auto aear shift indicator lamo does not liaht uo in auto mode
Diagnosis code when failure code is displayed T-1 T-2 T-3 T-4 T-5 T6 T-7 T-8 T-9 T-10T-11T-12T-13T-14
20-404 WA1 200-3

0
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER
TROUBLESHOOTING SYSTEM RELATED PARTS
Self-diagnosis display (Dis
Transmission controller error
WA1 200-3 20-405

0
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND
TROUBLESHOOTING CONDITIONS OF MACHINE CAUSED BY ABNORMALlTY
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY

AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
(1) TRANSMISSION CONTROLLER SYSTEM
I
Failure code Abnormal system Contents of abnormality
1) Defective backup lamp relay

2) Disconnection, defective contact, short circuit with
Short circuit, disconnection, chassis ground, or short circuit with power source in
or short circuit with power wiring harness between transmission controller Cl
10 (female) (11) - L54 (1)
source in backup lamp relay
system 3) Disconnection or defective contact in wiring harness
between backup lamp relay L54 (female) (2) - chassis
ground
4) Defective transmission controller
1) Defective modulated clutch outlet rotation sensor

2) Disconnection or defective contact in wiring harness
between transmission controller C4 (female) (9) - T16
Disconnection in modulated
11 (female) (2)
clutch outlet rotation signal
sensor system
between transmission controller C4 (female) (2) - T16
(female) (1)
1) Defective F ECMV solenoid

chassis ground, or short circuit with power source in
Short circuit, disconnection, wiring harness between transmission controller C2
or short circuit with power (female) (2) - T13 (female) (1)
12
source in F ECMV solenoid 3) Disconnection, defective contact, short circuit with
system chassis ground, or short circuit with power source in
wiring harness between transmission controller C2
(female) (13) - T13 (female) (2)
1) Defective R ECMV solenoid

2) Disconnection,defectivecontact,short circuitwith chassis
Short circuit, disconnection, ground, or shortcircuitwith power sourcein wiring harness
or short circuit with power between transmissioncontrollerC2 (female) (3) - Tll (female) (1)
13 source in R ECMV solenoid 3) Disconnection, defective contact, short circuit with
(female) (14) - Tll (female) (2)
1) Defective 1st ECMV solenoid

Short circuit, disconnection, ground, or short circuitwith power sourcein wiring harness
or short circuit with power between transmission controller C2 (female) (7) - T3 (female) (1)
14 source in 1st ECMV solenoid 3) Disconnection, defective contact, short circuit with
1) Defective 2nd ECMV solenoid

Short circuit, disconnection, ground, or shortcircuitwith power sourcein wiring harness
or short circuit with power between transmission controller C2 (female) (8) - T5 (female) (1)
15 source in 2nd ECMV sole- 3) Disconnection, defective contact, short circuit with
noid system chassis ground, or short circuit with power source in
20-406 WA1 200-3

0
OPERATIONS OF CONTROLLER AGAINST ABNORMALlTY AND
TROUBLESHOOTING CONDlTlONS OF MACHINE CAUSED BY ABNORMALlTY
Normal condition Operation of controller Condition of machine Diagnos

(voltage, current, resistance) against abnormality caused by abnormality code
1) Relay coil resistance: 200 - 400 R
2) Voltage between transmission controller Cl (11)
- chassis ground in neutral: Below 1 V
3) Resistance of harness between transmission Neutral (All ECMV Backup lamp does not
controller Cl (female) (11) - L54 (female) (1): output: OFF) light up when machine T-l
Max. 1 Q moves in reverse.
4) Resistance of harness between backup lamp
relay L54 (female) (2) - chassis ground:
Max. 1 R
1) Modulated clutch outlet rotation sensor

Resistance between T16 (male) (1) - (2): 500 - Assumes MOD/C
1000 R outlet rotation to be Gear is not shifted
Resistance between T16 (male) (11, (2) - chassis 2100 rpm. automatically. T-2
ground: Min. 1 MS2
1) Resistance between transmission controller C2

(female) (2) - (13): 10 - 20 R
2) Voltage between transmission controller C2 (2)
3) Resistance between transmission controller C2 Neutral (All ECMV
(female) (21, (13) - chassis ground: Min. 1 MQ output: OFF) Machine cannot travel. T-3
4) Resistance of harness between transmission
controller C2 (female) (21, (13) - 113 (female)
(11, (2): Max. 1 R

(female) (3) - (14): 10 - 20 Q
!I Voltage between transmission controller C2 (3)
- chassis ground in neutral: Below 1 V Neutral (All ECMV
3) Resistance between transmission controller C2 output: OFF) Machine cannot travel. T-4
(female) (31, (14) - chassis ground: Min. 1 MR
controller C2 (female) (3). (14) - Tll (female)
(l), (2): Max. 1 Q
I) Resistance between transmission controller C2

(female) (7) - (17): 10 - 20 R
8) Resistance between transmission controller C2 output: OFF) Machine cannot travel. T-5
controller C2 (female) (71, (17) - T13 (female)
(1). (2): Max. 1 R

(female) (8) - (18): 10 - 20 R
r) Resistance between transmission controller C2 output: OFF) Machine cannot travel. T-6
L) Resistance of harness between transmission
controller C2 (female) (81, (18) - T5 (female) (1).
(2): Max. 1 Q
WA1 200-3 20-407

0
TROUBLESHOOTING CONDlllONS OF MACHINE CAUSED BY ABNORMALITY
-ailwe code Abnormal system Contents of abnormality
1) Defective 3rd ECMV solenoid

chassis ground, or short circuit with power source in
Short circuit, disconnection, wiring harness between transmission controller C2
or short circuit with power (female) (9) - 17 (female) (I)
I6
source in 3rd ECMV solenoid 3) Disconnection, defective contact, short circuit with
(female) (19) - 17 (female) (2)
I) Defective R clutch drain valve solenoid

Short circuit, disconnection, chassis ground, or short circuit with power source in
or short circuit with power wiring harness between transmission controller Cl
18
source in R clutch drain (female) (8) - T23 (female) (I)
valve solenoid system 3) Disconnection or defective contact in wiring harness
between T23 (female) (2) - chassis ground
I) Defective joystick FNR switch system

between Cl (male) (71, (13) or C2 (male) (11, (12) - JSI
Short circuit or disconnec- (female) (1)
20 tion in joystick FNR switch 3) Disconnection, defective contact, short circuit with
system chassis ground, or short circuit in wiring harness
between JSl (female) (21, (31, (4) - C3B (female) (71,
(141. (15)
I) Defective joystick shift-up/shift-down switch system

between Cl (male) (71, (13) or C2 (male) (I), (12) - JSl
Short circuit or disconnec- (female) (1)
21 tion in joystick shift-up/shift- 3) Disconnection, defective contact, short circuit with
down switch system chassis ground, or short circuit in wiring harness
between JSl (female) (51, (61, (7). (8) - C3B (female) (81,
(91, (161, (17)
I) Defective travel speed sensor

2) Improper installation and adjustment of travel speed
sensor
Disconnection in travel 3) Disconnection or defective contact in wiring harness
22 speed sensor system between C5 (female) (2)- TO5 (female) (1)
between C5 (female) (I), (IO) - T15 (female) (2)
20-408 WA1 200-3

0
TROUBLESHOOTING CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Normal condition Operation of controller Condition of machine Diagnosi


(female) (9) - (19): 10 - 20 R
2) Voltage between transmission controller C2 (9)
3) Resistance between transmission controller C2 Neutral (All ECMV Machine cannot travel. T-7
(female) (91, (19) - chassis ground: Min. 1 MD output: OFF)
controller C2 (female) (91, (19) - 17 (female) (I),
(2): Max. 1 R
Draining speed of oil in

R clutch lowers. When
R is selected next time,
abnormally large gear
I) R clutch drain valve solenoid shift shock may be
Resistance between T23 (male) (1) - (2): R clutch drain valve made. If R clutch drain
5-15R solenoid output: OFF T-8
valve solenoid output
Resistance between T23 (male) (1). (2) - chassis is kept turned ON,
ground: Min. 1 MD hydraulic pressure is
not applied to R clutch
and machine cannot
travel in reverse.
I) In ‘F’: Machine
stops.
I) Voltage between C3B (14) - chassis ground 2) In ‘N’ or ‘R’: Ma-
When joystick FNR switch is in ‘F’: 17 - 30 V 1) When “N’ signal is
input: Sets in ‘N’ chine travels for-
When joystick FNR switch is not in ‘F’: ward suddenly.
Max. 1 V 2) $h:$i$$y;ignal is 3) Ins;N~r;l~~ ~~tpllt is
!) Voltage between C9B (7) - chassis ground
When joystick FNR switch is in ‘N’: 17 - 30 V input: Sets in ‘N”
immediately. 4) In ‘F’ or ‘R’: Gear is T-9
When joystick FNR switch is not in ‘N’: set in neutral
Max. 1 V 3) When no signals
are input: Holds for suddenly.
1)Voltage between C3B (15) - chassis ground 5) In ‘R’: Machine
When joystick FNR switch is in ‘N’: 17 - 30 V 2 set, then sets in
‘N’. stops.
When joystick FNR switch is not in ‘N’: 6) In ‘N’ or ‘F’: Ma-
Max. 1 V chine travels in
reverse suddenly.
1 Voltage between C5 (8) - chassis ground

When joystick shift-up switch (N.0) is in ON: Max. 1 V
When joystick shift-up switch (N.0) is in OFF: 17 - 30 V
When joystick shift-down switch (N.0) is in ON: Max. 1 V 1) Gear cannot be
When joystick shiidown switch (N.0) is in OA: 17- 30 V shifted up.
T-IO
1) Holds forward gear. 2) Gear cannOt be
When joystick shift-up switch (N.C) is in ON: 17 - 30 V shifted down.
When joystick shift-up switch (N.C) is in OFF: Max. 1 V
When joystick shiftdown switch (N.C)is in ON: 17 - 30 V
When joystick shiftdown switch 1N.C)is in OFF:Max. 1 V
1Travel speed sensor

Resistance between T15 (male) (1) - (2): 1) Gear shift pattern is
500 - 1,000 n I) Sets in manual different. T-11
Resistance between T15 (male) (1). (2) - chassis mode. 2) Machine overruns.
ground: Min. 1 MR
WA1 200-3 20-409

0
I‘ailure code Abnormal system Contents of abnormality
1) Defective engine rotation sensor

2) Improper installation and adjustment of engine rotation
sensor
3) Disconnection, defective contact, or short circuit with
chassis ground in wiring harness between transmission
Short circuit or disconnec-
controller C4 (female) (1) - T17 (female) (1)
23 tion in engine rotation
sensor system between transmission controller C4 (female) (9) - T17
(female) (2)
5) Short circuit in wiring harness between transmission
controller C4 (female) (1) - T17 (female) (1) and between
C4 (female) (3) - T17 (female) (2)
-
Short circuit or disconnec-

24 tion in memory (FEPROM) I) Defective transmission controller
1) Defective transmission oil temperature sensor

2) Short circuit with chassis ground in wiring harness
between transmission controller C3A (female) (11) - T19
Short circuit in transmission
(female) (1)
25 oil temperature sensor
3) Short circuit in wiring harness between FR2 (male) (12)
system
- Tl9 (female) (1) and between FR2 (male) (20) - Tl9
(female) (2)
1) Defective F ECMV fill switch

Short circuit in F ECMV fill 2) Short circuit with chassis ground in wiring harness
26 between transmission controller C3B (female) (2) - T14
switch system
(female) (1)
1) Defective R ECMV fill switch

Short circuit in R ECMV between transmission controller C3B (female) (10) - T12
27
fill switch system
(female) (I)
1) Defective 1st ECMV fill switch

Short circuit in 1st between transmission controller C3B (female) (3) - 14
28
ECMV fill switch system (female) (1)
1) Defective 2nd ECMV fill switch

Short circuit in 2nd between transmission controller C3B (female) (11) - T6
29 ECMV fill switch system (female) (1)
20-410 WA1 200-3

0
OPERATIONS OF CONTROLLER AGAINST ABN0RMALl-W AND
TROUBLESHOOTING CONDITIONS OF MACHINE CAUSED BY ABNORMALm
Normal condition Operation of controller Condition of machine Diagnosi!

I) Resistance between engine rotation sensor T17 ,) Can trave, with

(male) (I) - (2): 100 - 500 R Gear shift shock is
engine speed at
2) Voltage between transmission controller C4 made. T-12
2,100 rpm.
(female) (I) - (9): Min. 0.5 V
1) Learning function is Gear shift shock is

Gear shift shock is reduced by learning function. turned off and made. T-13
default data are
used.
1) Resistance between transmission oil tempera-

ture sensor T19 (female) (1) - (2): 38 - 48 kS2 When gear is shifted,
data of low transmis- Gear shift shock is
(Approx. 25°C) T-14
sion oil temperature made.
2) Voltage between transmission controller C3A
(female) (II) - (17): 1 - 5 V are used.
1) Resistance between transmission controller C3B

(female) (2) - chassis ground in neutral Neutral (All ECMV
output: OFF) Machine cannot travel. T-15
(F ECMV: OFF): Min. 1 MC?
I) Resistance between transmission controller C3B Neutral (~11 ECMV

(female) (IO) - chassis ground in neutral output: OFF) Machine cannot travel. T-16
(R ECMV: OFF): Min. 1 MR
I) Resistance between transmission controller C3B Neutral (~11 ECMV

(female) (3) - chassis ground in neutral output: OFF) Machine cannot travel. T-17
(1st ECMV: OFF): Min. 1 MR
I) Resistance between transmission controller C3B Neutral (All ECMV

(female) (1 I) - chassis ground in neutral output: OFF) Machine cannot travel. T-18
(2nd ECMV: OFF): Min. 1 Mh
WA1 200-3 20-411

0
I) Defective 3rd ECMV fill switch

Short circuit in 3rd ECMV fill between transmission controller C5 (female) (I 1) - T8
30
switch system (female) (I 1
I) Defective F or R ECMV fill switch

2) F ECMV fill switch: Disconnection or defective contact in
wiring harness between transmission controller C3B
Disconnection in F or R (female) (2) - T14 (female) (I)
32
ECMV fill switch system 3) R ECMV fill switch: Disconnection or defective contact in
wiring harness between transmission controller C3B
(female) (IO) - T12 (female) (1)
41 Defective transmission controller
1) Defective 1st. 2nd, or 3rd ECMV fill switch

Disconnection or defective contact in any of following
wiring harnesses
2) 1st ECMV fill switch: Transmission controller C3B
Disconnection in Ist, 2nd. or (female) (3) - T4 (female) (I)
33 3rd ECMV fill switch system 3) 2nd ECMV fill switch: Transmission controller C3B
(female) (I I) - T6 (female) (I)
4) 3rd ECMV fill switch: Transmission controller C5 (fe-
male) (11) - T8 (female) (1)
I) Defective F bypass solenoid

Disconnection or short power source in wiring harness between transmission
34 circuit with power source in controller Cl (female) (3) - T22 (female) (1)
F bypass solenoid system 31 Disconnection or defective contact in wiring harness
1) Defective F bypass solenoid

Short circuit in F bypass
35 between transmission controller Cl (female) (3) - T22
solenoid system
(female) (I)
20-412 WA1 ZOO-3
0
OPERATIONS OF CON-IXOLLER AGAINST ABNORMALlTY AND
Normal condition Operation of controller Condition of machine Diagnosi:


(female) (1 I) - chassis ground in neutral Neutral (All ECMV Machine cannot travel. T-19
output: OFF)
lF ECMV: OFF): Min. 1 MQ
I) Resistance between transmission controller C3B

(female) (2) - chassis ground in forward
When gear is shifted, Gear shift shock is
(F ECMV: ON): Below I Q
T-20
2) Resistance between transmission controller C3B data without fill sw’tch made.
(female) (IO) - chassis ground in reverse signals are used.
(R ECMV: ON): Below 1 R
I) Resistance between transmission controller C3B

(female) (3) - chassis ground during travel in
1st gear (1st ECMV: ON): Below 1 R
2) Resistance between transmission controller C3B When gear is shifted, Gear shift shock is
(female) (11) - chassis ground during travel in data without fill switch made_ T-21
2nd gear (2nd ECMV: ON): Below 1 R signals are used.
(female) (II) - chassis ground during travel in
3rd gear (3rd ECMV: ON): Below 1 Q
I) When harness is
disconnected:
Cannot operate at
all. (Since this
failure cannot be
distinguished from 1) F clutch makes gear
1) F bypass solenoid short circuit with shift shocks and it
Resistance between T22 (male) (I) - 12): power source, takes long time to
5-15R controller sets in engage (It engages T-22
Resistance between T22 (male) (I), (2) - chassis neutral and cannot at last).
ground: Min. 1 MR travel.) 2) F clutch cannot be
2) When harness has disengaged.
short circuit with
power source:
Controller sets in
neutral and can
travel.
1) F bypass solenoid I) F clutch makes gear

Resistance between T22 (male) (I) - (2): shift shocks and it
5-75n I) Stops outputting. takes long time to T-23
Resistance between 122 (male) (I), (2) - chassis engage (It engages
ground: Min. 1 MS2 at last).
WA1 ZOO-3 20-413

0
:ailure code Abnormal system Contents of abnormality
I) Defective R bypass solenoid

36 circuit with power source in controller Cl (female) (10) - T21 (female) (1)
R bypass solenoid system 3) Disconnection or defective contact in wiring harness
I) Defective R bypass solenoid

Short circuit in R bypass between transmission controller Cl (female) (IO) - T21
37
solenoid system (female) (I)
1) Defective 1st bypass solenoid

circuit with power controller Cl (female) (5) T20 (female) (1)
38
source in 1st bypass 3) Disconnection or defective contact in wiring harness
solenoid system between T20 (female) (2) - chassis ground
1) Defective 1st bypass solenoid

Short circuit in 1st
39 between transmission controller Cl (female) (5) - T20
bypass solenoid system
(female) (I)
20-414 WA1 200-3

0
Normal condition Operation of controller Condition of machine Diagnosis

1) When harness is
.disconnected:
Cannot operate at
all. (Since this
failure cannot be
distinguished from 1) R clutch makes gear
1) R bypass solenoid short circuit with shift shocks and it
Resistance between T21 (male) (1) - (2): power source, takes long time to
5-15P controller sets in engage (It engages T-24
Resistance between T21 (male) (I), (2) - chassis neutral and cannot at last).
ground: Min. 1 ML? travel.) 2) R clutch cannot be
short circuit with
power source:
Controller sets in
neutral and can
travel.
1) R bypass solenoid 1) R clutch makes gear

Resistance between T21 (male) (1) - (2): shift shocks and it
5-15R 1) Stops outputting. takes long time to T-25
Resistance between T21 (male) (11, (2) - chassis engage (It engages
ground: Min. 1 MR at last).
1) When harness is
disconnected:
Cannot operate at
all. (Since this
failure cannot be
distinguished from 1) 1st clutch makes
1) 1st bypass solenoid short circuit with gear shift shocks
Resistance between T20 (male) (I) - (21: power source, and it takes long
5-15R controller sets in time to engage (It T-26
Resistance between T20 (male) (I), (2) - chassis neutral and cannot engages at last).
ground: Min. 1 ML2 travel.) 2) 1st clutch cannot be
short circuit with
power source:
Controller sets in
neutral and can
travel.
1) 1st bypass solenoid 1) 1st clutch makes

Resistance between T20 (male) (I) - (2): gear shift shocks
5-15R 1) Stops outputting. and it takes long T-27
Resistance between T20 (male) (I), (2) - chassis time to engage (It
ground: Min. 1 MR engages at last).
WA1 200-3 20-415

0
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION
TROUBLESHOOTING CONTROLLER SYSTEM

CONTROLLER SYSTEM
20-416
0
TROUBLESHOOTING CONTROLLER SYSTEM
Auto shift
indicator
i'
TXWO2561
WA1 ZOO-3 20-417

0
TROUBLESHOOTING T-l
T-l Failure code [lo] (Short circuit, disconnection, short circuit with
power source in backup lamp relay) is displayed
is carried out when there is still an abnormality, so when disconnecting the
* This troubleshooting
removing the T-adapter and returning the connector
connector and inserting the T-adapter, or when
error code is no longer displayed on the monitor display, the
to its original position, if the
problem has been removed.
are properly inserted.
* Before carrying out troubleshooting, check that all the related connectors
to the next step.
f Always connect any disconnected connectors before going on
Cause Remedy
f
4YES
cGotoA
Is resistance
yes between L54
- (female) (2) and - Defective contact or
3
~- chassis ground disconnection in wiring
Is resistance normal? Repair or
harness between L54
YES between Cl . Max. 1 R replace
- (female) (11) and - * Turn starting NO (female) (2) and chassis
chassis ground ground
2 switch OFF.
- - normal? * Disconnect Cl Short circuit with chassis
Is resistance and L54. Repair or
* Min. 1 MR ground in harness
YES between Cl (female)
(17) and w (female) - *Turn starting NO between Cl (female) (11) replace
(1) normal? switch OFF. and L54 (female1 (1)
1
' * Disconnect Cl Defective contact or
Is failure code lo-
l Max. 1 R and L54. disconnection in wiring Repair or
displayed when
backup relay is _ * Turn starting harness between Cl replace
switch OFF. NO
replaced with other (female) (11) and L54
relay of same type? l Disconnect Cl (female) (1)
*Turn starting and L54.
switch OFF. I Defective backup lamp
Repair
* Replace backup NO I relay
relay with other relay of same type.
-Turn startino switch ON.
* Set directional lever to Ft. 5 YES Defective transmission
Repair
controller
Is vottage between
From A _ Cl (female) (11) _
and chassis Short circuit with power
ground normal? source in wiring harness ?epair or
l Turn starting .eplace
switch ON.
l Disconnect Cl
and L54.
* Max. 1 V
T-l Related electrical circuit diagram
Transmission
controller
Cl (MICl3)
Backurr lamp relay 1 23 11 11 ‘. 5fG
Backup lam
relay
TXW02444
20-418 WA1 200-3
0
TROUBLESHOOTING T-7
T-2 Error code [Ill (Disconnection in modulated clutch outlet rotation

signal sensor system) is displayed
* 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
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
3 YES Defective transmission

Replace
Is resistance controller
YES between C4
2 - (female) (9) and T16 -
Disconnection or defective
- (female) (2) normal?
Is resistance contact in wiring harness Repair or
n between C4 - Max. l R NO between C4 (female) (9) - replace
(female) (21and T16 - * Disconnect C4, T16, and T16 (female) (2)
1 (female) (1) normal? M02B.
-Turn starting switch OFF.
- Max. 1 R contact in wiring harness qepair or
T16 hale) 11) and (2)
* Disconnect C4, NO between C4 (female) (2) - splace
andbetween(1).(21and
chassis
groundnormal? T16, and M02B. 116 (female) (1)
-Turn starting
Between (1) - (2): switch OFF. Defective modulated
l
3epair or
500-lOOOR clutch outlet rotation
0 Pplace
Between (l), (2) - sensor
chassis ground:
Min. 1 MR
Disconnect T16.
* Turn starting
switch OFF.
T-2 Related electrical circuit diagram
RT2 (HD-85086)
TXWO2445
WA1 200-3 20-419

0
TROUBLESHOOTING T-3
T-3 Error code [I21 (Short circuit, disconnection, or shot-t circuit with
power source in F solenoid system) is displayed
the connector
connector and inserting the T-adapter, or when removing the T-adapter and returning
on the monitor display, the
to its original position, if the error code is no longer displayed
* Before carrying out troubleshooting, check that all the CaUSe Remedy
related connectors are properly inserted.
* Always connect any disconnected connectors before
going on to the next step.
4YES
GotoA
contact in wiring harness Repair or
between C2 (female) (2) - reolace
T13 (female) (1)
Short circuit with chassis

resistance bet- ’ - Disconnect C2 and T13.
l-l
Is
* Min. 1 MD ground in wiring harness Repair or
YES ween C2 (female) between C2 (female) 113) - replace
* Turn startina NO
(13) and T13 T13 (female1 (2)
--
I
switch OFF.-
* Disconnect C2 Disconnection or defective
T13 (male) (1) and (2) - Max. 1R and T13. contact in wiring harness Repair or
and between (1). (2) * Turn starting between C2 (female) (13) - replace
and chassis ground switch OFF. T13 (female) (2)
* Disconnect CZ
- Between (1) - and T13.
(2): 5 - 15 n I Defective F solenoid Replace
Between (1). (2) - NO
chassis ground:
Min. 1 MD
-Turn starting 8YES Defective transmission Repair or
switch OFF. controller replace
* Disconnect T13.
Shon circuitwith power
source in wiring harness Repair or
Ez C2 (female) (2) and _ -Turn starting awitch NC between C2 (female) (13) - replace
chassis ground ON. T13 (female) (21
6 * DisconnectC2 and 113.
,- normal? Short circuit with power
Is resistance - -Max. 1V Repair or
- Turn starting source in wiring harness
YES between C2 between C2 (female) (2) -Tl: replace
- sGtch ON. NO
(female) (2) and (female) (1)
* Disconnect C2
5
and Tl3. Short circuit in wiring
-From 1 harnessbetween C2 (female) Repair or
(2) -T13 (female) (1) and
replace
between C2 (female) (13l-
T13 (female1(2)
ground in wiring harness Repair or
* Turn starring I
between C2 (female) (2) - T13 replace
switch OFF. NO
(female) (1)
* Disconnect C2
and T13.
Transmission
controller
F solenoid
TXW02446
20-420 WA1 200-3
0
TBOUBLESHOOTING T-4
T-4 Error code [I31 (Short circuit, disconnection, or short circuit with
power source in R solenoid system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
Before carrying out troubleshooting, check that all the
Cause Remedy
Always connect any disconnected connectors before
QYES
Gotok
Is resistance bet-
YES ween ~2 (female)
3 - (3) and TM1 Disconnectionor defective
pIs resistance (female) (1) normal?
YES between C2 between C2 (female1(3l-
.Max.lR NO replace
- (female) (14) and - TM1 (female) (7)
chassis ground * Turn starting switch
2 OFF.
- normal? Short circuitwith chassis
Is resistance bet- * DisconnectCt and Tll. ground in wiring harness Repair or
YI * Min. 1 M R
ween C2 (female) between C2 (female) (14) - replace
(14) and 111 - -Turn staning switch NO
Tl 1 (female) (2)
1 (female) (2) normal? OFF.
p . DisconnectC2 and
Disconnectionor defective
* Max. 1 R Tll.
TM1(male1(11and(2) . Turn starting
andbetween(11,(21and batween C2 (female) (14l- replace
switch OFF. NO
chassis
groundnormal? ill (female) 12)
* Disconnect C2 and
Tll.
* Between (1) - (2):
5-154-t Defective R solenoid
l Between (1). (2) - NO
chassis ground:
Min. 1 MS-I
- Turn starting Defective transmission
switch OFF. controller
* DisconnectTMl.
Short circuit with power

between C2 #amale) (141- replace
Tll (female) (2)

Is resistance -* Turn startingswitch l Max. 1V source in wiring harness Repair or
YES between C2 between C2 (female) (3l- Tl’
ON. reDlace
- (female) t3) and (14) ’ NO (female) (1)
normal7 * DisconnectC2 and
5
CN14. Short circuit in wiring
From
Is resistance bet- ‘5-15Ct * Max. 1 V harness between C2 (female)
A Repair or
_ ween C2 (female) _ * Turn starting switch (3) - Tl 1 (female) (1) and
replace
(3) and chassis OFF. IO between C2 (female) (14) -
ground normal7 - Disconnect C2. Tll (female) (2)
* Min. 1 MR Shon circuit with chassis

-Turn starting switch ground in wiring harness Repair or
OFF. between C2 (female) (31-Tll replace
NO
* DisconnectC2 and (female) Ill
Tll.
Transmission
controller
R solenoid
TXW02447
WA1 200-3 20-42 1

0
TROUBLESHOOTING T-5
T-5 Error code 1141 (Short circuit, disconnection, or short circuit with
power source in 1st solenoid system) is displayed
* Before carrying out troubleshooting, check that all the Cause Remedy
Go to A.
contact in wiring harness IRepair or
between C2 (female) (7) - T3 Ireplace
(female) (1)

Is resistance bet- IRepair or
ground in wiring harness
YES ween C2 (female) between C2 (female) I171- T 3 ’replace
- (17) and ~3 (female) - ‘Turn starting switch NO (female) (2)
(2) normal? OFF.
1
1 . DisconnectC2 and Disconnectionor defective
between
Is resistance . Max. 1 R T3. contact in wiring harness IRepair or
T3 (male)11)and(21and
- “0”~;: starting switch NO between C2 (female) (17) - T:3 Imeplace
between(1).(21and (female) (2)
chassis groundnormal?
* Disconnect C2 and
. Between (1) - (2): T3.
5-155-Z Defective 1st solenoid
* Between (1). (2) - NO
chassis ground:
Min. 1 MC?
. Turn starting switch aYE S Defective transmission IReplace
OFF. controller
Is voltage between
* DisconnectT3. YES ~2 (female) (17) and
7- chassis ground Short circuit with power
- normal? source in wiring harness f3epair or
Isvoltage between _I L
between C2 (female) (17) -T 3 1,eplace
YES ~2 {female) (7) and _ -Turn starting N( D
(female) (2)
chassis ground wftch ON.
6 normal? * DisconnectC2 and T3.
Is resistance bet- *Max.lV FIepair or
* Turn starting switch source in wiring harness
ES_ wean C2 (female) _ ON. Ibetween C2 (female) (7) - T3 replaca
NO
(71 and (17) - Disconnect C2 and Iifemale) (1)
5 normal? T3. Short circuit in wiring
.5-15R . Max. 1 V Iharnessbetween C2 (female) FXepair or
A between C2 I17)- T3 (female) 11)and
--c ffemale)f7)and - * 2;; stamng swtch NO Ibetween C2 (female) (17) - TZ3 r,eplace
chassisground IIfemale) (2)
normal? * Diionnect C2.
* Min. 1 MR Repair or
* Turn starting switch reDlace
between C2 (female) (7) - T3
OFF. NO
(female) (1)
- DisconnectC2 and
T3.
Transmission
controller
id
TXWQ2448
20-422 WA1 200-3
0
TROUBLESHOOTING T-6
T-6 Error code [I!51 (Short circuit, disconnection, or short circuit with
power source in 2nd solenoid system) is displayed
Before carrying out troubleshooting, check that all the Cause Remedy
4YES
Go to A.
Is resistance bet-
YES ween c2 (fernate)
3 (8) and T5 (female) Disconnection or defective
P (1) normal? contact in wiring harness
Is resistancebet- - ?epair or
YES ween ~2 (female) -Max. IR between C2 (female) (8) - T5 Feplace
NO
(18) and chassis (female) (1)
- Turn starting switch
_2 ground normal? OFF.
Is resistance bet- * Disconnect CZ and T5. Repair or
* Min. 1 MR ground in wiring harness
yes ween C2 (female1
between C2 (female) (18) -T? replace
(18) and T5 - * Turn startingswitch NO
OFF. (female) (21
(female) (2)
1
- 1 normal7 I l DisconnectC2 and
IS resistsnce
belwee” Disconnection or defective
* Max. 1 R Ts.
T5 (male)Ill and12) contact in wiring harness Repair or
andbetweenIll, (2) - . :I; starting switch NO between CZ (female) (18) -I? replace
andchassisground (female) (2)
n0tmai? ~ * DisconnectC2 and
l Between (l)-(2): T5.
5-15R Defective 2nd solenoid Replace
* Between 11). 12)- NO
chassis ground:
Min. 1 MR
* Turn starting switch BYE! Defective transmission ?eplace
OFF. controller
Is voltage between
* DisconnectT5.
YES ~2 (female) (18) and
7 chassis ground
- normal? 3epair or
Is voltage between source in wiring harness
YES ~2 (female) (8) and between C2 (female) (18) - E Feplace

_ * Turn starting switch NC
chassisground ON. (female) (2)
6 normal? l DisconnectC2 and T13. Shoti circuit with power
Is resistance bet- * Turn startingswitch * Max. 1 V source in wiring harness ?epair or
YES_ ween cz (female) _ ON. between C2 (female) (8) -T5 .eplace
NO
(8) and (18) - DisconnectC2 and (female) (1)
_5 normal? T5.
From Shon circuitin wiringharness
Is resistance bet- *5-15R l Max. 1 V
A behveenC2 (female)(81-T5 3epair or
- ween C2 (female) _ *~F;stanmgswnch NO (female)(1) and betweenC2 ,eplace
(8) and chassis
ground normal? (female)(13) -T5 (female)(2)
* DisconnectCZ.
* Min. 1 MR ground in wiring harness Repair or
* 2;; aartlng swtch NO between C2 (female) (8) -TS replace
(female) (1)
. Disconnect C2 and
T5.
Transmission
controller
id
TXW02449
WA 1200-3 20-423
0
TROUBLESHOOTING T-7
T-7 Error code [IS] (Short circuit, disconnection, or short circuit with
power source in 3rd solenoid system) is displayed
* Before carrying out troubleshooting, check that all the
Cause Remedy
4YEL
Gotok
I Is resistancebet-
lfrxnalel 1
normau Repair or
IL contact in wiring harness
between C2 (female) (9) -l7 replace
-.. . -1 NO
(female) (1)
‘- -‘=2ing switch
Is I st C2 and 17. ground in wiring harness Repair or
YE bek,e.x,w between C2 (female) (19) -T; replace
staning switch NO
(female) (19) antd ~7 H *Turn
__ (female) (2)
1 (fema,e)(“‘__--_‘, I I W-F.
I
z.LrzJ
l7 Imale) (1)and12)
. Max. 1 R I * DisconnectC2 and
17.
contact in wiring harness
between C2 (female) (19) -T;
Repair or
replace
and betwean(1). (2)
and chassisground (female) (2)
- Disconnect C2 and
17.
l Between (1) - (2):
5-15R Defective 3rd solenoid bolace
* Between (11, (2) - 0
chassis ground:
Min. 1 MR
. Turn STartin swirch SYES Defective transmission
OFF. -I- controller
Is voltage between
* Disconnect17.
7 r-l
YES cz (female) (19) and
chassis around u
between C2 (female) (19) -Ti replace
Ifemale) (2)

source in wiring harness ?epair or
between C2 (female) (9) - l7 replace
(female) (1)
Shon circuit in wiring
harness between C2 (female)
Repair or
(9) - 17 (female) (1) and
replace
between C2 (female) (19) - T:
. DisconnectC2. (female) (2)
normal?-
* Min. 1 MQ Short circuit with chassis
-Turn starting switch
between C2 (female) (9) -T7 replace
OFF. NO
(female) (1)
* DisconnectC2 and
17.
Transiaission
controller
id
TXW02450
20-424 WA1 ZOO-3
0
TROUBLESHOOTING T-8
T-8 Error code [I81 (Short circuit, disconnection, or short circuit with
power source in R clutch drain valve solenoid system) is displayed
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Go to A.
YE
(8) and chassis

-Max. 1R
*Turn starting
NC
between T23 (female) (2) -
Repair or
replace
chassis ground
switch OFF.
* Disconnect T23.
NO between Cl (female) (8) - replace
T23 (female) (1)
IS reslstawe between - Max. 1 R Disconnection or defective

and T23.
l23 bnale)(11and2 and _ contact in wiring harness Repair or
* Turn starting
between(11,(2)and NO between Cl (female) (8) - replace
switch OFF.
chassisground normal? T23 (female) (1)
. Disconnect Cl
and T23.
* Between (1) - (2): Defective R clutch drain
5-15R valve solenoid
* Between (1). (2) - No
chassis ground:
Min. 7 MR
* Disconnect T23.
+ Turn starting
switch OFF.
controller
Is voltagebetween
Cl (female1(61 and _
From A -D
chassis ground Short circuit with power
normal? source in wiring harness Repair or
between Cl (female) (8) - replace
l Turn srening switch NO
ON. T23 (female) (I)
* DisconnectCl and
T23.
l Max. 1 V
Transmission
controller R clutch drain
valve solenoid
FRI (HO-660661 RTI (HD-860661
11 TXW02451
WA1 200-3 20-425

0
TROUBLESHOOTING T-9
T-9 Error code [201 (Short circuit or disconnection in joystick FNR

switch system) is displayed
1: This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
* Check that fuse ii (6) is normal.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Remedy
Defective transmission
Replace
controller
Disconnection, defective
I:;showninTable 11 contact, short circuit with
chassis ground, or short Repair or
circuit in wiring harness
- Turnstarting NO between JSl (female) (2). (3). replace
switch ON. [;;;C3B (female) (71, (14).
Is voltage between Disconnection or defective

JSl (2). (3). (4) and
chassis ground as
uo between Cl (male) l7). (13) or replace
C2 (male) (1). (12)- JSl
shown in Table 17 (female) (1)
l Turn starting
Defective joystick FNR
switch ON. Replace
NO switch
Table 1 Voltage measured with joystick FNR switch at each position

Position of FNR switch
F N R
Terminals
JSI (male) (1) - (2) C3B (14) - Chassis ground 20 - 30 V Max. 1 V Max. 1 V
JSl (male) (I) - (3) C3B (7) - Chassis ground Max. 1 V 20 - 30 V Max. 1 V
JSI (male) (1) - (4) C3B (15) - Chassis ground Max. 1 V Max. 1 V 20 - 30 V
Transmission Joust ick

control lever switch
TXW02452
20-426 WA1 200-3

0
TROUBLESHOOTING T-IO
T-10 Error code [211 (Short circuit or disconnection in joystick shift-

up/shift-down switch system) is displayed _ ’
* Check that fuse II (6) is normal.
Remedy
Replace
Is
__ ._
v&agebetween
.-.
yes L5 (ternale) v3). (9).
Disconnection,defective
- (16). (17) and contdct, short circuit with
2
_ chassisground as chassisground. or short
Is voltage shown in Table 17 circuit in wiring harness Repair or
YES_ between JSl (I) NO between JSl (female) (5). (6). replace
_ - Turn starting
(7). (8) - C5 (female) (8), (9).
and chassis switch ON. 116).(17)
1
p ground normal?
ISvoitage between Disconnectionor defective
JSl (5). (6). (7). (8) -2O-30V cOntactin wiring harness Repair or
and chassisground - -Turn starting NO between Cl (male) VI, (131 or replace
as shown in Table switch ON. C2 (male) (lb, 112)- JSl
17 (female) (1)
-Turn starting
switch ON. Replace
Table 1 Voltage measured with joystick shift-up/shift-down switch at each position
Shift-up Shift-down
Terminals switch ON switch ON
JSI (5) - Chassis ground C5 (17) - Chassis ground 20 - 30 v Max. 1 V
JSl (6) - Chassis ground C5 (91- Chassis ground Max. 1 V 20 - 30 v
JSl (7) - Chassis ground C5 (16) - Chassis ground Max. 1 V 20 - 30 v

JSI (8) - Chassis ground C5 (8) - Chassis ground 20 - 30 v Max. 1 V
T-IO Related electrical circuit diagram
Transmission Joust ick

controller lever switch
TXW02452
WA1 200-3 20-427

0
TROUBLESHOOTlNG T-11
T-11 Error code [22] (Disconnection in travel speed sensor system) is

displayed
Cause Remedy

controller Replace
Isresistance 1normal? II contact in wiring harness Repair or

Es between C5 _ *Max. 1 Q NO batwaen C5 (female) Ht.
replace
(female) (2) and T15 l Disconnect T75, C5, (10) -T15 (female) (2)
1 (female) (1) normal?
Is resistancebetween P M02A, U8, and L07. Disconnaction or defective
T15 lmalet (1) and (2) . Max. 1 R contact in wiring harness Repair or
and-n (V. (2) - * Disconnect T1.5, NO beween C5 (female) 12) - replace
and chassisground T15 (female) (1)
I
C5, M02A. L28, and L07.
normal? Ii * Turn starting switch OFF.
. Between (1) - (2):
Defective travel speed
wo- lOM)R Replace
NO sensor
* Between (l), (2) -
chassis ground:
Min. 1 MR
* Disconnect T15.
* Turn starting
switch OFF.
RT2 m-85086) 1I 5 IDTZ)

T-l 1 Related electrical circuit diagram
Work equipment
controller
TXW02453
20-428 WA1 200-3

0
TROUBLESHOOTING T-12
T-12 Error code [23] (Short circuit or disconnection in engine speed

I
sensor system) is displayed
Before carrying out troubleshooting, check that all the Cause
QYE!
Go to A.
Is resistance
YES between c4
3 (female) (9) and T17
Disconnection or defeotive
- Is resistance (female) (2) normal?
YES between C4 between C4 (female) (9) - T17 replace
- (female) 11)and -
.Max.lR NC
- DisconnectC4,T1J. LOJ, (female) (2)
2 chassis ground
and MO2B
*Turn starting switch OFF. Short circuitwith chassis
nect C4, NO between C4 (female) (1) -T17 replace
(female) (1)
)7, and M02B
, switch Disconnection or defective
between C4 (female) (1) - T17 replace
(female) (1)
* Turn starting
~100-500R
switch OFF. Defective engine speed
- Disconnect T17. qeplace
NO sensor
* Turn starting
switch OFF.

controller
Is resistance I I
between C4
From A
-I (female) (1) and (9)
normal? Y
Short circuit in wiring
harness between C4
Repair or
I (female) (1) -T17
replace
* Min. 1 MR NO (female) (1) and between
* Disconnect C4, C4 (female) (3) - T17
T17, L07, and (female) (2)
M02B
* Turn starting
switch OFF.

Main
Transmission monitor
LO7 I040 121
controller 3 I24ElTachometer
c4 (MICl.2) I I3FI
TXW02454
WA1 200-3 20-429

0
T-13 Failure code [24] (Short circuit, disconnection in EEP ROM) is

displayed
Remedy
Replace
controller
20-430 WA1 200-3

0
T-14 Error code 1251 (Short circuit in transmission oil temperature

J, This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
f Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy

Replace
YES betweenFlU
_ (male) (12) and - Short circuit in wiring
2 harness between FR2 Repair or
- (20) normal?
Is resistance (male) (12) -119 (female) replace
yES betweenc3A * Min. 1 MR NO (1) and between FR2 (male)
r- (female) (111 and - . Turn -Ring (20) -T19 (female) (2)
chassis ground switch OFF.
1
Is resinancebetwe& norrna’7 * Disconnect FR2
T19 (male)(1) and (2) * Min. 1 MC! and T19. Repair or
andbetween( - *Turn startin9 replace
switch OFF. NO between C3A (female)
andchassisground
IlOnlUl? * Disconnect C3A (ll)-T19 (female) (1)
- Between (1) - (2): and T19.
39 - 49 Id2 fat Defective transmission
Replace
25°C) NO oil temperature sensor
chassis ground:
Min. 1 MR
*Turn starting
switch OFF.
- Disconnect T19.
Transmission
controller
C3A(040201
T/M oil temerature 328 11 ‘. 5’u J T3 (DTZB)
WA1 200-3 20-43 1

0
TROUBLESHOOTING T-15, T-16
T-15 Error code [26] (Short circuit in F ECMV fill switch system) is
displayed
+ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
Jr Always connect any disconnected connectors before
Replace
controller
Is resistance bat-

Is resistance ground in wiring harness Repair or
between T14 hale) _ * Min. 1 MR NO between C3B (female) (2) replace
(1) and chassis s Disconnect C3B. T14, and -T14 (female) (1)
ground normal?
M02A.
. Turn starting switch OFF. Defective F ECMV fill
* Min. 1 MR Replace
* Disconnect T14. NO switch
* Turn starting
switch OFF.
T-16 Error code [271 (Short circuit in R ECMV fill switch system) is
displayed
Replace
controller
__/lsresistancebet- 1 Ii
between C3B (female) replace
(10) -T12 (female) (1)
Defective R ECMV fill

Replace
- Disconnect T12. NO switch
* Turn starting
switch OFF.
T-15, 16 Related electrical circuit diagram
TXW02456
20-432 WA1 200-3

0
T-17 Error code E281 (Short circuit in 1st ECMV fill switch svstem)
I is
displayed
Before carrying out troubleshooting, check that all the related connectors are orooerly inserted.
Always connect any disconnected connectors before going on to the next step. ’
ChUSe Remedy

Replace
controller
Is resistance bet-

between C36 (female) (3) replace
-T4 (female) (1)
(1) and chassis * Disconnect C3B. T4, and
MOZA
l Turn starting switch OFF. Defective 1st ECMV fill
- Min. 1 MR
* Disconnect T4. NO switch
* Turn starting
switch OFF.
T-18 Error code 1291 (Short circuit in 2nd ECMV fill switch system) is
displayed
Cause Remedy

Replace
controller

between C3B (female) replace
(ll)-T6 (female) (1)
Defective 2nd ECMV fill

Replace
. Disconnect T6. NO switch
-Turn starting
switch OFF.
WA1 200-3 20-433

0
TROUBLESHOOTING T-1Q
T-19 Error code [30] (Short circuit in 3rd ECMV fill switch svstem)
. is
displayed

Is resistance controller Replace
__ II
yes 0etweenC5
- (female) (11) and -
between T8 between CS (female) (11) replace
NO
(female) (1) and - * Min* ’ MR
* Disconnect C5. T8, and -T8 (female) (1)
chassis ground
* Turn starting switch OFF. Defective 3rd ECMV fill

* Min. 1 MR Replace
. Disconnect T8. NO switch
* Turn starting
switch OFF.
Transmission
TXW02457
20-434 WA1 200-3

0
T-20 Error code 1321 (Disconnection in F or R ECMV fill switch

system) is displayed
Cause Remedy
s Defective transmission Replace
M
3
- ‘0”;;. starting switch N( I

switch
* DisconnectT12.
tf T14 (female) (1) - Start engine.
YES is grounded to * Turn transmissioncut-oiR
switch OFF (Put out
chassis, is ‘32” lame).
2 displayed? . Turi parking brake
Is resistance - - switch OFF.
n between C3B *Turn startingswitch * Press brake.
. (female) (10) and - OFF. . Set directionalswitchin FI. I3efective F ECMV fill
T12 (female) (1) - Disconnect Tl4. Replace
IUO switch
n0ITlall -Start engine.
l Max. 1 R *Turn transmissioncut-offswitchOFF(Putout lamp).
*Turn parkingbrakeswitchOFF.
l Turn starting * Pressbrake. IDisconnection or defective qepair or
(female) (2) and T14 switch OFF. * Set directionalswitchto F. ,:ontact in wiring harness ‘eplace
(female) (11 normal? . Disconnect C3B, Ibetween C3B (female) (10)
T12, and M02k NO -T12 (female) (1)
* Max. 1 R
* Turn starting IDisconnection or defective
,Contact in wiring harness 3epair or
switch OFF.
NO Ibetween C3B (female) (2) - pplace
l Disconnect C3B.
T14 (female) (1)
T14, and M02A.
Transmission
Mod
CC”
TXW02456
WA1 200-3 20-435

0
T-21 Error code 1333 (Disconnection in lst, 2nd, or 3rd ECMV fill
* This troubleshooting is carried out when there is still an abnormalii, so when disconnecting the
Cause Remedy
,
Is resistance Defective 1st ECMV fill
_rl
Replace
YES betweenC5 switch
Ifemale) (11) and T6 _m_^^^
_- T,.
H *Turn starting between C5 (female) I1 1)- replace

(female) (lil and T6
(female) 11)normal? switch OFF. T8 (female) (1)
* Disconnect CS,
* Turn starting
I T8. and M02A
NO between C3B (female) (11) replace
switch OFF.
. Disconnect C3B. - T6 (female) (1)
- Max. T6, and M02A.

1R I Disconnection or defective
Repair or
* Turn starting I contact in wiring harness
NO between C3B (female) (3) - replace
switch OFF.
. Disconnect C3B. 14 (female) (1)
14. and M02A.
If TS (female) (1) is controller
YES grounded to
5 chassis, is ‘33”
- displayed?
ifT6 (female) (1) is Defective 3rd ECMV fill
grounded to . Td;‘F:startingswitch NO Replace
From A - switch
chassis, is ‘33” * DisconnectT6.
displayed? . Start engine.
- - Set directionalswitchin N.
- Turn starting - Set gear shift cnsition in %-I Defective 2nd ECMV fill 3eplace
switch OFF. NO switch
- Disconnect T6.
* Start engine.
* Set directional
switch in N.
* Set gear shift
position in 2nd.
Transmission
TXWO2457
20-436 WA1 200-3

0
T-22 Error code [341 (Disconnection or short circuit with power

source in F bypass solenoid system) is displayed
f Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4YEs Defective transmission

I ,A Replace
Is voltage
between
controller
YES Cl (female) (3) and
3 chassis ground
- normal?
Is resistance bet- source in wiring harness Repair or
YES weenT22 (female) - Max. 1 V N( between Cl (female) (3) - replace
(21and chassis - Turn starting switch TZ2 (female) (11
2 ground normal? OFF.
- . DisconnectCl and T22. Short circuit with chassis
Is resistance Repair or
* Max. 1 Q ground in wiring harness
YES between CI replace
between T22 (female) (2) -
(female) (3) and T22 - -Turn starting NO
switch OFF. chassis ground
p * Disconnect T22. Disconnection or defective
between T22 (male) * Max. 1 R
(1) and (2) and contact in wiring harness Repair or
between (11, (2) and - * Turn starting NO between Cl (female) (3) - replace
chassis ground switch OFF.
T22 (female) (1)
normal? - Disconnect Cl
* Between (1) - (2): and T22.
5-15R Defective F bypass
Replace
- Between (l), (2)- NO solenoid
chassis ground:
Min. 1 MR
* Turn starting
switch OFF.
. Disconnect T22.
Transmission
controller F brrass
k TXW02458
WA1 200-3 20-437

0
T-23 Error code [35] (Short circuit in F bypass solenoid system) is

displayed
This troubleshooting is carried out when there is still an abnormalii, so when disconnecting the
Before carrying out troubleshooting, check that all the related connectors are properly inSerted_
GWX! Remedy
2 Defective transmission
controller Replace
Is resistance bet-
ween Cl (female)
(3) and chassis Short circuit with chassis
ground normal? ground in wiring harness Repair or
between Cl (female) (3) - replace
* Min. 1 MR
* Turn starting switch T22 (female) (1)
OFF.
* Disconnect Cl and T22. Defective F bypass
. Between (1) - (2): Replace
5-15R solenoid
* Between (1 L (2) -
chassis ground:
Min. 1 MR
. Turn starting
switch OFF.
* Disconnect T22.
Transmission
controller F bylass
TXW02458
20-438 WA1 200-3

0
T-24 Error code [361 ( Disconnection or short circuit with power

source in R bypi ISS solenoid system) is displayed
-k Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Replace
controller

Repair or
source in wiring harness
replace
n between Cl (female) (10) -
T21 (female) (1)
2
I 1 I Short circuit with chassis
Is resistance A - Disconnect Cl and T21.
- Max. 1 R ground in wiring harness Repair or
YES between cl
* Turn starting NO between T21 (female) (2) - replace
(female) (3) and T21
* Disconnect T21.
between T21 (male) - Max. 1 R
11)and (2) and
between (1). (2) and - . Turn starting NO between Cl (female) (10) - replace
&s;,ground switch OFF.
T21 (female) (1)
* Disconnect Cl
* Between (1) - (2): and T21.
5-15R I Defective R bypass Replace
- Between (1). (2) - NO solenoid
chassis ground:
Min. 1 MD
* Turn starting
switch OFF.
- Disconnect T27.
Transmission
controller
Tl TXW0.2459
WA1 200-3 20-439

0
T-25 Error code [37] (Short circuit in R bypass solenoid system) is

displayed
+ Always connect any disconnected connectors before going on to the next step.
Cause Remedy
controller Replace
Is resistance bet-
YES ween Cl (female)
1 (10) and chassis Short circuit with chassis
Is resistance ground normal? ground in wiring harness Repair or
between l-21 tmale)
(11and (21and _ lMin.lMQ NO between Cl (female) (10) replace
between (1). (2) and l Turn starting switch OFF. - T21 (female) (1)
chassis ground
n0nllall l Disconnect Cl and T21.
. Between (1) - (2): Defective R bypass
Replace
5-15n NO solenoid
* Between (1). (2) -
chassis ground:
Min. 1 MD
. Turn starting
switch OFF.
* Disconnect T21.
I74
11 TXW02459
20-440 WA1 200-3

0
T-26 Error code 1381 (Disconnection or short circuit with power source
in 1st bypass solenoid system) is displayed
Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
I Cause 1 Remedy 1
4YES Defective transmission Replace

Is voltage between controller
7” Cl (female) 6) and _
Is resistance 1 normal? source in wiring harness 1 Repair or
YES between T20 NO between Cl (female) (5) - replace
- (female) (21and - . MaxV’ ”
* Turn starting switch T20 (female) (1)
2 chassisground
- normal? OFF.
resistance
Is * DisconnectCl and T20. Repair or
* Max. 1 R ground in wiring harness
YES between Cl
between T20 (female) (2) replace
(female) (5) and TZO - -Turn starting NO
1 (female) (1) normal? switch OFF. -chassis ground
- . Disconnect T20. Disconnection or
between T20 (male) * Max. 1 R Repair or
(1) and (2) and defective contact in
* Turn starting
between (1). (21 and - NO wiring harness between replace
;;z;7ground switch OFF.
Cl (female) (5) - T20
. Disconnect Cl
(female) (1)
- Between (1) - (2): and T20.
5-15R Defective 1st bypass
Replace
* Between (1). (2) - NO solenoid
chassis ground:
Min. 1 MD
* Turn starting
switch OFF.
. Disconnect T20.
11 TXW0.2460
WA1 200-3 20-441

0
T-27 Error code [391 (Short circuit in 1st bypass

__ solenoid system)
_ is
displayed
Cause Remedy

controller Replace

~~ between Cl (female) (5) - replace
T20 (female) (1)
* Between (1) - (2): Defective 1st bypass

Replace
5-15n solenoid
chassis ground:
Min. 1 MR
* Turn starting
switch OFF.
- Disconnect T20.
Transmission
controller
TI TXWO2460
20-442 WA1 200-3

0
T-28 Auto/Manual selector switch system
+ Always turn the starting switch OFF before disconnecting the connector or connecting the T-
adapter (or socket).
Cause Remedy

Replace
controller
$S/-
Disconnection in wiring
harness between L15 Repair or
II
replace
I
- Max. 1 R NO (female) (4) -chassis
(1) and L15 lfemalel * Disconnect Ll5. ground
I
ground, disconnection, or
* Disconnect C3B. Repair or
defective contact in wiring
* Auto/Manual replace
(male) (3) and (4) NO harness between C38
selector switch
(female) (1) - L15 (female)
ON: Max. 1 R (3)
OFF: Min. 1 MR
- Auto/Manual I Defective Auto/Manual
Replace
selector switch No selector switch
ON: Max. 1 R
OFF: Min. 1 MD
T-29 Kickdown switch system

Cause Remedy

Replace
Is resistance bet- controller
YES Wee” L15 (female)
(2) and chassis
_ 2 ground normal?
Is resistance
* Max. 142 NO (female) (2) -chassis replace
YES between c3A
(female) 20 and ~15 - - Disconnect L15. ground
1 (female) 11) normal?
* Disconnect C3A
defective contact in wiring Repair or
(male) (1) and (2) harness between C3A replace
* Kickdown switch (female) (20) - L15 (female)
ON: Max. 1 R (1)
* Disconnect L15. OFF: Min. 1 MD
* Kickdown switch Defective kickdown
qeplace
ON: Max. 1 R NO switch
OFF: Min. 1 MR
T-28, T-29 Related electrical circuit diagram

Kick-doun k
Transmission manual swrtch
TXW0246 1
WA1 200-3 20-443

0
T-30 Transmission cut-off switch signal system
f Always turn the starting switch OFF before disconnecting the connector or connecting the T-
Remedy

I controller
Is resistance bet-
YES veen CSA (female)
1 (10) andchassis
- ground normal? Repair or
Is resistance defective contact in wiring
*Transmission cut-off ND harness between C3A replace
between L12
(male) (1) and (2) switch (female) (10) - L12 (female)
ON: Max. 1 Q (1)
normal? OFF: Min. 1 h4Q
* Disconnect C3A L06. and M02A. Defective transmission
l Disconnect L12.
. Transmission NO cut-off switch
cut-off switch
ON: Max. 1 R
OFF: Min. 1 MR
Transmission
ed when stwoino on
left brake Pedal. 1
TXW02462
20-444 WA1 200-3
0
T-31 Steering lock switch signal system

* Always turn the starting switch OFF before disconnecting the connector or connecting the T-
Cause Remedy
YES Defective transmission

1 controller Replace
Is voltage between
C3B (female) (9)
and chassis 2 YES Defective steering lock
Replace
ground normal? switch
- Is voltage between
- Stat-t engine. _ STL (male) (1) and _ Short circuit with chassis
l Steering lock NO chassis ground ground, disconnection,
lever normal? or defective contact in Repair or
LOCK: 17 - 30 v - Start engine. NO wiring harness between replace
FREE: Max. 1 V * Steering lock C3B (female) (9) - STL
lever (female) (1)
LOCK: 17 - 30 v
FREE: Max. 1 V
Sleeri ng lock
Transmission
co
controller
WA 1200-3 20-445
0
T-32 Neutralizer relay signal system

* Check that the main monitor and alarm buzzer work normally.
Cause Remedy
YES Defective transmission

Replace
:ontroller
4YE! Iefective neutralizer

1 Replace
alay
Is voltage
between C3A (19) _
(female) (6) and
and chassis
:ontact in wiring harness
ground normal? Is voltage between Replace
between C3A (female) (6) -
j L56 (female) (1) Disconnect C3A, Nc
- Turn starting
l
(19)
C3B. and L5B.
switch ON. 2 Short circuit with chassis
. Short L58 (3) to (5).
. Parking brake Is resistance ground, disconnection, or
between L58 * Disconnect LB5
- Max. 1 R defective contact in wiring
Repair or
switch
- (female) (2) and - . Turn starting harness between L58 replace
ON --f OFF uo
l20-30V NO chassisground switch ON. (female) 11) - LO1 (female)
normal? (3)
. Parking brake switch ON --f OFF
* Disconnect L5B. *20-30V Disconnection or defective
L Repair or
l Max. 1 R contact in wiring harness
N0 between L58 (female) (2) -
replace
chassis ground

Parkino brake
Transmission switch
controller -
^ __.
Neutralizer
relay
Fuse (I 1
FS2 (S12)(t?luel
L59
Parkino brake 88E 0.5fY t,
safety relay 0.75fU LR~ (HD-760861
0 5fB
; li3A;i 0:5tIf ”
lpn I- --
4
20-446 WA1 ZOO-3

0
T-33 Buzzer signal system

* Check that the main monitor and alarm buzzer work normally.
+ Always turn the starting switch OFF before disconnecting the connector or connecting the T-

Replace
YES ween Cl ffemale)
1 (2) and chassis Disconnection or defective
- ground normal? contact in wiring harness
Is resstance bet- between Cl (female) (2) - Repair or
ween Cl (female) _ *DisconnectCl, NO Lo8 (female) (6) or L26 replace
(2) and chassis L08, and U8. (female) (16)
ground normal? * Max. 1 R Short circuit with chassis
- Disconnect Cl, ground in wiring harness Repair or
L08, and L28. NO between Cl (female) (2) - replace
* Min. 1 MR LO8(female) (6) or L28
(female) (16)
JLIE (DT2)
Transmission
controller
or
TXW02465
WA1 200-3 20-447

0
T-34 Network system
Call93 Remedy

controller Replace
between c3B (female) (4).
~ (121-LOS (female) (1 t, (31. Repair or
MO1 (female) (1). (12) or L26
(female) (11, (12). or V3A replace
(female) (8). (18)
I
- Min. 1 MR
I
I l
l
Disconnect c3B. LO8, MOl, L26, and V3A
Short LO8 (female) (1). (3) to chassis.
Shon circuit with chassis
between C3S (female) (41,
Repair or
replace
-Turn starting (12) -LOS (female) (1). (3).
switch OFF. MO1 (female) (1). (121or L26
(female) (1). (12). or V3A
- Disconnect C3B. (female) (8). (18)
L08, MOl, L26,
and V3A
I VHMS controller Transmission

I
controller
TXW02466
20-448 WA1 ZOO-3

0
T-35 Transmission controller power supply system

* Check that fuse II (6) is normal.

Is r&Stance bet- controller Replace
YES ween Cl (female) (6).
- W2). CZ (female) Ill), - Short circuit with chassis
1
_, (21) and chassis ground, disconnection,or
Is voltage between ground normal? defective contact in wiring Repair or
Cl (71, (13). c2 (1). harness between Cl (female) replace
NO 171,(13). C2 (female) (1). (12)
(12) and Cl (6). (12). - * Max* ’ n
c2 (11). (21) * Turn starting switch OFF. - FS5 (female) (6)
normal? * Disconnect Cl and C2.
*20-30V I contact in wiring harness Repair or
*Turn starting NO between Cl (female) (6). (12). replace
C2 (female) (1). (121-chassis
switch ON. ground
Fuse (II)
Transmission FS5 (M6)
controller f
Cl I
” 6 90A
RAI 0 (DTHD4) Battery
=Yz=
TXW02467
WA1 200-3 20-449

0
T-36 Short circuit in travel speed sensor system
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
2 YES Defective transmission Replace

YES between CS
- Short circuit in wiring
I r (female) (2) and
harness between CS (female)
Repair or
(2) -TlS (female) (11and
ween C5 (female) between Cl5 (female) (10) - replace
(2) and chassis T15 (female) (21
ground normal?
.I Short circuit with chassis
. Min. 1 MR
replace
1’
between C5 (female) (2) - TlE
-Turn starting
(female) (1)
switch OFF.
. Disconnect C5,
L07, M028, L28,
and T15.
York esuiumcot
controller
FR2 (HD-46082)
TXW02453
20-450 WA1 200-3

0
T-37 Short circuit in modulated clutch outlet rotation sensor system

Replace
YES ween C4 (female)
1 (2) and (9) Short circuit in wiring
normal? harness between C4 (female)
Is resistance bet- (21-T16 (female) (1) and Repair or
ween C4 (female) _ *Min.lMR NO between C4 (female) (9) -TIE replace
(2) and chassis - Turn starting switch OFF. (female) (21
ground normal? * Disconnect C4, M026, Short circuit with chassis
and T16. ground in wiring harness Repair or
‘Min. 1 MR
between C4 (female) (2) - replace
* Turn starting NO
switch OFF. T’16 (female) (1)
* Disconnect C4,
M02B. and T16.
J L26 (LIT21
Tra
con
Mod
con
TXW02445
WA1 200-3 20-45 1

0
T-38 Disconnection in transmission oil temperature sensor system
Ir Always connect any disconnected connectors before going on to the next step.
Cause Remedy

Reolace
controller
Is resistance bet-
YE? ween T19 (female)
(2) and chassis Disconnection or
2 defective contact in Repair or
- ground normal?
Is resistance bet- wiring harness between reolace
l Max. 1 R NO T19 (female) (2) -chassis
YES ween C3A (female)
(11)and T19 * Turn starting ground
1 (female) (1) normal? switch OFF.
- Disconnect C3A. Disconnection or
Is resiStancehet-
ween T19 (male) (1) * Max. 1 R defective contact in Repair or
and (2) and between - . Turn starting wiring harness between replace
switch OFF. NO C3A (female) (11) -T19
(1). (2) and chassis
ground normal? * Disconnect C3A (female) (1)
* Between (1) - (2): and 119.
3.8 - 4.8 R Defective transmission
?eplace
(at 25W NO oil temperature sensor
. Between (1). (2) -
chassis ground:
3.6 - 3.9 R
* Turn starting
switch OFF.
. Disconnect T19.
Transmission
contr
JT3 (LIT261
temperature sensor
20-452 WA1 200-3
0
T-39 Fl (Forward 1st gear) signal system
r Replace
IS reStStSnCe
_
bet-
normal?
II Defective transmission
controller
Repair or
- Stan engine. NO replace
ween C2 (female)
16) and chassis . Set FNR switch in ‘F” and shift-down
ground normal? switch to ‘Fl”: Max. 1 V
L Other setting than above: 17 - 30 V Shortcircuit with chassis
Min. 1 MQ ground in wiring harness Repair or
* Turn starting between M02A (female) replace
NO (13) - C2 (female) (6)
switch OFF.
* Disconnect C2 Disconnection or
* Max. 1 Q and M02.A. defective contact in
* Turn starting wiring harness between
switch OFF. NO
M02A (female) (13) - C2
- Disconnect C2 (female) (6)
and M02A.
Transmission h
joystick steering Modulated clutch
controller control I
c2 ~YIC21)
p. 5fW
FI signal 518 6
TXW02466
WA1 ZOO-3 20-453

0
T-40 Abnormality in auto shift indicator lamp
* Perform diagnosis steps 2 - 6 when all of the lst, 2nd, and 3rd auto shift indicator lamps are
defective.
CaUSe Remedy
1YES
Go to A.
Is resistance
YES between ~92
3 r (male) (1) and (2)
Is resistance be- normal?
Defective resistor V-92) Replace
YES tween L69 (male) * 5 - 6.2 Id2 NO
(6) and chassis . Turn starting switch
2 ground normal? OFF. Disconnection or
If L69 is replaced . DisconnectW2. defective contact in
*Max.lD Repair or
with another relay, - wiring harness between
* Turn starting NO replace
is operation L69 (female) (6) -chassis
switch OFF. ground
normal?
. l Disconnect L69.
*Turn starting
Defective illumination
switch ON. Replace
relay (L69)
* Turn auto/manual NO
selector switch
OFF (Auto shift mode).
* Turn starting Defective auto shift
* Turn startina switch ON.
switch ON. indicator lamp (1st. 2nd, Replace
_ .
- Turn IJO or 3rd)
auto/manual
selector switch OFF
(Auto shift mode). lyE! -
GotoB
* Turn starting switch kmktawbrtweaaL95
ON. YES haleImadI.87 h!&
Ill.temen
L96
Ifemak)
(21 _ Disconnection or defect%
6- andL86ImaW (11.and contactintiring haineaa
- klwemL97WrcidOland betweanLWfemale) (2) - L67
Is voltagebatweanL55 LBSImaIell11
lbxrf?al? Repair or
yEs tfemafe)(1).I.% Imale)(1). betweenL96(female)
*Max.lQ N( (2) - L66lmale)(1). or between replace
- (female)11).I.97 *Turn startingawitch
(female)(1) andL66 U7 ffemale)I21- L65(male)(1)
5 OFF.
_ lfemalell2)normal? . Disconnect lJ5, LS6,L67, Disconnectionor defective
Is resistance contact in wiring harness
-Max.lD l.57.L56,andI.% qepair or
between L69 between W5 (female) (1). L96
From A - (female) (5) and - Turn starting Pplace
l NO (female) (1L LS7 (female) (1)
chassis ground switch OFF. - L69 (female) 121
normal7 . Disconnect L95, L96, L97.
-5-6.2 kcz and L69.
* Turn starting
NO between L&9 (female) (5) - replace
switch OFF.
chassis ground
. Disconnect L69.
10 YE! Defective transmission

Replace
controller
Is voltage between
YES C2 (female) (5). (4). Shortcircukwithcower s.wce
9 (10) and chassis in tiring harnessbetweenQ
b resaance be 1 ground normal? 6emale)(5)- L62(male)(1). 3epair or
j tween C2 (female) - Max. 1 V
batweenCL(female)(4)- L63 Fplace
N( (male)(1t, or Mwaen Q
- (5). (4). (10) and - *Turn starting switch OFF
(female)DO)- L64Imale)(1)
a chassis ground * DisconnectCZ. L62, L63.
nounal) and L64 Shortdrcuk with chassisground
I
in wiringharnessbetweenQ Repair or
. Min. 1 MD . Turn starting switch ON.
(female)f5)- L62(male)(11.
From 8,~~ -Turn starting NO baween Cz Ifemale)14)- L63 replace
switch OFF. (male)(1). or bahwaenC2
Hamale)110)- L64hnale)11)
= Disconnect C2, L82,
*MaxlD L83, and L84. Disconnectionor defective
contact in wiring hamesa Repair or
*Turn starting switch batwaen C2 (female) f5)- L62 .eplace
OFF. VO (male) (1). between C2
* Disconnect C2, L92, L83, and L84. (female1(41 - L63 (male) (1).
or between C2 (female) (10) -
L64 (male1 (1)
20-454 WA1 200-3

0
Auto shift
indicator
Transmission
controller
51
T
FS2 (St2 Blue)
illumination
TXW02563
WA1 200-3 20-455

0
TROUBLESHOOTING OF MODULATED
CLUTCH CONTROLLER SYSTEM
(MC MODE)
Judgement table for modulated clutch control system related parts .............................................. 20-502
Operations of controller against abnormality and conditions of machine caused
by abnormality ................................................................................................................................. 20-504
Electric circuit diagram of modulated clutch control system .......................... .................................. 20-510
MC- 1 Error code [701 (Disconnection in boom RAISE/LOWER or bucket TILT/DUMP
pressure switch system) is displayed ............................................................................... 20-512
MC- 2 Error code 1721 (Abnormality in accelerator pedal sensor system) is displayed ............ 20-514
MC- 3 Error code 1731 (Short circuit in F/R ECMV fill switch system) is displayed.. .................. 20-515
MC- 4 Error code 1741 (Disconnection in Ist, 2nd, or 3rd ECMV fill switch system)
is displayed .......................................................................................................................... 20-516
MC- 5 Error code 1751 (Short circuit with chassis ground in lst, 2nd, or 3rd ECMV
fill switch system) is displayed ......................................................................................... 20-517
MC- 6 Error code 1761 (Short circuit in RPM-SET IDLE-UP/RESUME IDLE-DOWN
switch system) is displayed ............................................................................................... 20-518
MC- 7 Error code 1771 (Short circuit or disconnection in drive force control dial
system) is displayed ........................................................................................................... 20-519
MC- 8 Error code [781 (Short circuit or disconnection in travel speed control dial
MC- 9 Error code 1801 (Short circuit or disconnection in wheel rotation sensor
MC-10 Error code 1811 (Short circuit, disconnection, or short circuit with power source
in modulated clutch outlet rotation sensor system) is displayed ................................ .20-522
in engine speed sensor system) is displayed .................................................................. 20-523
MC-12 Error code 1831(Short circuit or disconnection in travel speed sensor system)
is displayed .......................................................................................................................... 20-524
MC-13 Error code [841 (Short circuit, disconnection, or short circuit with power source
in neutral cut solenoid system) is displayed ................................................................... 20-526
in modulated clutch ECMV solenoid system) is displayed ............................................ 20-527
MC-15 Short circuit in boom RAISE/LOWER or bucket TILT/DUMP pressure switch
system ................................................................................................................................ 20-528
MC-16 Disconnection in F ECMV fill switch system ....................................................................... -20-529
MC-17 Disconnection in R ECMV fill switch system ....................................................................... 20-529
MC-18 Disconnection in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system. .................... 20-530
MC-19 Abnormality in electronic governor voltage command system ........................................ -20-531
MC-20 Abnormality in transmission cut-off signal system ............................................................. 20-532
MC-21 Abnormality in modulated clutch ECMV fill switch system .............................................. .20-533
MC-22 Abnormality in right brake pedal switch system ................................................................. 20-534
MC-23 Abnormality in travel speed control ON/OFF switch system ............................................. 20-535
MC-24 Abnormality in RPM-SET ON/OFF switch system ............................................................... 20-536
MC-25 Abnormality in engine rotation output signal system ........................................................ 20-537
MC-26 Abnormality in power supply system of modulated clutch control system ................... 20-538
MC-27 Abnormality in network system ............................................................................................ 20-539
MC-28 Abnormality in Fl (Forward 1st gear) input signal system ............................................... -20-539
WA1 200-3 20-501

0
JUDGEMENT TAB .E FOR MODULATED CLUTCH
TROUBLESHOOTING corn OL SYSTEM RELATED PARTS
JUDGEMENT TABLE FOR MODULATED CLUTCH CONTROL

SYSTEM RELATED PARTS
Self-diagnosis display 1
-
;;E
Location of failure 2
3
m
P
E
8
-0
ii
,P
T
2
z
.E
5
._
z
I
2
::
s
8
.%
2
.k
E
I%
Failure mode
-
Bte
78
-
1 Machine cannot travel
2 Travel speed cannot be controlled 0

-
3 Travel speed control system operates while travel speed control ON/OFF switch is OFF
-
4 1 Travel speed control system operates while gear speed is F3 or R3
-
5 Travel speed control system operates while travel speed is below 1.5 km/h
-
6 Travel speed control system does not follow up travel speed control dial
7 Drive force does not change even if drive force control dial is turned 0
-
8 Drive force control system operates while gear speed is not Fl
-
9 Drive force control system does not follow up drive force control dial
10 Tire slip control system does not work 0

-
11 Tire slip control system works while tire slip control switch is “OFF”
-
12 ( Tire slip control system works while gear speed is not Fl
-
13 1 Tire slip control system works while work equipment is not operated
-
14 Engine speed does not rise even if accelerator pedal is pressed
-
15 Shock timelag is made when F & R gear is shifted
-
16 Engine speed does not change even if RPM SST ON/OFF switch is operated
-
17 Engine speed can be set while RPM SET ON/OFF switch is OFF
-
18 RPM-SET IDLE-UP/RESUME IDLE-DOWN switch does not work
-
19 Travel speed, drive force, and tire slip control system operates while cut-off switch is OFF
-
20 Multi-hydraulic control system does not work
-
21 Rising speed of work equipment is low
-
22 1 Display of engine speed is abnormal
-
23 1 Main monitor does not display modulated clutch control system information
Diagnosis code when failure coda is displayed

E
8
20-502 WA1 200-3

0
JUDGEMENT TABLE FOR MODULATED CLUTCH
TROUBLESHOOTING CONTROL SYSTEM RELATED PAFiTS
WA1 200-3 20-503

0
TROUBLESHOOTING CONDITIONS OF MACHINE CAUSED BY ABNORMALITY _

/ M~nlII
._.___- ATFD
.._- CLLITCH
___. _.. CONTROL
----. .--- SYSTEM
- - - _-__.
-ailure code Abnormal system Contents of abnormality
1) Defective bucket DUMP pressure switch

2) Defective bucket TILT pressure switch
3) Defective boom RAISE pressure switch
4) Defective boom LOWER pressure switch
5) Disconnection or defective contact in wiring harness between
HR3, HR4, HRIZ, HR13 (female) (2) - chassis ground
6) Disconnectionor defective contact in wiring harness between
Disconnection in boom modulated clutch controller M02A (female) (5) - HR4 (female) (1)
RAISE/LOWER or bucket 7) Disconnection or defective contact in wiring harness
70
TILT/DUMP pressure switch between modulated clutch controller M02A (female) (6) -
system HR3 (female) (1)
between modulated clutch controller M02A (female) (7) -
HR12 (female) (1)
HR13 (female) (1)
10) Defective modulated clutch controller
1) Defective accelerator pedal potentiometer

chassis ground in wiring harness between modulated
clutch controller M02A (female) (19) - L25 (female) (1)
Abnormality in accelerator chassis ground in wiring harness between modulated
72
pedal sensor system clutch controller M02A (female) (10) - L25 (female) (3)
4) Short circuit of wiring harness between modulated clutch
controller M02A (female) (19) - L25 (female) (1) with wiring
harness between modulated clutch controtler M02A
(female) (10) - L25 (female) (3)
1) Defective F ECMV fill switch

2) Defective R ECMV fill switch
Short circuit in F/R ECMV fill between modulated clutch controller M02A (female) (4) -
73 T14 (female) (1)
switch system
T12 (female) (1)
1) Defective 1st ECMV fill switch

3) Defective 3rd ECMV fill switch
Disconnection in lst, 2nd, or T4 (female) (1)
74 5) Disconnection or defective contact in wiring harness
3rd ECMV fill switch system
T6 (female) (1)
between modulated clutch controller M02A (female) (14)
- T8 (female) (1)
I) Defective 1st ECMV fill switch

3) Defective 3rd ECMV fill switch
4) Short circuit with chassis ground in wiring harness between
modulated clutch controller M02A (female) (2) - T4 (female) (1)
75 ground in 1st. 2nd, or 3rd
ECMV fill switch system
modulated clutch controller M02A (female) (I) - T6 (female) (I)
modulated clutch controller M02A (female) (14) - T8 (female) (I)
20-504 WA1 200-3

0
Normal condition Operation of controller Condition of machine Diagnosi!

(Voltage, current, resistance) against abnormality caused by abnormality code
1) Voltage between M02A (8) - chassis ground 1) NC solenoid = OFF 1) Machine condition
When work equipment control lever is in neutral: Max. 1 V
does not change
When work equipment control lever is in boom RAISE
position: 15 - 30 V particularly.
2) Voltage between M02A (7) - chassis ground 2) Hydraulic loss is
When work equipment control lever is in neutral: Max. 1 V increased if
When work equipment control lever is in boom LOWER machine travels at
position: 15 - 30 V
3) Voltage between M02A (6) - chassis ground speed of 10 km/h or
When work equipment control lever is in neutral: Max. 1 V below in F3 gear.
When work equipment control lever is in bucket TILT C-l
position: 15 - 30 V
4) Voltage between M02A (5) - chassis ground
When work equipment control lever is in neutral: Max. 1 V
When work equipment control lever is in bucket DUMP
position: 15 - 30 V
Note: Move each lever a little (to degree that work
equipment does not move actually) (for detection
of PPC pressure signal).
1) Voltage between M02A (10) - M02A (9): 4.75 - 5.25 V 1) Controls for low Engine speed does not
2) Voltage between M02A (19) - M02A (9): 0.5 - 4.75 V idling. rise even if accelerator
3) Voltage between M02A (19) - M02A (9) fat low idling):
0.5 - 1.6 V pedal is pressed.
4) Voltage between M02A (19) - M02A (9) (at high idling):
[Voltage at low idling + 2.1) - 4.75 V
Note: Above table shows standard potentiometer voltage c-2
by which controller can recognize dial area normally.
When adjusting potentiometer again, leave margin
to error judgment area. Adjust voltage in range
from 1.3 to 1.6 V at low idling. (Error judgment
area is as follows; Potentiometer voltage < 0.5 V or
Potentiometer voltage x- 4.5 V)
1) Resistance between F ECMV fill switch T14 (male) (1) - 1) Engages modulated 1) Drive force doesnot
chassis ground: clutch directly. changeevenif driveforce
When forward switch is set to measuring point: Max. 1 R 2) NC so)enojd = OFF controldial is operated.
When forward switch is set out of measuring point Min. 1 MC
2) Resistance between I? ECMV fill switch T12 (male) (1) 2) Tire slip control system C-3
- chassis ground: does not work.
When reverse switch is set to measuring point: Max. 1 R 3) Shock time lag is made
When reverseswitch is set out of measuring point Min. 1 MR when travel direction is
t Start engine, turn transmission cut-off switch OFF, turn
changed.
parking brake OFF, and press brake pedal.
1) Resistance between lstJ2nd/3rd ECMV fill switch T4, 1) Engages modulated 1) Drive force does
T6, T6 (male) (I) - chassis ground: . clutch directly. not change even if
$r;_n,se; to measunng point with shrft-up/down switch: 2) NC solenoid = OFF
drive force control
When set out of measuring point with shift-up/down dial is operated.
switch: Min. 1 MR 2) Shock time lag is
It Starl engine, set forward/reverse lever in N, and turn made when travel
manual switch ON. c-4
direction is
Note: Default when engine is started is 2nd. If shift-down
switch is pressed and held, gear is shifted down to changed.
1st. If shift-up switch is pressed and held, gear is
shifted up to 3rd.
1) Resistance between lstf2nd/3rd ECMV fill switch T4, 1) Engages modulated 1) Drive force does
T6, T8 (male) (1) - chassis ground:. clutch directly. not change even if
KzF;;t to measurmg pomt wrth shrft-up/down switch: 2) NC solenoid = OFF drive force control
dial is operated.
When set out of measuring point with shift-up/down
switch: Min. 1 MR 2) Shock time lag is
t Start engine, set forward/reverse lever in N, and turn made when travel c-5
manual switch ON. direction is
Note: Default when engine is started is 2nd. If shift-down
changed.
switch is pressed and held, gear is shifted down to
1st. If shift-up switch is pressed and held, gear is
shifted up to 3rd.
WA1 200-3 20-505

