7parte (901 1050pag)

TROUBLESHOOTING H-17
H-17 When rising, the Lift arm comes to move slowly at specific height
Inspection before diagnosis

• Deformation of Lift cylinder in appearance
Cause
• Expansion of Lift cylinder tube or damage inside
★ For other abnormal phenomena during Lift arm rise, see "H-16. The Lift arm moves slowly or the Lift arm rising force is insufficient."
H-18 The Lift cylinder cannot hold down the bucket (The bucket rises in the air)
See "H-16. The Lift arm moves slowly or the Lift arm rising force is insufficient."

• Is the stroke of the Lift arm control lever appropriate?
Cause
• Defective seat of suction valve on the Lift cylinder rod side of work equipment valve
• Oil leak from Lift cylinder piston seal
H-19 Hydraulic drifts of the Lift arm occur often
Ask the operator about the following:

• Have hydraulic drifts come to occur often suddenly? → Wastes pinched in valve or damage of parts
• Have hydraulic drifts come to occur often gradually? → Wear of parts

• Is the Lift arm spool at the neutral position? → The spool detent is defective
Diagnosis and Cause

• Does any leaking noise occur inside the Lift cylinder when hydraulic drift is measured? → The cylinder packing is defective
H-20 The Lift arm wobbles during operation
The bucket and the Lift arm moves up and down as the topography goes in digging or leveling with the Lift arm control lever in the
"HOLD" position.
Diagnosis and Cause

Check at first the hydraulic drift and if the Lift cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see "H-19. Hydraulic drifts of the Lift arm occur often."
2. When the Lift cylinder cannot lift the machine, see "H-18. The Lift cylinder cannot hold down the bucket."
3. When the Lift cylinder comes to enable to lift the machine after the Lift arm is operated several times with the normal hydraulic
drift and after the boom cylinder operates to full stroke → The cause is vacuum generated inside the cylinder
★ Frequent hydraulic drifts → The suction valve on the Lift cylinder rod side is defective
WA380-5 20-821
(10)
H-21 When the control lever is switched from "HOLD" to "RAISE," the Lift arm falls temporarily
Check of Phenomenon
• When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the Lift arm falls temporarily due
to its own weight. When the control lever is completely set to "RAISE," the Lift arm returns to normal.
Cause
• Improper adhesion of Lift arm spool check valve of the work equipment valve
20-822 WA380-5
(8)
H-22 The bucket does not tilt back
Ask the operator about the following: Cause

Work
• Has the bucket come not to work suddenly → Seizure or breakage of each Tank Pump
Steering PPC
Equipment Cylinder
equipment Valve Valve Valve
• Did any abnormal noise occur at the time (And where)?
a b c d e f g h i j
Clogging of pump suction port or mixing of much air in oil

• Was there the phenomenon that the bucket worked slowly?
→ Wear of parts or deformation of spring
The hydraulic pump and the switch pump are defective

• Is the stroke of the bucket control lever appropriate?
Breakage inside valve body (Bucket spool)

Defective operation of main relief valve
Damage of bucket cylinder piston seal

Defective operation of demand spool
The pump PTO does not drive
The relief valve is defective

The PPC pump is defective
The spool is defective

Remedy C ∆ ∆ ∆ ∆ ∆ Α X X
No.
Diagnosis ∆ X X X X X X X
1 The Lift arm cannot operate and the bucket cannot tilt back { { { { { { {
The bucket can lift the machine but cannot tilt back, or the Lift arm
2 operates but the Lift arm cannot tilt back { { {
The bucket can tilt back without load but cannot in digging or scoop-
3 { {
ing up
4 The hydraulic pump causes an abnormal noise { { {
5 Large hydraulic drift of bucket cylinder { {
When the engine is at full throttle, the steering operation is light
6 and too fast {
When the engine is at full throttle, the steering operation is heavy

7 {
and slow
WA380-5 20-823
(8)
H-23 The bucket moves slowly or the tilting-back force is insufficient
Inspection before diagnosis Cause

• Is the stroke of the bucket control lever appropriate? Work
Tank Steering PPC Cutoff
• Seizure of work equipment linkage bushing (Does any abnormal noise Equipment Cylinder
Pump Valve Valve Valve Valve
occur?)
a b c d e f g h i j
Defective operation of safety valve (With suction valve) on bucket cylinder bottom side
Check of Abnormality
• Make sure in an actual operation that the tilting-back force is insufficient.
• Measure the operating speed of the bucket, and make sure referring to
the criterion value table that the speed is abnormal
Defective operation or improper adjustment of main relief valve
Defective operation or improper adjustment of cutoff valve

Clogging of pump suction port or mixing of much air in oil
The hydraulic pump and the switch pump are defective
Wear or breakage inside valve body (Bucket spool)
Damage of bucket cylinder piston seal

Defective operation of demand spool
Defective operation of relief valve
Defective operation of spool
Remedy C ∆ ∆ ∆ ∆ ∆Α ∆ ∆
No.
Diagnosis ∆ X X X X X X X X X
The Lift arm rising force and speed are abnormal, and the bucket
1 tilting force and speed are abnormal { { { { { {
The Lift arm rising force and speed are normal, and the bucket tilt-
2 { { { {
ing force and speed are abnormal
When the oil temperature rises in No. 1, the bucket speed {
3
becomes worse
4 The hydraulic pump is causing an abnormal noise { {
When the engine is at full throttle, the steering operation is light
5 {
and too fast
When the engine is at full throttle, the steering operation is heavy
6 {
and slow
7 Large hydraulic drift of bucket cylinder { { {
The relief oil pressure from the relief valve of the work equipment
8 { { { {
valves is low
9 The relief oil pressure from the relief valve of the work equipment { {
valves is too high
20-824 WA380-5
(8)
H-24 The bucket comes to operate slowly in the midst of tilting-back

• Deformation of bucket cylinder in appearance
Cause
• Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see "H-23. The bucket moves slowly or the tilting-back force is insuffi-
cient."
H-25 The bucket cylinder cannot hold down the bucket
See "H-23. The bucket moves slowly or the tilting-back force is insufficient."

• Is the stroke of the bucket control lever appropriate?
Cause
• Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
• Oil leak from bucket cylinder piston seal
H-26 Hydraulic drifts of the bucket occur often
Ask the operator about the following:

• Have hydraulic drifts come to occur often suddenly? → Wastes pinched in valve or damage of parts
• Have hydraulic drifts come to occur often gradually? → Wear of parts

• Is the bucket spool at the neutral position? → Seizure of link bushing or the spool detent is defective
Check of Abnormality
• Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically
Cause
• Oil leak in bucket cylinder
• Improper adhesion of safety valve (With suction valve) on the bottom side
• Improper oil tight of bucket spool
WA380-5 20-825
(8)
The bucket wobbles during travel with cargo (The work equipment valve is set to
H-27 "HOLD")

• Pin of work equipment linkage and "play of bushing" (Is any abnormal noise heard?)
Cause
• Defective seal of bucket cylinder piston
• Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal phenomena, refer to
diagnoses for relevant abnormal phenomena.
H-28 When the control lever is switched from "HOLD" to "TILT," the bucket falls temporarily
Check of Phenomenon
• When the control lever is switched from "HOLD" to "RAISE" gradually at low idling of the engine, the bucket falls temporarily due
to its own weight. When the control lever is completely set to "TILT," the bucket returns to normal.
Cause
• Improper adhesion of bucket spool check valve of the work equipment valve
20-826 WA380-5
(8)
H-29 The control levers of Lift arm and bucket do not move smoothly and heavy
Check of Abnormality Cause

• Refer to the criterion value table and check if the lever operating efforts PPC Valve Work Equipment Valve
are large practically.
a b c d e f g h i j
Strain of valve body due to uneven tightening of valve mounting bolt
Improper roundness between work equipment valve body and spool

Improper clearance between work equipment valve body and spool
Defective operation of work equipment valve spool detent
Improper roundness between PPC valve body and spool
Improper clearance between PPC valve body and spool
Foreign matter pinched in work equipment valve spool

Foreign matter pinched in PPC valve spool
The work equipment valve spool is bent

The PPC valve spool is bent
Remedy ∆ ∆ C
No.
Diagnosis X X X ∆
When the machine is loaded and the oil pressure rises, the levers
1 come not to move smoothly { { { { {
2 The levers come not to move smoothly as the oil pressure rises { { { { {
The levers partly come not to move smoothly during operation
3 irrespective of oil pressure and oil temperature {
The levers totally come not to move smoothly during operation

4 irrespective of oil pressure and oil temperature { { { { {
WA380-5 20-827
(8)
H-30 E.C.S.S. does not work, and there is pitcing and bouncing
E.C.S.S.: Electronically controlled suspension system

Ask the operator the following questions. Cause
• Did the problem suddenly start? Sole- Accu- Con- Sen-
noid mula- trolle sor
Yes = Related equipment broken valve tor r
• Was there any abnormal noise when this happened?
Where did the noise come from? a b c d
• Did the problem gradually appear?

Yes = Wear of related parts, defective seal
Checks before troubleshooting

• Is operation of E.C.S.S. switch correct?
• Are the DIP switches and rotary switches on the back side of the main moni-
tor set correctly?
(See TESTING AND ADJUSTING, Adjusting machine monitor.)
Where did the noise come from?
• Are failure codes [D191KA] and [D191KB] displayed?
Defective seal, leakage of gas from high-pressure accumulator

(For details, see Troubleshooting for transmission system (TM mode).)
Defective actuation of solenoid valve (SOL1)
Defective actuation of controller
Defective speed sensor
Remedy
No. X X X X
Problems
Speed (3 km/h) for start of actuation of E.C.S.S. is greatly out of adjust-
1 ment Q Q
2 E.C.S.S. does not work when traveling loaded Q Q

3 E.C.S.S. does not work when traveling unloaded Q Q
When E.C.S.S. is actuated when traveling loaded, boom drops greatly
4 Q
(more than 30 cm)
5 E.C.S.S. does not work at all Q Q Q Q
20-828 WA380-5
(10)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
Connector types and mounting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-903

Connector layout drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-912
Electrical system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-918
Troubleshooting Code [E-1-a] (The engine does not start. (Starting system)). . . . . . . . . . . . . . . . . 20-920
Troubleshooting Code [E-1-b] (The engine does not start. (Engine stop solenoid system)) . . . . . 20-924
Troubleshooting Code [E-2] (The engine does not stop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-926
Troubleshooting Code [E-3] (Preheating is impossible or constant) . . . . . . . . . . . . . . . . . . . . . . . 20-928
Troubleshooting Code [E-4] (The engine power modes cannot be selected) . . . . . . . . . . . . . . . . 20-930
Troubleshooting Code [E-5] (The front wiper does not function) . . . . . . . . . . . . . . . . . . . . . . . . . 20-932
Troubleshooting Code [E-6] (The rear wiper does not function) . . . . . . . . . . . . . . . . . . . . . . . . . . 20-935
Troubleshooting Code [E-7] (The side wiper does not function (If equipped)). . . . . . . . . . . . . . . 20-936
Troubleshooting Code [E-8] (The wind washer does not function) . . . . . . . . . . . . . . . . . . . . . . . . 20-937
Troubleshooting Code [E-9] (The headlamp (Lo beam) does not light on). . . . . . . . . . . . . . . . . . 20-940
Troubleshooting Code [E-10] (The headlamp (Hi beam) does not function) . . . . . . . . . . . . . . . . . 20-943
Troubleshooting Code [E-11] (The clearance lamp does not light on (Small lamp)) . . . . . . . . . . . 20-945
Troubleshooting Code [E-12] (The turn signal does not blink). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-946
Troubleshooting Code [E-13] (The horn does not sound) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-948
Troubleshooting Code [E-14] (The air conditioner does not work or does not stop). . . . . . . . . . . 20-950
WA380-5 20-901
5
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

★ The address column of the table indicates each address of a connector placement diagram (diagram in
three dimensions) and an electrical circuit system diagram.
★ Symbols of the circuit diagram address column of the table:
TM: Transmission control system,WRK: Work equipment control system, MON: Monitoring system, E:
Electrical system.
★ The item enclosed by parentheses in the connector type column indicates the color of the connector
body. (B: Black, Br: Brown, G: Green, Gr: Gray, L: Blue, W: White.
Address
Number System
Connector Connector
No. Type
of Installation Name
Pins Layout Drawing
Drawing
TM WRK MON E
1.PS DT-T 2 Transmission 1st clutch solenoid AJ-4 M-8

1.SW DT 2 Transmission 1st clutch fill switch AJ-4 O-8
2.PS DT-T 2 Transmission 2nd clutch solenoid AJ-3 M-8
2.SW DT 2 Transmission 2nd clutch fill switch AJ-3 O-8
3.PS DT-T 2 Transmission 3rd clutch solenoid AJ-4 M-8
3.SW DT 2 Transmission 3rd clutch fill switch AJ-4 O-8
4.PS DT-T 2 Transmission 4th clutch solenoid AJ-5 M-8
4.SW DT 2 Transmission 4th clutch fill switch AJ-5 O-8
A1 M 6 Air conditioner blower motor and resistor U-2
A2 SWP 6 Air conditioner air mixing servomotor U-2
A3 M 2 Air conditioner thermistor U-2
A4 X 2 Air conditioner air servomotor U-8
A5 X 2 Air conditioner condenser switch T-1
A6 Yazaki 2 Air conditioner Hi-Lo switch T-1
A7 Yazaki 4 Air conditioner blower relay (Main) W-6
A8 Yazaki 4 Air conditioner blower relay (Hi) W-6
A9 Yazaki 4 Air conditioner blower relay (M2) W-6
A10 Yazaki 4 Air conditioner blower relay (M1) W-5
A11 Yazaki 4 Air conditioner condenser relay W-5
A12 Yazaki 4 Air conditioner condenser Hi (1) relay W-5
A13 Yazaki 4 Air conditioner condenser Hi (2) relay W-4
A14 Yazaki 4 Air conditioner MAG clutch relay W-4
A20 Terminal 1 Ground (Floor) T-2
A21 Yazaki 2 Water temperature sensor (Vehicle with automatic air W-3
conditioner)
Inside temperature sensor (Vehicle with automatic air
A22 Yazaki 2 conditioner) U-2
Outside temperature sensor (Vehicle with automatic air

A23 Yazaki 2 W-4
conditioner)
A24 DT-T 2 Diode (Vehicle with automatic air conditioner) W-3
A25 DT-T 2 Diode (Vehicle with automatic air conditioner) V-3
Intermediate connector (Vehicle with automatic air
A26 DT-T 2 conditioner)
W-3
AL1 M 6 Intermediate connector (Air conditioner relay) U-2

AL2 S (W) 12 Intermediate connector (Air conditioner relay) V-3
B01 DT-T 3 Air conditioner condenser motor A-7
B02 DT-T 3 Air conditioner condenser motor B-7
BR1 DT-T 2 Intermediate connector (Air conditioner condenser motor) J-2 W-6
WA380-5 20-903
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
C01 Yazaki 2 AM/FM radio C-9

C02 KES0 2 Speaker (Right) E-9
C03 KES0 2 Speaker (Left) G-9
C04 M 2 Front working lamp (Right) B-8 E-8
C05 M 2 Front working lamp (Left) B-8 E-8
C07 KES1 2 Room lamp C-8
C08 M 1 Door switch (Right) (Room Lamp) C-8
C09 M 1 Door switch (Left) (Room lamp) B-8
C10 — 2 Cigarette lighter A-7
C12 M 6 Front wiper motor A-7
C15 M 4 Rear wiper motor F-9
Kyoritsu
C17 4 Warning lamp switch D-9
ES
C18 Plug 1 Warning lamp (Beacon) C-8
C19 DT-T 6 Glass heater switch D-9
C29 M 1 Glass heater ON E-9
C33 H 1 Rear glass heater E-9
C35 H 1 Rear glass heater G-9
C38 M 1 Connector (Electric power take-off)
C39 Terminal 1 Ground (Radio) C-9 E-7
C40 Terminal 1 Ground (Cab) C-8
C41 M 1 Warning lamp F-9
C43 Yazaki 6 Side wiper switch E-9
C44 M 4 Right side wiper motor A-7
C45 M 4 Left side wiper motor A-7
C46 M 1 Intermediate connector (Power source) D-9
C47 Terminal 1 Ground (Cab) F-9
C47 AMP1720 16 A/C control AMP P-1