0
1) Defective RPM-SET/IDLE-UP switch, RESUME/IDLE-DOWN

switch
between modulated clutch controller M02A (female) (15)
Short circuit in RPM-SET - LllO (female) (1)
76 IDLE-UP/RESUME IDLE- 3) Short circuit with chassis ground in wiring harness
DOWN switch system between modulated clutch controller M02A (female) (16)
- LIIO (female) (3)
I) Disconnection, defective contact, or short circuit with

clutch controller M02B (female) (I) - F06 (female) (2)
clutch controller M02A (female) (10) - F06 (female) (1)
Short circuit or
3) Short circuit of wiring harness between modulated clutch
77 disconnection in drive force controller M02B (female) (1) - F06 (female) (2) with wiring
control dial system
harness between modulated clutch controller M02A
(female) (IO) - F06 (female) (1)
4) Defective drive force control dial
I) Disconnection, defective contact, or short circuit with

clutch controller M02B (female) (10) - F07 (female) (2)
Short circuit or clutch controller M02A (female) (10) - F07 (female) (1)
78 disconnection in travel 3) Short circuit of wiring harness between modulated clutch
speed control dial system controller M02B (female) (10) - F07 (female) (2) with wiring
harness between modulated clutch controller M02A
(female) (10) - F07 (female) (1)
4) Defective travel speed control dial
1) Defective wheel rotation sensor

clutch controller M02B (female) (I I) - F15 (female) (2)
Short circuit or 3) Disconnection or defective contact in wiring harness
80 disconnection in wheel between F15 (female) (3) - chassis ground
rotation sensor system 4) Short circuit of wiring harness between modulated clutch
controller M02B (female) (1 I) - F15 (female) (2) with wiring
harness between VHMS controller Vl (female) (3) - F15
(female) (1)
I) Defective modulated clutch outlet rotation sensor

Short circuit, disconnection, clutch controller M02B (female) (4) - T16 (female) (I)
or short circuit with power 3) Disconnection or defective contact in wiring harness
81
source in modulated clutch between modulated clutch controller M02B (female) (12)
outlet rotation sensor system - T16 (female) (2)
4) Short circuit with power source in wiring harness between
modulated clutch controller MOZB (female) (4) -chassis ground
20-506 WA1 200-3

0
Normal condition Operation of controller Condition of machine Diagnosb

I) Voltage between M02A (15) - chassis ground: I) Turns off RPM-SET Engine speed does not
When RPM-SET IDLE-UP/RESUMEIDLE-DOWNswitch IDLE-UP/RESUME change even if RPM-
is set to RESUME IDLE-DOWN position: Max. 1 V IDLE-DOWN SET switch is
When RPM-SET IDLE-UP/RESUME IDLE-DOWN function. operated.
switch is set to SET IDLE-UP position: 15 - 30 V
C-6
!I Voltage between M02A (16) - chassis ground:
When RPM-SET IDLE-UP/RESUMEIDLE-DOWN switch
is set to RESUME IDLE-DOWN position: 15 - 30 V
When RPM-SET IDLE-UP/RESUMEIDLE-DOWN switch
is set to RPM SET IDLE-UP position: Max. 1 V
I) Voltage between M02A (IO) - M02A (9): I) Slip ratio by drive 1) Drive force does
4.75 - 5.25 V force control dial = not change even if
!) Voltage between M02A (I) - M02A (9kO.5 - 4.75 V 100% drive force control
3) Voltage between M02A (I) - M02A 19) (Min.): dial is operated.
0.5 - 1.6V 2) Tire slip control
1) Voltage between M02A (19) - M02A (9) (Max.): system does not
[Min. voltage + 2.11 - 4.75 V work. c-7
Jote: Above table shows standard potentiometer voltage 3) Travel speed cannot
by which controller can recognize dial area be controlled.
normally. When adjusting potentiometer again,
leave margin to error judgment area. Adjust
voltage in range from 1.3 to 1.6 V at low idling.
(Error judgment area is as follows; Potentiometer
voltage c 0.5 V or Potentiometer voltage > 4.5 VI
I) Voltage between M02A (10) - M02A (9): 4.75 - 5.25 V I) Slip ratio by travel I) Drive force does
!) Voltage between M02A (10) - M02A (9): 0.5 - 4.75 V speed control dial not change even if
$1Voltage between M02A (10) - M02A (9) (Min.): 0.5 - 1.6 V = 100% drive force control
1) Voltage between M02A (IO) - M02A (9) (Max.): 2) Max. travel speed dial is operated.
[Min. voltage + 2.71 - 4.75 V = 12 km/h 2) Tire slip control
rlote: Above table shows standard potentiometer system does not
voltage by which controller can recognize dial work. C-8
area normally. When adjusting potentiometer 3) Travel speed cannot
again, leave margin to error judgment area. be controlled.
Adjust voltage in range from 1.3 to 1.6 V at low
idling. (Error judgment area is as follows;
Potentiometer voltage e 0.5 V or Potentiometer
voltage > 4.5 VI
I) Resistance between wheel rotation sensor PI5 1) Turns off tire slip I) Drive force does
(male) (2) - (3): 100 - 500 R control. not change even if
drive force control
dial is operated.
2) Tire slip control
system does not c-9
work.
3) Travel speed cannot
be controlled.
I) Modulated clutch outlet rotation sensor I) Turns off I) Drive force does
Resistance between T16 (male) (I) - (2): modulated clutch not change even if
500 - 1000 R control (Engages drive force control
Resistance between T16 (male) (I), (2) - chassis clutch directly). dial is operated.
ground: Min. 1 MS2 2) Tire slip control C-IO
system does not
work.
be controlled.
WA1 200-3 20-507

0
1) Defective engine speed sensor

clutch controller C4 (female) (1) - T17 (female) (1)
between modulated clutch controller C4 (female) (9) - T17
(female) (2)
Short circuit, disconnection, 4) Short circuit of wiring harness between modulated clutch
or short circuit with power controller MO28 (female) (51- T17 (female) (1) with wiring
82
source in engine speed harness between modulated clutch controller M02B
sensor system (female) (12) - T17 (female) (2)
modulated clutch controller M02B (female) (5) - T17
(female) (1)
1) Defective travel speed sensor

clutch controller M02B (female) (13) - T15 (female) (1)
Short circuit or between modulated clutch controller M02B (female) (12)
83 disconnection in travel - T15 (female) (2)
speed sensor system 4) Short circuit of wiring harness between modulated clutch
controller M02B (female) (13) - T15 (female) (1) with wiring
harness between modulated clutch controller MOZB
1) Defective neutral cut solenoid

2) Disconnection, defective contact, short circuit with chassis
ground, or short circuit with power source in wiring
harness between modulated clutch controller MO1 (female)
Short circuit, disconnection, (21) - HRl (female) (1)
or short circuit with power 3) Disconnection or defective contact in wiring harness
84
source in neutral cut between HRl (female) (2) - chassis ground
solenoid system 4) Defective modulated clutch controller
1) Defective modulated clutch ECMV solenoid

clutch controller MO1 (female) (16) - T9 (female) (2)
Short circuit, disconnection, chassis ground in wiring harness between modulated
or short circuit with power clutch controller MO1 (female) (7) - T9 (female) (1)
85
source in modulated clutch 4) Short circuit of wiring harness between modulated clutch
ECMV solenoid system controller MO1 (female) (16) - T9 (female) (2) with wiring
harness between modulated clutch controller MO1 (female)
(7) - T9 (female) (1)
20-508 WA1 200-3

0
Normal condition OPeratbn of COntrOller Condition of machine Diagnosi
1
1)1Engine speed sensor 1) Turns off 1) Drive force does

Resistance between T17 (male) (1) - (2): modulated clutch not change even if
500 - 1000 R control (Engages drive force control
Resistance between T17 (male) (I), (2) - chassis clutch directly). dial is operated.
ground: Min. 1 MD 2) Tire slip control
2) Voltage between M02B 6) - (12): Min. 0.5 V system does not
Note) Measure in AC range. work.
be controlled. c-11
4) Engine speed is not
displayed normally.
I
1) Travel speed sensor
Resistance between T15 (male) (1) - (2):
500 - 1000 R
Resistance between T15 (male) (11, (2) - chassis
ground: Min. 1 MR
I) Turns off tire slip
control.
2) Turns off
modulated clutch
control (Engages
clutch directly).
3) NC solenoid = OFF
1) Drive force does
not change even if
drive force control
dial is operated.
2) Tire slip control
system does not
work.
be controlled.
c-12
Voltage between MO1 (female) (21) - chassis 1) NC solenoid output Work equipment does
OFF not rise quickly. (When
ground short CkCUit with
(When short circuit
When work equipment control lever is operated: power source is made)
17-3ov with power source
is made, NC Neutral cut control
When work equipment control lever is in neutral: system does not work
Max. 1 V solenoid output c-13
(Machine condition
cannot be turned
off.) does not change
lte) Move the lever a little (to degree that work particularly). (When
equipment does not move actually) (for disconnection or short
detection of PPC pressure signal). circuit with chassis
ground is made)
Modulated clutch ECMV solenoid 1) Operates 1) Drive force does

Resistance between TS (male) (I) - (2): 5 - 15 R emergency spool. not change even if
Resistance between TS (male) (11, (2) - chassis 2) Turns ON drive force control
ground: Min. 1 MR emergency dial is operated.
operation switch. 2) Tire slip control
3) Cannot work (when system does not
short circuit with work.
c-14
power source is 3) Travel speed cannot
made on CNI (7) be controlled.
side). 4) Machine cannot
travel in any gear
speed.
WA 1200-3 20-509
0
ELECTRIC CIRCUIT DIAGRAM OF MODULATED
TROUBLESHOOTING CLUTCH CONTROL SYSTEM
ELECTRIC CIRCUIT DIAGRAM OF MODULATED CLUTCH

CONTROL SYSTEM
20-510 WA1 200-3

0
ELECTRIC CIRCUIT DIAGRAM OF MODULATED
TROUBLESHOOTING CLUTCH CONTROL SYSTEM
IMP-SET
IDLE-UP/
RESUME
Boom LOWER
switch
1st Ii I rmitcb
I-
0uMTuY
TXW02470
WA1 200-3 20-511

0
TFtOUBLESHOOTlNG MC1
MC-l Error code [70] (Disconnection in boom RAISE/LOWER or bucket

TILT/DUMP pressure switch system) is displayed
CaUSe Remedy
4M!
GotoA -
Is resistance
YES between HR12
3 (female) (1) and
-
Is resistance (2) normal? Defective boom LOWER
YES between HR13 -Start engine. pressure switch Replace
- (female) (1) and
- *bornLOWER operation
NC
2 Whenleveris operated
(2) normal? aliie:Max.lQ
‘Is- Whenleverisin
YES between HR3
l Start engine. neutral:Min. 1 MQ Defective boom RAISE
Replace
- (female) (1) and - * ‘Oorn RA’SE NO pressure switch
operation
1 (2) normal?
_ When lever is operated a little: Max. 1 R
Is resistance * Start engine. When lever is in neutral: Min. 1 MR Defective bucket TILT
between HRb . Bucket TILT Replace
(female) (1) and - pressure switch
operation NO
(2) normal? . When lever is operated a little: Max. 1 R
* Start engine. When lever is in neutral: Min. 1 MR
Defective bucket DUMP
Replace
operation NO pressure switch
When lever is
operated a little:
Max. 1 R 7YEs -
When lever is in Go to B.
Is resistance
neutral: YES between M02A
Min. 1 MR (female)6) and HR3 -
6 Disconnection or defective
- (female1(1) normal?
YES between MO24 - Max. 1 Q NO between M02A (female) (6) replace
(female) (5) and HR4 * Turn starting switch - HR3 (female) (1)
5
_ (female) (11normal? OFF.
- - DisconnectMO2and
- Max. 1 R _ HR3. contact in wiring harness Repair or
From A HR13 (female)(2) and 7 Turn starting
l NO between M02A (female) (5) replace
switch OFF.. ._- - HR4 (female) (1)
* Disconnect MO2 Disconnection or defective
- Max. 1 R and HRb. contact in wiring harness Repair or
Turn starting between HR3, HR4, HR12, replace
l
switch OFF. NO HR13 (female) (2) -chassis

* Disconnect HR3, ground
HRb, HR12, and
HR13. 9 YES Defective modulated
Replace
Is resistance clutch controller
II
between MO% (female) (8) replace
From 8 - HR13 (female) (1)
contact in wiring harness Sepair or
*Turn starting between M02A (female) (7) replace
NO
switch OFF. - HR12 (female) (1)
. Disconnect MO2
and HR12.
20-512 WA1 200-3

0
TROUBLESHOOTING MCI
MC-1 Related electrical circuit diagram
RA5 (DTI) RAIO (DTHD4)

2L 3 boocf ( 11000
Modulated clutch
controller
Wor
con
switch
WA1 200-3 20-513

0
TROUBLESHOOTING MC-2
MC-2 Error code [721 (Abnormality in accelerator pedal sensor system)

is displayed
* This troubleshooting is carried out when there is still an abnormality,
so when disconnecting the
Jr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
ChUSe Remedy
3 YES
GotoA -
Is resistance
yEs between M02A
- Ifemale) (10) and -
_ L25 (female) (3)
Is resistance normal? contact in wiring harness Repair or
YES between MWA
Max. 1 R
l NO between MOZA (female) replace
* Turn starting (10) - L25 (female) (1)
1 chassis ground
- Is resistance normal? switch OFF.
- * Disconnect MO2 and l.25.
between MOZA * Min. 1 MR ground in wiring harness Repair or
(female) (19) and - lTurn starting NO between M02A (female) replace
LZ5 (female) (1) switch OFF. (19) -L25 (female) (1)
normal? - lDisconnect MO2
- Max. 1Q Disconnection or defective
and l.25.
contect in wiring harness Repair or
*Turn starting
NO between M02A (female) replace
switch OFF.
(19) - L25 (female) 41)
and l-25.
6 YES Defective modulated
clutch controller Replace
YES Is voltage
- between I_25 (1) -
5
_ and (2) normal?
Isrssistsncebetween ~ ._ Defective accelerator
n ; M02A (female)110). *At low idling: NO pedal potentiometer Replace
(19) and chassis - 0.5-1.6V
4 At high idling: Short circuit of wiring
groundnormal?
harness between MO2A
I Is resistance 1 ~ (Low idling voltage + 2.1 VI - 4.75 V
- Min. 1 MQ -Turn staning switch ON. (female) (10) - L25 (female) Repair or
Fro~~j;~d ] * Turn starting (3) with wiring harness replace
NO
switch OFF. between M02A (19) - L25
* Disconnect MO2 (female) 11)
* Min. 1 MR and L25. Short circuit with chassis
* Turn starting ground in wiring harness Repair or
switch OFF.
uo between M02A (female) replace
l Disconnect MO2 (10) - L25 (female) (3)
and L25.
Accelerator
Pedal
Madulated clutch
con
ri+r TXW02472
20-514 WA1 ZOO-3

0
MC-3 Error code [73] (Short circuit in F/R ECMV fill switch system) is
displayed
Call!% Remedy
Defective modulated
Replace
clutch controller

YES between MO2A - Min. 1 MQ NC between M02A (female) replace
- (female) (4) and
- *Turn starting switch (3) -Tl2 (female) (1)
2 chassisground OFF.
- noma~‘~~ - DisconnectMOZA.C3B. Short circuit with chassis
l Min. 1 MD _ andT14. ground in wiring harness Repair or
YES between T12 (male)
- * Turn starting NO between M02A (female) replace
_jzy
1 11ground normal?
switch OFF. (4) -T14 (female) (1)
L _ * Disconnect M02A. C3B.
- Min. 1 M!3
.__ and T14.
between T14 (male) Defective R ECMV fill
. fur” .-. ..na
etrrrti
switch Replace
(1) and chassis NO
switch OFF-
* Disconnect T12.
*Min. 1 MR
Defective F ECMV fill
*Turn starting Replace
NO switch
switch OFF.
lDisconnect T14.
Transnission
TXWO2456
WA1 200-3 20-5 15

0
TROUBLESHOOTlNG MC-4
MC-4 Error code [741 (Disconnection in lst, 2nd, or 3rd ECMV fill
It Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4YE
Go to A.
If T4 (female) (1)
YES is grounded to
3- chassis, is ‘74”
displayed? Defective 1st ECMV fill
Is resistance
switch Replace
YES between MOZA -TUT” starting Switch N(
(14) and T8 -
OFF.
(female1
* Discomen 14.
2 (female) (1) normal? -Start engine.
- *Setf0WwdlmmrselsvsrinN Disconnection or defective
Is resistance *SOt~~~ShiilOV~illlSt.
*Max.lR contact in wiring harness Repair or
fis between MOZA
- * Turn starting NO between M02A (female) replace
(female) (1) and T6
switch OFF. (14) - T8 (female) (1)
- * Disconnect C5,
Is resistance Max. 1 R Disconnection or defective
l TB, M02A.
between M02A contact in wiring harness Repair or
* Turn starting
(female) (2) and T4 - NO between MO24 (female) (1) replace
switch OFF.
(female) (1) normal? -T6 (female) (1)
l Disconnect C3B.
*MaxlR TS, M02A. Disconnection or defective
* Turn starting contact in wiring harness Repair or
switch OFF. NO between M02.A (female) (2) replace
* Disconnect UB, - T4 (female) (1)
T4, M02k
If T8 (female) (1) clutch controller
YES is grounded to
5 chassis, is ‘74”
If T6 (female) (1) , displayed? Defective 3rd ECMV fill
is grounded to *T$;; starting switch NO switch
From A -
chassis, is ‘74” * Disckct T8.
displayed? * Stan engine.
- * Set forward/reverse lever in N.
* Turn starting . Set gear shift lever in 3rd. Defective 2nd ECMV fill
* Disconnect T6.
l Start engine.
* Set forward/reverse
lever in N.
l Set gear shift lever
in 2nd.

Transniarion
TXW0.2457
20-5 16 WA1 200-3

0
MC-5 Error code 1751 (Short circuit with chassis ground in Ist, 2nd, or
3rd ECMV fill switch system) is displayed -
* Before carrying out troubleshooting, check that all the related connectors are Drooerly inserted.
* Always connect any disconnected connectors before going on to the next step. ’
CaUSe Remedy
4YE! -
GotoA
YES_ [
(female) (21 and
YES between ~8 (mate) -Min.1 MQ NC between M02A (female) (2) replace
(1) and chassis *Turn starting switCh -T4 (female) (1)
_ 2 ground normal? OFF.
Is resistance - * DisconnactM&U, 635,
Min. 1 MD
l and TO. Defective 3rd ECMV fill
YES between T6 (male) Replace
- Turn starting
l NO switch
(1) and chassis
1 ground normal? switch OFF.
* Disconnect T8.
Is resistance lMin. 1 MR
between T4 (male) Defective 2nd ECMV fill
* Turn starting Replace
(1) and chassis - NO switch
switch OFF.
ground normal?
* Disconnect T6.
* Min. 1 MD
*Turn starting I Defective 1st ECMV fill
l Disconnect T4.

Is resistance Replace
clutch controller
yes between MOZA
5
chassis ground Short circuit with chassis
Is resistance normal? ground in wiring harness Bepair or
between M02A
* Min. 1 MD NO between M02A (female) replace
From A (female1(1) and
(14) - T8 (female) (1)
I
I&a~.sground 1 * Turn starting
switch OFF. Short circuit with chassis
* Min. 1 MR * Disconnect M02A. C5, and T8. ground in wiring harness ?epair or
Turn starting between MOZA (female) (1) *eplace
l NO
switch OFF. -T6 (female) (1)
* Disconnect
M02A. C3B, and
T6.
WA1 200-3 20-517

0
TROUBLESHOOTING Mt?A
MC-6 Error code [76] (Shot-t circuit in RPM-SET IDLE-UP/RESUME

IDLE-DOWN switch system) is displayed
CaUSt? Remedy

Isresistance Replace
clutch controller
between MOZA
- rhazground 11 Short circuit with chassis

yES between MO2A between M02A (female)
* Min. 1 MQ NO replace
(16) - LllO (female) (3)
*Turn starting
1 chassisground
_IS resistance switch OFF.
* Min. 1 MR l Disconnect MOZA and LllO. ground in wiring harness Repair or
between LllO
(male) (1). (2) and - *Turn starting NO between M02A (female) replace
(3) as shown in switch OFF. (15) - LllO (female) (1)
-Table 17 - Disconnect M02A
* Disconnect LllO. and LllO. Defective SET IDLE-UP
*Turn starting /RESUME IDLE-DOWN Replace
switch OFF. NO
switch
Table 1
RPM-SET IDLE- RESUMEJDLE-
UP switch ON DOWN switch ON
Between LllO (female) (1) - (2) Min. 1 MR Max. 1 R
Between LllO (female) (3) - (2) Max. 1 R Min. 1 MC?
MC-6 Related electrical circuit diagram RPM-SET

I OLE-UP/RESUME
IDLE-DOWN switch
Modulated clutch
con
LR7 (DTI) RAlO (DTHD4) Battery
TXW02473
20-518 WA1 200-3

0
MC-7 Error code 1771 (Short circuit or disconnection in drive force

control dial system) is displayed
* Always connect any disconnected connectors before going on to the next step. .
Remedy
GotoA -
- Ihaha;round 1 Short circuit with chassis

Is resistance ground in wiring hamesa Repair or
yEs belweenM02A between M02A (female) replace
*Min. 1 MR NO
*Turn starting awitch (10) - F06 (female) (1)
2 FO6 (female) (1) OFF.
pIs resistance - normal? * C&connect MOZA and Disconnection or defective
YES between MOZB *Max.lQ FO6. ‘i contact in wiring harness Repair or
- (female) (1) and - *Turn starting NO between M02A (female) replace
chassis ground switch OFF. (10) -H)6 (female) (1)
1
- normal? ‘ * Disconnect M02A
Isresistance Shon circuit with chassis
* Min. 1 MO and F06.
between MOZB ground in wiring harness Repair or
*Turn starting
(female) (1) and F06 - NO between M02B (female) (1) replace
switch OFF.
(female) (2) normal? - FO6 (female) (2)
* Disconnect M02B
*Max.10 and F06. Disconnection or defective
*Turn starting contact in wiring harness Repair or
switch OFF. NO between MOZB (female) (1) replace
* Disconnect M02B - F06 (female) (2)
and F06.
Replace
clutch controller
YEs Is voltage
- between F06 (2) -
5
and (3) normal?
Is resisance Defective drive force
between MOZA Replace
NO control dial
From A - (female) (10) and - ’ Drive force
MOZB (female) (1) control dial Short circuit of wiring
normal? At204’4V AtlOO%:lV harness between M02A
l Min. 1 MR *Turn starting switch ON. Ifemale) (10) - FO6 liemale) Repair or
+ Turn starting NO 11) with wiring harness replace
switch OFF. I between MO28 (female) (11
* Disconnect - FO6 (female) (2)
M02A. M02B.
and F06.
I
Modulated clutch Dial controlline

con the driving force
fi TXW02474
WA1 200-3 20-519

0
MC-8 Error code 1781 (Short circuit or disconnection in travel weed

.
control dial system) is displayed
Remedy
GotoA -
- [;;z;ground 11 Disconnection or defective

IS resistance contact in wiring harness Repair or
yes between MOZA between M02A (female)
*Min. 1 MD NC replace
*Turn starting switch I101 - F07 (female) (1)
2 Fo7 (female) (1) OFF.
- IS resistance normal? - * Disconnect MOZAand Disconnection or defective
YES between MO26 .Max.lR F07. contact in wiring hamess Repair or
- (female) (10) end - l Turn starting NO between M02A (female) replace
chassis ground switch OFF. (10) - F07 (female) (1)
1
- normal? * Disconnect M02A
Is resistance Short circuit with chassis
* Min. 1 MR and F07.
between MO26 ground in wiring harness Repair or
(female) (10) and - *Turn starting between MOZB (female)
switch OFF. NO replace
F07 (female) (2) (10) - F07 (female) (2)
normal? * Disconnect M02B
lMax.lf2 and F07. Disconnection or defective
* Turn starting I contact in wiring harness Repair or
switch OFF. NO between MOZB (female) replace
* Disconnect M02B (10) - F07 (female) (2)
and F07.
I Isvoltaae II

Replace
control dial
From A
Short circuit of wiring
normal? 1 At3km/h:4V At12km/h:lV harness between M02A
l Min. 1 MR *Turn starting switch ON. (female) (10) - F07 (female) Repair or
* Turn starting NO (1) with wiring harness peplace
switch OFF. between M02B (female)
* Disconnect (10) - F07 (female) (2)
M02A, M02B.
and F07.
Modulated clutch
Vehicle speed
controller
- MOZA (04020)
rffr TXW02475
20-520 WA1 200-3

0
MC-9 Error code [801 (Short circuit or disconnection in wheel rotation

I CaUSe Remedy
GotoA -
- I&ss;ground 11 Disconnection or defective

Is raaktance contact in wiring harness Repair or
yes between MOZB between F15 (female) (3) - replace
NO
- (female) (11) and - ’ Max* ’ a chassis ground
chassis ground lDisconnect F15.
2
- Is resistance ,normal? , *Turn starting Short circuit with chassis
ES between M02B l Min. 1 MR switch OFF. ground in wiring harness Repair or
- (female) (11) and - l Disconnect M02B NO between M02B (female) replace
FlS (female) (2) and F15. (11) - F15 (female) (2)
normal? * Turn starting
-Max.1 R switch OFF. /contact in wiring harness Repair or
_ *Disconnect M02B ,
NO between M02B (female) replace
and F15.
(11) - F15 (female) (2)
*Turn starting
*loo-500R switch OFF.
* Disconnect F15. L Defective wheel rotation Replace
*Turn starting N10 sensor
switch OFF.
Replace
H I
between MOZB
From A Short circuit of wiring
(female) (11) and Vl
-I (female) (3) normal? harness between M02B
Repair or
’- Min. 1..-
MS2 replace
- Disconnect M02B
Vl, and F15.
*Turn starting
switch OFF.
WA1 200-3
TROUBLESHOOTING MC-IO
MC-10 Error code [81] (Short circuit, disconnection, or short circuit

with power source in modulated clutch outlet rotation sensor
system) is displayed
CaUSe Remedy
GotoA -
resistence
Is contact in wiring harness Repair or
yRS between MO26 'MaX.lQ between M02B (female) replace
- (female) (4)and - NC
* DisconnectTX, (12) -T16 (female) (2)
2 chassisgmund
M02B. and C4.
- normal? Short circuit with chassis
Is resistance *Turn starting switch OFf
l Min. 1 MR ground in wiring harness Repair or
Eg between M02B
betwean MOZB (female) (41 replace
(female) (4) and T16 - .DisconnectT16,
NO
M02B, and C4. -T16 (female) (1)
1 (female) ~llnorrnal?
P l Turn starting
Is resistance *Max. 1 R Disconnection or defective
switch OFF.
between T16 _ * Disconnect T16,
(male) (1) and (2) between MO26 (female) (4) replace
M02B, and C4. ND
normal? -TN (female)(1)
* Turn starting
l600-1,OOOR switch OFF.
Defective modulated
* Disconnect T16.
clutch outlet rotation Replace
*Turn starting NO
sensor
switch OFF.
Defective modulated
From*Jijg%jf 1normal?
clutch controller

Replace
* source in wiring harness Repair or

*Max. 1 V between M02B (female) replace
* Disconnect T16, (4) -chassis ground
MOZB. and C4.
*Turn starting
switch ON.

JL26 (OT2)
Transmission
controller
TXW02445
20-522 WA1 200-3

0
MC-11 Error code 1821 (Short circuit, disconnection, or short circuit

with power source in engine speed sensor system) is displayed
related connectors are properly inserted. Cause Remedy
GotoA -
yES between MOZB
- T17 (female) (2)
‘Is resistance normal? contact in wiring harness Repair or
yes between MOZB
*MaX.1R N( between C4 (female) (9) - replace
* Disconnecr C4, T17, T17 (female) (2)
! chassis ground
L07, and MOZB.
- -Turn starting switch
l Min. 1 MR OFF. ground in wiring harness Repair or
- *Disconnect C4, NO between C4 (female) (1) - replace
T17 (female) (1)
I
1 (female) (1) normal? T17, L07, and
M02B.
lMax.lR Disconnection or defective
*Turn starting switch OFF.
*Disconnect C4,
(male) (1) and (2) NO between C4 (female) (1) - replace
T17, L07, and
T17 (female) (1)
MOZB.
*500-1,ooon I* Turn starting
1 switch OFF. Defective engine speed
* Disconnect T17.
l Turn starting NO jensor
switch OFF.-
6 YES Iefective modulated

Is voltage between :lutch controller
YES M02B (female) (5)
5 and chassis Short circuit with power
- ground normal? source in wiring harness Repair or
Is resistance
xtween M02B (female) (5) replace
From A _ between M02B _ *Max.lV NO
(female) (5) and
- T17 (female) (1)
* Disconnect C4,
(12) normal? T17, L07, and M02B. short circuit of wiring
*Turn starting switch ON. larness between M02B
* Min. 1 MR qepair or
female) (5) -T17 (female)
* Disconnect C4, NO ‘eplace
1) with wiring harness
T17, L07, and
xlween M02B (female)
M02B. 12) - T17 (female) (2)
* Turn starting
switch OFF.
MC-11 Related electrical circuit diagram Main

Transmission monitor
controller
Modulated clutch
controller
MOZB (040 16)
TXW02454
WA1 200-3 20-523

0
MC-12 Error code 1831 (Short circuit or disconnection in travel speed

f This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
C.WSB Remedy
4YE!
GotoA -
Is resistance
yRG between MO25
- Ifemale) (12) and -
-
T15 (female) (2)
normal?
yes between M02E between M02B (female)
*Max.lQ NC replace
(12) - T15 (female) (2)
*Disconnect Cf. T15,
? chassisgmund
L07, and M02B.
- Pnormal? *Turn starting switch Short circuit with chassis
lMin. 1 MR OFF. ground in wiring harness Repair or
- lDisconnectC5, NO betwesn M02B (female) replace
T15, L07, and (13) -T15 (female) (1)
I l
M02B.
Turn starting switch OFF.
between MOZB (female)
Repair or
NO replace
normal? (13)-T15 (female) (1)
1 M02B.
*5oo-wo0R *Turn starting
* Disconnect T15. switch OFF. Defective travel speed
Replace
sensor
l Turn starting NO
switch OFF.

Replace
n ES
5
figi%Jj- clutch controller
I
I
From A
-I
Is resistence
between MOZB
(female) (13) and
- l
Max. 1 V
Disconnect C5,
NO
between M02B (female)
(13) - T15 (female) (11
replace
1112) normal? T15, L07, and M02B. Short circuit of wiring

*Turn starting switch ON. harness between M02B
*Min. 1 MR Repair or
(female) (13) - T15 (female)
* Disconnect C5, nIO 11) with wiring harness
replace
T15, L07, and between MO25 (female)
M02B. (141- T15 (female) (2)
*Turn starting
switch OFF.
20-524 WA1 200-3

0
RT2(HD-850861 T15 IDTZ) SDeed S~"SO~
Transmission I II
TXW02453
WA1 200-3 20-525

0
MC-13 Error code [841 (Short circuit, disconnection, or short circuit

with power source in neutral cut solenoid system) is displayed
Cause Remedy
OYE!
GotoA -
[Is resistance lr-
Yf between HRl (female) (2) - replace
chassis ground
2
Is rssistance Short circuit with chassis
YES between MO1 ground in wiring harness Repair or
- (female) (21) and - *Turn starting NO between MO1 (female) (21) replace
HRl (female) (11 mitch OFF. - HRl (female) (1)
1
- normal? * Disconnect Mol.
Is resistancebetween ’ Disconnection or defective
*Max.lR HRI, and HR2.
HRl (male) (1) and contact in wiring harness Repair or
(2) and between (1). - ‘Turn atarting between MO1 (female) (21) replace
(2) and chassis switch OFF. 10
- HRl (female) (1)
mound normal? * Disconnect MO1
+ Between (1) - (2): and HRl.
5-15Q I Defective neutral cut
Replace
* Between (1). (2) - NO solenoid
chassis ground:
Min. 1 MR
*Turn starring switch OFF.
* Disconnect HRl. Replace
Is v&age between clutch controller
MO1 (female) (21)
From A
-I and chassis ground l-l
normal?
I source in wiring harness Repair or
- Max. 1V NO between MO1 (female) replace
* Turn starting (21) - HRl (female) (1)
switch OFF.
* Disconnect Mol. HRl,
and HR2.
*Turn starting switch ON.
JR3 (DTl)
Modulated clutch
controller
Nuetral cut
solenoid
HRZ (DTZ)
R2D TXW02477
20-526 WAIZOQ-3 .
0
MC-14 Error code 1851 (Short circuit, disconnection, or short circuit

with power source in modulated clutch ECMV solenoid system)
is displayed
* Before carrying out troubleshooting, check that all the related
CaUSe
connectors are properly inserted.
* Always connect any disconnected connectors before going
on to the next step.
4YEI -
II- GotoA
resistance
Is
YES_ between MO1
3 (female) (7) and T9 Disconnection or defective
PIs resistance (female1(1) normal? contact in wiring harness Repair or
yes between MO1 *Max.lR between MO1 (female) (7) - replace
N(
- (female) (16) and - *TurnStarting T9 (female) (1)
2 chassis ground switch OFF.
_ normal) *Disconnect MO1 and T9. Short circuit with chassis
+ Min. 1 MD ground in wiring harness Repair or
Turn starting between MO1 (female) (16) replace
Ifemale) (16) and T9 - l NO
switch OFF. -T9 (female) (2)
(female) (2) normal?
- l Disconnect MO1
*Max. 1 R and T9. contact in wiring harness
T9 (male)(1) and (2) Repair or
and between (1). (2) * Turn starting between MO1 (female) (16) replace
switch OFF. NO
- T9 (female) (2)
* Disconnect MO1
. Between (1) - (2): 1 and T9.
I Defective modulated
5-15s2 Replace
* Between (1). (2) - NO clutch ECMV solenoid
chassis ground:
Min. 1 MR
*Turn ataning switch OFF. 1 YEZ Defective modulated
* Disconnect T9. Replace
Is voltage between clutch controller
YES MO1 (female) (7)
6 and chassisground Short circuit with power
- normal? source in wiring harness
between MO1 (female) (7)
YES batween MOT *Max.lV NC replace
*Turn starting - T9 (female) (1)
(female) I71and (16)
5 normal? switch OFF. Short circuit of wiring
_ *DiaconnactMO1 and T9. harness between MO1
batween MO1 l5-15n *Turn starting switch ON. (female) (7) - T9 (female) Repair or
From A (female) (7) and * Turn starting NO (1) with wiring harness peplace
switch OFF. between MO1 (female) (16)
* Disconnect MOZ. - T9 (female) (2)
* Min. 1 MD Short circuit with chassis Repair or
*Turn starting ground in wiring harness
NO .eplace
switch OFF. between MO1 (female) (7)
* Disconnect MO1
- T9 (female) (1)
and T9.
Hodulated clutch
CO” solenoid
TXW02478
WA1 200-3 20-527

0
MC-15 Shot-t circuit in boom RAISE/LOWER or bucket TILT/DUMP

pressure switch system
Cause Remedy
4YE
Is resistance
r GotoA -
YES between M02A
- (female) (81 and -
3 Short circuit with chassis
- chassis ground
Is resistence “O”Tlel? ground in wiring harness Repair or
L
YES between MO2A *Min. 1 MR between M02A (female) (8) replace
- (femele) (7) end- .T;;;.mning
&t,.hN’ - HA13 (female) (1)
2 chassis ground
PIs resistance - normal? *Disconnect MO24 Short circuit with chassis
YES between MOZA * Min. 1 MD HR13, and i27. ground in wiring harness Repair or
(female) (6) and - Turn starting
l
NO between M02A (female) (7) replace
, chassis ground switch OFF. - HR12 (female) (1)
I Disconnect MOZA,
I
normal? l
l Min. 1 MD HR12. and L27.
between M02A ground in wiring harness Repair or
(female) (5) and *Turn starting
NO beween M02A (female) (6) replace
switch OFF.
- HR3 (female) (1)
* Disconnect MOZA
and HR3. Short circuit with chassis
* Min. 1 MD
I ground in wiring harness Repair or
*Turn starting
NO between M02A (female) (5) replace
awitch OFF.
- HR4 (female) (1)
* Disconnect MOZA
and HR4.
Replace
Is resistance II clutch controller
between M02A Short circuit of wiring
From A -
(female) (5). 16).(71, - harness between M02A
and (8) normal? (female) (5) - HR4 (female) Repair or
(1). between MOZA(female)
* Min. 1 MR NO replace
(6) - HR3 (female) (1).
*Turn atatting between MONA(female) (7) -
switch OFF. HR12 (female) (1). and
* Disconnect M02A. U7, HR3, bsrween MONA(female) (8) -
HR4, HR12, and HR13 HR13 (female) (1) with each
other

RAS (DTI) RAtO (DTHD4)
2L 31000 (
Modulated clutch
controller
37
Bucket dump
switch
Wor
con Bucket tilt
switch
Boom raise
switch
TXW0247 1
20-528 WA1 ZOO-3

0
TROUBLESHOOTING MC16, MC-17
MC-16 Disconnection in F ECMV fill switch system
Cause Remedy

Replace
YES between M02A 13)
- and Tl4 (female) - Disconnection or
1
r - (1) normal? defective contact in
Is voltage Repair or
wiring harness between
between T14 (1) . Max. 1 R NO replace
M02A (female) (3) - T14
and chassis - Disconnect C3B. (female) (1)
ground normal? M02A. and T14.
* * Turn starting switch OFF.
*20-30V Defective F ECMV fill
Turn starting
l NO switch
switch OFF.
* Disconnect T14.
. Start engine.
* Turn transmission cut-off
switch OFF (Put out lamp)
* Turn parking brake switch
OFF.
* Press brake.
MC-17 Disconnection in R ECMV fill switch system
Remedy

Replace
YES between M02A (4)
Disconnection or
1 -
and T12 (female) -
- (I) normal? defective contact in
Is voltage Repair or
between T12 (1) *Max. 1 R NO replace
M02A (female) (4) - T14
and chassis * Disconnect C3B, (female) (1)
ground normal? M02A. and T12.
p*20-30V . Turn starting switch OFF.
* Turn starting NO switch
switch OFF.
* Disconnect T12.
* Start engine.
l Turn transmission cut-off
switch OFF (Put out lamp)
* Turn parking brake switch
OFF.
l Press brake.
MC16, MC-17 Related electrical circuit diagram
Transmission
_ R fill switch
TXW0’2456
WA1 200-3 20-529

0
TROUBLESHOOTING MC18
MC-18 Disconnection in RPM-SET IDLE-UP/RESUME IDLE-DOWN

switch system
t Always connect any disconnected connectors before going on to the next step.
Remedy
4YE! Defective modulated

Replace
YES between LllO
3 Disconnection in wiring
- chassis ground
Is resistsnce IlOrlllsl? harness between LllO Repair or
YES between M02A (female) (2) -chassis replace
NC
- (female) (16) and - * Max. ’ R
l Turn starting ground
2 LllO (female) (3)
mrma,‘, switch OFF. Disconnection in wiring
Max. 1 R l Disconnect LllO. harness between MOZA Repair or
n ; between M02A l
- (female) (15) and - *Turn starting NO (female) (16) - LllO replace

LllO (female) 11) switch OFF. (female) (3)
1
n0rHlal? * Disconnect MOZA Disconnection in wiring
- Max. 1 R and L110. harness between MOZA Repair or
(male) (11,(2) and l Turn starting
NO (female) (15) - LllO replace
(3) as shown in switch OFF.
(female) (1)
l Disconnect MOZA
- Disconnect Lll 0. and LllO.
Defective RPM-SET IDLE
* Turn starting -UP/RESUME IDLE- IReplace
switch OFF. DOWN switch
Table 1
RPM-SET IDLE- RESUMEJDLE-
UP switch ON DOWN switch ON
Between LllO (female) (1) - (2) Min. 1 MR Max. 1 R
Between LllO (female) (3) - (2) Max. 1 R Min. 1 MR
electrical circuit diagram RPM-SET

MC-18 Related
IDLE-UP/RESUME
IDLE-DOWN switch
Modulated clutch
.
LR7 (DT~) RA5 (DTI) RAI 0 (DTHD4) Battery
4-j 2 000
TXW02473
20-530 WA1 200-3

0
MC-19 Abnormality in electronic governor voltage command system

3 YES source in wiring harness Repair or
between MO1 (female) replace
Is voltage between
(14) - 02 (female) (5)
YES MO1 (female) (14) _
2 and chassis
Is resistan ground nOrmal? Defective modulated
yes between MO1 Replace
* At low idling: NO clutch controller
chassis ground Max. 0.5 V
- normal? * At high idling: 3.8 - 5 V
Is resistance * Turn starting switch ON. ground in wiring harness Repair or
* Min. 1 MR
b&wean MO1 between MO1 (female)
NO replace
(female) (14) and (12 - ‘T”rn aaning (14) - Cl2 (female) (5)
(female) (5) normal? switch OFF.
c 1 l Disconnect MO1 Disconnection or
* Max. 1 R
* Turn starting
I and Q2. defective contact in Repair or
wiring harness between replace
switch OFF. NO
MO1 (female) (14) - 02
* Disconnect MO1 (female) (5)
and Q2.
Modulated clutch
controller OUANTUM
NO1 (NIC21) LRI (HD-95066)
)ELc.0”.*01 W1..1 1355( I
TXW02479
WA1 200-3 20-531

0
MC-21 Abnormality in modulated clutch ECMV fill switch system

;I’“” ) Defective modulated

resistance Replace
Is clutch controller
yes between M02A
- T10 (female) (11
Is resistance normal? ground in wiring harness Repair or
YES between MOZA between M02A (female) replace
l Min. 1 MR NO
*Turn starting (12) -TlO (female) (1)
1 T10 tfemale) (1)
_ normal? switch OFF. Disconnection in wiring
Is resistance
*Max. 1 R * Disconnect M02A and TlO. harness between M02A Repair or
between TlO (male)
(1) and chassis
- * Turn starting NO (female) (12) -TlO replace
ground normal? switch OFF. (female) (1)
Disconnect MO24
l
* Turn starting and TlO.

I Defective modulated
switch OFF.- Replace
clutch ECMV fill switch
l Disconnect TlO. No
-Turn starting switch ON
(Do not start engine): Min. 1 MR
When engine speed is above
500 rpm: Max. 1 Q
Modulated clutch
rnntrnlIPr
__ . _ _ MOO/C f i II
RT2 (HD-85086) T10 (011) switch
11’1711 =FE
- __-
lLLl
TXWO2480
WA1 200-3 20-533

0
TROUBLESHOOTING MC22
MC-22 Abnormality in right brake pedal switch system
f Check that fuse l(9) is normal.

or Always connect any disconnected connectors before going on to the next step.
Cause Remedy

Replace
clutch controller
ISvoltage between
YES_ MOZA (female) (18) _
3 and chassisground
normal? Defective right brake
Is resistance Replace
ES between Llll * Press right brake NC pedal switch
(female) (1) and FS2 - pedal: Max. 1 V
2 (female) (8) normal? Release right brake
Is resistance _ pedal:17-30V. Disconnection or defactive
YES b-en M02A * Max. 1 R contact in wiring harness Repair or
- (female) (18) and - * Turn starting NO between Ll 11 (female) (1) - replace
chassis ground switch OFF. FS2 (female) (8)
1
- pnormal? * Disconnect Ll 11
Is r&Stance Short circuit with chassis
* Min. 1 MS1 and FSZ.
between M02A ground in wiring harness Repair or
(female) (18) and - *Turn star%J between MOZA (female) replace
switch OFF. NO
Ll 11 (female) (2) (18) - Llll (female) (2)
normal? * Disconnect M02A
* Max. 1 R
* Turn starting
I and Llll. Disconnection or dafactive
switch OFF. batwaen M02A (female) replace
118) - Llll (female) (2)
* Disconnect M02A
and Llll.
Modu lated clutch Fuse (I 1

cant
i TXW0248 I
20-534 WA1 200-3

0
MC-23 Abnormality in travel speed control ON/OFF switch system
* Before carrying out troubleshooting, check that all the related connectors are properly inset-ted.

Replace
I Isresistance lr- clutch controller
YES between L24
3 Disconnection in wiring
~- chassis ground
Is resistance normal? harness between I24 Repair or
YES between M02A (female) (4) -chassis
NC replace
- Ifemale) (201 and - ’ Maxe ’ *
* Turn starting ground
2 chassis ground
switch OFF. Short circuit with chassis
‘Isresiaance “crme’7 ~-
between M02A *Min. 1 MR * Disconnect K4. ground in wiring harness Repair or
YE
(femaleI (20) and - *Turn starting NO between M02A (female) replace
L24 (female) (3) switch OFF. (20) - L24 (female) (3)
1
normal?
I Is resistance 1 . * Disconnect M02A
*Max.lR Disconnection in wiring
and l.24.
*Turn starting harness between M02A Repair or
switch OFF. NO (female) (20) - I24 replace
. Disconnect M02A (female) (3)
* Travel speed and L24.
control ON/OFF Defective travel speed
Replace
switch 0 control ON/OFF switch
ON: Max. 1 R
OFF: Min. 1 MR
* Disconnect f-24.
l Turn starting switch OFF.
Modulated clutch
M02A (04020) . Speed set
switch
LR7 IDTI) RA5 (DTI 1 RAlO (DTHD4) Battery
WA1 200-3 20-535

0
MC-24 Abnormality in RPM-SET ON/OFF switch system
* Check that fuse I(101 is normal.

Cause Remedy
Defective modulated
YES
Is voltage between
YES (female) (3)
M02B Short circuit with chassis
2 and chassis ground, disconnection,

- ground normal? defective contact, or short
circuit with powersource in
between L108
yf * RPM-SET ON/OFF NO wiring harness between replace
(female) (2) and -
switch OFF: Max. 1 V M02B (female) (3) - L108
1 chassis ground
ON:l?-3av (female) (1)
normal?
. Turn starting switch OFF.
*Max. 1 R Repair or
(female1 (1) and (2)
*Turn starting NO replace
between L108 (female) (2) -
l Disconnect L108.
* RPM-SET ON/OFF
Defective RPM-SET
switch Replace
ON: Max. 1 R b ON/OFF switch
OFF: Min. 1 MS2

* Turn starting switch OFF.
* Disconnect L108.
Nodu RPM-SET
cant
20-536 WA1 200-3

0
MC-25 Abnormality in engine rotation output signal system
YES Defective modulated
d
1and chassis r
clutch controller
Shon circuit with chassis
ground, disconnection,
Replace
ground normal? defective contact, or short

circuit with power source in Repair or
* Start engine. NO wiring harness between
: Min. 0.5 V MO25 (female) (14) - L28
(female) (4) or V3A (female)
I (7)
Modulated clutch
con
VHMS controller
Work eauiDment
controller L28 1040 16)
TXW02484
WA1 200-3 20-537

0
MC-26 Abnormality in power supply system of modulated clutch

control system
* Check that fuse I (9) is normal.

I Cause Remedy
YES Defective modulated

1 I Replace
clutch controller
Disconnection or
defective contact in
wiring harness between Repair or
MO1 (female)(8),(17). replace
(18)-MO1 W,M02A(9)
Disconnection or
defective contact in Repair or
- Max. 1R NO wiring harness between replace
. Turn starting MO1 (female) (91, M02A
switch OFF. (female) (9) - chassis
- Disconnect MO1 ground
and M02A.
Modulated clutch
con
TXW02485
20-538 WA1 200-3

0
TROUBLESHOOTING MC-27, MC-28
MC-27 Abnormality in network system
* See “T-34 Network system” in troubleshooting for transmission controller system.
MC-28 Abnormality in Fl (Forward 1st gear) input signal system
* See “T-39 Fl (Forward 1st gear) signal system” in troubleshooting for transmission controller
system.
WA1 200-3 20-539

0
TROUBLESHOOTING OF
WORK EQUIPMENT CONTROLLER
(JOYSTICK STEERING CONTROL) SYSTEM
(J MODE)
Judgement table for work equipment control system related parts ............................................... .20-602
Operations of controller against abnormality and conditions of machine caused
by abnormality ................................................................................................................................. 20-604
Electrical circuit diagram for joystick steering system ..................................................................... .20-608
J- 1 Error code I551 (Abnormality in travel speed sensor system) is displayed.. ....................... 20-609
J- 2 Error code 1561 (Disconnection or short circuit with chassis ground in
caution buzzer relay system) is displayed ....................................................................... 20-610

steering lever angle sensor system) is displayed ........................................................... 20-611
J- 4 Error code [581 (Deviation of steering lever angle sensor and frame
angle sensor potentiometer signals ................................................................................. 20-612
J- 5 Error code I591 (Disconnection or short circuit with chassis ground in

frame angle sensor system) is displayed. ........................................................................ 20-613

steering lever lock pressure switch system) is displayed .............................................. 20-614
J- 7 Error code [621 (Disconnection or short circuit with chassis ground in

steering neutral interlock relay system) is displayed ..................................................... 20-615
J- 8 Error code [631 (Disconnection, short circuit with chassis ground, or

short circuit with power source in steering main pressure control EPC
solenoid system) is displayed ........................................................................................... 20-616
J- 9 Short circuit with chassis ground in travel speed sensor system ......................................... 20-617
J-10 Steering speeds in both directions are different ..... ................................................................ 20-618
J-l 1 Abnormality in console switch (adjustment of steering lever angle sensor

and frame angle sensor is impossible) ............................................................................ 20-619
J-12 Abnormality in power source and voltage ............................................................................... 20-620
WA1 200-3 20-60 1

0
JUDGEMENT TABLE FOR WORK EQUIPMENT CONTROL SYSTEM
TROUBLESHOOTING (JOYSTICK CONTROL SYSTEM) RELATED PARTS
JUDGEMENT TABLE FOR WORK EQUIPMENT CONTROL

SYSTEM (JOYSTICK CONTROL SYSTEM) RELATED PARTS
ielf-di, nosis disp Ialy (Display of abnormal-m
Location of failure
Failure mode
63
Refer to
1 1 Engine cannot be started G mode
2 1 Steering speed is heightened -
3 1 Steering speed ir_lowered _ H-6
4 Response of steering system is heightened

5 Response of steermg system IS lowered
6 Steering speeds in both directions are different
7 Steering speed is heightened even at high travel speed
8 ( Machine is steered suddenly after engine is started
9 1 Engine can be started while machine is steered
IO ) Caution buzzer does not sound or keeps sounding M-16
Diagnosis code when failure code is displayed
20-602 WA1 200-3

0
OPERATIONS OF CONTROLLER AGAINST ABNORMALllY AND

-ailure code Abnormal system Contents of abnormality
I) Defective travel speed sensor

chassis ground in wiring harness between work equipment
controller L28 (female) (5) - T15 (female) (1)
Abnormality in travel speed
55 between work equipment controller L28 (female) (12) -
sensor system
T15 (female) (2)
4) Defective joint connector (JLI9, JL6, JL12, JM4)
5) Defective work equipment controller
I) Defective caution buzzer relay

controller L28 (female) (13) - L65 (female) (I)
Disconnection or short
56 circuit with chassis ground
between caution buzzer relay L65 (female) (2) - chassis
in caution buzzer relay
ground
system
I) 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
circuit with chassis ground chassis ground in wiring harness between work equipment
57
in steering lever angle controller L27 (female) (20) - JS2 (female) (1)
sensor (potentiometer) 4) Defective work equipment controller
system
I) Improper installation (Misalignment) of steering lever angle

sensor
2) Defective steering lever angle sensor
3) Improper installation (Misalignment) of frame angle sensor
Deviation of steering lever 4) Defective frame angle sensor
angle sensor and frame 5) Disconnection, defective contact, or short circuit with
58 chassis ground in wiring harness between L27 (female)
angle sensor potentiometer
signals (20) - JS2 (female) (1)
chassis ground in wiring harness between L28 (female)
(I) - L30 (female) (1)
I) Improper installation (Misalignment) of frame angle sensor

2) Defective frame angle sensor
Disconnection or short chassis ground in wiring harness between L28 (female)
circuit with chassis ground (I) - L30 (female) (I)
59
in frame angle sensor 4) Defective work equipment controller
(potentiometer) system
20-604 WA1 200-3

0
Normal condition Operation of controller Condition of machine Diagnosi

1) Resistance between travel speed sensor T15 Turns off steering Steering speed is
(male) (1) - (2): 500 - 1,OOOQ main pressure control heightened even at
EPC solenoid. high travel speed.
J-l
11 Voltage between relay L65 (1) - chassis ground Does not operate at Caution buzzer does
when caution buzzer is turned on: 20 - 30 V all. not sound or keeps
2) Resistance between work equipment controller sounding.
L28 (15) - chassis ground, caution buzzer relay:
200 - 4OOQ
3) Resistance between work equipment controller J-2
L28 (female) (15) - L65 (female) (1): Max. 1 R
4) Resistance between caution buzzer relay L65
(female) (2) - chassis ground: Max. 1 R
I) Voltage between work equipment controller L27 1) Turns off steering Steering speeds in
(20) - (9): 0.5 - 4.5 v main pressure both directions are
!I Resistance between steering lever angle sensor control EPC different.
JS2 (male) (1) - (2): 0 - 5 kS2 solenoid output.
2) Controls steering
J-3
lever angle sensor
signal voltage as
input voltage.
I) Voltage between work equipment controller L27 Turns off steering Steering speeds in
(20) - (9): 0.5 - 4.5 v main pressure control both directions are
2) Voltage between work equipment controller L28 EPC solenoid output. different.
(1) - L27 (9): 0.5 - 4.5 V
3) Resistance between steering lever angle sensor
JS2 (male) (1) - (2): 0 - 5 kQ
4) Resistance between frame angle sensor L30 J-4
(male) (1) - (2): 0 - 5 kD
1) Voltage between work equipment controller L28 1) Turns off steering Steering speeds in
(1) - L27 (9): 0.5 - 4.5 V main pressure both directions are
2) Resistance between frame angle sensor L30 control EPC different.
(male) (1) - (2): 0 - 5 kQ solenoid output.
2) Controls frame
J-5
angle sensor signal
voltage as input
voltage.
WA1 200-3 20-605

‘0
‘ailure code Abnormal system Contents of abnormality
1) Defective steering lock pressure switch

controller L27 (female) (1) - STL (female) (1)
between work equipment controller L27 (female) (2) -
Disconnection or short chassis ground
circuit with chassis ground 4) Defective work equipment controller
61
in steering lever lock
pressure switch system
1) Defective steering neutral interlock relay

Disconnection or short
controller L26 (female) (21) - L127 (female) (1)
circuit with chassis ground
62 3) Disconnection or defective contact in wiring harness
in steering neutral interlock
between L127 (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
with chassis ground, or ground, short circuit, or short circuit with power source in
short circuit with power wiring harness between work equipment controller L26
63
source in steering main (female) (2) - L29 (female) (2)
pressure control EPC 3) Short circuit with chassis ground in wiring harness
solenoid system between work equipment controller L26 (female) (16) -
L29 (female) (1)
20-606 WA1 200-3

0
OPERATIONS OF CONTROLLER AGAINST ABNORMALlTY AND
Normal condition Operation of controller Condition of machine Diagnosis

Voltage between work equipment controller L27 Turns on caution (In case of
(female) (1) - chassis ground: buzzer. disconnection}
l When steering lock lever is in LOCK: 20 - 30 V I) Transmission is
. When steering lock lever is in FREE: Max. 1 V kept in N.
2) Steering system is
operable normally.
(In case of short circuit

with chassis ground) J-6
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 work equipment controller L26 Does not operate at 1) Engine can be
(female) (21) - chassis ground: all. started while
l When steering lock lever is in NEUTRAL: Max. 1 V machine is steered.
2) Machine is steered
suddenly after J-7
engine is started
3) Engine cannot be
started.
Current flowing between work equipment controller Turns off steering I) Response of
L26 (2) - (16): 600 & 80 mA main pressure control steering system is
(Check on CGC monitor.) EPC solenoid output. lowered.
2) Steering speed is
lowered.
3) Response of J-8
steering system is
heightened
4) Steering speed is
heightened
WA1 200-3 20-607

0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK STEERING

SYSTEM
ram anell Stssrino

mtentioaetsr lock switch
TXW02486
WA1 200-3
TROUBLESHOOTING J-l
J-1 Error code 1551 (Abnormality in travel speed sensor system) is

displayed
Cause Remedy
4YE Defective work

equipment controller

between L26 (female) (5) - Repair or
JL19 (3), (5) - JL6 (3). (6) - replace
FR2 (7) - T15 (female) (1)
1 ye Is resistance 1 *Turn starting switch ON. contact in wiring harness Repair or
I between T15 between L26 (female) (5) - replace
NO
JL19 (3). (5) - JL6 (3). (61-
FR2 (7) - T15 (female) (1)
* Disconnect L28
Replace
NO sensor
I Defective joint connector

* Max. 1R (JL19, JL6, JL12, JM4) Replace
NO
* Turn starting
switch OFF.
l Disconnect JL19,
JL6, JL12, and
JM4.
J-l Related electrical circuit diagram
TXW02453
WA1 200-3
TROUBLESHOOTING J-2
J-2 Error code [56] (Disconnection or short circuit with chassis ground
in caution buzzer relay system) is displayed
* When the joystick steering lever is not being used, leave it at the neutral position.
Replace
- l;;ha;ground 11 withc&as$sis;md&
Is rssistance Repair or
yes between I.28 replace
- (female) (15) and - * Mi”-’ MC2 NO L28 (female) (15) - L66
* Turn starting (female) (1)
2 L65 Ifemale) (1)
-
Is resistance normat? . D~~~~nor.U8 and L65. Disconnection or defective
YES between L65 - Max. 1 R contact in wiring harness Repair or
- (female) (2) and - -Turn starting NO between L28 (female) (15) - replace
chassis ground switch OFF. L65 (female) (1)
1
- - normal? - Disconnect L28
Is resistance Disconnection or defective
* Max. 1 R and L65.
between L65 contact in wiring harness Repair or
_ * Turn starting between L65 &male) f21-
(male) (1) and (2) NO replace
normal? * Disconnect LG.
1
.200-400R
‘Turn starting Lo 1r caution buzzer Rep,ace
switch OFF.
* Disconnect L65.
J-2 Related electrical circuit diagram
Fuse (II Caution

FS2 (S 12)(B1ue)
Power 0.75fY
source > I 91A 9
I
L65
OlOAV 0.5fB 6 Jovst ick
Work eauipment~
controller 124AB 0.5fL : taut ion
L28 (04016) OIOAU 0.5fB buzzer
252 0.5fY :
J/S caution relay 252 15 ” 5fY relay
m
m
TXW024137
20-610 WA1 200-3

0
TROUBLESHOOTING J-3
J-3 Error code [57] (Disconnection or short circuit with chassis ground
in steering lever angle sensor system) is displayed
Remedy
Replace or
adjust neutral
position
neutral position)
(female) (20) and contact,short circuitwith
chassis ground, or short circuti Repair or
with power source in wiring replace
harnessbetween L27 ffemale)
(20) - JS2 (female)(1)
left (0.5 - 4.5 V) Defective steerintg lever
(female) (10) and Replace
* Lean steering angle sensor
lever to right or
left (0.2 - 5 kc11
Replace
Work eauiwnent
Pontentionetcl
TXWO.2488
WA1 200-3 20-611

0
TROUBLESHOOTING J-5
J-5 Error code 1591 (Disconnection or short circuit with chassis around
in frame angle sensor system) is displayed
When the joystick steering lever is not being used, leave it at the neutral position and turn the
joystick steering selector switch ON.
CaUSe Remedy
Improper installation of
Replace or
frame angle sensor
adjust neutral
(Deviation of neutral
position
position)
contact short circuit with
chassis ground, or short circuit Repair or
with power source in wiring replace
harness between LZ8 (female)
(1) - WO (female) 11)
Defective frame angle
Replace
l Change frame NO sensor
I J angle
-4.9-5.1 v
(0.2 - 5 kQ)
*Turn starting switch
Defective work
ON. Replace
IO equipment controller
Work eauiDment
Pontentioncter
rotentiometer
Txw024aa
WA1 200-3 20-613

0
TROUBLESHOOTING J-6
J-6 Error code [611 (Disconnection or short circuit with chassis ground
in steering lever lock pressure switch system) is displayed
f This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
* Before carrying out troubleshooting, check that ail the related connectors are properly inserted.
cause Remedy
4YE: Defective work

Replace
, fZ!Z&-H
YES between STL (1) between L27 (female) (2) - replace
.dl”““““h chassis ground
L
ground normal? Disconnection or defective
Is voltage contact in wiring harness Repair or
lo-2v
YES between L27 (1) between L27 (female) (1) - replace
- . Turn starting
and chassis STL (female) (1)
switch OFF.
_1 ground normal?
. Disconnect L27 Short circuit with chassis
~20-3ov and STL Repair or
_ lTurn starting between L27 (female) (1) replace
(male) (1) and (2) switch ON. NO
- STL (female) (1)
lTurn steering lock
* Max. 1 R pressure switch ON.
Defective steering lock
* Disconnect STL Replace
NO pressure switch
Start engine.
l
When steering
lock lever is in FREE:
Max. 1 R
When steering
lock lever is in LOCK:
Min. 1 MR
Work eou iDment

Steering lock
control ler
STL CDT21 switch
ry
WA1 200-3
TROUBLESHOOTING J-7
J-7 Error code 1621 (Disconnection or short circuit with chassis ground
in steering neutral interlock relay system) is displayed
j, This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
F
Cause Remedy
YES I Defective steering neutral

Replace
relay
1 4YEs Defective work

Is resistance equipment controller Replace
If L127 relay is yes between L127
replaced, is - (female) (2) and -
- chassis ground
system normal? contact in wiring harness Repair or
Is volt& between Il0rHIel7 i
between L127 (female) 12) - replace
* Replace L127 YES ~261female)
~1) _ - Max. 1 R NO
chassis ground
and chassis ground
with normal * Turn starting
2 normal?
relay. I switch OFF. Short circuit with chassis
Is resistance
between l.26 (21)
- Max. 1V * Disconnect L127. ground in wiring harness Repair or
- * Turn starting NO between l26 (female) replace
NO and L127 (female)
switch OFF. (21) - L127 (female) (1)
(1) normal?
* Disconnect l26 Disconnection or
l Max. 1 R and L127. defective contact in Repair or
. Turn starting
NO wiring harness between replace
switch OFF.
L26 (female) (21) - L127
* Disconnect U6
(female) (1)
and L127.
Work equipment
controller L26 (MIC21) L127
573 0.5fY
J/S neutral lock relay 573 21 ‘. 5fY
OlOBT 0.5fB ; Steer ins
m
nr) 3 neutral
< 5
6 relay
0
TXW02490
WA 1200-3 20-615
0
TROUBLESHOOTING J-8
J-8 Error code [631 (Disconnection, short circuit with chassis ground,
or short circuit with power source in steering main pressure
control EPC solenoid system) is displayed
CalIS Remedy
4YE! 5
GotoA.
Is resistance
YES between L26 Short circuit of wiring
3 (female) (6) and harness betwean I_26
pIs resistance (16) normal? (female) (6) - L2S (female) Repair or
y~5 betweenl.26 (2) with wiring harness replace
- (female) (16) and - * Min* ’ MR NC1 between U6 (female) (16)
i! chassis gmund * Turn starting and L29 (female) (1)
1Is resistance - normal? switch OFF.
* Min. 1 MD * Disconnect L26. Repair or
lfamalelf6l and - * Turn starting NO between L26 (female) (16) - replace
I
switch OFF- US (female) (1)
* Disconnect I_26
* Min. 1 MQ and l29.
*Turn starting
NO between L26 (female) (6) - replace
switch OFF.
US (female) (2)
. Disconnect l-26
*Turn starting and US. Defective steering main
switch OFF. pressure control EPC Replace
* Replace with solenoid
other same EPC
solenoid.
*Turn starting 5 YES Defective work
switch ON. is resistance Replace
between L26
From A - (female) (6) and -
chassisground Short circuit with power
normal? source in wiring harness rlepair or
* Max. 1 V NO between l.26 (female) (6) aplace
. Disconnect L26 - L29 (female) (2)
and l-29.
*Turn starting
switch ON.
Work equiDment Joust ick

controller EPC
solenoid
L29 (DT2)
111901
2 I191 I
TJW02491
20-6 16 WA1 200-3

0
TROUBLESHOOTING J-9
J-9 Short circuit with chassis ground in travel speed sensor system
Cause Remedy

2 YES
sensor Replace
Is resistance
YES between U8 Shon circuitof wiring harness
(female) (12) and - between L28 ifemale) (5) -
1 -
JL19 13).(5) - JL6 (3) , (6) -
Is resistance- (5) normal? Repair or
j FR2 (7)-T15 (female) (1) with
between L28 NO wimg harnessbetween L28 replace
* Max. 1 R
(female) (51 and - (female) (12) - L19 (11,(6) -
chassisground * Turn starting
JL6 (1). (81- JL12 (3). (1) - FR2
normal? switch OFF.
(8) -T15 (female) (2)
. Disconnect L28 and T15.
. Min 1 R Short circuit with chassis
* Turn starting NO Repair or
switch OFF. between L28 (female) (5) - reolace
* Disconnect L28 L19 (3). (5) - JL6 (31, (6) - FR2
and 115. (7) - T15 (female) (11
Transmission
TXW02453
WA1 200-3 20-617

TROUBLESHOOTING J-IO
J-IO Steering speeds in both directions are different

* If an error code is displayed, check the parts corresponding to it.
Cause
Deviation of steering
lever angle sensor or Repair or
frame angle sensor replace
potentiometer
20-618 WA1 200-3

0
TROUBLESHOOTING J-l 1
J-II Abnormality in console switch (adjustment of steering lever

angle sensor and frame angle sensor is impossible)
Remedy
4y~S Defective work

equipment controller Replace
Is voltage between
YES L27 (female) (14)
I and chassis ground
- normal?
Is resistance source in wiring harness Repair or
YES batweenC3A . Max. 1 V ND between L27 (female) (14) - replace
(female) 16) and JS3 -Turn starting switch JS4 (male) (1)
2 (female) (1) normal? OFF.
Is resistance - DisconnectL27 and JS4. Disconnection or defective
YES betwaen L27 * Max. 1 R -Turn starting switch ON contact in wiring harness Repair or
- (female) 114)and - * Turn starting NO between C3A (female) (6) - replace
JS4 (male) (1) switch OFF. JS3 (female) (1)
1
- - normal? * Disconnect C3A
Is resistance 1 Disconnection or defective
between console *Max. 1 R and JS3. contact in wiring harness
switchJS3 (male) - * Turn starting Replace
between L27 (female) (14) -
switch OFF. NO
(1) and JS4 (female) JS4 (male) (1)
_(l) normal? . * Disconnect I_27
* When left armrest is and JS4.
at rearmost position , Defective console switch
kwitch is ON): NO
Max. 1 R
. When left armrest is not at rearmost
position kwitch is OFF): Min. 1 MR
. DisconnectJLlS, JL6, JL12, and JM4.
J-l 1 Related electrical circuit diagram
Work equipment
controller L27 (04020)
Cons0 I
Transmission h joystick
steering controller
WA1 200-3 20-619

0
TROUBLESHOOTING J-12
J-12 Abnormality in power source and voltage
* Check that fuse I (10) is normal.
J, When the joystick steering lever is not being used, leave it at the neutral position.
j: Always connect any disconnected connectors before going on to the next step.
I Cause Remedy
1 YES Defective work

Replace
Is voltage between
L26 (female) (81, Disconnection or
(18) and chassis
ground normal? Repair or
l20-3ov NO L26 (female) (8). (181, (17) repiace
l Turn starting -FS2(10)-fuseI
switch ON.
Work eau i Pment

controller Fuse ( I )
LLO \MILZII FS2 (Sl 2 Blue 1
1.25fW
\ Power INPUTt 1.25fW 11. 25fW 101 58AI
/ Power INPUTS t 2.1
1
TJW02493
20-620 WA1 200-3
0
TROUBLESHOOTING OF WORK EQUIPMENT
CONTROLLER (REMOTE BOOM POSITIONER
CONTROL) SYSTEM
(W MODE)
Judgement table for work equipment controller related parts ......................................................... 20-652
Action taken by controller when abnormality occurs and problems on machine.. ....................... 20-654
Electrical circuit diagram for work equipment controller system ..................................................... 20-656
w- 1 Failure code [431 (Shot-t circuit, disconnection in damping solenoid) is displayed.. ........ 20-658
w- 2 Failure code 1441 (Short circuit in power source at hot end of damping
solenoid) is displayed ......................................................................................................... 20-659
w- 3 Failure code [451 (Short circuit in power source at return end of damping
solenoid) is displayed ......................................................................................................... 20-659
w- 4 Failure code [491 (Short circuit, disconnection in boom lever kick-out relay
w- 5 Failure code 1511 (Disconnection in boom RAISE, LOWER detection pressure
switch) is displayed ............................................................................................................ 20-661
W- 6 Failure code 1521 (Short circuit, disconneciton in boom angle potentiometer
w- 7 Sensor cannot be adjusted ...................................................................................................... 20-663
W- 8 Abnormality in engine speed signal system .......................................................................... 20-663
w- 9 Remote positioner RAISE, LOWER LEDs do not light up ..................................................... 20-664
W-IO Remote positioner RAISE stop lamp (CGC monitor) does not flash
(for 2.5 seconds) ................................................................................................................. 20-665
w-11 Remote positioner LOWER stop lamp KGC monitor) does not flash
(for 2.5 seconds) ................................................................................................................. 20-665
w-12 Buzzer for switch operation does not sound ......................................................................... 20-666
w-13 Shock when stopping boom (abnormality in boom lever detent switch) ......................... 20-667
w-14 Short circuit in boom RAISE, LOWER pressure detection switch.. ...................................... 20-668
WA1 200-3 20-65 1

0
JUDGEMENT ABLE FOR WORK EQUIPMENT CONTROLLER (REMOTE
TROUBLESHOOTING BOOM POSITIONER CONTROLLER SYSTEM) RELATED PARTS
JUDGEMENT TABLE FOR WORK EQUIPMENT CONTROLLER

(REMOTE BOOM POSITIONER CONTROLLER SYSTEM)
RELATED PARTS
Location of failure
Failure mode
20-652 WA1 200-3

0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

OCCURS AND PROBLEMS ON MACHINE
IEMOTE B( DM POSITIONER CONTROL ER SYSTEM
-ailure code Abnormal system Nature of abnormality
Defective damping solenoid

:; Short circuit in wiring harness between work equipment
controller L26 (female) (51, (15) and HRS (female) (11, (2)
3) Short circuit with ground, defective contact, or
disconnection in wiring harness between work equipment
43 Damping solenoid system
controller L26 (female) (5) - HRS (1)
4) Short circuit with ground, defective contact, or
disconnection in wiring harness between work equipment
controller L26 (female) (15) - HRS (2)
I) Defective damping solenoid

Short circuit with power 2) Short circuit with power source in wiring harness between
44 source in damping solenoid work equipment controller L26 (female) (5) - HRS (1)
system 3) Defective work equipment controller
1) Defective damping solenoid

Short circuit with power 2) Short circuit with power source in wiring harness between
45 source at return end of work equipment controller L26 (female) (15) - HRS (2)
damping solenoid system 3) Defective work equipment controller
1) Defective boom relay

2) Short circuit with power source, short circuit with ground,
defective contact, or disconnection in wiring harness
49 Boom kickout relay system
boom relay L45 (1)
3) Defective contact or disconnection in wiring harness
between boom relay L45 (female) (2) - chassis ground
Defective boom RAISE/LOWER switch

:; Defective contact or disconnection in wiring harness
between work equipment controller L27 (female) (5) - HR13
(female) (1)
Boom RAISE/LOWER switch between HR13 (female) (2) - chassis ground
51
system 4) Defective contact or disconnection in wiring harness
between work equipment controller L27 (female) (6) - HR12
(female) (1)
between HR12 (female) (2) and chassis ground
Defective boom angle potentiometer

:; Short circuit with power source, short circuit with ground,
F04 (female) (1)
31 Short circuit with power source, short circuit with ground,
Boom angle potentiometer defective contact, or disconnection in wiring harness
52 between work equipment controller L27 (female) (9) - F04
system
(female) (2)
4) Short circuit with power source, short circuit with ground,
F04 (female) (3)
20-654 WA1 ZOO-3

0
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when Rr$l&;$“n’,a$~;;rs ,‘,r;EgF

(voltage, current, resistance) abnormality is detected there is abnormality code
1) Resistance between work equipment controller Damping solenoid There is shock when
L26 (female) (5) and (15): 10 - 20 12 output: OFF stopping boom in
2) Voltage between work equipment controller L26 remote positioner
(female) (5). (15) and chassis ground: mode
Less than 1 V
3) Resistance of wiring harness between work W-l
equipment controller L26 (female) (51, (15) - HR9
(11, (2): Less than 1 Q
Voltage between work equipment controller L26 Damping solenoid There is shock when
(female) (5) and chassis ground: Less than 1 V output: OFF stopping boom in
remote positioner w-2
mode
Voltage between work equipment controller L26 Damping solenoid There is shock when
(female) (15) and chassis ground: Less than 1 V output: OFF stopping boom in
remote positioner w-3
mode
1) Resistance of relay coil: 200 - 400 R Boom lever kickout Boom does not stop at
2) Resistance of wiring harness between work output: OFF desired position in
equipment controller L26 (female) (20) - boom remote positioner
relay L45 (1): Less than 1 R mode (boom lever
3) Resistance of wiring harness between boom relay detent is not canceled) w-4
L45 (female) (2) and chassis ground:
Less than 1 R
1) When boom lever is at neutral, resistance Damping solenoid There is shock when
becomes as follows. output: OFF stopping boom in
2) Resistance between work equipment controller remote positioner
L26 (female) (5) and chassis ground: mode
Less than 1 R
and resistance between work equipment
w-5
controller L26 (female) (3) and chassis ground:
Less than 1 R
Voltage between work equipment controller L26 Remote positioner Remote positioner
(female) (19) and L27 (9): 0.3 - 4.8 V function: OFF function does not
work
W-6
WA1 200-3 20-655

0
ELECTRICAL CIRCUIT DIAGRAM
TROUBLESHOOTING FOR WORK EQUIPMENT CONTROLLER SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT

CONTROLLER SYSTEM
Fuse (I)
FS2 (S12Xeluel
Fuse M
20-656 WA1 200-3

0
ELECTRICAL CIRCUIT DIAGRAM
TROUBLESHOOTING FOR WORK EQUIPMENT CONTROLLER SYSTEM
Positioner
raise
indicator
(Green1
Boom kick out

solenoid
Bucket
positioner
solenoid
FLI (HD-26086)
Bucket
sositioner
Boom angle
sensor
FR2 (HD-46082) RT2 (HD-85086) T15 (DT2)
Boom lever
I detent switch
Boom lower
switch
R20
I// Boom dump
solenoid
Boom dumv
solenoid
TXW02495
WA1 200-3 20-657

0
TROUBLESHOOTING W-l
W-l Failure code M31 (Short circuit, disconnection in damping

solenoid) is displayed
f Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or
socket adapter).
Cause Remedy
YES Defective work

Replace
2 equipment controller
Is resistance
YE between L26 Short circuit with chassis
(female) (5) and 3 YES ground in wiring harness
Repair or
chassis normal? between I26 (female) (5),
_ Is resistance replace
between HR9 (15) - HR9 (female) (l),
1 l Disconnect L26.
NE (male) (1) and (2)
* Min. 1 MS2
I Is resistance I chassis normal?
Defective damping
I
between L26
* Disconnect HR9. NO solenoid wiring harness
(female) (5) and
(15) normal? t l Min. 1 MR Short circuit, defective
contact. or disconnection
* Disconnect L26. 4 YES in wiring harness Repair or
l15-2552
Is resistance between L26 (female) (5). replace
between HR9 (15) - HR9 (female) (1).
N (female) (1) and (2)
(2) normal?
Defective damping
* Disconnect HR9. solenoid
.15-25R
W-l Related electrical circuit diagram
Work equipment
cant rol ler
DUMP ins
solenoid
TJW02496
20-658 WA1 200-3

0
TROUBLESHOOTING w-2, w-3
W-2 Failure code [441 (Short circuit in power source at hot end of
damping solenoid) is displayed
Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or
socket adapter).
Cause Remedy
Defective work
Replace
Is voltage between equipment controller
L26 (female) (5)
* Disconnect L26. NO between L26 (female) (5) replace
l Turn starting and HR9 (female) (1)
switch ON.
- Max. 1 V
w-3 Failure code 1451(Short circuit in power source at return end of

damping solenoid) is displayed
CaUSe Remedy
Defective work
Replace
L26 (female) (15)
l Disconnect U6.
1
NO
between L26 (female)
Repair or
replace
* Turn starting (15) and HRg (female) (2)
switch ON.
- Max. 7 V
W-2, 3 Related electrical circuit diagram
Work equipment
cant
Dumping
solenoid
TJW02496
WA1 200-3 20-659

0
TROUBLESHOOTING w-4
W-4 Failure code [491 (Short circuit, disconnection in boom lever kick-
out relay system) is displayed
* Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or
socket adapter).
Cause Remedy
Defective work
Replace
harness between U6 Repair or
(female) (20) - L45’
(female) (1)

* Disconnea L46. NO between L26 (female) replace
- Min. 1 Mf2 (20) - L45 (female) (1)
W-4 Related electrical circuit diagram
Work equipment
coni Booim
kit k-out
SOI enoid
FS2 (Sl2 Blue 1

10 58A (
R20 TJW02497
20-660 WA 1200-3
0
TROUBLESHOOTlNG w-5
W-5 Failure code [511 (Disconnection in boom RAISE, LOWER

detection pressure switch) is displayed
* Always turn the starting OFF before disconnecting any connector to connect the T-adapter (Or
socket adapter).
Cause Remedy
YES Defective work

Replace
3 equipment controller
Is resistance
Defective contact or
YI between L27
disconnection in wiring
(female) (6) and - 4YE
(9) normal? is resistance (female) (6). (9) - HR12 replace
- Max. 1 R between HR12 (female) (1). (2)
2
- Turn starting NO (male) (1) and (2) -
Is resistance I nomtal?
YI switch OFF. Defective boom LOWER
Replace
* Disconnect U7. .Max.lR switch
* Boom lever: * Turn startingswitch0%
Neutral. * DisconnectHR12. Defective contact or
* Boom lever: Neutral.
- Max. 1R
5 YES
* Turn starting harness between I27 Repair or
switch OFF. (female) (5). (9) - HR13 replace
* Disconnect L27. (female) (lb, (2)
- Boom lever: n PIP
Neutral. Defective boom RAISE
switch Replace
- Max. 152 NO
- Max. 1D
-Turn starting * Turn starting switch OFF. Xsconnection or
switch OFF. l Disconnect HR13. fefective contact in
- Disconnect HR12, l Boom lever: Neutral. wiring harness between Repair or
HR13. iR12 (female) (2). HR13 replace
3
female) (2) - JR15 (5).
3). 16) -chassis grqund,
x defective joint
connector JR15
Work eauipment
pressure switch
Pressure switch
WA1 ZOO-3 20-66 1

0
TROUBLESHOOTING W-6
W-6 Failure code 1521(Short circuit, disconneciton in boom angle

potentiometer system) is displayed
socket adapter).
F
Remedy
YES Defective work

Replace
1 Short circuitwith power

Is voltage 3 YES between L27 (female)(9) -
Repair or
between L27 FO4(female) (2). L27 (female)
Is resistance (10) - F04 (female) (3). L27 replace
(female) (9) and YES between F04 (female) (19) - FO4(female) (1
(19) normal? - (female) (19). (9). -
2 Shcrf circuit in wiring hames!
_ (10) -chassis between L27 (female) (9) -
- 0.3 - 4.8 V
Is resistance nl%Tnal? F04 (female) (2) and between
* Turn starting Replace
switch ON.
between F04 * Min. 1 MR NO L27 (female) (10) - FO4
~6 (female) (1) and (2). - -Turn starting (female) (3). between L27
(2) and (3) normal? (female) (19) - F04 (female) I1
switch OFF.
- Between (1) and * Disconnect L27 and F04. Defective boom angle Repair or
(2): 0.2 - 5 kR NO potentiometer
l Between (2) and
(3):4-5M
* Disconnect F04.
Work eauipment
cant
JL24 (DT2)
Boom angle
Potentiometer
LR~ (DTI) RA5 (DTI) RAtO (DTHD4) Battery
TJWO2499
20-662 WA1 200-3

0
TROUBLESHOOTING w-7, W-8
W-7 Sensor cannot be adjusted

* For details of the method of operation, see STRUCTURE AND FUNCTION.
socket adapter).
* If the set switch display flashes in the set mode, check the installation of the boom angle
potentiometer.
Remote positioner
RAISE, LOWER
1
Is remote
ZYES
L Defective work
Replace
_ positioner set _
LEDS does not signal system
light up of flash Defective remote
normal?
positioner RAISEROWER RezaFeor
* Turn remote l See trouble- NO set switch or LED s&em
’I
positioner shooting W-10.
RAISEAOWER
set switch ON.
W-8 Abnormality in engine speed signal system
socket adapter).
Cause Remedy

Is resistanceberween euqipment controller Replace
MS I28 (female)(41and
- chassisnormal when - Defective contact or
1
_ MO28Wemale)(141is disconnection in wiring
Is resistance grounded to chassis? , harness between US Repair or
between L28 _ l DisconnectL28. NO (female) (4) and M02B replace
(female) (4) and * Max. 1 R (female) (14)
chassis normal? Short circuit with chassis
- Disconnect L28 ground in wiring harness Repair or
and MOZB. NO between L28 (female) (4) replace
* Min. 1 MD and MOZB (female) (14)
Work equipment Modulated

. . .
con
WA1 200-3 20-663

0
TROUBLESHOOTING w-9
W-9 Remote positioner RAISE, LOWER LEDs do not light up

* Check that CGC works properly.
Jc Always connect any disconnected connectors before going on to the next step.
socket).
* If fuse I-(11) is broken, check the wiring harness between the fuse and L136 (female) (1) and L136
(female) (I) for short circuit with chassis ground.
Defective work
Replace
euqipment controller
D&connectionor defective
contactin wiring harness
betweenI26 (female)(61- Repair or
Ll37 (male) (1). or betweenL28 recdace
(female)(14) - L13S(male)(1)
Short circuitwith chassis
,____.___.. groundin wiring harness
male) (1). - Disconnect L28, betweenU8 (female)(8) - Repair or
nale) (1) L137, and L139. NO Ll37 (male) (1). or betweenI26
1and chassis ground H * Min. 1 MR (female)(141-LES (male)(1)
normal7 II I Diinnection, defective
-2O-30V contact.or short circuitwith Repair or
* ~isxnn L136 NO chassisground in wiring
harnessbeween fuse I (11) -
- Turn starting L136(female) (1). L136
switch ON. (female)(1)
Work esuiDment Positioner

controller RAISE
indicator
(a reen)
Positioner
LOWER
indicator
(green)
TJW02501
20-664 WA1 200-3

0
TROUBLESHOOTING w-10, w-11
W-IO Remote positioner RAISE stop lamp (CGC monitor) does not
flash (for 2.5 seconds)
Cause Remedy
Defective CGC Repair or

replace
W-II Remote positioner LOWER stop lamp (CGC monitor) does not
flash (for 2.5 seconds)
Cause Remedy
Repair or
Defective CGC
replace
WA1 200-3 20-665

0
TROUBLESHOOTING w-12
W-12 Buzzer for switch operation does not sound
* Check that the main monitor and alarm buzzer work properly.
socket adapter).
Cause Remedy
Defective work
Is resiincebetween euqipment controller Replace
chassisnormalwhen Defective contact or

disconnectionin wiring
harness between L28
(female) MI- JL16 (1). (6) - Repair or
LO8(female) (6) replace
. Defective contact or
chassis normal? disconnacitonin wiring
harness between L28 -
(female) (16!- RES2 (1). (2) Repair or
and LO8. NO - JL6 (5). (6) -chassis replace
- Short circuit with chassis
.5-6kQ ground in tiring harness
between L28 (female) WI-
JL16 (1). (6) - LO8(female)
(6)
Work epu i Pment

controller
R20
TJW02502
20-666 WA1 200-3

0
W-13 Shock when stopping boom (abnormality in boom lever detent

switch)
* Check that the failure mode [491 is not displayed.

* When the boom lever is at neutral, [GNDI is input to the controller when the boom detent switch
is closed.
cause Remedy
4YE: Defective work

Replace
Is resistance equipment controller
*S between I_27
3 (female) (8) and Short circuit in wiring
Is resistance (9) nom-rat? harness between L27
Repair or
(female) (8) - HRll (female)
* Min. 1 MQ NC (1) and between L27 (female) replace
MS ;zEl%E9,- - * Turn starting (9) - HRl 1 (female1(2)
2 HRll (fern&) (1). switch OFF.
pIs resistancebetween (2) normal? Short circuit with chassis
* Disconnect L27 and ground in wiring harness
I.27 (female)(8). (9) * Min. 1 MD HRll. between L27 (female) (8) - Repair or
YES_ and chassis normal _
l Turn starting NO HRll (female) (11, or replace
when HI31 1 (female)
switch OFF. between L27 (female) f91-
1 (IokA$$ grounded
c s HRl 1 (female) (2)
l Disconnect L27
Is resistance Defectivecontact or
* Max. 1 R and HRll.
between HRll disconnectionin wiring Repair or
- * Turn starting harnessbetween LZ7 (female)
(male) (1) and (2) NO replace
switch OFF. (8) - HRll (female) (1). or
normal? * Disconnect l27 between L27 (female) (91-
HRl 1 (female) (2)
* At boom lever and HRll.
neutral: Max. 1 52 Defective boom lever
Replace
. Other than NO detent switch
neutral: Min. 1 MR
l Turn starting switch OFF.
. Disconnect HRll
Work
uipment Boom
Intro1 ler L27 (04020)
I ever
detent
3 (HD-76086) (DTt) switch
JL21 (DTIE)
JR13 (DTlB)
JLll (DTl) ,, LR~ (~~11 I RAlO (DTHD4) Battery
A7
TJW02503
WA1 200-3 20-667

0
W-14 Short circuit in boom RAISE, LOWER pressure detection switch
* Before carving out troubleshooting, check that all the related connectors are properly inserted.
cause Remedy
4YE Defective work

c
Replace
Is resistance equipment controller
YES_ between ~27 Short circuit in wiring
harness between L27
3 (female) (6) and (female) (6) - LRl 1 (2) - F22
is resistance (9) normal? (female) (1) and between L2i Repair or
(female) (9) - LRll (6) - F22
n j between L27 * Min. 1 MQ NC (female) (2) replace
(female) (5). (61, * Turn starting
switch OFF. Short circuitin wiring harness
i/OE,,i
and (9) normal? betweenL27 (female)(6) -
- - Disconnect L27 and HR13(female)(1) and betweer
* Min. 1 MR HRl l27 (female)(6) - HR12 Repair or
Yl
l Turn starting NO (female)(l), or between l27 replace
(female)(5) and HR13(female)
1 switch OFF. (11,HR12 (female)(1)
l Disconnect K7, Shortdr& withchassisgrow,
between HFi12 l Min. 1 MR HR12, and HR13. in wiringharnessbetweenL27
Repair or
(male) 11) and HR73 l Turn starting (female)(5) - HRl3 (female)(1)
;0 or betwell L27wemale)(6)- replace
(male) (1) -chassis switch OFF. HRl2 (female)(1). or between
* Disconnect U7, I27 Ifemale (9)- HR13(female)
l Min. 1 M~z HR12, and HR13. (2). HR12(female)12)
*Turn starting Defective boom RAISE Replace
switch OFF. NO switch or boom LOWER
* Disconnect HR12 switch
and HR13.
Work esuipment
cant
Dressure switch
Dressure switch
TJW02498
20-668 WA1 200-3

TROUBLESHOOTING OF MAIN MONITOR
SYSTEM
(M MODE)
Trouble data display ,.................................,................ ,.................. ........ .... ... ............i .................. ......... . 20-703
Electrical circuit diagram of main monitor system .......... .......... ................... ....... ...... .......... .............. 20-704
M- 1 Main monitor does not work ..................................................................................................... 20-706
M- 2 When starting switch is turned ON (within 3 seconds) and engine is started
(PRE-LUBE) immediately, all lamps stay lighted up ................................................................ 20-707
M- 3 Speedometer display does not work properly ......................................................................... 20-708
M- 4 Abnormality in shift indicator .................................................................................................... 20-709
a) Displays N even when directional lever is at F ................................................................. 20-709
b) Displays N even when directional lever is at R. ................................................................ 20-709
c) Does not display N even when FNR (Forward-reverse) switch is set in N ................... 20-710
d) Does not display F even when FNR (Forward-reverse) switch is set in F.. ................... 20-710
e) Does not display R even when FNR (Forward-reverse) switch is set in R .................... 20-710
M- 5 Turn signal display does not light up ....................................................................................... 20-712
a) L.H. turn signal display does not light up.. ....................................................................... .20-7X?
b) R.H. turn signal display does’not light up ......................................................................... 20-712
M- 6 Abnormality in parking display .................................................................................................. 20-713
a) Parking lamp display does not light up ............................................................................ .20-713
Parking lamp display stays lighted up ..............................................................................
b) -20-713
M- 7 Night lighting does not light up ................................................................................................ 20-714
M- 8 Abnormality in front working lamp. .......................................................................................... 20-715
a) Neither monitor display nor front working lamp light up.. ............................................. .20-715
b) Working lamp lights up but monitor display does not light up.. ................................... .20-715
c) Monitor display lights up but front working lamp does not light up ............................ 20-715
M- 9 Abnormality in rear working lamp ............................................................................................ 20-717
a) Neither monitor display nor rear working lamp light up.. .............................................. .20-717
b) Rear working lamp lights up but monitor display does not light up ............................ 20-717
Monitor display lights up but working lamp does not light up ..................................... .20-717
c)
M-10 Abnormality in transmission cut-off.. ........................................................................................ 20-719
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is
not switched and display does not change . ... ................ .. .. .......... ...... .. .............. .............. . 20-719
b) When monitor switch (transmission cut-off switch) is OFF, monitor display
goes out but cut-off function is actuated when pedal is depressed .. .. ............ ....._...... 20-719
c) When monitor display is turned off (transmission cut-off switch turned OFF),
cut-off function is always actuated ... ....... ...... .. ................ ... ..................... ........................... 20-719
d) Cut-off function is always actuated regardless of monitor display
(transmission cut-off switch ON or OFF) .... .. ... .. ................. ............ ...... .............................. 20-719
Monitor display lights up (transmission cut-off switch turned ON),
e)
but cut-off function is not actuated .... ............. ...........**..*.................***............................... 20-720
M-l 1 Abnormality in emergency steering normal display ............................................................... 20-721
Emergency steering normal display does not light up ........................................................... 20-721
M-12 Abnormality in emergency steering actuation display ........................................................... 20-722
a) Emergency steering actuation display does not light up ................................................. 20-722
b) Emergency steering actuation display stays lighted up .................................................. .20-722
WA1 200-3 20-701

0
M-13 Abnormality in parking brake dragging warning ..................................................................... 20-723
a) When parking brake is applied, buzzer sounds (intermittently) and
CAUTION lamp flashes even when directional lever is at N ........................................... 20-723
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 .................. 20-723
M-14 Abnormality in parking brake dragging warning (When joystick steering mode). ............. 20-725
a) When parking brake is applied, buzzer sounds (intermittently) and
CAUTION lamp flashes even when directional lever is at N ........................................... 20-725
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 .................. 20-725
M-15 When parking brake dragging warning is given, buzzer and CAUTION lamp
are actuated continuously, or they are not actuated .............................................................. 20-727
a) Actuated continuously .......................................................................................................... 20-727
Not actuated ..........................................................................................................................
b) 20-727
M-16 Abnormality in buzzer.. ............................................................................................................... 20-728
a) Buzzer does not sound when starting switch is at ON (for 3 seconds)
(during self-check) ................................................................................................................. 20-728
b) Buzzer always sounds .......................................................................................................... 20-728
M-17 Condition of monitor switches is not stored in memory.. ..................................................... -20-730
M-18 Service meter does not advance or advances while engine is stopped .............................. 20-731
a) Service meter does not advance.. ....................................................................................... 20-731
b) Service meter advances while engine is stopped ............................................................ .20-731
M-19 Buzzer is not made to sound by transmission controller ....................................................... 20-732
M-20 Abnormality in auto-greasing system ....................................................................................... 20-733
a) Forced greasing cannot be carried out .............................................................................. 20-733
b) Monitor display flashes rapidly (2 times/set) .................................................................... 20-733
c) Monitor display flashes slowly (1 time/r&. ...................................................................... 20-733
M-21 Failure code is not sent to main monitor (abnormality in network) ..................................... 20-735
20-702 WA1 200-3

0
TROUBLESHOOTING TROUBLE DATA DISPLAY
TROUBLE DATA DISPLAY

1. Outline
The speedometer display on the main monitor
is used to display the troubleshooting for each
control system. The nature of the troubleshoot-
ing is displayed as the failure action code, fail-
ure code, and the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the
network circuit. (Only the engine controller uses
a special parallel signal.)
2. Display of failure action code

This code informs the operator directly of the
abnormality, and takes action, such as stopping
the machine immediately.
7 ExamPle:When action code CALL is
There are three types of action code: EOO,EOI + I f SPEED \

CALL (EOI and CALL are displayed alternately),
and CALL. If a failure occurs suddenly, one of
these codes is shown on the speedometer dis-
play-
3. Failure code and time elapsed since failure

TDW01377
I
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
controller has failed, so carry out troubleshoot- ExamDle:When failure code ‘41’has
ing for the applicable controller. occurred 27 hours before
For failure that have occurred and been reset, Failure code
/
the failure code and the time elapsed since fail-
ure are displayed to make it easy to check fail-
I / SPEED /\
ures that are not occurring at present.

The failure codes for failures that are now oc-
curring flash, and the codes for failures that are
not occurring light up.
For details of the method of operating and trans-
ferring data to the trouble data display mode, TOW01378
see STRUCTURE AND FUNCTION for the main
monitor.
Note: If the engine is not stopped, it is impos-
sible to switch to the trouble data dis-
play mode, so the codes for failures
which can only be detected when the
engine is operating light up.
4. Failure codes list

See “Introduction” of Troubleshooting.
WA1 200-3 20-703

0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR

SYSTEM
20-704 WA1 200-3

0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM
l-l-% I
-~~-~~-~~-_~-~~-_________=
z
z
z
0
WA1 200-3
TROUBLESHOOTING M-l
M-l Main monitor does not work
YES
Defective main monitor Replace
1
Is voltage Defective contact or

between LO5 ll), - disconnection in wiring
(2) - (3) normal? . 2 YES Repair or
Is resisance harness between LO5
replace
- between LO5 (female) (1). (2) and FS2
*20-30V (female) (9)
* Turn starting
NO chassis ground
switch ON. Defective contact or
normal7 Repair or
-Turn starting NO replace
harness between LO5
switch OFF. (female) (3) - JL5 (2). (8)
* Disconnect L05. and LR7 (male) (4)
* Max. 1 R
M-l Related electrical circuit diagram
Bat terv
Bat tery~Battery/A~ relay
/I
TJW02506
20-706 WA1 200-3

0
TROUBLESHOOTING M-2
M-2 When starting switch is turned ON (within 3 seconds) and engine

is started (PRE-LUBE) immediately, all lamps stay lighted up
* Before carrying out troubleshooting,

,lated connectors are properly inserted.
check that all the re-
1
on to the next step.
1
YES
I I Defective PRE-LUBE
HOLD relay (L114)
Replace
If L114 is
replaced, do
lamps operate 2YEs
normally? When engine is
- tined, is voltage
* Turn starting Disconnection or
L between LO5 14) and -
switch OFF. NO chassisground defective contact in
* Replace Ll14 normal? wiring harness between Repair or
with normal relay .20-30V NO LO5 (female) (4) - JL15 replace
of same type. l Start engine. (4). (3) - SJ2 (female) (3)
* Turn starting - L57 (female) (1)
switch ON.
fl ml Starting switch PRE-LUBE

indicator
-1
1 swIt,ch 1
(orange)
;;;;;;;g
re I ay
PRE-LUBE
hold relay
Neutral
relay
a Rear frame
ENG
TJW02507
20-707
WA1 200-3
0
TROUBLESHOOTING M-3
M-3 Speedometer display does not work properly
* When error code is not displayed.

* Check that the gap between the speed sensor and gear is normal.
Cause Remedy
1 YES
Is resistance
between LO7
(female) (1) - (2) -
normal? Repair or
harness between LO7
.500-lktl NO replace
(female) (1). (2) -115
-Turn starting (female)(11, (2)
switch OFF.
* Disconnect L07.
Work ewiment
controller
128 hl4016)
Modulated clutch
Transmission I
Main monitor
TXW02453
20-708 WA1 200-3

0
TROUBLESHOOTING M-4
M-4 Abnormality in shift indicator

+ Check that error code is not displayed.
Ir Check that the transmission shifts.
+ The steering system must be in the steering wheel mode.
a) Displays N even when directional lever is at F
Cause
1 YES
Defective main monitor
Is voltage
between LO8 (7)
and chassis
harness between LO8
-2O-30V NO replace
(female) (7) and JSl
switch ON.
* Directional lever: F
bl Displays N even when directional lever is at R

Cause Remedy
I
1 YES
Is voltage
between LO8 63)
and chassis Defective contact or
ground normal? disconnection in wiring
Repair or
harness between LO8
*20-30V NO replace
(female) (8) and JSl
l Turn starting (female) (4)
switch ON.
* Directional lever: R
WA1 200-3 20-709

0
TROUBLESHOOTING M-4
c) Does not display N even when FNR (Forward-Reverse) switch is set in N.
1 YES
Is voltage
between LO8 (7) Short circuit with power
or (8) and chassis source in wiring harness
ground normal? between LO8 (female) (7)
Repair or
and JSl (female) (2) or
- Max. 1 V NO replace
harness between LO8
* Turn starting [female) (8) and JSl
switch ON. (female) (4)
* Set FNR (Forward-
Reverse) switch in
N.
d) Does not display F even when FNR (Forward-Reverse) switch is set in F.
Cause Remedy 1
f
1 YES
r Is voltage betvveen
LO8 (female) (7)
I
Replace

Repair or
harness between LO8
*20-30V NO (female) (7) - JL16 (4). (3) replace
* Turn starting and JSl (female) (2)
switch ON.
. Set FNR (Fotward-
Reverse) switch in
F.
e) Does not display R even when FNR (Forward-Reverse) switch is set in R.
1
Is voltagebetween
LO8 (female) (8)
and chassis
ground normal?
Repair or
*20-30V
l Turn starting
switch ON.
* Set FNR (Forwarcf-
Reverse) switch in
R.
20-710 WA1 200-3

0
TROUBLESHOOTING M-4
Transmissi on
JLl8 (DT2l
controller
Dn d-l
JL16 (DT2)
i TJWO2508
WA1 200-3 20-711

0
TROUBLESHOOTING M-5
M-5 Turn signal display does not light up
* Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the
monitor is not blown. T
Cause Remedy
al L.H. turn signal display does not light up
1 YES
Is voltage
between LO6 (14)
and chassis
1ground normal? harness between LO6
Repair or
* Repeats 0 V and NO replace
(female) (14) and L144
20-30V. (male) (1)
* Turn starting switch ON.
-Turn L.H. turn signal ON.
Cause Remedy
b1 R.H. turn signal display does not light up
1 YES Defective main monitor Replace

Is voltage
between LO6 (15)
and chassis
harness between LO6
-RepeatsOVand NO replace
20-30v. (male) (1)
*Turn starting switch ON.
* Turn R.H. turn signal ON.
R. H. turn L. H. turn
signal signal
I amp(25W) I amp (25W)
-
F20 TJW02509
20-712 WA1 ZOO-3
0
TROUBLESHOOTING M-6
M-6 Abnormality in parking display
* Before carwing out troubleshooting, check that all the related connectors are properly inserted.
al Parking lamp display does not light up Cause
3 YES
Is resistance
YES between T18
r (female) (2) and - Defective contact or
.B
L. 1gyfrl9rc”hc 11 disconnection in wiring
harness between T18 Repair or
Is voltage
- Max. (female) (2) - JMl (21, (7) replace
YES between LO6 (11) 1R NO
and chassis * Turn starting and chassis ground
1 ground normal? switch OFF.
_ Defectivecontact or
Is resistance P - Disconnect Tl8. disconnectionin wiring Repair or
-2O-30V
between T18 harness between LO6 replace
- * Turn starting NO
(male) (1) and (2) (fernale)(FR2ill)-RT2
switch ON. (N) and T18 (female) (1)
normal? * Turn parking
* Max. 1 R switch ON. Defective parking brake Replace
* Disconnect T18. NO indicator switch
*Turn starting
switch ON.
* Turn parking
switch ON.
b) Parking lamp display stays lighted up Cause Remedy

Is voltage
YE ; between T18 (1)
1 and chassis
11 source in harness
1ground normal? Repair or
I- I ,
between LO6 (female)
replace
*o-2v NO Ill)-FR2(11)-RT2(N)
(male) (1) and (2) -Turn starting T18 (female) (1)
switch ON.
* Turn parking switch OFF. Defective parking brake
- Min. 1 MD Replace
indicator switch
* Disconnect T18.
* Turn starting
switch ON.
* Turn parking
switch OFF.
Ma i n
Parking
RT2 (HO-85086)
brake
indicator
Tl TJW02510
WA1 200-3 20-713

0
TROUBLESHOOTING M-7
M-7 Night lighting does not light up

* Before starting troubleshooting, check that the lamp bulbs are not blown.
* 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 LO5 (female) (16).
1 YES
I Is valtaae
between LO5 (16)
ground normal?
*20-3ov
I
NO
harness between LO5
Repair or
replace
(female) (16) and FSZ
switch ON.
* Turn small lamp
switch ON.
Main
monitor LO5 (04020)
0.5fY
Small
lamp
relay
LR1 (HD-QKnRfi, IIIIIII n i

1 25fP
:___ k /, 1
I”0
asp m R.H. clearance
04 I 25fP nCIs, JHDIDTI)

.,A.', lL,D
rance
(5W)
G14
TJW02511
20-714 WA1 ZOO-3

0
TROUBLESHOOTING M-8
M-8 Abnormality in front working lamp

* Before starting troubleshooting, check that the monitor lighting is lighted up.
al Neither monitor display nor front working lamp light up
Cause Remedy
disconnsction in wiring
YES harness between L60 Repair or
(female) (1) - LO5 (female) replace
117). L75 (female) (5). CL6
(female) (1)
YES Defective front working

Replace
lamp relay
1
between L60 (1)
YE S between L66 (6)
1
l Max. 1 V
2
-Turn starting Max. 1 V between LO6 (1)
l
switch ON. Is voltage between
L60 f2), (4), (5) and
switch ON. harness between LO6 Repair or
NO chassis ground I
normal? l20-30V (female) (1) and L60 replace
4 * Turn starting (female) (6)
.20-30V
* Turn starting
switch ON. disconnection in wiring Repair or
N harness between L60 replace
(female) (21, (4), (5) and
FS5 (female) (1)
b) Working lamp lights up but monitor display does not light up

_
Is voltage
between LO5 (17)
3 Defective main monitor Replace

Repair or
harness between LO5
*20-30V NO replace
+ Turn starting (female) (1)
switch ON.
c) Monitor display lights up but front working lamp

does not light up
WA1 200-3 20-715

0
TROUBLESHOOTING M-8
Ma i n
eht
r
In onito r Fuse (II,
I amp
3 eft
amp
FL1 (HD-26066)
I.25fBr
I. 25fY I
I I
a
FZO
L60
Front
working
lam0
relay
Rear
L61
working
I amp
relay
Front
working
lamp
relay
D
!34
lamp
(R. H. 1
I amp
(L. H. )
ine
--
Working
I amp
TJW02512
20-716 WA1 200-3
0
TROUBLESHOOTING M-9
M-9 Abnormality in rear working lamp

* Before starting troubleshooting, check that the monitor lighting is lighted up.
a) Neither monitor display nor rear working lamp light up
I CaUSe Remedy
(female) (1) - LO5 replace
(female) (18). LRI
(female) (13)
YES
I Defective rear working Replace
3 lamp relay
between L61 (I ) Is voltage
YES between L61 (6)
and chassis 4YES
ground normal? - Is voltage - Defective main monitor Replace
*20-30V
2
*Turn starting , * Max. 1 V between LO6 (2)
switch ON. Turn starting NO and chassis
l
switch ON. ground normal?
harness between LO6 Repair or
*Max.lV NO (female) (2) and L61 replace
I t
-Turn starting (female) (6)
l20-30V
* Turn starting
switch ON. disconnection in wiring Repair or
NO harness between L61 replace
(female) (2). (41, (5) and
FS5 (female) (2)
b) Rear working lamp lights up but monitor display does not light up
CaUSe Remedy
I YES
Is voltage
between LO5 (18)
Repair or
harness between LO5
.20-30v NO replace
- Turn starting (female) (1)
switch ON.
cl Monitor display lights up but rear working lamp

does not light up
I Glse I Remedy
harness between L61
. (female) (1) - GO3 (female) Repair or
(1). GO7 (female) ULor L61
(female) (3) - GO2 (female)
(1). GO8 (female) Cl), or
blown working lamp bulb
WA1 200-3 20-717

0
TROUBLESHOOTING M-9
Main
monito r Fuse (II) aht
7 iamp
I-88-b eft
L J lamp
LRI MD-95086)
FLItHO-26066)
Im lr
”
Y
0
a
c
i 34 0
L60 L61 L75

Front Rear Front
:
* worklna
worixlna worklna
Worki ne It
lamp lamp IamP lamp k
lamp
relay relay relay (L. H. ) lamp
(R. H. )
TJWO2512
20-718 WA1 200-3

0
TROUBLESHOOTING M-10
M-l 0 Abnormality in transmission cut-off
a) When monitor switch (transmission cut-off switch) is pressed,

Cause Remedy
cut-off function is not switched and display does not change
bl When monitor switch (transmission cut-off switch) is OFF,

monitor display goes out but cut-off function is actuated when
pedal is depressed
(female) (3) - C3A replace
between LO6 (3) (female) (10) and M02A
and chassis (female) (11)
ground normal?
*MaxlV NO
* Turn starting
switch ON.
* Disconnect L12.
cl When monitor display is turned off (transmission cut-off switch CaUSt2

turned OFF), cut-off function is always actuated
2 YES harness between L12 Repair or
(female) (1) and C3A replace
(female) (10)
(female) (‘2)and
disconnection in wiring Repair or
harness between L12 replace
(female) (2) and chassis
ground
switch OFF.-
* Disconnect L12. Defective transmission
*Max.152 Replace
* Turn starting NO cut-off switch
switch OFF.
+ Disconnect L12.
dl Cut-off function is always actuated regardless of monitor

display (transmission cut-off switch ON or OFF)
1 YES Defective transmission Replace

controller
Is voltage
between C3A (10)
and chassis
harness between C3A
replace
WMaxlV NO (female) (10) and LO6
(female) (3). L12 (female)
(1)
WA1 200-3 20-719

0
e) Monitor display lights up (transmission cut-off switch turned

ON), but cut-off function is not actuated
Cause Remedy
Replace
cut-off switch
function work
YES
r)
‘
I Defective main monitor
disconnected?
* Disconnect L12.
1Does cut-off II
-Turn starting N
switch ON. Replace
controller

ground in harness
Repair or
between LO6 (female) (3)
- Disconnect L12. NO - M02A (female) (1 l),
. Turn starting C3A (female) (10) and
switch ON. L12 (female) (1)
*20-30V
Madulated clutch Main

controloer monitor
H02A (040201 LO6 (040 16)
Transmission I
controller
Transmission
cut-off switch
(OPEN at left
brake dePressed)
TJW02513
20-720 WA1 200-3

0
TROUBLESHOOTING M-l 1
M-II Abnormality in emergency steering normal display
Emergency steering normal display does not light up
*
Is voltage
between LO5 (10)
ground normal? disconnection in wiring Repair or
harness between LO5 replace
*20-30V NO
(female) (10) -chassis
- Turn starting
switch ON.
M-l 1 Related electrical circuit diagram
Main
LR2 (HD-85086)
TJW02514
WA1 200-3 20-721

0
M-12 Abnormality in emergency steering actuation display
* Always co&e6t any disconnected connectors before going on to the next step.
al Emergency steering actuation display does not light up

I- Cause Remedy
2 YES
Is resistance
YES between LO5
, r Wemale)(11) and
ground in harness Repair or
* Min. 1 MS2 NO between Lo5 (female) replace
(male) (1) and Rll -Turn starting switch OFF. (11) and Rll (female) (1)
* Disconnect LO5 and R12.
Defective emergency
* Min. 1 MD I
steering indicator switch
* Turn starting NO
switch ON.
lDisconnect Rll,
R12.
b1 Emergency steering actuation display stays lighted up
2 YES Defective main monitor

Is voltage
YES between LO5 (11) _
1 r and chassis Defective contact or
Repair or
harness between LO5
replace
(female) (11) and chassis
I
l Turn starting ground
(male) (2) normal? 1 switch ON.
I.
Defective emergency
-Max.lR Replace
steering indicator switch
- Start engine. NO
- Disconnect Rll,
R12.
Main
l-h?
TJW02514
R20
20-722 WA1 200-3

0
M-13 Abnormality in parking brake dragging warning
al When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even
when directional lever is at N
I
F
Cause Remedy

Is voltage between
LO5 (female) (8)
*20-30V NO replace
(female) (8) - JSl
switch ON.
* Directional lever: N
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
Ir Check that the synchronous flash is normal.
CaUSe Remedy
YES
Is voltage between Short circuit with power

LO5 (female) (8) supply in wiring harness
2 YES between LO5 (female) (8) Repair or
II - JSl (female) (3). or replace
defective directional
lever
switch ON.
I Defective main monitor Replace
* Directional lever:
*3kQ-4k,s2 NO
Other than N
. Turn starting
switch OFF.
* Disconnect LO5
WA1 200-3 20-723

0
Joust ick
Transmission lever
controller JSl LsWP12) switch
TJW02515
20-724 WA1 200-3

0
M-14 Abnormality in parking brake dragging warning (When joystick

steering mode)
a1 When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even
when directional lever is at N
:
See troubleshooting of
1 YES
transmission controller
system CTmode)
Is S-NET has any
trouble?
Repair or
*20-30V NO replace
*Turn starting
switch ON.
*Joystick lever
switch: N
bl When parking brake is applied, buzzer does not sound and CAUTION lamp does not light up even
when directional lever is at position other than N
* Check that the synchronous flash is normal.
Remedy
See troubleshooting of
1 YES transmission controller
Repair or
replace
system CT mode)
Is S-NET has any
trouble?

* Max. 1 V NO
*Turn starting
switch ON.
* Joystick lever
switch: F or R
WA1 200-3 20-725

0
Work Modulated
VHMS esuipment clutch Transm ission Main Jovst ck
controller controller controller contra I ler monitor lever switch
a a _I I
. JLI 5 (IIT
I 1:
TJW02516
20-726 WA1 200-3

0
M-15 When parking brake dragging warning is given, buzzer and

CAUTION lamp are actuated continuously, or they are not actuated
a) Actuated continuously
Cause Remedy
YES
1
Does buzzer stop

and lamp go out? Defective VHMS
Replace
controller
*Turn starting Does buzzer stop
NO and lamp go out? Defective contact or
switch ON.
* Connect LO7 Repair or
harness between LO7
(male) (6) to replace
*Turn starting NO (female) (6) and Vl
chassis ground.
switch ON. (female) (13)
- Connect Vl
(female) (13) to
chassis ground.
b) Not actuated
Cause Remedy
- IIefective main monitor Replace
Defective VHMS
Replace
controller

source in harness Repair or
between LO7 (female) (6) replace
-Turn starting NO
switch ON. and Vl (female) (13)
* Disconnect Vl
:
Main VHMS
TJW02517
WA1 200-3 20-727

0
M-16 Abnormal’rty in buzzer
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)
cause Remedy
Repair or
harness between LO6
replace
(male) (1)
Does buzzer
sound? 2 YES
Defective buzzer Replace
Is voltage between
* Turn starting L42 (female) (1)
switch ON. NO and chassis
ground nonnat? disconnection in wiring
* Contact L43 Repair or
harness between L42
(female) to *20-30V replace
NO (female) (1) and FS2
chassis ground. Turn starting
l
(female) (9)
switch ON.
b1 Buzzer always sounds

CaUSe Remedy
YES
1
If LO6 is II
Defective caution buzzer
relay Replace
Defective emergency
parking brake reset Replace
3
switch
If L89 is I
* Turn starting
switch OFF.
* Disconnect L99. ’ Defective buzzer

between L43 (male) (1) - Repair or
. Min. 1 MR. NI LO6 (female) (8) - I_89 replace
* Turn starting (female) (3) - L99
switch OFF. (female) (female) (3)
* Disconnect L06,
L89, L99, and
L43.
.
20-728 WA1 200-3
0
Emergency
Darkins brake
cancel switch
Main monitor LO6 (04016)

0.5fL
Buzzer OUTPUT 124A 8
VHMS
I-#7 TJW02518
WA1 200-3 20-729

0
M-17 Condition of monitor switches is not stored in memory
* Always connect any.disconnected connectors before going on to the next step.
cause Remedy

Is voltage
between LO7 (10)
and chassis
harnessbetweenL07
*20-30V NO replace
(female) (10) and LO9
* T&n starting (female) (2)
switch ON.
Battery relay
Main monitor LO7 (04012)
Starting switch 66AC 10 0.5fY -
R03 (DT2)
JR3 (DTl)
Start ina switch R20 TJW02519
20-730 WA1 200-3
0
M-18 Service meter does not advance or advances while engine is

stopped
a) Service meter does not advance
1 YES
Is voltage
between LO5 (5)
and chassis
ground normal?
*20-30V NO (female) (5) -alternator replace
* Start engine. terminal L, or defective
alternator
b1 Service meter advances while engine is stopped
I Cause I Remedy
1 YES
Is voltage
between LO5 (5)
and chassis
ground normal?
between LO5 (female) (5) Repair or
*o-5v NO -alternator terminal L, or replace
* Turn starting defective alternator
switch ON.
Alternator psg~
TJW02520
WA1 200-3 20-73 1

M-20 Abnormality in auto-greasing system
check that all the related connectors are properly inserted.

* Before carrying out troubleshooting,
a) Forced greasing cannot be carried out

Cause Remedy
See “Handling autc-

2 YES greasing system” in -
Operation and
mvoitage_
YES between GREl Maintenance Manual
1 (1) and chassis Defective contact or
ground normal? disconnection in wiring Repair or
Is voltage
_ . Max. 3 V harness between LO6 replace
between LO6 (5) NO
and chassis (female) (5) and GREl
* Turn starting switch ON.
ground normal? (female) (1)
*Turn auto-greasing
switch ON.
*Max.3V Defective main monitor Replace
l Turn starting NO
switch ON.
* Turn auto-greasing
switch ON.
b1 Monitor display flashes rapidly (2 times/set)
A
YES
1
Is voltage Defective contact or
between LO8 (5) disconnection in wiring
and chassis 2 YES harness between LO8 Repair or
ground normal?
_ Is voltage
’ (female) (5) and GREl replace
(female) (2)
l20-3ov between GREl
-Turn starting NO (2)and chassis - See “Handling auto-
switch ON. ground normal? greasing system” in -
.20-3ov NO Operation and
* Turn starting Maintenance Manual
switch ON.
c1 Monitor display flashes slowly (1 time/set) Remedy

Cause
Confirm that grease is not empty.
See “Handling auto-

greasing system” in -
Operation and
Maintenance Manual
Table 1 (Relationship between input signal and display)
WA1 200-3 20-733

0
Main
m
TJW025.22
20-734 WA1 200-3

0
M-21 Failure code is not sent to main monitor (abnormality in

network)
* Set dipswitch 3 at the rear of the main monitor to “F”.
Cause Remedy
1 VHMS lort wi PIE Transmission

coatrillle ontrol ler
/
TWW02601
WA1 200-3 20-735

0
TROUBLESHOOTING OF VHMS
CONTROLLER SYSTEM
(V MODE)
Operations of VHMS controller against abnormality and conditions of

machine caused by abnormality .................................................................................................... 20-804
List of alarm items displayed on CGC monitor .................................................................................. 20-820
Electrical circuit diagram for VHMS system ....................................................................................... 20-822
V- 1 [EgOI I (Engine oil level below LOW level) is displayed.. ..................................................... .20-824
V- 2 IE9021 (Engine oil pressure below specified pressure) is displayed .................................. .20-824
V- 3 IE9031 (Engine coolant temperature above specified temperature) is displayed.. ............ 20-824
V- 4 [E9041 (Engine coolant temperature above specified temperature) is displayed.. ............ 20-824
V- 5 IE9051 [Fuel level below specified level (before engine starts)1 is displayed.. .................. 20-825
V- 6 [E9061 [Fuel level below specified level (While engine is running)] is displayed.. ........... 20-827
V- 7 IE9071 (Torque converter oil temperature above 12OYJ is displayed ................................ .20-829
V- 8 IE9081 (Torque converter oil temperature above 130°C) is displayed ................................. 20-830
V- 9 [E9111 (Hydraulic oil temperature above 105°C) is displayed ........ .A.................................... 20-831
V-IO [E9121 (Low front or rear brake oil pressure) is displayed ................................................... 20-832
V-l 1 [E9131 (Low front brake oil pressure) is displayed ................................................................ 20-834
V-12 IE9151 (Low rear brake oil pressure) is displayed ................................................................. 20-836
V-13 I9161 (Disconnection or short circuit with chassis ground in
battery fluid level sensor “1”) is displayed ............................................................................ 20-838
V-14 19171 (Disconnection or short circuit with chassis ground in
V-15 19181 (Disconnection or short circuit with chassis ground in
V-16 IE9251 [Brake fluid level below specified level (before engine starts)] is displayed ......... 20-841
V-17 fE9261 [Brake fluid level below specified level (While engine is running)] is displayed.. 20-842
V-18 [E9271 [Coolant level below LOW level (before engine starts] is displayed.. .................... 20-843
V-19 IE9281 [Coolant level below LOW level (While engine is running)] is displayed.. ............ 20-844
V-20 IE9311 (Clogging of transmission oil filter) is displayed ....................................................... 20-845
V-21 [E9321 [Clogging of air cleaner (111 is displayed .................................................................... 20-847
V-22 [E9331 [Clogging of air cleaner (211 is displayed .................................................................... 20-849
V-23 IE9341 [Clogging of air cleaner (3)l is displayed .................................................................... 20-850
V-24 IE9351 [Clogging of air cleaner (411 is displayed .................................................................... 20-851
V-25 iE9371 (Abnormal charge by alternator) is displayed.. ......................................................... -20-852
V-101 [E8111 (Abnormality in NSW power source system) is displayed in history.. ................... 20-853
V-102 [E8121 (Short circuit with chassis ground in 24-V circuit of sensor power supply). ......... 20-854
V-103 IE8131 (Short circuit with chassis ground in 12-V circuit of sensor power supply) .......... 20-856
V-104 [E8141 (Short circuit with chassis ground in 5-V circuit of sensor power supply) ............ 20-857
V-105 IE8181 (Wrong connection of connector) is displayed in history ......................................... 20-858
V-106 IE821 I (Abnormal controller) is displayed .............................................................................. 20-858
WA1 200-3 20-801

0
v-107 [E824] (Communication with CGC and engine controller is impossible)
is displayed in history .............................................................................................................. 20-859
V-108 [E825] (Abnormality in S-NET communication between VHMS - transmission
controller) is displayed in history ............................................................................................ 20-860
V-l 09 [E8261 (Abnormality in S-NET communication between VHMS - modulated
clutch controller) is displayed in history ................................................................................ 20-862
v-110 [E8271 (Abnormality in S-NET communication between VHMS -work
equipment controller) is displayed in history ........................................................................ 20-864
V-III [E8281 (Abnormality in S-NET communication between VHMS - main monitor)
v-112 [E8311 (Abnormal controller) is displayed in history. ............................................................ 20-868
v-113 IE8411 (Short circuit with power source in buzzer output system)
V-l 14 IE8433 (Short circuit with power source in check lamp system)
v-115 IE8441 (Short circuit with power source in flash synchronizing signal system)
V-116 iE8611 (Disconnection or short circuit with chassis ground in
boom bottom pressure sensor system) is displayed in history.. ........................................ .20-872
V-l 17 IE8621 (Disconnection or short circuit with chassis ground in
boom head pressure sensor system) is displayed in history.. ............................................ .20-874
V-l 18 IE8631 (Disconnection or short circuit with chassis ground in
rear brake oil pressure sensor system) is displayed in history ........................................... 20-876
v-119 tE8641 (Disconnection or short circuit with chassis ground in
work equipment relief pressure sensor system) is displayed in history ........................... 20-878
V-l 20 [E8651 (Disconnection or short circuit with chassis ground in
front brake oil pressure sensor system) is displayed in history.. ....................................... .20-880
v-121 IE8661 (Disconnection or short circuit with chassis ground in
transmission main relief pressure sensor system) is displayed in history.. ...................... 20-882
v-122 [E8671 (Disconnection or short circuit with chassis ground in
steering relief pressure sensor system) is displayed in history.. ......................................... 20-884
V-123 IE8681 (Disconnection or short circuit with chassis ground in
torque converter outlet oil pressure sensor system) is displayed in history.. .................. 20-886
V-124 [E8711 (Disconnection or short circuit with chassis ground in
transmission modulation pressure sensor system) is displayed in history.. ..................... 20-886
transmission lubricating oil pressure sensor system) is displayed in history .................. 20-890
V-126 [E8741 (Short circuit with chassis ground in torque converter oil temperature
sensor system) is displayed in history ................................................................................... 20-892
V-127 [E8751 (Short circuit with chassis ground and with power source in hydraulic
oil temperature sensor system) is displayed in history.. ..................................................... .20-893
V-128 (E8751 (Short circuit with chassis ground in ambient temperature
sensor system) is displayed in history ................................................................................... 20-894
20-802 WA1 200-3

0
v-129 IE8781 (Disconnection or short circuit with chassis ground in
PPC relief pressure sensor system) is displayed in history ................................................ .20-896
v-130 IE8841 (Disconnection or short circuit with chassis ground
in torque converter inlet oil pressure sensor system) is displayed in history.. ................ 20-898
v-201 Disconnection or short circuit with power source in 24-V system
of sensor power supply ............................................................................................................ 20-900
v-202 Disconnection or short circuit with power source in 12-V system
V-203 Disconnection or short circuit with power source in 5-V system
V-204 Disconnection or short circuit with chassis ground in buzzer output system.. ................. 20-904
V-205 Disconnection or short circuit with chassis ground in check lamp system.. ..................... 20-905
V-206 Disconnection or short circuit with chassis ground in
flash synchronizing signal system .......................................................................................... 20-906
V-207 Short circuit with power source in boom bottom pressure sensor system ...................... 20-907
V-208 Short circuit with power source in boom head pressure sensor system .......................... 20-908
v-209 Short circuit with power source in rear brake oil pressure sensor system.. ..................... 20-909
v-210 Short circuit with power source in front brake oil pressure sensor system ..................... 20-910
v-21 1 Short circuit with power source in work equipment relief pressure sensor system.. ...... 20-911
v-212 Short circuit with power source in transmission relief pressure sensor system.. ............ 20-912
V-213 Short circuit with power source in steering relief pressure sensor system ...................... 20-913
V-214 Short circuit with power source in torque converter outlet oil pressure sensor system 20-914
V-215 Short circuit with power source in transmission modulation pressure sensor system.. . 20-915
V-216 Disconnection or short circuit with power source in
torque converter oil temperature sensor.. .............................................................................. 20-916
V-217 Disconnection in hydraulic oil temperature sensor system ................................................. 20-917
V-218 Disconnection in ambient temperature sensor system ......................................................... 20-918
v-219 Short circuit with power source in PPC relief sensor system ............................................. .20-919
v-220 Short circuit with chassis ground in fuel level sensor system ............................................ 20-920
v-221 Short circuit with power source in battery fluid level sensor “1” ....................................... 20-921
v-222 Short circuit with power source in battery fluid level sensor “2” ....................................... 20-922
V-223 Short circuit with power source in battery fluid level sensor “3”. ..................................... .20-923
V-224 Short circuit with chassis ground or power source in brake fluid level sensor.. ............. 20-924
V-225 Short circuit with power source in coolant level sensor ...................................................... 20-925
V-226 Short circuit with chassis ground or power source in
transmission oil filter clogging sensor ................................................................................... 20-926
V-227 Short circuit with power source in air cleaner clogging (I) relay system ......................... 20-927
V-228 Short circuit with power source in air cleaner clogging (2) relay system ......................... 20-928
v-229 Short circuit with power source in air cleaner clogging (3) relay system ......................... 20-928
V-230 Short circuit with power source in air cleaner clogging (4) relay system.. ....................... 20-929
V-231 Abnormal charge by alternator ............................................................................................... 20-930
WA1 200-3 20-803

0
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY
TROUBLESHOOTING AND CONDlTlONS OF MACHINE CAUSED BY ABNORMALrrY
OPERATIOF IS OF VHMS CONTROLLER AGAINST ABNORMALITY

AND COND TIONS OF MACHINE CAUSED BY ABNORMALITY
* List of alarm items displayed on CGC monitor: See page 20-820.
- I
Abnormal Failure -ailur ‘e Action
40. Contents of abnormality
system mode code code
-
1) Low engine oil level
1 pv$ne oil E901 --- 2) Abnormality related to engine controller (CENSE)
- * See alarm items displayed on CGC monitor
Engine oil 1) Low engine oil pressure

2
pressure E902 --- 2) Abnormality related to engine controller (CENSE) --_
- + See alarm items displayed on CGC monitor
Engine 1) Engine coolant temperature above 102OC (E903)

3 coolant E903 2) Engine coolant temperature above 105X (E904) ___
temperature E904 3) Abnormality related to engine controller (CENSE)
- It See alarm items displayed on CGC monitor
1) Low fuel level or defective fuel level sensor
Disconnec- E905 --- between V2A (female) (2) - R05 (female) (1)
tion E906
3) Defective VHMS controller
f See alarm items displayed on CGC monitor
Short 1) Defective fuel level sensor
4 Fuel level circuit with --- --_ 2) Short circuit with chassis ground in wiring harness Sensing is
chassis between V2A (female) (2) - R05-(female) (1) impossible.
ground 3) Defective VHMS controller
1) Low fuel level or defective fuel level sensor
Short 2) Short circuit with power source in wiring harness
circuit with E905 --- between V2A (female) (2) - R05 (female) (1)
power E906
source + See alarm items displayed on CGC monitor
-
1) Defective torque converter oil temperature sensor
Disconnec- ___ --- 2) Disconnection or defective contact in wiring harness Sensing is
tion between V2A (female) (3) - T24 (female) (1) impossible.
Short 1) Torque converter oil temperature above 120°C (E907)
Torque circuit with 2) Torque converter oil temperature above 130°C fE908)
5 :onverter oil __- Input voltage
chassis z 3) Defective torque converter oil temoerature sensor
< 0.3 v
:emperature ground E874 4) Defective VHMS controller ’
* For E907 and E908, see alarm items displayedon CGC monitor
Short circuit 1) Defective torque converter oil temperature sensor
with power _-- ___ 2) Short circuit with power source in wiring harness Sensing is
source between V2A (female) (3) - T24 (female) (1) impossible.
- 3) Defective VHMS controller
1) Defective hydraulic oil temperature sensor
Disconnec- _-- -__ 2) Disconnection or defective contact in wiring harness Sensing is
tion between V2A (female) (11) - HS (female) (1) impossible.
1) Hydraulic oil temperature above 105°C (E911)
2) Defective hydraulic oil temperature sensor
iydraulic oil Short circuit 3) Short circuit with chassis ground or with pcwer scurce in Fg< Tltage
6 with chassis 5911 _--
emperature wiring harness between V2A (female) (11)- HSl (female) (1)
ground f875
* For E911, see alarm items displayed on CGC monitor
Short circuit 1) Defective hydraulic oil temperature sensor
with power ___ 2) Short circuit with power source in wiring harness Sensing is
E875
source between V2A (female) (11) - HSl (female) (1) impossible.
- 3) Defective VHMS controller
1) Low front brake oil pressure (E912, E913)
2) Defective front brake oil pressure sensor
3) Defective joint connector JR14, JL2: or JR13
E912 4) Disconnection or defective contact m wiring harness Input voltage
Disconnec- between Vl (female) (2) - HR15 (female) (2)
tion c 0.5 v
::z 5) Disconnection or defective contact in wiring harness
between V2A (female) (7) - HR 15 (female) (3)
Brake oil t For E912 and E913, see alarm items displayedon CGC monitor
7
pressure (F) 1) Low front brake oil pressure (E912, E913)
2) Defective front brake oil pressure sensor
Short circuit 3) Short circuit with chassis ground in wiring harness
with chassis
ground
E3
E865
__- between Vl (female) (2) - HR15 (female) (2)
4) Short circuit with chassis ground in wiring harness Input voltage
between V2A (female) (7) - HR15 (female) (3) < 0.5 v
f For E912 and E913, see alarm items displayed on CGC
monitor
-
20-804 WA1 200-3

0
TROUBLESHOOTING AND CONDlTlONS OF MACHINE CAUSED BY ABNORMALlTY
Condition of Alarm P~~~e~&~ Phenomena under Resetting Diagnosi

Normal condition machine caused
by abnormality buzzer Other:’ x abnormal condition method code
Insufficient engine oil level Refillengineoil
--- _-_ __- --- Cummins engine controller or see Cummins V-l
(CENSE) defective ServiceManual.
Low engine oil pressure or $F;krssee
--_ -_- --- -__ Cummins engine controller v-2
(CENSE) defective ServiceManual.
Engine coolant temp. above
--- -__ --- ~~he~;ssee
_-- 102°C or 105”C, or Cummins
engine controller (CENSE) ServiceManual. YS
-
defective
:gPgrkeeps indicating
-_- _-_ --_
Low fuel level alarm is output --- ;:;
Resistance (between wrongly.
R05 (1) - (2))
FULL (100%): 10 R
Gauge keeps indicating FULL
l/2 (50%): 32 R --- --_ -__ Low fuel level alarm cannot - - - v-220
l/4 (25%): 49.5 R
be output.
EMPTY (0%): 85 R
(Max. power con-
sumption: 0.5 WI Gauge keeps indicating
_-- ___ _-- EMPTY.
Low fuel level alarm is output --- ;I;
wrongly.
Gauge keeps indicating 25°C.

_-- _-_ --- Alarm screen cannot be __- V-216
output.
Resistance (between
T24 (1) - (2)) Gauge keeps indicating 130°C. When ,eft is
Normal temperature 0 Alarm screen is output ;I;
wrongly. not satisfied.
(25°C): Approx. 40 kD - -- --- V-126
130aC: Approx. 1.7 kQ
Gauge keeps indicating 25°C.

_-- -__ --_ Alarm screen cannot be --_ V-216
output.
_-- ___ _-- Gauge keeps indicating 25°C. -_-

Alarm cannot be output. V-217
Resistance (between
v;oo’lC)- (2))
Gauge keeps indicating 13O’C. When left is v-9
A.lfJCrix. 3.5 - 4.0 M -__ 0 Alarm is output wrongly. not satisfied. V-127
A;p;ox. 37 - 50 kQ
-_- --_ _-- Gauge keeps indicating 25OC. -_- V-127

Alarm cannot be output.
Real-time monitor is dis-

played. v-10
When left is
-__ ___ Min. pressure is always v-11
0 not satisfied.
sensed. v-120
Alarm is sensed wrongly.
(Max. 0 MPa IO kg/cm?)
Voltage (between
‘J’p (;13-V(3)):
. - .
Real-time monitor is dis-
played.
--- --_ v-10
0 Min. pressure is always When left is
v-1 1
sensed. not satisfied.
Alarm is sensed wrongly. v-120
(Max. 0 kg/cm?
WA1 200-3 20-805

0
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALJTY
TROUBLESHOOTING AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Abnormal Failure Failure Action Abnormal

VO. Contents of abnormality
system mode code code condition
Short circuit 1)Shon circuit with power source in wiring harness between
7 Brake oil __-
with power --- --- V2A (female) (7) - HR15 (female) (3)
pressure (F) 2) Defective VHMS controller
source
1) Low rear brake oil pressure (E912, E915)
2) Defective rear brake oil pressure sensor
3) Defective joint connector JR14, JL?, or JR13
Disconnec-
E912 41 Disconnection or defective contact In wiring harness between
Input voltage
E915 --- Vl (female) (2) - HR16 (female) (2)
tion < 0*5V
E863 5) Disconnection or defective contact in wiring harness between
V2A (female) (8) - HR 16 (female) (3)
+ For E912 and E915, see alarm items displayed on CGC monitor
1) Low rear brake oil pressure (E912, E915)
Brake oil
2) Defective rear brake oil pressure sensor
a pressure (R)
Short circuit E912 3) Short circuit with chassis ground in wiring harness between
Vl (female) (2) - HR16 (female) (2) Input
with chassis Eg15 - _ _
4) Short circuit with chassis ground in wiring harness between < o 5v voltage
ground E863 V2A (female) (8) - HR16 (female) (3)
* For E912 and E915, see alarm items displayed on CGC monitor
Short circuit 1) Short circuit with power source in wiring harness between
with power --- --- WA (female) (8) - HR16 (female) (3) -_-
source 2) Defective VHMS controller
1)Defective battery fluid level sensor (1) or inscfricientcharge of battery
2) Disconnection or defective contact in wiring harness between 6-v cel,
Disconnec-
E916 --- WA (female) (1) - RA7 (female) (1)
tion 3) Defective VHMS controller voltage c 2 V
1) Defective battery fluid level sensor (1) or insufficientcharge of battery
g Battery fluid Short circuit 2) Short circuit with chassis ground in wiring harness between 6-v cell
level (1) with chassis E916 - - - WA (female) (1) - RA7 (female) (1)
voltage < 2 V
ground 31 Defective VHMS controller
+ See alarm items displayed on CGC monitor
Sensing is
with power --- --- V2B (female) (1) - RA7 (female) (1)
2) Defective VHMS controller impossible.
source
2) Disconnection or defective contact in wiring harness between 6V cell
Disconnec-
E917 --- V2B (female) (2) - RA6 (female) (1) voltage < 2 V
tion
t See alarm items displayed on CGC monitor
1) Defectivebatteryfluidlevelsensor(2) or insufficientcharge of battery
Battery fluid Short circuit 2) Short circuit with chassis ground in wiring harness between 6-V cell
lo level (21 with chassis E917 - - - V2B (female) (2) - RA6 (female) (1) voltage < 2 V
Sensing is
with power --- --- V2B (female) (2) - RA9 (female) (1)
impossible.
1) Defective battery fluid level sensor (3) or insufficientcharge of bsttery
2) Disconnection or defective contact in wiring harness between 6-V cell
Disconnec-
tion E918 --- V2B (female) (3) - RA9 (female) (1) voltage < 2 V
* See alarm items displayed on CCC monitor
11 Banery fluid Short circuit 2) Short circuit with chassis ground in wiring harness between 6-V cell
level (3) with chassis E918 - - - V2B (female) (3) - RA9 (female) (1) voltage < 2 V
rt See alarm items displayed on CGC monitor
Short circuit 1) Short circuit with power source in wiring harness between Sensing is
with power --- --- V2B (female) (3) - RA9 (female) (1) impossible.
1) Low front brake fluid level or defsctive front brake fluid level sensor
2) Low rear brake fluid level or defective rear brake fluid level sensor
Disconnec- E925 between V3A (female) (5) - HR6 (female) (1) Sensing is
tion E926 - - - 4) Disconnection or defective contact in wiring hamess between impossible.
V3B (female) (5) - HRlO (female) (1)
t See alarm items displayed on CGC monitor
Brake fluid 1) Short circuit with chassis ground in wiring harness between
Short circuit V3A (female) (5) - HR6 (female) (1)
l2 level Sensing is
with chassis - - - - - - 2) Short circuit with chassis ground in wiring harness between
impossible.
ground V3B (female) (5) - HRlO (female) (1)
Short circuit V3A (female) (5) - HR6 (female) (1) Sensing is
with power - - - - - - 2) Short circuit with power source in wiring harness between impossible.
source V3B (female) (5) - HI?10 (female) (1)
20-806 WA1 200-3

0
Condition of Alarm F$‘lUeist$y Phenomena under Resetting Diagnosis

by abnormality buzzer Other: x abnormal condition method code
Joltage (between V2A Real-time monitor is displayed.

--- -_- --- Max. pressure is always sensed. v-210
:7) - (3)): 0.7 - 5.3 v - - -
Real-time monitor is displayed.

Min. pressure is always v-10
___ --_ 0 sensed. When left is
not satisfied. v-12
Alarm is sensed wrongly. V-118
(Max. 0 MPa {O kg/cm211
Voltage (between
;;A (;)3-J3)):
. - . Real-time monitor is displayed.
Min. pressure is always v-10
--_ --_ 0 sensed. When left is
not satisfied. v-12
Alarm is sensed wrongly. V-118
(Max. 0 MPa {O kg/cm%

--_ -_- --- Max. pressure is always sensed. v-209
- - -
___ --- 0 When left is

Alarm is output wrongly. v-13
not satisfied.
Voltage (between
RA7 (1) - chassis): -__ __- When left is
0 Alarm is output wrongly.
not satisfied. v-13
5.5 - 6.5 V
___ __- _-_ Alarm cannot be output. ___ v-221
_-- _-_ Alarm is output wrongly. When left is

0 v-14
not satisfied.
Voltage (between
RA8 ( 1) - chassis): --- Alarm is output wrongly. When left is v-14
0
5.5 - 6.5 V not satisfied.
__- --_ --- Alarm cannot be output. -__ v-222
-_- When left is

0 Alarm is output wrongly. v-15
not satisfied.
Voltage (between
E (;)5-;hassrs): _-- _-_ 0 When left is v-15
Alarm is output wrongly.
. - . not satisfied.
__- ___ --- Alarm cannot be output. --- V-223
Alarm is always output (Wrong

_-a --- sensing). V-16
E925: Before engine is started. --- v-17
E926: After engine is started.
Voltage (between
HR6 (1) - chassis,
HRlO (1) - chassis)
--_ --- -__ Alarm cannot be output. __- V-224
--- --_ --- --- --- V-224
WA1 200-3 20-807

0

JO. Contents of abnormality
1) Coolant level below LOW or defective coolant level sensor
2) Defective joint connector JR2 or JR7
Disconnec- 3) Disconnection or defective contact in wiring harness between Sensing is
ES27 ---
tion V3A (female) (10) - GO6 (female) (1) impossible.
E928 4) Defective VHMS controller
* See alarm items displayed on CGC monitor
13 Coolant level Short circuit 1) Defective coolant level sensor
2) Short circuit with chassis ground in wiring harness between Sensing is
withchassis --- ---
V3A (female) (10) - GO1 (female) (1) impossible.
ground
Short circuit 1)Short circuit with power source in wiring harness between
Sensing is
with power --- --- V3B (female) (10) - GO6 (female) (1)
source 2) Defective VHMS controller impossible.
1)Clogging of transmission oil filter or defective transmission oil filter sensor (ROl)
2) Cl ging of transmission oil filter or defective transmission oil filter sensor (ROZ)
Disconnec- E931 --- 31 Dzective joint connector JR7 Sensing is
tion 4) Disconnection or defective contact in wiring harness between impossible.
Differential V3A (female) (11) - V2A (female) (1)
pressure on 5) Defective VHMS controller
14 transmission Short circuit 1)Short circuit with chassis ground in wiring harness between
oil filter V3A (female) (11) - R02 (female) (1) Sensing is
with chassis - -- ---
(clogging) ground 2) Defective VHMS controller impossible.
Sensing is
with power --- --- V3A (female) (11) - R02 (female) (1)
source
1)Ciogging of air cleaner (1) or defective dust indicator (1)
2) Defective dust indicator relay (1)
E932 ---
tion V3B (female) (1) - L132 (female) (6) impossible.
* See alarm items displayed on CGC monitor
!5 Clogging of
air cleaner (1) Short circuit 1) Short circuit with chassis ground in wiring harness between Sensing is
withchassis --- --- V36 (female) (1) - L132 (female) (6)
ground 2) Defective VHMS controller impossible.
Sensing is
with power --- --- V3B (female) (1) - L132 (female) (6)
source
1) Clogging of air cleaner (2) or defective dust indicator (2)
E933 ---
tion V36 (female) (2) - L133 (female) (6) impossible.
6 C!ogging of *See alam items displayed on CGC monitor
air cleaner (2) Short circuit 1)Short circuit with chassis ground in wiring harness between
V3B (female) (2) - L133 (female) (6) Sensing is
withchassis --- ---
ground 21 Defective VHMS controller impossible.
V3B (female) (2) - L133 (female) (6) Sensing is
with power --- ---
source
1) Clo ging of air cleaner (3) or defective dust indicator (3)
. dust indicator relay (3)
2) De 3ectlve
ES34 ---
tion V3B (female) (3) - L134 (female) (6) impossible.
,, Clogging of
withchassis --- --- V3B (female) (3) - L134 (female) (6)
ground
source
1) Clogging of air cleaner (4) or defective dust indicator (4)
E935 --- impossible.
tion V3B (female) (4) - 1135 (female) (6)
,8 Clogging of f See alarm items displayed on CGC monitor
with chassis --- - -- V3B (female) (4) - L135 (female) (6)
impossible.
impossible.
1) Defective alternator signal relay L152
2) Defective alternator
Disconnec- 3) Disconnection or defective contact in wiring harness between _ _ _
E937 ---
tion V2A (female) (4) - L152 (female) (6)
Alternator * See alarm items displayed on CGC monitor
9 terminal R
Short circuit 1) Short circuit with chassis ground in wiring harness between
voltage withchassis --- --- V2A (female) (4) - L152 (female) (6) ___
Short circuit 1)Short circuit with power source in wiring harness between V2A
with power --- --- (female) (4) - L152 (female) (61 - El4 (female) (2). El5 (female) (2) - - -
20-808 WA1 200-3

0
Condition of Alarm F$keekt$y Phenomena under Resetting Diagnos,

by abnormality buzzer Other:’ x abnormal condition method code
Low coolant level alarm is

_-- --- -__ output (E928 is sensed --- V-18
wrongly). v-19
Voltage (between
V3A (IO) - (9))
Coolant level normal:
Max. 1 V
-_- ___ --- Low coolant level alarm is not -_- ---
Coolant level output.
insufficient: 17 - 30 V
-_- --_ --- --- _-- v-225
--- _-- --_ Clogging alarm is output (E931 ---

is sensed wrongly). v-20
Voltage (between
V3A (11) - (9))
Filter normal: Max. 1 V Low coolant level alarm is not __ _
Filter clogged: 17 - 30 V --- --- --- output. V-226
--- --- -_- -__ -__ V-226
_-_ --- _-- $I;;:) is output wrongly --- v-21
Voltage (between
V3B (1) - chassis)
Filter normal: Max. 1 V --- -__ --_
Filter clogged: 17 - 30 V --- - -- Alarm cannot be sensed.
--- --_ --- ___ -__ V-227
--- ___ --- ;“:;;Tj is output wrongly -_- v-22

Joltage (between
J3B (2) - chassis)
:ilter normal: Max. 1 V
--- --- --- Alarm cannot be sensed. --_ -__
‘ilter clogged: 17 - 30 V
--- --_ _-- ___ _-_ V-228
--- --- --- t;;yj is output wrongly -_- V-23
Voltage (between
V3B (3) - chassis)
Filter normal: Max. 1 V
--- --- --- Alarm cannot be sensed. _-- _--
Filter clogged: 17 - 30 V
-_- --_ -__ --- ---

v-229
_-- --- __- g;;;j is output wrongly -_- V-24
Voltage (between
V3B (4) - chassis)
Filter normal: Max. 1 V
Alarm cannot be sensed. -__ ___
Filterclogged: 17-30V --- --- ---
_-- --_ ___ _-- -_- V-230
Abnormal charge level alarm ___ v-25

rVhen generating: 24 V --- --- --- is output wrongly. (E937)
Criterion
Min. 9.3 V (While
Pngine is running and
generating) --_ --- _-- Abnormal charge level alarm ___
V-231
Vlax. 9.3 V (While is output wrongly. (E937)
sngine is stopped)
Misjudgment ismadewhile engine is running.
___ ___ _-- -__ ___
Engine stop alarm may te sensed
wrongly
while engine is running.
-- --_
WA1 200-3 20-809
0
TROUBLESHOOTING AND CONDITIONS OF MACHINE CAUSED BY ABNORMALlTY
Abnormal Failure Failure Yction Abnormal

10. Contents of abnormality
system mode code code I condition
-
1) Disconnection or defective contact in wiring harness between Vl (female)
(6) - FS? El- Fuse - FS3 (6) - battery relay terminal B - battery (+I Below 12 V
NSW Dower 1) Short circuit with chassis ground in wiring harness between Sensing is
20 source (+24 Vl (female) (6). (7) - Fuse I (13)
impossibie.
VI (Battery)
1) Short circuit v&h power source in wiring harness between Vl (female)
--_ (6) - FS3 (5) - Fuse - FS3 (6) - battery relay terminal 8 - battery (+) Above 40 V
-
Disconnec- __- --- Vl (female) (2) - MTl, 2, 3, 4, 5 (female) (2) or between Vl Sensing is
---r
tion (female) (2) - HR15, 16 (female) (2). HS2, 3, 4 (female) (2) impossible.
1) Defective transmission main relief pressure sensor, torque converter
outlet oil pressure sensor, torque converter inlet pressure sensor,
transmission modulation pressure sensor, front brake pressure
sensor, rear brake pressure sensor, work equipment relief pressure
sensor, steering relief pressure sensor, or PPC pressure sensor
2) Defective joint connector JT2, JR14, or JL2
3) Shortcircuitwithchassisgroundin wiring harness betweenJTZ (female)121,(31,
24-v output Short circuit
-__ 14).(9 - MT5(female)(2), MT4 (female)12).MT3 (female)(2). MT2 (female)(2)
21 of sensor with chassis E812 Voltage is
41 Short circuit with chassis ground in wiring harness between JR14
power source ground below 14 V
(female) (2). (3). (4). (51, (6) - HS4 (female) (2). HS2 (female) (21,
HS3 (female) (Z), HR16 (female) (2). HR15 (female) (2)
5) Short circuitwith chassis ground in wiring harness between JLZ (female1
(4) - JT2 (female) (1) or between JLZ (female) (5) - JR14 (female) (1)
6)Short circuit with chassis around in wirina harness between
Vl (female) (2) - JL2 (female) (3) -
7) Defective VHMS contrdler
with power __- Vl (female) (2) - MTl, 2, 3, 4, 5 (female) (2) or between Vl Sensing is
---
source (female) (2) - HR15, 16 (female) (2). HS2, 3, 4 (female) (2) impossible.
-
Disconnec-
tion
__- -__
I between Vl (female) (3) - F15 (female) (1)
1) Defective wheel rotation sensor
Sensing is
impossible.
12-v output Short circuit Uoltage is

!2 of sensor with chassis --_ 2) Shon circuit with chassis ground in wiring harness between
E813 below 7 V
ground Vl (female) (3) - F15 (female) (1)
power source
1)Short circuit with power source in wiring harness between
_-- Sensing is
Vl (female) (3) - F15 (female) (1)
impossible.
-
Vl (female) (4) - RES3 (female) (I)
Disconnec- - - - 2) Disconnection or defective contact in wiring harness Sensing is
tion between Vl (female) (5) - MT1 (female) (2) impossible.
1) Defective transmission lubricating oil pressure sensor
i 2) Defectivefuel level sensor
5-v output of Short circuil 3) Short circuit with chassis ground in wiring harness between
__- Voltage is
!3 sensor power with chassis E814 Vl (female) (5) - MT1 (female) (2)
ground 4) Short circuit with chassis ground in wiring harness between below 3.4 V
source
Vl (female) (4) - RES3 (female) (1)
~5) Defective VHMS controller
1) Shon circuit with power source in wiring harness between
Short circuit Vl (female) (4) - RES3 (female) (1)
_-- 2)Short circuit with power source in wiring harness between Sensing is
with power
source Vl (female) (5) - MT1 (female) (2) impossible.
-
Disconnec- _ _ _ ___
VZA (female) (12). V3A (female) (9) - chassis ground
tion

-__ V2A (female) (9) - V36 (female) (121 ___
Wrong 2) Defective VHMS controller
!4 connection of 1) Short circuit with power source in wiring harness between
connector -__ V2A (female) (12). V3A (female) (9) - chassis ground _--
2) Defective VHMS cantroller
1) Disconnection, short circuit with chassis ground, or short
___ circuit in wiring harness between V2A (female) (9). (12). V3A
(female) (9). V3B (female) (12) - chassis ground GND is input
-
5
Abnormal - - - 1) Defective VHMS controller ___
- controller
Defective 1) Defective joint connector JLl
communication 2) Disconnection or defective contact in wiring harness
with CGC, Disconnec- between V4A (female) (6) - Dl (female) (G1, C2 (female) (A) Data are not
16 engine E824 updated
tion - - - 3) Disconnection or defective contact in wiring harness
controller
KXM~INS between V4A (female) (14) - Dl (female) (HI, C2 (female) (8)
4) Defective CGC, engine controller, or VHMS controller
20-810 WA1 200-3

0
Normal condition
Condition of
machine caused
by abnormalihy
Alarm
buzzer
railurehistc
“da;z ;
Phenomena under
abnormal condition
Datacannotbe saved.
Resetting
method -T
IXagno:
code
--- e-0 ___ (2 wiresare set. Failureoccursonly When left is v-101

whenbothwires are disconnected.) not satisfied.
Voltage (between --_ --_ -_- _--

--_
Fuse may be broken.
$ MO(;) - chassis):
--- ___ --_ Failure does not occur.

When left is v-101
not satisfied.
-__ _-- Abnormal value of power

v-201
source sensor
Voltage (between Hold until

--_ Abnormal value of power turning
V’&A2;5;hassisk Stops outputting. 0 source sensor v-102
starting
switch OFF.
-me -_- Abnormal value of power v-201

source sensor
__- --_ Abnormal value of power

VW_
v-202
source sensor
Voltage (between Aold until

Vl (3) - chassis): stops outputting. _-- 0 Abnormal value of power :urning v-103
ll- 13v source sensor darting
switch OFF.
--_ --- 4bnormal value of power

em_
v-202
source sensor
-_- --_ %bnormal value of power __-

__-
V-203
source sensor
iold until
Voltage (between
ibnormal value of power ,urning
Vl (41, (5) - chassis): stops outputting. e-e
0 starting
v-104
4-6V iource sensor
switch OFF.
__- -__ ___ ibnormal value of power

V-203
iource sensor
___ _-- -_- __-
-__ ___ ___

Voltage
V2A (9): 20 - 30 V
V2A (12): 0 - 5 V
V3A (9): 0 - 5 V
___ _--
V3B (12): 20 - 30 V
0 Connected to connector CNJA Nhen left is v-105

wrongly. not satisfied.
___ _-- _-- $I$ cannot be saved nor- When left is V-106
Y- not satisfied.
Communication with CGC and When left is

engine controller KENSE) is not satisfied. v-107
mpossible.
WA1 200-3 20-811

0
OPERATlONS OF VHMS CONTROLLER AGAINST ABNORMALITY

IO. Contents of abnormality
1) Defective joint connector JLl

Short circuit Data are not
V4A (female) (6) - Dl (female) (G), C2 (female) (A)
with chassis E824 - - - updated
Defective 3) Short circuit with chassis ground In wiring harness between
coomunu$ation ground V4A (female) (14) - Dl (female) (HI, C2 (female) (B)
4) Defective CGC, engine controller, or VHMS controller
!6 engine ’
controller 1) Defective joint connector JLI
&UMENflNS 2) Short circuit with power source in wiring harness between
Short circuit
V4A (female) (6) - Dl (female) (GI, C2 (female) (A) Data are not
with power E824 - - -
3) Short circuit with power source in wiring harness between updated
source
V4A (female) (14) - Dl (female) (H), C2 (female) (8)
4) Defective CGC. engine controller, or VHMS controller
1) Defective joint connector JL17, JL18. JL22, or JL23
2) Disconnection or defective contact in wiring harness between Received data
Disconnec- V3A (female) (8) - C36 (female) 14)
E825 ---
tion 3) Disconnection or defective contact in wiring harness between are not
V3A (female) (18) - C3B (female) (12) updated
Defective 1) Defective joint connector JL17, JL18. JU2, or JL23
communica- 2) Short circuit with chassis ground in wiring harness between Received data
Short circuit
~7 tion with V3A (female) (8) - C38 (female) (4)
with chassis E825 - - - 3) Short circuit with chassis ground in wiring harness between are not
~~r$;$~~_ ground updated
V3A (female) (18) - C3B (female) (12)
NET) 4) Defective transmission controller
1) Defective joint connector JL17, JL18. JL22, or JcZ3
2) Short circuit with power source in wiring harness between Received data
Short circuit
WA (female) (8) - C38 (female) (4) are not
with power E825 - --
source updated
V3A (female) (18) - C3B (female) (12)
1) Defective joint connector JLZ? or JL23
Disconnec- V3A (female) (8) - MO1 (female) (1)
E826 --- 3) Disconnection or defective contact in wiring harness between are not
tion
updated
V4A (female) (18) - MO1 (female) (12)
Defective
1) Defective joint connector JL22 or JL23
communica- Received data
2) Short CirCUit with chassis ground in Wiring harness between
tion with Short circuit
18 $;$hlated with chassis E826 - - - $d:$d
3) Short circuit with chassis round in wiring harness between
ground
V4A (female) (18) - MO1 (3emale) (12)
controller (S- 4) Defective modulated clutch controller
NET)
2) Short circuit with power source in wiring harness between Received data
Short circuit
V3A (female) (8) -MO1 (female) (1) are not
;o;h&rr’.“er E826 - -- 31 Short circuit with power source in wiring harness between updated
1) Defective joint connector JL22 or Jl23
Disconnec- V3A (female) (8) - I26 (female) (1)
E827 --- rp%lgtd
tion 3) Disconnection or defective contact in wiring harness between
V4A (female) (18) - L26 (female) (12)
Defective 1) Defective joint connector Jl.22 or Jl23
communica- 2) Short circuit with chassis ground in wiring harness between Received dat;
Short circuit
zg tion with with chassis E827 - - - V3A (female) (8) - L26 (female) (1) are not
3) Short circuit with chassis ground in wiring harness between updated
work equip- ground
ment control-
ler (S-NET)
2) Short circuit with power source in wiring harness between Received datr
Short circuit
V3A (female) (8) -L26 (female) (4) are not
with power E827 - --
source
1) Defective joint connector JL17, JL18, Jl22. or JL23
2) Disconnection or defective contact in wiring harness between Received datr
Disconnec- E828 --- V3A (female) (8) - LOB (female) (1)
tion 3) Disconnection or defective contact in wiring harness between are not
updated
WA (female) (18) - LOB (female) (3)
4) Defective main monitor
Defective 1) Defective joint connector JL17, JL18, JU2, or JL23

2) Short circuit with chassis ground in Wiring harness between Received datr
communica- Short circuit
30 tion with with chassis E828 - - - V3A (female) (8) - LO8 (female) (1)
3) Short circuit with chassis ground in wiring harness between ~~d~~td
main monitor ground
V3A (female) (18) - LO8 (female) (3)
(S-NET) 4) Defective main monitor
1) Defective joint connector JL17, JLl8, JL22, or JL23
Short circuit 2) Short circuit with power source in wiring harness between Received datr
with power E828 - -- V3A (female) (8) - LO8 (female) (1) are not
source
V3A (female) (18) - LO8 (female) (3)
4) Defective main monitor
31 Abnormal Handle E831 ___
- - - 1) Defective VHMS controller
controller error
20-812 WA1 200-3

0
Condition of Alarm ‘$~~e~~~ Phenomena under Resetting Diagnos

by abnormality buzzer Other:.’ x abnormal condition method code
Communication with CGC and

engine controller is impossible.
--- --- 0 When f-1 wire is shorted, When left is v-107
failure does not occur (Com- not satisfied.
munication is possible).
--- --_ Communication with CGC and When left is

0 v-107
engine controller is impossible. not satisfied.
--- --- 0 Display of real-time monitor When left is

V-108
does not change. not satisfied.
Voltage (between Display of real-time monitor

- - - --- When left is
V3A (8). (18) - chassis): 0 V-108
4-8V
--_ -__ Display of real-time monitor When left is

0 does not change. not satisfied. V-108
--- --_ 0 Display of real-time monitor When left is v-109

Voltage (between When left is

- - - - - - Display of real-time monitor
pA8(y, (18) - chassis): 0 v-109
--_ ___ Display of real-time monitor When left is

0 not satisfied. v-109
does not change.
--- -__ 0 Display of real-time monitor When left is v-110

Joltage (between
Display of real-time monitor When left is
J3A (8). (18) - chassis): - - - - - - 0 v-110
I-8V
Display of real-time monitor When left is

--_ ___ 0 v-110
--_ ___ 0 Display of real-time monitor When left is v-111

Voltage (between
- - - __- Display of real-time monitor When left is v-111
V3A (8), (18) - chassis): 0
4-8V
--_ _-_ Display of real-time monitor When left is

0 v-111
_-_ --- __- z$ayynnot be saved nor- When left is v-112

not satisfied.
WA 1200-3 20-813
0
-7
Abnormal Failure Izailur Actior Abnormal

Nt Contents of abnormality
system mode code code condition I
-
Disconnec- --_ ___ Vl (female) (16) - I99 (female) (2) _--
tion 2) Defective VHMS controller
Buzzer Short circuil 1) Short circuit with chassis ground in wiring harness between
3i with chassis --- _-- Vl (female) (16) - L99 (female) (2) _--
output
Short circuii 1) Short circuit with power source in wiring harness between
with power E841 -__ Vl (female) (16) - L99 (female) (2) Overcurrent
-
1) Disconnection or defective contact in wiring harness be&veer
Disconnec- --_ --_ Vl (female) (14) - LO6 (female) (10) --_
Check lamp Short circuit 1) Short circuit with chassis ground in wiring harness between
33 (For main with chassis --_ --_ Vl (female) (14) - LO6 (female) (10) ___
monitor) ground 2) Defective VHMS controller
with power E843 _-- Vl (female) (14) - LO6 (female) (10) Overcurrent
-
Disconnec- --- --_ Vl (female) (13) - LO7 (female) (6) -__
Flash
synchronizing Short circuit 1)Short circuit with chassis ground in wiring harness between
34 signal (For with chassis ___ Vl (female) (13) - LO7 (female) (6) _-_
main moni- ground 2) Defective VHMS controller
tor) Short circuit 1) Short circuit with power source in wiring harness between
with power E644 --_ Vl (female) (13) - LO7 (female) (6) Overcurrent
-
1)Defective boom bottom oressure sensor
2) Defective joint connector JF3 Sensed
Disconnec- _--
E861 3) Disconnection or defective contact in wiring harness between voltage is
tion
Vl (female) (1) - F06 (female) (3) below 0.5 V
Boom bonom
1) Defective boom bottom pressure sensor Sensed
35 pressure Short circuit
sensor with chassis __- 2) Short circuit with chassis ground in wiring harness between
voltage is
ground below 0.5 V
with power ___ Vl (female) (1) - F06 (female) (3)
-
I) Defective boom head oressure sensor
2) Defective joint connector JF3 Sensed
Disconnec- -__
E862 3) Disconnection or defective contact in wiring harness between voltage is
tion
Vl (female) (10) - F14 (female) (3) below 0.5 V
Boom head
II Defective boom head pressure sensor Sensed
36 Dressure Short circuit
sensor with chassis E862 --_ 2) Short circuit with chassis ground in wiring harness between voltage is
ground below 0.5 V
Short circuit I) Short circuit with power source in wiring harness between
with crower -__ e-m Vl (female) (10) - F14 (female) (3) -__
!) Defective VHMS controller
-
I) Defective work equipment relief pressure sensor
!I Defective joint connector JR14, JL2, JR16, or JR13
hzonnec- E864 --_ nput voltage
Vl (female) (2) - HS2 (female) (2)
: 0.5 v
V2A (female) (18) - HS2 (female) (3)
j) Defective VHMS controller
Nork equip-
nent relief I) Defective work equipment relief pressure sensor
37 Short circuit !) Short circuit with chassis ground in wiring harness between
xessure nput voltage
with chassis IE864 -em
Vl (female) (2) - HS2 (female) (2)
sensor $1Short circuit with chassis ground in wiring harness between : 0.5 v
ground
WA (female) (18) - HS2 (female) (3)
1)Defective VHMS controller
Short circuit I) Short circuit with power source in wiring harness between Sensing is
with power --- _-- WA (female) (18) - HS2 (female) (3) mpossible
source !I Defective VHMS controller
-
1) Defective transmission main relief pressure sensor
2) Defective joint connector JT2, JU, JT3, or JLll
3) Disconnection or defective contact in wiring harness between Input voltage
Disconnec-
E866 -__ Vl (female) (2) - MT2 (female) (2)
tion c 0.5 v
V2A (female) (6) - MT2 (female) (3)
Transmission
main relief 1) Defective transmission main relief pressure sensor
38 2) Short circuit with chassis ground in wiring harness between
pressure Short circuit
Vt (female) (2) - MT2 (female) (2) Input voltage
sensor with chassis E866 m-m
3) Short circuit with chassis ground in wiring harness between c 0.5 v

ground
V2A (female) (6) - MT2 (female) (3)
Short circuit 1)Short circuit with power source in wiring harness between
with power --_ WA (female) (6) - MT2 (female) (3) __-
20-814 WA1 200-3

0
TROUBLESHOOTING AND CONDITIONS OF MACHINE CAUSED BY ABNORMALllY
Condition of Alarm F~~~e~~~ Phenomena under Resetting Diagnosi

buzzer Other:’ x abnormal condition method code
by abnormality
___ --- __- Buzzer does not sound. --_ V-204

Buzzer is output when
alarm is made, when
load meter finishes --- _-- _-- ---
Buzzer does not sound. V-204
measurement, etc.
When output: Max. 1 V
Normally: 20 - 30 V stops When left is
-__ __- Buzzer does not sound. v-113
outputting. not satisfied_
--_ _-- _-- Check lamp does not light up. - - - v-205
$eb;zk$mp is Check lamp keeps lighting up.