21-2
C47 AMP040 20 A/C control AMP (Vehicle with automatic air conditioner) D-9
AMP1722
C48 45-2 12 A/C control AMP P-1
C48 AMP040 16 A/C control AMP (Vehicle with automatic air conditioner) D-9
C49 SWP 8 Left Servomotor R-1
C50 SWP 8 Right Servomotor M-3
C51 Yazaki 2 Diode (Vehicle with automatic air conditioner) M-3
CAN1 DT-T 3 Resistor N-1 F-1 J-8 B-2
CAN2 DT-T 3 Resistor R-9 J-9 K-8 B-2
CL1 S 8 Intermediate connector A-4 E-7
CL2 S (L) 12 Intermediate connector (Wiper motor) A-4
Intermediate connector (Vehicle with automatic air
CL5 S (W) 16 M-2
conditioner)
CL6 M 6 Intermediate connector (Vehicle with automatic air M-3 B-3 C-5
conditioner)
CL6 DT-T (G) 12 Intermediate connector (Monitor panel controller) W-4 K-4 C-4
CL7 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-2 B-4 K-4 C-5
CL8 DT-T (Gr) 12 Intermediate connector (Monitor panel controller) N-1 B-4 C-5
CL9 DT-T (Gr) 8 Intermediate connector (Monitor panel controller) O-1 B-4 K-4 C-6 B-5
20-904 WA380-5
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
CL10 DT-T (Gr) 8 Intermediate connector (Monitor panel controller) O-1 B-3 K-3 C-3
CL20 DT-T 2 Intermediate connector (Monitor panel controller) N-2 C-5
CN55 DT-T 2 Intermediate connector (Backup buzzer) K-8 P-2 V-8
COMBI M 3 Front combination lamp (Right) A-6 W-3
COMBI M 3 Front combination lamp (Left) E-1 W-2
DIODE DT-T 2 Diode (Parking brake solenoid) AG-8 P-8
DL DT-T (Gr) 12 Connector (S-NET) U-8 I-9 K-6 K-5
E01 DT-T 2 Intermediate connector (Starting motor) AB-1 W-4 B-1
E02 Terminal 1 Alternator R AD-3 X-5
E03 Terminal 1 Alternator B AD-3 X-5
E04 Terminal 1 Alternator E AD-3 X-5
E05 Terminal 1 Engine heater relay AC-9 Q-9 E-4
E06 Terminal 1 Engine heater relay AA-9 Q-9 F-4
E07 Terminal 1 Engine heater relay Z-9 Q-9 F-4
E08 DT-T 2 Engine coolant temperature sensor (Monitor) AC-1 O-8
E09 DT-T 2 Engine coolant temperature sensor (Preheater) AD-2 O-8 B-2
E10 DT-T 2 Air conditioner compressor magnet clutch AD-2
E11 DT-T 2 Diode (Air conditioner compressor) AD-4
E14 Terminal 1 Ground (Rear frame) AB-5 X-5 A-1
E26 DT-T 2 Engine oil level sensor AA-5 P-8
E27 DT-T 2 Engine speed sensor AC-6 L-8
E28 DT 2 Diode (Engine heater relay) AC-9 O-8 B-2
E29 Terminal 1 Engine oil pressure switch AB-5 P-8
E30 Terminal 1 Starting motor B AB-1 X-4
E31 DT-T 2 Diode AC-7 B-3
E32 DT-T 2 Diode (Fuel cut solenoid) AB-6 B-3
E33 DT-T 2 Dust indicator AB-9 P-8
E34 DT-T 3 Fuel cut solenoid AC-7 B-2
E36 Terminal 1 Air compressor magetic clutch Y-5
ER-1 DT-T (G) 8 Intermediate connector (Engine) Z-2 P-5 D-3
ER-3 DT-T (Gr) 8 Intermediate connector (Engine) AA-1 K-7 O-5 D-3
F01 M 6 Intermediate connector (R.H. Front lamp) A-5 U-3
F02 M 6 Intermediate connector (L.H. Front lamp) D-1 U-2
F03 Terminal 1 Horn (303 Hz) A-1 W-1
F04 Terminal 1 Horn (303 Hz) A-1 W-1
F05 Terminal 1 Horn (303 Hz) C-1 W-1
F06 Terminal 1 Horn (303 Hz) B-1 W-1
F07 DT-T 2 Switching pump cut-off solenoid C-1 R-8
F09 DT-T 3 Bucket positioner proximity switch A-3 Q-7 B-3
F10 DT-T 3 Bucket positioner proximity switch (Standard) A-3 Q-6 B-3
F13 DT-T 2 Lift arm damper solenoid C-1 R-8
F14 DT-T 2 Diode (Damper solenoid) D-1 R-7
F15 DT-T 3 Lift arm angle signal (For load meter) A-2 B-3 M-8
F16 DT-T 3 Lift arm bottom signal (For load meter) B-1 B-3 M-8
F17 DT-T 3 Lift arm rod signal (For load meter) B-1 B-3 M-8
WA380-5 20-905
(10)
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
F18 DT-T 3 Lift arm angle sensor (For boom EPC) A-5 H-8
F19 DT-T 3 Bucket positioner proximity switch (For bucket EPC) A-3 H-8
F20 DT-T 2 Lift arm RAISE EPC A-2 Q-4 G-8
F21 DT-T 2 Lift arm LOWER EPC A-1 G-8
F22 DT-T 2 Bucket CURL EPC A-1 G-8
F23 DT-T 2 Bucket DUMP EPC A-1 G-8
F24 DT-T 2 ATT. EXT. EPC (If equipped) A-3 I-8
F25 DT-T 2 ATT. RET. EPC (If equipped) A-2 I-8
F26 DT-T 2 Lift arm EPC cut-off solenoid B-1 H-8
F27 DT-T 2 Diode (For boom EPC cut-off solenoid) A-4 H-7
F30 Terminal 1 Ground (Front frame) C-1 Q-4 P-5 U-1 A-3
FF1 S 10 Intermediate connector (Front lamp) E-1 N-3
FF2 DT-T (Gr) 8 Intermediate connector (Work equipment sensor) D-1 K-4 N-6 C-3
FL1 S 12 Intermediate connector (Front lamp) W-1 J-3 K-3
FL2 DT-T (Gr) 8 Intermediate connector (Work equipment sensor) W-1 I-4 K-6 C-5
FL3 DT-T 6 Intermediate connector (Load meter) X-2 E-3 K-6
FL7 DT-T (Br) 12 Intermediate connector (Work equipment solenoid) N-2 E-7
FL8 DT-T (G) 8 Intermediate connector (Work equipment solenoid) N-2 E-6
FL9 DT-T 6 Intermediate connector (3rd lever solenoid) N-2 E-5
FS1 L 2 Intermediate connector (Fuse box) W-7 C-1 E-8
FS2 L 2 Intermediate connector (Fuse box) V-7 C-1 E-8
FS3 S (W) 16 Intermediate connector (Fuse box) V-8 C-1 K-7 G-8 E-8
FS4 S (W) 12 Intermediate connector (Fuse box) V-8 B-1 K-7 G-8 E-8
FS5 M 6 Intermediate connector (Fuse box) V-7 G-8
FS6 Plug 1 Intermediate connector (Fuse box) V-8
FS7 Plug 1 Intermediate connector (Fuse box) W-7
F.PS DT-T 2 Transmission F clutch solenoid AJ-6 N-8
F.SW DT 2 Transmission F clutch fill switch AJ-6 P-8
G01 Terminal 1 Backup buzzer J-9 Q-2 V-9
G02 Terminal 1 Backup buzzer J-9 Q-2 V-9
G04 M 2 Rear working lamp (Left) K-8 V-8
G05 M 2 Rear working lamp (Right) J-9 U-8
GR1 DT-T 4 Intermediate connector (Fan reverse solenoid, rear working L-7 O-4 U-6
lamp)
GR2 DT-T 2 Fan reverse solenoid L-7 Q-4
HEAD M 3 Head lamp (Right) A-6 W-3
HEAD M 3 Head lamp (Left) W-2
JT1 DT-T (B) 8 Centralized connector (Ground) AH-2 R-7 Q-7
JT2 DT-T (B) 8 Centralized connector (Shield) AG-2 R-6
JT3 DT-T 6 Centralized connector AF-8 R-5
L01 SWP 6 Parking brake switch M-5 B-7
L02 SWP 6 Dimmer switch, light switch M-5 B-1
L03 SWP 6 Turn signal and hazard switch M-6 B-1
L04 SWP 14 Shift switch M-3 B-6 A-8
L05 DT-T 2 Horn switch M-5 E-8
L07 DT-T 6 Machine monitor switch (Mode/Cancel selector switch) Q-1 B-8
20-906 WA380-5
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
L08 DT-T 6 Machine monitor switch (Screen selector switch) Q-1 A-8
L09 DT-T 2 Stop lamp switch Q-1 D-8
L10 DT-T 3 Left brake pressure sensor R-1 B-6
L11 DT-T 2 Air suspension seat S-1
L12 DT-T 4 R direction switch O-7 J-7 E-3
L13 DT-T 2 Lift arm N lock switch O-7 D-8
L14 DT-T 4 Kickdown and hold switch O-7 B-8 G-2
L15 DT-T 4 Load meter cancel and sub-total switch O-7 H-2 D-8
L16 M 2 Intermediate connector (DC converter) V-2
L17 M 4 DC24V/DC12V converter W-5
L18 Yazaki 2 DC12V socket W-3
L19 M 4 Flasher unit U-8 H-8
L20 M 2 Alarm buzzer U-8 I-7
L21 S 10 Front and rear wiper switch N-1
L25E DT-T 2 Lift arm and bucket EPC lever M-6 E-8
L25S DT-T 2 Work equipment lever electrical detent N-7 G-2 C-8
L26E DT-T 2 Lift arm and bucket EPC lever P-8 E-8
L26S DT-T 2 Work equipment lever electrical detent N-6 G-2 B-8
L27 DT-T 2 Lift arm and bucket EPC lever N-6 D-8
L27S DT-T 2 Work equipment lever electrical detent N-7 G-2 B-8
L28 DT-T 4 Lift arm and bucket EPC lever P-8 D-8
L29 DT-T 4 Lift arm and bucket EPC lever O-7 E-8
L30 DT-T 4 3rd EPC lever P-8 D-8
L31 M 6 Intermittent wiper timer W-7
L34 DT-T 4 Joystick lever positioner W-6 B-1
L35 DT-T 2 Joystick EPC solenoid P-1 E-1
L36 DT-T 2 Joystick EPC solenoid P-1 D-1
L37 DTM 12 Joystick lever switch M-6 K-8
L38 DT-T 3 Joystick N lock switch W-7 K-1 B-2
L39 DT-T 6 Joystick ON/OFF switch S-1 K-2 B-2
L40 DT-T 6 Steering speed mode switch S-1 K-1 B-1
L41 Relay 6 Joystick cutoff relay N-6 D-1
L42 Plug 1 Connector (Spare power supply) A-5
L43 Plug 1 Connector (Spare power supply) A-5
L44 M 6 Intermediate connector (Printer) V-3 I-7
L45 D-sub 25 Printer (Load meter) I-8
L46 G 4 Printer (Load meter) H-9
L51 AMP070 20 Monitor panel controller M-5 A-2 O-2 B-7 B-4
L52 AMP070 18 Monitor panel controller M-4 B-6
L53 AMP070 12 Monitor panel controller M-2 A-2 B-5
L54 AMP070 18 Monitor panel controller M-4 A-2 O-2 B-4
L55 AMP070 12 Monitor panel controller M-4 A-2 O-2 B-4 B-4
L56 AMP070 12 Monitor panel controller M-5 B-2 O-2 B-3
L57 AMP070 14 Monitor panel controller M-4 B-2
L58 AMP040 8 Monitor panel controller M-2
WA380-5 20-907
(10)
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
L61 DRC 24 Transmission and fan pump motor controller P-8 B-8 I-8 F-8 A-8
L62 DRC 40 Transmission and fan pump motor controller Q-8 C-8 J-8 F-8
L63 DRC 40 Transmission and fan pump motor controller Q-8 E-8 F-8 A-8
L71 DRC 24 Lift arm bucket and joystick controller Q-9 A-8
L72 DRC 40 Lift arm bucket and joystick controller Q-9 K-8 A-8 N-8
L73 DRC 40 Lift arm bucket and joystick controller R-9 K-8 B-8
L88 DT-T (Gr) 8 Engine mode selector motor P-1 B-8
L91 DT-T 6 Timer P-8 A-6
L92 DT-T 3 Intermediate connector (Pump bypass) Q-8 B-2
L93 Relay 5 Pump bypass relay Q-9 B-1
L100 Terminal 1 Ground (Floor) R-1 I-1 J-1 B-5
L101 S (W) 16 Intermediate connector (Relay sub-unit) T-9 D-2 I-7 E-7
L102 S (L) 16 Intermediate connector (Relay sub-unit) T-9 D-2 J-7 E-7
L103 S (W) 16 Intermediate connector (Relay sub-unit) S-9 E-2 J-7
L104 S (W) 16 Intermediate connector (Relay sub-unit) T-9 E-2 L-7 E-6
L105 S (W) 12 Intermediate connector (Relay sub-unit) T-9 F-2
L106 S (W) 16 Intermediate connector (Relay sub-unit) T-9 E-2 K-7
L111 — 5 Turn signal lamp and hazard relay X-7 I-9
L112 — 5 Air cleaner clogging relay W-7 I-9
L113 — 5 Steering selector relay W-8 D-1 J-9 F-7
L114 — 5 Automatic preheater relay V-8 J-9 F-7
L115 — 5 Engine controller power supply relay V-9 F-7
L116 — 4 Neutral safety relay W-7 D-1 J-9 F-6
L117 — 4 Backup lamp relay W-7 E-1 J-9
L118 — 4 Stop lamp relay V-8 K-9
L119 — 4 Horn relay V-8 K-9
L120 — 4 Parking brake relay V-8 E-1
L123 — 5 Lift arm detent relay (Standard) X-9 L-9 F-6
L124 — 5 Bucket detent relay (Standard) X-9 L-9 F-6
L125 — 5 Lift arm damper relay V-9 E-1
L126 — 4 Emergency steering relay X-8 F-1
L127 — 4 Front working lamp relay X-7 K-9
L128 — 4 Rear working lamp relay X-9 K-9
L129 — 4 Rear glass heater relay V-9
L130 — 4 Transmission pump cut-off relay V-9 F-1
L141 Relay 5 Printer relay T-1
L142 DT-T 2 Diode (Printer) W-3
L146 DT-T 2 Diode (Printer) T-1
L147 DT-T 2 Diode (Printer) T-1
LC.PS DT-T 2 Torque converter lockup solenoid (If equipped) AJ-5 N-8
LC.SW DT 2 Torque converter lockup fill switch (If equipped) AJ-5 P-8
LL5 DT 3 Intermediate connector (Vehicle with joystick) Q-1 F-5
LL6 DT-T (Gr) 12 Intermediate connector (Vehicle with joystick) Q-1 E-4
20-908 WA380-5
(10)
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
LL7 DT-T (G) 12 Intermediate connector (Vehicle with joystick) Q-1 J-7 E-4 K-5
LL8 DT-T (Gr) 8 Intermediate connector (Joystick switch) R-1 K-2 C-2
LR1 DTHD#12 1 Intermediate connector (Slow-blow fuse) X-2 J-2 D-5
LR2 DT-T (G) 12 Intermediate connector (Engine) V-2 J-7 K-4 D-5
LR4 L 2 Intermediate connector (Slow-blow fuse) X-1 J-2 E-5
LR5 DT-T 6 Intermediate connector (Auto grease controller) X-2 K-1
LR6 L 2 Intermediate connector (Ground) X-2 J-2 K-1
LR8 DTHD#8 1 Intermediate connector (Ground) X-2 J-2 L-5 K-2 D-5
LR9 DT-T (G) 12 Intermediate connector (Steering and brake oil pressure X-1 I-3 K-2
switch)
LR10 DT-T (Gr) 12 Intermediate connector X-1 I-3 K-3 D-5
LR13 DT-T 2 Intermediate Connecter ( Pump bypass) AE-7 J-1
W-3,
LT1 HD-24 31 Intermediate connector (Transmission) AF-2 I-6 K-4
PB.PS DT-T 2 Parking brake solenoid AJ-3 P-8

PB.SW DT-T 2 Parking brake indicate switch AJ-3 Q-8 P-8
R.PS DT-T 2 Transmission R clutch solenoid AJ-6 N-8
R.SW DT 2 Transmission R clutch fill switch AJ-5 O-8
R01 Terminal 1 Battery relay J-2 O-1 X-6 F-2
R02 Terminal 1 Slow-blow fuse L-2 P-1 F-4
R03 Terminal 1 Slow-blow fuse L-2 P-1 F-4
R04 Terminal 1 Battery relay L-1 O-1 X-6 F-2
R05 Terminal 1 Slow-blow fuse K-3 P-1 X-7 F-3
R06 Terminal 1 Slow-blow fuse K-3 P-1 F-3
R09 Terminal 1 Slow-blow fuse K-2 F-3
R11 Terminal 1 Slow-blow fuse K-3 X-7 F-3
R13 L-1 O-1 X-6 F-2
R14 Terminal 1 Battery relay L-1 O-1 X-6 F-2
R15 Terminal 1 Emergency steering relay J-1 O-1
R16 Terminal 1 Emergency steering relay J-1 N-1
R22 Terminal 1 Battery G-9 M-2 T-9 F-2
R24 DT-T 2 Diode (Battery relay) I-1 P-1 F-6
R25 DT-T 2 Diode (Battery relay) I-2 J-1 P-1 F-5
R26 DT-T 2 Diode (Starting motor) I-1 P-1 F-5
R27 DT-T 2 Diode (Starting motor) J-2 P-1 F-5
R29 DT-T 2 Fan pump EPC A-6 Q-3
R30 M 6 Rear combination lamp (Left) L-5 S-8
R31 M 6 Rear combination lamp (Right) H-9 S-8
R32 DT-T 2 Coolant level sensor B-8 X-8
R33 DT-T 2 Fuel level gauge sensor K-3 U-8
R34 M 2 License lamp L-6
R36 DT-T 3 Steering pump pressure switch E-1 Q-3 V-8
R37 DT-T 3 Emergency steering pressure switch D-1 Q-2 W-8
R38 DT-T 6 Auto grease controller N-1
WA380-5 20-909
5
Address
Number System
Connector Connector
No. Type
Pins Layout Drawing
Drawing
TM WRK MON E
R39 DT-T 2 Battery level sensor L-5 T-7

R43 KES1 2 Front windshield washer G-1
R44 DT-T 2 Diode (Washer) G-1
R45 KES1 2 Rear windshield washer H-1
R46 DT-T 2 Diode (Washer) G-1
R47 DT-T 2 Hydraulic oil temperature sensor A-6 W-1
R50 Terminal 1 Ground (Rear frame) I-9 M-1 T-1 D-1
R51 DT-T 2 Emergency brake switch 1 F-1 J-1
R52 DT-T 2 Emergency brake switch 2 F-1 J-1
R53 DT-T 2 Front brake accumulator low pressure switch F-1 J-1 W-8
R54 DT-T 2 Rear brake accumulator low pressure switch F-1 J-2 W-8
R55 DT-T 2 Intermediate connector (Rear brake oil temperature) J-2 P-3
R56 DT-T 2 Rear brake oil temperature sensor H-1 Q-3
R63 Terminal 1 Slow-blow fuse L-2
R64 Terminal 1 Ground (Rear frame) L-5
R65 DT-T 6 Cooler automatic tilt motor switch (If equipped). L-4
R66 DT-T 2 Cooler automatic tilt motor H-9
R68 Terminal 1 Fuel solenoid relay I-9 F-1
R69 Terminal 1 Fuel solenoid relay I-9 F-1
R72 DT-T 2 Fuel solenoid relay K-9 F-1
REV OUT DT-T 2 Speed sensor AG-2 N-8
S01 DT-T 6 Front working lamp switch O-1 C-8
S02 DT-T 6 Rear working lamp switch O-1 C-8
S03 DT-T 6 Transmission cut-off ON/OFF switch M-4 B-5
S04 DT-T 6 Right FNR selector switch N-9 H-8 K-2 C-8
S05 DT-T 6 Transmission cut-off set switch M-9 H-8
S06 DT-T 6 Torque converter lockup ON/OFF switch O-8 I-8
S07 DT-T 6 Lift arm damper ON/OFF switch O-1 B-5
S12 DT-T 6 Remote positioner set switch (Vehicle with joystick) N-7 I-2
S13 DT-T 6 Upper remote positioner ON/OFF switch (Vehicle with joy- N-9 I-2
stick)
Lower remote positioner ON/OFF switch (Vehicle with joy-
S14 DT-T 6 N-8 I-2
stick)
S15 DT-T 6 Automatic digging switch (Vehicle with joystick) N-9 J-2
S16 DT-T 6 Hydraulic fan reverse switch M-9 G-2
S17 DT-T 6 Auto grease switch O-8 A-8
S19 DT-T 6 Emergency steering check switch M-9 H-2 C-8
S21 DT-T 4 Engine power mode switch M-9 G-8 C-8
S22 DT-T 4 Auto shift mode switch N-7 G-8
S31 DT 4 Starting switch N-7 G-2 K-2 L-7 D-8
S32 DT-T 2 Starting switch N-9 D-8
T20 Terminal 1 Ground AI-2 Q-4
T21 DT-T 2 Pump bypass solenoid AG-8 K-1
TC.T DT-T 2 Torque converter oil temperature sensor AH-8 Q-8 Q-8
TEL DT-T (Gr) 12 Intermediate connector (KOMTRAX) Q-1 I-9 K-1 C-5
TM.T DT-T 2 Transmission oil temperature sensor AJ-3 Q-8 Q-8
20-910 WA380-5
(10)
5
TROUBLESHOOTING CONNECTOR LAYOUT DRAWING
CONNECTOR LAYOUT DRAWING
20-912 WA380-5
WA380-5 20-913
5
20-914 WA380-5
5
WA380-5 20-915
5
20-916 WA380-5
5
WA380-5 20-917
5
TROUBLESHOOTING ELECTRICAL SYSTEM DIAGRAM
ELECTRICAL SYSTEM DIAGRAM
20-918 WA380-5
TROUBLESHOOTING TROUBLESHOOTING CODE:
TROUBLESHOOTING CODE: [E-1-A]
[E-1-a]
TROUBLESHOOTING CODE: [E-1-a]

]
Troubleshooting Code Failure Code Controller Code The engine does not start. (Start-
Trouble ing system)
E-1-a) — —
Description of Trouble The starting motor system is defective, and the engine does not start.
Controller Reaction —
Effect on Machine The starting motor system is defective, and the engine does not start.
Related Information Check that the fuses A-2 and B-2 are not blown. (If they are blown, check if the related harness is short-cir-
cuited with the ground.).
Causes Standard Value in Normal State and Remarks on Troubleshooting

Specific 1.26 and
gravity above
1 Defective battery 25 V and
Voltage above
1) Starting switch ON.