--- _-- -_- itcFv;rscreen appears, -__ V-205
Wh& check lamp is
OFF: 20 - 30 V
stops Check lamp keeps lighting up. When left is
_-- _-- kgzzerscreen appears, v-114
outputting. not satisfied.
When alarm is made, caution lamp keeps
--- --- -_- lighting up or does not light up. Alarm is - - - V-206
displayed on CGC, however.
$ck;;i;i;g signal .
When alarm is made, caution lamp keeps
--- --- -__ lighting up or does not light up. Alarm is - - - V-206
OFF: 20 : 30 V
;08N;K)zIFat interval of displayedonCGC.however.
Whenalarmis made,caution lampkeeps
stops --- -__ lighting
upor doesnotlightup. Alarmis When left is v-115
outputting. displayedonCGC.however. not satisfied.
_-- _-- Load measured by load meter When left is

0 V-l 16
is always 0 ton. not satisfied.
doltage (between
;~j”:;:‘“: --- -_- Load measured by load meter When left is
. . 0 V-116
is always 0 ton. not satisfied.
--- -__ V-207
Accuracy dispersion depends

on operation of lever. When left is
__- -a- 0 (Back pressure cannot be v-117
not satisfied.
corrected with boom head
pressure.)
doltage (between Accuracydispersiondependson
f174 ‘“: $1,: When left is
--- --- 0 v-117
. - . $%$~s%~bot be corrected not satisfied.
with boom head pressure.)
-__ -__ -__ Load measured by load meter --- V-208

is extremely low.

_-- -_- Min. pressure is always When left is v-119
0
(0 MPa {O kg/cm?)
Joltage (between
;;2 $-$1)): Real-time monitor is displayed.
. - . --- Min. pressure is always When left is v-119
0 not satisfied.
sensed.
(0 MPa (0 kg/cm%

--- __- Max. pressure is always -__ v-21 1
sensed.

__- __- Min. pressure is always When left is v-121
0
(0 MPa (0 kg/cm%
Voltage (between
;;A (;13-;3)): Real-time monitor is displayed.
. - . _-_ --- Min. pressure is always When left is v-121
0 not satisfied.
sensed.
(0 MPa f0 kg/cm%

-_- --- __- -__ v-212
Max. pressure is always
sensed.
WA I 200-3 20-8 15
0
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALlTY

No. Contents of abnormality
1) Defective steering relief pressure sensor
2)Defective joint connector JR14, JL2, JR16 or JR13
3) Disconnection or defective contact In wiring harness between ,nput voltage
Disconnec- E867 --- Vl (female) (2) - HS3 (female) (2)
tion < 0.5 v
4) D&connection or defective contact in wiring harness between
Steering
39 relief 1) Defective steering relief pressure sensor
pressure 2) Short circuit with chassis ground in wiring harness between
Short circuit
Vl (female) (2) - HS3 (female) (2) Input voltage
with chassis E867 --- < 0.5 V
ground
with power --- --- V2A (female) (16) - HS3 (female) (3) Sensing is
source 2) Defective VHMS controller impossible
1) Defective torque converter outlet pressure sensor

2) Defective joint connector JTZ, JU,. JT3, or JLll
3) Disconnection or defective contact In wmng harness between lnput voltage
Disconnec-
E868 --- Vl (female) (2) - MT3 (female) (2)
tion c 0.5 v
WA (female) (5) - MT3 (female) (3)
Torque
converter 1) Defective torque converter outlet pressure sensor
4o outlet 2) Short circuit with chassis ground in wiring harness between
Short circuit Vl (female) (2) - MT3 (female) (2) Input voltage
pressure with chassis E868 - -- 3) Short circuit with chassis ground in wiring harness between c 0.5 V
ground WA (female) (5) - MT3 (female) (3)
with power --- --- V2A (female) (5) - MT3 (female) (3) --_
1) Defective transmission modulating pressure sensor
2) Defective joint connector JT2, JU, JT3: or JLll
3) Disconnection or defective contact in wmng harness between lnput voltage
Disconnec- E871 --- Vl (female) (2) - MT5 (female) (2)
tion 4) Diinnection or defective contact in wiring harness between < O-5 ’
WA (female) 115) - MT5 (female) (3)
Transmission
41 modulating 1) Defective transmission modulating pressure sensor
2) Short circuit with chassis ground m wiring harness between
pressure Short circuit Vl (female) (2) -MT5 (female) (2) Input voltage
wWasslS E871 - - - 3) Short circuit with chassis round in wiring harness between -Z 0.5 V
V2A (female) (15) - MT5 &male) (3)
Short circuit 1)Short circuit with power source in wiring harness between Sensing is
with power --- --- WA (female) (15) - MT5 (female) (3)
2) Defective VHMS controller impossible
source
2) Defective joint connector JT3 or JR1 1
3) Disconnection or defective contact in wiring harness between lnput voltage
Disconnec-
E872 --- Vl (female) (5) - MT1 (female) (2)
tion 4) Disconnection or defective contact in wiring harness between c 0G2 ’
WA (female) (14) - MT1 (female) (3)
51 Defective VHMS controller
11Defective transmission lubricating oil pressure sensor
Transmission 2) Short circuit with chassis ground in wiring harness between
42 lubricating oil Short circuit Vl (female) (5) - MT1 (female) (2) Input voltage
pressure ;$c:assts E872 - -- 3) Short circuit with chassis round in wiring harness between < 0.2 V
V2A (female) (14) - MT1 (Bemale) (31
Short circuit 2) Defective joint connector JT3 or JR11 Input voltage
with power E872 - - - 3) Shon circuit with power source in wiring harness between
< 4.8 V
source WA (female) (14) - MT1 (female) (3)
1) Defective ambient temperature sensor
Disconnec- ___ ___ 2) Diinnection or defective contact in wiring harness between t$‘f ;;oltage
tion WA (female) (10) - PHI (female) (1)
Short circuit 2) Short circuit with chassis ground or with power source in Input voltage
Ambient with chassis E877 ---
43 temperature wiring harness between V2A (female) (10) - PHI (female) (1) c 0.3 V
_ _ _ 2) Short circuit with power source in wiring harness between Input voltage
$$*p:;$ E877
V2A (female) (10) - PHl (female) (1) > 4.7 v
1) Defective PPC relief pressure sensor
2) Defective joint connector JR14, JL2! or JR7
3) Disconnection or defective contact m wiring harness Input voltage
44 PPC relief Disconnec-
E878 --- between Vl (female) (2) - HS4 (female) (2)
pressure tion < 0.5 v
41 Disconnection or defective contact in wiring harness between
20-8 16 WA1 200-3

0
Condition of Alarm I:ailurehistol Phenomena under Resetting Xagnosis

Normal condition machine cause d Saved: C
buzzer abnormal condition method code
by abnormal@ I Other: x
Real-time monitor is displayeo

-_- --- Min. pressure is always When left is
0
(0 MPa 10 kg/cm%
Voltage (between
;-;A ‘263’; (12)):
- . Real-time monitor is displayed
___ --_ Min. pressure is always When left is
0 v-122
(0 MPa {O kg/cm31
Real-time monitor is displayed

___ --- ___ Max. pressure is always _-- V-213
sensed.

--- Min. pressure is always When letI is
--- 0 not satisfied. V-123
sensed.
(0 MPa {O kg/cm%
Voltage (between
V2A (5) - (3)): Real-time monitor is displayed
0.7 - 5.3 v -__ --- Min. pressure is always When left is
0 V-123
(0 MPa f0 kg/cm%

_-- -__ ___ Max. pressure is always --_ V-214
sensed.

Min. pressure is always When left is V-124
(0 MPa 10 kg/cm3)
Voltage (between
;‘A_‘;_53’ ; (12)): Real-time monitor is displayed.
Min. pressure is always When left is V-124
(0 MPa IO kg/cm%

_-_ ___ __- Max. pressure is always ___ v-215
sensed.

t$rseyure IS always When left is
--- v-125
not satisfied.
(0 MPa’{O kg/cm%
Voltage (between Real-time monitor is displayed.

;;A U43); (12)): --- --- Min. pressure is alwavs When left is
V-125
. - . sensed. not satisfied.
(0 MPa (0 kg/cm?)

-__ Min. pressure is always When left is
0 V-125
(0 MPa {O kg/cm%
--- _-_ PM Clinic display is abnormal When left is V-128

0 not satisfied.
(held at -30°C).
Resistance (between
V2A (10) - (12)): PM Clinic display is abnormal When left is
Ambient temperature ___ ___ 0 V-128
(held at 100°C). not satisfied.
20% Approx. 12 kQ
0°C: Approx. 4 kQ
___ _-- PM Clinic display is abnormal When left is V-128
0
(held at -30°C). not satisfied.
PM Clinic is displayed.
Voltage (between Min. oressure is alwavs When left is
‘J2p_‘;‘3-Vf12”:
--- 0 sensed. not satisfied.
v-129
. . (0 MPa IO kg/cm?)
WA1 200-3 20-817

0

No. Contents of abnormality
1) Defective PPC relief pressure sensor
Short circuit 2)Short circuit with chassis round in wirin harness
between Vl (female) (2) - Y-lS4 (female) (2 Input voltage
with chassis E878 - - -
3) Short circuit with chassis ground in wirin harness < 0.5 v
44 PPC relief ground between V2A (female) (1) - HS4 (female) %3)
pressure 4) Defective VHMS controller
Short circuit 1)Shor-t circuit with power source in wirin harness
with power --- --- between V2A (female) (1) - HS4 (female 3 (3) _--
1) Defective torque converter inlet pressure sensor
2) Defective joint connector JT2, JU, JT3, or JLll
Disconnec- 3) Disconnection or defective contact in wiring harness
Input voltage
E884 --- between Vl (female) (2) - MT4 (female) (2)
tion c 0.5 v
4) Disconnection or defective contact in wirin harness
between V2B (female) (10) - MT4 (female) &
Torque 1) Defective torque converter inlet pressure sensor
45 converter Short circuit 2) Short circuit with chassis round in wirin harness
inlet pressure with chassis E884 - - - between Vl (female) (2) - xl T4 (female) ( ) Input voltage
3) Short circuit with chassis ground in wirin harness < 0.5 v
ground
between V2B (female) (10) - MT4 (female ; (3)
Short circuit 1)Short circuit with power source in wirin harness Sensing is
with power --- --- between V2B (female) (10) - MT4 (fema Pe) (3)
source
Disconnec- 1) Disconnection or defective contact in wiring harness of
___ --_ Sensing is
Vl (female) (8). (9)
tion impossible
SW power Short circuit 1) Short circuit with chassis ground in wiring harness of
46 source Sensing is
withchassis --- --- Vl (female) (8). (9)
(+24 VI impossible
Short circuit 1)Short circuit with power source in wiring harness of Vl Sensing is
with power --- --- (female) (8), (9)
impossible
Disconnec- ___ ---

1)Disconnection or defective contact in wiring harness of Sensing is
V2B (female) (8)
tion impossible
Short circuit 1)Short circuit with chassis ground in wiring harness of
47 Small lamp withchassis --- --- Sensing is
V2B (female) (8)
ON voltage ground 2) Defective VHMS controller impossible
Short circuit 1)Short circuit with power source in wiring harness of Sensing is
with power --- --- V2B (female) (8)
source
1) Disconnection or defective contact in wiring harness of Sensing is impossible
Disconnec- __- --_ V3A (female) (7) (Becauseof output of
tion 2) Defective VHMS controller mcdulated clutch)
Short circuit 1) Short circuit with chassis ground in wiring harness of Sensing is impcs-sible
Engine
withchassis --- --- V3A (female) (7) (Becauseof output of
48 speed (+) ground 2) Defective VHMS controller modulated clutch)
Short circuit 1) Short circuit with power source in wiring harness of Sensing is impossible
with power --- --- V3A (female) f7) (Becauseof output of
source 2) Defective VHMS controller modulatedclutch)
1)Defective cancel switch
Disconnec- ___ ___ 2) Diinnection or defective contact in wiring harness of Sensing is
tion V3A (female) (14) impossible
49 Cancel switch Short circuit 1) Defective cancel switch

2) Short circuit with chassis ground in wiring harness of Sensing is
(Load meter) ;;$ceKWS - - - - - -
V3A (female) (14) impossible
Short circuit 1)Short circuit with power source in wiring harness of Sensing is
with power --- --- V3A (female) (14)
impossible
1) Defective subtotal switch
Disconnec- -_- _-_ 2) Disconnection or defective contact in wiring harness of Sensing is
31 Defective VHMS controller
Subtotal 1) Defective subtotal switch
Short circuit Sensing is
50 swsw;; (Load 2) Short circuit with chassis ground in wiring harness of
withchassis --- --- impossible
V3A (female) (15)
Short circuit 1) Short circuit with power source in wiring harness of Sensing is
with power --- --- V3A (female) (15) impossible
1) Defective boom proximity sensor
Disconnec- _ _ _ _ _ _ 2) Disconnection or defective contact in wiring harness of Sensing is
Boom 1) Defective boom proximity sensor
51 proximity Short circuit Sensing is
withchassis --- --- 2) Short circuit with chassis ground in wiring harness of
sensor V3A (female) (16) impossible
Short circuit 1) Short circuit with power source in wiring harness of Sensing is
with power --- --- V3A (female) (16)
impossible
52 ky;;;ading %Z$$$j$&‘$ _ __ _ __ _--
mm pckr lcurca
20-8 18 WA1 200-3

0
Condition of Alarm F$‘Tebt&n’ Phenomena under Resetting Diagnosi:

buzzer Others’ x abnormal condition method code
by abnormality
PM Clinic
_-- __- Min. pressure is always When left is
0 v-129
Voltage (between sensed. not satisfied.
;‘p (;)3-$12)): (0 MPa {O kg/cm%
. - .
PM Clinic
_-- --_ ___ Max. pressure is always --_ v-219
sensed.

_-- --- Min. pressure is always When left is
0 v-130
(0 MPa {O kg/cm?)
Voltage (between Real-time monitor is displayed.

‘JJB ‘;Oj v (12)): Min. pressure is always When left is
. - . _-- __- 0 v-130
(0 MPa {O kg/cm?)

--- _-- -_- Max. pressure is always sensed. - - - - - -
(4.9 MPa {50 kg/cm?
VHMS doesnet operate.
_-- --_ -_- (2 wiresare sat. Failureoccursonly - - - - - -
whenbothwiresare disconnected.)
Voltage (between
Vl (81, (9) - chassis): --_ --- -_- Fuse may be broken. --- -__
20 - 30 v
___ ___ Failure does not occur. --_ -_-
Voltage (between
V2B (8) - chassis):
Small lamp ON:
ON: GND (When

canceled)
3FF: OPEN
Fuse is broken.
Switch is kept turned off.
ON: GND (When

subtotaled) Switch is kept turned off.
OFF: OPEN
___ ___ Fuse is broken. --_ -__
___ ___ Trigger is not applied and load

meter does not calculate load. --- -- -
Load measurement
-__ _-- -__ Trigger is not applied and load ___ __ _
!!?l!g: OPEN meter does not calculate load.
__- ___ -_- Trigger is not applied and load ___ ___
meter does not calculate load.
-__ _-- _-_ Data cannot be downloaded ___ _-_

with service tool.
WA1 200-3 20-819

0
TROUBLESHOOTING LIST OF ALARM ITEMS DISPLAYED ON CGC MONITOR
LIST OF ALARM ITEMS DISPLAYED ON CGC MONITOR

1. The check lamp output is driven with VHMS.
2. As the signal to synchronize flashing of the caution lamp output of the main monitor, the ON/OFF
output of VHMS is used. Permission of the alarm output is given by S-NET and is sent from VHMS
to main monitor.
3. The check lamp and caution lamp are set independentlv (When two failures occur, both flash).
Alarming condition I
Detecting Detecting
Detecting condition 1
condition 2 coldii 3 Resetting condition 1
I Before I While I Faihw _
. _.._.
No. Item Display range Detail of display range engine engine detectin ‘9 Resetting condition
starts is runningtime (seC)
H: Normal 1
Below LOW level L- Abnormal When left is not satisfied.
(Engine speed in rpm,

oil pressure in kPa)
Below followina linear
interpolation g%ph -i
Below specified 1
iNhen left is not satisfied.
(0. 0)
pressure
(800, 138)
y& 20;
(2200: 345)
Above 102OC
Above 102‘C
but 105°C alarm is not detected
Above 105OC Above 105°C 0 0 10
5 1Fuel level Below specifiedlevel Below 1 segment of gauge (11%) 0 -__ 10
-z-l Below specifiedlevel Below 1 segment of gauge (11%) --- 0 10
7 Torque converter Above 120°C
Above 120°C but 130°C alamt is not detected 0 0 10
oil temperature
8 Above 130°C Above 130°C 0 0 10
g Hydraulic oil 0 0 10
Above 105°C Above 105OC
temperature
,. Brake oil Below 14.7 MPa Below 14.7 MPa {150 kg/cm? 0 --- Nhen left is not satisfied.
pressure (F) (150 kg/cm3 and within 60 set after engine starts ---
,, K$Kpt-out Below 14.7 MPa {150 kg/cm’) --- 0 5
snd after 66 set after engine starts
13 Brake oil Below 14.7 MPa Below 14.7 MPa (150 kg/cm3 ___
0
pressure (F) I150 kg/cm3 and within 60 set after ermine starts ---
14 (Cut-in/Cut-out When left is not satisfied.
pressure)
Battery fluid level (11 Below LOW level
Below LOW level When left is not satisfied.

Below LOW level
= 6 V ceil is below 2 V
Below specifiedlevel OPEN = 24 V (Fluid level is low) 0 __- 10
Below specifiedlevel OPEN = 24 V (fluid level is low) - - - 0 10
Below LOW level OPEN = 24 V (Coolant is insufficient) 0 - - - 2
Below LOW level OPEN = 24 V (Coolant is insufficient) - - - 0 2
23 Transmission filter Above specified OPEN = 24 V (Clogging) and torque 0 2 JVhen left is not satisfied.
I differential pressure pressure converter oil temperature is above 50°C - - -
Above specified __- 0 2 JVhen left is not satisfied.
OPEN = 24 V (When clogged)
negative pressure
Above specified
26 Clogging of air
cleaner (3)
negative pressure
Above specified
negative pressure
Above specified
3
OPEN = 24 V (When clogged) Nhen left is not satisfied.
negative pressure
Above 9.3 V (While engine is running)
28 Voltage at alternator When charging is [Criterion while engine is running: Nhen left is not satisfied.
’ 2
termmal R abnormal Voltage of terminal R is above 9.3 V - --
I
or engine speed Z. 600 rpm)
20-820 WA1 ZOO-3

0
TROUBLESHOOTING LIST OF ALARM ITEMS DISPLAYED ON CGC MONITOR
Alarm output
[ Main monitor 1 1
output
Alarm Cancel Runer Error
Screen Check Caution
color switch lamp lamp No. fi
disf% On
Abnormal Yellow Installed Flashing --- --- 901 0 CENSE --- 0
Red Not installed - - - Flashing ON 902
Abnormal Yellow Installed - - - Flashing - - - 903
Abnormal Red installed --- Flashina ON 904

Insufficient
Insufficient
Abnormal Gauge 0
0 VHMS
Abnormal Red Installed --- Flashing ON 908 Gauge 0
Abnormal Red Installed - - - Flashing - - - 911 0 1 VHMS 1 --- / 0 1
‘ressurizing X _-- 0
VHMS
Abnormal 0 --- 0
‘ressurizing X -_- 0
VHMS
Abnormal Red 1Not installedl --- I Flashing 1 ON ( 915 0 _-- 0
Abnormal Yellow Installed Flashing --- --- 0 VHMS __- ___
Yellow 1 installed 1Flashina 1 - -- 1 --- 1 925 0

--- I
I
VHSM --- I
Abnormal Red Not installed - - - Flashing ON 926 -+ 0 -_- ---
Abnormal Yellow Installed Flashina --- --- 927

0 VHSM --- ---
Abnormal Red Not installed - - - Flashing ON 928 0 --- -__
Abnormal Yellow hlstalled Flashing --- --- 931 0 VHMS ___ ___
Abnormal 0 v-e __-
Abnormal 0 me_ _--
VHMS
Abnormal 0 --_ ---
Abnormal 0 --- ___
0 VHMS ___ ___
WA1 ZOO-3 20-821

0
FOR VHMS SYSTEM
-TR(3UBLESHOOTlNG ELECTRICAL CIRCUIT DIAGRAM
.ECTRICAL CIRCUIT DIAGRAM FOR VHMS SYSTEM
20-822 WA1 200-3

0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR VHMS SYSTEM
WA1 200-3 20-823

0
TROUBLESHOOTING V-l, v-2, v-3, v-4
V-l [EgOI] (Engine oil level below LOW level) is displayed
cause Remedy
Insufficient engine oil or Supply oil or

defect related to see Service
CUMMINS engine Manual of
controller (CENSE) CUMMINS
V-2 [E902] (Engine oil pressure below specified pressure) is displayed
1
Low engine oil pressure Check or see
or defect related to Service
CUMMINS engine Manual of
controller (CENSE) CUMMINS
V-3 [E903] (Engine coolant temperature above specified temperature)

is displayed
* This failure code is displayed when the engine coolant temperature is above 102°C but below
105°C (The caution lamp flashes but the buzzer does not sound).
Cause RtXllt?dy
Engine coolant
Check or see
~r~~~~~~a~~~~ ‘02”’ Service
Manual of
CUMMINS engine
CUMMINS
controller (CENSE)
V-4 [E904] (Engine coolant temperature above specified temperature)

is displayed
+ This failure code is displayed when the engine coolant temperature is above 105°C Crhe caution
lamp flashes and the buzzer sounds).
Cause Remedy
l~i ;igI?& ;;;;

temperature above 105% Service
20-824 WA1 200-3

0
TROUBLESHOOTING V-5
V-5 EE9051 [Fuel level below specified level (before engine starts)] is
displayed
to its original position, if the error code is no longer displayed on the CGC monitor display, the
* This failure code is displayed before the engine starts.
Cause Remedy
4YE Defective VHMS

I ISvoltage between Ir controller
Replace
R05 (female) 11)and

J Short circuit with power
yEs between ROS between V2A (female) (2) replace
- (female) (2) and . * DisconnectWA and - R05 (female) (1)
2 chassisground
R05.
-
If VZA (female)(21is normal7 Disconnection or defective
*Turn starting switch ON
groundedtochassis, - Max. 1 R contact in wiring harness Repair or
Yl is resistancebatwaen
NO between R05 (female) (2) - replace
R05 (female)(1) and - . Turn starting
;z;$ground switch OFF. chassis ground
1
* Disconnect R05. Disconnection or defective
Is resistance
bet-
*Max. 1 R
ween I305 hale) contact in wiring harness Repair or
*Turn starting ‘,,
between V2A (female) (2) - replace
switch OFF. R05 (female) (1)
. Disconnect V2A
. See Table 1. and R05. insufficient fuel or Suppiy fuel or
- Disconnect R05. defective fuel level replace fuel
NO sensor level sensor
Table 1
Fuel level 1 Resistance
1 FULL (100%) 1 Approx. 10 R 1
1 l/Z (50%) 1 Appror1

I 11 (25%) / Approx. 48.5 Q I
1 EMPTY (0%) 1 Aoorox. 85 R 1
WA1 200-3 20-825

0
TROUBLESHOOTING V-5
V-5 Related electrical circuit diagram
VHM
JR2 (DTI)
RAlO (DTHD4)
TJW02526
20-826 WA1 200-3

0
TROUBLESHOOTING V-6
V-6 [E906] [Fuel level below specified level (While engine is running)]
-
is displayed
This failure code is displayed before the engine starts.
Cause Remedy
Defective VHMS
Replace
controller
” Ick&sground 11 Short circuit with power

yfrS between R05 between VZA (female) (2) replace
-Max.lV NC
- DisconnectWA - R05 (female) (1)
2 chassis ground
and R05.
- If VZA (female)is normal? Disconnection or defective
P * Turn starting switch ON.
YES grounded10chassis, * Max. 1 R contact in wiring harness Repair or
ISresmance between _ between R05 (female) (2) - replace
- RO5(female)(1) and Turn starting
l NO
chassisground switch OFF. chassis ground
1
- - normal? * Disconnect R0.5.
Is resistance bet- Disconnection or defective
. Max. 1 Q contact in wiring harness Repair or
ween RO5 (male) NO
- -Turn starting between V&I (female) (2) - replace
(1) and (2) as
switch OFF. R05 (female) (1)
shown in Table l?
I
I I * Disconnect VZA
* See Table 1. and R05. Insufficient fuel or Supply fuel or
l Disconnect R05. defective fuel level replace fuel
NO sensor level sensor
Table 1
Fuel level Resistance
1 FULL (100%) 1 Approx. 10 R 1

l/2 (50%) Approx. 32 R
1 l/4 (25%) 1 Approx. 49.5 R I

EMPTY (0%) ) Approx. 85 R
WA1 200-3 20-827

0
TROUBLESHOOTING V-6
II Fuel level
sensor
TJW02526
20-828 WA1 200-3

0
TROUBLESHOOTING V-7
V-7 [ES071 (Torque converter oil temperature above 120°C) is displayed
1
2 YES Defective VHMS
Replace
1Is resistancebetwen II controller
I
YES WA Ifemale)(3). T24
, r (female)11)and Short circuit with chassis
_ chassisground ground in wiring harness
normal? Repair or
Is resistance between V2A (female) (3) replace
between T24 Imale) _ - Min. 1 MR NO -T24 (female) (1)
(1) and (2) as shown . Turn starting
in Table 17 Torque converter oil
switch OFF.
temperature is above Repair or
* Disconnect VZA and T24.
- See Table 1. 120°C or defective torque replace
* Turn starting NO converter oil temperature
switch OFF. sensor
* Disconnect T24.
Table 1
*j
Totsue converter
v-7 Related electrical circuit diagram oil temDerature
sensor bon i tar)
VHMS
LR7fDTI) _. RA5 (DTI) _,
l!
TJW02527
WA1 200-3 20-829

0
TROUBLESHOOTING V-8
V-8 [E908] (Torque converter oil temperature above 130°C) is displayed
A- This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
Cause Remedy

Replace
Is rasisIancabetween controller
YES 'kW(female) (3).
T24
- (female)(1) and
_ chassis ground
Is
resistance lwmal?
between T24 knale) * Min. 1 MQ NO
T24 (female) (1)
(1) and 12)as shown * Turn starting switch
, in Table 17 , OFF. Torque converter oil
* Disconnact V2A and T24. temperature is above Repair or
* See Table 1. 130°C or defective torque replace
l Turn starting NO converter oil temperature
switch OFF. sensor
* Disconnect T24.
Tome carlverter
V-B Related electrical circuit diagram YI II tmmmr
ni L*,llr*l,ature
sensor bon i tar)
VHMS
LR7 (0
m .*
RAlO [DTHD4)
TJW02527
20-830 WA1 200-3
0
TROUBLESHOOTING v-9
V-9 [E911] (Hydraulic oil temperature above 105°C) is displayed
Cause Remedy

Replace
Is resistance bat- controller
y,zs wean V2A (female)
, r (11). HSl ~famalel
._. Short circuit with chassis
between V2A (female) replace
batwaan HSl (male)
(11) - HSl (female) (1)
(11 and (2) as shown -Turn starting switch OFF.
I
- See
l
Table 1.
Turn starting
I
I - Disconnect V2A and
HSl.
Hydraulic oil temperature
is above 105% or
defective hydraulic oil
Replace
switch OFF. temperature sensor

* Disconnect HSl.
Table 1
Temperature Resistance
25°C Approx. 37’ - 50 kI2

105°C Approx. 3.0 - 3.6 kQ
VHMS
controller V2A(07018)
0. 5’Y JR16 (DTl)
Hydraulic oi I
LR2 (HD-85086) sensor
TJW02528
WA1 200-3 20-831

0
TROUBLESHOOTING v-10
V-IO [E912] (Low front or rear brake oil pressure) is displayed
* This failure code is displayed when the brake cut-out oressure is below 14.71 MPa (150 kg/cm? (for
60 seconds after the engine starts).
* Perform the following troubleshooting when the cut-out pres- Cause Remedy
sure is normal.
on to the next step. Low front brake oil
YES pressure or defective Check or
I front brake oil pressure replace
1 sensor
If HR15 is II
Low rear brake oil
Check or
pressure or defective rear
replace
brake oil pressure sensor
L
J--
. Turn starting
If HRlr ‘-
switch OFF. GotoA -
discon
Disconnect HRlS.
l
SC+=raiiure code
NO dr--
l Start engine.
di
Contact of wiring harness
* Turn starting between V2A (female) (8) Repair or
switch OFF. - HR16 (female) (3) with replace
. Disconnect HR16. chassis ground
* Start engine. h _.
round normal? * DisconnectVZA and Contact of wiring harness
HR16. between V2A (female) (7) Repair or
* Min. 1 MD
VO - HR15 (female) (3) with replace
- Turn starting
chassis ground
switch OFF.
l Disconnect V2A
and HR15. 7 YES -
Go to 8.
YF
HR16 ffamale) 13)and

* Max.1 Q
*Turn starring switch . __
between JR14 (female) (6)
- HR15 (female) (2)
Repair or
replace
OFF.
I if WA (female) 17) is I * DisconnectJR14 Disconnection or defective
From A between WA Ifemaie) (8) - replace
HR16 (female) (3)
l Max. 1 R and HR16. contact in wiring harness Repair or
-Turn starting between WA (female) (7) - replace
NO
switch OFF. HR15 (female) (3)
l Disconnect V2A
and HR15.
Defective VHMS
Replace
YES ween JR14 (female)
- (5). HR16(female)(2) -
-
9 and chassisground Contact of wiring harness
Is resistance bat- normal? between JR14 (female) (5) Repair or
yfcS ween JR14 (female) _ - HR16 (female) (2) with replace
* Min. 1 MQ NC
- (6), HR15 (female) - -Turn starting switch chassis ground
a (2) and chassis OFF.
IfJR14 ground - normal? - DisconnectJR14 Contact of wiring harness
gmundedto chz Min. 1 MD
l
and HR16. between JR14 (female) (6) Repair or
From S _ is resistancebetween - HR15 (female) (2) with replace
HR16 (female)(2) and - * Turn start@ NO
chassisground chassis ground
switch OFF.
normal?
* Disconnect JR14 Disconnection or defective
- Max. 1 R and HR15 contact in wiring harness Repair or
-Turn starting between JR14 (female) (5) replace
NO
switch OFF. - HR16 [female) (2)
. Disconnect JR14
and HR16.
20-832 WA1 200-3

0
VHMS
JR13 (DTIB)
Front brake
oi I Pressure
Rear brake
oil Pressure
RAlO(DTHD4)
TJW02529
WA1 ZOO-3 20-833

0
V-II [E913] (Low front brake oil pressure) is displayed

* This failure code is displayed when the cut-in/cut-out pressure of the front brake is below 14.71
MPa (150 kg/cm21 (60 seconds after the engine starts).
* Perform the following troubleshooting when the front brake cut-in/cut-out pressure is normal.
Remedy
. .-
IYF!
-
GotoA
H -Max.10 NC between JR14 (female) (6) replace

*Turn startino switch - HR15 (female) (2)
d
- Min. 1 MR
).~$m?ct
ii14 and Contact of wiring harness
between V2A (female) (7) - Repair or
Yl
*Turn starting NO HRt5 (female) (31 with replace
- Disconnect V2A
* Max. 1 D and HR15. contact in wiring harness Repair or
replaced with rear . Turn starting NO
between WA (female) (7) - replace
switch OFF. HR15 (female) (3)
- Disconnect V2A
and HR15. Low front brake oil
- Turn starting
pressure or defective Check or
switch OFF.
IO front brake oil pressure replace
* Replace with
sensor
(normal) rear
brake oil
pressure sensor. Defective VHMS
Replace
*Start engine. controller
From A (61. HRl5 (female)

(2) and chassis Contact of wiring harness
ground normal? between JR14 (female) Check or
* Min. 1 MQ NO (6) - HR15 (female) (2) replace
l Turn starting with chassis ground
switch OFF.
* Disconnect JR14
and HR15.
20-834 WA1 ZOO-3

0
V-II Related electrical circuit diagram
VHMS controller %,, Im-,A.,,,l
JL21fDTlBl
Front brake
oi I Pressure
RA5 (LITI)
RAlU(DTHD4)
qmp
TJW02530
WA1 200-3 20-835

0
V-12 [ES151 (Low rear brake oil pressure) is displayed
* This failure code is displayed when the cut-in/cut-out pressure of the rear brake is below 14.71 MPa
(150 kg/cm21 (60 seconds after the engine starts).
* Perform the following troubleshooting when the rear brake cut-in/cut-out pressure is normal.
cause Remedy
Gotok -
HR16 (female)(2) and

between JR14 (female) (5) - replace
*Turn startingswitch HR16 (female) 12)
Contact of wiring harness

between WA (female) (8) - Repair or
Yl HR16 (female) (3) with replace
Hi%6 (female1(31and chassis ground
1
1If rear brake oil * Disconnect WA Disconnectionor defective
- Max. 1Q and HR16. contact in wiring harness Repair or
-Turn starting NO between V2A (female) (8) - replace
switch OFF. HR16 (female) 13)
l Disconnect V2A
-Turn starting and HR16. Low rear brake oil
Check or
switch OFF. pressure or defective rear
IO replace
. Replace with brake oil pressure sensor
(normal) front
brake oil
pressure sensor. 5 YES Defective VHMS
Replace
. Start engine. Is resistance bet- controller
ween JR14 (female)
From A M (5). HR16 (female) -
(2) and chassis Contact of wiring harness
ground normal? between JR14 (female) Check or
NO (5) - HR16 (female) (2) replace
. Min. 1 MD
with chassis ground
l Turn starting
switch OFF.
- Disconnect JR14
and HR16.
20-836 WA1 200-3

0
VH
e
ure
TJW02531
WA1 200-3 20-837

0
V-13 [916] (Disconnection or short circuit with chassis ground in

battery fluid level sensor “1 “I is displayed
-)r Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Perform the following troubleshooting when the battery fluid level is normal.
F=-
Remedy

Is resistance bet- Replace
controller
YES wean V2B (female)
- (11, RA7 (female) (1) -
_ 2 and chassisground
ifV28 (female) (1) [s ground in wiring harness Repair or
normal?
YES grounded to chassis. between V2B (female) (1)
_ 1s resistance batwean _ l Min. 1 MR NO replace
RA7 (female) (1) and
- RA7 (female) (1)
*Turn starting switch OFF.
1 $aEa;?ground
* Disconnect V2B and RA7. Disconnection or defective
Is voltage bet-
*Max.1 Q contact in wiring harness Repair or
ween RA7 (male)
- *Turn starting NO between VZB (female) (1) - replace
(1) and chassis
switch OFF. RA7 (female) (1)
ground normal?
- l Disconnect V2B
Defective battery fluid
-5.5-6.5V and RA7.
level sensor ‘1’ or Charge or
. Disconnect RA7. i.
insufficient battery replace
charge
VHMS
RA2 (DTP/DT 1)
TJW02532
20-838 WA1 200-3

0

battery fluid level sensor “2”) is displayed
*
Replace
Is resistancebet- controller
YES ween VZB (female)
- (2). RA8 (female) (1) - Short circuit with chassis
2 and chassisground
If V26 (fern ground in wiring harness Repair or
normaI?
between V2B (female) (2) replace
YES gs$:: EC;:;, _ *Min.lMR NO
RA6 (female) (1) and - RAB (female) (1)
1 chassisground l Turn starting switch OFF.
- normal? - Disconnect V2B and RAB. Disconnection or defective
Is voltage bet- contact in wiring harness Repair or
- Max. 1 Q
ween RAB (male) between VZB (female) (2) - replace
- - Turn starting NO
(1) and chassis RA6 (female) (1)
switch OFF.
ground normal?
Disconnect VZB
l
Defective battery fluid
- 5.5 - 6.5 V and RAB. level sensor ‘2’ or Charge or
- Disconnect RAB. NO
I insufficient battery replace
charge
V-l 4 Related electrical circuit diagram
VHMS
Battery
TJW02532
WA1 200-3 20-839

0

battery fluid level sensor “3”) is displayed -
ChJSe Remedy
_ MS
3 ._- Defective VHMS
Replace
Is reskance bet- controller
YES wee” V2B (female)
- 131.RA9 (female) (1) - Short circuit with chassis
_ 2 and chassisground
If V2B (female)(3) is ground in wiring harness Repair or
normal?
ES grourjdedtochassis, - - between VZB (female) (3) replace
_ Is re%tance between _ . Min. f MD NO
- RA9 (female) (1)
RA3 (female)11)and
1 chassisground * Turn starting switch OFF.
- normal? * Disconnect VZS and FiA9. Disconnection or defective
Is voltage bet- Repair or
* Max. 1 R contact in wiring harness
ween RA9 (male) between V26 (female) (3) - replace
- * Turn starting NO
(1) and chassis RA9 (female) (1)
switch OFF.
ground normal?
* Disconnect VZB Defective battery fluid
.5.5-6.5V and RA9. Charge or
level sensor ‘3’ or
- Disconnect RA9. ’ replace
NO insufficient battery
charge
VHMS
TJW02532
20-840 WA1 200-3

0
TROUBLESHOOTING V-16
V-16 [E9251 [Brake fluid level below specified level (before engine
starts)] is displayed
CaUSe Remedy
Low front brake fluid Supply or

YES
I level or defective front replace brake
1 I brake fluid level sensor fluid
If HRlO (female) (11

Low rear brake fluid level Supply or
is grounded to YES
chassis,does failure I or defective rear brake replace brake
code disappear? fluid level sensor fluid
2
* Turn starting
If HR6 (Lemale) (1) is
H
switch OFF. Defective VHMS
_ groundedto Replace
- Ground HRlO controller
dwsfailure
(female) (1) to No :~~~~s
appear?
chassis.
* Turn starting *Turn starting Disconnection or defective
switch ON. switch OFF. contact in wiring harness Repair or
- ___..__I
urouno
ll”C
“no Ie -.-.ce between _ -Max.lQ NO between V3A (female) (5) - replace
. Turn aarting HR6 (female) (1)
(female) (1) to
switch OFF.
chassis. * DisconnectV3A and HR6. Disconnection or defective
* Turn starting - Max. 1 Q contact in wiring harness Repair or
switch ON. * Turn starting NO between V3B (female) (5) - replace
switch OFF. HRlO (female) (1)
* Disconnect V3B
and HRlO.
Front brake
oil level
VHMS controller
ake
el
TJW02533
WA1 200-3 20-841

0
V-17 [E926] [Brake fluid level below specified level (While engine is
running)] is displayed
+I Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* This failure code is displayed while the engine is running.
Cause Remedy
YES Low front brake fluid Supply or

level or defective front replace brake
brake fluid level sensor fluid
Low rear brake fluid level Supply or

or defective rear brake replace brake
code disappear? fluid level sensor fluid
II 2
*Turn starting
switch OFF. 4 YES Defective VHMS
Replace
* Ground HRlO controller
(female) (1) to code disappear?
chassis.
* Turn starting * Turn starting Disconnection or defective
switch ON. switch OFF. contact in wiring harness Repair or
. Ground HR6 between V3A (female) (5) - replace
(female) (1) to h Jj &&$gmund HR6 (female) (1)
1
chassis.
*Turn starting
switch ON.
* Max. 1 R
* Turn starting
I
NO
switch OFF-
* DisconnectV3A and HR6.
between V3B (female) 15) -
Repair or
replace
switch OFF. HRlO (female) (1)
* Disconnect V3B
and HRlO.
Front brake
oil level
VHM
ake
el
,,,I
TJW02533
20-842 WA1 200-3

0
V-18 [ES271 [Coolant level below LOW level (before engine starts] is
displayed
* Always connect any disconnected connectors before going on to the next step,
CaUSe Remedy
Coolant level below LOW

level or defective coolant Supply or
level sensor replace coolarr
4 YE! Defective VHMS

Replace
controller
I.,
If GO6 (female) (1)
and 12) are shorted $j%j$jz~
to each other, does Disconnection or
failure code - IS resistance
IL
ground normal? defective contact in
Repair or
- 0)
disa ear?
MS between JR2 Imale) replace
. Max. 1 R N( GO6 (female) (2) -chassis
* Turn starting and (1) and
* Turn starting switch
switch OFF. I iI between JR7 (male) ground
- (2) and (1) normal? OFF.
* Short GO6
* Disconnect G06.
(female) (1) and * Max. 1 R Defective JR2 or JR7 Replace
l Turn starting NO
- Turn starting switch OFF.
switch ON. Disconnection or
* Disconnect JR2
- Max. 1R and JR7.
Repair or
. Turn starring wiring harness between
NO replace
switch OFF. V3A (female) (10) - GO6
* Disconnect V3A
and G06.
VHMS
RAlO (DTHD4)
000 1
--I
GO6CDT11
Coolant level
sensor
TJW02534
WA1 200-3 20-843

0
V-19 [E9281 [Coolant level below LOW level (While engine is running)]
is displayed
* Always connect any disconnected connectors before going on to the next step. .
* This failure code is displayed while the engine is running.
Cause Remedy
Coolant level below LOW

Y ‘ES Supply or
level or defective coolant
level sensor replace coolar
1 4Ylz Defective VHMS

Replace
1If GO6 (female) (1) I controller
Disconnection or
I
* Turn starting N?
GO6 (female) (2) -chassis
* Turn starting switch
switch OFF. ground
* Short GO6
(female) (1) and . Disconnect G06.
Defective JR2 or JR7 Replace
(2) to each other. NO
mTurn starting
switch ON. Disconnection or
- Max. 1R
I
Repair or
s Turn starting wiring harness between
NO replace
switch OFF. V3A (female) (10) - GO6
l Disconnect V3A (female) (1)
and G06.
VHMS
Coolant level
TJW02534
20-844 WA1 ZOO-3

0
v-20 [E931] (Clogging of transmission oil filter) is displayed
-k Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Sr Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Clogging of transmission
oil filter or defective Check or
transmission oil filter replace
sensor (ROl )
Clogging of transmission
and (2) are shorted
YES oil filter or defective Check or
to each other, does
transmission oil filter replace
sensor (R02)
- Turn starting If ROZ(female)
switch OFF. and (2) are shorted 4YE
Gotok -
Is resistance
disappear? YES between R02
(female) (1) and 3 (female) (2) and ROl Disconnection or defective
(2) to each other. * Turn starting PIf v3A (female)I11 I is (female) (1) normal? contact in wiring harness Repair or
switch OFF. groundedto chassis, p - between R02 (female) (2) - replace
. Disconnect ~02. _ is resistancebetween _ -Max.lQ NI
ND RO2Uynale) (1) and . Turn starting ROl (female) (1)
- Short R02 chassrsground switch OFF.
(female) (1) and normal? Disconnection or defective
*Disconnect
ROl and AOi
(2) to each other. - Max. 1 R
* Turn starting between V3A (female) Ill) replace
NO
switch OFF. - RO2 (female) (1)
* Disconnect V3A
and R02. 6 YES Defective VHMS
Replace
Is resistancebet- controller
YES ween ~101(female)
5 (2) and chassis Disconnection or
- ground normal? defective contact in
From A _ between JR7 * Max. 1 R NO replace
ROl (female) (I) - chassis
(male) (3) and (1) * Turn starting
ground
normal? switch OFF.
* Disconnect ROl. Defective joint connector
l Max. 1 R Replace
* Turn starting NO (JR71
switch OFF.
l Disconnect JR7.
WA1 200-3 20-845

0
VHMS
TJW02535
20-846 WA1 ZOO-3

0
V-21 [E9321 [Clogging of air cleaner (I)] is displayed
ChUSe Remedy
Replace
If connector B06
Y ES Defective dust indicator
does failure code Replace
relay 1
* Turn starting
switch OFF. 4 YE:
-I- Gotok -
* Disconnect B06.
n Is resistance bet-
* Turn starting
MS ween V3B (female) _
switch ON. 3 (1) and L132 Disconnection or defactivc
. Turn starting - Is resistance bet- (female) (61 normal? contact in wiring harness Repair or
switch OFF. ween B06 (female)
-Max.lQ NC behnreen V3B (female) (1) replace
l Replace with N- (1). 1132 (female) (2) -
*Turn starting L132 (female) (6)
another relay. 0 and chassis ground
switch OFF.
l Turn starting normal? Contact of wiring harness
p * DisconnectV3B and L132
switch ON. . Max. 1 R between 606 (female) (1). Repair or
* Turn starting NO L132 (female) (2) with replace
* Disconnect B06 and L132.
Defective VHMS
controller Replace
Is resistance bet-
From A _ ween L132 (female) _
Disconnection or
(3) and chassis
ground normal? defective contact in
Repair or
* Max. 1 $2 NO replace
L132 (female) (3) -
* Turn starting chassis ground
switch OFF.
- Disconnect L132.
WA1 200-3 20-847

0
VHMS
C
Dust
indicator
I relay
Dust
indicator
2 relay
Dust
indicator
3 relay
Dust
indicator
4 relay
TJW02536
20-848 WA1 200-3
0
V-22 [E933] [Clogging of air cleaner (211 is displayed
ChJSe Remedy
Defective dust indicator 2 Replace
1
If connector 807
is disconnected, Y ES Defective dust indicator
Replace
does failure code I relay 2
disappear?
I 2
-Turn starting
switch OFF. relay 2 is replaced 4 YE5 -
-r Gotok
. Disconnect 807. with another relay, Isresistamcebet-
P
. Turn starting YES ween ~38 (femaw
switch ON. 3 - (2) and L133 Disconnection or defective
* Turn starting - (female) 16) normal?
Is resistancebet- contact in wiring harness Repair or
switch OFF. ween 807 (female) between V3B (female) (2) - replace
l Replace with NC
L133 (female) (6)
another relay. and chassisground
switch OFF.
l Turn starting normal? Contact of wiring harness
- * DisconnectV3E and L136
switch ON. - Max. 1 R between 807 (female) (1) - Repair or
-Turn starting NO L133 (female) (2) with GND replace
switch OFF. harness or chassis ground
lDisconnect 807 and L133.
Replace
controller
Is resistance bet-
From A _ ween L166 (female) _ Disconnection or
(3) and chassis
NO replace
l Max. 1 R L133 (female) (3) -
-Turn starting chassis ground
switch OFF.
. Disconnect L133.
* The related electrical circuit diagram is the same as that for V-21. See V-21.
WA1 200-3 20-849

0
V-23 [E934] [Clogging of air cleaner (3)] is displayed

J, This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
J, Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
‘ES
Defective dust indicator 3
I
If connector B08
is disconnected, Y FS Defective dust indicator
does failure code Replace
relay 3
disappear?
I
*Turn starting
switch OFF. relay 3 is replaced 4 YE!
Ir GotoA. -
- Disconnect 808.
h Is resistance bet-
* Turn starting
YES ween ~36 (female) _
switch ON.
3 (3) and L134 Disconnection or defective
*Turn starting - bat-
Is resistance (female) (6) normal? contact in wiring harness Repair or
switch OFF. ween Bo8 (female) P _
-Max.lQ between V3B (female) (3) - replace
l Replace with - (1). L134 (female) (2) - N(
*Turn starting L134 (female) (6)
another relay. h10 and chassisground
switch OFF.
* Turn statting normal? Contact of wiring harness
. Okconnect V3B and L136
switch ON. * Max. 1 D between 808 (female) (1) - Repair or
-Turn starting NO L134 (female) (2) with GNC replace
. Disconnect BOB and L134.
Defective VHMS
Replace
controller
From A Disconnection or
[groundnormal? 1i defective contact in
c I qepair or
I
- Max. 10 NO 1134 (female) (3) -
* Turn starting chassis ground
switch OFF.
- Disconnect L134.
20-850 WA1 200-3

0
V-24 [E935] [Clogging of air cleaner (411 is displayed
j, This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
to its original positio& if the error code is no longer displayed on the CGC monitor display, the
cause Remedy
Defective dust indicator 4 Replace
is disconnected, Defective dust indicator

Replace
does failure code relay 4
- Turn starting If dust indicator
GotoA. -
Is resistance bet-
disaopear?
yEs wee” V3B (female) _
switch ON. 3 (4)and Ll35 Disconnection or defective
- Turn starting - Is resistance bet- (female1(6) normal? contact in wiring harness Repair or
mritch OFF. wsen 609 (female) between V3B (female) (4) - replace
.Msx.lR NC
. Replace with - 11).L135 (female) (2) - L135 (female) 16)
*Turn starting
another relay. NO and chassis ground
switch OFF.
. Turn starting normal? Contact of wiring harness
- . DisconnectV3B and L135
switch ON. * Max. 1 R between B69 (female) (1) - Repair or
* Turn starting NO L135 (female) (2) with GND replace
- Disconnect BO9 and L135.
Replace
controller
1
Is resistance bet- 11
wen L135 (female)
From A -
(3) and chassis Disconnection or defective
ground normal? contact in wiring harness Repair or
between L135 (female) (3) - replace
0 Max. 1 R NO
chassis ground
*Turn starting
switch OFF.
. Disconnect L135.
WA1 ZOO-3 20-851

0
V-25 [E9371 (Abnormal charge by alternator) is displayed
* Perform the following troubleshooting when fuse 1410) is not broken. If fuse IO is broken, check
the wiring harness between the fuse and L152 for short circuit with the chassis ground.
Cause Remedy
Gotok -
/ES
-Max.ln ._
NI between L152 (female) 12) replace
. Turn starting - ERl (female) 6)
switch OFF.
- Disconnect L152 and Disconnection or defective
ERl contact in wiring harness Repair or
between FS2 (male) (9) am replace
IO
L152 (female) (1). (3)
Defective alternator
alternator terminal I Seplace
NO signal relay fL152)
R and chassis
.28t2V
qepair or
* Start engine. Defective alternator
NO rplace
6 YES Defective VH MS
qeplace
Is resistance II controller
YES bstweenV2A
r; l-l (female) (4) and Disconnection or defective
contact in ti!ing harness qepair or
between V2A (female) (4) - aplace
L152 (female) (6)

- Max. 1V source in wiring harness qepair or
. Turn starting NO between L152 (female) ‘eplace
switch OFF. (21- ERl (female) (5)
* Disconnect L152
and ERl.
srenal relay
TJW07.537
20-852 WA1 200-3

0
TROUBLESHOOTING v-10-I
v-101 [E8111 (Abnormality in NSVV power source system) is displayed

in history
* Perform the following troubleshooting when fuse 1413) is not broken. If fuse I-113)isbroken, check
the wiring harness between the fuse and VHMS for short circuit with the chassis ground.
* Since the GND line harness of VHMS cannot be disconnected basically (for the multi-pole design),
its disconnection is not taken up as a cause.
Cause Remedy

controller Replace
Isvoltage
between Vl (6) Disconnection, defective
and chassis contact, or short circuit
around normal? with power source in
Repair or
wiring harness between Vl
*20-30V NO replace
(female) (6) - F63 (5) -fuse
* Turn starting - FS3 (6) - battery relay
switch ON. terminal 6 - battery (+)
VHMS controller
Fuse (I) Slow blow
Bat terv Battery
\
ROI R02.B
TJWO2538
WA1 200-3 20-853

V-102 [E812] (Short circuit with chassis ground in 24-V circuit of

sensor power supply)
Remedy
Defect of sensor,
YES
disconnection of which
turns off failure code
1
If MT 2,3.4, and 5
are disconnected Defect of sensor,
YES
one by one, does - disconnection of which
failure code turns off failure code
-Turn starting
I Short circuit with chassis
4 YES between JT~ (female) (2). Repair or
If JT2 is (3). 14). (5) -MT 5 (female) replace
(2). MT4 (female) (2). MT3
turn starting codedisappear? 1disconnected, (female), (2)) MT2 (female)
switch OFF. When does failure code (2)
* Turn starting
disconnecting disappear?
switch ON. between pins of JT2 Go to A. -
each connector, -When connecting i - Turn startina NO
turn starting each connector, switch ON. -
switch ON. turn starting I
switch OFF. When *Turn starting ,. 1 Eective JT2, JR14, or Replace
disconnecting
.switch
. ._ON.
Repair or
replace

between JL2 (female) (4) -
JTZ (female) 11)or between replace
JL2 (female) (5) - JR14
(female) (1)
-Turn starting
1disconnected. 11
switch ON.
P Defective VHMS
Replace
controller

1normal7 ground in wiring harness Repair or
IU replace
N between Vl (female) (2) -
- Min. 1 MR
JU (female) (3)
- Turn starting
switch OFF.
- Disconnect Vl
and JL2.
20-854 WA1 200-3

0
Transmission
main relief
Pressure sensor
Torque converter
outlet oil
VHMS Con t ro I ler v, ~07020~ Pressure sensor
Torque converter
inlet oil
Pressure sensor
Transmission
modulated oil
Pressure sensor
J T2 (DT2)
Front brake oil

Pressure sensor
Rear brake oil

Pressure sensor
Work eauipment relief

oil Dressure sensor
Steering relief
oil Pressure sensor
Pressure sensor
TJW02533
WA1 200-3 20-855

0
V-103 [E813] (Short circuit with chassis ground in 12-V circuit of

sensor power supply)
Cause Remedy
YES Defective wheel rotation

Replace
1 sensor
If F15 is
disconnected, _
does failure code 2 YES Defective VHMS
disappear? Is resistance x controller Replace
- betweenV1
*Turn starting
switch ON. NO chassis ground Short circuit with chassis
normal? ground in wiring harness Repairor
- Min. 1 MQ NO between Vl (female) (3) - replace
F15 (female) (1 J
l Turn tiarting
switch OFF.
l Disconnect VI
and F15.
Wheel rotat ion

VHMS controller Vl (07020) FL2 (HD-25086) Fl 5 (DT2)
sensor
0.75fG
)OUtPUt (t24v)]307/ 3 E 307 1 307
TJW02540
20-856 WA1 200-3

0
V-104 [E814] (Short circuit with chassis ground in 5-V circuit of sensor
power supply)
Remedy
1
Y ES Defective transmission
lubricating oil pressure Replace
sensor
YES Defective fuel level

sensor Replace
If R05 is
YES disconnected,
disappear? does failure code
I Gotok -
disappear?
* Turn starting - between R05
switch ON. 2 * Turn starting Ne (female) (1) and -
Is resisrance switch ON. chassis ground Short circuit with chassis
between Vl ll0rmal7 ground in wiring harness Repair or
- (female) (5) and - * Min. 1 MR Nf between R05 (female) (1) replace
ND chassis ground - Turn starting - RES3 (female) (2)
normal? switch OFF.
* Disconnect R05 and Short circuit with chassis
- Min. 1 MR
RES3. ground in wiring harness Repair or
* Turn starting
NO between Vl (female) (5) - replace
switch OFF.
MT1 (female) (2)
. Disconnect Vl
and MTl.
Replace
controller
between Vl
From A (femaie) (4) and
~&ahaground 11 Short circuit with chassis
NO between Vl (female) (4) - replace
l Min. 1 MR
RES3 (female) 1
* Turn starting
switch OFF.
* Disconnect Vl
and AES3
VHMS controller
RT2 (HD-85086) Transmission

lubricating oil
Pressure sensor
TJW0254 I
WA1 200-3 20-857

0
TROUBLESHOOTING V-105.106
V-105 [E818] (Wrong connection of connector) is displayed in history
Cause Remedy

Replace
Is voltagebetween controller
WA (9). (12). V3A
(9). V3 B (121 and - Disconnection, defective
chassis ground as contact, short circuit with
shown in Table 17
Repair or
chassis ground, or short
replace
NO circuit in wiring harness
of improper voltage
Table 1
WA (9) -chassis ground V2A (12)-chassis ground V3A (9) - chassisground V3B (12)-chassis ground
Voltage (VI 20 - 30 v o-5v Q-5v 20 - 30 v
VHMS
TJW02542
V-106 [E821] (Abnormal controller) is displayed
Defective VHMS Replace or

controller (Failure in reinstall
securing memory) software
20-858 WA1 200-3
0
V-107 [E824] (Communication with CGC and engine controller is

impossible) is displayed in history
Cause Remedy
Defective CGC, engine

4YE! 5
controller, or VHMS Replace
Ir
I IS voltaae between
controller

Repair or
1 having abnormal value replace
m.*, w’mdcz uem.

bmw.3mJL,
m
IU
uamaw,z
d 01 Uemde, K m *
*Min.lMQ
* Turn starting
nnritch OFF.
1
NO
,ground in wiring harness
Ihaving abnormal value
Repair or
replace
hllll JL1 L‘nmdd II,

_._ H * Disconnect JLl. Disconnection or
ween JLl (male) (1)
and (2) and (6) and
E-II C2. Dl, and V4A. defective contact in Repair or
NO wiring harness having replace
between JLl (3) and
no switch OFF. abnormal value
- Disconnect jL1, C2, Dl, and V4A.
- Turn starting I IDefective joint connector
Replace
switch OFF. NO ,TJLl)
- Disconnect JLl .
VH
TJW02543
WA1 200-3 20459

0
V-108 fE8251 (Abnormality in S-NET communication between VHMS -

transmission controller) is displayed in history
* If E826, E827, and E828 occur simultaneously, disconnection, defective contact, short circuit with
chassis ground, or short circuit with power source has occurred in the VHMS controller or in the
wiring harness between V3A (8) and JL22 (1).
CallSo Remedy
Go to A. -
-. [tWC;;ss~sgrOund 1 1 Short circuitwith chassis

resistance
Is ground in wiring harness Repair or
MS betweenV3A -Min. 1 MS2 between V3A (female) (8) replace
Nf
(female) (8) and C3B . Turn starting - C3B (female) (4)
c (female) (4) normal? switch OFF. Disconnection or
_ - DisconnectV3A and
* Max. 2 R as. Repair or
- -Turnstarting NO replace
(male) (I) and (8) WA (female) (8) - C3B
switch OFF.
(male) (1) and (2)

I Disconnect V3A
NO
l
and C3B.
(female) (4)
Defective joint connector

(JL22)
Replace
Disconnect JL22.
- Max. 1D
* Turn starting I Defective joint connector
Replace
switch OFF. NO (JL17)
-Disconnect JL17.
Go to B. -
I Is resistance II
Replace
Defective joint connector

Replace
FromA i= * Turn starting NO (JL18)
- Max. 1V
* Disconnect V3A
and C3B.
11
NO
switch OFF.
* Disconnect JL18. Short circuit with power
between V3A (female) (8)
- C3B (female) (4)
Repair or
replace
*Turn starting
switch ON.
10 YE: Defective transmission
Replace
YES ~38(female) 112)
1s resrstancebe- ground normal? source in wiring harness Repair or
YES tween VW (female) replace
* Max. 1 V NI between V3A (female)
- (18). C3B (female) -
(12) and chassis . DisconnectV3A (18) - C3B (female) (12)
8 and US.
- ground normal? Short circuit with chassis
Is resistance *Turn starting switch ON
betweenV3A * Min. 1 MR ground in wiring harness Repair or
From B -) (female) (18) and - l Turn starting NO between V3A (female) replace
r.Z3;.Z;,male)112) switch OFF. (18) - C3B (female) (12)
- l Disconnect V3A Disconnection or
= Max. 2 R and C3B defective contact in Repair or
. Turn starting NO wiring harness between replace
switch OFF. WA (female) (18) - C3B
* Disconnect V3A (female) (12)
and C3B.
20-860 WA1 200-3

0
V-109 [E826] (Abnormality in S-NET communication between VHMS -

modulated clutch controller) is displayed in history
wiring harness between V3A (8) and JL22 (I).
Cause Remedy
4YE!
IC Gotok
Is voltage between
YES MO1 (female) It)
Is resistancebet-- ground normal? source in wiring harness Repair or
ween V3A (female) between V3A (female) (8) replace
. (81,MO1(female) (1) - -Max.lV
. DisconnectV3A
NC
- MO1 (female) (11
and chassisground
and Mol.
normal? Short circuit with chassis
- *Turn starting switch ON
l Min. 1 MD ground in wiring harness Repair or
l Turn starting NO between V3A (female) (8) replace
switch OFF. - MO1 (female) (1)
* Disconnect V3A Disconnection or defective
and Mol. contact in wiring harness Repair or
between JU2
(male) (1) and (7)
MO1 (female) (1)
. Disconnect V3A
* Turn starting I Defective joint connector

Replace
* Disconnect JL22.
7 YE:
Go to B. -
Is resistancebet-
YES ween WA (female)
- (18). M01 (female) -
6 (12) and chassis Short circuit with chassis
Is resistance ground normal? ground in wiring harness Repair or
YE between V3A between V3A (female) replace
* Min. 1 MR NC
(female) (181and - (18) - MO1 (female) (12)
. Turn starting
5 MO1(female) (12)
switch OFF.
normal?
Is resistance I - * DisconnectWA and MO1
sMax.2R contact in wiring harness Repair or
between JU3
From A * Turn starting NO betvveen V3A (female) (18) replace
(male) (1) and (7)
switch OFF. - MO1 (female) (12)
-I normal7 t
* Disconnect V3A
- Max. 1R and Mol. Defective joint connector
-Turn starting Replace
0 (JL23)
switch OFF.
. Disconnect JL23.
a MS Defective modulated
Replace
clutch controller
Isvoltage between
MO1 (female) (12) _
From 0 -
ground normal? source in wiring harness Repair or
- Max. 1 V NO between V3A (female) replace
l Disconnect V3A (18) - MO1 (female) (12)
and Mol.
l Turn starting
switch ON.
20-862 WA1 200-3

0
TWW02601
WA1 200-3 20-863

0
V-110 [E8271 (Abnormality in S-NET communication between VHMS -

work equipment controller) is displayed in history
wiring harness between V3A (8) and JL22 (I).
Cause Remedy
4YE! -
6 I c Gotok
$SZ&~H
I Is resistancebet- I ground in wiring harness Repair or
IL
y~z ween V3A Ifemale) between V3A (female) (8 replace
-Max.lV NC
- (8). L26 (female) (1) -
- DisconnectV3A - l.26 (female) (1)
2 and chassisground
and LZ6.
- normal? Disconnaction or defective
Is resistance - . Turn starting switch ON
* Min. 1 MD contact in wiring harness Repair or
YES betweenV3A
- (female) (8) and LZ6 - * Turn starting NO between V3A (female) (8) - replace
(female) (1) normal? switch OFF. L26 (female) (1)
1
* Disconnect V3A Disconnaction or defective
Is resistance *Max.2!.2 and L26. contact in wiring harness Repair or
between JL22 _ *Turn starting
(male) (1) and (2) switch OFF. NO
U6 (female) (1)
normal? * Disconnect V3A
- Max. 1R and L26.
. Turn starting Defective joint connector
Replace
switch OFF. NO (JU2)
. Disconnect JL22.
7 YE! -
Is resurtancebet-
Go to 0.
YES wee” V3A (female)
- (181.L26 (female) -
_ 6 (121and chassis Short circuit with chassis
Is resistance ,ground normal? ground in wiring harness Repair or
Y ; betweenV3A between V3A (female) replace
. Min. 1 MQ N(
*Turn starting (18) - L26 (female) (12)
L26 (female) (12)
switch OFF.
“o”nal? Disconnection or defective
I Is resistance I * DisconnectV3A and LZ6
lMax.2R contact in wiring harness Repair or
between JL23
From A . Turn starting NO between V3A (female) (181 replace
-I (male) (1) and (2) I switch OFF. - L26 (female) (12)
normal?
I l Disconnect V3A
- Max. 1R and L26. Defective joint connector
-Turn starting Replace
IO (JK3)
switch OFF.
. Disconnect JL23.

Replace
Is voltage between equipment controller
From S _ L26 (female) (12) _
*Max.lV NO between V3A (female) replace
l Disconnect V3A (18) - L26 (female) (12)
and L26.
-Turn starting
switch ON.
20-864 WA1 200-3

0
II II II
TWW02601
WA1 200-3 20-865

0
V-l 11 [E828] (Abnormality in S-NET communication between VHMS -

main monitor) is displayed in history
wiring harness between V3A (8) and JL22 (1).
CaUSS! Remedy
GotoA. -

between V3A (female) (81 replace
(female) (8) and LO8 - LO8 (female) (1)
(female) (11 normal?
. DisconnectWA and Disconnection or defective
aMax.2R 1 L08. contact in wiring harness Repair or
* Turn starting NO between V3A (female) (8) - replace
(male) (1) and (8) LO8 (female) (1)
switch OFF.
normal?
* Disconnect V3A
*Max.lR and L08. Defective joint connector
between JL17 Replace
. Turn starting (JL22)
(male) (1) and (6) switch OFF.
. Disconnect JU2.
.Max.lR
*Turn starting Defective joint connector
Replace
. Disconnect JL17.
7 YE -
Go to 8.
Is resistance
YES between JL23
6 (male) (1) and (8) -
normal? Defective joint connector
Is resistance qeplace
YES_ between JL18 _ * Max. 1 R NC (JL23)
(male) (1) and (6) -Turn starting
5
- normal? switch OFF.
Is voltage between * Disconnect JU3. Defective joint connector
- Max. 1 D ?eplace
Lo8 (female) (1) (JL18)
From A -c * Turn starting NO
and chassis
ground normal? switch OFF.
- Disconnect JL18. Short circuit with power
. Max. 1 V source in wiring harness qepair or
* Disconnect V3A between V3A (female) (8) aplace
NO
and L08. - Lo8 (female) (1)
* Turn starting
switch ON.
10 YE!
Is voltage between
YES LO8 (female) (3)
Is reswance bet- - ground normal? source in wiring harness Repair or
yes waen WA (female) between V3A (female) replace
*Max.lV N(
- (181. LO8(female) (3) -
s DisconnectV3A (18) - Lo8 (female) (3)
8 and chassisground
and L08.
Is resistance - * Turn starring switch ON
. Min. 1 MR ground in wiring harness Repair or
betweenV3A
From 6 -) (female) (18) and - . Turn starting NO betwean V3A (female) replace
LO8(female) (3) switch OFF. (18) - Lo8 (female) (3)
_normal? _ * Disconnect V3A Disconnection or
* Max. 2 R and LO8 defective contact in Repair or
-Turn starting wiring harness between replace
NO
switch OFF. V3A (female) (18) - Lo8
* Disconnect V3A (female) (3)
and L68.
20-866 WA1 200-3

0
Transmission
ontroller
TWW02601
WA1 200-3 20-867

0
TROUBLESHOOTING V-l 12
V-112 [E831] (Abnormal controller) is displayed in history
Jr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
20-868 WA1 200-3

0
V-l 13 [E8411 (Short circuit with power source in buzzer output

system) is displayed in history

Replace
controller
Isvoltage between
Vl (female) (16)
* Max. 1 V NO between Vl (female) (16) rePlace
- I39 (female) (2)
- Turn starting
switch OFF.
* Disconnect Vl
and L9g.
l Turn starting
switch ON.
Emergency
Parking brake
cancel switch
Main monitor LO6 (040 16) L89 (M4)

0.5fL
Fues (I)
VHMS controller Vl (07020) FS2 (S12 Blue)
Caution
Caution buzzer buzzer
relay
TJW02518
WA1 200-3 20-869

0
V-114 [E843] (Short circuit with power source in check lamp system)
is displayed in history
J, Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective VHMS
Replace
controller
Is voltage between
Vl (female) (14)
between Vl (female) (14) replace
* Max. 1 V NO
- LO6 (female) (10)
-Turn starting
switch OFF.
. Disconnect VI
and L06.
* Turn starting
switch ON.
VHMS Controller Main monitor
TJW02545
20-870 WA1 200-3

0
V-115 [E844] (Short circuit with power source in flash synchronizing

signal system) is displayed in history
Cause Remedy

Replace
Vl (female) (13)
; Max. 1 V NO between Vl (female) (13) replace
* Turn starting - LO7 (female) (6)
switch OFF.
* Disconnect Vl
and L07.
*Turn starting
switch ON.
VHMScontroller Main monitor
WA1 200-3 20-871

0
V-116 [E861] (Disconnection or short circuit with chassis ground in

boom bottom pressure sensor system) is displayed-in history
* Perform the following troubleshooting when fuse II-9 is not broken. If fuse II-9 is broken, check the
wiring harness between the fuse, VHMS controller, and F06 (female) (2) for short circuit with the
chassis ground.
Cause Remedy
4YES
* .I Go to A.
Is resistance
YES between JF3
3 r (male) (1) and (4)
Is resistance bet- Defective joint connector
YES ween ~06 (female) _ l Max. 10 NO (JF3)
(31 and chassis * Turn starting switch
_ 2 ground normal? OFF. Short circuit with chassis
If F06 (female) (3) is
YES groqded to chassis, * Min. 1 MR - Disconnect JF3. ground in wiring harness Repair or
_ IS resonancebetween _ between Vl (female) (1) -
Vl (female1 (1) and l Turn starting NO replace
1 switch OFF. FfE (female) (3)
ck%?grc”“d
n 1 * Disconnect Vl
*Max.10 and F06. contact in wiring harness Repair or
of boom head l Turn starting between Vl (female) (1) -
NO replace
pressure switch, is switch OFF. F06 (female) (3)
* Disconnect Vl
. Turn starting and F06.
switch ON. Defective boom bottom
NO pressure sensor
YES Defective VHMS

controller
- Max. 1 Q
-Turn starting
NO
Fo6 (female) (2) - Vl
(female) (81, (9)
Repair or
replace
switch OFF.
. Disconnect F06
and Vl.
204372 WA1 200-3

0
TkOUBLESHOOTlNG V-116
VHMS
Boom
bottom
pressure
sensor
TWW02602
WA1 200-3 20-873

0

boom head pressure sensor system) is displayed in history
* Perform the following troubleshooting when fuse II-9 is not broken. If fuse II-9 is broken, check the
wiring harness between the fuse, VHMS controller, and F14 (female) (2) for short circuit with the
chassis ground.
Cause Remedy
4YES -
Gotok
Is resistance
ez betweenJF3
8 (male) (1) and (5)
normal? Defective joint connector
Replace
_ .Max.lR NO (JF3)
*Turn starring switch
&_ ground normal? OFF. Short circuit with chassis
If F14 (female) (31 if
yES groundedto chasrx * Disconnect JF3. ground in wiring harness Repair or
* Min. 1 MD
_ I* resistancebetween _ between Vl (female) (10) replace
- Turn starting NO
Vl (female) (10) and
chassisground switch OFF. - F14 (female) (3)
lDisconnect Vl Disconnection or
replaced with that and F14. defective contact in Repair or
of boom bottom *Turn starting NO wiring harness between replace
pressure switch, is switch OFF. Vl (female) (10) - F14
l Disconnect Vl (female) (3)
*Turn starting and F14.
Defective boom head
switch ON. Replace
NO pressure sensor
Defective VHMS Replace

controller
-
Repair or
i---- wiring harness between
NO replace
Max. 1 Q F14 (female) (2) - Vl
* Turn starting (female) (81, (9)
switch OFF.
* Disconnect F14
and Vl.
20-874 WA1 200-3
0
VHMS
controller
TJW02548
WA1 200-3 20-875

0

rea.r brake oil pressure sensor system) is displayed in history
* If E864, E865, E867, and E868 occur simultaneously, disconnection, defective contact, or short
circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JR14
(female) (1).
Cause Remedy
Defective rear brake oil
I
Replace
pressure sensor
1 4YE
1 If rear brake oil 1 Ilf HR16 (female) (2) is Ir GotoA. -
1 pressuresensor is 1

between Vl (female) (2) - replace
. Turn starting
HR16 (female) (2)
switch OFF.
* Replace pressure Disconnection or defective
sensor with JR14 (male) (1) and
- Max. 1R I Vl. contact in wiring harness Repair or
(5). between JL2 between Vi% (female) (8) -
normal one. * Turn starting NO replace
-Turn starting HR16 (female) (31
switch OFF.
switch ON. * Disconnect HR16
- Max. 1 Q Joint connector having
and V2k
-Turn starting improper resistance Replace
switch OFF. IO (JR14, JL2, or JR131
. Disconnect JR14,
Jl2, or JR13.
Replace
I Is resistance bet- 1r controller

YI ,~~~ between Vl (female) (2) - replace
HR16 (female) (2)
From Aie/ * Turn starting

switch OFF.
* Disconnect V2A
NO
- HR16 (female) (3)
Repair or
replace
lMax.lR Disconnection or defective

and HR16. Repair or
. Turn starting contact in wiring harness
between HR16 (female) (1) replace
switch OFF.
-chassis ground
. Disconnect
HR16.
20-876 WA1 200-3

0
VH
JRl3tDTlB)
RAlO (DTHD4)
Battery 8L
TJW02531
WA1 200-3 20-877

0

work equipment relief pressure sensor system) is displayed in
history
inserted.
+r Before carrying out troubleshooting, check that all the related connectors are properly
short
* If E863, E865; E867, and E878 occur simultaneously, disconnection, defective contact, or
ground has occurred in the wiring harness between VI (female) (2) and JR14
circuit with chassis
(female) (I).
Cause Remedy
MS Defective work
equipment relief Replace
pressure sensor
l
sensor is replaced
with normal one,
system normal?
. Turn starting
switch OFF.
Replace
pressure sensor
wth normal
one. (steering
oil pressure
is
I r
I
YI
2
If HSZ Ifemale I31 is
grounded to chassis, is
resistance between WA
(181 and
Ifemale)
chassis
switch OFF.
round normal?
* Disconnect HS2
YES
3
1If HS2
*Turn
NO
OFF.
Vl.
Ifemale)
round normal?
- Max. 1 R
starting
* Oisconnect
(2) is
grounded to chassis, is
resistance between Vl
bnale) (2) and chassis
switch
HS2 and
NI
Gotok
between Vl (female) (2) -
HS2 (female) (2)
behveen V2A (female) (18)
- HS2 (female) (3)
Joint connector having

-
Repair or
replace
Repair or
replace
sensor) - Max. 1 R and WA. improper resistance

* Turn starting * Turn starting Replace
0 fJR14, JL2, JR16, or
switch ON. switch OFF.
JR13)
* Disconnect JR14,
JL2, JRl6, or
JR13. 7 YE! Defective VHMS
Replace
1 tS resistanca bet- ir controller

ground in wiring harness qepair or
between Vl (female) (2) - .eplace
HS2 (female) (2)
5
1Is resistance I ground in wiring harness 3epair or
between V2A (female) pplace
FromA ~~~0{~~ * Turn starting NO
switch OFF. (18) - HS2 (female) (2)
l Disconnect V2A Disconnection or defective
*Max.lR and HS2. qepair or
* Turn starting between HS2 (female) (1) - aplace
IO
l D&connect HS2,
20-878 WA1 200-3

0
VHMS
ipment
ii
e sensor
RAlO [DTHDI)
Bat terv
000 I
TJW02550
WA1 ZOO-3 20-879

0

front brake oil pressure sensor system) is displayed in history
Jr Always connect any disconnected connectors before going on to the next step.
Ir If E863, E864, E867, and E878 occur simultaneously, disconnection, defective contact, or short
(female) (1 I.
Cause Remedy
Defective front brake oil

Replace
pressure sensor
4YES
GotoA -
tf HR15 (female) CZ! is
YES groupded to chassis,
_ IS resistance between _
3 ;f;;kNand Disconnection or defective
If HR15 (female)(3) is normal? contact in wiring harness Repair or
groundedto chassis.
* Turn starting
n is resistancebetween _ aMax.lC.2 NC between Vl (female) (2) - replace
WA (female)(7) and * Turn starting switch HRl5 (female) (2)
switch OFF. 2 f;~~7ground OFF.
- Replace Is resistance between - DisconnectHRlS Disconnection or defective
‘I,,,
pressure sensor JR14 (male) (1) and * Max. 1 R and Vl. contact in wiring harness Repair or
(6). between JLZ between VZA (female) (7) -
with normal * Turn starting NO replace
~0 (male) (3) and (51, or
one. (rear brake betwean JR13 (male) switch OFF. HRl5 (female) (3)
oil pressure 1 and 6 normal?
. Disconnect HR15
sensor) -Max.1 R Joint connector having
and V2A.
. Turn starting -Turn starting improper resistance Replace
switch OFF. IO (JR14, JL2, or JR131
switch ON.
l Disconnect JR14,
JL2, or JR13.
7 YES
1r
Defective VHMS
1IS resistance bat- Replace
controller

M between Vl (female) (2) - replace
~ HR15 (female) (2)
5
I Isresistance I Repair or
From A dig::; 1 between VZA (female) (7) replace
- Turn starting NO
switch OFF. - HR15 (female) (3)
* Disconnect V2A Disconnection or defective
* Max. 1 R and HR15. Repair or
l Turn starting replace
0 between HR15 (female) (1)
switch OFF. -chassis ground
* Disconnect HR15.
20-880 WA1 200-3

0
VHMS
JR13tDTIB1
Fran t brake
oi I Pressure
TJW07.530
WA1 200-3 20-881

0

transmission main relief pressure sensor system) is displayed in
history
* Before carrying out troubleshooting, check that ail the related connectors are properly inserted.
+ If E868, E871, and E884 occur simultaneously, disconnection, defective contact, or short circuit with
chassis ground has occurred in the wiring harness between Vl (female) (2) and JT2 (female) (1).
Cause Remedy
main relief pressure Replace
sensor
4YEI
Go to A. -
If MT2 (female)(2) is
MS groundedto chassis,
_ 1sresistancebetween _
sensor is replaced 3 Vl (female)(2) and
- chassisground Disconnection or defective
If MT2 (female)(3) is normal? , contact in wiring harness Repair or
groundedto chassis,
Yl is resistancebetween _ .Max.lQ NC between Vl (female) (2) - replace
* Turn starting
*Turn starting switch MT2 (female) (2)
switch OFF. OFF.
. Replace pressure , * DisconnectMT2 and Disconnsction or defective
sensor with Imale)
(1)and12).kwaen * Max. 1 Q Vl. contact in wiring harness Repair or
normal one. JLZImaW(31and (0. between V2A (female) (6) -
*Turn starting NO replace
- Turn starting switch OFF. MT2 (female) (3)
switch ON. . Disconnect MT2
* Max. 1 n and WA. Joint connector having
l Turn starting improper resistance (JTZ, Replace
switch OFF. 0 JK, JT3, or JLll)
* Disconnect JTZ,
JL2, JT3, or JLll.
Replace
controller
Yl
iS[
1Is resistancebet- 1 ground in wiring harness Repair or
YE . Min. 1 MQ NO between Vl (female) (2) - replace
*Turn starting switch MT2 (female) (2)
6 OFF.
I Is resistance - DisconneciVl and Short circuit with chassis
1
From A -f%$%~ . Min. 1 MR
- Turn starting
switch OFF.
between VZA (female) (6)
- MT2 (female) (3)
replace
. Disconnect VZA Disconnection or dsfsctive

.Max.lR and MTZ. contact in wiring harness Repair or
* Turn starting between MT2 (female) (1) - replace
0
l Disconnect MT2.
20-882 WA1 200-3

0
VHMS
.._ Transmission
main relief
ensor
TJWO2552
WA1 200-3 20-883

0

steering relief pressure sensor system) is displayed in history
* If E863, E864, E865, and E878 occur simultaneously, disconnection, defective contact, or short
(female) (1).
Cause Remedy
ES Defective steering relief

pressure sensor
1 GotoA. -
1 If steering relief 1

HS3 (female) (2)
switch OFF.
- Replace pressure Disconnection or defective
sensor with (1)ad (41.between
(male) - Mar 1R 1 Vl. contact in wiring harness Repair or
JU Imale) Bland(5). between WA (female) (16) replace
normal one. berwem JR16(male1121
*Turn starting NO
switch OFF. - HS3 (female) (3)
and(41.or- JR13
switch ON. * Disconnect HS3 Joint connector having
l Max. 1 R and V2k improper resistance
* Turn starting
(JR14, JU, JR16, or
switch OFF.
JR13)
* Disconnect JR14,
JU, JR16, or
Ir
JR13. Replace
I IS resistancebet- controller
(21, HS3 (female) (2)

and chassisground Short circuit with chassis
ween VZA (female)
normal
. _. -MI2
I IL
YE NC between Vl (female) (2). replace
(16). HS3 (female) -Turn starting switch HS3 (female) (2)
Ai61 - DisconnectVI and Short circuit with chassis

* Min. 1 MD 1 HS3. ground in wiring harness Repair or
From * Turn startino NO between V2A (female) replace
switch OFF.- (16) - HS3 (female) (3)
. Disconnect V2A Disconnection or defective
- Max. 1 R and HS3. contact in wiring harness Repair or
- Turn starting
IO between HS3 (female) (1) - replace
* Disconnect HS3.
20-884 WA1 200-3

0
VHMS
Steering
relief oil
sensor
TJW02553
WA1 200-3 20-885

0

torque converter outlet oil pressure sensor system) is displayed
in history
* If E868, E871, and E884 occur simultaneously, disconnection, defective contact, or short circuit with
chassis ground has occurred in the wiring harness between VI (female) (2) and JT2 (female) (1).
Cause Remedy
Defective torque
YES Replace
converter outlet oil
pressure sensor
4YE! -
1 Gotok
If MT3 Wemale)(2) is
rlf tOmu 000v.3-ter
YES grounded to chassis,
outlet oil pressure _ ts resistancebetween _
sensor is replaced 3 Vl (female)(2) and Disconnection or defective
chassis,ground
If MT3 (female)(3) is contact in wiring harness Repair or
; gmundedto chassis, * Max. 1 n
-gfUMf.
. ISresistancebetween _ NC
* Turn starting *Turn starting switch MT3 (female) (2)
WA (female)(5) and
switch OFF. &&siiTground OFF.
* Replace pressure - - DisconnectMT3 and Disconnection or defective
sensor with ImaId and(4). betwen . Max. 1R Vl. contact in wiring harness Repair or
JKlmabJfllaed(41, *Turn starting between ‘&!A (female) (5) - replace
normal one. NO
- Turn starting switch OFF. MT3 (female) (3)
switch ON. . Disconnect MT3
lMax.lR Joint connector having
and V2k
*Turn starting improper resistance (JT2, Replace
switch OFF.
IO JU, JT3, or JLll)
l Disconnect JT2,
Jl.2, JT3, or JLl 1.
Replace
yEs ween Vl (female)
- (2). MT3 (female) (2) -
- and chassis ground
Is resistancebet- normal? ground in wiring harness Repair or
wean WA (female) --Min. 1 MS2 - between Vl (female) (2) - replace
YI NC
(5).MT3(female) (31 - * Turn starting switch MT3 (female) (2)
5 and chassisground OFF.
normal? - * DisconnectVl and Short circuit with chassis
I Is resistance I
* Min. 1 MR MT3. ground in wiring harness Repair or
From A ~~~rr?.~~ * Turn starting NO between V2A (female) (5) replace
switch OFF. - MT3 (female) (3)
* Disconnect WA Disconnection or defective
*MaxlR and MT3. contact in wiring harness Repair or
* Turn starting between MT3 (female) (1) - replace
- Disconnect MT3.
20-886 WA1 200-3
0
Tome converter
VHMS outlet oil
ensor
TJW02554
WA1 200-3 20-887

0

transmission modulation pressure sensor system) is displayed
in history
* if E864, E865, E867, and E878 occur simultaneously, disconnection, defective contact, or short
circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JT2
(female) (I 1.
Cause Remedy
YES Replace
modulation pressure
sensor
4YE -
If MT5 (female) (2) is
yEs gryded to chassis,
_ IS resistance between _
3 Vl (female) (2) and
If MT5 (femalejob ~o~$ground contact in wiring harness Repair or
; groundedto chassis,
n . ISresistancebetween - Max. 1 Q between Vl (female) (2) - replace
* Turn starting v2A (female)(151and - ‘$ starting switch N’ MT5 (female) (2)
switch OFF. i FoEi&ground
- Replace pressure - Disconnact MT5 and Disconnection or defective
- Max. 1 R Vl. contact in wiring harness Repair or
sensor with
JL2 (male) 13)and(4). between V2A (female) (15) replace
normal one. - Turn starting NO
I bshwnJT3lmakl~1lad
U. orbetwen JLll ImaW switch OFF. - MT5 (female) (3)
l Turn starting
switch ON. * Disconnect MT5
.Max.lR and WA.
improper resistance (JT2, Replace
. Turn starting
JO JL2, JT3, or JLll)
switch OFF.
mDisconnect JT2,
JL2, JT3, or JLll.
7 YE Defective VHMS
Replace
Is resistance bet- fr controller

MT5 (female) (2)
5
I Is resistance I
From A -jz;?tt * Turn starting
switch OFF.
NO
between V2A (female)
(15) - MT5 (female) (3)
Repair or
replace
- Max. 1 R
* Turn starting
. Disconnect V2A
and MT5
between MT5 (female) (1) -
Repair or
replace
. Disconnect MT5.
20-888 WA1 200-3

0
I
sor
TJW02555
WA 1200-3 20-889
0
V-125 [ES721 (Disconnection or short circuit with chassis ground in

transmission lubricating oil pressure sensor system) is
displayed in history
Cause Remedy
lubricating oil pressure Replace
sensor
1 4YE!
Gotok -
transmlsslon If MT1 (female) (2) is
lubricatingoil yEs younded to chassis,
pressure sensor is _ u.resistancebetween_
replaced with 3 Vl (female1(5) and Diaconnaction or defective
normal one, is It MT1 &zmale)(3) is chassisgmund
1:. em normal? YES youndedtochassis, RQRMR between Vl (female) (5) -
_ 1sresisrancebenueen _ -Max.lQ NC replace
* Turn starting VZA (female)(14) and *Turn starting switch MT1 (female) (2)
switch OFF. 2 r;h%&s$ground OFF.
* Replace pressure Is resistance bet- - - DisconnectMT1 and Disconnection or defective
sensor with ween .JT5 (male) (1) * Max. 1 R Vl. contact in wiring harness Repair or
and (5) and between - Turn starting between V2A (female) (14) replace
normal one. l
NO
NIO JLll (male) (1) and - MT1 (female) (3)
switch ON. r4) “orr”a’L . Disconnect MT1
* Max. 1 R and VZA. Joint connector having
* Turn starting improper resistance (JT3 Replace
NO orJRl1)
switch OFF.
* Disconnect JT3
and JR11
BYE: Defective VHMS
Replace
controller

YI between V2A (female) replace
(14) - MT1 (female) (3)
6
Is resistance bet- Short circuit with chassis
yes wen V2A (female) ground in wiring harness Repair or
- (14). MT1 (female) * Turn starting NO between Vl (female) (5) - replace
(3) and chassis MT1 (female) (2)
5 switch OFF.
- , ground normal?
+ Disconnect Vl
Is resistance Short circuit with chassis
From A betwee” MT1 - Min. 1 MD and MTl. ground in wiring harness Repair or
- (female) (1) and - -Turn starting between V2A (female)
uo replace
chassisground switch OFF. (14) - MT1 (female) (3)
normal? . * Disconnect V2A
. Max. 1 R and MTI. Disconnection or defective
contact in wiring harness Reoair or
* Turn starting
NO betwean MT1 (female) (1) -
switch OFF.
chassis ground
* Disconnect MTl.
20-890 WA1 ZOO-3

0
Transmission
VHMS lubricating
oil pressure
sensor
1
rb7 TJW02556
WA 1ZOO-3 20-891
0
V-126 [E874] (Short circuit with chassis ground in torque converter oil
temperature sensor system) is displayed in history

Replace
Is reGstanc8between controller
YES WA (female) (3). T24
- (female)(1) and
,_ chassisground
IlOmMl? ground in wiring harness Repair or
Is resistance
between V2A (female) (3) replace
between T24 _ *Min.lMR NO
- T24 (female) (1)
(male) (1) and 12) *Turn starting
normal? switch OFF.
Defective torque
. Disconnect V2A and T24.
- 40 kf2 at normal converter oil temperature Replace
temperature NO sensor
(25°C)
-Turn starting
switch OFF.
* Disconnect T24.
Torque convert er
V-126 Related electrical circuit diagram oil temperatur e
I_--.__
sensor unon I Ior)
VHMS kUKl
controller
20-892 WA1 200-3

0
V-127 [E8751 (Short circuit with chassis ground and with power
source in hydraulic oil temperature sensor system) is displayed
in history
* Before carrying out troubleshooting, check that all the related connectors are orooerly inserted.
* Always connect any disconnected connectors before going on to the next stei. ’
Cause Remedy

Replace
Ez V2A (female) (11)
PIs rasisIaGce
belwaan ground normal? source in wiring harness
y~z VZAifemale) IllI. HSl - p Replace
-Max.lV NO between V2A (female)
- (female) (1) and * Turn startingswitch (7 1) - HSl (female) (1)
1 chassisground OFF.
_ _normal? - DisconnectWA and HSl. Short circuit with chassis
* Min. 1 MR *Turn startingswitch ON. ground in wiring harness
between HSl replace
- * Turn starting NO between V2A (female)
(male) (1) and (2) (female)(l)
switch OFF. (ll)-HSl
normal?
* Disconnect V2A and HSl.
- 3.5 - 4.0 M at
Defective hydraulic oil
normal Seplace
NO temperature sensor
temperature
(25°C)
* Turn starting
switch OFF.
* Disconnect HSl.
VHMS
roller
V2A(07018)
Hrdraul ic oi I
LR2 (HO-85086) sensor
8 2801
TJW02528
WA1 200-3 20-893

0
V-128 [E875] (Short circuit with chassis ground in ambient

temperature sensor system) is displayed in history
J, Always connect any disconnected connectors before going on to the next step.
-
Cause Remedy
4YE: Defective VHMS

Replace
YES VIA (female) (10)
3 r and chassis Short circuit with chassis
- Is resistanoe
between ground normal? Repair or
; VZAIfemale)(10).PHl -- Max. 1 v _
NC between V2A (female) replace
- (female1(1) and - -Turn starting switch (10) - PHl (female) (1)
dwsis ground OFF.
nonal? < - Disconnect V2A and PHl Short circuit with chassis
* Min. 1 MR Turn Rarting switch ON. ground in wiring harness Repair or
- Turn starting NO between V2A (female) replace
switch OFF. (10) - PHl (female) (1)
l Disconnect V2A
Is resistance Disconnection or
* Max. 1 R and PHl.
between PH 1 defective contact in Repair or
- * Turn starting
(male) (1) and (2) IO wiring harness between replace
switch OFF.
normal? V2A (female) (10) - PHl
* Disconnect V2A
(female) (1)
* Approx. 12 kf2 at and PHI.
normal I Defective ambient
temperature NO temperature sensor
(25’C)
*Turn starting
switch OFF.
- Disconnect PHl.
VHMS
rol ler VZA (070 I81
.
temperature
LR2 (~~-85086)
0.76fE
TJWO2557
20-894 WA1 200-3

0
TBQUBLESHOOTING v-129

PPC relief pressure sensor system) is displayed in history
Ir If E863, E864, E865, and E867 occur simultaneously, disconnection, defective contact, or short
(female) (1).
Cause Remedy
YES Defective PPC relief

Replace
pressure sensor
1 4 YE? -
Gotok
If HS4 (female)(2) is
If PPC relief pressure MS groundedto chassrs,
sensor is replaced rsresotance between _
3 - Vl (female)(2) and Disconnection or defective
with normal one, is - ;has$ground
system normal? If HS4 (female)(3) is o a contact in wiring harness Repair or
El groundedto chassis,
YI is r&stance betwean _ - Max. 1 Q N( between Vl (female) (2) - replace
* Turn starting V2A (female)(11and -Turnstarting switch HS4 (female) (2)
switch OFF. 2 chassisground OFF.
l Replace pressure normal? * Disconnect HS4 and
sensor with * Max. 1 R Vl. contact in wiring harness Repair or
normal one. * Turn Starting NO between V2A (female) (1) - replace
switch OFF. HS4 (female) 13)
-Turn starting
switch ON. * Disconnect HS4
-Max. 1R and V2A.
improper resistance Replace
* Turn starting
IO (JR14, JU, or JR71
switch OFF.
* Disconnect JR14
JL2, or JR7.
7 YE: Defective VHMS
Replace
yfzs ween Vl (female)
- (2). HS4 (female) 12) -
_ 6 and chassis ground Short circuit with chassis
Is resistancebet- normal? ground in wiring harness Repair or
YES ween VZALfemale) P
* Min. 1 MR - between Vl (female) (2) - replace
NC
- (1). HS4Jfemale) (3) - *Turn starting switch HS4 (female) (2)
5 and chassisground OFF.
-
Is resistance ~ normal? . DisconnectVl and Short circuit with chassis
between HS4 * Min. 1 MR I ground in wiring harness Repair or
From A - (female) (1) and - -Turn starting NO between V2A (female) (1) replace
chassisground _. . .
Switch ncF - HS4 (female) (3)
normal?
*Discon lnect V2A Disconnection or defective
- Max. 1 Q and HS4. contact in wiring harness Repair or
. Turn starting between HS4 (female) (1) - replace
NO
. Disconnect HS4.
20-896 WA1 200-3

0
VHMS
JR14tDT2)
RA5 (DTt)
RAlO(DTHD4)
000 I
WA1 200-3 20-897

0

torque converter inlet oil pressure sensor system) is displayed
in history
+ If E866, E868, and E871 occur simultaneously, disconnection, defective contact, or short circuit with
chassis ground has occurred in the wiring harness between VI (female) (2) and JT2 (female) (1).
Cause Remedy
YES Defective torque

converter inlet oil Replace
pressure sensor
iS -
Gotok
1 .~.
YES ground&dtc chassis,
_ IS reststance between _
3 Vl (female) (2) and
If chassis wo”“d contact in wiring harness
svstem normal?. Repair or
YES gmu?ded to chassis, .normal)
_ IS resmance between _ - Max. 1 R N IO between Vl (female) (2) - replace
- Turn starting VZB (female) (10) and * Turn starting switch MT4 (female) (2)
switch OFF. 2 ;has$is,ground OFF.
- Replace pressure kresatancebetwenJT2 - o a _ *Disconnect MT4 and Disconnection or defective
sensor with (male)(1) ard (3). between - Max. 1 Q ‘ VI. contact in wiring harness Repair or
_ JK Imale) Ill and (3). between V2B (female) (10)
normal one. NO replace
NO bSweenJT3Imale)~l)and - -Turnstarting
- Turn starting (3).orbetween JLll (male) switch OFF. - MT4 (female) (3)
(11and I21normal? - Disconnect MT4
switch ON.
- Max. 1 R and V2B. Joint connector having
Turn starting
l
improper resistance (JT2 Replace
NO JL2, JT3, or JLll)
switch OFF.
* Disconnect JT2,
JL2, JT3, or JLll.
7YE S Defective VHMS
Replace
1 Is resistance bet- II controller

3 between Vl (female) (2) - peplace
MT4 (female) (2)
5
I Is resistance I
FromAdgCt%; 1 between V2B (female) .eplace
- Turn starting NO
(10) - MT4 (female) (3)
switch OFF.
- Disconnect V2B Disconnection or defective
l Max. 1 R and MT4. ,contact in wiring harness Iepair or
- Turn starting 1between MT4 (female) (1) - ,eplace
IO
switch OFF. ,chassis ground
- Disconnect MT4.
20-898 WA1 200-3

0
VHMS
Tome t:onverter
inlet oi I Dressure
sensor
Cl
TJW02559
WA1 200-3 20-899

0
V-201 Disconnection or short circuit with power source in 24-V

system of sensor power supply
k Always connect any disconnected connectors before going on to the next step.
* Since the GND line harness of VHMS cannot be disconnected basically (for the multi-pole design),
CaUSe Remedy

controller Replace
Is voltage between
YES Vl (female) 12) and _ Short circuitwith power
1 r chassis around source in wiring harness
I normal?- II between Vl (female) (2) and
MTI, 2,3,4,5 (female) (2). Repair or
NO and berween Vl (female) (2) replace
lfcmalsl I21 and hrrl, 2, l Min. 1 V and HR15.16 (female) (2).
3.4,5 Ifemale) (21, and *Turn starting switch OFF. HS2,3,4, (female) (21
between V1 Ifemale) (2)
and HR15. 16 (female) * Disconnect Vl, MT1 - 5, HR15.16, and HS2 - 4. Disconnectionor defective
(2). HS2.3.4, (female)
. Turn sartina switch ON. contact in wiring harness Repair or
between Vl (female) (2) and replace
* Max. 1R MTl. 2.3,4,5 (female) (2).
* Turn starting and between Vl (femaie) (2)
and HR15, 16 (female) (2),
switch OFF. HS2,3,4, (female) (2)
* Disconnect Vl,
MT1 - 5, HR15,
16, and HS2 - 4.
20-900 WA1 ZOO-3

0
Transmission
main relief
Pressure sensor
Toraue converter
outlet oil
Pressure sensor
Torque converter
inlet oil
Pressure sensor
Transmission
modulated oil
Pressure sensor
FRZIHD-46082) RT2 (HD-85086)
LR2(HD-85086) JRl4tOT2)
A 5OOC o'75f8
Front brake oil

Pressure sensor
Rear brake oil

Pressure sensor
Work equipment relief

oil Pressure sensor
Steering relief
oil Pressure sensor
Pressure sensor
TJW02539
WA1 200-3 20-901

0
V-202 Disconnection or short circuit with power source in 12-V

system of sensor power supply
f Since the GND line harness of VHMS cannot be disconnected basically (for the multi-pole design),
I CaUSe 1 Remedy

YES Vl (female) (3). F15
- (female) Ill and - Short circuit with power
1 chassis ground
If Vl (female) (3) is normal?
gmundedtochassis. - s between Vl (female) 13) - replace
IS resistance between _ * Max. 1 V NO
FlS (female) (1)
F15 @male) (1) and lTurn starting switch OFF.
&E;,ground
Disconnect Vl and F15.
l Disconnection or
*Turn starting switch ON. defective contact in Repair or
-Max.lQ
*Turn starting NO
Vl (female) (3) - F15
switch OFF.
(female) (1)
* Disconnect Vl and F15
Wheel rotation
VHMS controller
sensor
VI (07020) FL2 (HD-25086) F 15 (DT2)
)O”fP”f (f24V)j307( 3 B 307 1 307
TJW02540
20-902 WA1 200-3
0
V-203 Disconnection or short circuit with power source in 5-V system

of sensor power supply
* Since the GND line harness of VHMS cannot be disconnected b
4YEs
rk voltage between fA GotoA. -

between R05 (female) (1) - replace
RES3 (female) (2)
1 normal? Disconnection or defective
* Max. 1 R contact in wiring harness Repair or
RES3 (female) (1) * Turn starting between R05 (female) 11) - replace
and chassis ground switch OFF. RES3 (female) (2)
Is resistance - Disconnect R05 I Short circuit with power
l-l
between Vl .Max.lV and RES3. source in wiring harness Repair or
(female) (4) and . Turn starting between Vl (female) (4) -
NO replace
REs3 (female) (1) switch OFF. RES3 (female) (1)
normal? l Disconnect Vl and RES3.
s Max. 1 Q * Turn starting switch ON. Disconnection or defective
* Turn starting contact in wiring harness Repair or
switch OFF. NO between Vl (female) (4) - replace
* Disconnect Vl FiES3 (female) (1)
and RESJ.
Defective VHMS
Replace
controller
~ha&sground 11 Short circuit with power

- Max. 1V NC
*Turn staning MT1 (female) (2)
switch OFF.
1normal? - DisconnectVl and MTl. Disconnection or
* Max. 1 R -Turn Sartina switch ON. defective contact in Repair or
* Turn starting wiring harness between replace
NO
switch OFF. Vl (female) 6) - MT1
* Disconnect Vl (female) (2)
and MTl.

VHMS controller
Transmi ss ion
lubrica tina oil
Dressur e sensor
TJW02541
WA1 200-3 20-903

0
V-204 Disconnection or short circuit with chassis ground in buzzer

output system
*
Replace
MS Wee” Vl (female)
- (16). LSS (female1 (2) -
1 ~ Short circuit with chassis
If Vl (female) (16) is _ a”d chassis ground ground in wiring harness Repair or
normal?
grounded to chassis,
between Vl (female) (16)
is resiRance between _ * Min. 1 MC? NO replace
L99 @male) (2) and l Turn starting - L99 (female) (2)
ckzssztground
switch OFF. Disconnection or
l Disconnect Vl and L99. defective contact in Repair or
* Max. 1 R
* Turn starting NO wiring harness between replace
switch OFF. Vl (female) (16) - L99
. Disconnect Vl (female) (2)
and L99.
V-204 Related electrical

circuitdiagram
Emergency
parking brake
cancel switch
Main monitor L89

LO6 (040 16) (M4)
0.5fL I
0.. 3 124AC
I8 i> t
1
I
Fues (11
VHMS controller Vl (07020) II FS:
- ! (S12 Blue)
I
ion
er
A TJW02516
20-904 WA1 200-3

0
V-205 Disconnection or shot-t circuit with chassis ground in check

lamp system
Jc Always connect any disconnected connectors before going on to the next step.

Replace
I Is resistance bet- II controller I
YES ween VI (female)
- (14).LO6 (female) -
_ 1 (10) and chassis Short circuit with chassis
‘If Vl (female)(14) is ground normal? ground in wiring harness Repair or
ground&to chassis, between Vl (female) (14) replace
is resistancebetween _ . Min. 1 MQ NO
LO6(female) (10) and - LO6 (female) (10)
*Turn starting
chassisground
normal? switch OFF. Disconnection or
* Disconnect Vl and L06. defective contact in Repair or
l Max. 1 R
. Turn starting NO wiring harness between replace
switch OFF. Vl (female) (14) - LO6
* Disconnect Vl (female) (10)
and LO&
Main monitor
TJW02545
WA1 ZOO-3 20-905

0
V-206 Disconnection or short circuit with chassis ground in flash

synchronizing signal system
Cause Remedy

Replace
controller
1
~~;za;;ssis ground f Short circuit with chassis
grounded to chassis, replace
NO between Vl (female) (13)
is resistance between - Min. 1 MQ
LO7 (female) (61 and *Turn startina - LO7 (female) (6)
- Max. 1Q I switch OFF.-

* Disconnact Vl and L07.
Disconnection or
replace
-Turn starting NO wiring harness between
switch OFF. Vl (female) (13) - LO7
. Disconnect Vl (female) (6)
and L07.
VHMS controller Main monitor

LO7 (04012)
TJW02546
20-906 WA1 200-3

0
V-207 Short circuit with power source in boom bottom pressure

sensor system
Cause Remedy

Replace
controller
Is voltage bet-
ween VI (female)
(1) and chassis Short circuit with power
- Max. 1 V NO
F06 (female) (3)
* Turn starting
switch OFF.
* Disconnect Vl
and F06.
* Turn starting
switch ON.
TJW0.2547
WA1 200-3 20-907

0
V-208 Short circuit with power source in boom head pressure sensor
system
j, Always connect any disconnected connectors before going on to the next step.
Cause Remedy

Is voltage bet- controller
ween Vl (female)
(10) and chassis Short circuit with power
between Vl (female) (10) replace
l Max. 1 V NO
- F74 (female) (3)
* Turn starting
switch OFF.
mDisconnect Vl
and F14.
* Turn starting
switch ON.
VHMS
TJW02548
20-908 WA1 200-3
0
V-209 Short circuit with power source in rear brake oil pressure
sensor system
I cause I Remedy

Replace
Is voltagebetween controller
V2A (male) (8).
HR16 (female) (3) -
and chassis ground
normal?
.Max.lV NO
- HR16 (female) (3)
*Turn starting
switch OFF.
l Disconnect V2A
and HR16.
*Turn starting
switch ON.
V-209 Relatedelectrical circuit diagram
JR13 (DTlB)
JR14 (DT2)
e
oil wessure
RA5 CDT11
RAt 0 (DTHD4)
Bat terv OL
TJW02531
WA1 200-3 20-909

0
V-210 Short circuit with power source in front brake oil pressure
sensor system

Replace
Is voltagebeMeen controller
VZA (female) (7).
HR15 (female) (3) - ~ Short circuit with power
and chassisground source in wiring harness Repair or
normal?
~between V2A (female) (7) replace
Max. 1 V NO
l
- HR15 (female) (3)
l Turn starting
switch OFF.
l Disconnect WA
and HR15.
l Turn starting
switch ON.
JR13 (DTIB)
LR7 (DTI)
RAI 0 (DTHD4)
000 I
TJW02530
20-910 WA1 200-3
0
TROUBLESHOOTING v-21 1
V-211 Short circuit with power source in work equipment relief

pressure sensor system
Remedy
t-=
ISvoltage between Replace
controller
V2A (female) (18).
HS2 (female) (3) and -
IllJmlal? source in wiring harness Repair or
NO between V2A (female) replace
* Max. 1 V
(18) - HS2 (female) (3)
* Turn starting
switch OFF.
. Disconnect V2A
and HS2.
-Turn starting
switch ON.
VHMS
con
JR/6 (DTII
Work esuiment
relief oil
.e sensor
TJW02550
WA1 200-3 20-911

0
TROUBLESHOOTiNG v-212
V-212 Short circuit with power source in transmission relief pressure

sensor system
Cause Remedy
Defective VHMS
Replace
controller
I
MT2 (female)(3)
and chassisground Short circuit with power
nO~~l7 source in wiring harness Repair or
NO between WA (female) (6) replace
* Max. 1 V
- MT2 (female) (3)
-Turn starting
switch OFF.-
* Disconnect WA I I
and MT2.
*Turn starting
switch ON.
Transmission
VHMS nain relief
cvessure sensor
l-l
TJWO2552
20-912 WA1 200-3

0
V-213 Short circuit with power source in steering relief pressure

sensor system
Cause
--I
Remedy

VZA (female) (16).
HS3 (female) (3) and -
nOrf?l~l? source in wiring harness Repair or
NO between V2A (female) replace
* Max. 1 V
-Turn starting (16) - HS3 (female) (3)
switch OFF.
* Disconnect V2A
and HS3.
- Turn starting
switch ON.
VHMS
con ol ler VI (07020)
il
sensor
TJW02553
WA1 ZOO-3
V-214 Short circuit with power source in torque converter outlet oil
It Always connect any disconnected connectors before going on to the next step.
Cause Remedy

Replace
I Is voltase between I I controller
V2A (f&ale) (5).
MT3 (female) (3) -
and chassis ground
tl0iTllal7 source in wiring harness Repair or
- Max. 1 V NO
- MT3 (female) (3)
l Turn starting
switch OFF.
. Disconnect WA
and MT3.
* Turn starting
switch ON.
lortoe converter
VHMS outlet oil
Dressure sen t.or
20-914 WA1 200-3

0
V-215 Short circuit with power source in transmission modulation

Cause Remedy

Replace
V2A (female) (151,
MT5 (female) (3) -
and chassis ground
normal? source in wiring harness Repair or
between V2A (female) replace
* Max. 1 V NO
(15) - MT5 (female) (3)
* Turn starting
switch OFF..
* Disconnect V2A I I
and MT5.
l Turn starting
switch ON.
Transmission
VHMS modulated oil
&roller VI fO70201 wassure sensor
TJWO2555
WA1 200-3 20-915

0
V-216 Disconnection or short circuit with power source in torque

converter oil temperature sensor
CallSe Remedy
3 YES Defective VHMS Replace

YES T24 (female) (1)
If V2A Wemale)(3) is _ ground normal? source in wiring harness Repair or
MS groundedto chassis, between V2A (female) (3) replace
_ ISresistancebetween _ - Max. 1 V NO
T24 (female)(1) and - T24 (female) (1)
1 chassisground Disconnection or
y normal? * Disconnect V2A and T24.
Is resistance * Turn starting switch ON. defective contact in Repair or
-Max. IQ wiring harness between
between T24 replace
*Turn startina NO
(male) (1) and (2) V2A (female) (3) - T24
switch OFF.-
normal? (female) (1)
I * Disconnect V2A
- 40 kC2at normal Defective torque
and T24.
temperature converter oil temperature Replace
NO sensor
(25’C)
* Turn starting
switch OFF.
l Disconnect T24.
Torsue converter
V-216 Related electrical circuit diagram oil temperature
or)
VHMS
JL.21 (DTIB’ III
-44
aa J4
aa
41
TJW02527
20-916 WA1 200-3
0
V-217 Disconnection in hydraulic oil temperature sensor system
t Before carrying out troubleshooting, check that all the related connectors are properly inserted.
I Cause I Remedy
Defective VHMS
Replace
controller
Disconnection or
* 3.5 - 4.0 kQ at
No
- Disconnect V2A and HSI.
I
I
V2A (female) (11) - HSl
(female) 11)
Defective hydraulic oil Replace

temperature sensor
normal NO
temperature
(25°C)
*Turn narting
switch OFF.
* Disconnect HSl.
VHMS
TJW02528
WA1 ZOO-3 20-917

0
V-218 Disconnection in ambient temperature sensor system
Cause Remedy

Replace
If V2A (female) (lo! is controller
Y,-s grounded to chess%
_ 15 resistance between _
Disconnection or
1 PHl (female) (1) and
y &a3ass~Tground defective contact in
Repair or
Isresistance k wiring harness between replace
between PHl _ . Max. 1 R NO VZA (female) (10) - PHl
(male) (1) and (2) Turn starting
l (female) (1)
normal? switch OFF.
Defective ambient
lApprox. 12 kS2at . Disconnect V2A and PHl.
l
Replace
temperature sensor
normal NO
temperature
(25’C)
*Turn starting I I I
switch OFF.
l Disconnect PHl.
VHMS
JR13 (DTIB)
TJW02557
20-918 WA1 200-3
0
V-219 Short circuit with power source in PPC relief sensor system
or Before carrying out troubleshooting, check that all the related connectors are properly inserted.
ReDlace
Repair or
replace
switch OFF.-
- Disconnect V2A
and HS4.
- Turn starting
switch ON.
VHMS
JR7 (DTl)
LR7 (DTI)
TJW02558
WA1 200-3 20-919

0
V-220 Short circuit with chassis ground in fuel level sensor system
CaUSe Remedy

Replace
If VZA (female) (2) is controller
Es gcouqded to chasss.
IS resistance belween _
1 r R05 (female) (1) and Short circuit with chassis
-I*r&sancebet- ~Ft%t~~““dI I ground in wiring harness
Repair or
replace
ween R05 (male) _ .Min.lMQ NO
- R05 (female) (1)
(1) and (2) as *Turn starting
shown in Table 11 switch OFF.
- Disconnect V2A and RO5. Defective fuel level
* See Table 1.
sensor
* Disconnect RO5 NO
Table 1
Resistance
Between (1) - (2) Between (1) - chassis grouncI
FULL (100%) Approx. 10 Q
l/2 (50%) Approx. 32 R
Min. 1 MP
l/4 (25%) Approx. 49.5 Q
1 EMPTY (0%) 1 Approx. 85 R
VHM
LR2 (HD-85086)
TlW02526
20-920 WA1 200-3

0
V-221 Short circuit with power source in battery fluid level sensor “1”
Cause Remedy

Replace
V2B (female) (1).
RA7 (female) 11) and -
chassisground
normal?
betweenV2B (female)(1) replace
* Max. 1 V NO
- RA7 (female) (1)
*Turn starting
switch OFF.
- Disconnect V2B
and RA7.
*Turn starting
switch ON.
VHMS controller LR~(HD-85086) RA3 (DT21
1
Bat terv
RAl (DTZ/DTl)
TJW02532
WA1 200-3 20-92 1

0
Cause Remedy

Replace
IS voltage between controller
V26 (female) (2).
RAE (female1(1) and -
lXXfT#el? source in wiring harness Repair or
NO between V2B (female) (2) replace
. Max. 1 V
- RA8 (female) (11
*Turn starting
switch OFF.
* Disconnect V2A
and RA8.
l Turn starting
switch ON.
VHMS
RA2 (DT2/DTI)
RA7 (DTl)
Battery
Jevel sensor TJW02532
20-922 WA1 200-3

Cause Remedy

qeplace
V28 (female) (3).
RAS (female) (1) and -
chassis ground
IlO~al? source in wiring harness qepair or
between V2B (female) (3) ,eplace
*Max.lV NO
- RA9 (female) (1)
. Turn starting
switch OFF.
. Disconnect V2B
and RA9.
* Turn starting
switch ON.
VHMS controller LR2 (HD-85086) RA3 CDT21
RAl(DTZ/DTl)
TJW02532
WA1 ZOO-3 20-923

0
V-224 Short circuit with chassis ground or power source in brake fluid
level sensor
cause Remedy
Defective front brake

level sensor Replace
ween HRlO (male) ES Defective rear brake level

(1) and chassis Replace
sensor
. Turn starting
switch OFF. 4YE
* Disconnect HRlO.
ween HR6 (female)
1Isresktance
bet- 1r Gotok -
. Measure vccl ween V3A (female) I I
resistance when 1 ‘A IS). HR6 (female) (1) I-l
front brake tank Short circuit with chassis
. Turn starting
is empty. switch OFF.
* Disconnect HR6
h
*Turn stanina switch - HR6 (female) (‘1)
(female). 1and chassis OFF. -
* Measure ?I? * DisconnectV3A and Short circuit with chassis
II
resistance when * Min. 1 MQ ground in wiring harness Repair or
rear brake tank is * Turn starting between V3B (female) (5) replace
empty. switch OFF.- _- -HRlO (female) (1)
- Disconnect V3B
and HRIO.
Replace
_1Is voltage between 1 1 controller
5hort circuit with power

;ource in wiring harness Repair or
cetween V3A (female) (5) replace
From A -
- HR6 (female) (1)
-Turn starting NO setween V3B (female) (5) replace
switch OFF. - HRlO (female) (1)
* Disconnect V3B
and HAlO.
- Turn starting
switch ON.

Front brake
oil level
VHMS controller
ake
el
-n%-
TJW02533
20-924 WA1 200-3
0
V-225 Short circuit with power source in coolant level sensor
Cause
IS voltage between
V3B ~fermle) 110).
GO6 (female) (1) and
chassis ground
*Max. 1 V
* Turn starting
switch OFF.
* Disconnect V36
and G06.
* Turn starting
switch ON.
1 YES
NO
Defective VHMS
controller

between V3B (female)
(10) - GO6 (female) (1)
IReplace
Repair or
replace
VHMS
RAlO (DTHD4)
Coolant level
TJW02534
WA1 200-3 20-925

0
V-226 Short circuit with chassis ground or power source in

transmission oil filter clogging sensor
ChJSt? Remedy
2 YES
oil filter or VHMS Replace
Is voltage between
MS V3A (female) (11). controller
, r R02 (female) (1) and
_ chassisground Short circuit with power
Is resistancebat- normal? source in wiring harness Repair or
ween V3A (female) between V3A (female) replace
- ’ Max* ’ ” NO
(111, R02 (female)
*Turn starting switch OFF. (11) - R02 (female) (1)
(1) and chassis
around normal? . Disconnect V3A and R02.
- Turn starting switch ON. Short circuit with chassis Repair or
l Min. 1 MR
- Turn starting NO ground in wiring harness replace
switch OFF. between v3A (female)
- Disconnect (11) - R02 (female) (1)
V3A and R02.
VHMS
Transmission
TJW02535
20-926 WA1 200-3

0
V-227 Short circuit with power source in air cleaner clogging (1) relay
system
Cause Remedy

V3B (female) (1) _
and L132 (female) Short circuit with power
(6) normal? source in wiring harness Fieoair or
between V3B (female) (1)
- Max. 1V NO
- L132 (female) (6)
* Turn starting
switch OFF.
* Disconnect V3B
and L132.
-Turn starting
switch ON.
VHMS
controller
DUS t
ind icator
I r clay
Dus t
ind icator
2 r clay
-vindicator 31
-vindicator
141
-IDust
TJW02536
WA1 200-3 20-927

0
TROUBLESHOOTING V-228.229
system
Cause Remedy

hplace
V3B (female) (2)
(61 normal? source in wiring harness aepair or
. Max. 1 V
L133 (female) (6)
* Turn starting
switch OFF.
- Disconnect V36
and L133.
-Turn starting
switch ON.
system
Cause Remedy

Replace
V3B (female) (3)
(6) normal? source in wiring harness Repair or
between V3B (female) (3) replace
- Max. 1 V NO
- Ll34 (female) (6)
- Turn starting
switch OFF.
. Disconnect V3B
and L134.
* Turn starting
switch ON.
20-928 WA1 200-3

0
system
Cause Remedy
1 MS Defective VHMS
Replace
V3B (female) (4)
(6) normal? source in wiring harness Repair or
* Max. 1 V
- L135 (female) (6)
* Turn starting
switch OFF.
mDisconnect V36
and L135.
* Turn starting
switch ON.
WA1 200-3 20-929

0
V-231 Abnormal charge by alternator
j, Before carrying out troubleshooting, check that all the related connectors are properly inserted.
1 Is resistance bet-
1ween WA (female) I
1 YES
(4). L152 (female) 16)

( 1
I
t-=--v=
I
Defective VHMS
controller I
I
Replace

and chassis ground
n0l-nlal?
ground in wiring harness Repairor
l Min. 1 MR NO
- L152 (female) (6) - El4
-Turn starting (female) (2), El5 (female)
switch OFF. I?\
,L,
l Disconnect V2A. I I
L152, and JE3.
VHM
Alternator
signal relay
-
Fuse (I)
FS2 (SlZBlue)
-___ m--l
TJWO7.537
20-930 WA1 ZOO-3
0
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
H- 1 Machine does not move ........................................................................................................... 20-I 002

H- 2 Machine lacks power or speed (every speed range). ........................................................... .20-1003
H- 3 Excessive time lag when starting machine or shifting gear ................................................ 20-l 004
H- 4 Torque converter oil temperature is high ............................................................................... 20-1005
H- 5 Steering does not turn .............................................................................................................. 20-l 006
H- 6 Turning, response of steering is poor .................................................................................... 20-I 007
H- 7 Joystick lever is heavy.. ............................................................................................................ 20-1008
H- 8 Steering wheel shakes or jerks ................................................................................................ 20-I 009
H- 9 Turning radius is different between left and right at maximum steering ......................... 20-1010
H-10 Wheel brakes do not work or braking effect is poor ............................................................ 20-1010
H-II Wheel brakes are not released or brakes drag ...................................................................... 20-1011
H-12 Boom does not rise.. ................................................................................................................. 20-1012
H-13 Boom moves slowly or does not have sufficient lifting power .......................................... .20-1013
H-14 When raising boom, becomes slow at certain height .......................................................... 20-1014
H-15 Boom cylinder cannot hold down bucket ............................................................................... 20-1014
H-16 Boom has large amount of hydraulic drift ............................................................................. 20-1014
H-17 Boom fluctuates while working ............................................................................................... 20-1015
H-18 Boom drops momentarily when lever is operated from HOLD to RAISE.. ........................ 20-1015
H-19 Bucket does not tilt ................................................................................................................... 20-1016
H-20 Bucket is moves slowly or has insufficient tilt back power.. ............................................... .20-1017
H-21 Bucket movement becomes slow during tilt back.. .............................................................. .20-1018
H-22 Bucket cylinder cannot hold down bucket.. ............................................................................ 20-1018
H-23 Bucket has large amount of hydraulic drift ............................................................................ 20-1018
H-24 Bucket fluctuates while traveling under load (work equipment valve HOLD). .................. 20-1019
H-25 Bucket dumps momentarily when lever is operated from HOLD to TILT .......................... 20-1019
H-26 Boom and bucket levers do not move smoothly .................................................................. 20-l 020
WA1 200-3 20-1001

0
TROUBLESHOOTING H-l
H-l Machine does not move

Ask the operator the following points
. Did the machine suddenly stop moving?
Yes = Component seized or damaged
. Was there any abnormal noise when the
machine stopped moving?
Yes = Component broken.
Checks before troubleshooting

. Is oil level in transmission case correct?
. Is monitor display normal?
. Is drive shaft broken?
I Transmission
No. Problems
6) Transmission Low at every speed range. IololoTOl

7 modulating Low at certain speed ranges.
- 8 pressure too low Indicator fluctuates violently.
9 Pilot pressure defective
10 Torpue converter relief valve pressur- --- ‘----
11 Torpue converter regulator valve pressure IOO m
Note 1: If the solenoid valve and hydraulic pres-

The following symbols are used to indicate the action
sure are normal, the “m” in the Causes to be taken when a cause of failure is located.
column indicates that the valve spool X: Replace 0: Repair
does not work. A: Adjust C: Clean
Note 2: If the transmission clutch pressure is

low, but the cause cannot be found in
the above table, a possible cause is
cracks in the valve or transmission.
20- 1002 WA1 200-3

0
iROUBLESHOOTlNG H-2
H-2 Machine lacks power or speed (every speed range)

. Is oil level transmission case correct?
. Is there any leakage of oil from joints of
piping or valves?
. Is parking brake or wheel brake dragged?
Checking for abnormalities

l Engine high idling speed
l Torque converter stall speed
. Machine travel speed
l Transmission clutch pressure (both high
pressure and low pressure)
. Pressure at outlet port of torque con-
verter pump
. Pilot reducing pressure
8
Relief pressure at torque converter too low
(Items 5 and 7 normal)
0
9 Torque converter regulator valve pressure (outlet port

0
pressure) toolow
,. Iron or alumimum particles stuck to strainer of transmission

0
case.
11 Modulating pressure drops when oil temperature rises. 0
WA1 200-3 20- 1003

0
TROUBLESHOOTING H-3
H-3 Excessive time lag when starting machine or shifting gear

. Is there any leakage of oil from joints of
piping or valves?
4 Transmission modulating pressure too low in every speed

0000
range
6 As in Items 4; indicator fluctuates violently 0

6 Torque converter oil temperature is above operating range. 0 0
20- 1004 WA1 200-3

0
TROUBLESHOOTING H-4
H-4 Torque converter oil temperature is high

. Does torque converter oil temperature I I I I I I /
go up during torque converter stall, and
down when the torque converter is not
installed?
Yes = Normal (incorrect selection of gear
speed)

. Is transmission filter clogged?

Ir If the oil temperature is normal but the
oil temperature gauge is outside the
operating range, the oil temperature
gauge is defective.
1 Pump makes abnormal noise when oil temperature is low. 0
2 High idling and low idling speeds are too low. 0 0

3 Hvdraulic oressure at inlet oort of torque converter too low 0
4 Transmission modulating pressure too low lolo/ 1 1 I
WA1 200-3 zo-1005

0
TROUBLESHOOTING H-5
H-5 Steering does not turn

- Did the problem suddenly start?
Yes = Related equipment broken
l Was there any abnormal noise when this
happened? Where did the noise come
from?

l Is the oil level in the hydraulic tank cor-
rect?
Is the type of oil correct?
. Is the steering shaft broken?
. Has the safety bar been removed from
the frame?
. is steering valve open?
2 Steering wheel turns only in one direction (left or right)
3 1Steering wheel is heavy in both directions (left and right)
4 1Work equipment moves I I Inl

5 Work equipment does not move 00
6 Abnormal noise comes from around PTO 00
7 Abnormal noise comes from around PPC pump or hydraulic tank 0
I
Oil pressure is low or there is no pressure in
When steering both directions (left and right) 0000
relief pressure
is measured Oil pressure is low or there is no pressure in
one direction (left or right)
,9 When steering pilot valve output pressure is measured, oil

pressure is found to be low or there is no oil pressure lololol
When PPC valve (Orbit-roll) Oil pressure is low lo101 1

basic pressure iS measured There is no oil oressure lolol I
Ir There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is felt in the steering, check the operation of the work equipment also.
20- 1006 WA1 200-3

0
TROUBLESHOOTING H-6
H-6 Turning, response of steering is poor

. Did the problem suddenly start?
. Was there any abnormal noise when this
from?
l Was there previously any symptom, such
as difficulty in steering?
Yes = Wear of related equipments, de-
fective seal

. Is the oil level in the hydraulic tank cor-
rect?
No. Problems I I I
I Turning, response of steering is poor in both directions (left and right) IO/O 10 10 I()( 0 /
, .. .. .
10101 l0l0l0J
5 ( Work equipment moves
.
. equipment
_ .worn --- I I I -
6 also speed IS slow oww 0
7 Abnormal noise comes from around PTO 0
8 Abnormal noise comes from around steering pump or hydraulictank 0 0
9 Abnormal noise comes from around switch pump or hydraulictank 00
I
Oil pressure is low or there is no pressure in o(-j(-Jooonlnl I InI
--I
10 When steering
relief pressure
is measured
both directions (left and right)
Oil pressure is low or there is no pressure in

11 one direction (left or right) I0 I I
When steering pilot valve output pressure is measured, oil
12 0 0
pressure is found to be low
When PPC valve (Orbit-roll) basic pressure is measured, oil

13 pressure is found to be low
0
* 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.
WA1 200-3 20- 1007

0
TROUBLESHOOTING H-7
H-7 Joystick lever is heavy

. Is the steering difficult to turn?
Yes = Go to H-6
. Measure the operating effort and turn-
ing speed, and check the STANDARD
VALUE TABLE to see if they are abnor-
mal.

l Did the problem suddenly start?
l Was there previously any symptom, such
as heavy steering?
Yes = Wear of related equipment, defec-
tive seal

rect?
l Is the tire inflation pressure correct?
Remedy/+/
No. Problems /x/x x
1 Steering is heavy when turned in both directions (left and right) 000
2 Steering is heavy when turned in one direction (left or right)
S Steering is heavy even when joint between steering shaft and

Orbit-roil is disconnected I I 101
When s=adng Oil pressure is low in both directions (left and right) 0 0
relief pressure
is measured Oil nressure is low in one direction (left or riaht) 1 1 1
When steering pilot valve output
6
pressure is found to be low
20- 1008 WA1 200-3

0
TROUBLESHOOTING H-8
H-8 Steering wheel shakes or jerks

. Is the steering difficult to turn?
Yes = Go to H-6
. Is there any abnormal noise from around
the steering equipment?

. Is the steering wheel play correct?
. Is there any abnormality in the connec-
tion between the steering shaft and the
steering pilot valve?
. Is the tire inflation pressure correct?
No. Problems
1 Steering wheel shakes or jerks in both directions (left and right) lO[OlOj~
2 Steering wheel shakes or jerks in one directions (left or right)
S During operations or when traveling (when steering is neutral),

steering wheel shakes or jerks in both directions (left and right)
4 During operations or when traveling (when steering is neutral),

steering wheel shakes or jerks in one direction Cleftor right)
6 Steering wheel jerks or there is excessive shock when

steering is operated to end of its stroke
6 Work equipment also jerks 0

7 Oil pressure is unstable in both directions
When steering 000
(left and right)
- relief pressure
is measured Oil pressure is unstable in one direction
8
(left or right)
Oil pressure is unstable in both directions

g When steering
(left and right) 0
pilot valve
output pressure
Oil pressure is unstable in one direction
10 is measured
(left or right)
11 When PPC valve (steering pilot valve) basic pressure is

measured, oil pressure is found to be unstable
WA1 200-3 20-l 009

0
TROUBLESHOOTING H-9, H-10
H-9 Turning radius is different between left and right at maximum

steering
Causes and Remedy
Defective adjustment
l of joystick lever
stopper (4
H-10 Wheel brakes do not work or braking effect is poor

. Measure the actual brake performance,
and check if there is actually an abnor-
mality or whether it is just the feeling of
the operator. For details, see TESTING
AND ADJUSTING, Measuring brake per-
formance.
Ask the operator the following points.

l Did the problem suddenly start?
l Was there any abnormal noise when this
from?
. Did the problem gradually appear?
Yes = Wear of related equipments, de-
fective seal

rect?
l Is the brake pedal play correct?
l Is there any leakage of oil from the brake
tube?
Is there any deformation of the tube?
. Is the tire inflation pressure and tread
pattern correct?
20-1010 WA1 200-3

0
TROUBLESHOOTING H-l 1
H-11 Wheel brakes are not released or brakes drag

Ask the operator the following points.
. Did the problem suddenly start?
. Was there any abnormal noise when this
from?

l Does the brake pedal come back fully?
. Is the parking brake still applied (ON)?
No
1
When remaining pressure is released from brake accumulator 0

3
circuit with left brake pedal only, brake is released
I
When remaining pressure is released from brake accumulator

4 0
circuit with right brake pedal only, brake is released
When air bleed plug in wheel poeion is loosened, oil flows

5 0
out and brake is released
6 When air bleed plug is loosened, a large amount of oil flows out 0 ()
When brake disc wear is measured and brake pedal is released,

7 0
piston returns
-
When brake disc wear is measured and brake pedal is released,
8 00
piston does not return
-
WA1 200-3 20-l 011

0
TROUBLESHOOTING H-12
H-12 Boom does not rise

. Did the problem suddenly fail to rise?
+ Seizure or damage to various units.
l Was unusual noise produced? (Where did
it emanate from?)
l Were there previous signs of the boom
slowing down?
+ Wear of parts of flattening of spring.

. Is oil level in hydraulic tank correct?
. Is travel of lift arm control lever and spool
correct?
unable to rise. Or, the bucket operates but the boom is
20-1012 WA1 200-3

0
H-13 Boom moves slowly or does not have sufficient lifting power
. Is the travel of the boom control lever
and also the spool of the work equip-
ment control valve correct?
l Seizure of work equipment linkage bush-
ing.
(Does emits abnormal noise)
l If the boom speed lowers when it is
loaded, it must be overloaded. Check the
load meter in this case.
Fault check
There is a strong relationship between faults
involving lifting force and lifting speed. Such
faults appear initially in the from of insuffi-
cient lifting speed. Measure the lifting speed
of the lift arm when loaded and refer to the
standard value table to determine whether
or not there is a fault.
Ming speed is low.
2 Bucket tilt back force and speed are normal but boom lifting
speed is slow. 0 00
3 Some as Item 1 except that boom lifting speed becomes

particularly low when oil temperature rises. 0
4 Hydraulic pump emits abnormal noise. 00
6 When the engine is at full, steering action is light and

excessively fast. 0
6 When the engine is at full, steering action is heavy and slow. 0
7 Cylinder has a large amount of hydraulic drift. 00
6 The relief pressure of relief valve of work equipment control

0 000
valve.
WA1 ZOO-3 20-1013

0
TROUBLESHOOTING H-14, H-15, H-16
H-14 When raising boom, becomes slow at certain height

0. External deformation of boom cylinder.
Cause
l Swollen or internally damaged boom cylinder tube.
* Regarding other faults occurring during boom rise, refer to item “H-13 Boom moves slowly or
does not have sufficient lifting power”.
H-15 Boom cylinder cannot hold down bucket
Refer to item “H-13 Boom moves slowly or does not have sufficient lifting power”.

. Is travel of boom spool of work equipment control valve correct?
Cause
. Defective boom cylinder rod side suction valve seat of work equipment control valve
. Oil leakage from boom cylinder piston seal
H-16 Boom has large amount of hydraulic drift

l Did the hydraulic drift suddenly become large?
+ Dirt lodged in valve or damaged parts.
. Did the hydraulic drift gradually become large?
+ Worn parts.

l
Is the boom spool in the hold position?
+ Seized ring bushing, defective spool detent.
Troubleshooting and cause

l When measuring hydraulic drift, internal leakage of boom cylinder makes oil leakage noise.
-_j Damaged cylinder packing.
. When measuring hydraulic drift, boom cylinder does not make oil leakage noise.
-_j Defective oil sealing of boom spool.
+ Defective check valve between pipings.
20-1014 WA1 200-3

0
TROUBLESHOOTING H-17, H-18
H-17 Boom fluctuates while working
During excavation or ground leveling when the boom control lever is in the “HOLD” position, the
bucket and boom move up and down in accordance with the terrain.
Troubleshooting and cause

Check the amount of hydraulic drift and whether or not the machine body can be lifted up by the
boom cylinder.
1. If the amount of hydraulic drift is greater than the standard value, refer to item “H-16 Boom
has large amount of hydraulic drift”.
2. If the machine body can not be lifted up by the boom cylinder, refer to item “H-15 Boom
cylinder cannot hold down bucket”.
3. If the amount of hydraulic drift is normal and the machine body can be lifted up by the boom
cylinder after the boom is moved several times to cause the boom cylinder to move through its
entire stroke -+ the trouble is due to the generation of a vacuum in the cylinder.
* If a vacuum is generated frequently + defective suction valve on boom cylinder rod side.
H-18 Boom drops momentarily when lever is operated from HOLD to

RAISE
The boom drops momentarily under its own weight when the boom control lever is gradually
shifted from the “HOLD” position to the “RAISE” position while the engine is at low idling. When
the control lever is put completely into the “RAISE” position, the boom moves normally.
Cause
l Defective seating of work equipment control valve or boom spool check valve.
WA1 200-3 20-l 015

0
H-19 Bucket does not tilt back

l Did the bucket suddenly cease to move?
+ Seized or damaged equipment.
l Was any abnormal noise emitted (where
did it emanate from?)
l Was there previous signs of the bucket
slowing down?
+ Worn parts or flattening of spring.

. Is the travel of the bucket control lever
and spool correct?
20-1016 WA1 200-3

0
H-20 Bucket moves slowly or has insufficient tilt back power

. Is the travel of the bucket control lever
and the work equipment control valve
spool correct?
l Seizure of bushing in bucket linkage?
(Does emits abnormal noise?)
Fault checks
l Check deficient tilt back force by per-
forming actual work.
. Measure the operating speed of the
bucket and check it against the standard
value table to determine whether or not
it is normal.
Boom lifting force and lifting speed are abnormal and also
1 0000 0
bucket tilt force and tilt speed are abnormal.
Boom lifting force and lifting speed are normal but bucket tilt
2 0 ooc
force and tilt speed are abnormal.
Phenomena of item 1 become particularly bad when the oil

3
temperature increases.
0
4 The hydraulic pump emits an abnormal noise. 00
action is light and excessively fast when the engine
WA1 200-3 20-1017

0
TROUBLESHOOTING H-21, H-22, H-23
H-21 Bucket movement becomes slow during tilt back

l External deformation of bucket cylinder.
Cause
l Swollen or internally damaged bucket cylinder tube.
l As to other faults which occur when operating bucket, refer to item “H-20 Bucket moves
slowly or has insufficient tilt back power”.
H-22 Bucket cylinder cannot hold down bucket

Refer to item “H-20 Bucket moves slowly or has insufficient tilt back power”.

. Is the travel of bucket spool of work equipment control valve correct?
Cause
l Defective seat of safety valve (with suction valve) of the rod side of bucket cylinder of work
equipment valve.
l Oil leakage from seal of bucket cylinder piston.
H-23 Bucket has large amount of hydraulic drift

l Did the hydraulic drift suddenly become large?
+ Dirt lodged in valve or damaged parts.
l Did the hydraulic drift gradually become large?
+ Worn parts.

. Is the bucket spool in the hold position?
+ Seized ring bushing, faulty spool detent.
Fault check
. Use the standard value table to check whether or not the hydraulic drift of the bucket is
actually large.
Cause
l Oil leakage in bucket cylinder
l Defective seating of safety valve (with suction valve) at bottom side.
Defective oil sealing of bucket spool.
l Defective check valve between pipings.
20-1018 WA1 ZOO-3

0
TROUBLESHOOTING H-24. H-25
H-24 Bucket fluctuates while traveling under load

(work equipment valve “HOLD”)

l Excessive play in pin and bushing of work equipment linkage. (Was an abnormal noise
produced?)
Cause
l Defective piston seal of bucket cylinder.
. Defective safety valve (with suction valve) for the head side of bucket cylinder.
If the above symptoms occur together, refer to the troubleshooting items corresponding to
each fault. _ .
H-25 Bucket dumps momentarily when lever is operated from HOLD

to TILT
The bucket dumps momentarily under its own weight when the bucket control lever is gradually
shifted from the “HOLD” position to the “TILT” position while the engine is at low idling.
When the control lever is put completely into the “TILT” position, the bucket moves normally.
Cause
. Defective seating of bucket spool check valve of work equipment valve.
WA1 200-3 20-1019

0
H-26 Boom and bucket levers do not move smoothly

Fault check
Using the standard value table, check
whether or not the operating effort of the
lever is large.
20-1020 WA1 200-3

0
DISASSEMBLY AND ASSEMBLY STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

1. STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) 4. TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS
fl In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque fl Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Nominal No.
Thread diameter Width mm mm Nm kgm
of bolt across flats 02 14 34.3 ± 4.9 3.5 ± 0.5
03, 04 20 Varies depending on 93.1 ± 9.8 9.5 ± 1
mm mm kgm 05, 06 24 type of connector. 142.1 ± 19.6 14.5 ± 2
Nm 10, 12 33 421.4 ± 58.8 43 ± 6
6 10 13.2 ± 1.4 1.35 ± 0.15 14 42 877.1 ± 132.3 89.5 ± 13.5
8 13 31 ± 3 3.2 ± 0.3
10 17 66 ± 7 6.7 ± 0.7
12 19 113 ± 10 11.5 ± 1 5. TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS
14 22 177 ± 19 18 ± 2
fl Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
16 24 279 ± 30 28.5 ± 3 Tightening torque
18 27 382 ± 39 39 ± 4
Thread diameter Width across flat
Nominal No.
20 30 549 ± 59 56 ± 6 mm mm Nm kgm
22 32 745 ± 83 76 ± 8.5 7.35 ± 1.47
08 8 14 0.75 ± 0.15
24 36 927 ± 103 94.5 ± 10.5 11.27 ± 1.47
10 10 17 1.15 ± 0.15
27 41 1320 ± 140 135 ± 15 12 12 19 17.64 ± 1.96 1.8 ± 0.2
30 46 1720 ± 190 175 ± 20 14 14 22 22.54 ± 1.96 2.3 ± 0.2
33 50 2210 ± 240 225 ± 25 16 16 24 29.4 ± 4.9 3 ± 0.5
36 55 2750 ± 290 280 ± 30 18 18 27 39.2 ± 4.9 4 ± 0.5
39 60 3290 ± 340 335 ± 35 20 20 30 49 ± 4.9 5 ± 0.5
24 24 32 68.6 ± 9.8 7± 1
30 30 32 107.8 ± 14.7 11 ± 1.5
33 33 — 127.4 ± 19.6 13 ± 2
Thread diameter Width 36 36 36 151.9 ± 24.5 15.5 ± 2.5
of bolt across flats 42 42 — 210.7 ± 29.4 21.5 ± 3
52 52 — 323.4 ± 44.1 33 ± 4.5
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
2. TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

fl In the case of flared nuts for which there is no special instruction, tighten to the torque given in
the table below.
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
3. TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

fl In the case of split flange bolts for which there is no special instruction, tighten to the torque
mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
30-002 WA1200-3
5
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the 2. Precautions when carrying out installation work
general precautions given below when carrying out the operation.] • Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
1. Precautions when carrying out removal work • Install the hoses without twisting or interference.
• If the coolant contains antifreeze, dispose of it correctly. • Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from • Bend the cotter pins and lock plates securely.
entering. • When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded
• When draining oil, prepare a container of adequate size to catch the oil. portion with 2 – 3 drops of adhesive.
• Confirm the match marks showing the installation position, and make match marks in the neces- • When coating with gasket sealant, clean the surface and remove all oil and grease, check that there
sary places before removal to prevent any mistake when assembling. is no dirt or damage, then coat uniformly with gasket sealant.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when • Clean all parts, and correct any damage, dents, burrs, or rust.
disconnecting the connectors. Do not pull the wires. • Coat rotating parts and sliding parts with engine oil.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when • When press fitting parts, coat the surface with anti-friction compound (LM-P).
installing. • After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• Check the number and thickness of the shims, and keep in a safe place. • When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then
• When raising components, be sure to use lifting equipment of ample strength. connect securely.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in • When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and
turn. align the direction of the hook.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt • When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
from entering after removal. side.
fl Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations. fl When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
1) Hoses and tubes using sleeve nuts other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
Nominal
Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times,
number
stopping the cylinder 100 mm from the end of its stroke.
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
4. After doing this, run the engine at normal speed.
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
fl When using the machine for the first time after repair or long storage, follow the same
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
procedure.
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
3. Method of disassembling, connecting push-pull type coupler
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
fl There are 2 types of push-pull type coupler. The method of disassembling and connecting is
2) Split flange type hoses and tubes different, so see the following page when disassembling and connecting the coupler.
Nominal Flange (hose end) Sleeve head (tube end) Split flange 4. Precautions when completing the operation
number • If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
04 07379-00400 07378-10400 07371-30400 the engine to circulate the water through the system. Then check the water level again.
05 07379-00500 07378-10500 07371-30500 • If the hydraulic equipment has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
3) If the part is not under hydraulic pressure, the following corks can be used. • If the piping or hydraulic equipment have been removed, always bleed the air from the system
Nominal Dimensions after reassembling the parts.
Part Number fl For details, see TESTING AND ADJUSTING, Bleeding air.
number D d L
06 07049-00608 6 5 8 • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15 Taper 1/8
øD
ød
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28 L
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34 DEW00401
WA1200-3 30-003
5
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION, COATING MATERIALS
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER COATING MATERIALS

Type 1 Type 2 fl The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
1) Hold the mouthpiece of the tightening portion and push 1) Hold the mouthpiece of the tightening portion and push
body (2) in straight until sliding prevention ring (1) con- body (2) in straight until sliding prevention ring (1) con- fl For coating materials not listed below, use the equivalent of products shown in this list.
tacts contact surface a of the hexagonal portion at the tacts contact surface a of the hexagonal portion at the
male end. male end.
• 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. Used for plas-
790–129–9050 20 g Polyethylene
LT–1B tics (except polyethylene, polyprophylene,
(2 pes.) container
tetrafluoroethlene and vinyl chloride), rub-
ber, metal and non-metal.
• Features: Resistance to heat and chemi-

Polyethylene cals
2) Hold in the condition in Step 1), and push until cover (3) 2) Hold in the condition in Step 1), and turn lever (4) to the LT–2 09940–00030 50 g
container • Used for anti-loosening and sealant pur-
contacts contact surface a of the hexagonal portion at right (clockwise).
the male end. pose for bolts and plugs.
Disassembly
790–129–9060 Adhesive: • Used as adhesive or sealant for metal, glass

(Set of adhe- 1 kg and plastic.
LT–3 sive and Hardening Can
hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT–4 790–129–9040 250 g
container
Holtz • Used as heat-resisting sealant for repair-
790–126–9120 75 g Tube
MH 705 ing engine.
3) Hold in the condition in Steps 1) and 2), and pull out 3) Hold in the condition in Steps 1) and 2), and pull out • Quick hardening type adhesive
whole body (2) to disconnect it. whole body (2) to disconnect it.
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790–129–9140 50 g
1735 container • Used mainly for adhesion of metals, rub-
bers, plastics and woods.

• Quick cure type (max. strength after 30 min-
Aron-alpha Polyethylene
790–129–9130 2g utes)
201 container
• Used mainly for adhesion of rubbers, plas-
tics and metals.
• Features: Resistance to heat, chemicals

Loctite Polyethylene • Used at joint portions subject to high tem-
648-50 79A–129–9110 50 cc
container peratures.
• Hold the mouthpiece of the tightening portion and push • Hold the mouthpiece of the tightening portion and push
body (2) in straight until sliding prevention ring (1) con- body (2) in straight until sliding prevention ring (1) con-
tacts contact surface a of the hexagonal portion at the tacts contact surface a of the hexagonal portion at the • Used as adhesive or sealant for gaskets
LG-1 790–129–9010 200 g Tube
male end to connect it. male end to connect it. and packing of power train case, etc.
Gasket • Used as sealant for various threads, pipe
sealant Polyethylene joints, flanges.
1 kg
Connection
LG-5 790–129–9080
container • Used as sealant for tapered plugs, elbows,
nipples of hydraulic piping.
30-004 WA1200-3
5
6
DISASSEMBLY AND ASSEMBLY COATING MATERIALS, SPECIAL TOOL LIST
SPECIAL TOOL LIST

Category Komatsu code Part No. Q'ty Container Main applications, features fl Tools with part number 79T- - cannot be supplied (they are items to be locally manufac-
tured).
• Features: Silicon based, resistance to heat, fl Necessity: ■: Cannot be substituted, should always be installed (used).
cold ●: Extremely useful if available, can be substituted with commercially available part.
LG-6 790-129-9020 200 g Tube • Used as sealant for flange surface, tread. fl New/remodel: N: Tools with new part numbers, newly developed for this model.
• Used as sealant for oil pan, final drive case, fl R: Tools with upgraded part numbers, remodeled from items already available for
etc. other models.
Gasket fl Blank: Tools already available for other models, used without any modification.
• Features: Silicon based, quick hardening
sealant fl Tools marked fi in the Sketch column are tools introduced in special sketches (See SKETCHES OF
type
LG-7 790-129-9070 1 kg Tube • Used as sealant for flywheel housing, in-
SPECIAL TOOLS).
take manifold, oil an, thermostat housing,
etc. fl Tools having Nos. SMT-fififi-fifififi are shown for manufacture in the field and are not set as
special tools (their prices are not set). Accordingly, they cannot be supplied.
Three bond • Used as heat-resisting sealant for repairing
790–129–9090 100 g Tube engine.
1211
• Used as lubricant for sliding portion (to pre-

Molybde- LM-G 09940-00051 60 g Can vent from squeaking). Ne- New/
num Component Symbol Part No. Part Name ces- Q’ty re– Sketch Nature of work, remarks
sity model
disulphide • Used to prevent seizure or scuffling of the
lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting. SMT-890-1700 Push tool ■ 1 N fi
• Used as lubricant for linkage, bearings, etc. 1 • SMT-890-1710 • Sleeve ■ 1 N fi Press fitting of bearing
Disassembly,
• Used for lubrication (prevention of creaking) assembly of damper B • SMT-890-1720 • Spacer ■ 1 N fi
G0-T of sliding parts. cover assembly
(No. 0)
SGY0-400-T 400 g Belows type • Used for press fitting, shrinkage fitting, 2 SMT-890-1810 Push tool ■ 1 N fi
prevention of scuffing and seizure of Press fitting of dust seal
threaded parts 3 SMT-890-1820 Push tool ■ 1 N fi
Hyper white • Used for lubrication of linkages, bearings, etc.
grease • Does not dirty work equipment and working SMT-890-1200 Ass’y–Draw ■ 1 N fi
clothes much. 1 • SMT-890-1210 • Socket ■ 1 N fi Press fitting of retainer and oil seal
G2-T • Mixed with lubricant containing
SGY2-400-T 400 g Belows type
(No. 2) molybdenum disulfide (LM-G and LM-P) so • SMT-890-1220 • Guide ■ 1 N fi
that quality will not be deteriorated by Disassembly,
chemical reaction. assembly of torque C 2 SMT-890-1230 Socket ■ 1 N fi Press fitting of bearing
converter assembly
SYG2-400LI • General purpose type 3 • SMT-890-1240 Test/J ■ 1 N fi AdjuSMTent pre-load on input
SYG2-350LI gear bearing
G2-LI SYG2-400LI-A Various Various
• SMT-890-1250 Test/J ■ 1 N fi
Removal, installation of
SYG2-160LI 4 SMT-890-1310 Wrench ■ 1 N fi modulated clutch piston nut
SYGA-160CNLI Press fitting of transmission front
1 SMT-890-1410 Socket ■ 1 N fi housing bearing
SYG2-400CA • Used for normal temperature, light load
Grease SYG2-350CA bearing at places in contact with water or
SMT-890-1500 Ass’y–Draw ■ 1 N fi
G2-CA Various Press fitting of transfer output
SYG2-400CA-A Various steam. 2 • SMT-890-1510 • Socket ■ 1 N fi shaft oil seal
SYG2-160CA
SYGA-160CNCA Disassembly, • SMT-890-1520 • Guide ■ 1 N fi
assembly of Press fitting of transfer output
Molybdenum 400 g • Used for places with heavy load transmission D 3 SMT-890-1530 Socket ■ 1 N fi shaft dust seal
disulphide SYG2-400M (10 per Belows type assembly Press fitting of transfer output
lubricant case)
4 SMT-890-1540 Socket ■ 1 N fi shaft coupling cover
Press fitting of transfer output
5 SMT-890-1550 Socket ■ 1 N fi shaft bearing
6 SMT-890-1560 Socket ■ 1 N fi Support of transfer output shaft
Socket (Width across Removal, installation of transfer
7 790-302-1280 flats: 55 mm) ■ 1 coupling bolt
WA1200-3 30-005
5
6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Component ISymbol Part No. ( Part Name I~~Q’ty/~~~$ketch) Nature of work, remarks Component
T
I!Symbol Part No. Part Name ~%&‘tyl$$ketchl Nature of work, remarks 1
793-890-2500 Push tool n 1 N
I 4 / I
l 793-890-2510 - Shaft n 1 N
l 793-890-2520 l Nut n 1 N
1 l 793-890-2570 . Spring n 4 N Press fitting of boom bushing
l 793-890-2580 l Guide n 1 N
Press fitting of bearing
Removal, installation,
disassembly,
V
assembly of work
equipment assembly
.04530-l 1222 l Eyebolt H 2

I
Xsassembly,
assembly of center
tinge
2 Press fitting of ring bushing
l 793-890-2750 l Guide w 1 N
l 793-890-2760 l Ring n 1 N
l 793-890-2770 l Bolt n 4 N
l 01580-02016 l Nut n 4
Press fitting of bushing l 04530-I 1222 l Eyebolt n 2

-
792-340-I 120 Nut wrench n 1
Removal, installation of sleeve
1
796-550-1310 nut
Wrench H 1
Disassembly,
assembly of axle
‘inal drive . brake W
SMT-890-3100 Tool assembly n 1
assembly
SMT-890-3110 Cylinder
3 I I I I Press fitting of dust seal I
l
Adjustment of hub bearing

SMT-890-2430 Push tool BIN0 3 SMT-890-3120 * Piston
I I I I I preload
I I I I
SMT-890-2440 Push tool /U I- N 0 SMT-890-3130 l Shaft
SMT-890-3140 l Plate
-
30-006
0
!J3B*sm !#33lca~~
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
OF SPECIAL TOOLS .w *~t~k~~~~~~~~l~t~~~~~~~(~-~~~~~~~~~~.

NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
$~a-~y~~i~~~Bl
St AJ-U70-007
#3 k&T&,
lii8CMli
co.5tm R0.64.2mIo:tl
Thisspaceris eauivalentto one in jigdrawingNo. AJ-U70-007
#3 of KomatsuEC .
Chamferoutsidecornersto CO.5and roundinsidecornersto R0.6 - RI.2
unlessotherwisespecified. #AmI 1
V mWll?fA R’l?
1 ; HEAT TREATMENT 1 CASE DEPTH MATERIAL
pI,;mj- . ss4cJo
PAMT CM
MASS (kg1 PART NAME
SJFACE mAT.arz
1 SPACER
SCALE
NONE
ThissPaceris euuivalentto one in jigdrawingNo. AJ470-007#2 of KomatsuMEC .

Chamferoutsidecornersto CO.5and roundinsidecornersto R0.6 - RI.2 WA1200
(31 1
unlessotherwisespecified. APPLICATION Q’TY
V . I
I HEAT TREATMENT CASE DEPTH MATERIAL
/ .
I HEAT TREATMENT CASE DEPTH MATEATAL p(AT&
tiIOl! #A#WL /Idenim andtmerinn HRC26-32 s45c MASS (kg) PART NAME RDJTOFI
PAMT (R SJmcE
TE4r.coK
MASS (kg) PART NAME
sJ?=da
TREIT.lm PUSH TOOL
12 SLEEVE
SCALE
NONE
WA1 200-3 30-007

0
53i$T*$!Rz !+35kJX!sr$H
:d) *~t=~~~~~~~~~~Wt~~~~~~~~~-~~~~~~~~~~.
1 B2/B3 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
” A ” $38 ” A ” $3 $jJ
Detailof "A" Detailof "A"
r-;-5------
y-+_
‘=Q
\‘::\,_ _----
111
1.4,ik, t-4 I I III I
L” I . .
ti ---
--._---
____ ‘#lBA
LF-~j-------
ThissDaceris eauivalentto one in jig drawingNo. AJ-D70-008-B

of KomatsuMEC . Thismater is equivalentto one in jig drawingNo. AJ-U70-008-A
of KomatsuMEC .
Chamferoutsidecornersto CO.5and round insidecornersto R0.6 - R0.8unless Chamferoutsidecornersto CO.5and roundinsidecornersto R0.6 -R0.8unless
otherwisesmified. otherwisespecified.
WA
1200(31 1 WA1200
(31 1
APPLICATION Q’TY APPLICATION B’TY
I HEAT TREATMENT 1 CASE OEPTH MATERIAL I HEAT TREATMENT CASE DEPTH MATER IAL
.
ss400
I
PmTrti Fmii ss400

MASS [kg) PART NAME PAINT WI MASS [kg) PART NAME PAINT OR
SUFFACETFEATXOM
8.5 , PUSH TOOL / 4.8 PUSH TOOL
SWACETREAT.CXJE
SCALE SCALE
NONE 142,o,A NONE
30-008 WA1 200-3

0
53l?e*uL 4-33sE!s#iH
( NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
-‘- --
:‘p q.$
co \ ;f
oocc; 0-J
a* 0
8 / .
-- 1
1, -
.----------
--L
V
I
:
I q I r-7-Y
k/ It: ,f
I _-------I
’ i
86. 67
I I I.
\ i
‘,
I ‘.
I
l I
a-------
1 1
WA1200131
I
I I
APPLICATION
1 Q’TY
: HEAT TREATMENT
I
I $~l;t’Z~I&%Q!~o”oi 40-85155-OOA #l3i~t16. [. ; CASE DEPTH MATERIAL
I KflTICti!
r
I
( ---f I
Thissocketis equivalent
to one in ii9drawing MASS Ik g)
8.8
PART NAME
ASS'Y-DRAW
PAMT
(R
SURFACE
TREAT.coDE
i i- No. 40-85155-OOA
AwazuPlant. I I
-7 i SCALE
NONE
WA1 200-3
33l#*%l2t mIE!81$m
1 Cl (2/3) 1
It)
‘7 1.47 0.15
77
WAi200131 1
175 .. APPLICATIONQ’TY
I HEAT TREATMENT 1 CASE DEPTH MATERIAL
&423295311301 HRC5863 SCM415H
MASS (kg1 I PART NAME PAINTOR
SURFACE
lREAT.cooE
Thissocketis eauivalent
to one in jigdrawingNo. 40-85t55-001
AwazuPlant. 5.7 1 SOCKET
SCALE
NONE
30-010 WA1 200-3

0
53##-wi !l333kIB%H
-&I *~t~kb~~~~~~~~Wt~~l~~~~~~-~~~ff~~~~~~.
I Cl (3/3) I NOTE:Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
_ 8
-9 _ 170 I
6 66 *
_,4 ~
7v z G
(r0
1 0
as
W 00 / n1wJ 44
o- --- .
2 __&__-_-___ J5,driIled g
hole g
Thissocketis ecmivalent
to one in iio drawingNo. 40-85155-002
AwazuPlant.
SUEFACE
TREU.CODE
YC .I. I
PLATE s43c / i ii : 3.1 GUIDE

PART NAME MATER I AL jUY/nr y@ REMARKS SCALE
NONE
WA1 200-3 11
5H#*mi !fs33cm~~
-w *iTlcd: t3~~~~-fi~~ll~~-~~~-C~~f;flt-Wlo)~ff~~~~~1.
I c2 NOTE: Komatsu
cannot accept any responsibility for special tools manufactured according to these sketches.
------__-_
------
\
to one in jig drawingNo. 40-85161-001
AwazuPlant.
30-012 WA1 200-3

0
m#*%m !#3mZao
w *lzlt-.k ~~~~~~~~LWl~~~~~~~~~-~~~~~~~~~~.
1 C3(1/2) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
I I I
T$;I~ wjjP$#i4m&# 40-85227-001 BtI~&P;hbc

ThisSocket is ealiivalent to one in jig drawing No. 40-85227~001 Awazu Plant.
PIPE STKM13A 1 1 10.5” c .