Among battery relay terminals R13, R01,
R04 and machine body. Voltage 20 - 30 V
1) Starting switch OFF.

2) Disconnect the connector S31 and the terminal R13.
3) Insert a T-adapter.
Harness among S31 (female) 2, battery
relay and the terminal R13.
2 Disconnection between battery ★ Measure continuity from S31 (female) Continuity Yes
relay body and related harness
2 in the diode range.
1) Starting switch ON.
Between battery (+) terminal and (-) termi- Voltage 20 - 30 V
nal.
1) Starting switch OFF. 2) Disconnect the (-) terminal of the battery relay.
Harness between battery relay (-) terminal Resistance 1 Ω and
and machine body. below
1) Starting switch OFF. 2) Disconnect the connector E01.
3) Insert a T-adapter. 4) Starting switch "Start."
Possible Causes and Between E01 1 and machine body. Voltage 20 - 30 V
Disconnection between n start-
Standard Values 3 ing motor and related harness 1) Starting switch ON.
Between starting motor B terminal and Voltage 20 - 30 V
machine body
3) Insert a T-adapter. 4) Starting switch ON.
4 Defective alternator (regulator)
1 V and
Between E01 2 and machine body Voltage below
Among S31 1, 2, 3 and machine body
(Starting switch "Start" between 3 and Voltage 20 - 30 V
machine body)
1) Starting switch OFF.
2) Disconnect the starting switch terminals B, BR and C.
1 Ω and
Between starting switch terminal B and BR Resistance below
Disconnection between starting
5 switch and related harness
Between starting switch terminal B and C Resistance 1 Ω and
below
1) Stating switch OFF. 2) Disconnect the connectors S31, FS3 and
L116.
3) Connect a T-adapter.
Harness between S31 (female) 1 and FS3 1 Ω and
Resistance
(female) 1 below
Harness between S31 (female) 1 and L116 1 Ω and
(female) 3 Resistance below
20-920 WA380-5
(10)
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-1-a]
Troubleshooting Code Failure Code Controller Code The engine does not start.
Trouble
E-1-a) — — (Starting system)

1) Stating switch OFF. 2) Disconnect the connector TEL.
Harness between TEL (female) 7 and 1 Ω and
Disconnection between Resistance
TEL (female) 8 below
6 short connector (TEL) and
related harness 1) Stating switch OFF. 2) Disconnect the connectors TEL and L116.
Harness between TEL (male) 8 and L116 Resistance 1 Ω and
(female) 3 below
1) Stating switch OFF. 2) Disconnect the connectors L79 and L116.
3) Connect a T-adapter. 4) Shifter switch "Neutral."
5) Starting switch "Start."
Between L113 4 and machine body. Voltage 20 - 30 V
Between L113 3 and machine body. Voltage 20 - 30 V
1 V and
Between L113 1 and machine body. Voltage
below
1) Stating switch OFF. 2) Disconnect the relays L113 and L116.
Disconnection between relay Harness between L113 (female) 3 and Resistance 1 Ω and
7 L116 (female) 1. below
(L113) and related harness
Between the relays L113 (male) 1 and
Resistance 200 - 400 Ω
2.
1) Stating switch OFF. 2) Disconnect the connector L04.
Harness between L113 (female) 4 and Resistance 1 Ω and
L04 (female) 1. below
Possible Causes and Stan- 1) Stating switch OFF. 2) Disconnect the connectors L101 and L102.
dard Values 3) Connect a T-adapter.
Harness between L101 (female) B and 1 Ω and
L102 (female) B. Resistance below
1) Stating switch OFF. 2) Disconnect the connectors L102 and E01.
Harness between L102 (female) D and
E01 (female) 1.
★ Measure the continuity from L102 D Continuity Yes
8 Disconnection between relay
(L116) and related harness side in the diode range.
1) Stating switch OFF. 2) Disconnect the relay L116. 3) Connect a T-
adapter.
Between the relays L116 (male) 1 and Resistance 200 - 400 Ω
2.
1) Stating switch OFF. 2) Disconnect the connector L04.
3) Connect a T-adapter. 4) Starting switch "ON."
Among L04 1, 3 and machine body. Voltage 20 - 30 V
9 Disconnection between shift 1) Stating switch OFF. 2) Disconnect the connectors L04 and FS4.
switch and related harness
Harness between L04 (female) 1 and 1 Ω and
FS4 (female) 2. Resistance below
1) Stating switch OFF. 2) Disconnect the connector R26.
Between R26 (male) 2 and 1.
Disconnection among ★ Measure the continuity from the 2
10 diodes R26, R27 and related Continuity Yes
harness side in the diode range.
★ Measure the continuity from the 1
side in the diode range. Continuity No
★ The diode R26 can be replaced.
WA380-5 20-921
(10)
Trouble (Starting system)
E-1-a) — —
1) Stating switch OFF. 2) Disconnect the connector R27.
Between R27 (male) 2 and 1.
side in the diode range. Continuity Yes
Continuity No
side in the diode range.
★ The diode R27 can be replaced.
1) Stating switch OFF. 2) Disconnect the connectors L102, R26 and
Disconnection among R27.
10 diodes R26, R27 and related 3) Connect a T-adapter.
harness
Harness between L102 (female) D and Resistance 1 Ω and
R26 (female) 2. below
Harness between L102 (female) D and 1 Ω and
Resistance
1) Stating switch OFF. 2) Disconnect the connectors E01, R26 and R27.
Harness between E01 (female) 1 and Resistance 1 Ω and
Harness between E01 (female) 1 and 1 Ω and
Resistance
1) Stating switch OFF. 2) Disconnect the connectors FS2 and FS4.
3) Connect a T-adapter. 4) Starting switch ON.
Between FS3 1 and machine body. Voltage 20 - 30 V
Possible Causes and Stan- Among FS1 1, 2 and machine body. Voltage 20 - 30 V
dard Values 1) Stating switch OFF. 2) Disconnect the connectors LR1 and LR4.
3) Connect a T-adapter. 4) Starting switch ON.
Between LR1 1 and machine body. Voltage 20 - 30 V
Among LR4 1, 2 and machine body. Voltage 20 - 30 V
1) Stating switch OFF. 2) Disconnect the connectors FS1, FS2, LR1 and LR4.
Harness between FS1 (female) 1 and 1 Ω and
LR1 (male) 1. Resistance below
Disconnection between fuse
11
and related harness Harness between FS1 (female) 2 and Resistance 1 Ω and
LR4 (male) 1. below
Harness between LR4 (male) 2 and FS2 1 Ω and
Resistance
(female) 1. below
1) Stating switch ON. 2) Slow blow fuse (firm power supply).
Among terminal R02, R03 and machine 1 Ω and
Resistance
body. below
1) Starting switch OFF. 2) Disconnect the flow blow fuse (firm power
supply) terminal R02 and the battery relay terminal R01.
Harness between the flow blow fuse 1 Ω and
(firm power supply) terminal R02 and the Resistance
battery relay terminal R01 below
1) Starting switch OFF. 2) Disconnect the flow blow fuse (firm power
supply) terminal R05 and the battery relay terminal R04.
Harness between the flow blow fuse
1 Ω and
(firm power supply) terminal R05 and the Resistance below
battery relay terminal R04
1) Stating switch OFF. 2) Disconnect the connector S04.
12 Defective FNR switch mode
selector switch 1 V and
Between S04 4 and machine body. Voltage below
20-922 WA380-5
(10)
5
Related circuit diagram
WA380-5 20-923
5
TROUBLESHOOTING CODE: [E-1-B]
[E-1-b]
TROUBLESHOOTING CODE: [E-1-b]
Trouble (Engine stop solenoid system)
E-1-b) — —
Description of Trouble The engine stop solenoid system is out of order, and the engine does not start.
The engine stop solenoid system is out of order, and the engine does not start. (The starting motor rotates,
Effect on Machine
but the engine does not start.)
Related Information —

1) Starting switch OFF. 2) Disconnect the connector R72. 3) Connect a
Defective fuel cut solenoid T-adapter.
1
relay
Between R72 (male) 1 and 2. Resistance 50 - 90 Ω
1) Starting switch OFF. 2) Disconnect the connector E34. 3) Connect a
T-adapter.
Between E34 (male) A and C.
2 Defective fuel cut solenoid.
Resistance 0.6 - 1.0 Ω
Between E34 (male) B and C. Resistance 37 - 46 Ω
1) Starting switch OFF. 2) Disconnect the connector L91. 3) Insert a T-
adapter. 4) Connect the connector.
Starting switch 24 V and
"ON." Voltage above
Between L91 1 and 2
Starting switch Voltage 16 V and
3 Defective timer "Start." above
For 2 to 4 sec.
16 V and
from Starting Voltage above
Between L91 5 and 6 Switch "ON."
Other than the 1 V and
Voltage
above below
1) Starting switch OFF. 2) Disconnect the connectors E34, L91, S31,
R12, R68, R72 and L102. 3) Connect a T-adapter.
Harness between R12 and R68. Resistance 1 Ω and

below
1 Ω and
A.
Harness between R69 and E34 (female)
Resistance
below
Possible Causes and Stan- Harness between S31 (female) 4 and 1 Ω and
L91 (female) 1. Resistance below
dard Values
1 Ω and
E34 (female) B.
Harness between S31 (female) 4 and Resistance
Disconnection of harness below
4 (Disconnection, defective
contact) Harness between L91 (female) 5 and 1 Ω and
Resistance
R72 (female)1. below
Harness between L91 (female) 6 and 1 Ω and
R72 (female) 2. Resistance below
Harness between L91 (female) 4 and Resistance 1 Ω and
R102 (female) D. below
Between L91 (female) 2 and machine 1 Ω and
Resistance
body. below
Between E34 (female) C and machine 1 Ω and
body. Resistance below
1) Starting switch OFF. 2) Disconnect the connectors E34, L91, S31,
R12, R68, R72 and L102. 3) Connect a T-adapter.
1 Ω and
Among R12, R68 and machine body. Resistance
above
Among R69, E34 (female) A and 1 Ω and
machine body. Resistance above
★ In the above two cases, the flow blow fuse is blown.
5 Ground fault of harness
1 Ω and
E34 (female) B and machine body.
Among S31 (female) 4, L91 (female) 1,
Resistance
above
L91 (female) 5, R72 (female) 1 and 1 Ω and
machine body. Resistance above
1 Ω and
E34 (female) B
Harness between L91 (female) 1 and
Resistance above
★ In the above three cases, the fuse B-1 is blown.
20-924 WA380-5
(10)
5
TROUBLESHOOTING CODE: [E-1-B]
[E-1-b]
WA380-5 20-925
5
TROUBLESHOOTING TROUBLESHOOTING CODE: [E-2]
TROUBLESHOOTING CODE: [E-2]

Troubleshooting Code Failure Code Controller Code
Trouble The engine does not stop.
E-2 — —
Description of Trouble The engine stop solenoid system is out of order, and the engine does not stop.
Effect on Machine Even if the starting switch (ignition key switch) is set to "OFF," the engine does not stop.

1) Starting switch OFF. 2) Disconnect the connector R72. 3) Connect a
Defective fuel cut solenoid T-adapter.
1
relay
Between R72 (male) 1 and 2. Resistance 50 - 90 Ω
T-adapter.
Between E34 (male) A and C.
2 Defective fuel cut solenoid.
Resistance 0.6 - 1.0 Ω
Between E34 (male) B and C. Resistance 37 - 46 Ω
1) Starting switch OFF. 2) Disconnect the connector L91. 3) Insert a T-
adapter. 4) Connect the connector.
Starting switch 24 V and
"ON." Voltage above
Between L91 1 and 2
Starting switch Voltage 16 V and
Possible Causes and Stan- "Start." above
dard Values 3 Defective timer
16 V and
For 2 to 4 sec. Voltage
above
Between L91 5 and 6 from Starting
Switch "ON." 1 V and
Voltage below
★ Unless the engine stops when the connector L91 is disconnected,
the timer needs not be inspected.
T-adapter.
Between E34 (male) A and machine Voltage 1 V and
body. below
4 Hot short-circuit of harness Between E34 (male) B and machine 1 V and
Voltage
body. below
★ Unless the engine stops when the connector E34 is disconnected,
the cause is the solenoid or the fuel circuit system (mechanical sys-
tem).
20-926 WA380-5
(10)
WA380-5 20-927
5

Troubleshooting Code Failure Code Controller Code Preheating is impossible or con-
Trouble stant.
E-3 — —
Description of Trouble The preheating system is out of order, and preheating is impossible or constant.
Effect on Machine Preheating is impossible or constant.
Related Information When any failure code appears, diagnose the machine referring to the failure code "D182KZ" related to the
monitor. The monitoring function (Code : 04104) enables to check engine coolant temperature.

1) Starting switch OFF. 2) Disconnect the connectors E05, E06 and E07.
★ Solid part check
1 Defective intake air heater relay Between E05 and machine body. Resistance 19 - 25 Ω
Between E06 When the relay is ON Resistance 1 Ω and below

andE07 When the relay is OFF Resistance 1 MΩ and above
1) Starting switch OFF. 2) Disconnect the heater terminal.
2 Defective intake air heater
Between heater terminal and ground Resistance
1) Starting switch OFF. 2) Disconnect the connectors L102, E05, E06,
E07, R11 and heater terminal. 3) Connect a T-adapter.
Disconnection of harness (Dis- Resistance 1 Ω and below
3 connection, defective contact) E05.
(Intake air heater system) Harness between R11 and E06. Resistance 1 Ω and below
Harness between E07 and heater termi- Resistance 1 Ω and below
nal.
1) Starting switch OFF. 2) Disconnect the connectors L102, E05, E06,
E07, R11 and heater terminal. 3) Connect a T-adapter.
Among L102 (female) 4, E05 and Resistance 1 MΩ and above
machine body
★ In cases other than the above, the fuse B-0 will be blown.
4 Ground fault of harness (Intake
air heater system) Among R11, E06 and machine body Resistance 1 MΩ and above
Among E07, heater terminal and Resistance 1 MΩ and above
machine body
In case other than the above two paragraphs, the slow blow fuse will
be blown.
Possible Causes and 1) Starting switch OFF. 2) Disconnect the connector E09. 3) Connect a
Standard Values T-adapter.
Defective engine coolant tem-
5 perature sensor At the time of 10 °C Resistance 7 - 11 kΩ
Between E09
(male) (A) and (B) At the time of 100 °C Resistance 0.1 - 0.5 kΩ
1) Starting switch OFF. 2) Disconnect the connectors L55 and TWH. 3)
Ground fault of harness (Engine Insert a T-adapter.
6 coolant temperature sensor sys-
tem) Among L55 (female) 3, E09 (A) and Resistance 1 MΩ and above
machine body
1) Starting switch OFF. 2) Disconnect the connector L55. 3) Connect a
T-adapter.
7 Defective monitor panel Between L55 At the time of 10 °C Resistance 7 - 11 kΩ
(female) 3 and
machine body At the time of 100 °C Resistance 0.1 - 0.5 kΩ
1) Starting switch OFF. 2) Disconnect the connector L114. 3) Connect
a T-adapter.
Between L114 (male) 1 and 2 Resistance 200 - 400 kΩ
1) Starting switch OFF. 2) Disconnect the connector L114. 3) Replace
8 Defective preheater relay the preheater relay (114) with another relay. 4) Starting switch ON.
The preheater relay (L114) is
The machine operates normally. out of order.
The machine does not operate normally. The preheater relay (L114) is
normal.
1) Starting switch OFF. 2) Disconnect the connectors L151 and L114.
Disconnection of harness (Dis- 3) Connect a T-adapter.
9 connection, defective contact)
(Preheater relay system) Harness between L114 (female) 2 and Resistance 1 Ω and below
L51 (female) B
1) Starting switch OFF. 2) Disconnect the connectors L52 and S32.
Disconnection of harness (Dis- 3) Connect a T-adapter.
10 connection, defective contact)
(Starting switch R1 system) Harness between L52 (female) A and Resistance 1 Ω and below
S32 (female) 1
20-928 WA380-5
(10)
WA380-5 20-929
(7)

Troubleshooting Code Failure Code Controller Code The engine power modes cannot
Trouble
E-4 — — be selected.
Description of Trouble The engine power mode system is out of order, and the power modes cannot be selected.
Effect on Machine The engine power modes cannot be selected.

1) Starting switch OFF. 2) Disconnect the connector S21. 3) Connect a T-
adapter.
★ Solid part check
1 Defective power mode
selector switch In the economy
Between S01 (male) mode Resistance 1 MΩ and above
1 and 4
In the power mode Resistance 1 Ω and below
1) Starting switch OFF. 2) Replace L115 with any other relay. 3) Starting
switch "ON."
2 Defective power mode It returned to normal. The power mode selector relay is
selector relay out of order.
The power mode selector relay is
It does not return to normal.
normal.
1) Starting switch OFF. 2) Disconnect the connectors S21, L102, L88, L61
and FS33. 3) Connect a T-adapter.
Harness between S21 (female) 4, L61 Resistance 1 Ω and below
(female) 6 and L102 (female) 7
Harness between S21 (female) 1 and
Resistance 1 Ω and below
machine body
L88 (female) 5 Resistance 1 Ω and below
★ In the above three cases, the power mode cannot be selected.
Harness between FS3 (female) 5 and Resistance 1 Ω and below
3 Disconnection of harness L88 (female) 4, L102 (female) 6
Possible Causes and
Standard Values Resistance 1 Ω and below
L102 (female) 0
★ In the above two cases, the economy mode cannot be selected.
machine body Resistance 1 Ω and below
Harness between L88 (female) 7 and Resistance 1 Ω and below

L102 (female) 8
★ In the above two cases, the economy mode cannot be changed to the
power mode, and the power mode cannot be changed to the economy
mode.
1) Starting switch OFF. 2) Disconnect the connectors S21, L102 and L61.
Among S21 (female) 4, L61 (female) 6,
Resistance 1 MΩ and above
L102 (female) 7 and machine body
Among L88 (female) 3, L102 (female) 0
and machine body Resistance 1 MΩ and above
★ In the above two cases, the economy mode cannot be selected.
4 Ground fault of harness Among FS3 (female) 5, L88 (female) 4, Resistance 1 MΩ and above
L102 (female) 6 and machine body
★ In the above case, the fuse B-6 will be blown.
Among L88 (female) 7, L102 (female) 8
and machine body
★ In the above two cases, the economy mode cannot be changed to the
power mode, and the power mode cannot be changed to the economy
mode.
20-930 WA380-5
(10)
Troubleshooting Code Failure Code Controller Code The engine power modes
Trouble
E-4 — — cannot be selected.

1) Starting switch OFF. 2) Disconnect the connectors S21, L102 and
L61. 3) Connect a T-adapter. 4) Starting switch ON.
Among S21 (female) 4, L61 (female) 6, 1 V and
Voltage
L102 (female) 7 and machine body below
Possible Causes and Stan- ★ In the above case, the fuse B-6 will be blown when the power
dard Values 5 Hot short-circuit of harness mode is selected.
Among L88 (female) 7, L102 (female) 8 1 V and
Voltage
and machine body below
★ In the above case, the economy mode is changed to the power
mode, and the power mode is changed to the economy mode
automatically without operation.
WA380-5 20-931
(10)

Trouble The front wiper does not function
E-5 — —
Description of Trouble • Since a fault occurs in the front wiper, switch timer, or harness, the front wiper does not function
Effect on Machine • The front wiper does not function

1) Turn starting switch OFF.
2) Disconnect connector C12.
3) Connect T-adapter.
4) Turn starting switch ON.
Between C12 2 - body (Wiper switch Lo) Voltage 20 - 30 V
1 Front wiper motor fault
Between C12 1 - body (Wiper switch Hi) Voltage 20 - 30 V
Between C12 6 - body Voltage 20 - 30 V
When the wiper switch is turned OFF during running of the wiper, the voltage
is applied between the C12 5 - body until the wiper motor stops
1) Turn starting switch OFF
Between L31 3 - body Voltage 20 - 30 V
2 Wiper timer (relay) fault
Between L31 4 - body (Wiper switch INT) Voltage 20 - 30 V
Between L31 2 - body (Wiper switch washer
Possible Causes and side) Voltage 20 - 30 V
Standard Values
Between L31 5 - body (The voltage is output intermittently by wiper switch
INT) 20 to 30 V → 0 V → 20 to 30 V → 0 V repeated
2) Disconnect connector L21.
3 Front wiper switch fault
Between L21 (Male) 7 - 5 (Wiper switch Lo) Resistance 1 Ω and below
Between L21 (Male) 7 - 4 (Wiper switch Hi) Resistance 1 Ω and below
Between L21 (Male) 7 - 2 (Wiper switch Resistance 1 Ω and below
INT)
Between L21 (Male) 3 - 5 (Wiper switch
INT)
Others Resistance 1 MΩ and above
20-932 WA380-5
(10)
Troubleshooting Code Failure Code Controller Code The front wiper does not func-
Trouble
E-5 — — tion

2) Disconnect connectors L21, L31, and C12.
Harness between L21 (Female) 2 -
L31 (Female) 4
Between L21 (Female) 2, L31
(Female) 4 - body Resistance 1 MΩ and above
Harness between L21 (Female) 3 - Resistance 1 Ω and below

L31 (Female) 5
Harness disconnection or (Female) 5 - body
ground fault
4 ★ Fuse A-7 blows in ground Harness between L21 (Female) 5 - Resistance 1 Ω and below
C12 (Female) 2
fault case.
Between L21 (Female) 5, C12
Possible Causes and (Female) 2 - body Resistance 1 MΩ and above
Standard Values
C12 (Female) 1
Between L21 (Female) 4, C12
(Female) 1 - body
C12 (Female) 5 Resistance 1 Ω and below
Between L31 (Female) 6, C12 Resistance 1 MΩ and above

(Female) 5- body
2) Disconnect connectors FS4, L21, C12, C15, C43, C44, and C45.
Harness disconnection or 3) Connect T-adapter
ground fault
5 ★ Fuse A-7 blows in ground Harness between L21 (Female) 7 - Resistance 1 Ω and below
FS4 (Female) 7
fault case.
Between L21 (Female) 7, FS4
WA380-5 20-933
(10)
5
20-934 WA380-5
5

Trouble The rear wiper does not function
E-6 — —
Description of Trouble • Since a fault occurs in the rear wiper, switch, or harness, the rear wiper does not function.
Effect on Machine • The rear wiper does not function.

1 Rear wiper motor fault Between C15 2 - body (Wiper switch Lo) Voltage 20 - 30 V
Between C15 1 - body Voltage 20 - 30 V
2 Rear wiper switch fault 2) Disconnect connector L21.
Between L21 (Male) 7 - 9 (Wiper switch Lo) Resistance 1 Ω and below
Between L21 (Male) 8 - 9 (Wiper switch Resistance 1 Ω and below
Possible Causes and OFF)
Standard Values
2) Disconnect connectors L21 and C15.
Harness between L21 (Female) 8 - C15
(Female) 3 Resistance 1 Ω and below
Between L21 (Female) 8, C15 (Female) 3 - Resistance 1 MΩ and above

body
Harness disconnection Harness between L21 (Female) 9 - C15

or ground fault (Female) 2
3 ★ Fuse A-7 blows in
Between L21 (Female) 9, C15 (Female) 2 -
ground fault case. body Resistance 1 MΩ and above
2) Disconnect connectors FS4, L21, C12, C15, C43, C44, and C45.
Harness between L21 (Female) 7 - FS4
Between L21 (Female) 7, FS4 (Female) 7 - Resistance 1 MΩ and above

body
Related circuit diagram (See item E-5.)
WA380-5 20-935
(10)
5
Troubleshooting Code Failure Code Controller Code The side wiper does not function
Trouble (If equipped)
E-7 — —
Description of Trouble • Since a fault occurs in the side wiper, switch, or harness, the side wiper does not function.
Effect on Machine • The side wiper does not function.

2) Disconnect connectors C44 and C45.
• Right side wiper
1 Side wiper fault is applied between the C44 2 - body until the wiper motor stops
Between C44 4 - body (Power) Voltage 20 - 30 V
• Left side wiper
2 Side wiper switch fault 2) Disconnect connector C43.
Possible Causes and
Standard Values Between C43 (Female) 3 - 2 (Wiper switch
Lo) Resistance 1 Ω and below
Between C43 (Female) 2 - 1 (Wiper switch Resistance 1 Ω and below

OFF)
2) Disconnect connectors C43, C44, and C45.
Harness between C43 (Female) 2 - C44
(Female) 1 (C45 (Female) 1) Resistance 1 Ω and below
Between C43 (Female) 2, C44 (Female) 1 Resistance 1 MΩ and above

(C45 (Female) 1 - body)
Harness between C43 (Female) 1 - C44
Harness disconnection Resistance 1 Ω and below
(Female) 2 (C45 (Female) 2)
or ground fault
3 ★ Fuse A-7 blows in Between C43 (Female) 1, C44 (Female) 2
(C45 (Female) 2) Resistance 1 MΩ and above
ground fault case.
2) Disconnect connectors L21, L31, FS4, R43, R45, C12, C15, C43, C44, and
C45.
Harness between C43 (Female) 3 - FS4 Resistance 1 Ω and below
(Female) 7
Between C43 (Female) 3, FS4 (Female) 7 -
and body
20-936 WA380-5
(10)
5
Troubleshooting Code Failure Code Controller Code The wind washer does not func-
Trouble tion
E-8 — —
• Since a fault occurs in the window washer motor, switch, timer (Front only), or harness, the wind washer
Description of Trouble
does not function.
Effect on Machine • The wind washer does not function.
• When the wiper function is normal (When the wiper function is also abnormal, first diagnose the wiper
Related Information function fault in E-5).

2) Disconnect connectors R43 and R45.
1 Washer motor fault • Front washer motor
Between R43 1 - body Voltage 20 - 30 V
• Rear washer motor
Between R45 1 - body Voltage 20 - 30 V
• Common to front switch and rear switch
• Front switch
Possible Causes and Between L21 (Male) 7 - 6 (Washer switch
Standard Values 2 Wiper switch fault Resistance 1 Ω and below
ON)
Between L21 (Male) 7 - 6 (Washer switch
OFF)
• Rear switch
Between L21 (Male) 7 - 0 (Washer switch
ON) Resistance 1 Ω and below
Between L21 (Male) 7 - 0 (Washer switch Resistance 1 MΩ and above

OFF)
Between L21 (Male) 7 - 9, and 0 (Washer
wiper Lo switch ON)
Wiper timer (Relay) fault
3 (Front wiper only) Between L31 3 - body Voltage 20 - 30 V
Between L31 2 - body (Washer switch ON) Voltage 20 - 30 V
Between L31 5 - body (0.2 - 0.8 sec. after the Voltage 20 - 30 V
washer switch was turned ON)
WA380-5 20-937
(10)
5
Troubleshooting Code Failure Code Controller Code The wind washer does not func-
Trouble
E-8 — — tion

2) Disconnect connectors L21, R43, R45, and L31.
• Front washer motor circuit
R43 (Female) 1 Resistance 1 Ω and below
Between L21 (Female) 6, R43 Resistance 1 MΩ and above

(Female) 1 - body
L31 (Female) 2
(Female) 2 - body
Harness disconnection or Harness between L21 (Female) 3 -

Possible Causes and L31 (Female) 3 Resistance 1 Ω and below
Standard Values ground fault
4 ★ Fuse A-7 blows at occur-
Between L21 (Female) 3, L31 Resistance 1 MΩ and above
rence of a ground fault. (Female) 3 - body
• Rear washer motor circuit
Between L21 (Female) 0, R45 Resistance 1 MΩ and above

(Female) 1 - body
2) Disconnect connectors L21, L31, FS4, R43, R45, C12, C15, C43, C44,
and C45.
FS4 (Female) 7
Between L21 (Female) 7, FS4
20-938 WA380-5
(10)
WA380-5 20-939
5
Troubleshooting Code Failure Code Controller Code The headlamp (Lo beam) does
Trouble not light on
E-9 — —
• Since a disconnection (Ground fault) occurs in the switch, lamp, or harness in the headlamp system, the
headlamp (Lo beam) does not light on.
Effect on Machine • The headlamp (Lo beam) does not light on.

2) Disconnect the connector HEAD of the left and right.
1 Lamp fault
Between HEAD 2 (Left and right) - body
Voltage 20 - 30 V
(Lamp switch: 2nd row)
(Lamp switch: 2nd row, Dimmer switch: Lo) Voltage 20 - 30 V
Possible Causes and
Standard Values Between L02 2 - body (Lamp switch: 2nd
row) Voltage 20 - 30 V
Between L02 4 - body (Lamp switch: 2nd Voltage 1 V and below

row, Dimmer switch: Lo)
Lamp switch or dimmer
2 switch fault Between L02 4 - body (Lamp switch: OFF,
Voltage 20 - 30 V
Dimmer switch: Hi)
Between L02 (Male) 1 - 2 (Lamp switch:
2nd row)
Between L02 (Male) 4 - 6 (Dimmer switch:
Lo) Resistance 1 Ω and below
20-940 WA380-5
(10)
Troubleshooting Code Failure Code Controller Code The headlamp (Lo beam) does
Trouble
E-9 — — not light on

2) Disconnect connectors L02, FS4, FS5, left HEAD and right HEAD.
FS4 (Female) A
Between L02 (Female) 1 - FS4
(Female) A harness - body Resistance 1 MΩ and above

FS5 (Female) 4
Between L02 (Female) 2 - FS5
(Female) 4 harness - body
Harness between FS5 (Female) 5 -
right HEAD (Female) 2
Between FS5 (Female) 5 - right HEAD
(Female) 2 harness - body Resistance 1 MΩ and above
Harness between FS5 (Female) 6 - Resistance 1 Ω and below

Harness disconnection or left HEAD (Female) 2
Possible Causes and ground fault Between FS5 (Female) 6 - left HEAD
Standard Values 3 ★ Fuses A-1, A-12, and A-13 Resistance 1 MΩ and above
2 harness - body
blow at occurrence of a
ground fault.
right HEAD (Female) 1 Resistance 1 Ω and below
Between L02 (Female) 4 - right HEAD Resistance 1 MΩ and above

Harness between L02 (Female) 4 - left
HEAD (Female) 1
Between L02 (Female) 4 - left HEAD
Harness between FS5 (Male) 4 - 5 Resistance 1 Ω and below

(Including fuse A-13)
Between FS5 (Male) 4 - 5 harness -
body
Harness between FS5 (Male) 4 - 6
(Including fuse A-12) Resistance 1 Ω and below
Between FS5 (Male) 4 - 6 harness - Resistance 1 MΩ and above

body
Between L02 (Female) 6 - body Resistance 1 Ω and below
WA380-5 20-941
(10)
20-942 WA380-5
5
Troubleshooting Code Failure Code Controller Code The headlamp (Hi beam) does not
Trouble function
E-10 — —
• Since a disconnection (Ground fault) occurs in the switch, lamp, or harness in the headlamp system, the
headlamp (Hi beam) does not light on.
Effect on Machine • The headlamp (Hi beam) does not light on.

2) Disconnect the connector HEAD on the left and right.
1 Lamp fault
Between HEAD 2 (Left and right) - body Voltage 20 - 30 V
(Lamp switch: 2nd row)
Voltage 20 - 30 V
(Lamp switch: 2nd row, dimmer switch: Hi)
Between L02 2 - body (Lamp switch: 2nd
row) Voltage 20 - 30 V
Between L02 3 - body (Lamp switch: 2nd Voltage 1 V and below

row, Dimmer switch: Hi)
Lamp switch or dimmer Between L02 3 - body (Lamp switch: OFF,
2 Voltage 20 - 30 V
switch fault Dimmer switch: Lo)
Between L02 (Male) 1 - 2 (Lamp switch: Resistance 1 Ω and below
Possible Causes and 2nd row)
Standard Values
Between L02 (Male) 3 - 6 (Dimmer switch:
Hi)
2) Disconnect connectors L02, FS4, FS5, and left HEAD and right HEAD.
(Female) A Resistance 1 Ω and below
Between L02 (Female) 1 - FS4 (Female) A Resistance 1 MΩ and above

harness - body
Harness disconnection Harness between L02 (Female) 2 - FS5
or ground fault Resistance 1 Ω and below
(Female) 4
★ Fuses A-1, A-12, and
3 A-13 blow at occur- Between L02 (Female) 2 - FS5 (Female) 4
harness - body Resistance 1 MΩ and above
rence of a ground
fault. Harness between FS5 (Female) 5 - right Resistance 1 Ω and below
HEAD (Female) 2
Between FS5 (Female) 5 - right HEAD
Harness between FS5 (Female) 6 - left
HEAD (Female) 2 Resistance 1 Ω and below
Between FS5 (Female) 6 - left HEAD 2 har- Resistance 1 MΩ and above

ness - body
WA380-5 20-943
(10)
Troubleshooting Code Failure Code Controller Code The headlamp (Hi beam) does
Trouble
E-10 — — not light on

right HEAD (Female)
Between L02 (Female) 3 - right HEAD
(Female) harness - body Resistance 1 MΩ and above
Harness between L02 (Female) 3 - left Resistance 1 Ω and below

HEAD (Female)
Between L02 (Female) 3 - left HEAD
Harness disconnection or Resistance 1 MΩ and above
Possible Causes and ground fault (Female) harness - body
Standard Values 3 ★ Fuses A-1, A-12, and A-13 Harness between FS5 (Male) 4 - 5
blow at occurrence of a (Including fuse A-13) Resistance 1 Ω and below
ground fault.
Between FS5 (Male) 4 - 5 harness - Resistance 1 MΩ and above
body
Harness between FS5 (Male) 4 - 5 Resistance 1 Ω and below
(Including fuse A-12)
Between FS5 (Male) 4 - 5 harness -
body
Between L02 (Female) 6 - body Resistance 1 Ω and below
20-944 WA380-5
(10)
5
Troubleshooting Code Failure Code Controller Code The clearance lamp does not light
Trouble on (Small lamp)
E-11 — —
• Since a disconnection (Ground fault) occurs in the switch, lamp, or harness in the clearance lamp system,
the clearance lamp does not light on.
Effect on Machine • The clearance lamp does not light on (Small lamp).

2) Disconnect the connector COMB1 (Left and right).
1 Lamp fault 4) Turn starting switch ON.
Between COMB1 1 (Left and right) - body
Voltage 20 - 30 V
(Lamp switch: 1st row)
Between L02 5 - body (Lamp switch: 1st
Voltage 20 - 30 V
2 Lamp switch fault row)
Between L02 (Male) 1 - 5 (Lamp switch: 1st
row)
2) Disconnect connectors L02, FS4, FS5, and left HEAD and right HEAD.
Possible Causes and Harness between L02 (Female) 1 - FS4 Resistance 1 Ω and below
Standard Values (Female) A
Between L02 (Female) 1 - FS4 (Female) A
harness - body
Between L02 (Female) 2 - FS5 (Female) 4 Resistance 1 MΩ and above

harness - body
Harness disconnection Harness between L02 (Female) 2 - COMB1
or ground fault right (female) 1
★ Fuses A-1, A-14, and
3 Between FS5 (Female) 2 - COMB1 right
A-15 blow at occur- (Female) 1 harness - body Resistance 1 MΩ and above
rence of a ground
fault. Harness between FS5 (Female) 3 - COMB1 Resistance 1 Ω and below
right (Female) 1
Between FS5 (Female) 3 - COMB1 right
Harness between FS5 (Male) 1 - 2 (Includ-
ing fuse A-13) Resistance 1 Ω and below
Between FS5 (Male) 1 - 2 harness - body Resistance 1 MΩ and above

Harness between FS5 (Male) 1 - 3 (Includ-
ing fuse A-12) Resistance 1 Ω and below
Between FS5 (Male) 1 - 3 harness - body Resistance 1 MΩ and above

Between COMB (Female) (Left and right) 3 -
body Resistance 1 Ω and below
WA380-5 20-945
(10)
5

Trouble The turn signal does not blink
E-12 — —
• Since a disconnection (Ground fault) occurs in the switch, relay, or harness in the turn signal system, the
turn signal does not blink.
Effect on Machine • The turn signal does not blink.