I
!3 BOSS SS4O”P ’ ’ ’ n f
01 GEAR 543
PART NAME
SYM.
1
I HEAT TREATMENT 1 CASE DEPTH IAPPLICATIONI Q’TY
rIIJNi / HRC20-30 m
! Thermal%/!t!of material,
c ‘__. . . -
1
u -PA-RT NAME
- SAE~~;lr"h-En?fdd
MASS (kg1 PAINT Cfl
(NONE)
TJ
ss -p-t-/ I SWFACE,,IREAT.COE
fi 4 A jij
. 42C-.13-15120 1.56 T!~I/~J I
DETAIL OF SAE I NVOLUTE SPL I NE SH,AT
SCALE PART NO.
11
NONE ?!S,MT,89.0: 124,O.d
WA1 200-3 30-013
0
%#*%I3 CINCH
2s:) *~t~~~~~~~~~~l~t~~~~~~~~~-~~~~~~~~~~.
Thissocketis euuivalent
to one in jigdrawing
No. 40-85228-001
AwazuPlant.
inioiutespline
60X22X2. 5
!iiOo”1 “10.19;
I
_iHAtI- s43c 1 1 '$.
I 1 E3lA
Pressureangle 20” 00 I PART NAME MATERIAL UV!3$ffs~ REMARKS
4‘/;r;‘Jr Ex774‘/ti3Yk
J f Thermal refining of material
SWACE TiEAT.CODE
Detail of involute spline shaft
125.o.L
30-O 14 WA1 200-3
0
53l!#*+Jlz DIZZY
d
-
c
-- -------_--_ k
,= z
z
y _-co.5
++
\
A
i ),
/\ A
/'
co.5
-22-l
- 218
(240)
d
&00
A-A
‘\
03 PIPF $TKMM i 4.8 +127xt8

I s43c 1 2.2t22
WM.
I
PART NAME 1MATERIAL ewi3 qAsp REMARKS SCALE
NONE
WA1 200-3
!&%*a2 ~71~~H
l__!L-l NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
------
----- -------- --&________
100 I
This socket is equivalent to one in jig drawing No. 40-85159-001 Awazu Plant.
WdPOO131 1
I HEAT TREATMENT CASE DEPTH APPLICATION O’TY
04 BAR /SS4OOP2 10.051. MATERIAL
I s53c
7 b-L#i.hh
PI ATF 1 I 1.5 I. AIlTmi
s53c
I Flame hardening
I
02 PiPE ~TKMI~Ai l6.1 i$lOOXt6 j MASS (kg1 PART NAME PAINTL-R
I
I s53c 1 i-2.2 I. SURFACETAEAT.WOE
SYM. PART NAME j MATER[AL[UY~~f;~j REMARKS ]
9.9 SOCKET
SCALE
NONE
30-016 WAl200-3
0
33fR*$m 6v.%IE%H
1 D2(1/3) -1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
120 *
204 WAlXtO131 1
1
APPLICATION Q’TY
. I
$o"old
I$!l&WBirsbti40-85154-OOA ME&H, FumB!
MASS (kg) PART NAME PAINT(R
SUR?Q
TREAT.COOE
13.2 ASS'Y-DRAW
to one in jigdrawingNo. 40-85154-OOA
AwazuPlant.
SCALE
NONE
WA1 200-3 30-017

0
53-fe*%i& t%3?kIWer$H
%&I *~t~~d~~~~~~~~Wt~~~~7~~~~-~~~~~~~~~~.
1 D2 (2/3) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Harden, turn with lathe, then finish with sandpaper
I Surface must be sharp and free
-25. 5_ 44. 5kO. I__ 120 w WAi200

131 1 1
I- I-
APPLICATION B'TY
HEAT TREATMENT CASE DEPTH MATERIAL
,;,:232953 1130 HF?C58-63 SCM415H

MASS(kg) PART NAME PAIN3
OF!
*g/i W~I~~WB~B~ 40-85154-001 #%P~3I SURFACE
TREAT.CUOE
8.3 SOCKET
This socket is euuivalent to one in jigdrawingNo. 40-85154-001
AwazuPlant. SCALE
NONE
30-018 WA1 200-3

0
53s*at $34WX@El
m *Iat-k bQ~:~~M~~~FG-~,t~~~~~b-Wlo)~~~~~~~~.
1 D2(3/3) 1
154 r’
27. 5 66 m
16. 5 -
C-
S%
7v 4:’
OD
r
_--- ----- u
I 145 I
__J
02 BAR .s43c 10,5.

01 PLATE s43c 1 4.4 .
SYM. PART NAME MATERI AL ffJY/Wyczp REMARKS
WAlX)O
I31 1
I HEAT TREATMENT 1 CASE DEPTH APPLICATION Q’JY 4
MATERIAL
RTM[
m' ztiy$igzk I HRC30-36
I after f inishiw
MASS (kg) PART NAME PAINT (El
Thissocketis euuivalent to one in jig drawing SUFFACE TREAT.COoE
NO. 40-85154-002
AwazuPlant. 4.9 GUIDE
SCALE
NONE
WA1 200-3 30-019

0
fpt#*%m !i33#IW%H
-82 *iat-h ~~~~~~~~~Wt~~~~~~~~~-~~~~~~~~~~.

Y
v
40 I I i I
93. 5 83
* 196. 5 N
131 ) 1
f WA1200
r ; HEAT TREATMENT 1 CASE DEPTH /APPLICATION I ~‘17
afterf inishim s53c

MdSS (kg) PART NAME FAINT OR
SWFACf
TREAT.COOE
Thissocketis euuivalent
AwazuPlant. 7.6 SOCKET
SCALE
NONE
30-020 WA1 200-3

0
m#*4!m !f33ZkIWls$B
‘rl) *Faclt-k ~~~~~~~~LWt~9l~~~~~~-~~~~~~~~~~.

$o”,IL!
WI#%WBrnSI 40-85153-001 I!ama.
Thissocketis eouivalent
AwazuPlant.
q@@
,li\ ~#ll~ltf~
V
May be finished
with latheafterheattreatment .___ ,_.
WAlZCU131 I 1
t HEAT TREATMENT CASE DEPTH APPLICATION O’TY
%&~XF? L MATERIAL
K&N; Hardening and tefiwering
! after finishing
HRC36w42 SEE DWG
03 i GUIDF I s53c II 12.2. MASS (kg) PART NAME PAINT OR
WIFACE lFEAT.cooE
1 OCKFT I s53c II 16.9. 9.1 SOCKET
WM. PART NAME 1MATER I AL ]UlY/¶j@$~ REMARKS SCALE
NONE
WA1 200-3
30-02 1
0
53-#+*#i42 !4+3s#IE?sl$rn
,&) *~lt-~13~~:~~~~~~tt-7~~~~~~t-Wle>-ff~~~~~~.
-__ i,\. / j
_
,d /,A&;.L
I,
q.k===J= j
I
I
t---
1’
!
--._ f----i ‘\
-3 i
I
i
8
/
I
a--
j 1
/
; c__-__-__-__-__-ji_”
~_______________~ \
c 5 drilled hole
U70-OP/TF-85156-2 $I@
/ / Stamp
/ / 40 20 z:_:
1’ -=----,“I v / /
ii5-T“
I
I;\‘
---_-- _--- III \ / / L
---__ __-__-__-__
/ii /
t t I .
I I I /I I I!I !I I
I__-__-__-__-__-_i
- May be finished wi th lathe after heat tr eatment
ii ” i_______________J
1 WAiZOO(3) 1 I
*n”aM\ %:+Ig%WHm&f 40-85 156-00 1 @ii,“7’66,

This socket is equivalent to one in jis drawing No.40-85156-001 Awazu Plant.
NUNt t SKR?"" 8 9 0 - 1 5 5 0 n
30-022 WA1 200-3
0
33%*s!m $39?kIE?BI$B
is..) *~t~~$~~~~~~~~Wt~~L~7~~~~-~~~ff~~~~L~.
D6 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
6-13. 5Zfy
6-13.5. drilled hole
INI I I I I I I I A Hole H7*.01*
I /
j /
I
-_-
1 I/,
40- ,85157-00
This socket is ewivalent to onein ii47 drawing No. 40-85157-001 AwazuPlant.
v I31 (
1 WA1200 1
-I
02 I HEAT TREATMENT CASE DEPTH APPLICATION Q’TY
01 ;
01353-32335i BOLT $%i Standardoart 6 1 !. II 7z&itARiz L MATERIAL
BAR ss4ooi3 , 2 ! 0.‘02!. !

poRrrar, Harden1ng andtenweri rig
: after finishing HRC36-42 SEE DWG
02 j BAR s53c 1 Qm. I MASS (kg) PART NAME PRINTari
SURFACETREAT.CODE
/ s53c ! 1 I koi. 8.4 SOCKET
SYM. / PART NAME MATER I AL if1y/91j ‘r’csy , REMARKS j SCALE
NONE
WA1 200-3 30-023

0
53-~*sRZ !i3E%Js%H
:A) Milt-~ ul1~~:~~~~~t-~~~-cr~~~~-‘31~39rff~~~~~~.

,rj-_-
JLL--
1
_ $228.6
31 I -clYu
t;’
2150
07-k‘/:j
yyIck;I:p
Lowerhinge
Upperh irwe
I
SCALE
NONE
WA1 200-3
30-024
0
53s*wi $333aw3~
1 Kl(Wi’) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
*,“,I% %Yc/ZS%%WHrn
I@3 AJ-lJ70-004 #Z $?lS&:ap&a.
~~Xit$%$Plt CO.5 3-?%!YtRO. 6-l. Zlz-c~nra,L I:
Thismater is euuivalerrt
to one in jig
drawingNo. AJ-U70-004
#2 of KomatsuMEC
Chamferoutsidecornersto CO.5and round
insidecornersto R0.6 -Rf.2unless
0 Thismater is euuivalentto one in iio

drawingNo. AJ-U70-004
#I of KomatsuMC .
Chamferoutsidecornersto CO.5and round
insidecornersto R0.6 -RI.2unless
V
I HEAT TREATMENT 1 CASE DEPTH I-

-_.
.. _
.
_
FllRiItq BA#lut KlRTrow~ &A#;RJ -MA&ii
Hardening and tempering
HRC26+32 I Hardening and tempering HRC26-32
I
I s45c
MASS (kg) PART NAME PAINTal MASS (kg) PAINT OR
I
PART Ntd4E
23.4 GUIDE
PART NO.
ISURFACE ilEAT.CUIE
16
SCALE
I
GUIDE
!iUFAIX lEAT.COE
-
SCALE PART NO.
-
; I
NONE I$M,T, tj9,0, 2 1,2Q ,A
I NONE I
I
-2
$M,T, - Ej 9,0,
WA1 200-3 30-025
0
!iMf+*BE +$3zKls~~
*w *~t~~~~~~~~~~IWt~~t~~~~~~-~~~~~~~~~~.
This spacer is equivalent to one in jig drawing

No. AJ-U70-004 #4 of Komatsu MEC _
I
\/
Chamfer outside corners to CO.5 and round inside This spacer is equivalent to one in jig drawing
corners to R0.6 - R1.2 unless otherwise specified. No. AJ-U70-004 #3 of Komatsu MEC .
WAiZOO
I31 1
.
I . ; HEAT TREATMENT 1 CASE DEPTH 1 mum 1Q’TY II-IEAT TREATMENT -CASE DEPTH R~PUCA~~’
Q’T~
I
Klmf #t;ARWl/ ~~~26-32 MATERIAL wRi1a;

IkAwzL H/q--J+32MATERIAi
I Hardening and tempering s45c I Hardening and tempering S45C'
L 1
PAINT OR MASS (kg) ; PART NAME PAINT OR
MASS (kg) PART NAME
SIK-AGE rnbT.COoE SlFHCE TEAT. COPE
16 GUIDE . 6 i GUIDE .
SCALE PART NO, SCALE -; PART NO.
NONE
;
I
ISM,T
-, Ej 9,0, - 2 NONE 1 $M,T,E)9,0,21,3Q tA
30-026 WA1200-3
0
53l!l8*24Em !f33?kIEfiH
-El *~t~~~~~~~~~~l~t~~~~~~~l~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured accordingto these sketches.
MIN
MIN 4
(31
WA1200 1
APPLICATION Q’TY ! HEAT
v
TREATMENT CASE DEPTH
I HEAT TREATMENT CASE DEPTH MATERIAL . I
. I P@llI@lf
PuITrm’ ss400 I HRC30*36
MASS (kg) PART NAME FAINT 08 MASS (kg) PART NAME PAINTOR
SURAIX
lFFAT.CWE SUIFACZ
PLATE
TlEAT.CCOE
1.2 17.5 GUIDE
SCALE SCALE
NONE NONE
WA1 200-3 30-027

0
53f$3*llai $-333cEEBa
*&I *Eat-k ~~~~~fi~~~~t~~~~~~~~~-~~~~~~~~~~.

Q9
02 01
MIN -----+
MIN
0-W
++
R z
A
---_- -8- 2 P
I
-- 5
C
_ _c1
+
80
t-
v<4 PLACES
SURFACE
TFlEAT.CC#lE
18.54 1 GUIDE
SCALE
NONE
30-028 WA1 200-3

0
M#*%l~ !f3BcLE@B
‘iz) *Elt-h ~~~~~~~~~Wt~~t~~~~~~-~~~~~~~~~~.
1 K1(6/7) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
MIN
36X3
\ WAi2ooI31 1
I HEAT TREATMENT 1 CASE DEPTH 1APPLICATION O'TY
MATERIAL
Fal;lolj E$Ai%c;R
L HB248~285
Hardening and tempering s45c
M&S (kg) PART NAME PllINl
OR
SWdCE ~~.CODE
6 GUIDE I
I SCALE II I’ PART NO. /\ SCALE

NONE I~;S,MT:Q9,0:222,O,fi NONE
WA1 200-3 30-029

0
53B*4m !#33%a@H
1 K1(7/7) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
PLACES
V
HEAT TREATMENT CASE DEPTH
01I
RlFmq #iAm L
, Hardening and tempering
I
O? BAR SS4OOB 2 0.07 . M&S lkgl PART NAME PAINT OR

SWACE TREAT.CME
s45c 1 11 . 11.14; GUIDE \’
SYM. PART NAME MATERIAL B’lYIsEI q@y GEMARKS SCALE
NONE
30-030 WA1 200-3

0
5MR*sm #S#IJSE4
m *~t~~~~~rh~~~l~t~~~~~~~~~-~~~ff~~~~~~.
--- I_---
-y----- “-- 1
II
J
:: ii :
l__-Ll-_____ I _-_-u-__
t--
HA1200
(31 1
APPLICATION Q’TY
. I
PmTl
MASS (kg) PART NAME PAINT WI
WFACI lHEAT.COOE
. PUSH TOOL
SCALE
NONE 230.0.A
WA1 200-3 30-03 1
0
1 Q(N) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
This spacer is equivalent to one in jig

drawing No. AJ-U70-011 #l of Komatsu MEC .

drawing No. AJ-U70-011 #12 of Komatsu MEC . f&ruw~ co.5 U#li R0.64.2 mwl:t-~
Chamfer outside corners to CO.5 and round inside \-
corners to R0.6 - R1.2 unless otherwise specified.
Chamfer outside corners to CO.5 and round inside

V
corners to R0.6 - R1.2 unless otherwise specified.
IHEAT TREATMENT CASE DEPTH RIGTIM- Q’TY . ; HEAT

I ~~~ TREATMENT / CASE DEPTH 1 m[n~r(,g 1Q’TY
P&q #iAM% L p[RTIoN~ #khf&RL HRC26-32 aMA;;;FL
I HRC26-32 MA;E;FL I Hardening and tempering
I
PAINT IJA PART NAME PAINT OR
MASS (kg) PART NAME MASS (kg) S&FACE TREAT.=
SUFACE TREAT.COOE
, 13.3’ SLEEVE
7.2 SLEEVE .
\ I I
.
PART NO.
- 2'3,1Q ,A
SCALE
I ZjM,T-
PApT NO. 1’
-2
SCALE
1 SM,T,-
;
NONE , 8 9,0, NONE I ; E)9,0,
30-032 WA1 200-3
0
53l%*ai !#3sIE!lsis~
Finish corners smoothly with grinder
I
t I
I HEAT TREATMENT 1 CASE DEPTH 1 MATERIAL
to one in jig drawing No. AJ-U70-011 #3 of Komatsu MEC

Kf?iIoN~ . ss400
FAINT IJR
This spacer is equivalent
MASS (kg) PART NAME ’
SURFACE TEAT.CCXE
22 PLATE .
SCALE ; PART NO.
NONE I
I SjM,T, L 8 9,0,- ;i
WA1200-3 30-033
0
53l?B*%l~ 434xcNm
.&I *~t~~~~~~~~~~~~c~~~~~~~~~-~~~ff~~~~~~.
'his spacer is equivalent to one in jig This spacer is equivalent to one in jig
Irawing No. AJ-U70-006-C of Komatsu MEC . drawing No. AJ-U70-006-B of Komatsu MEC _
Chamfer outside corners to CO.5 and round Chamfer outside corners to CO.5 and round
inside corners to R0.6 - R0.8 unless inside corners to R0.6 - R0.8 unless
S/ii f YBX~~#JZ t3 AJ-U70-006-D &,TbL W f ~3J%k%&b I$ AJ-U70-006-A I%Taii;t

This spacer is equivalent to one in jig This spacer is equivalent to one in jig
drawing No. AJ-U70-006-D of Komatsu MEC . drawing No. AJ-U70-006-A of Komatsu MEC .
” A ” +j-jFJ$@
Detai I of “A” Detai I of “A”
!5U!w CO.5 lk#ia R0.6w0.8 i;mm:te #ji$,!~~#.i

CO.5 tm RO.bO.8 mlIm~t.
Chamfer outside corners to CO.5 and round
inside corners to R0.6 - R0.8
30-034 WA1200-3
0
5m*mc 433?DxBH
m *ixllt:‘k ~~~~~~~~~Wt~~/l~~~l~-~~~~~~~~~~.
1 Vl (l/8) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
---2
\ \
1 tlA1200
(31 1 1
APPLICATION1 Q’TY
, HEAT TREATMENT CASE DEPTH MATERIAL
. I
mum!
MASS (kg) PART NAME PAINT OR
SIBFACE
TREAT.CCllE
I
PUSH TOOL I
SCALE
NONE
WA1 200-3 30-035

0
53lYF*%It !l3%kIIE@H
:d) *lzlr-1 d3~~~~~~~L~tt_3~~T~~I~.-~~Wff~~~~~1.

-1
‘8V m40
Threaddepth:40
IHEAT TREATMENT
I
CASE DEPTH mang!j Q’TY

$$I! ~73$~~$%lli l!i AJ-U70-001
#I&i?i3~ ;pw11~~1ImtWL
This spaceris equivalentto one in jig drawing No. AJ-U70-001
HRC26-32 MA;;;FL
#l of Komatsu MEC 1 Hardening and tempering ,
: MASS (kg) PART NAME PAINTOR

&i#Wi CO.,5 tidli R0.64.2 I;-tbm~:t~ 98 SHAFT
SWAE mAT.COOE
Chamfero&side corners to CO.5 and round inside corners to RO.6 - Rj.2

unless otherwise swcif ied. SCALE
NONE
30-036 WA1 200-3

0
alt#*%m Oxfam
m *~jl-~:13~~~;ht;~~~~t-31,~~~~t~.-wl~a~~~~~~~.
Actually positioned on part No. 793-890-2510
#2 ill3~rrnai v
This spacer is equivalent to one in jig drawing No. AJ-U70-001 #2 of Komatsu MEC . . I idEAT TREATMENT CASE XJEPTH
wRTrar;
Chamferoutsidecornersto CO.5and roundinsidecornersto R0.6 - RI.2

I !
&A&EL
PART
HRC26*32
NAME
MATERIAL
s45c
PAINT OR
unlessotherwisesmcified. SlFAcE TFEAT. COE
NUT .
SCALE PART NO.
NONE 1 z9,3,Ej9,0,25,2Q ,A
WA1200-3
30-037
0
53R*wL !l+iSKLEsl$B
1 VI (4/8) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
ItAJ-U70-001
#4~~ir;b3t
drawing No. AJ-U70-001 #4 of Komatsu MEC .

drawing No. AJ-U70-001 #3 of Komatsu MEC
Chamfer outside corners to CO.5 and round inside Chamfer outside corners to CO.5 and round inside
corners to R0.6 - R1.2 unless AMIWIM 0 ’ TY corners to R0.6 - R1.2 unless MPLIWIJN Q’TY
I I
. I HEAT. TREATMENT CASE DEPTH MATERIAL I I HEAT TREATMENT 1 CASE DEPTH MATERIAL
I %ma L HRC26*32 s45c I 1 HRC26?32 s45c
mI@( Hardening and tempering MiI@( Harder?$%kempering
MASS (kg) PART, NAME PAINTOR MASS (kg) PART NAME PAINT OR
WFKETREAT. COOE SWFACE TEAT.CUE
9 SLEEVE 17.5 I
SLEEVE .
SCAiE SCALE PART NO.
NONE NONE
30-038 WA1 200-3

0
53-#f*wi +-3+%.IE@R
.&I *~t~k$~~~~~~~I~~~~1~~~~~~-~~~~~~~~~~.
$ g@$lo Thread depth : 10

Make 6 holes at
639 equal intervals
This spacer is equiva I ent to one in j ig drawing No. AJ-U70-001 #6 of Komatsu MEC I
This spacer is equivalent to one in j ig drawing No. AJ-U70-001 #5 of Komatsu MEC .