Between L111 4 - body (Power) Voltage 20 - 30 V
Between L111 3 - body (Turn signal switch Voltage 20 - 30 V
= Neutral)
1 Turn signal relay fault
Between L111 2 - body (Turn signal switch
Voltage 20 - 30 V
= Neutral)
Between L111 (Male) 3 - 4 (Between con-
tacts)
Possible Causes and 4) Turn starting switch ON.
Standard Values
Between L03 2 - body (Turn signal switch: L 20 - 30 V and 0 V
or R) Voltage repeated
Between L03 3 - body (Turn signal switch: Voltage 20 - 30 V and 0 V
R) repeated
2 Turn signal switch fault Between L03 4 - body (Turn signal switch: 20 - 30 V and 0 V
Voltage
L) repeated
Between L03 (Male) 2 - 3 (Turn signal
switch: R)
Between L03 (Male) 2 - 4 (Turn signal
switch: L) Resistance 1 Ω and below
Between flasher unit pin 3 - body Voltage 20 - 30 V
3 Flasher unit fault
Between flasher unit pin 4 - body (Turn sig- 20 - 30 V and 0 V
nal switch L or R) Voltage repeated
20-946 WA380-5
(10)

Trouble The turn signal does not blink
E-12 — —
2) Disconnect connectors L101, L03, FS3, COMB1 (Left and right), R30,
R31, and flasher unit pins 3 and 4.
flasher unit pin 3 Resistance 1 Ω and below
Between L101 (Female) 3 - flasher Resistance 1 MΩ and above

unit pin 3 harness - body
flasher unit pin 4
Between L03 (Female) 2 - flasher unit
pin 4 harness - body Resistance 1 MΩ and above

FS3 (Female) 5 Resistance 1 Ω and below
Between L101 (Female) 5 - FS3 Resistance 1 MΩ and above

Harness disconnection or COMB1 right (Female) 3
Possible Causes and
Standard Values ground fault Between L03 (Female) 3 - COMB1
4 ★ Fuse B-5 blows at occur- right (Female) 3 harness - body Resistance 1 MΩ and above
rence of a ground fault.
COMB1 left (Female) 3
Between L03 (Female) 4 - COMB1 left
Between L03 (Female) 3 - R31 Resistance 1 MΩ and above

R30 (Female) 1
Between L03 (Female) 4 - R30
Between COMB1 (Female) (Left and Resistance 1 Ω and below

right) 3 - body
Between R30 (Female) 6, R31
(Female) 6 - body
Between flasher unit pin 1 - body Resistance 1 Ω and below
WA380-5 20-947
(10)
5

Trouble The horn does not sound
E-13 — —
• Since a disconnection or (Ground fault) occurs in the switch, relay, horn, or harness in the horn system,
the horn does not sound.
Effect on Machine • The horn does not sound.

3) Connect T-adapter (Insert).
Between L119 1, 3 - body (Power) Voltage 20 - 30 V
Between L110 2 - body (Horn switch: OFF) Voltage 20 - 30 V
1 Horn relay fault Between L119 2 - body (Horn switch: ON) Voltage 1 V and below
Between L119 5 - body (Horn switch: ON) Voltage 20 - 30 V
Between L119 (Male) 1 - 2 (Coil resistance) Resistance 200 - 400 Ω
Between L119 (Male) 3 - 5 (Between pints) Resistance 1 MΩ and above
Between horn switch pin - body (Horn Voltage 1 V and below
switch: ON)
Between horn switch pin - body (Horn
Voltage 20 - 30 V
2 Horn switch fault switch: OFF)
Possible Causes and
Standard Values 1) Turn starting switch OFF.
2) Disconnect the horn switch pin.
Between horn switch pin - body (Switch: Resistance 1 Ω and below
ON)
3 Horn fault
Between horn pin - body (Horn switch: ON) Resistance 35 - 45 Ω
2) Disconnect the horn pin, horn switch pin, and connectors L103 and FS4.
Harness between FS4 (Female) 1 - L103
(Female) 9, A Resistance 1 Ω and below
Harness disconnection Between FS4 (Female) 1, L103 (Female) 9, Resistance 1 MΩ and above
or ground fault A - body
4 ★ Fuse A-1 blows at
Harness between horn switch pin - L103
occurrence of a Resistance 1 Ω and below
(Female) 0
ground fault.
Between horn switch pin, L103 (Female) 0 -
body Resistance 1 MΩ and above
Harness between horn pin - L103 (Female) Resistance 1 Ω and below

B
Between horn pin, L103 (Female) B - body Resistance 1 MΩ and above
20-948 WA380-5
(10)
WA380-5 20-949
5
Troubleshooting Code Failure Code Controller Code The air conditioner does not work
Trouble or does not stop.
E-14 — —
Description of Trouble The air conditioning system is out of order, and the air conditioner does not work or does not stop.
Effect on Machine The air conditioner does not work or does not stop.
Related Information This troubleshooting is only for the connection between the air conditioner and the operator cab. For trou-
bleshooting of air conditioner body, refer to the Shop Manual of Air Conditioner.

Check the fuse B-D. When the fuse is blown,
1) Starting switch OFF. 2) Disconnect the connectors FS3 and A7. 3) Insert a
T-adapter.
Among FS3 (female) E, A7 (female) 2 and
machine body Resistance 1 MΩ and above
In cases other than the above, the relay A7, the blower motor and the con-
nection harness are out of order.
Ground fault of power Check the fuse B-E. When the fuse is blown,
1
supply harness 1) Starting switch OFF. 2) Disconnect the connectors FS3, C47, A7, A8, A9,
A10, A11 and A14. 3) Insert a T-adapter.
Among FS3 (female) F, C47 (female) 8, A7
(female) 1, A8 (female) 1, A9 (female) 1, Resistance 1 MΩ and above
A10 (female) 1, A11 (female) 1, A14
(female) 1 2 and machine body
In cases other than the above, each relay, the control amplifier and the con-
nection harness are out of order.
1) Starting switch OFF. 2) Disconnect the connector C47. 3) Insert a T-
adapter.
Harness between C47 Starting switch ON. Voltage 20- 30 V

Defective power supply (female) 8 and A Starting switch OFF. Voltage 1 V and below
of control amplifier (Dis-
2 connection or short-cir- When the above is abnormal,
Possible Causes and cuit of harness for 1) Starting switch OFF. 2) Disconnect the connectors 47 and F3. 3) Insert a
Standard Values control amplifier) T-adapter.
Harness between C47 (female) 8 and FS3 Resistance 1 Ω and below
(female) F
Between C47 (female) A and machine body. Resistance 1 Ω and below
1) Starting switch OFF. 2) Disconnect the connectors A7, A8, A9, A10, A11
and A14. 3) Connect a T-adapter.
Between A7 (female) Starting switch ON. Voltage 20- 30 V

1 and machine body Starting switch OFF. Voltage 1 V and below
Harness between A8 Starting switch ON. Voltage 20- 30 V

(female) 1 and 4 Starting switch OFF. Voltage 1 V and below
Defective power supply Harness between A8 Starting switch ON. Voltage 20- 30 V
of relay (Disconnection (female) 1 and 4
3 or short-circuit of har- Starting switch OFF. Voltage 1 V and below
ness for relay) Starting switch ON. Voltage 20- 30 V
Harness between A10
(female) 1 and 4 Starting switch OFF. Voltage 1 V and below
(female) 1 and
machine body Starting switch OFF. Voltage 1 V and below
(female) 1 2 and
machine body Starting switch OFF. Voltage 1 V and below
20-950 WA380-5
(10)
5
Troubleshooting Code Failure Code Controller Code The air conditioner does not
Trouble
E-14 — — work or does not stop.

When the above six items are abnormal, check the following
1) Starting switch OFF. 2) Disconnect the connectors A7, A8, A9, A10,
A11, A14 and FS3. 3) Connect a T-adapter.
Harnesses among A7 (female) 1, A8
(female) 1, A9 (female) 1, A10 Resistance 1 Ω and below
(female) 1, A11 (female) 1, A14
(female) 1 2 and FS3 (female) F
Defective power supply of
3 relay (Disconnection or short- Among A8 (female) 4, A9 (female) 4, Resistance 1 Ω and below
A10 (female) 4 and machine body
Possible Causes and circuit of harness for relay)
Standard Values 1) Starting switch OFF. 2) Disconnect the connectors A12, A13 and A1.
Among A12 (female) 3 4, A13
(female) 3 4, A1 (female) 1 and Resistance 1 Ω and below
machine body.
In cases other than the above, each relay and its connection harness
are abnormal.
1) Starting switch OFF. 2) Disconnect the connectors B01 and B02. 3)
Defective condenser ground Connect a T-adapter.
4 (Disconnection of condenser
harness) Among B01 (female) 3 B02 (female) Resistance 1 Ω and below
3 and machine body.
WA380-5 20-951
(10)
5
20-952 WA380-5
(10)
5
TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE
(S MODE)
Method of using troubleshooting charts ................................................................................................. 20-1002

S-1 Starting performance is poor (Starting always takes time) ........................................................ 20-1006
S-2 Engine does not start
(1) Engine does not turn ......................................................................................................... 20-1007
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected) ..................... 20-1008
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected) .................. 20-1009
S-3 Engine does not pick up smoothly (Follow-up is poor) ............................................................. 20-1010
S-4 Engine stops during operations ................................................................................................ 20-1011
S-5 Engine does not rotate smoothly (Hunting) .............................................................................. 20-1012
S-6 Engine lacks output (or lacks power) ........................................................................................ 20-1013
S-7 Exhaust smoke is black (Incomplete combustion) .................................................................... 20-1014
S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................ 20-1015
S-9 Oil becomes contaminated quickly ........................................................................................... 20-1016
S-10 Fuel consumption is excessive ................................................................................................. 20-1017
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down ........................................ 20-1018
S-12 Oil pressure caution lamp lights up (Drop in oil pressure) ........................................................ 20-1019
S-13 Oil level rises (Water, fuel in oil) ............................................................................................... 20-1020
S-14 Coolant temperature becomes too high (Overheating) ............................................................ 20-1021
S-15 Abnormal noise is made ........................................................................................................... 20-1022
S-16 Vibration is excessive ............................................................................................................... 20-1023
WA380-5 20-1001
(7)
(10)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLE-

SHOOTING CHARTS
This troubleshooting chart is divided into three sec-

tions: questions, check items, and troubleshoot-
ing.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspection without using
troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make final
confirmation.
[Questions]
Sections [A] + [B] in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in [B] are items
that can be obtained from the user, depending on
the user's level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under [C] in
the chart on the right correspond to this.
Causes
The serviceman narrows down the causes from
information [A] that he has obtained from the user
and the results of [C] that he has obtained from his
own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of prob-
ability, starting with the causes that have been (b) (2) (3)
marked as having the highest probability form
information gained from [Questions] and [Check
items].
(a)
Questions
[A] (b)
(c)
(d)
(e)
[B]
Check items
[C]
i
shooting
Trouble-
ii
iii
20-1002 WA380-5
(9)
(7)
The basic method of using the troubleshooting chart is

as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with , and of these, causes that have a high probabil-
ity are marked with .
Check each of the [Questions] are [Check items] in
turn, and marked the or in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for that
item to make final confirmation of the cause.
Causes
1. For [Confirm Section, ask repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with to use as reference
)n
ctio
for locating the cause of the failure. However,
inje
do not use this when marking calculations to
sive
narrow down the causes.
zle
renc
xces
2. Use the in the Cause column as reference
ner
noz
for [Degree of use (Operated for long period)]
ent
erfe
er li
p (e
g
ion
m
in the [Questions] section as reference.
imin
d
, int
pum
e
n
ject
l
i
er e
As a rule, do not use it when calculating be
, cyl
rger
on t
d in
ion
included if necessary to determine the order
lean
ring
cha
ecti
ject
eize
for troubleshooting.
air c
urbo
r inj
ston
e in
, s
rope
ged
ctiv
ged
n pi
ed t
Defe
Clog
Clog
Wor
Seiz
Imp
1 Confirm recent repair history
2 Degree of use Operated for long period
WA380-5 20-1003
(7)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five
causes. Let us explain here the method of using this causal relationship to pinpoint the most probable
cause.
S-7 Exhaust gas is black (incomplete combustion)
General causes why exhaust gas is black
Causes
• Insufficient intake of air
• Improper condition of fuel injection
d)
ad
n)
• Excessive injection of fuel
eize
d he
ctio
er s
inje
r an
lung
at
arge
sive
e se
e
ck, p
renc
xces
zzle
och
valv
p (ra
ent
n no
turb
erfe
p (e
lve,
r
r
e
inde
lem
uffle
imin
ranc
, int
pum
pum
ctio
een
f va
er e
, cyl
ed m
rger
inje
clea
on t
etw
ct o
ion
ion
lean
ring
cha
air b
ecti
zed
onta
ject
ject
lve
logg
Legend
air c
urbo
r inj
r va
, sei
ston
e in
e in
c
e of
: Possible causes (judging from Questions and check items)
d, c
e
rope
rope
ged
ctiv
ctiv
ged
ctiv
: Most probable causes (judging from Questions and Check items)
n pi
ed t
she
kag
: Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Blue under light load

Engine oil must be added more frequently
Suddenly
Power was lost
Gradually
Non-specified fuel has been used
Noise of interference is heard from around turbocharger
Dust indicator is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Match marks on fuel injection pump are out of alignment

Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Troubleshooting
Speed of some cylinders does not change when operating

on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-1004 WA380-5
(9)
(7)
Five causes
Step 1
Clarify the relationship between the three

symptoms in the [Questions] and [Check items]
section and the five Causes items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the

horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 shows that the closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
WA380-5 20-1005
(7)
(9)
TROUBLESHOOTING S-1
S-1 Starting performance is poor

(Starting always takes time)
General causes why exhaust smoke comes out but
engine takes time to start
• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel
(At ambient temperature of –10°C or below, ASTM
D975 No. 2 diesel fuel is used)
★ Battery charging rate Causes
Charging rate
Ambient 100 % 90 % 80 % 75 % 70 %
uck)
temperature
er st
20°C 1.28 1.26 1.24 1.23 1.22
ank
t
0°C 1.29 1.27 1.25 1.24 1.23
ung
l
elem alve sea
ping
ance
r
eate
t
–10°C 1.30 1.28 1.26 1.25 1.24
ttery
k, pl
fuel
r
el pi
or c
air h
filte
(rac
ve, v
ent
le in
d ba
nsat
in fu
er
• The specific gravity should exceed the value for the
uze
r
ake
le
inde
rain
g
p
o
nozz
rate
f val
min
mpe
p ga
pum
h
charging rate of 70% in the above table.
l int
, air
, cyl
ump
r, st
her
erio
r
i
aner
tor
act o
nato
t
tion
st co
pum
trica
ging
• In cold areas the specific gravity must exceed the
tion
tion
reat
filte
ring
gula
ed p
t
r de
ir cle
injec
alter
cont
elec
value for the charging rate of 75% in the above table.
boo
clog
injec
injec
air b
feed
fuel
ston
e
o
r
f
a
ctive
ctive
ctive
ctive
ctive
ctive
ctive
ctive
age,
ged
tive
tive
ged
ged
ged
n pi
Defe
Defe
Defe
Defe
Defe
Defe
Leak
Defe
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Wor

Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Indicator lamp does not light up

Replacement of filters has not been carried out according to operation Manual
Non-specified fuel has being used
Dust indicator lamp is red
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
Check items
Timing lock on fuel injection pump does not match

Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found to be clogged

Heater mount does not become warm
Is voltage 26–30V between alternator terminal B and terminal E Yes
with engine at low idling? No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
»Adjust
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
» Use a test stand
20-1006 WA380-5
(10)
(7)
TROUBLESHOOTING S-2
S-2 Engine does not start
(1) Engine does not turn Causes
General causes why engine does not turn

• Seizure inside engine
n
★ For seizure inside the engine, carry out the trou-
witc
ctio
it
bleshooting for S-4 Engine stops during opera-
nne
ery
ircu
ty s
tion.
batt
al co
safe
ng c
id
ated
itch
leno
tarti
• Failure in power train
min
r
y or
o
y
o t
rela
g sw
• Defective electrical system
rior
of s
t so
r
rela
gm
te
ttery
dete
ttery
el cu
ar
artin
iring
artin
fety
g ge
e ba
e ba
e sa
e or
e fu
e st
e st
ew
r i n
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ken
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Bro
Questions

Condition of horn when Horn does not sounds
starting switch is turned
ON Horn volume is low
Speed of rotation is low
When starting switch is Makes grating noise
turned to START, pinion Soon disengages pinion again
moves out, but
Makes rattling noise and does not turn
When starting switch is turned to START, pinion does not
Check items
move out
When starting switch is turned to ON, there is no clicking

sound
Battery terminal is loose
Troubleshooting of defective wiring in starting circuit
When starting switch is turned ON, linkage is not actuated

When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low

For the following conditions 1) - 5), turn the starting switch
OFF, connect the cord, and carry out troubleshooting
1) When terminal B and terminal C of starting switch are
connected, engine starts
Troubleshooting
2) When terminal B and terminal C of starting motor are

3) When terminal B and terminal C of safety relay are
4) When terminal of safety switch and terminal B of starting
motor are connected, engine starts
5) There is no 24V between battery relay terminal b and
terminal E
When ring gear is inspected directly, tooth surface is found to
be chipped
Cannot be moved by hand even when linkage of fuel cut
solenoid is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
—
WA380-5 20-1007
(7)
(9)
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust smoke comes

out (Fuel is not being injected)
General causes why engine turns but not exhaust smoke

comes out
• Supply of fuel impossible
• Supply of fuel extremely small
• Improper selection of fuel (particularly in winter)
Selection of fuel according to Causes

Type of ambient temperature
fuel –22 –4 14 32 50 68 86 104°F
d)
–30 –20 –10 0 10 20 30 40°C
eize
er s
ASTM D975 No. 2
key
lung
nk
Diesel oil
el ta
aft,
ASTM D975A
ck, p
on
No. 1
e sh
in fu
pist
p (ra
ng
iner
driv
d
ump
hole
pipi
i
leno
rain
stra
pum
nk
mp
ed p
fuel
r, st
her
t so
in ta
mp
n pu
ed
ion
reat
e
filte
king
l cu
l us
u
en f
fuel
ject
p
ctio
air b
feed
e
r fue
fuel
, lea
brok
e fu
e in
inje
ent
ged
rope
ged
ged
ged
ctiv
ctiv
ffici
ed,
ken
Clog
Defe
Clog
Defe
Clog
Clog
Insu
Seiz
Imp
Bro

Questions

Exhaust smoke suddenly stops coming out (when starting again)
Replacement of filters has not been carried out according to
Operation Manual
Fuel tank is found to be empty
There is leakage from fuel piping
When starting switch is turned ON, linkage is not actuated
Check items
When fuel filter is drained, fuel does not come out

1) No fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel spurts out even when injection pump piping sleeve
nut is loosened
Rust and water are found when fuel tank is drained
Inspect injection pump directly

When control rack is pushed, it is found to be heavy, or does
not return
Troubleshooting
Inspect feed pump directly

When fuel filter, strainer are inspected directly, they are found
to be clogged
When feed pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
Cannot be moved by hand even when linkage of fuel cut
solenoid is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
20-1008 WA380-5
(9)
(7)
TROUBLESHOOTING S-2
(3) Exhaust smoke comes out but

engine does not start (Fuel is
being injected) Causes
.)
r, etc
General causes why exhaust smoke comes out
)
tuck
but engine does not start
leve
cap
er s
y
spra
cker
• Lack of rotating force due to defective electri-
lung
tank
em
ater
e, ro
e
cal system
syst
ctiv
k, p
ttery
fuel
i r he
(valv
r
defe
(rac
fuel
nt
er
le in
d ba
i
ke a
l
tem
er
e
r
rain
e
ump
zle,
elem
rain
r in
d
r ho
• Improper selection of fuel and oil
rate
e sys
inta
n
p st
noz
i
i
, cyl
r, st
a
on p
terio
e
ner
valv
ed
ical
ing,
h
pum
tion
reat
filte
ring
l us
a
i
ectr
ject
e
ken
ogg
e
d
l
njec
air b
eed
air c
r fue
uel
ston
e or
, bro
e in
e el
e, cl
f
f
rope
ged
ged
ged
ged
ged
ctiv
ctiv
ctiv
ctive
n pi
kag
Defe
Defe
Defe
Clog
Clog
Clog
Clog
Clog
Wor
Defe
Imp
Lea
Suddenly failed to start
Questions
When engine is cranked, abnormal noise is heard from

around cylinder head
Non-specified fuel is being used
Operation Manual
Indicator lamp does not light up
Starting motor cranks engine slowly
When fuel lever is placed at FULL position, it does not contact stopper
Check items
1) Little fuel comes out even when injection pump piping

sleeve nut is loosened
2) No fuel comes out even when fuel filter air bleed plug is
loosened
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly

When control rack is pushed, it is found to be heavy, or
does not return
When fuel filter, strainer are inspected directly, they are
Troubleshooting
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
When air cleaner element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or
operation is too heavy
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
WA380-5 20-1009
(7)
(9)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly

(Follow-up is poor)
General causes why engine does not pick up smoothly Causes

ap
y
seat
spra
nk c
• Improper fuel used
lve
el ta
tive
nce
d va
er
efec
ger
in fu
fere
r lin
e an
ent
ng
er
n
d
r
nter
rain
aine
pipi
e
hole
e
lem
zle,
p pl
valv
ranc
d
cylin
er, i
p st
noz
r
er e
fuel
pum
r, st
her
clea
t of
pum
harg
n
lean
ing,
reat
filte
king
ntac
ctio
tion
lve
c
r
air b
eed
air c
urbo
uel
, lea
inje
r va
ston
e co
njec
f
f
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
ed i
n pi
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
Questions
Operation Manual
Engine pick-up suddenly became poor
Color of exhaust gas
Black
Check items

High idling speed under no load is normal, but speed
suddenly drops when load is applied
When air cleaner element is inspected directly, it is found to

be clogged
found to be clogged
When feed pump strainer is inspected directly, it is found to be
Troubleshooting
clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or does not return
When valve clearance is checked directly, it is found to be
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-1010 WA380-5
(7)
TROUBLESHOOTING S-4
S-4 Engine stops during operations

General causes why engine stops during operations Causes
• Seized parts inside engine
c.)
r , et
)
tuck
leve
• Overheating
er s
cker
★ If the engine is overheating and the engine
rod
lung
nk
e, r o
el ta
nt
stops, carry out troubleshooting for over-
ey
ring
ting
ck, p
ston
(valv
e
ft, k
ui pm
in fu
heating.
a
nec
p pi
ft be
p ( ra
ng
iner
sha
(See S-14 Coolant temperature becomes
stem
iner
con
y eq
ole
pipi
pum
in
stra
ksha
pum
e
too high)
stra
nk
r tra
er h
v
e sy
in
on,
iliar
fuel
p dr
in ta
r t ra
• Failure in power train
ump
feed
cran
valv
eath
gea
ion
pist
ter,
x
king
pum
p au
owe
uel
ject
ed p
l
zed
i
a If the engine stops because of a failure in
c
zed
zed
r
zed
f
i
air b
ynam
fuel
, lea
f
pum
e in
in p
fuel
, sei
ent
, sei
, sei
, sei
e
the power train, carry out troubleshooting
ged
ged
ged
ged
ctiv
en d
ffici
ken
ure
ken
for the chassis.
ken
ken
ken
ken
Clog
Clog
Defe
Clog
Clog
Insu
Brok
Fail
Bro
Bro
Bro
Bro
Bro
Bro
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Questions
Engine overheated and stopped

stopped
Engine stopped slowly
There was hunting and engine stopped
Replacement of filters has not been carried out according
to Operation Manual
Fuel level lamp lights up
Engine rotates, but stops when power train is operated
Check items
Does not turn at all

When it is attempted to Turns in opposite direction
turn by hand using
barring tool Moves amount of backlash
Shaft does not turn
Troubleshooting of chassis
Metal particles are found when oil is drained
Remove oil pan and inspect directly

Remove head cover and inspect directly
Troubleshooting
When gear train is inspected, it does not turn

Rotates when pump auxiliary equipment is removed
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
Inspect feed pump directly
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
Add
WA380-5 20-1011
(7)
(10)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly

(Hunting)
General causes why engine does not rotate smoothly Causes
• Air in fuel system
p
zzle
pum
• Defective governor mechanism
d no
eed
• Defective electrical governor mechanism
p an
nd f
(engine with electrical governor)
pum
nk a
nk
el ta
★
k
If hunting stops when electrical governor rod is
el ta
r
c
erno
feed
ol ra
rnor
in fu
disconnected, carry out troubleshooting for the
n fu
iner
gov
een
ontr
ove
troubleshooting for electric system.
er
tw ee
hole
in ta w
betw
rain
stra
of g
t of
of c
o
k
l
it be
n
o
r, st
her
men
ump
is to
rcuit
ion
ion
circu
reat
filte
erat
erat
just
i
fuel
ed p
c
e d
air in
air b
air in
fuel
spe
e ad
e op
e op
ent
f e
ged
ged
ged
idle
ged,
ctiv
ged,
ctiv
ctiv
ffici
Clog
Clog
Clog
Defe
Defe
Defe
Clog
Insu
Clog
Low
Occurs at a certain speed range
Questions
Occurs at low idle

Condition of hunting
Occurs even when speed is raised
Occurs on slopes
to Operation Manual
Rust, water are found when fuel tank is drained
Check items
When feed pump is operated,

1) No response, light, return is quick
2) No response, light, return is normal
Engine speed sometimes rises too far
Engine is sometimes difficult to stop
When governor lever is moved it is found to be stiff

When injection pump is tested, governor is found to be
Troubleshooting
improperly adjusted
does not return
When feed pump strainer is inspected directly, it is
found to be clogged
found to be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
20-1012 WA380-5
(9)
(7)
TROUBLESHOOTING S-6
S-6 Engine lacks output

(or lacks power) Causes
General causes why engine lacks output
ent
stm
m
y
seat
spra
hrag
adju
tank
lve
tive
diap or diap
e
d va
fuel
renc
ctiv
efec
m
er
e an
hrag
ung
g
n
ent
defe
er
erfe
sat
le, d
i pi n
i
pum ainer
(if non-specified fuel is used, output drops)
rain
hol e
e
inde
lem
p pl
valv
pen
ranc
, int
p
ge,
z
• Lack of output due to overheating
p st
noz
tr
fuel
er e
pum
, cyl
her
com
rger
er, s
nka
t of
clea
ate
ion
reat
lean
★ If there is overheating and lack of output,
king
ring
ntac
er li
estg
cha
tion
t
ost
lve
l
ject
f i
air b
carry out troubleshooting for S-14 overheat-
feed
air c
l lev
fuel
urbo
, lea
e bo
e co
r va
ston
njec
ew
n
ing.
t fue
rope
ged
ged
ged
ctiv
ged
ged
ctiv
ged
ctiv
ed t
n pi
ed i
Defe
Clog
Clog
Clog
Defe
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Ben
Imp
Suddenly
Power was lost
Gradually
Questions

to Operation Manual
Black
Check items
High idling speed under no load is normal, but speed

suddenly drops when load is applied
High idle speed of engine is low
When air cleaner element is inspected directly, it is found to be

clogged
found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found

to be clogged
is stopped
does not return
When valve clearance is checked directly, it is found to be
When lever is placed at FULL position, it does not contact stopper
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
WA380-5 20-1013
(7)
(9)
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black Causes
d)
ad
)
tion
eize
d he
njec
er s
at
ray
r an
e se
lung
e sp
ve i
arge
valv
essi
e
ctiv
ck, p
renc
och
er
and
(exc
defe
r lin
p ( ra
ent
turb
erfe
lve
g
r
ce
i nde
mp
lem
zle,
uffle
imin
, int
pum
een
aran
f va
u
z
er e
, cyl
n no
ed m
rger
on t
w
ct o
e cle
ion
ion
t
lean
ir be
ring
ctio
cha
ecti
onta
ject
ject
logg
valv
air c
a
inje
urbo
r inj
ston
e in
e in
c
e of
d, c
e
r
rope
rope
ged
ctiv
ctiv
ged
ctiv
n pi
ed t
she
kag
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
Suddenly became black
Color of exhaust gas Gradually became black
Questions

Suddenly
Power was lost
Gradually
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp

When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting

is stopped
When check is made using delivery method, injection timing
is found to be incorrect
When valve clearance is checked directly it is found to be
When muffler is removed, exhaust color returns to normal
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
Correct
Adjust
Adjust
Adjust
Clean
20-1014 WA380-5
(7)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
★ Do not run the engine at idle for more than 20 Causes
minutes continuously. (Both low and high idle)
r
arge
General causes why oil consumption is excessive
och
• Abnormal combustion of oil
Turb
al
d
• External leakage of oil
hea
n se
ce
em
e
oler
• Wear of lubrication system
urfa
hos
der
oke
syst
er
s
r lin
cylin
her
), br
seal
pl ug
r oi l
e
reat
k
inde
d
nd
uide
inta
n or
ter o
pi ng
eal,
n
ain
e
er e
or b
, cyl
bine
m, g
om
ar s
il pa
il dr
il pi
il fil
ing
low
ther
r
ring
in fr
n re
oole
t tur
(ste
mo
mo
mo
mo
on r
at b
brea
roke
ston
cked
al a
oil c
e fro
e fro
e fro
e fro
lve
pist
a l
n va
n se
n se
ged
n, b
n pi
t su
kag
ken
kag
kag
kag
ken
Clog
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Bro
Lea
Lea
Lea
Confirm recent repair history Bro
Oil consumption suddenly increased
Questions
Engine oil becomes contaminated quickly

Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in clutch or TORQFLOW transmission or damper
chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be
Troubleshooting
clogged with dirty oil

There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be
dirty with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
WA380-5 20-1015
(7)
(10)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly Causes
• Entry of exhaust gas due to internal wear
• Clogging of lubrication passage
end
• Improper oil used
e
rbin
• Operation under excessive load
tube
er tu
ose
er
ain
r lin
harg
i l dr
r
athe
inde
er o
ui de
boc
lack
, bre
, cyl
harg
t tur
g
is b
r
e
ther
o ol e
ring
valv
r
al a
e
rboc
oke
t
il fil
brea
oil c
ston
e se
lve,
t sm
u
o
t
ged
n va
ged
ged
ged
ctiv
n pi
aus
Clog
Defe
Clog
Clog
Clog
Wor
Wor
Exh
Questions

Non-specified oil is being used
Black
Carry out troubleshooting for “S-7 Exhaust smoke is black”.

Excessive
Amount of blow-by gas
Check items
None
When oil filter is inspected, metal particles are found
When exhaust pipe is removed, inside is found to be dirty
with oil
Engine oil temperature rises quickly

When breather element is inspected directly, hose is
broken or is found to be clogged with dirty oil
Troubleshooting
When oil filter is inspected directly, it is found to be clogged

When oil cooler is inspected directly, it is found to be clogged
Turbocharger oil drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to
be catching or broken
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
20-1016 WA380-5
(9)
(7)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive Causes
• Leakage of fuel
)
tion
ge
ter
on)
njec
linka
el fil
(pist
ive i
g, fu
trol
mp
r
er
ce ss
cove
l con
pipin
d pu
n g
ng
y
p plu
p (ex
spra
f fue
ead
timi
e
fuel
f e
pum
h
pum
e
lder
nt o
tion
nsid
from
side
le ho
stme
injec
tion
eal i
el in
o
age
t i
injec
injec
nozz
adju
oil s
fuel
of fu
leak
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Defe
Defe
Leak
Defe
Defe
Defe
Defe
Exte
Questions

More than for other machines of same
Condition of fuel model
consumption Gradually increased
Suddenly increased
Black
Exhaust smoke color
White
There is irregular combustion
Check items
When exhaust manifold is touched immediately after starting engine,

temperature of some cylinders is low
Match mark on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is excessive

Troubleshooting
When control rack is pushed, it is found to be heavy, or does not return

When check is made using delivery method, injection timing is found
to be incorrect
Remove feed pump and inspect directly
When engine speed is measured, low idling and high idling speeds
are found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
WA380-5 20-1017
(7)
S-11 Oil is in coolant, or coolant

spurts back, or coolant level
goes down
General causes why oil in coolant Causes
• Internal leakage in lubrication system

• Internal leakage in cooling system
et
gask
k
bloc
ing
ler
head
l coo
, O-r
der
g
cylin
ittin
core
ead,
in oi
by p
er h
r tra
oler
s in
ylind
rack
used
owe
il co
nal c
en o
en p
en c
s ca
Brok
Brok
Hole
Brok
Inter
Questions

Suddenly increased
Oil level
Gradually increased
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white
Check items
Excessive air bubbles inside radiator, spurts back

Hydraulic oil, transmission oil is cloudy white
When hydraulic oil, transmission oil is drained, water is
found
shooting
Trouble-

Pressure-tightness test of cylinder head shows there is leakage
Replace
Replace
Replace
Replace
Replace
Remedy
20-1018 WA380-5
(10)
(7)
S-12 Oil pressure caution lamp lights

up (Drop in oil pressure)
General causes why oil pressure lamp lights up
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
★ Standards for engine oil selection
Selection of oil according to Causes

Type of oil ambient temperature
–30 –20 –10 0 10 20 30 40°C
SAE30CD
SAE10WCD
Engine oil
g
ipin
SAE10W-30CD
n
n
il pa
sor
l pa
lic p
ing
SAE15W-40CD
sen
e oi
r
alve
de o
drau
braz
nso
l
ure
d
urna
e
tor v
el se
insi
insi
d hy
n
ipe
valv
mp
il pa
ress
g, jo
on p
il
ilter
iner
gula
ipe
l lev
she
l pu
in o
lief
in o
p
oil p
stra
oil f
l
arin
, cru
e oi
e re
e re
e oi
e oi
suct
uel
i l
of o
n be
ctiv
ctiv
ctiv
ged
ged
ged
ctiv
ctiv
king
er, f
ken
Defe
Defe
Defe
Defe
Defe
Lack
Clog
Clog
Clog
Wor
Wat
Lea
Bro

Questions

Operation Manual
Caution lamp lights up
Lights up at low idle
Condition when oil Lights up at low, high idle
pressure lamp lights up
Lights up on slopes
Sometimes lights up
Check items
There is crushing, leakage from hydraulic piping (external)

Oil level sensor lamp lights up
When oil level in oil pan is inspected, it is found to be low
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
Carry out troubleshooting
for “S-13 Oil level rises”.
When oil filter is inspected, it is found to be clogged

Troubleshooting

Oil pump rotation is heavy, there is play
There is catching of relief valve or regulator valve, spring or
valve guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out
When oil pressure is measured, it is found to be within
standard value
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
Add
WA380-5 20-1019
(7)
(9)
S-13 Oil level rises (Water, fuel in oil)

★ If there is oil in the coolant, carry out troubleshooting Causes
for “S-11 Oil is in coolant, or coolant spurts back, or
coolant level goes down”.
ver
General causes why oil level rises
d co
seal
hea
• Water in oil (milky white)
ent
mp
ket
side
• Fuel in oil (diluted, and smells of diesel fuel)
i pm
ace
n pu
gas
• Entry of oil from other component
g in
surf
-ring
equ
leev
ctio
k
ead
bloc
n
seal
pi pi
ary
s
e
re, O
d, h
j
r
n
e
g
i
der
hold
l
from
ittin
stat
rear
side
aux
hea
r co
cylin
rmo
by p
rt in
zzle
oole
ged
mp
der
fuel
side
e
e no
e pu
cylin
e pa
ama
ade
e th
oil c
e of
ks in
sm
ctiv
ctiv
ctiv
ctiv
n, d
kag
ken
ken
Defe
Hole
Defe
Defe
Defe
Crac
Wor
Lea
Bro
Confirm recent repair history Bro
Questions

There is oil in radiator cooling water
Fuel must be added more frequently
Exhaust smoke is white
When engine is first started, drops of water come from
muffler
Leave radiator cap open. When engine is run at idling,
Check items
an abnormal number of bubbles appear, or water spurts back

Oil level goes down in clutch, TORQFLOW transmission,
or damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Water temperature is low

Pressure-tightness test of cylinder head shows there is leakage
Troubleshooting

Inspect rear seal directly
When pump auxiliary equipment is removed, seal is found to
be damaged
Remove injection pump and inspect directly
Defective contact with thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-1020 WA380-5
(10)
(7)
S-14 Coolant temperature becomes too

high (Overheating)
General causes why coolant temperature becomes too Causes
high
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
re
• Defective cooling circulation system
ratu
en)
• Rise in oil temperature in power train
ket
mpe
t op
aug
lley
gas
★ Carry out troubleshooting for chassis.
re g
ns
s no
n pu
il te
or fi
ead
u
er o
doe
oole
rn fa
t
alve
pera
diat
d, h
tat (
vert
g
core
er
oil c
, wo
ittin
re v
d ra
hea
ump
tem
wat
mos
con
ator
by p
essu
ping
ken
she
der
ater
er p
ing
rque
ther
, bro
radi
, cru
cylin
p
e pr
l
ade
ew
wat
o
l i
o
s
in to
e
of c
ged
ged
ged
sm
ctiv
ctiv
ctiv
belt
ken
ken
Clog
Defe
Hole
Clog
Defe
Lack
Clog
Defe
Rise
Bro
Bro
Fan
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Radiator water level sensor lights up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
There is play when fan pulley is rotated