r
EM?li co.5 w R0.64.2 trfIa~t.
Chamfer outside corners to CO.5 and round inside WA1200
131 1 1Fii8hftdii co.5 tm R0.6~1.2mlIfJ~L biAl200
131 1
corners to RO. 6 - Rl. 2 un I ess
APfINXIoN O’TY
Chamfer outside corners to CO.5 and round inside
corners to RO. 6 - Rl. 2 unless
v APPLIUm O’TY
I
lHEAT TREATMENT CASE DEPTH MATERIAL I HEATBAi;FATMENT CASE DEPTH MATERIAL
PQRiroW! . ss4go FURiiQJ! Hardening and tempering HRC26*32 S45G
PART NAME ’ PAINT OR MASS (kg) PART NAME PAINT OR
MASS (kg) SWACE
TREAT-COLE
SIRWE TEAT.COCE
2.6 PLATE 7.8 PLATE
SCALE SCALE
NONE NONE
WA1 200-3
30-039
0
53B*$IE m?u~~~
%B.i)
mls-bc ~~~~~fi~~I~c~7ts~~~m-~~~ff~~~~~~.
IdbarOER Specifications of spring
(EquaI I Y spaced)
41
[ 9% Outside diameter Cm) 1 32 /
1 ojB@ Wire diameter Cum) 1 3 2 1
1 I&X* Freeheight W 1 46 1
/.x5- I
A-A
8&U ?f~x;ctf$ H#i!$~1bUla $!;8$ A32-03 ~~,",~~a.
This spring is equivalent to compressivecoil spring,product
No. A32-03, manufacturedby SANESU Co.,Ltd.
$88~TNM#J~ hl#
AJ-801-024
tr3
I%tbh
This spacer is equivalent to one in jig drawing No. AJ-801-024 #3 of Komatsu MEC
WAl200(31 4
v
APPLICATION Q’TY
(wAi200131
_ 1 HEAT TREATMENT CASE DEPTH MATERIAL
, HEAT TREATMENT CASE OEPTH ~~UTIM 0.n I
wirm~ wmz L FaiLor SEE DWG
~~~30-36 MATERIAL
1 Hardening and tempering s45c MASS (kg) PART NAME PUNT [R
MASS (kg1 PART NAME PAM IBI SRdCE TIBT.wDE
SIFUI TR5AT.W SPRING
39.9 GUIDE SCALE ’ PART NO.
SCALE
NONE NONE
30-040 WA1200-3
0
53lB-ala
!f?3?#IE!sr$B
:w *Ht-k ~~~~~fi~~~~t~~~~~~~l~-~~~~~~~~~~.
t
WAVOOi31 1
M’lICllTIM Q’ TY
,HEAT TREATMENT CASE DEPTH MATERIAL
A-A
,mim~ . . ss400
MASStkg) PART NAME PAINT
OR
SW&E TREAT .COOE
$8 bi3SfAitWl~ Iii AJ-801-024
#4131~&3, 7.8 RING .
This spacer is equivalent to one in jig drawing No. AJ-801-024 #4 of Komatsu MEC _ SCALE PART NO.
NONE j ‘7y9,3,89,0,25,90 ,A
WA1 200-3
30-04 1
0
53?#*$Im %3%7IE@O
22) *~c~k~~~~h~~~LW~~~1~~~~~~-~~~ff~~~~~~.
Q/5
This spacer is equivalent to one in j ig drawing No. AJ-801-024 #7 of Komatsu MEC .

MAi 6
APRI@TION 0 ’ TY
F&U%! . . SS40OB
PART NAME PAINT OR
MASS (kg)
SWXE TFWT.W
1.1 BOLT.
SCALE PART NO.
NONE
30-042 WA1 200-3
0
5m*wi !f34zkIE@H
.&Ii)*l.ac-k ~~~~~~~~I~l~~/l~~~~~-~~~~~~~~~~.
WA1200
131 1
AfJFtICATI~ Q’TY
I HEAT TREATMENT CASE DEPTH’ MATERIAL
lxlli,i
MASS (kg) PART NAME PUNTIIF!
SWACE TWJ.CWE
PUSH TOOL
SCALE
NONE
WA1 200-3 30-043

0
%f#*wi $-3-3i#IE!sl$H
m *~t~~~~~~~~~~~Wt~~l~~~~~~-~~~~~~~~~~.
RO.5QT /
RO.5 max.
Chamfer corners to C0.5, unless otherwise specified.
MATERIAL
s45c
PAINT OA
SIRFdCE TREAT.UXE
I I
This spacer is ivalent to one in jig drawing No. AJ-801-002#501 of Komatsu MEC . L
SCALE
-.-.. . .._ -_
NONE
30-044 WA1200-3
0
33lB*sm $-333=W~~
1 V2(3n) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Chamfer corners to C0.5, unless otherwise specified.
I &EAT TFIEATMENTI CASE DEPTH 1 MATERIAL

WRiIoN! W&R t ]HRC26-32 s45c
i! MhCC~l/rl~I PART NAME PdINT IIA
SWACE TEAT -CUE
7.8 SLEEVE I .
This spacer is equivalent to one in jig drawing No. AJ-801-002 #502 of Komatsu MEC .
SCALE PART NO.
NONE
WA1200-3 30-045
0
33lR*sIlz !$3-EkIE!sl$B
*ia *iziJt-kl b~~~~~~~~~t~~~S~~~~~-~~~~~~~~~~.

hT?l\tsPhdld
CO.5 tmi%Pld
R0.6-1.2 k~~oIo:t,
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R0.8 unless
This spacer is equivalent to one in jig drawing No. AJ-801-002 #401 of Komatsu MEC . SCALE
NONE
30-046 WA1200-3
0
33-$T*sm !#+!s?kiI~~rn
m *~t~kb~~~~~~~~Wt~~l~~~~~~-~~~~~~~~~~.
I v2(5/7) I NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
t-lb
tually positioned on part
This spacer is equivalent to one in jig drawing No. AJ-801-002 #7 of Komatsu MEG .
&4188ll co.5 SkdiR0.6*1.2

tmn:tt
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R1.2
unless otherwise specified.
.
I
lHEAT TREATMENT
v CASE DEPTH
$$iu;r~318$Z%iB6
It AJ-801-002#402 RiirQh
This spacer is equivalent to one in jig drawing No. AJ-801-002 #402 of Komatsu MEC .
Riq &ABE t .MATERIAL

HRC24*30
f Hardening
I
and tempering of material
I
s45.c
MASS (kg) 1 PART NAME PAINT OR
SWFAE TiEAT.COE
I o-9 I BOLT .
1 2.5 1 NlJT - I silkci Tml.cm
SCALE
NONE
WA1200-3 30-047
0
m *Bll-dr $~~~~~~~~~t~~l~~~nl~-~~~~~~~~~~.
- I
v
I
A-A
1 I
lHEAT TREATMENT CASE DEPTt( MATERlAL

Spit 1lr3WSMlii l!ii 13;WWL
AJ-801-002 &KN! !$iA#Wt HRC30+36 s45c
This equivalent to one
spacer is in jig drawing No. AJ-801-002 a3 of Komatsu MEC . MASS (kg) PART .NAME PAINTOR
SWACE TfE~T.COlE
tiwffi#lii co.5MludR0.64.2RROIKtl 20 GUIDE
Chamfer outside CO.5 and round inside corners to R0.6 - R1.2 unless
corners to SCALE ; PART NO.
-NONE
30-048 WA1 200-3

0
m#*%l* #$4?ax!88$B
-83 ~~t-~c3~~:~;pl_fi~~~~t-~,1~~~~~zS-~Je)~it~~~~~~.
4 - ZZ+'J
--
A-A
\ I WA
12Oi[31 1
V APWUfIa( Q’ TY
AJ-801-002#4 lll%M
SiItrr38fiMMi110 .
‘IHEAT TREATMENT CASE DEPTH MATERIAL
This spacer is equivalent to one in jig drawing No. AJ-801-002 #4 of Komatsu MEC . ~RiHM! . . ss400
MASS (kg) PART NAME PAINTOR
~dM#t CO. 5 MN R0.6d.2 M114):ts 13 RING
SWACE TEAT. CmlE
.
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R1.2 unless
otherwise specified. SCALE PART NO.
NONE I7,9,3,@9,0, 7,6Q tA
WA1200-3
30-049
0
53s*$!E !f33?kIErs$H
-&I *~t~~~~~~~~~~~~r~~t~~~~l~-~~~ff~~~~~~.
*&a, EAI%;$E~f@6’nf A J -0 0 1 9 3 P @%,“,T’dj~,
This tool assembly is equivalent to one in jig drawing No.AJ-00193P Mooka Plant.
Length of bolt is Processed io 24mm.
\ 0 8 J-fiiilb t. 1 J IS 1 1 1 - If?01 6, 39ifEa24mm

--- cLq=\ \ \ 1 @p\__ __I;: \ 07 I~dd3ld 1 JIS 1 2 1 - IMlOxl.5, L=65
-__-__-__- ‘(, -- 06 I~-Y-P~JC~ I ~1s I 4 I - 1~16x2, ~=50
1 J ,s I , ) _ [Nominal size :6. cwwo4994

08 IEye bolt Thread length 74mm 01 tiEt’J29 %lMB# 1 - rT!;tRl-30
07 IC~P bolt 1 JIS 1 2 1 - IMlOxl.5, L=65 SYM. PART NAME MATERIAL R'TVSET
;;;; REMARKS WA1200 (31 1
06 iCa~ bolt I JIS I 4 I - 1~16x2. L=~O APPLICATION Q'TY
05 IHexagon bolt 1 J IS 1 3 1 - jM3Ox3. L=l65 HEAT TREATMENT CASE DEPTH MATERIAL

I I
30-049-l WA1 200-3

0
w#*sm !l-sscLE&H
2%) *~t~~~~~~~fi~~LWI~~L~~~~~~-~~~ff~~~~~~.
5-11 drilled hole

($fiEx!iic)
(DISP DWG)
4-M16x2330
3-101’1 79’115 20. 5

3-10 drilled hole
seat hole I5
MASS (kg) PART NAME PAINT

OR
*n"nlX,
+iRI%;iW@m;f AJ-00193P-02 8%&7.660 52. 0 CYLINDER
SURFACE
TREAT.
CODE
This cylinder is equivalent to one in jig drawing No.AJ-00193P-02 Mooka Plant. SCALE
NONE t szi";"" 8 !4 0 -?I 1 1 0 n
WA1 200-3 30-049-2
0
53#f*%B ~1~~~
*&) *~t~kd~~~h~~~LWt~~t~~~~~~-~~~~~~~~~~.
3-52f’J
I 240 I
This Piston is equivalent to one in jig drawing No.AJ-00193P-01 Mooka Plant. SCALE
NONE f S;";"" 8 9 0 - 3 1 2 0 A
WA1 200-3
30-049-3
0
53-?%*4!m +33?kIE%El
-83 *~t~~~~~~~~~~r~t~~t~~~~l~-~~~~~~~~~~.
This shaft is esuivalent to one in .iis drawing No.AJ-00193P-04 This Plate is equivalent to one in jig drawing No.AJ-00193P-03
Mooka Plant. Mooka Plant.
cwwo4997
WAI200 (3) 2 WA1200(31 I

APPLICATION Q'TY APPLICATION Q'TY
HEAT TREATMENT CASE DEPTH MATERIAL HEAT TREATMENT CASE DEPTH MATERIAL
PORTION PORTION
ss400 ss400
MASS (kg) PART NAME PAINT
OR MASS (kg) PART NAME PAINT
OR
SURFACE
TREAT.
COOE SURFACE
TREAT.
CODE
SHAFT PLATE
SCALE SCALE
NONE + SIR;""'8 9 0 - 3 1 3 0 n NONE f Spei";""
8 9 0 - 3 14 0 n
WA1 200-3 30-049-4
0
53l%*wz
DISASSEMBLY AND ASSEMBLY DT CONNECTOR PIN
REMOVAL OF DT CONNECTOR PIN INSTALLATION OF DT CONNECTOR PIN
1. Using needle-nose pliers, tweezers, or pulling tool 1. Hold wire (4) at 30 mm on rear side of crimped part
Xl from DT connector, pull out wedge (I). (Photo of contact.
shows male side)
__
i :
2. Separating contact fixing claw (2) in connector from 2. Insert wire (4) on grommet side of connector.
contact with flat-head screwdriver, tweezers, or pull- Ir Insert contact at end of wire (4) straight in
ing tool Xl, pull out wire to reset fixing claw. grommet hole until it clicks.
* Insert the wire until you catch a click (a sound ,
made when the contact passes the fixing claw)
and feel the contact collide with the end wall.
Ir Pull the wire a little in the pull-out direction to
confirm that the contact at the end of the wire
is not removed.
3. Holding shield rubber (grommet) (3), pull out wire 3. After inserting all wires, install wedge (1).
(4).
30-050 WA1 200-3

0
53FB*~&
DISASSEMBLY AND ASSEMBLY HD CONNECTOR PIN, REPAIR PROCEDURE OF HARNESS
REMOVAL OF HD CONNECTOR PIN REPAIR PROCEDURE OF HARNESS
1. Select tool matched to wire size of pin to be re- Remove cover of wire.
moved from “Special Tools List”, and install it to * For the length of cover to be removed, see the
wire. following table.
Wire size Length of cover to

JIS 1 SAE beremoved (mm)
0.5 2 - 24AWG 3.96 - 5.54

0.5 - 0.85 16 - POAWG 6.35 - 7.92
1.25 - 2.0 14 - IGAWG 6.35 - 7.92
2.0 - 3.0 12 - 14AWG 5.64 - 7.21
2
8.0 8 - IOAWG 10.9 - 12.5 @Vi04861
2. Insert tool Xl in clearance between wire and con- I 15.0 / 6AWG 1 10.9 - 12.5 I
nector seal driver (1) until it is stopped by contact.
t Use a tool a little larger than the wire.
* Take care not to break the wire and connector
pin. Remove pin (1) of crimping tool X2.
3. Pull out wire (2) together with tool Xl. Raise and turn knob (2) to select a size matched to
wire size. (AWG sizes in above table are indicated
on tool X2.)
Loosen locknut (3) and turn adjustment screw (4).
INSTALLATION OF HD CONNECTOR PIN

Insert contact (5) in crimping tool X2.
1. Hold wire (2) at 30 mm on rear side of crimped part * Turn adjustment screw (4) so that the top of
of contact. contact (5) will be flush with upper end a of the
tool hole, then tighten locknut (3).
2. Insert wire on grommet side of connector. 6. Insert wire (6) in contact (5).
* Insert contact straight in grommet hole until it
clicks. 7. Grip handles to crimp contact.
* Insert the wire until you catch a click (a sound * Grip the handles to the stroke end, and they
made when the contact passes the fixing claw) open automatically.
and feel the contact collide with the end wall.
t Pull the wire a little in the pull-out direction to
confirm that the contact at the end of the wire
is not removed.
WA1 200-3
aE#*mi ri-;;‘iT?i bAss’y
DISASSEMBLY AND ASSEMBLY ENGINE MOUNT Ass’y
,’ nzz+Y t 12) LT-ZA@bKt
/'
WA1 200-3
mR*sm r>-;i’iT’9i bAss’y
DISASSEMBLY AND ASSEMBLY ENGINE MOUNT Ass’y
Ii-);‘iTrfi t+Ass’y(2/3)
ENGINE MOUNT Ass’y (2/3)
16.2-6. 9kom
llGHTEN,Nt TORD”f TlGniEWlltTORPUE
fi - C 'I7 :j
il%Lh7 45-49.5Nm IffIJI 24-28Nm
(4. 6-5. Okom) (2. 5-2. 6kom)
(33.1-37. Okomi
_-.-__-__-_.-__-__---I
--.
l-
CWW04867
WA1 200-3 30-053

0
33fl3+*%3 IIj-;i‘;Y’+ i bAss’y
DISASSEMBLY AND ASSEMBLY ENGINE MOUNT Ass’v
Ii-;;‘>?‘3 i bAss’y(3/3)
ENGINE MOUNT Ass’y(3/3)
Unspecified tightening torque shall be as follows.
(1) Bolts: Conform to KES 04. 123. 1
1. #%?Q)&LGGVX#Wlrf-t? i-JL3wctzha. Impact wrench
(1)%x. b KES 04. 123. 1 4 >I\“3 b L>f (2) Hose clamps: Conform to KES D 07281, D 07289
(3) PT thread: Conform to KES 04. 123. 3
(2)*-X:3427” D 07281, D 07289
Change direction of hose clamp 180” each for double
(3)Fr;taC KES 04. 123. 3
clamp portion.
Engine oil
Total volume: 290 .r? PATTERN
Exchange volume: 260 e MUFFLER OUTLET
Oil grade: E015-40CD cwwo4931
Meet API CE or CF grade
For muffler stack installation follow steps below.

a. Prepare pattern as shown and fit the pattern to
the muffler outlet pipe. Mark lines along the
pattern outside 4 places with unelasable pen.
b. Assemble muffler stack with matching its flange
to the mark. If adjustment at hole on muffler
stack is not enough, max. 5 mm shifting is
permitted.
30-054 WA1 200-3

0
53lF#*%lz /I-‘j;~--i;;:P&Ass’y
DISASSEMBLY AND ASSEMBLY COOLING SYSTEM Ass’y
3-Y i9 ‘-i ;ifLsAss’y(l/3)

COOLING SYSTEM Ass’y (l/3) ’
-__-k:=::
-----__-__
WA1 200-3
33%*siil~ 3-‘J ig>X?&Ass’y
3-11 i?-iX5-&Ass’y(2/3)
COOLING SYSTEM Ass’y (213)
-
-_
-
3
;Nm
Skem)
X--
CWWO4869
30-056 WA1 200-3

53##-%li~ 3 - ‘J i$%-i;(&Ass’y
3‘ - ‘/ i 9-i Xf&Ass’y(3/3)
COOLING SYSTEM Ass’y (3/3)
~-ii__ u =ii=i= ------
,i_~~~+Ig$LI~~
-__-_____-
___
________------j----- __
____-----
,______------ ,fL&$
” &A (I :z)
-_-
(FROM Ctwo4868~
77%. (2)
HTC?P'1-SIN /
RADIATOR
v (FROM ~~~04868) (FROM ~~~048681 '_'
CWWO4870
WA1 200-3 30-057

0
3Mf-ii!s 7z~-IIL9>3Ass’y
DISASSEMBLY AND ASSEMBLY FUEL TANK Ass’y
7 ZL--JI~ i?Ass’y(1/4)
FUEL TANK Ass’y(l/4)
A 1
-__-_____-_____-______------
z:
-3\
----__ ---_ @____ ’ ‘%\
I”4 (
’ lb-4ib
‘m’ !
-_ -
--_
+_x
(TO CWWO4874)
‘--_-_/i ,,,,F’
A- =-+!
CWW04871
30-058 WA1 200-3

0
33fR*siEl 7 LL-IIL~ i3Ass’y
7.1--MO~Ass’y(2/4)
FUEL TANK Ass’y (2/4)
Z(G2-Ll)XttKt.
:%?-I.,,
II “ATICED
AREA
J-J 11:s) I-I (1 :5)

IFROM CWWO4871)
GG [If:61
/
i
‘-1
“1
cwwo4872
WA1 200-3 30-059

0
M+*$m 7~-IW~~9Ass’y
7 ~--~l&i3Ass’y(3/4)
(25-31. 5kem)
H-H II :2. 5)
30-060 WA1 200-3

0
53~*slZ 7x-IlbSi3Ass’y
DISASSEMBLY AND ASSEMBLY FUEL TANK Ass’v
7 x--h9 i?Ass’y(4/4)
'~77-Pi~17owx4 '1?3>t'i'/l
REARCOYBINITIOH
LAYP
FULL 3681.9L
(FROM CWWO4871)
c-c t1:2. 5)
(FROM ~~~04873)
D-D (1:2)
(FROM ~~~04873)
B-B (1:2. 5)
(FROM CWWO4872)
E-E (1:2. 51
(FROM ~~~04873)
F-F (1:2. 51
PTl/2
P (1:2. 5)
(FROM CWWO4872)
&_________ __-__-__;________
-_____&-------i------n__
________-))
/
CWWO4874
WA1 200-3 30-061

0
53@-3m IP=I iAss’y
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER Ass’y
717’1 iAss’y(V2)
AIR CONDITIONER Ass’y(l/2)
TltHTEYinG TOPDUE
fi#Ek9 3.43~4.4lNm
(0. 35-O. 45kam)
B-B
(FROM CWWO4876)
F-F
/PH :2.5)
J-J (TO
D-D
(FROM CWWO4876)
30-062 WA1 200-3

0
53%*$&t 171 iAss’y
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER Ass’y
17=1 iAss’y(2/2)
AIR CONDITIONER Ass’y (212)
r B (TO CWWO4875)
~~&_-+L-~~~!l~ c c i
I ___-i-“________________
I T
i--B i A
A mi
CWW04876
WA1 200-3 30-063

0
5383*wE IP=I ;f \“+ e>gAss’y
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER PIPING Ass’y
17=I if\“4 ts”i9Ass’y(l/2)

AIR CONDITIONER PIPING Ass’y(V2)
--<__
ii/ ,_-----* r-7 ._> ______L_L________L
____-__Ld_-______
“y
‘:
“,
ii__
-_-
“Yy._
_-__-__-________
“1 4
.
_ ---____
- -____
i
_‘_‘____-__-__T_
30-064 WA1 200-3

0
fpB83*$43~ 17’3 >/\“I’ I?> 9Ass’y
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER PIPING Ass’y
17=I il\“q l?‘i9Ass’y(2/2)

AIR CONDITIONER PIPING Ass’y(2/2) 2. Precautions for filling air conditioner with refrigerant
(1) Keep the ambient temperature above 3°C (since the system does not work if the ambient temperature
1. Attention to connection of piping is below 3°C).
(1) Coat ND-OIL8 (Compressor oil for non-freon) on O-ring. (2) Use Freon gas (R134a) as refrigerant.
Be sure not to use oil of sniso base and liquid lubricants of CRC (mineral oil).
(3) Before filling the air conditioner with refrigerant, be sure to evacuate the air conditioner by repetitive
(2) Remove the plugs of the air conditioner parts (devices and hoses) just before connecting those parts evacuation method. (The degree of vacuum must be above 750 mmHg.1
(to prevent dust and water from entering those parts).
(4) The standard quantity of refrigerant to be supplied is 1.3 - 1.5 kg.
(3) Connect each hose securely by using two spanners.
(Hold the device side with one spanner and tighten only the flare nut of the hose with another (5) Take care not to supply liquid Freon to the refrigerant system by holding the refrigerant can upside
spanner.) down or handling it wrongly.
(4) Do not connect the ports of receiver conversely. (6) Do not operate the compressor before filling the air conditioner with refrigerant.
(5) Tightening torques of the following parts must be as shown, unless other specified. 3. Inspection after assembly
1) Bolt: Conform to KES 04. 123. 1 Impact wrench
2) Taper thread: Conform to KES 04. 123. 3 (I) Check that proper quantity of refrigerant was supplied to the air conditioner.
3) Nut: Conform to KES DO1597 Judge and adjust the quantity of refrigerant by the following method.
4) Pipe connecting parts
Operating pressure of Number of bubbles passing
Remedy
compressor through receiver sight glass I
Bubbles pass sometimes or Discharge refrigerant through
0.1 MPa Il.0 kg/cm*}
do not pass at all. pressure valve to proper level.
0.06 - 0.1 MPa -
Proper Bubbles pass continuously.
CONDI out IO.6 - 1.0 kg/cm*)
0 Ml6 x 1.5
-
12 - 15
{I18 1471 CONDZ out a Insuffi- Connect charging hose to compressor
ret to unit in cient 0.06 MPa to.6 kg/cm*} Bubbles pass continuously. and supply refrigerant to proper level.
Nut type D l/2 G M22 x 1.5 20 - 25 CONDl in b (2) Check the air conditioner starting normally.
24 I196 - 2451 CONDZ in
4. Precautions for discharging gas
D 518 0 M24 x 1.5
30 - 35 Unit out
27 (294 - 343) (1) Before discharging gas, perform the oil return work (work to return compressor oil in the piping to the
compressor).
. Oil return procedure: Set the fan switch to the MAX position and run the engine at low idling
and operate the air conditioner for 5 minutes.
Block joint (2) Be sure to discharge the gas through the high-pressure valve.
~~
5. Precautions for repair work
(1) If a defective part is installed and the refrigerant needs to be discharged to repair that part, perform
the oil return work, then discharge the refrigerant gradually through the valve rubbers installed to the
. After tighten up, if the gas shall leak, clean and apply ND-OIL8 to the flares. And tighten as high-pressure and low-pressure valves of the compressor. (It is very dangerous to disconnect the
mentioned above. piping without reducing the pressure in the cooling system. Never do that.)
6) Tube joint to click as assembly. (2) When repairing the air conditioner, be sure to put on protective goggles. (If refrigerant enters your
eyes, you may lose your eyesight.)
(3) Do not repair the air conditioner in a dusty or damp place.
(4) Once refrigerant is discharged and supplied again for a repair work, check the compressor oil.
(Specified quantity of oil: 130’~* cc, ND-OIL81
6. Never leave the machine outdoors without installing the cab.

When it is obliged to do so, take measures to protect the air conditioner (indoor unit) from rainwater.
WA1 200-3 30-065

0
53+#*2m "iif fAss’y
DISASSEMBLY AND ASSEMBLY DAM PER Ass' y
9kfAss’y(l/2)
DAMPER Ass’ y (l/2)
TlC”TENlNG TOROUE
ti#bJid 245-309Nm
16x2
\/
TlG”TENlHG TORPUE TIGHTENING TORPUE

P#bh9 5.9--ll.8Nm Pbkhl 98-123Nm
(0. 6-l. 2Ksm) (10~12.5Ks.m)
cwwo487a
30-066 WA1 200-3

0
53E#*sR~ ZI ; b J3--IL/ \“JldAss’y
DISASSEMBLY AND ASSEMBLY CONTROL VALVE Ass’y
3 =/ I- II --/LI\‘/I, j'Ass'y
CONTROL VALVE Ass’y

,,GHTEHl”G TDlO”E
f#bh3 294-314Nm
{30-32komI
E-E
TlGHTEnIYG TOlO”
OQik5’ Zll-240Nm
(?.I.+24.5komI
Ok81
30-068
0
53%*%lZ b IL3 7 El -Ass’y
DISASSEMBLY AND ASSEMBLY TORQFLOW Ass’v
b/L? 7 q -Ass’y(l/2)
TORQFLOW Ass’y(1
Y
(TO CWWO
WA1 200-3
mf#*mz b IL3 7 II -Ass’y
DISASSEMBLY AND ASSEMBLY TORQFLOW Ass’y
F /td’ 7 q -Ass’y(2/2)
TORQFLOW Ass’y (2/2)
P (1 :2. 5)
Y
(FROM
cwwo4879) CWWO4880
30-070 WA1 200-3

0
DISASSEMBLY AND ASSEMBLY TORQFLOW ASSEMBLY
GENERAL DISASSEMBLY, ASSEMBLY OF TORQFLOW ASSEMBLY
Disassembly procedure Assembly procedure

1. Preparation work 1. Preparation work
Support the vehicle body with wood blocks, Support the vehicle body with wood blocks,
etc. so that the TORQFLOW assembly will etc. so that the transmission assembly will
be horizontal. be horizontal.
A Support the transmission securely, too, 2. Connection of TORQFLOW assembly
so that it will not fall down when the 1) Fit the O-ring to the connecting parts of
TORQFLOW assembly is disconnected. converter assembly (9) and transmission
2. Wiring harness assembly (IO).
Remove wiring harness (1). & O-ring: Grease (G2-LI)
Ir Remove the wiring clamp, too. 2) Sling converter assembly (9) and install
3. Tubes it to transmission assembly (IO) with the
1) Remove the clamp, 2 mounting bolts, 25 mounting bolts.
and remove bracket (2).
2) Remove the 6 mounting bolts and drain 6 kg Converter assembly:
tube (3). Approx. 1,450 kg
3) Remove the 6 mounting bolts and drain r+ kg Transmission assembly:
tube (4). Approx. 3,750 kg
4) Remove the 6 mounting bolts and drain 3. Lubrication hose
tube (5). Install lubrication hose (8).
5) Remove the 8 mounting bolts and drain * Secure the lubrication hose with the hose
tube (6). clamp.
6) Remove the 8 mounting bolts and lubri- 4. Tubes
cation tube (7). 1) Fit the O-ring and install lubrication tube
4. Lubrication hose (7) with the 8 bolts.
Remove lubrication hose (8). 2) Fit the O-ring and install drain tube (6)
* Remove the hose clamp, too. with the 8 bolts.
5. Removal of TORQFLOW assembly 3) Fit the O-ring and install drain tube (5)
1) Sling converter assembly (9) temporarily with the 6 bolts.
and remove the 25 mounting bolts. 4) Fit the O-ring and install drain tube (4)
2) Disconnect converter assembly (9) and with the 6 bolts.
transmission assembly (IO) from each 5) Fit the O-ring and install drain tube (3)
other. with the 6 bolts.
Ir Pull out the torque converter hori- 6) Install bracket (2) with the 2 bolts and
zontally until the input shaft of the clamp.
transmission is disconnected. 5. Wiring harness
Install wiring harness (I).
r+lkg Converter assembly: * Secure the wiring harness with the wir-
Approx. 1,450 kg ing clamp.
r+ kg Transmission assembly:
Approx. 3,750 kg
* For the disassembly procedure of the
converter assembly, see CONVERTER
ASSEMBLY.
* For the disassembly procedure of the
transmission assembly, see TRANS-
MISSION ASSEMBLY.
cwwo4950
WA1 200-3 30-070- 1

0
53l!R-$m =I if f- SAss'y
DISASSEMBLY AND ASSEMBLY CONVERTER Ass’y
3 x\“- 9Ass’y(l/6)
CONVERTER Ass’y (l/6)
K-K Y (TO CWWO4883)
(TO CWWO4883) (TO CWWO4883)
i f=fl
_+,q
GG(i:i) E-E (I : I)
T/Clild-t
PDRT PF T/C EXlT
TlGHTENlWC TDROUE
913th944.1553.9Nm
(4. 5--5. 5 kern)
- .
‘1
\\I?4
‘1. t
N-N
'ti (TO CWWO4884) “;/
AC- AC
CWWO4881
WA1 200-3 30-071

0
H#*$m Zl iJ<-9Ass’y
=I id- 9Ass’y(3/6)
CONVERTER Ass’y (3/6)
(FROM cwwo48811
LT-2@b
A h
TlG”iENlNG TOROUE
h?lb9 58.6-73. 5Nm
(6-7. Skeml
A-A
(FROM CWWO4881) (FROM cwwo4881)
cwwo4883
WA1 200-3 30-073

0
53~*mk J j/t- SAss’y
1 id- gAss’y(4/6)
LT-PM
(2%31.5koml
3uat1'I WC- 1
(42C-13-172603
Ilctxt. SEE NOTE I
J-J
(FROM CWWO4881)
LT-Ptt
LT-2ltle
I
c-c
(FROM CWWO4881)
CWW04884
30-074 WA1 200-3

0
mB*sHz 1 id- SAss’y
=I id - 9Ass’y (5/6)
z- --_
(TO 214)
-I+!
,CWWO4866. CWWO466;)
CWW04885
WA1 200-3 30-075

0
53~*w45 3 iJ\“- SAss’y
ZI id- 9Ass’y(6/6)
CONVERTER Ass’y (6/6) _ When assembling oil seal (07012-50110), coat with LG-
5 on fitting face of the housing (42G13-15250) lightly
and after assembling, wipe off the rest completely.
Shim is 2 division type. Right and left shims shall

be same thickness and pieces.
When adjusting preload for input transfer taper

roller bearing, do as follows.
(11 Obtain as preload of 0 - 1.08 Nm (0 - 0.11 kgm}
from single shaft A, B, C, D, E.
[When setting orderly do as follows]
After setting shaft A and E, obtain the combined
preload 0 - 2.16 Nm IO - 0.22 kgm1 from shaft B.
Further when setting shaft C, obtain the combined
preload 0 - 3.24 Nm (0 - 0.33 kgm1 from shaft C. 42C-15-15150
Further when setting all of gears after setting D,

obtain the combined preload 0 - 5.40 Nm {O - 0.55
kgm} from shaft D.
(2) After preloads have been adjusted, check all
gears that there are no plays.
Gear Speed reduction ratio

A-B 68/74=0.919
A-C 68/74=0.919
tt!fi&t9L6
A-D 68/74=0.9 19 VIEW FROM OUTPUT SIDE cwwo4934
A-E 58/74=0.784
I
Following right and left assemble position about

PTO gear 42C-13-15140 and 42C-13-15150.
30-076 WA1 200-3

0
DISASSEMBLY AND ASSEMBLY CONVERTER ASSEMBLY
GENERAL DISASSEMBLY, ASSEMBLY OF CONVERTER ASSEMBLY
Disassembly procedure * Pull out the modulated clutch assembly

1. Breather and breather hose with forcing screws (12 mm).
I) Remove breather hose (I 1. * Pull out the modulated clutch assembly
2) Remove the 2 mounting bolts, then re- horizontally so that the inner race and
move breather (2) and the block as one outer race of the roller bearing will not
unit. be tilted when they are disconnected
3) Remove elbow (3). from each other.
2. Lubrication hoses and block
I) Remove lubrication hoses (4) and (5). lel kg Modulated clutch assembly: 220 kg
* Remove the hose clamps, too.
2) Remove the 4 mounting bolts, flange, f For the disassembly procedure of the
and remove lubrication hose (6). modulated clutch assembly, see DISAS-
* Remove the hose clamp, too. SEMBLY, ASSEMBLY OF MODULATED
3) Remove the 4 mounting bolts and block CLUTCH ASSEMBLY.
(7). 9. Torque converter assembly and PTO and
4) Remove lubrication hose (8). transfer assembly
3. Lubrication tubes and blocks 1) Remove the 19 mounting bolts, then re-
I) Remove the 3 joints and lubrication tube move torque converter assembly (28)
(9). from PTO and transfer assembly (29).
2) Remove the 2 joints each from lubrica-
tion tubes (IO), (II), (121, and (131, then I+ kg Torque converterassembly:
remove those tubes. 430 kg
3) Remove the 2 mounting bolts, block (141, &I kg PTO and transfer assembly:
and bracket (15). 800 kg
4) Remove the 3 mounting bolts and block * For the disassembly procedure of the
(16). torque converter assembly, see DIS-
4. Main relief valve and torque converter relief ASSEMBLY, ASSEMBLY OF TORQUE
valve assembly CONVERTER ASSEMBLY.
Remove the 7 mounting bolts and main re- * For the disassembly procedure of the
lief valve and torque converter relief valve torque converter assembly, see DIS-
assembly (17). ASSEMBLY, ASSEMBLY OF PTO
5. Torque converter regulator valve assembly AND TRANSFER ASSEMBLY.
I) Remove the 4 mounting bolts and block 2) Remove coupling (30) from torque con-
(18). verter assembly (28).
2) Remove sleeve (19).
3) Remove the 4 mounting bolts, cover (201,
and block (21).
4) Remove the 4 mounting bolts and torque
converter regulator valve assembly (22).
5) Remove valve block assembly (23).
6. Modulated clutch ECMV assembly
I) Remove the 3 mounting bolts and cover
(24).
2) Remove the 4 mounting bolts and modu-
lated clutch ECMV assembly (25).
7. Rotation sensor
Loosen the locknut and remove rotation sen-
sor (26).
8. Modulated clutch assembly
Remove the 10 mounting bolts and modu-
lated clutch assembly (27).
* Since the hexagon socket head bolt is
not used for mounting, do not remove
it.
WA1 200-3 30-076- 1

0
Assembly procedure 4. Modulated clutch ECMV assembly 9. Breather and breather hose
1. Torque converter assembly and PTO and I) Fit the O-ring and install modulated 1) Install elbow (3).
transfer assembly clutch ECMV assembly (25) with the 4 2) Install breather (2) with the 2 bolts.
I) Install coupling (30) to torque converter bolts. 3) Install breather hose (I).
assembly (28). * Secure the hose with the hose clamp.
2) Fit the O-ring to the connecting parts of &I ks Mounting bolt:
torque converter assembly (28) and PTO 27.4 - 34.3 Nm f2.8 - 3.5 kgm}
and transfer assembly (29). 2) Install cover (24) with the 3 bolts.
& O-ring: Grease (G2-LI) 5. Torque converter regulator valve assembly
3) Install torque converter assembly (28) to I) Fit the O-ring and install valve block as-
PTO and transfer assembly (29) with the sembly (23) with the 4 bolts.
19 bolts. w Mounting bolt:
* Since the outer race and inner race 44.1 - 53.9 Nm (4.5 - 5.5 kgm1
of the tapered roller bearing are 2) Fit the O-ring and install torque converter
coupled with each other, drop about regulator valve assembly (22) with the 4
6 cc of engine oil (E030-CD or EOIO- bolts.
CD) onto the sliding surfaces of the w Mounting bolt:
rollers. 44.1 - 53.9 Nm 14.5 - 5.5 kgml
3) Fit the O-ring and install block (21) and
63ks Torque converter assembly: cover (20) with the 4 bolts.
430 kg 4) Fit the O-ring and install sleeve (19).
!I+ks PTO and transfer assembly: & O-ring: Grease (G2-LI)
800 kg 5) Fit the O-ring and install block (18) with
2. Modulated clutch assembly 4 bolts.
Fit the O-ring and install modulated clutch 6. Main relief valve and torque converter relief
assembly (27) with the 10 bolts. valve assembly
6 O-ring: Grease (G2-LB Fit the gasket and install main relief valve
* Since the outer race and inner race of and torque converter relief valve assembly
the roller bearing are coupled with each (17) with the 9 bolts.
other, drop about 6 cc of engine oil m Mounting bolt:
(E030-CD or EOIO-CD) onto the sliding 58.8 - 73.5 Nm j6.0 - 7.5 kgm}
surfaces of the rollers and insert the 7. Lubrication tubes and blocks
modulated clutch assembly horizontally, 1) Fit the O-ring and install block (16) with
taking care not to tilt it. the 3 bolts.
2) Install bracket (15) and block (14) with
r+lkg Modulated clutch assembly: 220 kg the 2 bolts.
3) Fit the gasket and install lubrication tubes
3. Rotation sensor (131, (121, (II), and (IO) with the 2 joints
Install rotation sensor (26) and secure it with each.
the locknut. w Joint:
& Threaded part of sensor: 44.1 - 53.9 Nm 14.5 - 5.5 kgm1
Gasket sealant (LG-51 4) Fit the gasket and install lubrication tube
* Put the rotation sensor tip lightly against (9) with the 3 joints.
the gear tooth tip in the modulated clutch w Joint:
and return by l/2 - 1 turn and secure 44.1 - 53.9 Nm 14.5 - 5.5 kgm1
with the locknut. 8. Lubrication hoses and block
m Locknut: 49.0 - 68.6 Nm (5 - 7 kgm1 Install lubrication hose (8).
* Secure the hose with the hose clamp.
Install block (7) with the 4 bolts.
Fit the O-ring and install lubrication hose
(6) with the 4 bolts and the flange.
Install lubrication hoses (5) and (4).
* Secure the hoses with the hose
clamps.
30-076-Z WA1 200-3

0
DISASSEMBLY, ASSEMBLY OF MODULATED CLUTCH ASSEMBLY

1. Cage 1. Shaft
I) Remove the 4 mounting bolts and cage I) Press fit the inner race of roller bearing
(I). (33) to shaft (31).
* Pull out the cage with forcing screws * Using a press, fit the bearing until
(12 mm). the end of its inner race touches the
2) Remove snap ring (2), then remove bush- shoulder of the shaft.
ing (3) and ball (4) from cage (I). 2) Install seal ring (32) to shaft (31).
2. Case 6 Seal ring: Grease (G2-LI)
1) Remove snap ring (5). 3) Install seal rings (30) and (29) to shaft
2) Remove the 2 mounting bolts and case (31).
(6). & Seal ring: Grease (G2-LI)
3) Remove ball bearing (7) from case (6). * Install the seal rings as shown in the
* Use a press to remove the ball bear- following figure.
ing. I
3. Cover and input drum assembly
1) Remove cover and input drum assembly
(34).
2) Remove snap ring (81, plate (9), and ball
(IO).
3) Remove snap ring (II), cover (121, and
ball (13).
4) Remove input drum (17) from cover (14).
5) Remove snap ring (15) and ball bearing
(16).
cwwo4953
* Use a press to pull out the ball bear-
ing.
I
4. Discs and plates Output drum
1) Remove snap ring (18) and plate (19). Install drum (28) with the 12 bolts.
2) Remove damper (20). 6 Threaded parts:
3) Remove 19 discs (21) and 18 plates (22) Liquid adhesive (LT-2)
alternately. m Mounting bolt:
4) Remove damper (23). 98 - 123 Nm IlO. - 12.5 kgm1
5. Piston Piston
1) Using tool C4, remove nut (24). I) Install piston (27).
2) Remove plate (25). 2) Install seal ring (26) to plate (25).
3) Remove seal ring (26) from plate (25). 6 Seal ring: Grease (G2-LI)
4) Remove piston (27). j, Install the seal ring as shown in the
Ir Push out the piston from the shaft following figure.
side with forcing screws (12 mm).
6. Output drum
Remove the 12 mounting bolts and drum
(28).
Ir Push out the drum from the shaft side
with forcing screws (12 mm).
7. Shaft
1) Remove seal rings (29) and (30) from
shaft (31).
2) Remove 2 seal rings (32) from shaft (31).
3) Remove the inner race of roller bearing
(33) from shaft (31).
* Use a bearing puller to pull out the
bearing.
WA1 200-3 30-076-3

0
3) Install plate (25). 2) Install input drum (17) to cover (14).

4) Using tool C4, install nut (24). 3) Install ball (13) and cover (12) and se-
& Threaded parts of nut: cure them with snap ring (II).
Liquid adhesive (LT-2) * Put the ball in the ball hole of the
* Install the nut with the chamfered drum, then install the cover, match-
periphery to plate (25). ing its ball groove to the ball.
w Nut: 4) Install ball (IO) and plate (9) and secure
. .313.8 - 392.3 Nm I32 - 40 kgm}

them with snap ring (8).
4. Discs and plates * Put the ball in the ball hole of the
I) Install damper (23). cover, then install the plate, match-
* install the damper with the cork side ing its ball groove to the ball.
to the piston. 5) Install cover and input drum assembly
2) Install 19 discs (21) and 18 plates (22) (34).
alternately. 6. Case
f Soak the discs in clean engine oil I) Install ball bearing (7) to case (6).
(E030-CD or EOIO-CD) for at least 2 Using a press, fit the bearing until
minutes before installing them. the end of its outer race touches the
3) Install damper (20). shoulder of the cover.
* Install the damper with the cork side After press fitting the bearing, drop
to plate (19). about 6 cc of engine oil (E030-CD or
4) Install plate (19) and secure it with snap EOIO-CD) onto the sliding parts and
ring (18). rotate the bearing 10 turns to spread
5. Cover and input drum assembly the oil.
1) Using tool C2, install ball bearing (16) to 2) Fit the O-ring to the cover and install
cover (14) and secure it with snap ring case (6) to shaft (31) and secure them
(15). with the 2 bolts.
* Press fit the bearing until the end of & O-ring: Grease (G2-LI)
its outer race touches the shoulder * Push the inner race of ball bearing
of the cover. (7) with a press until its end touches
* After press fitting the bearing, drop the shoulder of the shaft.
about 6 cc of engine oil (EOSO-CD or * Check that the ball bearing is fitted
EOIO-CD) onto the sliding parts and perfectly, then tighten the 2 bolts.
rotate the bearing 10 turns to spread 3) Install snap ring (5).
the oil. 7. Cage
I) Install ball (4) and bushing (3) to cage
(I) and secure them with snap ring (2).
* Put the ball in the ball hole of the
bushing, then install the cage, match-
ing its ball groove to the ball.
2) Fit the O-ring and install cage (I) with
the 4 bolts.
6 O-ring: Grease (G2-LI)
cwwo4955
30-076-4 WA1 200-3

0
DISASSEMBLY, ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
Disassembly procedure 7. Shaft

1. Preparation work I) Remove the 4 mounting bolts and plate
Set the torque converter assembly vertically (21) from shaft (22).
with the input shaft side up. 2) Remove seal ring (23) from shaft (22).
* Adjust the height of the torque converter 3) Remove the inner race of roller bearing
assembly so that the mounting bolts can (19) from shaft (22).
be removed from the underside of the * Use a bearing puller to pull out the
case. inner race.
2. Case 4) Remove sleeve (24) from shaft (22).
Remove the 13 mounting bolts, then remove
the torque converter from case (I).
* Install a hanging bolt (12 mm) to the
input shaft end and lift off the torque
converter vertically with the all internal
parts of the case assembled.
* Place the removed torque converter with
the input shaft side up on a work table.
3. input shaft
1) Remove the 20 mounting bolts and shaft
(2).
2) Remove the inner race of tapered roller
bearing (3) from shaft (2).
* Use a bearing puller to pull out the
inner race.
4. Case and turbine assembly
I) Remove 36 mounting bolts and case and
turbine assembly (4).
2) Remove snap ring (5) and wire (6).
3) Remove snap ring (7) and cover (8).
4) Remove turbine (9).
* Pull out the turbine with forcing
screws (IO mm).
5) Remove ball bearing (IO) from case (II).
* When removing the ball bearing with
a press, do not push its snap ring
side.
5. Stator
1) Remove snap ring (12) and stator (13).
2) Remove spacer (14).
6. Pump assembly
Remove pump assembly (15).
Ir Remove the pump assembly verti-
cally so that the inner race and outer
race of the roller bearing will not be
tilted when they are disconnected
from each other.
Remove 16 mounting bolts, retainer (161,
and guide (17) from pump (18).
Remove the outer race of roller bearing
(19) from guide (17).
* Use a press to remove the outer race.
Remove drain plug (20) from pump (18).
CWWO4956
WA1 200-3 30-076-5

0
Assembly procedure 3. Stator

1. Shaft 1) Install spacer (14).
Install sleeve (24) to shaft (22). 2) Install stator (13) and secure it with snap
* Install the sleeve by expansion fit. ring (12).
Press fit the inner race of roller bearing 4. Case and turbine assembly
(19) to shaft (22). 1) Install ball bearing (IO) to case (11).
f Push the inner race with a press un- * Push the ball bearing with a press un-
til its end touches the shoulder of til its snap ring touches the shoulder
the shaft. of the case.
Install plate (21) to shaft (22) with the 4 * After press fitting the bearing, drop
bolts. about 6 cc of engine oil (E030-CD or
Install seal ring (23) to shaft (22). EOIO-CD) onto the sliding parts and
& Seal ring: Grease (GZ-LI) rotate the bearing 10 turns to spread
2. Pump assembly the oil.
1) Install drain plug (20) to pump (18). Install turbine (9).
w Drain plug: * Support the inner race of the ball bear-
9.8 - 12.7 Nm Il.0 - 1.3 kgm} ing and push the turbine with a press
2) Press fit the outer race of roller bearing until the shoulder of the turbine
(19) to guide (17). touches the end of the inner race.
Ir Apply bearing compound to 4 places Install cover (8) and secure it with snap
of the periphery of the bearing. After ring (7).
installing the outer race, wipe off the Install wire (6) and secure it with snap
projected compound so that it will ring (5).
not enter the bearing. Install case and turbine assembly (4) with
the 36 bolts.
* Match the internal oil groove on case
to the drain plug of the pump.
& Threaded parts of mounting bolt:
Liquid adhesive (LT-2)
m Mounting bolt:
49 - 59 Nm 15 - 6 kgm1
5. Input shaft
1) Install the inner race of tapered roller bear-
ing (3) to shaft (2).
C_ i lO--20mm * Push the inner race with a press until
cwwo4957 its end touches the shoulder of the
shaft.
* Push the outer race with a press un- 2) Install shaft (2) with the 20 bolts.
til its end touches the shoulder of & Threaded parts of mounting bolt:
the guide. Liquid adhesive (LT-2)
3) Install guide (17) and retainer (16) to m Mounting bolt:
pump (18) with 16 bolts. 245 - 309 Nm (25.0 - 31.5 kgml
6 Threaded parts of mounting bolt: 6. Case
Liquid adhesive (LT-21 Install the torque converter to case (I) with
m Mounting bolt: the 13 bolts.
59 - 74 Nm IS.0 - 7.5 kgml * Install a hanging bolt (12 mm) to the in-
4) Install pump assembly (15) to shat (22). put shaft end, then sling and install the
Ir Since the outer race and inner race torque converter vertically.
of the roller bearing are coupled with & Threaded parts of mounting bolt:
each other, lower the pump assem- Liquid adhesive (LT-2)
bly vertically, taking care not to tilt w Mounting bolt:
it. 245 - 309 Nm (25.0 - 31.5 kgml
30-076-6 WA1 200-3
0
CONVERTER ASSEMBLY
DISASSEMBLY, ASSEMBLY OF PTO AND TRANSFER ASSEMBLY
20
\ /
CWWO4982
WA1 200-3
30-076-7
0
Disassembly procedure Modulated clutch gear (Gear E) Assembly procedure Install cage (31) with the 17 bolts.
Rotation sensor 1) Remove the 8 mounting bolts, cage (211, 1. Case A Threaded parts of mounting bolt:
Loosen the locknut and remove rotation sen- and shims (22). Install the outer races of tapered roller bear- Liquid adhesive (LT-2)
sor (1). * Check the thickness and quantity of ings (201, (151, and (IO) to case (39). w Mounting bolt:
Cover the shims. f Push each outer race with a press until 245 - 309 Nm (25.0 - 31.5 kgm1
Remove the 12 mounting bolts and cover 2) Remove the outer races of tapered roller its end touches the shoulder of the case. Using a push-pull scale, check that the
(2). bearings (23) and (24) from cage (21). 2. Input gear (Gear A) rotational force at the gear tooth tip is
PTO gear 1 (Gear D) * Use a bearing puller and a press to I) Install the outer race of tapered roller within the standard range.
1) Remove the 6 mounting bolts, cage (31, pull out the outer races. bearing (36) to cage (37). j, Rotational force of gear:
and shims (4). 3) Remove gear (25). * Push the outer race with a press un- 0 - 1.08 N (0 - 0.11 kg}
Ir Check the thickness and quantity of 4) Remove snap ring (26), then remove the til its end touches the shoulder of Ir If the rotational force is out of the
the shims. outer race of roller bearing (27) from gear the cage. standard range, adjust it by chang-
2) Remove the outer race of tapered roller (25). 2) Fit the O-ring and install shims (38) and ing the shim thickness.
bearing (5) from cage (3). * Use a bearing puller to pull out the cage (37) with the 8 bolts. * Adjustment range of shim thickness:
* Use a bearing puller to pull out the outer race. + The shims are of 2-piece split type. 1.3 - 2.7 mm
outer race. 5) Remove the inner races of tapered roller Set them to the standard thickness * Types of shims:
3) Remove coupling (6). bearings (23) and (28) from gear (25). temporarily on each side. 0.15 mm, 0.2 mm, 0.5 mm
4) Remove snap ring (7) from coupling (6). * Use a bearing puller to pull out the * Standard thickness of shims: 2.0 mm IO) Fit the O-ring and install coupling (30).
5) Remove gear (8). inner races. 3) Install the inner races of tapered roller 11) Install holder (29) with the mounting
6) Remove snap ring (9) from gear (8). Input gear (Gear Al bearings (36) and (33) to gear (35). bolts.
7) Remove the inner races of tapered roller I) Remove the mounting bolts and holder * Push each inner race with a press a Threaded parts of mounting bolt:
bearings (5) and (IO) from gear (8). (29). until its end touches the shoulder of Liquid adhesive (LT-2)
* Use a bearing puller to pull out the 2) Remove coupling (30). the gear. m Mounting bolt:
inner races. 3) Remove the 17 mounting bolts and cage 4) Install gear (35). 824 - 1,030 Nm I84 - 105 kgm1
PTO gear 2 (Gear C) (31). 5) Install spacer (34). 3. Modulated clutch gear (Gear El
I) Remove the 8 mounting bolts, cage (1 I), 4) Remove oil seal (32) from cage (31). 6) Install the outer race of tapered roller 1) Install the inner races of tapered roller
and shims (12). 5) Remove the outer race of tapered roller bearing (33) to cage (31). bearings (28) and (23) to gear (25).
+ Check the thickness and quantity of bearing (33) from cage (31). * Push the outer race with a press un- * Push each inner race with a press
the shims. * Use a bearing puller to pull out the til its end touches the shoulder of until its end touches the shoulder of
2) Remove the outer race of tapered roller outer race. the cage. the gear.
bearing (13) from cage (1 I). 6) Remove spacer (34). 7) Using tool Cl, press fit oil seal (32) to 2) Install the outer race of roller bearing
+ Use a bearing puller to pull out the 7) Lift off gear (35). cage (31). (27) to gear (25) and secure it with snap
outer race. 8) Remove the inner races of tapered roller * Thinly apply gasket sealant (LG-5) to ring (261.
3) Remove gear (14) bearings (33) and (36) from gear (35). the oil seal fitting part of the cage. Ir Push the outer race with a press un-
4) Remove the inner races of tapered roller * Use a bearing puller to pull out the After fitting the oil seal, wipe off the til its end touches the shoulder of
bearings (13) and (15) from gear (14). inner races. projected sealant. the gear.
* Use a bearing puller to pull out the 9) Remove the 8 mounting bolts, cage (37), f Press fit the oil seal until the flange 3) Install gear (25).
inner races. and shims (38). of tool Cl touches the cage. * Drop about 6 cc of engine oil tE030-
5. PTO gear 3 (Gear BI * Check the thickness and quantity of & Oil seal lip: Grease (G2-LI) CD or EOIO-CD) onto the sliding parts
I) Remove the 8 mounting bolts, cage (161, the shims. of the bearing and rotate the bearing
and shims (17). IO) Remove the outer race of tapered roller 10 turns to spread the oil.
Ir Check the thickness and quantity of bearing (36) from cage (37). 4) Install the outer races of tapered roller
the shims. * Use a bearing puller to pull out the bearings (24) and (23) to cage (21).
2) Remove the outer race of tapered roller outer race. j, Push each outer race with a press
bearing (18) from cage (16). Case until its end touches the shoulder of
Ir Use a bearing puller to pull out the Remove the outer races of tapered roller the cage.
outer race. bearings (IO), (15), and (20) from case (39). 5) Install shims (22) and cage (21) with the
3) Remove gear (19) * Use a bearing puller to pull out the outer 8 bolts.
4) Remove the inner races of tapered roller races. * Drop about 6 cc of engine oil (E030-
bearings (18) and (20) from gear (19). CD or EOIO-CD) onto the sliding parts
f Use a bearing puller to pull out the CWWO4958 of the bearing and rotate the bearing
inner races. 10 turns to spread the oil.
30-076-8 WA1 200-3

0
* The shims are of 2-piece split type. 4) Fit the O-ring and install shims (17) and 6. PTO gear 1 (Gear D)
Set them to the standard thickness cage (16) with the 8 bolts. I) Install the inner races of tapered roller
temporarily on each side. * The shims are of 2-piece split type. bearings (IO) and (5) to gear (8).
* Standard thickness of shims: Set them to the standard thickness * Push each inner race with a press
2.0 mm temporarily on each side. until its end touches the shoulder of
6) Using a push-pull scale, check that the * Standard thickness of shims: 2.0 mm the gear.
rotational force at the gear tooth tip is 5) Using tool C3 (2/2), check that the rota- 2) Install snap ring (9) to gear (8).
within the standard range. tional force at the center of the gear is 3) Install gear (8).
* Rotational force of gear: within the standard range. 4) Install snap ring (7) to coupling (6).
0 - 1.08 N (0 - 0.11 kg} * Rotational force of gear: 5) Install coupling (6).
* If the rotational force is out of the 0 - 2.16 Nm IO - 0.22 kgm} 6) Press fit the outer race of tapered roller
standard range, adjust it by chang- * If the rotational force is out of the bearing (5) to cage (3).
ing the shim thickness. standard range, adjust it by chang- + Push the outer race with a press un-
* Adjustment range of shim thickness: ing the shim thickness. 3) Install the outer race of tapered roller til its end touches the shoulder of
1.3 - 2.7 mm * Adjustment range of shim thickness: bearing (13) to cage (II). the cage.
* Types of shims: 1.3 - 2.7 mm * Push the outer race with a press un- 7) Fit the O-ring and install shims (4) and
0.15 mm, 0.2 mm, 0.5 mm * Types of shims: til its end touches the shoulder of cage (3) with the 6 bolts.
4. PTO gear 3 (Gear BI 0.15 mm, 0.2 mm, 0.5 mm the cage. & O-ring: Grease (G2-LII
I) Install the inner races of tapered roller 4) Fit the O-ring and install shims (12) and Ir The shims are of 2-piece split type.
bearings (20) and (19) to gear (19). cage (I I) with the 8 bolts. Set them to the standard thickness
* Push each inner race with a press * The shims are of 2-piece split type. temporarily on each side.
until its end touches the shoulder of Set them to the standard thickness * Standard thickness of shims: 2.0 mm
c312 /2)
the gear. temporarily on each side. 8) Using tool C3 (l/2), check that the rota-
2) Install gear (19). \ Ir Standard thickness of shims: 2.0 mm tional force at the center of the gear is
* PTO gear 2 and PTO gear 3 are dif- 5) Using tool C3 (2/2), check that the rota- within the standard range.
ferent parts and they must be in- tional force at the center of the gear is * Rotational force of gear:
stalled in the correct directions re- within the standard range. 0 - 5.40 Nm 10 - 0.55 kgm)
spectively. There are 2 identification Rotational force of gear: * If the rotational force is out of the
grooves on the end of gear (19). In- 0 - 3.24 Nm (0 - 0.33 kgm) standard range, adjust it by chang-
stall gear (19) with those identifica- CWWO4960 If the rotational force is out of the ing the shim thickness.
tion grooves on the cage side (torque standard range, adjust it by chang- * Adjustment range of shim thickness:
converter side). (The following fig- 5. PTO gear 2 (Gear Cl ing the shim thickness. 1.3 - 2.7 mm
ure is the gear seen from the torque 1) Install the inner races of tapered roller Adjustment range of shim thickness: * Types of shims:
converter side.) bearings (15) and (13) to gear (14). 1.3 - 2.7 mm 0.15 mm, 0.2 mm, 0.5 mm
f Push each inner race with a press Types of shims:
Ii 14
until its end touches the shoulder of 0.15 mm, 0.2 mm, 0.5 mm
the gear.
2) Install gear (14).
* PTO gear 2 and PTO gear 3 are dif-
ferent parts and they must be in-
stalled in the correct directions re-
spectively. There is 1 identification
groove on the end of gear (14). In-
stall gear (14) with those identifica-
tion grooves on the cage side (torque
converter side). (The following fig- CWWO4961
ure is the gear seen from the torque

3) Install the outer race of tapered roller converter side.) :WWO4960
bearing (18) to cage (16).
* Push the outer race with a press un-
til its end touches the shoulder of
the cage.
WA1 200-3 30-076-9

0
7. Cover
Fit the gasket and install cover (2) with the
12 bolts.
8. Rotation sensor
Install rotation sensor (I) and secure it with
the locknut.
& Threaded parts of sensor:
Gasket sealant (LG-5)
* Put the rotation sensor tip lightly against
the side of the input gear in the PTO and
transfer assembly and return by l/2 - 3/
4 turns and secure with the locknut.
m Locknut: 49.0 - 68.6 Nm (5 - 7 kgml
30-076-10 WA1 200-3

0
%%*sm bY>/x< y>z~>Ass’y
DISASSEMBLY AND ASSEMBLY TFIANSMISSION Ass’y
F jiX 5 Y 2 3 >Ass’y(l/3)
TRANSMISSION Ass’y (l/33)
GP-Llrt GZ-LIB8
+,-*[ %$gg\
\__-----_____--M )--- -
I!1 I -7-i E-r-
CWWO4686
WA1 200-3 30-077

0
53l!B*%l~ b5iX:*~-iaiAss’y
DISASSEMBLY AND ASSEMBLY TRANSMISSION Ass’v
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III /I I A / \ 1.
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4AEiW 98--123Nm @ JURPAEEOF IIAMFEP CASE
~10~12.5toml 123
LT-244
COAT.I," LT-* A-A IFROM ~~~048851 CWWO4887
30-078 WA1 200-3

0
m#*smk b5>iX*~_jsiAss’y
DISASSEMBLY AND ASSEMBLY TRANSMISSION Ass’y
b 3 i it : Y -i EI i Ass’y (3/3)
TRANSMISSION
8#6ff 2861Ni293.
Bkal R#Rlf 1562N(l59.3kal
l”ITlLLED LOAD lHSTlLLE0 LOlO
WA1 200-3 30-079

0
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
GENERAL DISASSEMBLY, ASSEMBLY OF TRANSMISSION ASSEMBLY
Disassembly procedure * The mounting bolts are classified into 3

1. Preparation work lengths. Make match marks on them to
Raise the transfer section vertically and sup- indicate their respective locations.
port it with wood blocks, etc. so that the 7. Valve seats
transmission will be horizontal. I) Remove the 4 mounting bolts and valve
2. Lubrication tubes seat (20).
1) Remove the 2 joints each from lubrica- * The mounting bolts are classified into
tion tubes (I), (21, (31, (4) and (51, then 2 lengths. Make match marks on
remove those tubes. them to indicate their respective lo-
* Remove the tube clamps, too. cations.
2) Remove the 2 mounting bolts and block 2) Remove valve seat (21).
(6). 3) Remove 14 mounting bolts and valve
3) Remove the 2 mounting bolts and block seat (22).
(7). 8. Breathers
3. Oil filter assembly I) Remove 2 breathers (23) and 2 elbows
1) Remove the 1 mounting bolt and 3 sets (24).
of 1 nut and 1 stud bolt, then remove 2) Remove the 4 mounting bolts and flange
cover (8) and 4 spacers (9). (25).
2) Remove 3 mounting bolts, oil filter as- 9. Transmission assembly and transfer and park-
sembly (IO), and cover (I 1). ing brake assembly
4. Forward-reverse control valve assembly I) Sling transmission assembly (26) tem-
I) Remove the 4 mounting bolts, reverse porarily.
clutch ECMV assembly (121, and bypass 2) Remove the 23 mounting bolts and dis-
fill and drain valve assembly (13). connect the transmission assembly (26)
* The mounting bolts are classified into and transfer and parking brake assem-
2 lengths. Make match marks on bly (27) from each other.
I
them to indicate their respective lo- A When removing the transmission,
.:_
cations. take care extremely so that the trans-
2) Remove the 4 mounting bolts, forward fer and parking brake assembly will
clutch ECMV assembly (141, and bypass not fall down.
fill valve assembly (15). Shift the transmission toward the in-
* The mounting bolts are classified into put shaft until its output shaft comes
2 lengths. Make match marks on out of the transfer.
them to indicate their respective lo- Place the removed transmission as-
cations. sembly on blocks with the input shaft
5. Gear speed control valve assembly side up.
I) Remove the 4 mounting bolts, 1st clutch For the disassembly procedure of the
ECMV assembly (16), and bypass fill transmission assembly, see DISAS-
valve assembly (17). SEMBLY, ASSEMBLY OF TRANSMIS-
* The mounting bolts are classified into SION ASSEMBLY.
2 lengths. Make match marks on For the disassembly procedure of the
them to indicate their respective lo- transfer and parking brake assembly,
cations. see DISASSEMBLY, ASSEMBLY OF
2) Remove the 4 mounting bolts and 2 sets TRANSFER AND PARKING BRAKE
of the 2nd clutch ECMV assembly and ASSEMBLY.
3rd clutch ECMV assembly (18). 10. Strainer
Ir The mounting bolts are classified into I) Remove the 2 mounting bolts and drain
2 lengths. Make match marks on plug (28).
them to indicate their respective lo- 2) Remove the 4 mounting bolts and 4 cov-
cations. ers (29).
6. Lubrication relief valve assembly 3) Remove the 4 springs (30) and 4 mag-
Remove the 3 mounting bolts and lubrica- nets (31).
tion relief valve assembly (19). 4) Remove 4 cases (32).
I
I CWWO4962
WA1 ZOO-3
Assembly procedure assembly (19) with the 3 bolts. * The mounting bolts are classified into
1. Preparation work * The mounting bolts are classified into 3 2 lengths. When installing them,
Support the transfer with blocks, etc. so that lengths. When installing them, check check their respective locations by
it will be vertical. their respective locations by the match the match marks made when they
2. Strainer marks made when they were removed. were removed.
1) Fit the O-ring and install 4 cases (32). w Mounting bolt: w Mounting bolt:
& Periphery of O-ring: 58.8 - 73.5 Nm 16.0 - 7.5 kgml 27.4 - 34.3 Nm 12.8 - 3.5 kgm}
Grease (G2-LI) 7. Gear speed control valve assembly 9. Oil filter
2) Install 4 magnets (31) and 4 springs (30). f The ECMV assembly for gear speed con- 1) Fit the O-ring and install cover (11) and
3) Fit the O-ring and secure 4 covers (29) trol and that for forward-reverse control oil filter assembly (IO) with the 3 bolts.
with 4 bolts each. are different from each other. The cover m Mounting bolt:
4) Fit the O-ring and install drain plug (28) of the ECMV assembly for gear speed 58.8 - 73.5 Nm IS.0 - 7.5 kgml
with the 2 bolts. control is secured with hexagon bolts. 2) Install the 3 stud bolts, then install the 4
& O-ring: Grease (G2-LI) 1) Fit the O-rings and install the 2 sets of spacers (9) and cover (8) with the 1 bolt
3. Transmission assembly and transfer and park- the 3rd clutch ECMV assembly and 2nd and 3 nuts.
ing brake assembly clutch ECMV (18) with the 4 bolts each. 10. Lubrication tube
1) Fit the O-ring to the connecting parts of * The mounting bolts are classified into I) Install block (7) with the 2 bolts.
transmission assembly (26) and transfer 2 lengths. When installing them, 2) Install block (6) with the 2 bolts.
and parking brake assembly (27). check their respective locations by 3) Fit the gasket and install lubrication tubes
6 O-ring: Grease (G2-LI) the match marks made when they (51, (41, (31, (21, and (I) with 2 joints each.
2) Sling transmission assembly (26) and in- were removed. w Joint:
stall it to transfer assembly (27) with the w Mounting bolt: 44.1 - 53.9 Nm I4.5 - 5.5 kgm}
23 bolts. 27.4 - 34.3 Nm 12.8 - 3.5 kgm)
A When installing the transmission, 2) Fit the O-ring and install bypass fill valve
take care extremely so that the trans- assembly (17) and 1st clutch ECMV as-
fer and parking brake assembly will sembly (16) with the 4 bolts.
not fall down. * The mounting bolts are classified into
* After installing the transmission, sup- 2 lengths. When installing them,
port it with blocks, etc. check their respective locations by
4. Breathers the match marks made when they
1) Install flange (25) with the 4 bolts. were removed.
& Mating faces of flange and case: w Mounting bolt:
Gasket sealant (LG-51 27.4 - 34.3 Nm (2.8 - 3.5 kgm}
2) Install 2 elbows (24) and 2 breathers (23). 8. Forward-reverse control valve assembly
& Elbow and breather: The ECMV assembly for forward-reverse
Gasket sealant (LG-5) control and that for gear speed control
5. Valve seat are different from each other. The cover
1) Fit the O-ring and install valve seat (22) of the ECMV assembly for forward-re-
with 14 bolts. verse control is secured with hexagon
w Hexagon socket head bolts (6 socket head bolts.
pieces): Fit the O-rings and install the bypass fill
58.8 - 73.5 Nm IS.0 - 7.5 kgm} valve assembly (15) and forward clutch
2) Fit the O-ring and install valve seat (21). ECMV assembly (14) with the 4 bolts.
3) Fit the O-ring and install valve seat (20) + The mounting bolts are classified into
with the 4 bolts. 2 lengths. When installing them,
* The mounting bolts are classified into check their respective locations by
2 lengths. When installing them, the match marks made when they
check their respective locations by were removed.
the match marks made when they m Mounting bolt:
were removed. 27.4 - 34.3 Nm {2.8 - 3.5 kgm}
w Mounting bolt: Fit the O-ring and install bypass fill and
58.8 - 73.5 Nm IS.0 - 7.5 kgm} drain valve assembly (13) and reverse
6. Lubrication relief valve assembly clutch ECMV assembly (12) with the 4
Fit the O-ring and install lubrication valve bolts.
WA1 200-3 30-079-Z

0
DISASSEMBLY, ASSEMBLY OF TRANSMISSION ASSEMBLY
Il/2 27
40
Lk
\ -55 ”
54
30-079-3 WA1 200-3

0
TRANSMISSION ASSEMBLY
WA1 200-3 30-079-4

0
Disassembly procedure 5. Reverse clutch plates and discs 13. Forward clutch and 3rd clutch carrier assem- 2) Remove piston (83) from housing (82).
1. Preparation work 1) Remove 6 springs (27). bly 3) Remove seal ring (84) from housing (82).
Set the transmission assembly on blocks, * The length of the springs depends 1) Remove the 4 mounting bolts and collar 4) Remove seal ring (85) from piston (83).
etc. with the input shaft side up. on the clutch. Put tags, etc. to the (54). lg. 2nd clutch sun gear
2. Case springs to indicate their respective 2) Remove 2 seal rings (55) from collar (54). Remove gear (86).
1) Remove 7 sleeves (1). locations. 3) Lift off forward clutch and 3rd clutch car- 20. 2nd clutch carrier and 1st clutch assembly
* Apply a bearing puller, etc. to the 2) Remove 8 plates (28), 7 discs (29), and rier assembly (56). 1) Remove 2nd clutch carrier and 1st clutch
groove on the inside wall of the 48 springs (30) alternately. 4) Remove snap ring (57), ball bearing (58), assembly (87).
sleeve to pull out the sleeve. 6. Reverse clutch ring gear and gear (59). * Utilizing the bolt holes of the carrier,
2) Remove the 3 mounting bolts and case Remove ring gear (31). * Use a press to pull out above parts. pull out the assembly with a puller.
(2). 7. Reverse clutch housing and piston 5) Remove collar (60) from ball bearing (61). 2) Remove the 30 mounting bolts and cage
3. Housing 1) Remove housing (32). * Use a press to pull out the bearing. (88).
Remove the 24 long bolts, 6 short bolts, and * Remove the housing and piston as 1 6) Remove shaft (62) and ball (63) from car- 3) Remove snap ring (89) and spacer (90)
housing (3). unit. rier (64). from cage (88).
4. Input shaft, reverse clutch carrier and reverse 2) Remove piston (33) from housing (32). * Remove the 4 sets. * Remove the snap ring, compressing
sun gear assembly 3) Remove seal ring (34) from housing (32). 7) Remove 2 gears (65) each, 4 needle roller the spring with a press.
1) Sling the input shaft end and remove 4) Remove seal ring (35) from piston (33). bearings (66) each, and 4 thrust washers 4) Remove 3 springs (91) from cage (88).
the input shaft, reverse clutch carrier and 8. Connecting ring gear (67) each. 5) Remove piston (92) from cage (88).
reverse sun gear assembly (4). 1) Remove the 8 mounting bolts and plate * Remove the 4 sets. 6) Remove seal ring (93) from piston (92).
* Sling the input shaft vertically so that (36). 8) Remove the outer race of roller bearing 7) Remove snap ring (94) and ball bearing
the inner race and outer race of the 2) Remove ring gear (37). (26) from carrier (64). (95) from cage (88).
taper roller bearing under the carrier 3) Remove snap ring (38) from ring gear * Use a bearing puller to pull out the * Use a bearing puller to pull out the
will not be tilted when they are dis- (37). outer race. ball bearing.
connected from each other. 9. Forward clutch plates and discs 14. 3rd clutch ring gear 8) Remove snap ring (96) and collar (97)
2) Remove snap ring (5) and spacer (6). 1) Remove 6 pins (39) and 12 pins (40). 1) Remove the 8 mounting bolts and plate from cage (88).
3) Remove cage (7). Ir The length of the pins depends on (68). 9) Remove ball bearing (98) from cage (88).
Ir Use a puller to remove the cage. the clutch. Put tags, etc. to the pins 2) Remove ring gear (69). * Use a bearing puller to pull out the
4) Remove ball bearings (8) and (9) from to indicate their respective locations. 3) Remove snap ring (70) from ring gear ball bearing.
cage (7). 2) Remove 6 springs (41). (69). 10) Remove seal rings (99) and (100) from
Jr Use bearing puller to pull out the * The length of the springs depends 15. 3rd clutch housing and piston cage (88).
bearings. on the clutch. Put tags, etc. to the 1) Remove housing (71). 11) Remove hub (101).
5) Remove the 8 mounting bolts and cage springs to indicate their respective * Remove the housing and piston as 1 12) Remove 2 seal rings (102) from hub (101).
(IO). locations. unit. 13) Remove 9 discs (103), 8 plates (104), and
* Pull out the cage with forcing screws. 3) Remove 9 plates (42), 8 discs (43), and 2) Remove piston (72) from housing (71). 9 springs (105) alternately.
6) Remove 2 seal rings (11) from cage (IO). 72 springs (44). 3) Remove seal ring (73) from housing (71). 14) Remove snap ring (106) from carrier
_
7) Remove snap ring (12) and gar (13). 10. Forward clutch ring gear 4) Remove seal ring (74) from piston (72). (107).
8) Remove snap ring (14). Remove ring gear (45). 16. 2nd clutch plates and discs 15) Remove shaft (108) and ball (109) from
9) Remove shaft (15). 11. Forward clutch housing and piston 1) Remove 6 springs (75). carrier (107).
+ Use a press to pull out the shaft. 1) Remove housing (46). * The length of the springs depends * Remove the 4 sets.
10) Remove seal ring (16) from shaft (15). * Remove the housing and piston as 1 on the clutch. Put tags, etc. to the 16) Remove gear (IIO), 2 needle bearings
11) Remove snap ring (17) and gear (18). unit. springs to indicate their respective (111) each, and 2 thrust washers (I 12)
12) Remove ball bearing (19) from shaft (15). 2) Remove piston (47) from housing (46). locations. each.
* Use a press to pull out the ball bear- 3) Remove seal ring (48) from housing (46). 2) Remove 6 pins (76) and 12 pins (77). * Remove the 4 sets.
ing. 4) Remove seal ring (49) from piston (47). Ir The length of the pins depends on 21. Output shaft assembly and housing
13) Remove shaft (20) and ball (21) from car- 12. 3rd clutch plates and discs the clutch. Put tags, etc. to the pins 1) Remove 6 mounting bolts and output
rier (22). 1) Remove 6 springs (50). to indicate their respective locations. shaft assembly (113) from housing (114).
* Remove the 4 sets. f The length of the springs depends 3) Remove 4 plates (78), 3 discs (79), and * Pull out the output shaft with forcing
14) Remove gear (23), 2 needle bearings (24) on the clutch. Put tags, etc. to the 24 springs (80). screws.
each, and 2 thrust washers (25) each. springs to indicate their respective 17. 2nd clutch ring gear 2) Remove snap ring (115) and cage (116)
* Remove the 4 sets. locations. Remove ring gear (81). from shaft (I 17).
15) Remove the inner race of roller bearing 2) Remove 5 plates (51), 4 discs (52), and 18. 2nd clutch housing * Use a press to pull out the cage.
(26). 30 springs (53) alternately. I) Remove housing (82). 3) Remove seal ring (I 18) from cage (I 16).
* Use a bearing puller to remove the * Remove the housing and piston as 1 4) Remove snap ring (119) and ball bearing
inner race. unit. (120) from shaft (I 17).
30-079-5 WA1 200-3

0
* Use a press to pull out the ball bear- 7) Install seal rings (100) and (99) to cage 15) Install cage (88) to carrier (107) with the 2) Install 12 pins (77) and 6 pins (76).
ing. 038). 30 bolts. * The length of the pins depends on
5) Remove seal ring (121) from shaft (117). & Seal ring: Grease (G2-LI) & Threaded parts of mounting bolt: the clutch. Before installing each pin,
* Install seal ring (100) as shown be- Liquid adhesive (LT-2) check its length.
low. w Mounting bolt: * Pin length:
98 - 123 Nm (IO.0 - 12.5 kgml (77); 208 mm, (76); 223 mm
16) Install 2nd clutch carrier and 1st clutch 3) Install 6 springs (75).
assembly (87) to the output shaft. * The length of the springs depends
Ir Push the assembly with a press until on the clutch. Before installing each
the end of the inner race of the ball spring, check its length.
bearing touches the shoulder of the * Free length of spring: 56.9 mm
shaft. 7. 3rd clutch housing and piston
3. 2nd clutch sun gear 1) Install seal ring (74) to piston (72).
Assembly procedure Install gear (86). & Seal ring: Grease (G2-LI)
1. Output shaft assembly and housing 4. 2nd clutch housing * The seal ring must be installed in
1) Install seal ring (121) to shaft (117). I) Install seal ring (85) to piston (83). the correct direction. When install-
6 Seal ring: Grease (G2-LI) & Seal ring: Grease (G2-LI) ing it, check its direction (Install it as
2) Install ball bearing (120) to shaft (117) * Install the seal ring as shown below. in the 2nd clutch).
and secure it with snap ring (119). 8) Install ball bearing (98) to cage (88). 2) Install seal ring (73) to housing (71).
J, Push the bearing with a press until * Push the ball bearing with a press & Seal ring: Grease (G2-LII
the end of its inner race touches the until the end of its outer race touches f The seal ring must be installed in
shoulder of the shaft. the shoulder of the cage. the correct direction. When install-
3) Install seal ring (118) to cage (116). 9) Install collar (97) to cage (88) and secure ing it, check its direction (Install it as
6 Seal ring: Grease (G2-LI) it with snap ring (96). in the 2nd clutch).
4) Install cage (116) to shaft (117) and se- IO) Install ball bearing (95) to cage (88) and 3) Install piston (72) to housing (71).
cure it with snap ring (115). secure it with snap ring (94). 4) Install housing (71).
* Push the outer race of the bearing * Push the ball bearing with a press 8. 3rd clutch ring gear
with a press until it touches the until the end of its outer race touches 1) Install snap ring (70) to ring gear (69).
shoulder of the cage. the shoulder of the cage. 2) Install ring gear (69).
5) Install output shaft assembly (113) to 11) Install seal ring (93) to piston (92). CWWO4967 3) Install plate (68) with 8 bolts.
housing (114) with the 6 bolts. & Seal ring: Grease (G2-LI) & Threaded parts of mounting bolt:
& Threaded parts of mounting bolt: * Install the seal ring as shown below. 2) Install seal ring (84) to housing (82). Liquid adhesive (LT-2)
Liquid adhesive (LT-2) a Seal ring: Grease (G2-LI) m Mounting bolt:
m Mounting bolt: f Install the seal ring as shown below. 98 - 123 Nm (IO.0 - 12.5 kgml
98 - 123 Nm (10.0 - 12.5 kgml 9. Forward clutch and 3rd clutch carrier assem-
2. 2nd clutch carrier and 1st clutch assembly bly
I) Set 2 thrust washers (112) each and 2 Install the outer race of roller bearing
needle bearings (I 1 I) each to gear (I IO), (26) to carrier (64).
then install them to carrier (107). j, Push the outer race with a press un-
* When installing, take care not to til its end touches the shoulder of
bruise the thrust washers. the carrier.
* Install the 4 sets. Set 2 thrust washers (67) each and 2
2) Set ball (109) to shaft (1081, then install needle bearings (66) to gear (65), then
them to carrier (107). CWW04966 install them to carrier (64).
* Match the ball to the cut of the car- * When installing, take care not to
rier and push the shaft with a press 12) Install piston (92) to cage (88). CWW04968 bruise the thrust washers.
until it is flush with the carrier. 13) Install 3 springs (91) to cage (88). * Install the 4 sets.
* Install the 4 sets. 14) Install spacer (90) and secure it with snap 3) Install piston (83) to housing (82). Install ball (63) to shaft (62), then install
3) Install snap ring (106) to carrier (107). ring (89). 4) Install housing (82). them to carrier (64).
4) Install 9 discs (103), 8 plates (1041, and 9 * Install the snap ring, compressing the 5. 2nd clutch ring gear * Match the ball to the cut of the car-
springs (105) to carrier (107) alternately. spring with a press. Install ring gear (81). rier and push the shaft with a press
5) Install 2 seal rings (102) to hub (101). * Installed load of spring: 6. 2nd clutch plates and discs until it is flush with the carrier.
6 Seal ring: Grease (G2-LI) 1,697 N {I73 kg1 1) Install 4 plates (781, 3 discs (791, and 24 * Install the 4 sets.
6) Install hub (101) to carrier (107). springs (80) alternately. Install gear (59) to carrier (64).
WA1 200-3 30-079-6

5) Press fit collar (60) to ball bearing (58). 3) Install 12 pins (40) and 6 pins (39). 3) Set ball (21) to shaft (201, then install 19. Housing
* Push the collar with a press until its j, The length of the pins depends on them to carrier (22). Install housing (3) with 24 long bolts and 6
shoulder touches the end of the in- the clutch. Before installing each pin, * Match the ball to the cut of the car- short bolts.
ner race. check its length. rier and push the shaft with a press 6 Threaded parts of short mounting
6) Install bearing (58) to carrier (64) and * Pin length: until it is flush with the carrier. bolt: Liquid adhesive (LT-2)
secure it with snap ring (57). (40); 315 mm, (39); 315 mm * Install the 4 sets. w Long bolt:
Ir Push the bearing with a press until 14. Connecting ring gear 4) Install ball bearing (19) to shaft (15). 353 - 392 Nm I36 - 40 kgm1
the end of its outer race touches the 1) Install snap ring (38) to ring gear (37). * Push the ball bearing with a press Short bolt:
shoulder of the carrier. 2) Install ring gear (37). until the end of its inner race touches 98 - 123 Nm {IO.0 - 12.5 kgml
7) Install forward clutch and 3rd clutch car- 3) Install plate (36) with 8 bolts. the shoulder of the shaft. 20. Case
rier assembly (56). & Threaded parts of mounting bolt: 5) Install gear (18) and secure it with snap 1) Install case (2) with the 3 bolts.
8) Install 2 seal rings (55) to collar (54). Liquid adhesive (LT-2) ring (17). m Mounting bolt:
& Seal ring: Grease (G2-LII w Mounting bolt: 6) Install shaft (15) to carrier (22). 490 - 608 Nm (50 - 62 kgml
9) Install collars (54) with 4 bolts. 98 - 123 Nm {IO.0 - 12.5 kgm} + Push the outer race of the ball bear- 2) Fit the O-ring and install 7 sleeves (I).
& Threaded parts of mounting bolt: 15. Reverse clutch housing and piston ing with a press until its end touches
Liquid adhesive (LT-2) 1) Install seal ring (35) to piston (33). the shoulder of the carrier.
w Mounting bolt: 6 Seal ring: Grease (G2-LI) 7) Install snap ring (14).
98 - 123 Nm I10.0 - 12.5 kgm} * The seal ring must be installed in 8) Install gear (13) and secure it with snap
10. 3rd clutch plates and discs the correct direction. When install- ring (12).
I) Install 5 plates (511,. 4 discs (521, and 30 ing it, check its direction (Install it as 9) Install 2 seal rings (I I) to cage (IO).
springs (53) alternately. in the 2nd clutch). & Seal ring: Grease (G2-LI)
2) Install 6 springs (50). 2) Install seal ring (34) to housing (32). IO) Install cage (IO) to carrier (20) with the 8
* The length of the springs depends 6 Seal ring: Grease (G2-LI) bolts.
on the clutch. Before installing each * The seal ring must be installed in & Threaded parts of mounting bolt:
spring, check its length. the correct direction. When install- Liquid adhesive (LT-2)
* Free length of spring: 68.8 mm ing it, check its direction (Install it as w Mounting bolt:
11. Forward clutch housing and piston in the 2nd clutch). 98 - 123 Nm {IO.0 - 12.5 kgm}
1) Install seal ring (49) to piston (47). 3) Install piston (33) to housing (32). 11) Install ball bearing (9) to cage (7).
& Seal ring: Grease (G2-LI) 4) Install housing (32). * Push the ball bearing with a press
* The seal ring must be installed in 16. Reverse clutch ring gear until the end of its inner race touches
the correct direction. When install- Install ring gear (31). the shoulder of the cage.
ing it, check its direction (Install it as 17. Reverse clutch plates and discs 12) Install cage (7) to cage (IO).
in the 2nd clutch). I) Install 8 plates (281, 7 discs (291, and 48 * Push the cage with a press until the
2) Install seal ring (48) to housing (46). springs (30) alternately. end of the inner race touches the
& Seal ring: Grease (G2-LI) 2) Install 6 springs (27). shoulder of the cage.
* The seal ring must be installed in * The length of the springs depends 13) Install ball bearing (8) to cage (7).
the correct direction. When install- on the clutch. Before installing each * Push the inner race and outer race
ing it, check its direction (Install it as spring, check its length. of the ball bearing simultaneously
in the 2nd clutch). * Free length of spring: 133 mm with a press until the end of the outer
3) Install piston (47) to housing (46). 18. Input shaft, reverse clutch carrier and reverse race touches the shoulder of the
4) Install housing (46). sun gear assembly cage.
12. Forward clutch ring gear I) Install the inner race of roller bearing 14) Install spacer (6) and secure it with snap
Install ring gear (45). (26) to carrier (22). ring (5).
13. Forward clutch plates and discs * Push the inner race with a press un- 15) Install seal ring (16) to shaft (15).
I) Install 9 plates (421, 8 discs (431, and 72 til its end touches the shoulder of & Seal ring: Grease (G2-LII
springs (44) alternately. the carrier. 16) Sling the input shaft end and install the
2) Install 6 springs (41). 2) Set 2 thrust washers (25) and 2 needle input shaft, reverse clutch carrier and
* The length of the springs depends bearings (24) to gear (231, then install reverse sun gear assembly (4).
on the clutch. Before installing each them to carrier (22). * Sling the input shaft vertically so that
spring, check its length. * When installing, take care not to the inner race and outer race of the
* Free length of spring: 168 mm bruise the thrust washers. taper roller bearing under the carrier
Ir Install the 4 sets. will not be tilted when they are
coupled with each other.
30-079-7 WA1 200-3

0
DISASSEMBLY, ASSEMBLY OF TRANSFER AND PARKING BRAKE ASSEMBLY
29
28
27 \
32
WA1 200-3
30-079-8
0
Disassembly procedure Pull out the assembly evenly with Remove the outer race of roller bearing Assembly procedure
Ir When removing only the parking brake as- forcing screws. After it is pulled out (30) from cage (29). * When installing only the parking brake as-
sembly from the TORQFLOW assembly or to the shaft end, lift it off. * Use a bearing puller to pull out the sembly to the TORQFLOW assembly or ve-
vehicle body, see REMOVAL, INSTALLATION For the disassembly procedure of the out races. hicle body, see REMOVAL, INSTALLATION
OF PARKING BRAKE ASSEMBLY. parking brake assembly, see DISAS- Remove gear (31). OF PARKING BRAKE ASSEMBLY.
1. Front coupling SEMBLY, ASSEMBLY OF PARKING * Pull out the gear straight so that the 1. Case
I) Remove the mounting bolts and holder BRAKE ASSEMBLY. inner race and outer race of the roller Install the outer races of roller bearings (24)
(I). 5. Output shaft and gear assembly bearing will not be tilted when they and (32) to case (33).
2) Remove coupling (2). I) Remove the 8 mounting bolts and cover are disconnected from each other. * Push each outer race with a press until
2. Cage (14). Remove the inner races of roller bear- its end touches the shoulder of the case.
1) Remove the 6 mounting bolts, cage (31, 2) Remove output shaft and gear assembly ings (30) and (32) from gear (31). 2. Input gear
and shims (4). (15). * Use a bearing puller to pull out the 1) It-&all the inner races of roller bearing
* Check the thickness and quantity of 3) Remove spacer (16) and gear (17) from inner races. (32) and (30) to gear (31).
the shims. shaft (IS). 8. Case * Push each inner race with a press
2) Remove dust seal (5) from cage (4). * Use a press to pull out the spacer 1) Remove the outer races of roller bear- until its end touches the shoulder of
3) Remove oil seal (6) from cage (4). and gear simultaneously. ings (24) and (32) from case (33). the case.
3. Rear coupling 6. Idler gear * Use a bearing puller to pull out the 2) Install gear (31).
I) Remove the bolts and holder (7). I) Remove the 2 mounting bolts and plate outer races. * Insert the gear straight so that the
2) Remove coupling (8). (19). 2) Remove tapered roller bearing (34) from inner race and outer race of the roller
4. Parking brake assembly 2) Remove the 18 mounting bolts and cage case (33). bearing will not be tilted when they
I) Remove 2 mounting bolts and flange (9). (20). Ir Use a bearing puller to pull out the are coupled with each other.
2) Remove sleeve (IO). * Pull out the cage with forcing screws bearing. 3) Install the outer race of roller bearing
* Screw a hanging bolt (12 mm) in the (12 mm). (30) to cage (29).
sleeve to pull out the sleeve. * Pull out the cage straight so that the * Push the outer race with a press un-
3) Remove 2 plugs (11) and 2 sets of bolt inner race and outer race of the roller til its end touches the shoulder of
and washer (12). bearing will not be tilted when they the cage.
* Any bolts and washers may be re- are disconnected from each other. 4) Install cage (29) with the 18 bolts.
moved, since they will be used to 3) Remove the outer race of roller bearing * Insert the cage straight so that the
secure the parking brake. Do not re- (21) from cage (20). inner race and outer race of the roller
move any of the 4 hexagon socket * Use a bearing puller to pull out the bearing will not be tilted when they
head bolts. outer race. are coupled with each other.
4) Install the removed 2 sets of bolt and 4) Remove gear (22). 5) Install joint (28) and secure it with snap
washer (12) in the plug holes. * Pull out the gear straight so that the ring (27).
* Screw in the 2 sets of bolt and washer inner race and outer race of the roller 6) Fit the O-ring and install cage (26) with
alternately and slowly to pull the pis- bearing will not be tilted when they the 6 bolts.
ton in the packing brake toward the are disconnected from each other. & O-ring: Grease (G2-LI)
housing. 5) Remove the 4 mounting bolts and joint 7) Fit the O-ring and install plate (25) with
(23) from gear (22). the 2 bolts.
6) Remove the inner races of roller bear- 3. Idler gear
ings (21) and (24) from gear (22). Press fit the inner races of roller bear-
* Use a bearing puller to pull out the ings (24) and (21) to gear (22).
inner races. -Lr Push each inner race with a press
7. Input gear until its end touches the shoulder of
Remove the 2 mounting bolts and plate the gear.
(25). Install joint (23) to gear (22) with the 4
Remove the 6 mounting bolts and cage bolts.
(26). Install gear (22).
* Pull out the cage straight so that the * Insert the gear straight so that the
inner race and outer race of the roller inner race and outer race of the roller
bearing will not be tilted when they bearing will not be tilted when they
5) Remove the remaining 10 mounting bolts are disconnected from each other. are coupled with each other.
and parking brake assembly (13). Remove snap ring (27) and joint (28).
* Do not remove the 4 hexagon socket Remove the 18 mounting bolts and cage
head bolts. (29).
30-079-9 WA1 200-3

0
4) Install the outer race of roller bearing 5. Parking brake assembly 6. Rear coupling iii) Calculate shim thickness c.
(21) to cage (20). 1) Fit the O-ring and set the parking brake I) Install coupling (8). l c = (a -b) - (0.05 to 0.10)
* Push the outer race with a press un- assembly (13) in position, then tighten 2) Install holder (7) with the bolts. * The bearing is pushed in by 0.05
til its end touches the shoulder of the 10 bolts temporarily. & Threaded parts of mounting bolt: to 0.10 mm with the cage.
the cage. 2) Remove the 2 sets of bolt and washer Liquid adhesive (LT-2) * Standard shim thickness (Refer-
5) Fit the O-ring and install cage (20) with (12) from parking brake assembly (131, w Mounting bolt: ence): 0.8 to 2.0 mm
the 18 bolts. then install parking brake assembly (13) 2,059 - 2,354 Nm (210 - 240 kgml * Types of shims: 0.15, 0.20 mm
6 O-ring: Grease (G2-LI) with the 12 bolts in total. 7. Cage
* Insert the cage straight so that the * Loosen the bolts and washers alter- 1) Using tool D2, press fit oil seal (6) to
inner race and outer race of the roller nately and slowly so that the piston cage (3).
bearing will not be tilted when they in the parking brake will not be tilted. Sr Thinly apply gasket sealant (LG-5) to
are coupled with each other. & Threaded parts of mounting bolt: the oil seal fitting part of the cage.
w Mounting bolt: Liquid adhesive (LT-2) After fitting the oil seal, wipe off the
245.0 - 308.7 Nm I25.0 - 31.5 kgm} m Mounting bolt: projected sealant.
6) Fit the O-ring and install plate (19) with 205.9 - 269.7 Nm I21.0 - 27.5 kgml f Push the oil seal until the flange of
the 2 bolts. the tool touches the cage.
4. Output shaft and gear assembly & Oil seal lip: Grease (G2-Lll
I) Install tool D6 to case (31).
cwwo4974
.D6 3) Install selected shim (4) and cage (3) with

the 6 bolts.
* Since the shims are of 2-piece split
type, be sure to set them to the same
thickness on both sides.
4) Using tool D3, install dust seal (5) to cage
(3).
* Push the dust seal until the flange of
3) Install 2 plugs (11) to parking brake as- cwwo4973 the tool touches the cage.
sembly (13). & Dust seal lip: Grease (G2-LII
4) Fit the O-ring and install sleeve (IO). 2) Select the shim thickness according to
2) Install gear (17) and spacer (16) to shaft & Sleeve: Grease (G2-LI) a
the following procedure.
(18). 5) Fit the O-ring and install flange (9) with i) Install cage (3) to case (33) tempo-
* After installing the gear, push it with the 2 bolts. rarily and measure distance a be-
a press until the end of the spacer 6) Remove tool D6. tween the cage end and case end.
touches the shoulder of the shaft. 7) Using tool D5, install tapered roller bear- * Do not install any shim at this
3) Install output shaft and gear assembly ing (34) to case (33). time.
(15). Ir Since the bearing is an assembly, ii) Remove cage (3) and measure cage
4) Install cover (14) with the 8 bolts. handle it as one unit, when replac- thickness b.
ing.
* Press fit the bearing one side by one
and insert the ring without fail.
8. Front coupling
I) Install coupling (2).
2) Install holder (1) with the bolts.
w Mounting bolt:
2,059 - 2,354 Nm 1210 - 240 kgm1
WA1 200-3 30-079- 10

0
REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY (FROM VEHICLE BODY)
Preparation of tools Removal procedure

* Prepare the tools used for removal and in- 1. Remove the mounting bolts and holder (I).
stallation work. f When using a booster wrench to loosen
@ Shackle (2 pieces) the mounting bolts, hold it securely with
* If the shackles are not manufactured to a rope or a band from above so that it,
the specified dimensions, they may in- bolts, and wrench adapter will not come
terfere with some parts and may not be Off.
usable. 2. Remove coupling (2).
3. Remove the 2 mounting bolts and flange
45Lt (3).
,Min. 45 30MT
30M 4. Remove sleeve (4).
Max. 30 , , Max. 30 18M
Min. 18
f Screw a hanging bolt (12 mm) in the
sleeve to pull out the sleeve.
?
-_ j r‘ 5. Remove 2 plugs (5) and 2 sets of bolt and
washer (6).
* Any bolts and washers may be removed,
since they will be used to secure the
parking brake. Do not remove any of the
4 hexagon socket head bolts.
6. Install the removed 2 sets of bolt and washer
(6) in the plug holes.
0 Guide bolt (3 pieces) Sr Screw in the 2 sets of bolt and washer
alternately and slowly to pull the piston
in the parking brake toward the housing.
I
MR : S43C-D
MateriaI:S43C-D CWWO4984
I I CWWO4986 1
7. Remove the parking brake assembly (7) ac-

cordina to the following procedure.
Remove the remaining 10 mounting
bolts.
* Do not remove the 4 hexagon socket
head bolts.
Using forcing screws, pull out parking
brake assembly (7) to a position where 2
shackles @ can be installed.
Install 2 shackles @ as shown in the fig-
ure.
Sling parking brake assembly (7) from
both sides of the transmission.
CWW04983
30-079-11 WA1 200-3

0
5) Using output shaft (8) as a guide, slide Installation procedure m Mounting bolt:
off parking brake assembly (7) to the rear 1. Install parking brake assembly (7) according 205.9 - 269.7 Nm (21.0 - 27.5 kgm}
of the vehicle body. to the following procedure and tighten the
IO mounting bolts temporarily.
1) Install shackles @ as shown in the fig-
ure.
2) Sling parking brake assembly (7) from
both sides of the transmission and slide
it toward the transfer until it is placed on
output shaft (8) perfectly.
CWW04986
CWW04987
3. Install 2 plugs (5) to parking brake assembly
(13).
4. Fit the O-ring and install sleeve (4).
& Sleeve: Grease (G2-LI)
5. Fit the O-ring and install flange (3) with 2
bolts.
CWW04988 6. Install coupling (2).
7. Install holder (1) with the bolts.
3) Remove shackles @ and install 3 guide f When using a booster wrench to tighten
bolts @ as shown in the figure. the mounting bolts, hold it securely with
4) Push parking brake assembly (7) toward a rope or a band from above so that it,
the transfer to set it to the position for bolts, and wrench adapter will not come
installation. Off.
5) Tighten the 10 bolts temporarily and re- & Threaded parts of mounting bolt:
move guide bolts 0. Liquid adhesive (LT-2)
w Mounting bolt:
2,059 - 2,354 Nm I210 - 240 kgm)
CWW04989
2. Remove 2 sets of bolt and washer (6) from

parking brake assembly (7), then install park-
ing brake assembly (13) with the 12 bolts in
total.
Sr Loosen the bolts and washers alternately
and slowly so that the piston in the park-
ing brake will not be tilted.
WA1 200-3 30-079-12

0
DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY
Assembly procedure
1
Disassembly procedure
1. Plate 1. Housing
IO Remove snap ring (1) and plate (2). 1) Using tool D2, install oil seal (20) to hous-
6 I 2. Plates and discs
Remove 9 plates (3),8 discs (41, and 8 springs
ing (19).
+ Thinly apply gasket sealant (LG-5) to
(5). the oil seal fitting part of the hous-
3. Drum 1 ing. After fitting the oil seal, wipe off
Remove drum (6). the projected sealant.
4. Spacer * Press fit the oil seal until the flange
Remove spacer (7). of the tool touches the housing.
5. Drum 2 & Oil seal lip: Grease (G2-LI)
I) Remove 2 sets of bolt and washer (8).
* These are the bolts moved when the
parking brake assembly was re-
moved.
+ Loosen the 2 sets alternately and
slowly, checking that the piston is
coming out toward the drum.
2) Remove the 4 bolts and drum (9).
3) Remove snap ring (IO) from drum (9).
6. Piston
I) Remove piston (II).
2) Remove seal rings (12) and (13) from
piston (11).
7. Springs 2) Using tool D3, install dust seal (18) to
Remove 14 springs (14) and 14 springs (15). housing (19).
8. Bearing * Press fit the dust seal until the flange
Remove snap ring (16) and bearing (17). of the tool touches the housing.
* Use a bearing puller to pull out the bear- & Dust seal lip: Grease (G2-LI)
ing. 1
9. Housing
1) Remove dust seal (18) from housing (19).
2) Remove oil seal (20) from housing (19).
Ii CWW04978 1
2. Bearing
Install bearing (17) and secure it with snap
ring (16).
* Push the bearing with a press until its
end touches the shoulder of the hous-
ing.
CWWO4976
30-079- 13 WA1 200-3

0
3. Springs 6. Spacer
Install 14 springs (15) and 14 springs (14). Install spacer (7).
4. Piston Jr Insert the spacer vertically, since it is
I) Install seal rings (13) and (12) to piston used as the inner race of the roller bear-
(II). ing, too.
* Install the seal rings as shown in the 7. Drum 2
following figure. Install drum (6).
I I 8. Plates and discs
I 1 I Remove 9 plates (3), 8 discs (41, and 8 springs
(5) alternately.
d Plate
Install plate (2) and secure it with snap ring
(I).
I - cwwo4979
I
2) Place piston (I 1) on the spring.
* Match the dowel pin of the housing
to the pin hole of the piston.
5. Drum 2
I) Install snap ring (IO) to drum (9).
2) Place drum (9) over piston (11) and se-
cure it with the 4 bolts.
* Tighten the bolts slowly so that the
piston will not be tilted in the hous-
ing.
3) Tighten the 2 sets of bolt and washer (8)
in the plug holes.
* Use the bolts and washers for the
parking brake assembly temporarily.
Do not remove them until the park-
ing brake assembly is installed to the
transfer.
* Tighten the 2 sets alternately and
slowly, checking that the piston is
moving toward the housing.
WA1 200-3 30-079-14

0
5M*i#m lW7Ass’y
DISASSEMBLY AND ASSEMBLY VALVE Ass?
I\” /I/ j'Ass'y
VALVE Ass’y
_-_-_-_-_
_________---
_-_-_-_
_________-__
-
1i
L-J AA f?l ll7-h
I I
30-080 WA1 200-3

0
mB*$m t-/l/~;, bSiX2 y-i~1>i5-fiAs.s’y
DISASSEMBLY AND ASSEMBLY T/C, T/M LINE Ass’y
bIL=Ii, b?i7(: ~‘jaiffiAss’y(V5)

T/C, T/M LINE Ass’y(V5)
d‘-_________!_______-_____-__-
D-D
-__r__-__7____ .-~_-._-__r__-__-_-
B-B(1 :2)
___--- _-----_-____ --__
_------_______
>.:---
F-F
-_--__-__-___
-__-__-__-__-__-__
_-__
._-__3
Y<
I’ ,/
,‘,, 3
5,’
0
_&_ 0
CWW04889
WA1 200-3 30-081

0
!im*@3 bJI*=Ii, b5i5Z:s~-i~i~-fiAss’y
IdLO, ~~jsc~8~~~i~~iAss’y(2/5)
T/C, T/M LINE Ass’y(2/5)
/--1
--_,
\
‘\
\ n
(TO CW'w;892)
r\
_Ip-__ L--r_ ___-;_-__-__h_ . ,' \ '\\
A__-_ -________ __-__-__-__
I “\ '\\
I:0 CWWO48921
\( \
r
CWWO4890
30-082 WA1 200-3

0
5M#*%l3
bJtXi, bYi;c< ~‘-iai5i>Ass’y
T/C, T/M LINE Ass’y
bAai, b3i;c-i ~_jai5OAss’y(3/5)

___-______ 1
it-
-------. AIR BLEEOIHG PLUG
c-c (1 :2)
(FROM CWWO48921 E-E
Y
(FROM CWWO4889)
CWW0489 1
WA1 200-3
30-083
0
33B+*?im t+Jb=I>, b?iX<-~_iz;5_I;Ass’y
bl1,=Ii, bPii: ~_j~1=/3-IiAss'y(4/5)
(FROM CtWO4890)
PC1 2)
CWW04892
30-084 WA1 200-3

0
53@f*sm bILzli, b~iX.*~-ia>i4>Ass’y
DISASSEMBLY AND ASSEMBLY T/C, T/M LINE Ass’v
T/C, T/M LINE Ass’y (5/5)

1. Bolt tightening torque per KES 04. 123. 1 impact
wrench (Table 2).
2. Install hoses free from twisting.
3. KES 00. 258. 1 (Contaminant inspection method

and contaminant limit in hydraulic circuit) and
KES 00. 248. 1 (Contaminant removing method
during manufacturing hydraulic parts and con-
taminant defecting method of finished parts and
contaminant limit) shall be satisfied.
4. Tightening torque of pipe thread per KES 04.

123. 3.
5. Adjust number of shims so that of parallelism

within 0.15 between center pin and matching
surface of output yoke of transmission front
end.
6. Use oil
E03@CD . .. Atmospheric temperature 0°C Min.
EOIO-CD . ..Atmospheric temperature +lO”C
Max.
6. 7. Oil capacity 360 Q

At oil change 280 Q
8. Oil inlet and air extract method at 1st oil

inletting
(At 1st time, oil level is not stabirized because
the air was into oil circuit. So check oil level as
follows)
(I) Pour oil 300 Q into oil filler.
(2) Run the engine. Then add oil 60 Q when oil
level gauge starts to move downward.
8.
(3) Check oil level to be oil level of engine idle
after idling engine 5 minutes.
(4) Leave half a day as engine stop. Bleed air
of torque converter oil cooler after loosen-
ing air bleeding plug of torque converter oil
cooler.
(5) Then run the engine and keep idle 5 min-
utes or more. So confirm oil level in regu-
lated area.
WA1 200-3 30-085

0
53l%*%l2 7’U’V -i t 7 bAss’y
DISASSEMBLY AND ASSEMBLY PROPELLER SHAFT Ass%
T”n4?-i -tt 7 bAss’y

PROPELLER SHAFT Ass’y
I
L__~~______I_~__-__-__-_; 4 i ’L_~I_-___-LI__I_-__-__-_~ 4
TlGWTEHlWG TDLPUE
343-427Nm
I ilG”TEYlYG TORPUE
8fiClb9 iiIth7 343-427Nm
(35-43. 5kaml
CWW04893
30-086 WA1 200-3

0
53lB*Bl3 7Ui bP//XlLAss’y
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASS’Y
7 q i I\ ;i7// XIbAss’y(l/Z)
FRONT AXLE Ass’y (l/2)
(31 P6(425-22-13520. 425-22-13530.

425-22-13540) 41’.‘7. ~/r\lbf(btL)
+ (0. 610. 1)ta‘ikicti.
CWW04894
WA1 200-3 30-087

0
DISASSEMBLY AND ASSEMBLY FRONT AXLE Ass’;
7ni b73JWAss’y(2/2)
FRONT AXLE As&y (2/2)
NW04895
30-088 WA1 200-3

0
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
DISASSEMBLY, ASSEMBLY OF FRONT AXLE ASSEMBLY
1 Disassembly procedure
1. Draining oil
Assembly procedure
1. Breather
1) Remove 3 level plugs (I ). Install breather (13).
2) Remove 3 drain plugs (2) and drain the 2. Tubes
oil from the axle. 1) Install 6 connectors (12).
2) Install tubes (II), (IO), and (9).
- : Quantity of drained oil: 670 e w Tube nut:
15.7 - 23.5 Nm (1.6 - 2.4 kgm}
&I kg Axle assembly: 3. Shaft
16,100 kg (Without oil) Fit the O-ring and install shaft (8) with the 2
Sensor assembly bolts.
1) Remove the mounting bolts and clip (5). 4. Sensor assembly
2) Remove the 2 mounting bolts, sensor I) Assemble the sensor assembly accord-
assembly (61, and shims (7). ing to the following procedure.
* Check the thickness and quantity of i) Insert the sensor until its tip touches
the shims. the flange of the axle.
Shaft ii) Measure the clearance between the
Remove the 2 mounting bolts and shaft (8), sensor fitting faces of the flange and
Tubes housing.
Remove tubes (91, (IO), and (11) and 6 con- iii) Adjust the shims so that the clear-
nectors (12). ance between the sensor tip and the
Remove breather (13). housing in the axle will be as fol-
lows.
* Clearance at sensor tip:
0.6 -C 0.1 mm
* Types of shims: 0.2, 0.3, 1.0 mm
* Combine the shims so that the
number of them will be mini-
mized.
2) Fit selected shims (7) and the O-ring and
install sensor assembly (6) with the 2
bolts.
w Bolt: 98 - 123 Nm {IO - 12.5 kgml
3) Install clip (5) with the bolts.
5. Supplying oil,
I) Fit the O-ring and install 3 drain plugs
(2).
w Drain plug:
127 - 176 Nm I13 - 18 kgm)
2) Fit the O-ring and supply oil into the axle
and install 3 level plugs (1).
G Oil: 670 L?(AX0751
w Level plug:
127 - 176 Nm (13 - 18 kgml
CWW02772
WA1 200-3 30-088-l

0
53f%*%lilz ‘/ P - 7 3 X JbAss’y
DISASSEMBLY AND ASSEMBLY REAR AXLE Ass’y
‘H’-P%WAss’y(l/2)
REAR AXLE Ass’y (l/2)
I. M94fV4l. ‘IL\V4l
STD. OPT.
94f ttll 165/65-57155.5/80-57
'11.441 1 52x57 1 44x57
J7lfid4JL /AKO75li.KES.90.751)I 670Q/
cwwo4902
WA1 200-3 30-089

0
53fE*%Z ‘IT-J3XJbAss’y
DISASSEMBLY AND ASSEMBLY REAR AXLE ASS’Y
‘/ +‘--B3XJLAss’y(2/2) _
REAR AXLE Ass’y (2/2)
WA1 200-3
fffR*wi REAR AXLE ASSEMBLY
DISASSEMBLY, ASSEMBLY OF REAR AXLE ASSEMBLY

1. Draining oil 1. Breather
I) Remove 3 level plugs (I). Install breather (11).
2) Remove 3 drain plugs (2) and drain the 2. Tubes
oil from the axle. 1) Install 6 connectors (IO).
2) Install tubes (91, (81, and (7).
- : Quantity of drained oil: 670 .4 m Tube nut:
15.7 - 23.5 Nm Il.6 - 2.4 kgml
& kg Axle assembly: 3. Shaft
16,100 kg (Without oil) Fit the 2 O-rings and install 2 shafts (6) with
support the 2 bolts each.
Remove the 30 mounting bolts and support 4. support
(5). Install support (5) with the 30 bolts.
Shaft m Mounting bolt:
Remove the 2 mounting bolts each and 2 1,520 - 1,910 Nm I155 - 195 kgml
shafts (6). 5. Supplying oil
Tubes 1) Fit the O-ring and install 3 drain plugs
Remove tubes (71, (81, and (9) and 6 connec- (2).
tors (IO). m Drain plug:
Breather 127 - 176 Nm I13 - 18 kgml
Remove breather (I I). 2) Supply oil into the axle and install 3 level
plugs (I).
G# Oil: 670 .@.(AX0751
w Level plug:
127 - 176 Nm I13 - 18 kgm}
cwwo2773
WA1 200-3 30-090-l

0
a~*%!43 ? 7 3 f ‘I PAss’y
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL CARRIER Ass’y
?7 + -v ‘I PAss’y(F) (l/5)
DIFFERENTIAL CARRIER Ass’y (F) (l/5)
CWWO4896
WA1 200-3 30-09 1

0
53fiff-sm 7‘7 + t ‘I 7Ass’y
DISASSEMBLY ANti ASSEMBLY DIFFERENTIAL CARRIER Ass’y
?7+ + ‘J JAss’y(F) (2/5)

DIFFERENTIAL CARRIER Ass’y (F) @/5)
CLEARANCE
COAT GREASE G2-Ll
i LT-2Lf
APPLY LT-2 ON THREAD
A-A (FROM cwwo4896)

CWWO4897
30-092 WA1 200-3

0
%‘3-v ‘IPAss’y
a$E*mi
DIFFERENTIAL CARRIER Ass’y
? 7 + -r ‘I 7Ass’y (R) (315)

DIFFERENTIAL CARRIER Ass’y (R) (315)
Z-2413 4-24X3
/
I
c1w04904
WA1 200-3
30-093
0
53-?s*$Im 77 + P 'I JAss’y
?7 + -v ‘I PAss’y(R) (4/5)
DIFFERENTIAL CARRIER Ass’y (R) (4/5)
to.2 to.3 t1.0
CLEARANCE
A-A (FROM cwwo4904)
30-094 WA1 200-3

0
aBE*%l.a F-7 3 P ‘I PAss’y
1. Adjustment of differential side bearing.

Tighten nut (568-22-11611) to obtain pre-load as
follows.
Pre-load: 15.7 - 31.4 kN 11,600 - 3,200 kg1
2. Adjustment of bevel pinion bearing.

Select shims (427-22-11460, 427-22-l 1470, 427-
22-11480, 427-22-11490) to obtain pre-load as
shown.
Pre-load: 7.8 - 35.3 kN I800 - 3,600 kg}
3. Installation of bevel pinion and gear

(I) Select shims (42C-22-11371, 42C-22-11381,
42C-22-11390) to obtain specified mounting
distance on the end face of pinion (42G22-
11211).
(2) Install gear ass’y and adjust bearing pre-
load. See item 1.
(3) Adjust backlash to 0.43 - 0.61 mm by using
nut (568-22-I 1611).
4. Oil seal (428-22-11780) and dust seal (428-22-

. .. . .
11790) installatron posmon and greasrng 1s as
shown. Other to be per KES 83. 271. 2.
WA1 200-3 30-095

0
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL CARRIER ASSEMBLY
REMOVAL, INSTALLATION, DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL CARRIER ASSEMBLY
4 5
4
3
‘\
‘\
-1
“\ -” /
‘\.(J
‘\
13
‘\ .\ Ii j
-_-.-_
cwwo2774
so-095 1 WA1 200-3

0
Removal procedure Disassembly procedure 8) Disassemble the pinion gear assembly Assembly procedure
1. Differential carrier assemblv 2. Cover according to the following procedure. 1. Differential assembly
1) Remove the 13 mounting bolts and cover Remove the 2 mounting bolts and cover (8). i) Secure pinion gear assembly (34) I) Install bevel gear (44) to case (41) with
assembly (3). Ir Front differential carrier only with a press and remove locknut (35) the 20 bolts.
2) Remove gear (4). 3. Flange with wrench WI. & Mounting bolt:
3) Remove shaft assembly (5). Remove snap ring (9) and flange (IO). ii) Using a press, remove sleeve (37) Liquid adhesive (LT-2)
4) Remove the mounting bolts and t-piece * Front differential carrier only from pinion gear (36). w Mounting bolt:
(7). 4. Lock plate iii) Remove inner race (38A) from pin- 824 - 1,030 Nm (84 - 105 kgml
5) Remove 23 mounting bolts and differen- Remove the 4 mounting bolts and 2 lock ion gear (36). 2) Install 2 bushings (43) to case (41).
tial carrier assembly (6). plates (I I). iv) Remove spacer (38B) and inner race * Front differential carrier only
5. Cage assembly (38C) from sleeve (37). 3) Install tube (42) to case (41).
kg
&?I Differential carrier assembly: 1) Remove the 2 mounting bolts and * Front differential carrier only
1,570 kg bracket (12). 4) Install the inner race of bearing (27) and
2) Remove the 22 mounting bolts and cage thrust washer (40) to case (41).
assembly (13). & Contact faces of thrust washer
3) Remove shims (14) from cage (15). (40) and side gear (39):
* Check the thickness and quantity of Axle oil (AX075).
the shims. 5) Install side gear (39) to case (41).
4) Remove the mounting bolts, holder (16), 6) Assemble the pinion gear assembly ac-
and shims (17). cording to the following procedure.
* Check the thickness and quantity of i) Using a press, install collar (38E) and
the shims. outer race (38F) to pinion gear (36).
5) Remove coupling (18). * Push the outer race until its end
6) Remove the 4 mounting bolts and cage touches the pinion gear.
(19). v) Using a press, remove outer race ii) Using a press, install outer race (38D)
7) Remove dust seal (20) from cage (19). (38D) from pinion gear (36). to pinion gear (36).
8) Remove oil seal (21) from cage (19). vi) Using a press, remove collar (38E) * Push the outer race until its end
9) Remove pinion (22) from cage (15). and outer race (38F) from pinion gear touches the pinion gear.
IO) Remove the inner race of roller bearing (36).
(23) from cage (15).
11) Remove the inner race of roller bearing
(24) from pinion (22).
* Use a press to pull out the inner race.
12) Remove the outer races of roller bear-
ings (23) and (24) from cage (15).
+ Use a bearing puller to pull out the
outer races.
6. Differential assembly
I) Remove the 4 mounting bolts and 2 caps
(25). I cwwo4991
2) Remove 2 nuts (26).
3) Remove differential assembly (28) and 2 iii) install inner race (38C) and spacer
outer races of bearing (27) from carrier 9) Remove side gear (39). (38B) to sleeve (37).
(29). IO) Remove the inner race of bearing (27) iv) Install sleeve (37) to pinion gear (36).
4) Remove the 8 mounting bolts and case and thrust washer (40) from case (41). VI Install inner race (38A) to pinion gear
(30). 11) Remove tube (42) and 2 bushings (43). (36).
5) Remove the inner race of bearing (27) Ir Front differential carrier only
and thrust washer (31) from case (30). 12) Remove the 20 bolts and bevel gear (44).
6) Remove side gear (321, then remove spi-
der shaft (33) and pinion gear assembly
(34) as one unit.
7) Remove 4 pinion gear assembly (34)
from spider shaft (33).
WA1 200-3 30-095-2

0
vi) Secure pinion gear assembly (34) just it into the following range with becomes 15.7 Nm Il.6 kgml. 9) Install cage (19) to cage (15) with the 4
with a press and tighten nut (35) with the adjustment nut. iv) Measure distance b between the bolts.
wrench WI. * Rotational force: holder and pinion end. w Mounting bolt:
m Nut: 20.6 - 23.5 N (2.1 - 2.4 kg} v) Calculate shim thickness c. 157 - 196 Nm (16 - 20 kgml
882 - 1,080 Nm I90 - 110 kgn f The rotational force may be mea- . c = (b - a) - (0 to 0.04) 10) Install coupling (18) to pinion (22), then
35 sured by winding a string onto * Select shims so that their thick- fit the O-ring.
plane half part b. (79.4 - 95.1 N ness will be 0 to -0.04 mm less 6 Yoke end, shaft spline:
/ ,38A
I8.1 - 9.7 kg)) than the clearance. Lubricant (LM-G)
* Types of shims: 11) Install the selected shims and holder (16)
0.05, 0.2, 0.3, 1.0 mm with the bolts.
* Combine the shims so that the & Mounting bolt:
number of them will be mini- Liquid adhesive (LT-2)
mized. w Mounting bolt:
vi) Install the selected shims and tighten 2,450 - 3,040 Nm (250 - 310 kgml
the bolt. 12) Fit the O-ring to cage (15).
vii) Rotate cage (15) to fit the bearing, 13) Adjust the shim thickness for the differ-
then check that the starting torque is ential carrier according to the following
15.7 - 52.0 Nm (I.6 - 5.3 kgm). procedure.
7) Install the assembly of 4 pinion gear as- * If the starting torque is out of the * After the bearing, pinion gear, bevel
semblies (34) and spider shaft (33) to above range, adjust the shims gear, etc. is replaced, adjust the
case (41). again. shims.
8) Install side gear (32). iv) After adjusting, check that the ad- b a
i) Measure distance a between carrier
* Move the side gear to check that the justment nut groove on the plain half (29) and pinion gear (22).
pinion gear rotates lightly. side is at the position where the lock
9) Install the inner race of bearing (27) and plate is inserted.
thrust washer (31) to case (30). 2. Cage assembly
& Contact faces of thrust washer 1) Install the outer races of roller bearings a
(31) and side gear (32): (24) and (23) to cage (15).
Axle oil (AX075). * Push each outer race until its end
IO) Install case (30) to case (41) with the 8 touches the shoulder of the cage.
bolts. 2) Install the inner race of roller bearing
m Mounting bolt: (24) to pinion (22).
824 - 1,030 Nm (84 - 105 kgml * Push the inner race until its end CWW02777
11) Install the 2 outer races of bearing (27) touches the pinion.
to cases (41) and (30). 3) Install pinion (22) to cage (15). 6) Fit the O-ring to cage (19). cwwo2778
12) Install differential assembly (28) to car- & Bearing: Axle oil (AX0751 7) Install oil seal (21) to cage (19).
rier (29). * Press fit the bearing, rotating the 8) Install dust seal (20) to cage (19). ii) Calculate standard value b.
13) Tighten 2 nuts (26) onto carrier (29) tem- cage. Stop press fitting when a load * Fitting dimension c of dust seal: l b=(427+c)-(121.69id)
porarily. is applied. 4 mm from cage end * Dimensions c and d are indicated
* Check that the carrier can be rotated * Limit the press fitting force to the & Fitting part of oil seal: at the end of the pinion shaft on
lightly with the hand. minimum load to insert the bearing. Gasket sealant (LG-I) or (LG-5) the unit of l/100 mm. (Take care
14) Install 2 caps (25) to carrier (29) with the 4) Install the inner race of roller bearing & Seal lip: Grease (G2-LI) of plus and minus.)
4 bolts. (23) to pinion (22).
15) Adjust the preload on the differential side 5) Adjust the thickness of the shim for the
bearing according to the following pro- input bearing according to the following
cedure. procedure.
i) Bring the lock groove of the nut on the i) Measure thickness a of the holder.
bevel gear side to the position where ii) Install coupling (18) to pinion (22),
the lock plate is inserted. then install holder (16) temporarily
ii) Rotate the bevel gear until it rotates with the bolts.
smoothly. Sr Do not install the shims at this
iii) Measure the rotational force of the time.
bevel gear at large end a, then ad- iii) Fitting the bearing, loosen the bolt
gradually until the starting torque CWWO7776 cwwo2787
30-095-3 WA1 200-3

0
iii) Calculate shim thickness e. 3. Lock plate Installation procedure

. e=b-a Install 2 lock plates (11) with the 4 bolts. 6. Differential carrier assembly
* Types of shims: 0.2, 0.3, 1.0 mm m Mounting bolt: 1) Fit the O-ring to differential carrier as-
* Combine the shims so that the 245 - 309 Nm (25 - 31.5 kgml sembly (6).
number of them will be mini- 4. Flange 2) Install differential carrier assembly (6)
mized. Install flange (IO) and snap ring (9). with the 23 bolts.
14) Install selected shims (14) to cage (15) Ir Front differential carrier only
and install it to cage (29) with the 22 5. Cover r+lkg Differential carrier assembly:
bolts. Install cover (8) with 2 bolts. 1,570 kg
w Mounting bolt: * Front differential carrier only w Mounting bolt:
1,520 - 1,910 Nm 1155 - 195 kgml m Mounting bolt: 1,520 - 1,910 Nm (155 - 195 kgm}
15) Install bracket (12) to cage (15) with the 98 - 123 Nm {IO - 12.5 kgml 3) Install t-piece (7) with the bolt.
2 bolts. w Mounting bolt:
m Mounting bolt: 1,520 - 1,910 Nm 1155 - 195 kgml
1,520 - 1,910 Nm I155 - 195 kgml 4) Install shaft assembly (5).
16) Adjust the backlash of the bevel pinion 5) Install gear (4).
according to the following procedure. 6) Install cover assembly (3) with the 16
1: Adjust movement of the bevel gear bolts.
with the adjustment nuts. When mov- w Mounting bolt:
ing the bevel gear, turn the nuts on 245 - 309 Nm I25 - 31.5 kgm)
both sides in the same direction by
the same angle so that the preload
on the bearing will not change.
i) Apply dial gauge W2 to the outer
end of the bevel gear.
ii) Adjust the backlash into the
specified range with the adjust-
ment nuts.
Ir Backlash: 0.43 - 0.61 mm
* Fix the pinion gear and mea-
sure at 3 - 4 places.
iii) Thinly apply minium to the tooth
surfaces of the bevel gear and
check the tooth contact.
* Rotate the bevel gear and
check that the convex and
concave faces are in the fol-
lowing ranges respectively.
(146) mm
I-_
kg--63mml 169~83mA
I3 CII
cwwo2779
WA1 200-3 30-095-4

0
53s*%I2 7 ~-ffJlr& j’k+Ass’y
DISASSEMBLY AND ASSEMBLY FINAL & BRAKE Ass’y
7Ff f IL& i’k’F_Ass’y(l/4)

FINAL & BRAKE Ass’y (l/4) LT-2ltdi IT-PM6
548’
f!d
\0_-_-_
_ 1, ‘_
/’
/’
-_
‘\
‘\’ r
0 \‘;:
P (I :I1 0(1:1)
2 PLACES
(84-105Kaml CWWO4898
30-096 WA1 200-3

0
53lB*%!a 7~-ItJl,&7”1/-+Ass’y
7 P 4 f/b & i‘ L/ - +Ass’y (2/4)

FINAL & BRAKE Ass’y(214) LT-2tt LT-2Pt
J-J
il6HTENl”G TORDUE
PUbAd 245-309Nn
(25~31.5Komi
M
-I_____
__-__-__-
CWWO4899
WA1 200-3 30-097

0
53f#s*~Z T’dTJlr&?L/-+Ass’y
7 P f f JL & i‘ I/ - +Ass’y (3/4)

FINAL & BRAKE Ass’y(3/4)
B-B (FROM CWWO4898)
TiCHTEWlNt TORDUE
PtkAd 34.3-44.
(3.5~4.5K
(21 I21
H-H E-E
cww04900
30-098 WA1 200-3

0
%%*%3 7p4flL&?‘L-+Ass’y
DISASSEMBLY AND ASSEMBLY FINAL & BRAKE ASS’Y
7 57+ $-Jr, & i‘ I/ - +Ass’y (414)

FINAL & BRAKE Ass’y(4/4)
9 + 7 b (42C-22-12820)@hj$j 1. Floating seal installation Adjustment of wheel bearing.

. (1) To install floating seals, put tube (42C-22- Select shims (42C-22-12230, 42G22-12240, 42C-
1.2 F7” L -g : 0.306-0.564mm
13231) upright. 22-12250) to obtain pre-load as shown.
L t 7 b (42C-22-12820)#iA@ (2) O-ring (562-33-I 1922, 428-33-l 1650) to be Pre-load: 11.8 - 70.6 kN 0,200 - 7,200 kg}
. clean with EOIO-CD.
.x 2 F7’t -f : 0.089-0.346mm
(3) Coat with EOIO-CD on O-ring contact faces When assembling carrier ass’y (42C-22-12201)
5. 2@H7”3& y b<7’J >YQIl)lr> F‘;pL-g(-tr .:, of retainer (42G33-113223, cylinder (42C-33- and hub (42C-22-12710), thru screw hole Y to be
112531, retainer (42C-33-11331) and hub met with drill hole Z under drain plug.
I.44 brD7?ti $%!z~$$:).
(42C-22-12710).
L t 7 P (42C-22-12830)#Ai$ (4) Coat with EOlO-CD on O-ring contact sur- Disc wear indicator installation
. faces of seal (42G33-11410), and install O- (1) When assembling 9 plates (562-33-21231)
1. Y P7”L - 8 : 0.175-0.445nlIn
ring (562-33-11922) into these seals without from tube (42C-22-132311, the center of
L t 7 b (42C-22-12830)$$A$$ twisting. tooth lack to be met with the center of
(5) Coat with EOIO-CD on O-ring contact sur- tooth lack of gear (42C-33-11231).
faces of seal (42C-33-115103, and install O- (2) When assembling one plate (562-33-21231)
6. ring (428-33-11650) into these seals without from piston (42G33-11121), tooth must ex-
twisting. ist on the tooth lack of gear (42C-33-11231).
(6) Install half of seal ass’y (O-ring and seal) (3) Brake without cap (42C-33-12140).
into hub, retainer and cylinder by pressing (4) Push shaft (42C-33-12110) and adjust guide
O-ring with cylindrical tool as shown. (Fig. (42C-33-12130) until mating the surface of
441-883Nm I45-9OkgmI (%RS& b IL 3)
1) shaft (42C-33-12110) and the surface of
7. ;f;l’-JL<7 ‘) ~~‘~~$& (7) Mating faces “a” of seal (42C-33-11410, guide (42C-33-12130), and fix with nut.
9 4 (42C-22-12230,42C-22-12240, 426-22-12250) +%
42C-33-11510) to be clean and free of dust. (5) Install cap (42C-33-12140).
Coat with EOIO-CD on surface “a” before
z LT -t%‘SsG%;ilei+s. assembling. (Fig. 2)
3E%f-S?: 11.8-70.6kN I1,200-7,200kgI
8. 3 t ‘J 7Ass’y(42C-22-12201) &/\7*(42C-22-12710) 2. Degrease mating surface of seal (562-33-11941)
and cylinder (42C-33-112531, and apply Loctite
t-$ij.sl;f-~?~k$ /\10BL 9 ‘:, 7’RY &+-P ‘I 70)
#648 before assembling.
~L-~i~~~~~i’Jftz~Q~~ar~~~~~
3. Brake testing procedure
&oIZk.
(1) Bleed air from brake cylinder with bleeder
9. (566-32-I 1430).
(2) Brake oil to be pressurized to 175 MPa 1178
kg/cm*} and left for 5 minutes. Pressure
drop to be Max. 2.94 MPa 13 kg/cm*).
4. End play of No. 1 planetary bearing (adjustment

not to be required)
Before inserting planetary shaft (42C-22-12820)
( 2 ) y”;z I- Y (42C-33-11121)f$Q 7”L - b (562-33- . End play: 0.306 - 0.564 mm
21231) 1 f%zi. 4-V (42C-33-11231)a 4 9 ‘j\T - After inserting planetan/ shaft (42G22-12820)
. End play: 0.089 - 0.346 mm
s!ss&wQ~EiW13rt- btif&ati t-i%loL
tr. 5. Endplay of No. 2 planetary bearing (adjustment
not to be required)
Before inserting planetan/ shaft (42C-22-12830)
. End play: 0.175 - 0.445 mm
After inserting planetary shaft (42C-22-12830)
. End play: 0.103 - 0.392 mm
6. Studs (01145-93045) to be sunk to incomplete

thread.
Tightening torque to 441 - 883 Nm I45 - 90
kgm1
WA1 200-3 30-099

0
DISASSEMBLY AND ASSEMBLY FINAL DRIVE AND BRAKE ASSEMBLY
DISASSEMBLY, ASSEMBLY OF FINAL DRIVE AND BRAKE ASSEMBLY
36
---.-__
\ ,------ \ /I
L
80
/ -i____/- CWWO2780 )
-L
30-099- 1 WA1 200-3

0
Disassembly procedure 8. Hub ring-- gear assembly 12. Tube Assembly procedur
1) Remove the 8 mounting bolts, retainer 1) Remove plug (70) and O-ring from tube 1. Gear
&I kg Final drive and brake assembly: 5,450 kg (34), and shims (35). (74). 1) Fit the O-ring and install guide (82) to
* Check the thickness and quantity of 2) Remove the inner race from roller bear- gear (75).
1. Cover assembly the shims. ing (50). 2) Fit the O-ring to shaft (84).
I) Install the 16 mounting bolts and cover 2) Remove hub ring gear assembly (36). 3) Remove retainer (72) and 3 washers (73). 3) Insert shaft (84) in gear (75). Pass guide
assembly (3). 3) Remove the O-ring from tube (74). 4) Remove the 34 mounting bolts and gear (82) and lever (83) onto the shaft in or-
2) Remove the O-ring from cover (4). 4) Remove the 2 mounting bolts and 2 (75). der, then install spring pin (80).
3) Remove spacer (5). plates (37). 13. Gear 4) Fit the O-ring and install plug (79).
4) Remove the 3 mounting bolts and shaft 5) Remove retainer (38) and O-ring. 1) Remove plugs (76) and (77) and O-rings. w Plug: 58.8 - 78.4 Nm 16 - 8 kgm)
(6). 6) Remove seal (39) and O-ring. 2) Remove plugs (78) and (79) and O-rings. 5) Install plug (78).
2. Sun gear 7) Remove ball (40). 3) Remove spring pin (80). 6) Fit the O-ring and plug (77).
Remove gear (7). 8) Remove the inner race of roller bearing 4) Remove cap (81) and guide (82). 7) Fit the O-ring and install plug (76) to gear
3. Carrier assembly (Large) (41) from hub (42). 5) Remove lever (83) and shaft (84). (75).
1) Remove the 4 cap bolts and carrier as- 9) Remove the 16 mounting bolts and 8 w Plug:
sembly (8). plates (43). 44.1 - 53.9 Nm 14.5 - 5.5 kgm)
2) Remove the O-ring from carrier assem- 10) Remove ring gear (44) from hub (42). 2. Tube
bly (8). 9. Wheel hub assembly 1) Fit the O-ring to tube (74).
3) Remove 4 shafts (10) from carrier (9), 1) Remove 61 stud bolts (45) from wheel & Fitting part of O-ring:
then remove 4 balls. (11). hub assembly (46). Grease (G2-LI)
-k Remove the 4 sets. 2) Remove the outer race of roller bearing 2) Install gear (75) to tube (74) with the 34
4) Remove 4 gears (12) from carrier (9). (41) from hub (51). bolts.
* Remove the 4 sets. 3) Remove seal (47) and O-ring. m Mounting bolt:
5) Remove the bearing (13) from gear (12). 4) Remove retainer (48) and seal (49). 824 - 1,030 Nm (84 - 105 kgml
Jr Remove the 4 sets. 5) Remove the O-ring from seal (49). 3) Fit 3 washers (73) and install retainer
6) Remove snap ring (14) from gear (12). 6) Remove the O-ring from hub (51). (72).
* Remove the 4 sets. 7) Remove the outer race of roller bearing 4) Install the inner race of roller bearing
4. Ring gear (50) from hub (51). (50) to tube (74).
I) Remove the 16 mounting bolts and 8 10. Cylinder and piston assembly 5) Fit the O-ring and install plug (70).
plates (15). 1) Remove the 16 mounting bolts and cyl- 3. Wheel hub assembly
2) Remove ring gear (16). inder (52). 1) Press fit the outer races of roller bear-
5. Shaft assembly 2) Remove the O-ring from cylinder (52). ings (41) and (50) to hub (51).
I) Remove shaft assembly (17). 3) Remove oil seal (53) and seal (54). * Press fit each outer race until its end
2) Remove snap ring (19) and gear (20). 4) Remove the O-ring from seal (54). touches the shoulder of the hub.
3) Remove spacer (21) from shaft (18). 5) Remove plug (55) and O-ring. 2) Fit the O-ring to hub (51).
6. Carrier assembly (Small) 6) Remove bleeder (56). a O-ring: Grease (G2-LI)
I) Remove carrier assembly (22). 7) Remove plug (57) and O-ring. 3) Install retainer (48) to hub (51).
2) Remove spacer (24) from carrier (23). 8) Remove 3 plugs (58). 4) Fit the O-ring to seal (49).
3) Remove snap ring (25) and pin (26). 9) Remove 2 plugs (59) and 2 O-rings. a Seal: Engine oil (EOIO-CD)
* Remove the 3 sets. 10) Remove 2 plugs (60) and 2 O-rings. * Before fitting the O-ring, remove the
4) Remove 3 balls (27). 11) Push in guide (61) and remove 8 dowel blooming white powder from its sur-
5) Remove 3 gears (28) from carrier (23). pins (62) and 8 plates (63). face with engine oil (EOIO-CD).
6) Remove 2 bearings (29) and spacer (30). 12) Remove 8 guides (61) and 8 springs (64). * Before fitting the O-ring, check that
* Remove the 3 sets. 13) Remove piston (65) from cylinder (52). it is not skewed.
7) Remove snap ring (31) from gear (28). 14) Remove seals (66) and (67) from piston
* Remove the 3 sets. (65).
7. Hub and brake assembly 11. Discs and plates
1) Sling hub and brake assembly (32) tem- 1) Remove 10 plates (68) and 9 discs (69)
porarily, then remove the 36 mounting alternately.
bolts and the assembly. 2) Remove gear (71).
2) Remove the O-ring and plate (33).
WA1 200-Z 30-099-2

0
5) Install seal (49) to retainer (48). 8) Install 61 stud bolts (45) to hub (51). * After installing the seal, check that 8) Remove wheel hub assembly (46) and
& Retainer: Engine oil (EOIO-CD) * Tighten each stud bolt to the incom- the O-ring is not skewed. hub rina aear assembly (36).
* Check the O-ring contact face of the plete thread portion. * After installing the seal, measure di-
retainer is free from flaw, dust, etc. * Check that each stud bolt has an mension a at 4 places on the periph-
* Use a push jig to install the seal. identification mark. ery and reduce the dimensional dif-
* After installing the seal, check that * Tightening dimension (Reference): ference below 1 mm (similarly to seal
the O-ring is not skewed. 139 mm (49)).
* After installing the seal, measure di- w Stud bolt: IO) Fit the O-ring to tube (74).
mension a at 4 places on the periph- 441 - 883 Nm I45 - 90 kgm} & O-ring: Grease (G2-LI)
ery and reduce the dimensional dif- II) Install hub ring gear assembly (36).
ference below 1 mm. & Fitting face of bearing seal:
Engine oil (EOIO-CD)
5. Adjustment of preload on wheel bearing
1) Install wheel hub assembly (46) and hub
ring gear assembly (36).
& Bearing: Axle oil (AX075)
2) Install preload adjustment jig W3 with
the 3 bolts.
3) Checking the oil pressure with oil pres-
sure gauge 0, apply the following speci-
CWW02784 fied hydraulic pressure to preload ad-
justment jig W3 with a hydraulic pres-
cwwo4993 4. Hub ring gear assembly sure pump.
I) Press fit the inner race of roller bearing * Specified hydraulic pressure:
6) Fit the O-ring to seal (47). (41) to hub (42). 40.8 MPa (400 kg/cm*)
& Seal: Engine oil (EOIO-CD) 2) Install ring gear (44) to hub (42). 4) Close needle valve @ and remove the
t Before fitting the O-ring, remove the 3) Install 8 plates (43) with the 16 bolts. coupler.
blooming white powder from its sur- & Mounting bolt: 5) Rotate the hub wheel assembly suffi-
face with engine oil (EOIO-CD). Liquid adhesive (LT-21 ciently to fit the bearing. 6. Discs and plates
* Before fitting the O-ring, check that w Mounting bolt: * Check that the hydraulic pressure is Remove gear (71).
it is not skewed. 245 - 309 Nm 125 - 31.5 kgm} about 38.8 MPa (380 kg/cm*}. If it is Install 10 plates (68) and 9 discs (69) al-
7) Install seal (47) to hub (51). 4) Install ball (40). below that level, raise it again ac- ternately.
& Hub: Engine oil (EOIO-CD) 5) Fit the O-ring to retainer (38). cording to step 3). Install the 9 plates from the tube side,
Check the O-ring contact face of the 6) Install retainer (38) to hub (42). 6) Measure dimension b between cylinder matching the centers of their cuts to the
hub is free from flaw, dust, etc. 6 Retainer fitting part: upper face and piston upper face with a centers of the cuts of the indicator
Use a push jig to install the seal. Grease (G2-LI) depth micrometer. mounting part of the gear.
After installing the seal, check that 71 Install 2 plates (37) with 2 bolts. * Measure the dimension at 3 places Install the 1 plate from the piston side,
the O-ring is not skewed. & Mounting bolt: and obtain the average. matching its tooth to the cut of the indi-
After installing the seal, measure di- Liquid adhesive (LT-2) 7) Calculate shim thickness d. cator mounting part of the gear.
mension a at 4 places on the periph- w Mounting bolt: l d = (a - b - c) + (0 to 0.1) 7. Cylinder and piston assembly
ery and reduce the dimensional dif- 98 - 123 Nm {IO - 12.5 kgm} * a: 86.99 mm, c: 40.09 mm 1) Install seals (67) and (66) to piston (65).
ference below 1 mm (similarly to seal 8) Fit the O-ring to seal (39). * Types of shims: 0.2, 0.3, 1.0 mm & Periphery of seal: Grease (G2-LB
(49)). 6 Seal: Engine oil (EOIO-CD) * Combine the shims so that the num- * Before installing the seals, check the
* Before fitting the O-ring, remove the ber of them will be minimized. piston grooves for flaw and foreign
blooming white powder from its sur- matter.
face with engine oil (EOIO-CD). 2) Install piston (65) to cylinder (52).
Sr Before fitting the O-ring, check that & Piston surface: Grease (G2-LI)
it is not skewed. 3) Install 8 springs (64) and 8 guides (61).
9) Fit the O-ring and seal (39) to retainer 4) Push in guide (61) and install 8 dowel
(38). pins (62) and 8 plates (63).
6 Retainer: Engine oil (EOIO-CD) 5) Fit the O-ring to cylinder (52).
* Check the O-ring contact face of the
retainer is free from flaw, dust, etc.
* Use a push jig to install the seal.
30-099-3 WA1 200-3

0
6) Install cylinder (52) to gear (75) with the iii) Install cap (81) to guide (82). 10. Carrier assembly (Small) 14. Sun gear
16 bolts. m Cap: I) Install snap ring (31) to gear (28). Install gear (7).
w Mounting bolt: 117.6 - 161.7 Nm (12 - 16.5 kgm) * Install the 3 sets. 15. Cover assembly
824 - 1,030 Nm (84 - 105 kgml 2) Install spacer (30) and 2 bearings (29). Install shaft (6) with the 3 bolts.
7) Fit the 2 O-rings and install 2 plugs (60) * Install the 3 sets. 6 Mounting bolt:
to cylinder (52). 3) Install 3 gears (28) to carrier (23) with 3 Liquid adhesive (LT-2)
m Plug: 58.8 - 78.4 Nm (6 - 8 kgm) balls (27) and 3 pins (26). m Mounting bolt:
8) Fit the 2 O-rings and install 2 plugs (59) 4) Install 3 snap rings (25). 245 - 309 Nm (25 - 31.5 kgml
to cylinder (52). 5) Install spacer (24) and carrier assembly Install spacer (5).
w Plug: (22). Fit the O-ring and install cover assembly
9.8 - 12.7 Nm Il.0 - 1.3 kgm1 11. Shaft assembly (3) with the 16 bolts.
9) Install 3 plugs (58). I) Install spacer (21) to shaft (18). w Mounting bolt:
IO) Fit the O-ring and install plug (57). 2) Install gear (20) and snap ring (19) to 245 - 309 Nm I25 - 31.5 kgm}
11) Install breather (56) to cylinder (52). shaft (18).
& Threaded parts of breather: 3) Install shaft assembly (17).
Gasket sealant (LG-51 12. Ring gear
12) Fit the O-ring and install plug (55) to cyl- 15) Fit the O-ring to seal (54). 1) Install ring gear (16) to ring gear (44).
inder (52). 6 Seal: Engine oil (EOIO-CD) 2) Install 8 plates (15) with the 16 bolts.
m Plug: * Before fitting the O-ring, remove the & Mounting bolt:
34.3 - 44.1 Nm I3.5 - 4.5 kgml blooming white powder from its sur- Liquid adhesive (LT-2)
13) Check the brake seal according to the face with engine oil (EOIO-CD). m Mounting bolt:
following procedure. f Before fitting the O-ring, check that it 245 - 309 Nm 125 - 31.5 kgml
i) Install an oil pressurizing connector is not skewed. 13. Carrier assembly (Large)
to pressurizing port a. 16) Install seal (54) to cylinder (52). I) Install snap ring (14) to gear (12).
ii) Supply oil through pressurizing port & Cylinder: Engine oil (EOIO-CD) * Install the 4 sets.
a and bleed air through bleeder b. * Check the O-ring contact face of the 2) Install bearing (13) to gear (12).
iii) Keep the piston operating hydraulic cylinder is free from flaw, dust, etc. * Install the 4 sets.
pressure at 175 MPa (178 kg/cm*] and * Use a push jig to install the seal. 3) Install 4 gears (12) to carrier (9) with 4
close the hand valve. * After installing the seal, measure di- balls (II) and 4 shafts (IO).
iv) Check that the pressure does not fall mension a at 4 places on the periph- 4) Fit the O-ring to carrier assembly (81, then
more 0.29 MPa (3 kg/cm*) in 5 min- ery and reduce the dimensional dif- install them with the 4 cap bolts.
utes. ference below 1 mm (similarly to seal m Mounting bolt:
b (49)). 123 - 157 Nm I12.5 - 16 kgm}
17) Install oil seal (53) to cylinder (52). Ir When installing the carrier assembly
& Oil seal fitting part: LOCTITE 648 to the hub, match through tap hole a
& Oil seal lip: Grease (G2-LI) of the hub to hole b under the drain
Wheel hub assembly and hub ring gear assem- plug of the carrier.
a bly
I) Install wheel hub assembly (46).
6 Bearing: Axle oil (AX0751
2) Install hub ring gear assembly (36).
& Bearing: Axle oil (AX0751
3) Install the selected shims (35) and retainer
CWWO.2781 (34) with the 8 bolts.
& Mounting bolt:
14) Adjust the disc wear indicator according Liquid adhesive (LT-2)
to the following procedure. w Mounting bolt:
i) Apply pressure to the brake. 1,520 - 1,910 Nm I155 - 195 kgm}
ii) Rotate guide (82) with shaft (84) Hub and brake assembly I 6 CWWO2785 1
pushed in and adjust the shaft end Fit the O-ring and plate (33) to tube (74).
flush with the guide end, then se- Install hub and brake assembly (32) with
cure the shaft with the nut. ’ the 36 bolts.
w Nut: w Mounting bolt:
237.7 - 321 Nm I24 - 33 kgm} 2,450 - 3,040 Nm (250 - 310 kgm}
WA1 200-3 30-099-4

0
53l?B*%l~ J/S & P--4L/iC bAss’y
DISASSEMBLY AND ASSEMBLY J/S & ARM-REST Ass’y
J/S & 7-LaLL/ bAss’y(V3)

J/S & ARM-REST Ass’y(V3)
D-D (1~2)
CWWO4906
WA1 200-3
53lE*sm J/S & P--41/X bAss’y
DISASSEMBLY AND ASSEMBLY J/S & ARM-REST Ass’v
J/S & 7--l/X FAss’y(2/3)

J/S & ARM-REST Ass’y(2/3)
OF FRAME ANGLE
DIRECT "ARNESS
TOWARD RIGHT-FRONT
Z(l:l)
7b-b%KT>L3P@
DETAILS OF POTENT10 METER
OF FRANE ANGLE
CWWO4906
cwwoh4g06
cwwo4907
WA1 200-3 30-101

0
%!#*%I2 J/S & 7-h L X b Ass’y
DISASSEMBLY AND ASSEMBLY J/S & ARM-REST Ass’v
J/S & Y--bit bAss’y(3/3)

J/S & ARM-REST Ass’y(3/3)
1. Method of assembling joint (Cf. Q, A-A): 8. Method of auto correction of offset angle of
I-l) Assemble lever (42C-40-12310) in the same lever and frame potentio (0 & *) (Calibration):
direction (as shown) of slit of upper joint 8-1)Straighten vehicle and J/S lever (42C-40-
ass’y (42C-40-123201, and install lever to the 12310). (Direction may be desided at a
top limit of serration. guess.)
I-PITurn lever toward fore-and-aft of vehicle. 8-2) Put steering lock lever on “LOCK” position
Assemble, joint ass’y (42C-40-12480) so that (Lower side). When arm-rest situated at
grease nipple turn in the direction as shown. storage position (most backward), slide
arm-rest at forward optional position.
2. Adjustment of slide rail in the direction of fore- 8-3) Start engine and keep low-idling.
and-aft (Cf. A-A, D-D): 8-4)Slide J/S console in the storage position
Before assembling cover etc. tighten + marked (most backward). Switch (42A-06-15140) go
bolt (01435-00814/direction for up-and-down) on. (Cf. A-A)
and [XI marked bolt (01435-OlOPOldirection for 8-5) Put steering lock lever on “FREE” position
right-and-left) temporarily so that bracket (42C- (Upper).
40-12160) can slide smoothly, and then tighten 8-6)Calibration ends normally if it sounds “Pi-
them firmly. Pi-Pi” after 1 second.
Note: During operation 1 to 6, do not move
3. Adjustment of slide rail of joint cover (Cf. P): steering lever. If calibration ends abnor-
When assembling cover (42G40-12350, 42C-40- mally, check assembling angle of
12360) and slide rail (42C-40-123401, tighten bolt potentio (0 & Ir). And, restart calibra-
(01435-00620) for slide rail, bracket (42C-40- tion.
12380) temporarily and adjust them so that two
slide rails parallel each other. And then tighten
them firmly.
4. Adjustment of stopper bolt for J/S (Cf. Q, and

below):
When turning vehicle on low-idling, adjust
length of bolt for adjustment of steering angle
bX_marked/ 01010-80620) so that gap of frame-
end stopper can be almost 37 - 40 mm.
5. Lever for fore-and aft adjustment of J/S and

lever for up and down adjustment of arm-rest
and assembling stopper plate (Cf. S, T, B-B D-D):
5-I) Before assembling cover etc. assemble le-
ver (42C-40-122403 as shown without
handle part.
5-2)After assembling cover etc. assemble
handle part at an angle of 30” clockwise
from vertical upper position.
5-3)And then adjust the position of plate (42C-
40-12250) so that plate touches stopper bolt
at an angle of 60” on turning back counter-
clockwise from “LOCK” position.
6. Unless otherwise specified, tightening torque of

bolt-nut to conform to KES 04.123. l/
7. Method of assembling U-joint. (Cf. 2):

7-1)Assemble lever (42C-40-12450) at right
angle from direction of slit of pilot valve
(42C-40-12550).
7-2)Turn lever toward fore-and-aft and as-
semble U-joint ass’y (42G40-12470) so that
grease-nipple turn in the direction as
shown.
WA1 200-3
53s*%I& i‘k3XZf~Ass’y
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM Ass’y
i’k-+>X%Ass’y(1/2)
BRAKE SYSTEM Ass’y (l/2)
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WA1 200-3
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30- 104 WA1 200-3

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DISASSEMBLY AND ASSEMBLY LOADER CONTROL Ass’y
q-$hII bU--ILAss’y
LOADER CONTROL Ass’y
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WA1 200-3
5m*%a 7 I/ - &Ass’y
DISASSEMBLY AND ASSEMBLY FRAME Ass’y
7 I/-LAss’y(V4)
FRAME Ass’y(l/4)
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cwwo4912
30-106 WA1 200-3

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53llT*%RzE 7 I/ - AAss’y
7 I/ - LAss’y (2/4)
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53l!s*%l~ 7 I/--Ass’y
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cwwo4914
30-108 WA1 200-3

0
53%+~%El32 7 I/ - s&A&y
7 I, - LAss’y (4/4)
FRAME Ass’y(4/4) pin head 3 to 5 times with copper head ham-
0 t>sk>5sl&a7z%%m 16. To assure contact on each contact surface,

repeat step 15 three times. Then, tighten bolts
@ and @ with torque M36: 2,450 - 3,040 Nm
16. {250 - 310 kgm} and M45: 4,510 - 5,490 Nm
I460 - 560 kgm} again.
17. Remove all bolts @,.
Measure clearance between retainer and
frame at 3 positions on circumference using
q Center hinge assembling procedure thickness gauge and calculate average clear-
1. Attach-seal to front and rear frames and re- ance value. Use shims so that average clear-
tainer (42C-46-13210, 42C-46-13230) so that ance is 0.08 to 0.18 mm. In this case, total
seal lip faces outside. (See section A-A) thickness of shims must not exceed any mea-
Lock front and rear frame seals with plate sured clearance.
(42C-46-13340, 427-46-11330). 18. Keeping rear frame not to slide. Remove bolts
2. Press fit bearing cup (One side). Make sure @ and @ and set shim adjusted in step 17.
that bearing cup contacts tightly to bottom. 19. Perform steps 15 and 16.
3. Install a set of bearing cone and spacer. (Bear- 20. Remove bolts @ and @ one after the other,
ing is adjusted as a set. Never change combi- apply Locktite #262 and tighten them with
nation) specified torque. (Degrease fully the tapped
4. Press fit bearing cup. thread.)
5. Install retainer with 6 retaining bolts placed 21. Perform steps 15, 16 and 20 for upper pin
equally at 60” for upper side and 10 bolts at bolts (01010-62485). In this case use tightening
36O for lower side. Tighten bolts uniformly torque for M20 in steps 15 and 16.
with the following torque. 22. Remove jack from under rear frame lower
. Upper hinge bearing retainer: hinge.
137 Nm {14 kgm] + 10 % . Apply sufficient grease inside of bearing
6. . Lower hinge bearing retainer: when assembling.
441 Nm I45 kgm} f 10 % . Supply grease into upper hinge and lower
6. Loosen bolts once. Then tighten them uni- hinge shafts and steering hinge until
formly to torque specified in step 5. grease exude from dust seal after assem-
Measure clearance between retainer and front bling.
and rear frames at 4 positions equally places
on circumference. And calculate average clear- Adhesion procedure (rear axle support bushing as-
ance value. Use shims so that average clear- sembling procedtire.)
ance is 0.08 to 0.18 mm. In this case, total 1. Remove dirt and oil with cleaning liquid etc.
thickness of shims must be not exceed any 2. Clean bushing contact surface with cloth
measured clearance. soaked with primer (428-99-80080).
7. Add shims adjusted in step 6 and install re- 3. After coating primer, apply instant adhesive
tainer with the following torque. (428-99-80070). within 5 minutes. (Primer will
. Upper hinge 824 - 1,030 Nm (84 - 105 dry instantly.)
kgm) for each of 6 bolts * Apply adhesive of about 18 g to each
. Lower hinge 2,450 - 3,040 Nm {250 - 310 bushing (42C-46-17140). (Slightly smaller
kgm) for each of 10 bolts than 0.01 g per contact area of 1 cm*)
8. Press fit bushing (42C-46-13320, 42C-46-13330) * Set time of adhesive is 30 to 60 seconds.
to front frame. Set time: Time from starting of adhesive
9. Install bushing @ into rear frame lower hinge. to end of assembling bushing to axle sup-
10. Install bushing (42C-46-13120) into rear frame port.
upper hinge. 4. Press bushing quickly onto axle support.
11. Install retainer (42C-46-13110) onto upper pin. (Caution) Never mix adhesive and primer.
Bolt @: Tightening torque:
824 - 1,030 Nm {84 - 105 kgm) 0 Rear axle support bushing disassembling proce-
12. Install front frame between rear frame hinge dure.
and insert upper pin. 1. Insert blade end of knife and remove bushing
Bolt 0: Tightening torque: and support throughout circumference.
824 - 1,030 Nm I84 - 105 kgm} In this case, if it is difficult to peel them, handy
13 Insert lower pin and bushing into lower hinge torch to about 100°C.
and install retainer. (See view Y) 2. After removing bushing, apply peeling liquid
14. Place jack under rear frame lower hinge. Keep (427-46-11890) to remained adhesive and wipe
front frame to contact firmly to bushing @ with cloth after 2 or 3 minutes.
without clearance.
15. After tightening retainer bolts @ and @ of a Unspecified tightening of bolts and nuts shall be
lower hinge with torque M36: 2,450 - 3,040 in accordance with KES 04.123. 1 Impact wrench.
Nm (250 - 310 kgm) and M45: 4,510 - 5,490
Nm I460 - 560 kgm) respectively, tap lower
WA1 200-3
53?%#*mi fj:- F&7- FAss’y
DISASSEMBLY AND ASSEMBLY GUARD & HOOD Ass’y
ti- F & 7 - FAss’y(l/2)

GUARD & HOOD Ass’y(V2)
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cwwo4915
30-l 10 WA1 200-3

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53lY+*im
Yf- F& 7 - FAss’y
GUARD & HOOD Ass’y
?i- F & 7 - F’Ass’y(2/2)

GUARD & HOOD Ass’y(2/2)
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WA1 200-3
30-l 11
0
m#*i#Rsr 7RP/7’5~ b7%-.L+t&‘- b, AAX/\“-Ass’y
DISASSEMBLY AND ASSEMBLY FLOOR/PLATFORM SUPPORT, A/C COVER Ass’y
7 qT/703 Y I- 7 ij -&VT% b, NC~~+Ass’y

FLOOR/PLATFORM SUPPORT, A/C COVER Ass’y
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cwwo4917
30-l 12 WA1 200-3

0
w#*%E 3 2’1 -/L/~-Y -i ~Ass’y
DISASSEMBLY AND ASSEMBLY CONSOLE/DASH Ass’v
a i ‘1 --Ib/3f Y -i z~Ass’y(l/2)
CONSOLE/DASH Ass’y(V2)
F-F l1:2. 5)
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3.43--4.41Nm(0.35--0.45Kom)0~t.
1. TtGHiEWlYGTOPdUE OF LlSTED PARTS APWE SHALL BE
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CWWO4918
WA1 200-3 30-113

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tENB*%Z 1 i ‘1 -lb/g ‘2 -i ~Ass’y
DISASSEMBLY AND ASSEMBLY CONSOLE/DASH Ass’y
=I i’/-Jb/+~ _ixAss’y(2/2)
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WA1 200-3
53-fB*%m #aa 9 i 3Ass’y
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK Ass’y
fG&& 9 i 3Ass’y
HYDRAULIC TANK Ass’y
TlC”TEHlNG iORD”E
illtbh9 9.8s13Nm
(I. O-l. Jksml
A-A (I :2. 5)
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Ofi1M 79-93Nm
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BREATHER SET PRESS
I'l-7FYb.E 0.14MPa
(I. 4ke/cm')
WA1 200-3
5f-liB*sE X f 7’ ‘J i 5%i~E$$Ass’y
DISASSEMBLY AND ASSEMBLY STEERING HYDRAULIC LINE Ass’y
51T 7 ‘/ > ~~~&~~Ass’y

STEERING HYDRAULIC LINE Ass’y
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cwwo4921
30-l 16 WA1 200-3

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53fB*~Z
DISASSEMBLY AND ASSEMBLY El - “i ‘I i + - ?Ass’y
LOADER LINKAGE Ass’y
II-Sf’l i+-‘;i’Ass’y(l/3)
LOADER LINKAGE Ass’y(li3)
cwwo4922
WA1 200-3
30-117
0
alR*%R.a q - $2’‘J i 3_- ';;‘Ass' y
DISASSEMBLY AND ASSEMBLY LOADER LINKAGE Ass’y
q-Sf’J i++Ass’y(2/3)
LOADER LINKAGE Ass’y(2/3)
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30-l 18 WA1 200-3

0
53f#-%~ 4?~37=‘3 blf7-i 3 tAss’y
DISASSEMBLY AND ASSEMBLY KICKOUT POSITIONER Ass’y
+d7+ ~~_;;‘-i~fAss’y
KICKOUT POSITIONER Ass’y
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30-120 WA1 ZOO-3

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5M*sm RY~=YK+-P/ l?=Ass’y
DISASSEMBLY AND ASSEMBLY ROPS CANOPY Ass’y
q Y 7” Y ;i + -fi 1 f?Ass’y
ROPS CANOPY Ass’y
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WA1 200-3 30-l 21

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53f@*%az 17-51 >'jXTP'J i9Ass’y
DISASSEMBLY AND ASSEMBLY EMERGENCY STEERING Ass’y
r~--~I:i~~TP’~irAss’y(l/2)
EMERGENCY STEERING Ass’y(V2)
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30- 122 WA1 200-3

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EMERGENCY STEERING Ass’y
JX’-9 I i-iXf7 ‘I >3”Ass’y(2/2)

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cwwo4927
WA1 200-3
30-123
0
m?#*%aI XT7 r/ i9-i ‘I XfAss’y
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER Ass’y
X5?‘) j9-i ‘J XfAss’y(l/2)

STEERING CYLINDER Ass’y(l/2)
00
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CWWO4928
30- 124 WA1 200-3

0
'I 7 I---i ‘J i9’Ass’y
53f#*%Z
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER Ass’y
‘J 7 F -i ‘I iYAss’y(l/2)
LIFT CYLINDER Ass’y(l/2)
cwwo4929
WA1 200-3
30- 126
0
T)l%*aE ‘I 7 b 9 ‘I i 9’Ass’y
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER Ass’y
1. Install U-packing, piston seal, rod dust seal, and

O-ring, taking care not to damage them.
2. Before assembling, clean each part.

After assembling, cover piping ports and holes
for pin to prevent entrance of dust.
3. When inserting back-up rings for O-ring, warm

them in water of approx. 50 to 60°C and install
under due pressure.
4. Tighten bolts to conform to KES 04. 123. 1.
5. Ensure that threaded portion of piston (707-36-

30013) and nut (01010-61670) are completely
clean of all oil (grease). Apply hardener (Primer
T manufactured by LOCTITE JAPAN CORP.) to
each 6 places of threaded portion.
Then apply 0.5 cc - 0.7 cc bonding agent
(LOCTITE No. 262 manufactured by LOCTITE
JAPAN CORP. or equiv.) on to T 6 places of
piston screws and tighten bolt at torque of 245
- 309 Nm 125 - 31.5 kgm1.
Then leave them for about 30 minutes (for the
time of hardening the bonding agent).
6. In the first operation after assembling the cylin-

der (including reassembling), deaeration of the
cylinder shall be completely performed, particu-
larly for the first 3 to 5 strokes, (extension and
retraction) shall not load the set pressure of
relief valve at the stroke ends.
7. In transit, keep the assembly in most retracted

condition.
WA1 200-3 30-127

0
53$3*4m Sflli7“i ‘J i$Ass’y
DISASSEMBLY AND ASSEMBLY DUMP CYLINDER Ass’y
gi7“‘j ‘J XfAss’y(l/2)
DUMP CYLINDER Ass’y(V2)
cwwo4930
30-128 WA1 200-3

0
DISASSEMBLY AND ASSEMBLY DUMP CYLINDER As.9
1. Install U-packing, piston seal, rod dust seal, and

O-ring, taking care not to damage them.
2. Before assembling, clean each part.

After assembling, cover piping ports and holes
for pin to prevent entrance of dust.
3. When inserting back-up rings for O-ring, warm

them in water of approx. 50 to 60°C and install
under due pressure.
4. Tighten bolts to conform to KES 04. 123. 1.
5. Ensure that threaded portion of piston (707-36-

36030) and nut (01010-62085) are completely
clean of all oil (grease). Apply hardener (Primer
T manufactured by LOCTITE JAPAN CORP.) to
each 6 places of threaded portion.
Then apply 0.5 cc - 0.7 cc bonding agent
(LOCTITE No. 262 manufactured by LOCTITE
JAPAN CORP. or equiv.) on to T 6 places of
piston screws and tighten bolt at torque of 490
- 608 Nm {50 - 62 kgm1.
Then leave them for about 30 minutes (for the
time of hardening the bonding agent).
6. In the first operation after assembling the cylin-

der (including reassembling), deaeration of the
cylinder shall be completely performed, particu-
larly for the first 3 to 5 strokes, (extension and
retraction) shall not load the set pressure of
relief valve at the stroke ends.
7. In transit, keep the assembly in most retracted

condition.
WA1 200-3 30-129

0
DISASSEMBLY AND ASSEMBLY OIL COOLER
PROCEDURE FOR DISASSEMBLY AND ASSEMBLY OF

MESABI OIL COOLER ASSEMBLY
• Outline
1. General locations of oil cooler assembly
WA1200-3 30-131
6
30-132 W1200-3
6
2. Specifications, points
The overall dimensions are extremely large: approximately length 2162 mm x width 2880 mm x
depth 143 mm. The total number of tubes is 912. The tubes have a top-bottom two- stage structure
and there are four tubes to each line.
1) When mounted on the machine, it is difficult to pinpoint the location of any leakage. It is only
possible at the front face at places where there are no ribs.
2) There is a top-bottom two-stage structure. To remove the tubes at the bottom (bottom core),
first remove the tubes at the top (top core), then remove the tubes at the bottom. (Even if the
top retainer clip is removed, it is still difficult to move.)
fl When assembling, assemble the tubes at the bottom first, then assemble the tubes at the
top.
For the above reasons, carry out repairs or replacement when mounted on the machine only at the
front where it easy. For other locations, take the machine to the repair shop and set the machine
horizontal.
3. Tool list for disassembly and assembly
Component Symbol Part No. Part name Q’ty Details of operation

A 793-803-1110 Support installer 1
B 793-803-1130 Tube installer 1 Removal, installation of core

Disassembly and C 793-803-1120 Breaker tool 1
assembly of oil
cooler assembly D 799-301-1600 Air leak checker 1
Checking for leakage of
E 793-803-1150 Flange 1 air from core
F 793-803-1160 Flange 1
4. Supply parts list

No. Part No. Part name Q’ty Remarks
1 LM35780 Rubber seal 1,824
2 LM63377 Copper washer 2,736

3 LM33567 Tube retainer 912
4 LM33083-107 Air baffle 2
5 LM123-10-4200 ITS tube 912

6 LM48622 Tube support 912
Note: The pressure is high, so a blind plug cannot be used. For this reason, no blind plug is available
as a supply part.
WA1200-3 30-133
6
DISASSEMBLY OF MESABI OIL

COOLER ASSEMBLY
Preparatory work
1) Wash the oil cooler assembly with a hot
water washing machine. Turn it over and
wash it from the opposite side also.
fl Pressure: Max. 1200 PSI, 8.3 MPa
{Max. 84.4 kg/cm2}
fl Water temperature:
Max. 180° F {Max. 82° C}
fl Do not use steam.
2) After completing the washing, blow with air

to completely remove any water.
3) Set the oil cooler assembly on a horizontal

workstand.
fl To make it possible to put objects on
top of the oil cooler, spread cardboard
or a wooden board on top of the oil
cooler.
fl If it is necessary for a worker to get on
top when carrying out the work, put a
strong wooden board on top of the oil
cooler to prevent any excessive force
from being applied to the tubes or fins.
Disassembly
fl When removing all the tubes, first remove the

two lines at the front face, then turn the oil
cooler assembly over and remove the two lines
from the rear face.
1. Remove the support bars.

fl Before removing the support bars, make
counter marks to show the position when
assembling.
30-134 W1200-3
6
DISASSEMBLY AND ASSEMBLY BOTTOM DUMP
OIL
CYLINDER
COOLER
2. Removal of tubes
fl When removing the tubes, start from the
top core.
1) Use pliers to grip the tubes in the retainer

clip.
2) To clean, blow with air and wipe off any

dirt.
3) When removing the tubes, move the copper

washer down towards the fins to prevent
any resistance.
4) To make it easier to remove the tubes, coat

the top seal, bottom seal, and area around
the tube support with lubricating oil.
WA1200-3 30-135
6
5) If the tube and rubber seal have stuck to-

gether and the tube is difficult to remove,
use breaker tool C to move the tube and
make it easier to remove.
6) Using tube installer B, remove the tube from

the bottom seal.
fl Set the round portion of the tube installer
parallel to the tube fins, put the lower
jaw in contact with the plate of the cen-
ter tank, and tighten the handle.
ª1: Position to put round portion in contact
at first
(after pushing the fins with the round
portion and removing slightly)
7) The tube cannot be removed in the one

movement, so insert the round portion of
the tube installer at the side of the copper
seal and tighten the handle until the tube
end is removed.
ª2: Position to put round portion in contact
for second time
fl After carrying out the procedure in Steps 6)

and 7), check that the connection of the tube
support has been completely removed.
30-136 W1200-3
6
8) If the tube is stiff and does not move, use

tube installer B and support installer A to-
gether when removing.
fl When the spigot joint portion comes out
completely, stop pushing. If it moves too
much, the tube support may contact fins
and bend them, so be careful not to push
too much.
9) Remove the tube.

fl When removing the tubes from the top
seal, be sure to remove in a parallel di-
rection and be careful not to damage
the tube end or cause kinks.
10) In the places where the square rib of the oil

cooler is, it is not possible to use the tool
properly as it is, so use breaker tool C to
change the angle of the tube fins 90° before
removing.
11) Grasp of the tip of the rubber seal with fine-

nosed pincers and pull out.
3. After completing disassembly of the top two

stages, turn over and repeat the procedure to
disassemble the bottom two stages.
WA1200-3 30-137
6
ASSEMBLY OF MESABI OIL

COOLER ASSEMBLY
Preparatory work
Wipe with a cloth or blow with air to clean the
surface and inside of the holes of all parts.
Assembly
1. Installation of tubes
1) Install the rubber seal by hand.
fl If it is cold and the rubber seal is stiff,
warm it up in hot water before install-
ing.
fl An oil film will cause leakage of oil, so
do not use lubricating oil on the seal.
fl Tap with a flat hammer to bring portion
a of the rubber seal into tight contact.
fl If the rubber seal is concave as shown in

the figure on the right after it is inserted,
it has been inserted too far and the in-
side diameter has become smaller. When
the tube is inserted, force will be brought
to bear on the seal and it will be dam-
aged, so be extremely careful not to in-
sert it too far when installing.
2) Coat the inside surface of the rubber seal

and end of the tube thoroughly with oil.
30-138 W1200-3
6
3) Coat the tube support thoroughly with oil

also.
4) Check that the copper washer has entered

both ends of the tube.
• Top end: 2
• Bottom end: 1
fl When inserting vertically on the machine,
to prevent the copper washer at the bot-
tom end from falling out, insert just be-
fore inserting the tube into the bottom
seal.
5) Align the top end of the tube with the posi-

tion of the hole in the rubber seal, then in-
sert.
6) Check the position of the tube support.
7) Align the bottom end of the tube with the

position of the hole in the rubber seal and
insert it slightly by hand.
WA1200-3 30-139
6
8) Insert the tube support by hand until just

before the meshing part enters.
fl If the tool is used to insert when the
tube and rubber seal hole are not aligned,
the rubber seal will be in the same con-
dition as when it is pushed and inserted
too far. This will cause damage to the
rubber seal, so do not push it in by force.
9) Using tube installer B and support installer

A, insert the tube until the copper washer is
seated completely against the end face of
the rubber seal.
10) Using pliers, install the retainer clip between

the copper washers.
fl Align the position of the tabs of the re-

tainer clip to prevent the air from escap-
ing.
(To prevent reduction of the cooling ef-
fect)
fl When disassembling partially, if the po-

sition of the air buffer is moved, return it
to its original position when assembling.
30-140 W1200-3
6
11) If the position of the tube support is not

correct, the support bar cannot be as-
sembled, so use breaker tool C to align the
position of the tube support.
12) If the tube is bent for some reason, use

breaker tool C to straighten it.
13) At the corner portion, if there is a rib, it is

extremely difficult to carry out the work, so
be extremely careful when aligning the po-
sition of the holes and inserting.
fl Always carry out the work with two work-
ers and use bright lighting.
14) At the corner portion, assemble four lines of

tubes together.
fl After completing the assembly of the bot-
tom tubes, assemble the top tubes.
WA1200-3 30-141
6
2. Installing support bar

After installing at the front face, align the counter
marks made during disassembly and install the
support bars.
3. Using the lifting hook, turn the oil cooler over

and repeat the same procedure to assemble the
two lines on the opposite side.
Pressurizing test
1. Install flange E to the oil cooler outlet port.
2. Fit flange F to the oil cooler inlet port, then

install air leak checker D.
3. Apply air pressure and maintain it.

fl Air pressure:
0.88 – 1.03 MPa {9.0 – 10.5 kg/cm2}
fl Coat with soapy water to check that there is
no leakage of air at the jig portion.
4. Disconnect the basic pressure hose for the air.
5. Check that there is no drop in the air pressure

for one hour.
fl If the air pressure goes down, coat with
soapy water and check for the sound of air
leakage, or use a bath with clean water to
pinpoint the location of the air leakage.
30-142 W1200-3
6
40 MAINTENANCE STANDARD
Engine mount ............................................... 40- 2 Axle mount .................................................. 40-34

Transmission mount.. ................................. 40- 4 Center hinge pin.. ....................................... 40-36
Damper.. ....................................................... 40- 6 Steering pump.. .......................................... 40-38
Torque converter, transmission, Switch pump ................................................ 40-39
brake cooling and brake pump .......... 40- 7 Steering demand valve .............................. .40-40
Input transfer . PTO ..................................... 40- 8 Diverter valve ............................................. 40-42
Modulated clutch ......................................... 40-10 Steering cylinder mount.. .......................... 40-43
Torque converter.. ...................................... 40-I 1 Emergency steering pump ........................ 40-44
Transmission ............................................... 40-12 Brake valve .................................................. 40-45
Transfer ........................................................ 40-16 Slack adjuster ............................................. 40-47
Main relief, torque converter Brake.. ........................................................... 40-48
relief valve ............................................ 40-18 Parking brake ............................................... 40-50
Torque converter regulator valve ............... 40-20 Work euipment pump No. 1 ...................... .40-52
By-pass fill valve .......................................... 40-21 Work euipment pump No. 2 ....................... 40-53
By-pass fill valve and PPC valve ..................................................... 40-54
by-pass drain valve .............................. .40-22 PPC relief valve ........................................... .40-56
ECMV ............................................................. 40-23 Pump control relief valve .......................... 40-57
Lubricating oil relief valve.. ........................ .40-25 Main control valve ....................................... 40-58
Drive shaft.. .................................................. 40-26 Hydraulic cylinder ........................................ 40-60
Center support.. .......................................... 40-27 Bucket positioner and
Differential.. .................................................. 40-28 remote positioner .................................. 40-63
Final drive .................................................... 40-32 Bucket linkage .............................................. 40-64
WA1 200-3 40-l

MAINTENANCE STANDARD
ENGINE MOUNT
ENGINE MOUNT
n n
i56* 6koml
SWWO4865
40-2 WA1 200-3

MAINTENANCE STANDARD TRANSMISSION MOUNT
TRANSMISSION MOUNT
z-__
B-0
A-A
SWWO4666
40-4 WA1 200-3

MAINTENANCE STANDARD TRANSMISSION MOUNT
A3~_.____________
--r---r------ ,---,-=jqpqy
SWW04667
Unit: mm
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
Clearance between trunnion and size clearance limit
1 Shaft Hole
torque converter case
320 -0.125 +0.089 0.125 -

Replace
-0.214 0 0.303
Clearance between O.D. of shaft

2 90 0 +0.035 0 - 0.070
and I.D. of rubber cushion -0.035 0
Clearance between O.D. of rubber +0.123 +0.089 -0.123 -

3 125
cushion and I.D. of bracket hole +0.083 0 -0.006
Standard shim thickness: 1.5 mm (parallelism of coupling mating joint

4 Thickness of mount shim
of transmission output shaft and sensor of sensor pin: Max. 0.5 mm)
WA1 200-3 40-5

MAINTENANCE STANDARD DAMPER
DAMPER
4.4* 1.4Nm 1.4 * 2.4Nm 279*29Nm 279*29Nm

~0.45*0.15ksnl I0.75*0.25kPml ~28.5*3.0kml {28.5h 3.0kml
__-
j__-_
,c--
,i_-_ /
112*9.8Nm
111.5* l.Okrrml
ii il
1
____
__-
i
111.5* l.Okoml
SJWO4868
Unit: mm

-
I I
Clearance between bearing and

1 shaft
120 +0.018 0 -0.038 -

+0.003 -0.020 -6.003 0
Clearance between bearing and 0 -0.008 -0.037 -

2 housing 215 -0.030 0.025
-0.037 0.022
-
Clearance between inner body +0.018 +0.077 0.029 -
3 and shaft 120 0.1 Replace
+0.003 +0.047 0.074
Standard size Tolerance Repair limit

4 Wear of surface in shaft and oil seal
0
150 I -0.160 I
I -0.100
Wear of surface in sleeve and oil 0

5 seal 180 -0.160
-0.100
-
6 Backlash of spline 0.091 - 0.261
WA1 200-3
TORQUE CONVERTER, TRANSMISSION,
MAINTENANCE STANDARD BRAKE COOLING AND BRAKE PUMP
TORQUE CONVERTER, TRANSMISSION, BRAKE COOLING

AND BRAKE PUMP
4 2
SWWO3285
Unit: mm
Model Standard clearance Clearance limit
SARl4) 200 I 0.14 - 0.19 I 0.22 I

1 Side clearance SARl4) 200 0.14 - 0.19 0.22
SAR(3) 71 0.10 - 0.15 0.19
SAR(2) 28 0.10 - 0.15 0.19
SARl4) 200 0.06 - 0.14 0.20
Clearance between inside diameter SARI41 200 0.06 - 0.14 0.20

2 of plain bearing and outside Replace
diameter of gear shaft SARl3) 71 0.06 - 0.149 0.20
SARl2) 28 I 0.06 - 0.125 I 0.20 I

-
Model ( Standard size 1 Tolerance 1 Repair limit 1
I I I I
SARl4) 200 14 l.5
0
3 Insertion depth of pin SAR(4) 200 I3 -0.5
SARl3) 71 13 I 4.5
O I - I
-
SAR(2) 28 1 - 1 - I-l
4 Rotating torque of spline shaft 29.4 - 48.1 Nm f3.0 - 4.9 kgm} I
-
Revolution
Model
tram)
Discharge
Oil: EOlO-CD
Temperature: 45 - 55°C 2,000
SAR(2) 28 1 20.6 {210) 1 49 t 43 1
WA1 200-3 40-7

MAINTENANCE STANDARD INPUT TRANSFER - PTO
INPUT TRANSFER . PTO
All IHt
9JBOO110
40-8 WA1 200-3

MAINTENANCE STANDARD INPUT TRANSFER - PTO
Unit: mm
Standard size
0.15 - 0.32
WA1 200-3 40-9

MAINTENANCE STANDARD MODULATED CLUTCH
MODULATED CLUTCH
7
110.3*12.3Nm 353*39.2Nm
II 1,l)cI 1 rlEl,__l ,*c,,, 1
93800111
Unit: mm
No
seal ring contact
Total assembly thickness of 19 discs
WA1 200-3
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
277* 31. 9Nm 53.5*4.9Nm

(26.25 i3.25ko.I (5.5*0.5knml
\ I i
‘277* 31. 9Nm

(26.25 * 3.25 kom)
‘66.2* 7.35Nm
(6.75* 0.75kom 1
9JBOO112
Unit: mm

I I
inside diameter of seal ring contact
1 Plate with
surface of retainer +0.040 hard
0180 0 180.5
chromium
or replace.
Inside diameter of seal ring contact +0.035
2 085 85.1
surface of sleeve 0
0
Width 5.95 5.45
Wear of seal ring of -0.1
3
retainer
Thickness 6.3 *o. 1 5.67
Replace
4 Thickness of plate 9 20.1 8.5
-
5 Thickness of retainer 32 eo.1 31.5
WA1 200-3 40-l 1

MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
--_---
0 -----_
i 110.3*12.3Nm
~ll.25*1.25knmI
110.3*~2.3Nm 110.3~12.3Nm
(11.25*1.25kaml (11.25*1.25kPml
9JBOO113
40-12 WA1 200-3

Unit: mm
Standard size Repair limit
Free Installation Installation Free Installation

1 No. 1 clutch spring (6 PCS.)
length length load length load
133 94 379.5 N 322.6 N

138.7 kg} 125.02 (32.9 kg}
168 106 536.4 N 456.0 N

2 No. 2 clutch spring (6 PCS.) 157.92
154.7 kg) l46.5 kg}
357.9 N 304.0 N
3 No. 3 clutch spring (6 PCS.) 68.8 55 64.67 t31.0 kg}
136.5 kg}
42.7 N 358.9 N
4 No. 4 clutch spring (6 PCS.) 56.9 43 t43.0 kg} 53.49 l36.6 kg}
! I I I
9.5 8.5 1,697 N 1.443 N

5 No. 5 clutch spring (3 PCS.) 1173.0 kg} 8.93 1147.1 kg}

and 7 plates for No. 1 clutch
I 83.8
I kO.39 79.5

and 8 plates for No. 2 clutch 95.0 +0.41 90.2

and 4 plates for No. 3 clutch 50.2 kO.30 47.5
Total assembly thickness of 4 discs Replace

9 and 3 plates for No. 4 clutch 39.0 ~0.26 36.9
I I I

10 and 8 plates for No. 5 clutch I 77.6 I 20.41 I 72.8
11 Thickness of No. 1 - 4 clutch disc 5.4 kO.1 4.87

-
12 Thickness of No. 5 clutch disc 4.8 ao. 1 4.27
13 Thickness of No. 1 - 4 clutch plate 5.8 +o. 1 5.22

I I I
14 Thickness of No. 5 clutch plate 4.3 +O.l 3.87
Width 3 -0.01 2.7

15 transmission input shaft
Thickness 3.5 20.1 3.35
-0.01
Wear of seal ring of Width 4 -0.03 3.6
16 transmission output
shaft
Thickness 4.6 eo.12 4.45
Width 6 -0.01 5.5

17
No. 5 clutch
Thickness 6.8 +0.15 6.65
WA1 200-3 40-l 3

Unit: mm
sun
18 Backlash between No. 1, 2, 3 0.16 - 0.40
gear and planetary pinion
19
I Backlash between No. 1 planetary
pinion and inside teeth of ring gear I
0.18 - 0.43
I
Backlash between No. 2, 3 planetary
20 0.19 - 0.47
I pinion and inside teeth of ring gear I I Replace
4
21 Backlash between No. sun gear 0.17 - 0.39
and planetary pinion
22 Backlash between No. 4 planetary 0.18 - 0.44

pinion and inside teeth of ring gear
23 Side clearance of planetary pinion 0.35 - 0.80 (Both sides)
40-14 WA1 200-3

MAINTENANCE STANDARD TRANSFER
TRANSFER
277 *31.%m
-{Z&25* 3.25kml
17*147.lNm 2207*147.lNm
1u5f15 km1 {225*15 kern1
,_*,.
(24.;
9JBOO114
40-l 6 WA1 200-3

MAINTENANCE STANDARD TRANSFER
Unit: mm
Standard size I Tolerance I Repair limit

Outside diameter of oil seal contact
1
surface of front coupling
+0.052
0140 139.8
+0.027
-
Outside diameter of oil seal contact +0.052
2 0140 139.8
surface of rear coupling +0.027
-
Backlash between input gear and
3 0.20 - 0.44
idler gear
Backlash between idler gear and out-

4 0.20 - 0.44
put gear
-
I I I
Standard
size fii i:ta$dr;e 1nte;znce
Interference between input gear and
5
bearing
0140 +0.078 0 0.060 - 0.060 -

Replace
+0.060 -0.025 0.103 0.103
Interference between input gear

6 bearing and transfer case
Interference between idler gear and

7 bearing
Interference between idler bear bear-

8 ing and transfer case
Interference between output shaft +0.045 0.023 - 0.023 -

9 0120 +0.023 Jo20 0.065 0.065
and bearing
Interference between front output 0 -0.014 -0.016 - -0.016 -

10 bearing and transfer case
0215 -0.030 -0.060 0.060 0.060
Interference between spacer and 0140 +0.052 0 0.027 - 0.027 -

bearing +0.027 -0.025 0.077 0.077
Interference between rear output 0210 0 -0.014 -0.016 - -0.016 -

bearing and parking brake cover -0.030 -0.060 0.060 0.060
WA1 200-3 40-17

MAINTENANCE STANDARD MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
66.2*7.35Nm
4 ‘3 ‘0 (6.75*0.75koml
\
A-A
9JB00115
40-l 8 WA1 200-3

MAINTENANCE STANDARD MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
Unit: mm
No Check item Criteria Remedy

-
Clearance between main relief valve

1 spool and valve body
Clearance between main relief valve

2 spool and piston
-
Clearance between torque converter
3
relief valve spool and valve body
-
4 relief valve spool and piston
Valve spring of main relief valve

(Outside)
Valve spring of main relief valve

(Inside)
7 Piston spring of main relief valve
Valve spring of torque converter re-

a lief valve
Piston spring of torque converter re-

9
lief valve
WA1 200-3 40-19

MAINTENANCE STANDARD TORQUE CONVERTER REGULATOR VALVE
TORQUE CONVERTER REGULATOR VALVE
49*4.9Nm
5 * 0.5 kern)
A-A
Unit: mm

- -
I I
Tolerance
size clearance limit
1 Shaft Hole
regulator valve spool and valve body
-
040 -0.035 +0.016 0.035 0.081
-0.045 0 0.061
Clearance between torque converter -0.020 +0.021 0.020 -

2 022 -0.030 0 0.071
regulator valve spool and piston 0.051
Standard size Repair limit Replace
regu- Free Installation Installation Free Installation

3 Valve spring of torque converter
lator valve (Outside) length length load length load
156.9 N
155.6 116.0 kg}
Valve spring of torque converter regu-

4 ~
-
Piston spring of torque converter
5
40-20 WA1 200-3

MAINTENANCE STANDARD BY-PASS FILL VALVE
BY-PASS FILL VALVE

(For forward clutch and 1st speed clutch)
39. 2 * 9.6 Nm 4. 9 f INm

(4 f lkoml {O. 5 f 0. lkom)
9JB00117
Unit: mm
No. Check item Criteria

T Remedy
Standard Clearance
size &I ~;Z limit
Clearance between by-pass fill valve
spool and valve body
040 -0.035 +O.Oll 0.035 -

0.076
-0.045 0 0.056

I
Return spring of by-pass fill valve Free Installation Installation Free Installation
(Outside) length length load length load
63.7 N 60.8 N
33.4 17.3 32.4
(6.5 kg} f6.2 ka}
Return spring of by-pass fill valve 33.3 N 31.4 N

3 (Inside) 38.2 17.3 37.1
(3.4 kg} 13.2 kg}
WA1 200-3 40-21

MAINTENANCE STANDARD BY-PASS FILL VALVE AND BY-PASS DRAIN VALVE
BY-PASS FILL VALVE AND BY-PASS DRAIN VALVE

(For reverse clutch)
H 4.9 f 1 Nm
(0.5*0.1 koml
I’ ?t 1 ; tL,8,b 4.9 * f 1 Nm
(0. 5 0. I knm1
9JBOOl18
Unit: mm

-
Clearance between by-pass fill valve

1
Clearance between by-pass drain

2
valve spool and valve body
-
Replace
Return spring of by-pass fill valve

3 (Outside)
Return spring of by-pass fill valve (In-

4
side)
5 Return spring of by-pass drain valve
40-22 ‘#Al 200-3

MAINTENANCE STANDARD ECMV
ECMV
(For modulated clutch)
30. 9 *3. 43 Nm
13. 15 *O. 35kam)
9JBOOl 19
Unit: mm
-
Standard
Clearance between flow sensor valve

1
3
Replace
4 Spring for fill switch
5
-
WA1 200-3 40-23

MAINTENANCE STANDARD ECMV
(For transmission)
30. 9 *3. 43 Nm
(3. 15 *O. 35komI
9JBOO120
Unit: mm

-
Clearance between flow sensor valve

1
-
019 -0.035 +0.013 0.035 0.064
-0.045 0 0.058
-
Clearance between oressure contra -
2 014 -0.035 +O.Oll 0.035 0.062
valve spool and valve body -0.045 0 0.056
Clearance between pressure contra -

3 05.7 -0.035 +0.012 0.035 0.063
valve SDOOI and oiston -0.045 0 0.057
Replace
I
4 Spring for fill switch length load
length length load
15 13 41.7 N 14.7 37.6 N

(4.25 kg} c3.83 kg}
33.5 29.5 4.9 N 32.8 4.4 N

5 Return spring of flow sensor valve CO.45 kg}
(0.5 kg}
of pressure control 10.6 N 9.5 N

Return spring 15.9
6 16.2 11.7 Il.08 kg} IO.97 kg}
valve
40-24 WA1 200-3

MAINTENANCE STANDARD LUBRICATING OIL RELIEF VALVE
LUBRICATING OIL RELIEF VALVE
66.2*7.35Nm
1 6.75i 0.75 kam]
A-A
SJBOO121
Unit: mm
Tolerance
Clearance between lubricating oil size clearance limit
1 Shaft Hole
relief valve spool and valve body
I I I
-
022 -0.035 +0.013 0.035 0.078
-0.045 0 0.058
-
Replace
Standard size I Repair limit
2
Valve
valve
spring of lubricating oil relief
,I:
WA1 200-3 40-25
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
385.4*41.2Nm '277*31.4Nm 176.5*19.6Nm

(39.3*4.2koml t28.3*3.2bd (18.0*2.0ksm)
176.5*19.6Nm
~l8.0*2.0hl
1
I I I
fl
367.8*24.5Nm 367.8*24.5Nm
{37.5*2.5kPmI
367.8*24.5Nm 367.8*24.5Nm 385.4*41.2Nm 213.8*6.9Nm

(37.5*2.5ksml ~37.5~2.5knml (39.3+4.2kml (21.8*0.7ksml
SJWO4869
40-26 WA1 200-3

MAINTENANCE STANDARD CENTER SUPPORT
CENTER SUPPORT
Unit: mm
No.
Clearance between case and

1
bearing
2
-
5 Wear of oil seal surface
WA1 200-3 40-27

MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL (I/Z)
A-A
40-28 WA1 200-3

Unit: mm
-
No
Clearance of bearing outer race in

differential gear assembly
shaft bearing
7
_
11
12
13
-
14 Backlash of differential gear 0.31- 0.40
15 Preload of pinion bearing 7.8 - 35.3 N {800 - 3,600 kg}

Adjust
16 Preload of side bearing 15.7 - 31.4 N {l,SOO - 3,200 kg1
17 Rear face runout of bevel gear 0.13

-
Standard thickness of shims for
18 differential cage 1.3
-
WA1 200-3
DIFFERENTIAL (2/2)
176.5* 19.6Nm 1715*195Nm 277*31.4Nm

(18.0+2.0koml (175*20kPml (28.3* 3.2bmJ
927* 103Nm
(94.5* 10.5koml
2746 i294Nm
~260-t30ko.1
1715 *195Nm 927* 103Nm

il75i20kml 194.5* IO.5kPml
SJWO4872
Unit: mm

1 Thickness of side gear washer
9.0 8.5
Replace
2 Thickness of pinion gear washer
sleeve 10.8 10.3
3 Wear of oil seal surface 0

160 -0.100 159.84
40-30 WA1 200-3

MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
277131.4Nm
~28.3~3.2ksmI 277*31.4Nm
(28.3*3.2ksml
277*31.4Nm
,(28.3*3.2bml
1715*195Nm
-~175*2Okaml
\
12
\
152*24.5Nm
~15.5~2.5kivnl
i5 i IO II 2 3 13 4
SJWO4873
40-32 WA1 200-3

MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
No.
I Check item
I
Criteria Remedy
Tolerance
Standard Standard Clearanc
, Clearance between planetary shaft
Shaft Hole
and bearing
+0.018 0 -0.038- 0 _
90
0 -0.020
2 I Clearance between planetary gear I 155 0 -0.035 -0.075 -

and bearing -0.025 -0.075 -0.010
3 Clearance between planetary shaft +0.041 +0.025 -0.041 -

99.982 +0.026 0 -0.001
I and bearing I
Clearance between +0.025 -0.005 -0.076 -

4 I and bearing planetary gear I 190.5 0 -0.051 -0.005
5 Clearance between ring gear hub +0.127 +0.051 -0.127 -

479.425 +0.076 0 -0.025
I and bearing I
6 I Clearance
bearing
between wheel hub and
I 679.45
+0.076
0
-0.050
-0.130
-0.206 -
-0.050
Clearance between axle -0.020 +0.051 -0.020 -

7 housing 409.575 0.111
and bearing -0.060 0
Replace
Clearance between wheel hub and +0.051 -0.044 -0.165 -
* bearing 546.1 0 -0.114 -0.044

9 Thickness of retainer at ring gear
hub mount
40 to.1 39.6
Standard clearance Clearance limit

Backlash between planet gear and
IO
sun gear
0.25 - 0.66

11 0.28 - 0.83
ring gear
12 Backlash between planet gear and

0.27 - 0.72
I sun gear I
13 0.30 - 0.91
ring gear I I
,4 Thickness of standard shim for
2.4
wheel hub I
WA1 200-3 40-33

MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
5000*490Nm 5000*490Nm 5000*490Nm

~510*50ksm~ (510*50id ~510*50koml
19.6Nm
176.5-t 2746*294Nm
~l8.0*2.0hl (280~30koml
2746*294Nm
(280~3Okp.l
B-B
SJW04874
40-34 WA1 200-3

MAINTENANCE STANDARD AXLE MOUNT
Unit: mm
- 1
No Check item Criteria ~ Remedy

-
Tolerance
Clearance of shaft and hole
1 (Front support side) Shaft Hole
(Before press-fit bushing)
+4.000 +0.175 -4.000 -

540 0 0 +0.175
-
-0.076 +0.522 0.270 -
2 (Front support side) 530 -0.185 -0.345 0.707 1.6
(After press-fit bushing)
+4.000 +0.175 -4.000 -
3 (Rear support side) 540 0 0 +0.175
(Before press-fit bushing)
-0.076 +0.522 -0.270 - Replace
(Rear SUDDO~~side) 530 -0.185 -0.345 0.707 1.6
(After p&s-fit bushing)

I I
Thickness of thrust washer
8 kO.2
-0.21
6 Thickness of thrust plate 53
-0.35
-
7 Thickness of rear bushing 5 -to.1
a Thickness of front bushing 5

I
20.1
I -
- I I
WA1 200-3 40-35

MAINTENANCE STANDARD CENTER HINGE PIN
CENTER HINGE PIN
927*103Nm
{94.5*10.5kml
(When adiustinQ 441*44Nm

with shim) 145*4.5bml
927*103Nm (When adjusting
194.5*10.5kml 'with shim)
(Final value) 2746 *294Nm
18 {260* 30koml
(Fina I value)
53.9
15.52
17
5’ Ii \ '2746*294Nm
A-A B - B 5000*4QONm (280*3Okml
(510*50kaml
sxwo4935
40-36 WA1 200-3

MAINTENANCE STANDARD CENTER HINGE PIN
Unit: mm
-
No. Check item
I Criteria
I Remedy
Clearance between lower hinge pin

1 and bushing
I 228.6 -0.079
-0.050 +0.078
0 0.050
0.157- I
Clearance between lower hinge pin -0.050 +0.072 0.050 -
2 and (small) 228.6 -0.079 0 0.151 1.0
spacer
3
-
and bearingbetween
Clearance lower hinge pin I 228.6 -0.079
-0.050 0
+0.025 0.104-
0.050 I
4 and (large) 228.6 -0.079 0 0.151 1.0

_
spacer between
Clearance lower hinge pin I -0.050 +0.072 0.050 - I
5 spacer (large) and bushing 305.0 -0.137 0 0.236-

Clearance between lower hinge I -0.056 +o.oss 0.056 I
Clearance between front frame and +0.025 -0.074 -0.151 -
6 upper hinge bearing 269.875 0 -0.126 -0.074
upper
7 and rear frame -0.079
Clearance between hinge pin I 187.325 -0.050 0
+0.072 0.151-
0.050 I
Clearance between upper hinge pin -0.050 +0.025 0.050 -
8 and bearing 187.325 -0.079 0 0.129
- Replace
Clearance between front frame and +0.025 -0.093 -0.175 -
9 lower hinge bearing 355.6 0 -0.150 -0.093
10 bushing 248 -0.079 0 0.151-

Clearance between rear frame and I -0.050 +0.072 0.050 I
Clearance at press-fitted part of seal +0.26 +0.072 -0.260 -
11 of upper hinge pin 210
+0.16 0 -0.088
Clearance at press-fitted part of seal +0.260 +0.081 -0.260 -

12 of lower hinge pin 310
+0.160 0 -0.079
Clearance between lower hinge +0.242 +0.072 -0.242 -

13 250
-
bushing and frame (upper) I +0.196 0 -0.124 I
Clearance between lower hinge +0.325 +0.089 -0.325 -
14 325
bushing and frame (lower) I +0.268 0 -0.179 I

15 Height of lower hinge spacer (small)
177.2 *o. 1
16 Height of lower hinge spacer (large) 220 to. 1
17
Thickness
retainer
for lower hinge and
I
45
I kO.8
I
Shim thickness for lower hinge and
18 3.0
retainer I I
Shim thickness for lower hinge and Adjust
19 2.52
retainer I I
Shim thickness for upper hinge and
retainer 2.62
WA1 200-3 40-37

MAINTENANCE STANDARD STEERING PUMP
STEERING PUMP
(HPF160 + 160)
66*6.9Nm
{6.73~0.7kml
68.j*9.81Nm
i7.0*l.Obd
9JYOO286
40-38 WA1 200-3

MAINTENANCE STANDARD SWITCH PUMP
SWITCH PUMP
(HPV160 + HPF160)
34.3*4.9Nm
~3.5*0.5l@ml
24.5*4.9Nm 66*6.9Nm
~2.5*0.5koml {6.73*0.7bml
\
l-----l
9JYOO287
WA1 200-3 40-39

MAINTENANCE STANDARD STEERING DEMAND VALVE
STEERING DEMAND VALVE
7 C
A --I
2 I
A-A
svwo3soo
40-40 WA1 200-3

MAINTENANCE STANDARD STEERING DEMAND VALVE
Unit: mm
Remedy
WA1 200-3
MAINTENANCE STANDARD DIVERTER VALVE
DIVERTER VALVE
A-A SEW01614
Unit: mm
-
I I
1 Clearance between body and spool

I I I I
I
-0.023 +0.015 0.020 -
40
-0.005 +0.007 0.030

Replace
2 Spool spring length length load length load
122.6 a4 216.7 N 120.7 205.9 N

122.1 kg} I21.0 kg}
-
79.2 54.5 5.6 N 77.9 5.3 N
3 Check valve spring IO.57 kg} fO.54 kg}
79.2 57.5 4.9 N 77.9 4.6 N

4 Check valve spring {0.50 ka) IO.47 kg)
-
40-42 WA1 200-3

MAINTENANCE STANDARD STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
A-A
SJWO4876
Unit: mm
-
I Tolerance I I
Clearance between mounting pin

1 and bushing connection of steering
cylinder rod and frame
-0.043 +0.025 0.131 -

160 -0.106 0 0.043 1.0
Clearance between mounting pin

2 and bushing at connection of
steering cylinder bottom and frame
Replace
Connection of steering cylinder and
3
front frame
120 -0.25
O
I
135 +;
I 0 - 3.25
Connection of steering cylinder rod

4 120:.25 135+:,
snd rear frame

5 width of spacer
7.0 to.5
WA1 200-3 40-43

MAINTENANCE STANDARD EMERGENCY STEERING PUMP
EMERGENCY STEERING PUMP

Model SAM131100 + 100
A-A
‘2
SWWO3661
Unit: mm
No. 1 Check item Criteria Remedy
Pump model Standard clearance Clearance limit

Clearance between gear case and
1
side plate gear
SAM(3)lOO 0.10 - 0.15 0.19 Replace
I I
Clarance between inside diameter of plain

SAM(3)lOO 0.020 - 0.043 0.075
bearing and outside diameter of gear shaft
Standard size Tolerance

Replace
4 1 Rotating torque of spline shaft I 13.7 - 23.5 Nm Il.4 - 2.4 kgm}
Standard Fcepalr '.

ltmlt
Pump model Rerrtf:on Pressure discharge discharge
Discharge ‘.I-..., , IO,,“;“\
lLilllllli , Wmin)
- Oil: EOlO-CD
Temperature: 45 to 55°C
1 ?0.6 MPa
SAM(3)lOO + 100 2000 -
210 kg/cm? 352 312
I I
WA1 200-3
MAINTENANCE STANDARD BRAKE VALVE
(RIGHT)
SWWO4877
Unit: mm

-
Clearance between pedal

1 hole and bracket hole
! I I !
-
10 -0.025 +O.l 0.175 0.25
-0.075 0 0.025
-
2 Clearance between roller and pin 10 -0.025 +O.l 0.175 0.25
-0.075 0 0.025
-

3 Outside diameter of roller
0
30 29.2
-0.5
I
I
4 Control spring
length height load length load
4.6 N
34 33.5 33
IO.47 kg)
-
11.8 N
5 Control spring 46.3 46.0 45.3
Il.2 kg}
60.8 N
6 Return spring 86.2 58 78
16.2 ka1
17.7 N
7 Spring 17 16.5 16.2
- I (1.8 kg}
16.7 N
8 Return spring 31.5 19.5 28
(1.7 kg}
-
WA1 200-3 40-45

MAINTENANCE STANDARD BRAKE VALVE
(LEFT)
7.3Nm
0.75kom
152*24.5Nm /
~15.5*'2.5koml
Unit: mm

-
/ St;$xd / shafofer”““Ho,e 1 $eyici~ ( Clsa;;ce

Clearance between pedal mount
1 hole and bracket hole
-
10 -0.025 +O.l 0.175 0.25
-0.075 0 0.025
-
-
2 Clearance between roller and pin 10 -0.025 +O.l 0.175 0.25
-0.075 0 0.025
3 Outside diameter of roller

0
30 29.2
-0.5
Replace
4 Control spring
5 Control spring
I 46.3 34.3
45.9 N
(4.7 kg}
45.3
N
6 Return spring 86.2 58 60.8 78
(6.2 kg}
7 Return spring 31.5 19.5 16.7 N 28

(1.7 kg1
WA1 200-3
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
55.9* 6.9Nm
(5.7*0.7kml
1 I2*9.8Nm
(1 1.5* l.Okml
SXW04878
Unit: mm
-
Tolerance
1 Clearance between body and piston Shaft Hole
-0.030 +0.074 0.030 -

55 0.250
-0.076 0 0.150

2 Slack adjuster spring length load length load
length
117.7 N
246 88
I12 kg}
123.6 N
3 Check valve spring 44.8 38 112.6 kg} -
-
WA1 200-3 40-47

MAINTENANCE STANDARD BRAKE
BRAKE
\
i’ I I \
\
\
I_------%_/ 7 G
927i-98 Nm
194.5*IO km1 SXWO4879
40-48 WA1 200-3

MAINTENANCE STANDARD BRAKE
Unit: mm

1 Return spring length length load length load
124.9 104.8 1,600 N 123.0 1,520 N

1163 kg) f154.9 kg}

2 Thickness of plate
3.1 kO.1 2.85
Thickness of disc 6.7 eo.3 6.2

I I
Replace
Wear of contact surface of oil seal

I 0
-0.230 I
Wear of surface
piston seal
Wear of surface
in contact with
in contact with
839.5
I +0.140
0
+0.140
I
piston seal 864 0
I
Standard Repair limit
Deformation of friction surface of I
plate
Max. 0.5
Deformation of friction surface of

8 disc Max. 0.7
L
WA1 200-3 40-49

MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
2207 f 147.INm 2207 * 147.1Nm

(225 *I5 ken I
1 (225 ~15 kernI
I
237. 8 f 31.9 Nm
(24.25 f 3.25 kern)
9JBOO122
40-50 WA1 200-3

MAINTENANCE STANDARD PARKING BRAKE
Unit: mm

1 No. 1 Clutch spring (14 PCS.)
I lenoth lenath load lenath load
113 77.4 2,444 N 101.7 2,200 N

I249.2 kg} 1224.3 kg}
No. 2 Clutch spring (14 PCS.) 111 77.4 1,313 N 99.9 1,182 N
2 1133.9 kg} 1120.5 kg}

Total assembly thickness of 8 brake
3 discs and 9 separator plates
61.6 -co.41 56.8
- Replace
Thickness 4.0 kO.05 3.9

4 Separator plate
Distortion 0.20 0.6
Thickness 3.2 +0.08 2.77
5 Brake disc
Lining groove
depth (One side)
0.45
+0.7
0 I 0.235
Lining thickness
0.7 20.16
(One side) I I I
626.6 N ~176.5 N 405 N
6 Load on wave spring (Height: 3.2 mm) 163.9 kg} {*I8 kg) 141.3 kg}
WA1 200-3 40-51

MAINTENANCE STANDARD WORK EQUIPMENT PUMP No. 1

HPV160 + 160
66* 6.9Nm
(6.73*0.7kp.l
24.5i4.9Nm
~2.5*0.5kPml
30.5*3.5Nm
~3.11*0.36bml
34.3*4.9Nm
~3.5*0.5lwnI
9JYOO288
40-52 WA1 200-3

MAINTENANCE STANDARD WORK EQUIPMENT PUMP No. 2

HPV95 + 95
34.3i4.9Nm
(3.5*0.5kp.l
24.554.9Nm
30.9*3.43Nm
{3.15*0.35bml
66.2*7.35Nm
16.75*0.75kml
\
66.7*9.81Nm
(7.0*l.O!all
9JYooza9
WA1 200-3 40-53

MAINTENANCE STANDARD PPC VALVE
PPC VALVE
SVWO3605
40-54 WA1 200-3

MAINTENANCE STANDARD PPC VALVE
Unit: mm
No. I Check item I Criteria

I Remedy
Standard size
I Repair limit
I
Centering spring Free Installation Installation Free Installation
1 (Bucket dump, boom lower) length length load length load
5.4 N
39.9 34.5 iO.55 kg} - Replace if
damaged or
Centering spring 21.1 N deformed
2 56.7 34.5 i2.15 kg} -
(Bucket tilt, boom raise)
1
33.3 N
3 Metering spring 33.5 29.4 c3.4 kg) -
14.7 N
4 Return spring 26.2 17.5 (1.5 kg} -
WA1 200-3 40-55

MAINTENANCE STANDARD PPC RELIEF VALVE
PPC RELIEF VALVE
152 *24.5Nm 108 f 14.7Nm 39.2* l.ONm

~l5.5*2.5k.m1 1 2 i 11.0*1.5koml (4* lkml
34.3ik.SNm
13.5*0.5kml
SJWO4897
Unit: mm

1 Main valve spring length length load length load
Replace
17.6 N 13.7 N
44.5 32.5 Il.79 kg} - (1.4 kg}
46.9 N 37.4 N
2 Poppet spring 31.0 25.5 c4.78 kg) - 6.8 kg1
WA1 200-3
MAINTENANCE STANDARD PUMP CONTROL RELIEF VALVE
PUMP CONTROL RELIEF VALVE
I 52 f 24.5Nm 108 f 14.7Nm 39.2* l.ONm

{15.5*2.5bml 1 2 (1 l.O* 1.5koml (4* Ibml
34.3+4.9Nm
13.5*0.5!Qml
SJW04897
Unit: mm
-
-
Free I Installation I Installation I Free I Installation I

1
length length load length load
Replace
17.6 N 13.7 N
44.5 32.5 f1.79 kg} - il.4 kg}
36.9 N 29.5 N
Poppet spring 31.0 26.7
13.77 kg} - i3.0 kg}
WA1 200-3
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE
152.0*24.5Nm
\
A-A c-c
3
68.7*9.8Nm 304+9.8lNm
(7.0*I.Okaml 131.0*I.Obml
B-B D-D E-E
9JYOO290
40-58 WA1 200-3

MAINTENANCE STANDARD MAIN CONTROL VALVE
Unit: mm
1 Spool return spring

-

- Replace
4 Main valve spring

-
5 Check valve spring

-
6 Float selector valve spring

-
7 Unloader valve spring

-
6 Relief valve poppet spring
WA1 200-3 40-59

MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOOM CYLINDER
2450*250Nm
(250*25kml
SJWO4898
Unit: mm
No. Check item Criteria I Remedy
Clearance between boom cylinder

1
rod and bushing
-
240 -0.050 +0.247 0.084 0.669
-0.122 +0.034 0.369
Replace
Clearance between piston rod -
2 240 -0.050 +0.519 0.471 1.0
mounting pin and bushing -0.122 +0.421 0.641
Clearance between cylinder bottom -0.050 +0.519 0.471 -

3
mounting pin and bushing 240 -0.122 +0.421 0.641 1.0 I
I Standard size Tolerance

I Repair limit
I
1
4 Cylinder bore
+0.2
360 0
40-60 WA1 200-3

BUCKET CYLINDER
2450*250Nm 277* 32Nm

1250*25kml (28.25*3.25kPml
SJW04899
Unit: mm
No. Check item Criteria
I
T Remedy
Clearance
limit
Clearance between bucket cylinder
1
rod and bushing
0.622
- Replace
Clearance between piston rod
2 1.0
mounting oin and bushing
Clearance between cylinder bottom

3 1.0
mounting pin and bushing
-
1
4 Cylinder bore
+0.2
300 n
WA1 200-3 40-61

STEERING CYLINDER
1150*120Nm 176.5* 19.6Nm

~117.5~12.5kem1 ~18*2kml
i I
SJWO4900
Unit: mm
Clearance between steering

cylinder rod and bushing

4 Cylinder bore
+0.20
225 0
40-62 WA1 200-3

MAINTENANCE STANDARD BUCKET POSITIONER AND REMOTE POSITIONER
BUCKET POSITIONER AND REMOTE POSITIONER
2
17.2*2.5Nm
(1.75*0.25kPml
A-A -1
SJWO4901
Unit: mm
1 Clearance of bucket positioner switch 3-5
Clearance of remote positoner

2 3-5 Adjust
switch
Clearance between bucket

3 0.5 - 1
positioner protector and switch
WA1 200-3 40-63

MAINTENANCE STANDARD BUCKET LINKAGE
BUCKET LINKAGE
20
II
20
18
\
I!
SJWO4902
40-64 WA1 200-3

d e
d’
b c
I7
A-A B-0 c-c
n n
d
d e
b b
14
D-D E-E F-F
d
d
b b la C b
13’ a I2
G-G H-H J-J
SJWO4903
WA1 200-3 40-65

Unit: mm
No. 1 Check item Criteria Remedy
, Clearance between bushing and pin at

each end of bucket link
-
180 -0.043 +0.401 0.352 1.0
-0.106 +0.309 0.507
-0.050 -
240 +0.519 0.471 1.0
2 Clearance parts of bushing
connecting between boom andandbucket
pin at -0.122 +0.421 0.641
-0.056 - Replace
280 +0.605 0.549 1.0
3 connecting parts of bushing
Clearance between boom andandframe
pin at -0.137 +0.493 0.742 (Replace
when pin
4 Clearancebetweenbushingand pin at connecting 180 -0.043 +0.401 0.352 -
1.0 has scuff
parts of bucketcylinder rod and bellcrank -0.106 +0.309 0.507
mark, too)
5 Clearancebstwas~ bushing and pin at connecting 180 -0.043 +0.401 0.352 -
-0.106 +0.309 0.507 1.0
parts of bucket cylinder bottom and frame
6 Clearance between bushing and pin at 240 -0.052 +0.519 0.471 -

connecting parts of bellcrank and boom -0.122 +0.421 0.641 1.0
7 I Clearancebetweenbushingand pin at connecting I 240 -0.050 +0.519 0.471 -

parts of boom cylinder bottom and frame -0.122 +0.421 0.641 1.0
Clearance between bushing and pin at connecting -0.050 +0.519 0.471 -

240 1.0
parts of boom cylinder rod and boom -0.122 +0.421 0.641
Length of pin Width of bushing Width of collar Width of color

a b C
Connecting parts of bucket cylinder
and bellcrank
393 20.3 209.5 t 0.1 91.3 f 0.1 91.3 f 0.1
IO
I
Connecting parts of boom and frame 655 2 0.3 304.5 + 0.1 / 174.7+0.1-
II Connecting parts of boom and bucket 594 -c 0.3 349.4 t 0.1 121.8 + 0.1 121.8 f 0.1
I If clearance
ofd+e
I2 Connecting parts of bucket link and becomes
bucket 461 f 0.3 259.5 f 0.1 91.3 + 0.1 109.3 f 0.1
2.5 mm,
replace
I3 Connecting
bucket link parts of bellcrank and 443 f 0.3 259.5 f 0.1 91.3 * 0.1 91.3 f 0.1 bushing
and collar.
I4 Connecting parts of boom cylinder
and frame 580.5 * 0.3 274.4 + 0.1 121.8 + 0.1 183.3 + 0.1
I5 I Connecting
boom
parts of bellcrank and
I
594 * 0.3 349.4 * 0.1 121.8 + 0.1 121.8 * 0.1
I6 Connecting parts of bucket cylinder

and frame 411 * 0.3 209.5 + 0.1 109.3 + 0.1 91.3 + 0.1
,7 Connecting parts of boom and boom

cylinder 479 f 0.3 274.4 + 0.1 101.8 * 0.1 101.8 + 0.1

I8 Wear of bucket tooth
504 340
Ig Wear of wear plate 70 12 Replace

I I I
20 Wear of edge protector 189 40

I I I
21 Wear of side edge protector 83 30
WA1 200-3
90 OTHERS
Transmission hydraulic circuit diagram ................................................... 90- 2

Brake circuit diagram .................................................................................. 90- 4
Work euipment hydraulic circuit diagram (l/2) ....................................... 90- 7
Work euipment hydraulic circuit diagram (2/2) ....................................... 90- 9
Electrical circuit diagram (I/i’) ................................................................... 90-I 1
Electrical circuit diagram (2/i’) ................................................................... 90-13
Electrical circuit diagram (3/i’) ................................................................... 90-15
Electrical circuit diagram (4i7) ................................................................... 90-17
Electrical circuit diagram (5/7) ................................................................... 90-19
WA1 200-3 90-l

OTHERS TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
90-2 WA1200-3
6
OTHERS TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
1. Transmission case
2. Strainer
3. Transmission and torque converter
charging pumps
4. Torque converter charging pump
5. Oil filter
6. Main relief valve
7. Torque converter relief valve
8. Torque converter
9. Torque converter regulator valve
10. Oil cooler
11. Transmission lubricating circuit
12. Transfer lubricating circuit
13. PTO and input transfer lubricating circuits
14. Modulated clutch lubricating circuit
15. Lubricating oil relief valve
16. Brake circuit (see brake circuit diagram)
17. Parking brake pilot lamp switch
18. Parking brake (Builtin transmission)
19. Clutch No. 1 (Reverse) ECMV
20. Clutch No. 1 (Reverse) by-pass fill valve
and by-pass drain valve
21. Clutch No. 1 (Reverse)
22. Clutch No. 2 (Forward) ECMV
23. Clutch No. 2 (Forward) by-pass fill valve
24. Clutch No. 2 (Forward)
25. Clutch No. 3 (3rd speed) ECMV
26. Clutch No. 3 (3rd speed)
27. Clutch No. 4 (2nd speed) ECMV
28. Clutch No. 4 (2nd speed)
29. Clutch No. 5 (1st speed) ECMV
30. Clutch No. 5 (1st speed) by-pass fill valve
31. Clutch No. 5 (1st speed)
32. Pilot oil filter
33. Modulated clutch ECMV
34. Modulated clutch
35. Transmission control valve oil temperature
sensor
a. From parking brake emergency actuation

valve port A
b. To parking brake solenoid valve port P
c. From parking brake solenoid valve port T
WA1200-3 90-3
6
OTHERS BRAKE CIRCUIT DIAGRAM
BRAKE CIRCUIT DIAGRAM
90-4 WA1200-3
6
OTHERS BRAKE CIRCUIT DIAGRAM
1. Torque converter, transmission, brake

cooling and brake pump
1A. Torque converter pump
1B. Transmission pump
1C. Brake cooling pump
1D. Brake pump
2. Strainer
3. Accumulator charge valve
3A. Safety relief valve
3B. Relief valve
3C. Strainer
4. Check valve
5. Low pressure sensor
6. Rear brake accumulator
7. Front brake accumulator
8. Emergency brake switch
9. Brake valve (left)
10. Transmission cut-off switch
11. Brake valve (right)
12. Stop lamp switch
13. Rear slack adjuster
14. Front slack adjuster
15. Parking brake solenoid valve
16. Parking brake switch
17. Parking brake (Built in transmission)
18. Parking brake pilot lamp switch
19. Brake oil tank
20. Parking brake emergency actuation valve
21. Transmission (see transmission hydraulic
circuit diagram)
A. From transmission main circuit
WA1200-3 90-5
6
DataKom Publishing Corporation
440 North Fairway D&e _
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications PROPOSAL FOR MANUAL OR CSS REVISION
Fax No. (847) 970-4186
DATE: FOR INTERNAL USE ONLY - No. PMR
NAME OF COMPANY: CITY:
I DEPARTMENT:
STATE OR PROVINCE::
COUNTRY:
NAME:
4NUAL DESCRIPTION: CSS PROGRAM - e.g: Lookup, Parts or Service
4NUAL OR CSS CD NO: CSS PROGRAM RELEASE VERSION:
4NUAL OR CSS CD ISSUE DATE: CSS BOOK PUBLISHER:
OOK DESCRIPTION
ACHINE MODEL 8 S/N:
ANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE 8 PAGE NUMBERS:
ROBLEM:
rtach photo or sketch.

more space is needed, use another sheet.
FOR INTERNAL USE ONLY

ORRECTIVE ACTION:
PROPFRN.WF’D 071:

SM Wa1200 3

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SEBM018206

WA1200-3 50001 and up

• WA1200-3 mount the Cummins QSK60 engine.

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

The affected pages are indicated by the use of the

‡ Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGE

Time of Time of Time of Time of Time of

‡ 00- 1 6 10-18 10-46 10-74

Time of Time of Time of Time of Time of

10-103 10-144 10-185 10-225 20- 1 2

Time of Time of Time of Time of Time of

20-109 1 20-146 1 20-233 2 20-301 2 20-435 2

Time of Time of Time of Time of Time of

20-519 2 20-620 2 20-721 2 20-825 2 20-865 2

Time of Time of Time of Time of Time of

20-906 2 20-1015 2 30-033 5 30-069 5 30-084 5

Time of Time of Time of Time of Time of

30-114 5 40-12 40-54

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

2. When carrying out any operation, always PREPARATIONS FOR WORK

16. When removing components, be careful not

18. As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Electrical volume: Each issued as one

1. See the page number on the bottom of the

Special safety precautions are

Special technical precautions

Places that require special at-

. If a part cannot be smoothly removed from

A Slinging with one rope may cause

Wire ropes 4) Do not sling a heavy load with ropes form-

20 43.1 4.4 hanging angle. On the other hand, two

-k The allowable load value is estimated to

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

• Used to prevent rubber gaskets, rubber

• Features: Resistance to heat and chemi-

790–129–9060 Adhesive: • Used as adhesive or sealant for metal, glass

• Quick hardening type adhesive

• Quick hardening type adhesive

• Features: Resistance to heat, chemicals

• Used as adhesive or sealant for gaskets

• Used as sealant for various threads, pipe

• Features: Silicon based, quick hardening

Three bond • Used as heat-resisting sealant for repairing

• Used as lubricant for sliding portion (to pre-

SYG2-400LI • General purpose type

• Used for normal temperature, light load

Molybdenum 400 g • Used for places with heavy load

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)

Thread diameter Width