Radiator shroud, inside of underguard are clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Power train oil temperature enters red range faster than
engine water temperature
Temperature difference between top and bottom radiator tanks

Carry out troubleshooting for chassis.
is excessive
Temperature difference between top and bottom radiator tanks
is slight
Troubleshooting
When water filler port is inspected, core is found to be clogged

When function test is carried out on thermostat, it does not
open even at cracking temperature
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set
pressure is found to be low
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy —
Add
WA380-5 20-1021
(7)
(10)
S-15 Abnormal noise is made

★ Judge if the noise is an internal noise or an external Causes
noise.
ead
etc.)
)
General causes why abnormal noise is made
ition
d)
der h
i on)
ver,
eize
f pos
ject
cylin
er le
• Abnormality due to defective parts
er s
ce
n
out o
r
• Abnormal combustion
rock
aran
r line
l ung
r and
ive
e
• Air sucked in from intake system
c
e
oard
e cle
cess
linde
alve
eren
ck, p
enc
arge
pum oz z l e
m (v
ing b
sh
x
r
g, cy
valv
f
p (ra
boch
e
r
p (e
inte
f
nn
ckla
nter
yste
divid
n rin
i ng
t of
pum
n tur
ctio
a
belt
er, i
b
lve s
ush
n
pisto
fler (
i nj e
train
wee
e
i on
i on
harg
n
m
ic va
b
n, fa
just
muf
r bet
d
r of
ject
ject
zed
r
e
a
c
ynam
z
wea
urbo
r ge
d fa
e ad
, sei
e in
of ai
side
, sei
e in
rme
rope
ssive
ctiv
ged
ctiv
ct in
en d
ctiv
ed t
sing
age
Defe
Defo
Defe
Defe
Clog
Defe
Brok
Leak
Seiz
Imp
Exce
Mis
Questions
Condition of abnormal Gradually occurred

noise Suddenly occurred
Black
Metal particles are found in oil filter
Engine pickup is poor and combustion is abnormal
Check items

Abnormal noise is loud when accelerating engine
Leakage of air between turbocharger and cylinder head, loose clamp
Vibrating noise is heard from around muffler

Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is
Troubleshooting
stopped
When control rack is pushed, it is found to be heavy, or does
not return
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside
standard value
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
20-1022 WA380-5
(7)
S-16 Vibration is excessive

★ If there is abnormal noise together with the vibra- Causes
tion, carry out troubleshooting also for “S-15
tuck)
n)
Abnormal noise is made”.
ctio
etc. s
i on
ned
i nj e
General causes why vibration is excessive
ush
ver,
alig
per)
fuel
en c
ker le
• Defective parts (abnormal wear, breakage)
mis
dam
sive
ring
brok
, roc
• Improper alignment
n
aft (
xces
bea
a i
valve
• Abnormal combustion
er tr
lts,
h
t sh
klas
ain
p (e
g bo
(
pow
m
utpu
d, m
e
bac
pum
st
ntin
y
and
lve s
de o
g ro
n
ing
u
i on
i
r tra
o
ic va
g i ne
m
ctin
insi
ject
s
gea
u
ynam
e
nne
ngin
b
f en
e in
part
m
r
d
n co
rope
ter o
n ca
ctiv
se e
ctive
ken
Defe
Wor
Wor
Imp
Cen
Loo
Defe
Bro
Questions
Suddenly increased
Condition of vibration
Gradually increased
Metal particles are found in oil filter
Oil pressure is low at low idling
Check items
Vibration occurs at mid-range speed

Vibration follows engine speed
Exhaust smoke is black

Remove side cover and inspect directly
Troubleshooting
Inspect directly for loose engine mounting bolts, broken cushion

Inspect inside of output shaft (damper) directly
When face runout and radial runout are inspected, they are
found to be incorrect
Remove front cover and inspect directly
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
WA380-5 20-1023
(7)
30 DISASSEMBLY AND ASSEMBLY
How To Read This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2

Precautions When Carrying Out Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Special tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
Removal and Installation of Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
Removal and Installation of Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
Removal and Installation of Radiator and Fan Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
Removal and Installation of Aftercooler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
Removal and Installation of Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
Removal and Installation of Nozzle Holder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
Removal and Installation of Fan and Fan Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-35
Removal and Installation of Fuel Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
Removal and Installation of Parking Brake Disc Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
Removal and Installation of Torque Converter and Transmission Assembly . . . . . . . . . . . . . . . . . . . 30-41
Disassembly and Assembly of Transmission Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
Disassembly and Assembly of Transmission Clutch Pack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-57
Disassembly and Assembly of Parking Brake Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
Disassembly and Assembly of Torque Converter Assembly (Standard Specification) . . . . . . . . . . . . 30-80
Disassembly and Assembly of Torque Converter Assembly (Lock-Up Specification). . . . . . . . . . . . . 30-84
Removal and Installation of Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90
Removal and Installation of Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-93
Disassembly and Assembly of Axle Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
Disassembly and Assembly of Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102
Removal and Installation of Center Hinge Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-121
Removal and Installation of Cab Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128
Removal and Installation of Cab and Floor Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-129
Removal and installation of operator's cab glass (Stuck glass). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132
Removal and Installation of Transmission, Work Equipment, and PPC Pump Assembly . . . . . . . . . . 30-140
Removal and Installation of Steering, Switching, and Fan Pump Assembly . . . . . . . . . . . . . . . . . . . . 30-141
Removal and Installation of Steering Demand Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142
Removal and Installation of E.C.S.S. Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
Removal and Installation of Work Equipment Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-144
Disassembly and Assembly of Hydraulic Cylinder Assembly (Steering, Lift, and Bucket
Cylinder Assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-146
Removal and Installation of Hydraulic Tank Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-154
Removal and Installation of Work Equipment Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-156
Removal and Installation of Counter Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160
Removal and Installation of Air Conditioner Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-161
Removal and Installation of Air Conditioner Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-164
Disassembly, Assembly of Operator's Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-165
WA380-5 30-1
(10)
(7)
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
HOW TO READ THIS MANUAL

REMOVAL AND INSTALLATION OF
ASSEMBLIES
Special tools Installation
• Special tools that are deemed necessary for • Except where otherwise instructed, install parts
removal or installation of parts are listed. is the reverse order of removal.
• List of the special tools contains the following • Instructions and precautions for installing parts
kind of information. are shown with [*1] mark in the INSTALLATION
1) Necessity Section, identifying which step the instructions
are intended for.
t: Special tools which cannot be substi-
tuted, should always be used. • Marks shown in the INSTALLATION Section
q: Special tools which are very useful if stand for the following.
k:
available, can be substituted with com-
This mark indicates safety-related pre-
mercially available tools.
cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly
developed for this model. This mark gives guidance or precau-
a: tions when doing the procedure.
R: Tools with upgraded part numbers,
2:
remodeled from already available tools
This mark stands for a specific coating
for other models.
agent to be used.
Blanks: Tools already available for other models,
3:
used without any modification. This mark indicates the specified
3) Circle mark (Q) in sketch column: torque.
5:
A circle mark means that a sketch of the spe-
This mark indicates an amount of oil or
cial tool is presented in the section of
water to be added.
Sketches for Special Tools.
a Part No. of special tools starting with 79*T
Sketches of special tools
means that they are locally made parts and as
• Various special tools are illustrated for the con-
such not interchangeable with those made by
venience of local manufacture.
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Removal
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
k:
doing the work.
This mark gives guidance or precau-

This mark shows that there are instruc-

[*1] :
tions or precautions for installing parts.
6:
This mark shows oil or water to be
drained.
4 : Mass of a part or component.
30-2 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
DISASSEMBLY AND ASSEMBLY OF

ASSEMBLIES
Special tools Assembly
• Special tools which are deemed ncessary for dis- • Section titled ASSEMBLY contain procedures,
assembly and assembly are listed in this section. precautions and the know-how for the work, as
• List of the special tools contains the following well as the amount of oil or water to be added.
kind of information. • Various symbols used in the ASSEMBLY Sec-
1) Neccessity tion are explained and listed below.
k:
t: Special tools which cannot be substi- This mark indicates safety-related pre-
tuted, should always be used. cautions which must be followed when
q: Special tools which are very useful if doing the work.
available, can be substituted with com-
mercially available tools. This mark gives guidance or precau-
2) Distinction of new and existing special tools
2:
N: Tools with new part numbers, newly This mark stands for a specific coating
developed for this model. agent to be used.
R: Tools with upgraded part numbers,
3:
remodeled from already available tools This mark indicates the specified
for other models. torque.
Blanks: Tools already available for other models,
5:
used without any modification. This mark indicates an amount of oil or
water to be added.
3) Circle mark (Q) in sketch column:
A circle mark means that a sketch of the spe-
cial tool is presented in the section of Sketches of special tools
Sketches for Special Tools. • Various special tools are illustrated for the con-
a Part No. of special tools starting with 79*T venience of local manufacture.
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Disassembly
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or water
to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
k:
doing the work.
This mark gives guidance or precau-

6:
This mark shows oil or water to be
drained.
WA380-5 30-3
(5
10)
2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precau-
tions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number of thickness of the shims, and keep in a safe place.
• When raising components, be sure to use lifting equipment of ample strength.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from enter-
ing after removal.
a Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal Plug (nut end) Nut (elbow end)
number
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
2) Split flange type hoses and tubes

Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions (mm)

Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
30-4 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pins and lock plates securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with anti-friction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or coolant, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydrau-
lic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylin-
der 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
a When using the machine for the first time after repair or long storage, follow the same procedure.
WA380-5 30-5
(10)
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

★ Tools with part number 79{T-{{{-{{{{ can not be supplied (they are items to be locally manufac-
tured).
★ Necessity: : Cannot be substituted, should always be installed (used)
z: Extremely useful if available, can be substituted with commercially available
part.
New/remodel: N: Tools with new part numbers, newly developed for this mode.
R: Tools with upgraded part numbers, remodeled from items already available
for other modeles.
Blank: Tools already available for other models, used without any modification
★ Tools marked { in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPE-
CIAL TOOLS).
New/
Nece Sket
Component Symbol Part No. Part Name ssity
Q’ty remo
ch Nature of work, remarks
del
A 1 790-331-1110 Wrench z 1 Tightening of cylinder head bolt
1 795-799-1130 Gear z 1
Engine assembly 2 795-799-1900 Pin z 1
G Removal of fuel injection pump
3 795-799-1950 Lock pin z 1
4 795-799-1390 Plate z 1
1 793T-607-1190 Bracket z 1 {
Removal, installation of parking
K 2 722-14-13130 Plate z 1 brake disc and plate
3 01011-62020 Bolt z 1
793T-607-1190 Bracket z 1 {
1 722-14-13130 Plate z 1
01011-62020 Bolt z 1
793T-607-1130 Push tool z 1 {
3 790-101-5421 Grip z 1
Parking brake assembly 01010-81240 Bolt z 1
4 793T-607-1140 Spacer z 1 { Disassembly, assembly of parking
brake assembly
H
5 792T-446-1150 Push tool z 1 {
6 797T-423-1141 Push tool z 1 {
793T-512-1110 Push tool z 1 N {
8 790-101-5421 Grip z 1
01010-81240 Bolt z 1
9 793T-607-1160 Spacer z 1 {
10 793T-607-1180 Push tool z 1 { Press-fitting of front coupling cover
793T-607-1210 Lifting tool z 2 {
Transmission assembly F 2 Lifting up of clutch pack assembly
793-607-1230 Pin z 2
1 790-201-2170 Plate 1
2 790-201-2730 Spacer 1
C2 Press fitting of bearing
3 796-465-1120 Push tool 1
Transmission assembly
(continued) 4 790-201-2740 Spacer 1
1 793-607-1110 Seal holder 1 N
C3 Assembly of piston seal
2 793-607-1120 Seal holder 1 N
C12 799-301-1500 Oil leak tester kit 1 Check of operation of piston
790-501-5000 Unit repair stand z 1
Torque converter 790-501-5200 Unit repair stand z 1 Disassembly, assembly of torque

B
assembly 790-901-2110 Bracket z 1 converter assembly
790-901-2150 Plate z 1
WA380-5 30-7
(10)
2
(7)
Nece New/ Sket

Q’ty remo
del
793T-522-1140 Push tool 1 N {
1 Press fitting of bearing (wheel side)
793T-522-1150 Spacer 1 N {
2 797T-423-1290 Push tool 1 { Press fitting of bearing (Deff. side)
Axle assembly J
3 793T-522-1160 Push tool 2 N { Press fitting of oil seal sleeve
793T-522-1171 Seal support 2 N {
4 Assembly of axle housing
01016-30860 • Bolt 6
790-501-5000 z
1 or
Disassembly, assembly of differen-
D1 790-501-5200 Unit repair stand z tial assembly
2 790-901-2110 Bracket z
3 790-901-1331 Plate z
1 793T-522-1110 Push tool {
D2 2 790-101-5421 Grip Press fitting of oil seal
3 01010-81240 Bolt
1 793T-522-1110 Push tool {
Differential assembly 2 793T-522-1120 Spacer {
D3 Press fitting of dust seal
3 790-101-5421 Grip
4 01010-81240 Bolt
D4 790-201-2740 Push tool
Press fitting of pinion gear bearing
D5 793T-522-1130 Push tool N {
1 790-301-1720 Adapter
2 799-101-5002 Hydraulic kit
D6 Check of brake oil for leakage
3 793-605-1001 Brake tester
4 790-101-1102 Hydraulic pump
No-load operating torque of limited
D7 796-751-1510 Wrench 1
slip differential
1 790-101-2300 Push puller 1
2 793-520-2370 Push tool 1
3 793-520-2350 Push tool 1
Removal, installation of center hinge
Center hinge pin E1 4 793-520-2540 Guide 1 pin
5 793-520-2360 Bar 2
6 790-101-1102 Hydraulic pump 1
7 790-101-2102 Puller (30 tons) 1
30-8 WA380-5
(10)
2
Nece New/ Sket

Q’ty remo
del
790-502-1003 Repair stand z 1 Disassembly, assembly of hydraulic
1 cylinder assembly
790-101-1102 Hydraulic pump z 1
790-102-2303 Wrench assembly z 1
2 or For steering cylinder head
790-330-1100 Wrench assembly z 1
790-302-1270 Socket (Width
3
across flats: 50 mm) z 1 For steering cylinder piston nut
790-102-4300 Wrench assembly z 1 For boom and bucket cylinder pis-

4 tons
790-102-4310 Pin z 1
5 790-720-1000 Expander z 1
796-720-1640 Ring z 1
07281-00909 Clamp z 1
796-720-1680 Ring z 1 For assembly of piston ring
Hydraulic cylinder 6
I 07281-01589 Clamp z 1
assembly
796-720-1690 Ring z 1
07281-01919 Clamp z 1
790-201-1702 Push tool kit z 1
• 790-101-5021 Grip z 1
For assembly of cylinder head
7 • 01010-80816 Bolt z 1
bushing
• 790-201-1751 Push tool z 1
• 790-201-1841 Push tool z 1
790-201-1500 Push tool kit z 1
• 790-101-5021 Grip z 1
For assembly of cylinder head dust
8 • 01010-80816 Bolt z 1 seal
• 790-201-1560 Plate z 1
• 790-201-1650 Plate z 1
799-703-1200 Service tool kit 1
Vacuum pump
799-703-1100
(100V) 1
Air conditioner Vacuum pump

assembly
X 799-703-1110
(220V) 1 Charging of air conditioner gas
Vacuum pump
799-703-1120 (240V) 1
799-703-1401 Gas leak detector 1

2-1 793-498-1120 Clear plate 2
2-2 793-498-1130 plate 2
Operator’s cab glass X Installation of operator’s cab glass
2-3 793-498-1110 Magnet 2
3 793-498-1210 Lifter (Suction cups) 2
WA380-5 30-9
(10)
2
(7)
SPECIAL TOOL ILLUSTRATIONS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D2-1 Push tool

D3-1 Push tool
D3-2 Spacer
30-10 WA380-5
(9)
2
D5 Push tool
F2 Lifting tool
WA380-5 30-11
(9)
2
(7)
H1 Bracket
H3 Push tool
30-12 WA380-5
(9)
2
H4 Spacer
H5 Push tool
WA380-5 30-13
(9)
2
(7)
H6 Push tool
H8 Push tool
30-14 WA380-5
(9)
2
H9 Spacer
H10 Push tool
CWW10424
WA380-5 30-15
(9)
2
(7)
J1-1 Push tool
J1-2 Spacer
30-16 WA380-5
(9)
2
J2 Push tool
J3 Push tool
WA380-5 30-17
(9)
2
(7)
J4 Seal support
K1 Bracket
30-18 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY

REMOVAL 3) Disconnect the air conditioner hoses (4)
and (5) and also disconnect the overflow
hose of the reservoir tank from the clamp.
WARNING! Park the machine on flat
ground and set the frame lock bar to
the frame. Then, lower the work equip-
ment to the ground completely and
stop the engine. Apply the parking
brake and put the blocks under the
wheels. CPW10702
WARNING! Disconnect the battery (-)

terminal in advance.
1. Degas the air conditioner. [*1]

2. Drain coolant.
3. Engine hood assembly
See Paragraph 2 of "Removal of Cylinder
Head Assembly" to remove the engine hood 4) Disconnect the air conditioner hoses (6)
assembly. and (7) at the air conditioner compressor
4. Bulkhead assembly (8) and remove the hose clamps to bring
1) Disconnect the transmission breather them to the bulkhead side.
hose (1).
2) Remove the connector (3) of the engine
stop solenoid relay (2).
CPW10703
CPW10701
WA380-5 30-19
(10)
2
(7)
5) Disconnect the dust indicator hose and 10) Lift the bulkhead assembly (14) slowly
the air intake hose (9) and remove the air and remove it.
cleaner assembly (10). ★ Lift the air conditioner hoses and the
rubber sheet at the same time and
remove them.
4 Bulkhead Assembly: 92 kg
CPW10704
CPW10706
6) Remove the connector (11).

7) Sling the bulkhead assembly and remove
the mounting bolts (12) and (13).
8) Remove the lock bolts to the right and to
the left of the rubber sheet. 5. Disconnect the starting motor wiring harness
★ Find them carefully because they are (15), the air heater replay wiring harness
located below the main frame and (R11) and (16), the engine ground wiring har-
cannot be found easily. ness (17), the emergency steering motor wir-
ing harness (18) and the connectors (19) and
(20).
6. Disconnect the car heater hose (21).
CPW10705
CPW10707
9) Lift the bulkhead assembly a bit and pull

out the two drain hoses of the air condi-
tioner unit from the clamp. (Machine right
side) 7. Disconnect the car heater hose (22) and
remove the clamp.
8. Disconnect the radiator outlet hose (23).
CPW10708
30-20 WA380-5
(9)
2
9. Lift and remove the muffler assembly (24). 15. Disconnect the turbo outlet hose (37).
4 Muffler assembly: 36 kg
10. Disconnect the aftercooler outlet hose (25).

11. Disconnect the radiator inlet hose (26).
12. Disconnect the aeration hose (27). CPW10711
CPW10709
16. Disconnect the accelerator cable (38). [*2]

17. Disconnect the fuel suction hose (39) and
return hose (40) and remove the clamp from
the engine. [*3]
18. Remove the clamp and disconnect the tube
(41) from the engine.
13. Air cleaner bracket

1) Remove the dust indicator connector (28).
2) Disconnect the ground wiring harness
(29) and also remove the heater replay
(30).
3) Disconnect the breather hose (31) from CPW10712
the head cover, remove the clamps (32)
and (33) and bring it to the left side of the
engine.
4) Remove the fuel filter (34) from the
bracket.
5) Remove the air cleaner bracket (35).
14. Disconnect the spill hose (36).
19. Disconnect the wiring harness (42) from the

emergency motor and bring it to the engine
side.
20. Remove the engine oil drain valve (43).
CPW10710
CPW10713
WA380-5 30-21
(9)
2
(7)
21. Engine assembly 6) Remove the engine assembly (48) from

1) Use a lever block to sling the engine the torque converter by adjusting the lift-
assembly. ing height and angle with the lever block
2) Remove the engine mounting bolts (44) and the crane.
and (45).
4 Engine assembly:
★ Hold the nuts for the lower side to
820 kg
prevent them from turning
together. [*4]
[*5]
CPW10714 CPW10717
3) Use the hydraulic jack [1] and the block [2] INSTALLATION
to support the torque converter side of
the torque converter and transmission • Carry out the installation in the reverse order
assembly. to removal.
[*1]
• Fill the air conditioner with gas (R134a).
[*2]
• See the paragraph of "Adjustment of
Accelerator Pedal" in Testing and Adjust-
ing engine speed.
[*3]
• Bleed air from the fuel system.
[*4]
Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
[*5]
★ Check that and o-ring is nested in the
4) Remove the flywheel case (46) and 12 torque converter housing.
pieces of the mounting bolts (47) on the
★ Adjust the height of the pilot cover very
torque converter side.
5) Turn the drain tube of the engine oil pan carefully so that it enters the hole of the
aside until it comes to the fuel tank. flywheel smoothly. Never insert it in the
hole by force.
• Coolant supply
Feed coolant up to the neck of the radiator.
Start the engine to circulate coolant and
check the coolant level in the reservoir tank.
• Oil supply
CPW10716
Feed engine oil (designated one) up to the
specified level.
30-22 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION CYLINDER
OF CYLINDER HEAD
HEAD ASSEM-
ASSEMBLY
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY

SPECIAL TOOL 4) Remove the baffle mounting brackets (6)
and (7).
New/Modified
Necessity
Quantity
Sketch
Part
Symbol Part Number Name
A1 790-331-1110 Wrench ● 1
REMOVAL

1. Drain coolant.
1) Disconnect the exhaust pipe (1). 5) Remove the connector (8) and then
2) Disconnect the hose (2) between the res- remove the back buzzer (9).
ervoir tank and the radiator on the reserve 6) Remove the connector (10).
tank side and remove it from the engine 7) Remove the cover and then remove the
hood clamp. connector (11) of the fan motor.
CPW10718 CPW10721
3) Remove the rubber sheet (3) and the baf- 8) Remove the stays (12) and (13) and then
fle (4). remove the rear mounting bolts (14) and
(15).
CPW10719
CPW10722
WA380-5 30-23
(9)
2
(7)
OF CYLINDER HEAD
HEAD ASSEM-
ASSEMBLY
9) Use a lever block to sling the engine hood 4. Lift and remove the muffler assembly (21).
and remove the right and left mounting
4
bolts (16) and (17). Muffler assembly: 36 kg
CPW10726
10) Lift the engine hood assembly (18) slowly

and remove it. 5. Air cleaner bracket
1) Remove the dust indicator sensor connec-
4
Engine hood assembly: 260 kg tor (22).
2) Disconnect the ground wiring harness
(23), and remove the heater relay (24).
3) Disconnect the breather hose (25) from
the head cover, remove the clamps (26)
and (27) and bring it to the left side of the
engine.
CPW10724 4) Remove the fuel filter (28). [*2]
5) Remove the air cleaner bracket (29).
CPW10727
3. Disconnect the dust indicator hose and the air

intake hose (19) and remove the air cleaner
assembly (20). [*1]
CPW10725
30-24 WA380-5
(9)
2
OF CYLINDER HEAD
HEAD ASSEM-
ASSEMBLY
6. Disconnect the aftercooler outlet pipe 13. Remove the turbocharger and exhaust mani-
(30). [*3] fold assembly (39). [*7]
7. Remove the muffler mounting bracket (31). 14. Disconnect the aeration hose (40).
8. Remove the air intake connector (32).
CPW10731
15. Remove the head cover (41). [*8]

9. Disconnect the turbo outlet pipe (33). [*4] ★ Before removing it, clean the area around
10. Remove the exhaust connector (34) and the it.
bracket (35). [*5] 16. Disconnect 6 pieces of the high-pressure
11. Remove the heat shielding board (36). injection pipe (42). [*9]
17. Disconnect the spill hose (43).
CPW10729
CPW10732
12. Disconnect the turbo lubrication hose (37)

and the drain tube (38). [*6] 18. Remove the holder (44) and then remove the
nozzle holder assembly (45). [*10]
CPW10730
CPW10733
WA380-5 30-25
(9)
2
(7)
OF CYLINDER HEAD
HEAD ASSEM-
ASSEMBLY
19. Remove the rocker arm assembly (46). [*11] INSTALLATION

★ Loosen the locknut and also loosen the
adjustment nut 2 - 3 turns. • Carry out installation in the reverse order to
removal.
[*1]
Bolt of air cleaner mounting

clamp:
9.8 - 11.76 Nm {1.0 - 1.2 kgm}
CPW10734
Clamping bolt on air intake hose
turbo side:
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*2]
[*3]
Nut of air intake pipe intermediate

20. Remove the push rod (47). [*12]
clamp:
10.8 - 26.5 Nm {1.1 - 2.7 kgm}
[*4]
Nut of clamp on turbo side:

6.9 - 8.8 Nm {0.7 - 0.9 kgm}
CPW10735
Nut of pipe intermediate clamp:
10.8 - 26.5 Nm {1.1 - 2.7 kgm}
[*5]
Nut of exhaust connector clamp:

6.9 - 8.8 Nm {0.7 - 0.9 kgm}
21. Cylinder assembly [*13] [*6]

Remove 26 pieces of the head bolt (48) and
Joint on turbo lubrication hose cyl-
then remove the cylinder head assembly
inder block side:
(49).
19.6 - 28.4 Nm {2.0 - 2.9 kgm}
4 Cylinder head assembly: 52 kg [*7]
Tighten the exhaust manifold

mounting bolt following the proce-
dures below and apply the torques
below.
CPW10736 • First turn: In the order from the first

one shown in the figure,
23.5 ± 4 Nm {2.4 ± 0.4 kgm}
• Second turn: From the 1st to 4th bolts
only shown in the figure,
23.5 ± 4 Nm {2.4 ± 0.4 kgm}
• Third turn: In the order from the first
one shown in the figure,
43.1 ± 6 Nm {4.4 ± 0.6 kgm}
30-26 WA380-5
(9)
2
OF CYLINDER HEAD
HEAD ASSEM-
ASSEMBLY
• Fourth turn: From the 1st to 4th bolts [*13]

only shown in the figure, • Install the cylinder head assembly follow-
43.1 ± 6 Nm {4.4 ± 0.6 kgm} ing the procedures below:
★ Check that there is no dust and foreign
matter on the cylinder head mounting
surface and inside the cylinder.
1) Attach the cylinder head gasket to the cyl-
inder block.
★ Check that the gasket is correctly
nested in the block hole.
2) Lift the cylinder head assembly and set it
into the cylinder block.
3) Tighten the cylinder head mounting bolts
in the order shown in the figure.
Apply engine oil to the

threaded portion and the seat
surface of the mounting bolt.
[*8]
Cylinder head mounting bolts:
Head cover mounting bolts:
23.5 ± 3.9 Nm {2.4 ± 0.4 kgm} First time: Tighten them in the order
from [1] - [26] by applying
[*9] the torque of,
70 ± 5 Nm {7.1 ± 0.51 kgm}
High-pressure injection pipe Second time:Check that all of the bolts
sleeve nut: have been tightened in the
24 ± 4 Nm {2.45 ± 0.41 kgm} same order with the above
torque.
[*10]
Third time: Tighten the long bolts ([1],
★ Clean the nozzle holder mounting portion, [2], [7], [8], [9], [10], [15], [16],
check that there is no foreign matter [17], [18], [23], [24], [25] and
inside the sleeve and then assemble the [26]) with the torque of,
holder and the nozzle holder assembly. 145 ± 10 Nm {14.8 ± 1.0 kgm}
★ Apply a little engine oil to the rubber Fourth time: Check that the long bolts in
boots. the third time have been
[*11] tightened with the above
• When installing the rocker arm assembly, torque.
check that the rocker arm ball is certainly At the end: When the A1 tool is used,
nested in the push rod. tighten the bolts 90° ± 5°
additionally in the order
Rocker arm assembly mounting from [1] to [26] with the
bolt: 65 ± 5 Nm {6.6 ± 0.5 kgm} angle tightening wrench
(Tool A).
Rocker arm adjustment screw lock- When the tool A is not used,
nut: 24 ± 2.4 Nm {2.45 ± 0.24 kgm} place counter marks on the
bolts and the heads and
• See the paragraph of "Adjustment of tighten the bolts 90° ± 5°
Valve Clearance" in Inspection and additionally.
Adjustment and adjust the valve clear-
ance.
[*12]
• Check that the push rod is certainly
nested in the tappet.
★ Rotate the push rod to check if it
rotates smoothly.
WA380-5 30-27
(9)
2
(7)
RADIATOR AND
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION FAN MOTOR
OF RADIATOR ASSEMBLY
AND FAN MO-
REMOVAL AND INSTALLATION

OF RADIATOR AND FAN
MOTOR ASSEMBLY
DJW05921
REMOVAL
1. Drain engine coolant.
Head Assembly" and remove the engine hood
assembly.
3. Remove the lock and the hinge mounting
bolt, remove the hydraulic oil cooler assem-
bly (1) and bring it to the engine side.
4. Disconnect the fuel tank air bleeding hose (2).
CPW10739
5. Remove the cover (3).

6. Disconnect the hydraulic hoses (4), (5), and
(6) from the motor. [*1]
• Coolant supply
Feed coolant up to the neck of the radiator.
Start the engine to circulate coolant, and CPW10740
check the coolant level in the reservoir tank
again.
30-28 WA380-5
(10)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF RADIATOR
RADIATOR AND AND
FAN MOTOR FAN MO-
ASSEMBLY
7. Disconnect the radiator outlet hose (7) on the 11. Lift and remove the radiator fan motor
torque converter cooler side. assembly (14).
8. Disconnect the radiator inlet hose (8) and the
4
aeration hose (9). Radiator fan motor assembly:
9. Disconnect the aftercooler inlet hose (10) and 195 kg
the outlet hose (11).
CPW10744
CPW10741
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
CPW10742 [*2]
★ See the paragraph of "Bleeding Air from
Fan Motor Circuit" in TESTING AND
ADJUSTMENT and bleed air from the fan
motor circuit.
Hose clamping bolt:

5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
10. Use a lever block to sling the radiator fan • Coolant supply
motor assembly, and remove the left mount- Feed coolant up to the neck of the radiator.
ing bolt (12) and the right mounting bolt (13). Start the engine to circulate coolant, and
check the coolant level in the reservoir tank
again.
CPW10743
WA380-5 30-29
(10)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY
REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION

OF AFTERCOOLER ASSEMBLY OF FUEL INJECTION PUMP
REMOVAL SPECIAL TOOL
New/Modified
Necessity
Quantity
Sketch
Symbol Part Number Part Name
assembly.
2. Sling the aftercooler assembly (3) and discon- 1 795-799-1130 Gear ● 1
nect the aftercooler inlet hose (1) and the out-
2 795-799-1900 Pin ● 1
let hose (2). G
3. Remove the mounting bolts and then remove 3 795-799-1950 Lock pin ● 1
the aftercooler assembly (3). 4 795-799-1390 Plate ● 1
4
Aftercooler assembly: 31 kg REMOVAL

1. Remove the rubber sheet (1) and baffle (2).

CPW10745
CPW10746
INSTALLATION
removal.
[*1]
2. Remove the engine stop solenoid (3). [*1]
Hose clamping bolt:
3. Disconnect the accelerator cable (4). [*2]
5.9 ± 0.5 Nm {0.6 ± 0.05 kgm}
4. Disconnect the fuel tube (5). [*3]
5. Disconnect the lubrication hose (6). [*4]
6. Remove the oil filler port (7).
7. Disconnect the muffler drain tube (8).
CPW10747
30-30 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP
8. Disconnect the fuel return hose (9). [*5] 12. Remove the cap (14).
13. Remove the nut (15) and the washer
(16). [*7]
★ Remove the nut and the washer carefully
so that they do not drop in the case.
CPW10751
9. Use the tool G1 to rotate the crankshaft in the

positive rotation direction to push the gear in
the compression top dead point positioning
pin (10) of the No. 1 cylinder.
★ Press the pin lightly to the gear and rotate 14. Use the tool G4 to pull the drive gear of the
it slowly. injection pump, and loosen the engagement
with the shaft.
CPW10752
10. Disconnect the west gate hose (11) and then

disconnect the boost compensator tube (12). 15. Remove 2 pieces of the mounting bolt (17)
11. Disconnect 6 pieces of the high-pressure and 4 pieces of the mounting nut (18) and
injection pipe (13) from the pump, and then remove the fuel injection pump assem-
remove the clamp in the middle. [*6] bly (22). [*8]
CPW10750 CPW10753
WA380-5 30-31
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP
INSTALLATION 3) Reverse the position of the timing pin

(20), bring the groove of the timing pin to
• Carry out installation in the reverse order to the pointer (21) in the pump and tighten
removal. the plug (19) temporarily.
[*1] ★ When the tooth of the pointer (21)
★ See the paragraph of "Adjustment of does not match the hole of the timing
Engine Stop Solenoid" in Inspection and pin, turn the shaft of the fuel injection
Adjustment and adjust the solenoid. pump to match the pointer tooth of
the hole.
[*2]
★ See the paragraph of "Adjustment of
Accelerator Pedal" in Inspection and
Adjustment and adjust engine speed.
[*3]
Joint bolt:
36 ± 5 Nm {3.67 ± 0.51 kgm}
[*4]
Joint bolt:
8 ± 2 Nm {0.8 ± 0.2 kgm}
[*5]
Joint bolt: 4) Align the pump cam shaft to the pump

36 ± 5 Nm {3.67 ± 0.51 kgm} drive gear, assemble the fuel injection
pump assembly (22) and tighten the
[*6] mounting nut (18) and bolt (17).
Sleeve nut: Nut: 44 ± 6 Nm {4.49 ± 0.6 kgm}

24 ± 4 Nm {2.45 ± 0.41 kgm}
[*7] [*8]
• Install the fuel injection pump by following
the procedures below:
1) Check that No. 1 cylinder is at the position
of the compression top dead point. CPW10753
★ See Paragraph 10 of Removal.
2) Remove the plug (19) and then remove
the timing pin (20).
30-32 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION NOZZLE HOLDER
OF NOZZLE ASSEMBLY
HOLDER ASSEM-
5) Set the washer (16) in and tighten the nut REMOVAL AND INSTALLATION
(15) temporarily.
★ Attach the washer and the nut care- OF NOZZLE HOLDER ASSEM-
fully so that they do not drop in the BLY
case.
★ Tighten the nut temporarily by apply- REMOVAL
ing the torque of about:
50 Nm {4.9 kgm), disengage the tim- WARNING! Disconnect the battery (-)
ing pin and tighten the nut by apply- terminal in advance.
ing the specified torque.
6) Disengage the timing pin (10).
assembly.
2. Disconnect the dust indicator hose and the air
intake hose (1), and remove the air cleaner
CPW10754 assembly (2). [*1]
CPW10755
7) Remove the plug (19), reverse the posi-

tion of the timing pin (20) to set it in and
attach the plug to the injection pump.
Plug: 14.7 Nm {1.5 kgm}
8) Tighten the drive nut (15) of the fuel injec- 3. Remove the muffler assembly (3).
tion pump permanently.
Nut: 4 Muffler assembly: 36 kg

178 ± 13 Nm {18.2 ± 1.3 kgm}
9) Carry out the following installations in the

reverse order to removal.
CPW10756
4. Air cleaner bracket

1) Remove the dust indicator sensor connec-
tor (4).
2) Disconnect the ground wiring harness (5),
and remove the heater relay (6).
3) Remove the clamps (8) and (9) of the
breather hose (7) from the bracket (11).
WA380-5 30-33
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION NOZZLE
OF NOZZLE HOLDER
HOLDER ASSEM-
ASSEMBLY
4) Remove the fuel filter (10) from the 10. Remove the holder (17) and then remove the
bracket (11). [*2] nozzle holder assembly (18). [*5]
5) Remove the air cleaner bracket
(11).
CPW10760
CPW10757
INSTALLATION
5. Disconnect the aftercooler outlet pipe • Carry out installation in the reverse order to
(12). [*3] removal.
6. Remove the muffler mounting bracket (13). [*1]
Bolt of air cleaner mounting

clamp:
9.8 - 11.76 Nm {1.0 - 1.2 kgm}
[*2]
[*3]
Nut of air intake pipe intermediate

clamp:
10.8 - 26.5 Nm {1.1 - 2.7 kgm}
[*4]
7. Remove the air intake connector (14). High-pressure injection pipe

★ Remove it for No. 4 and No. 5 nozzle sleeve nut:
holder assemblies. 24 ± 4 Nm {2.45 ± 0.41 kgm}
8. Disconnect 6 pieces of the high-pressure
[*5]
injection pipe (15). [*4]
9. Disconnect the spill hose (16). ★ Clean the nozzle holder mounting portion,
check that there is no foreign matter
inside the sleeve and assemble it.
★ Apply a little engine oil to the rubber
boots.
CPW10759
30-34 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION
FANOF FAN
AND AND
FAN FAN MOTOR
MOTOR AS-
ASSEMBLY
REMOVAL AND INSTALLATION OF FAN AND FAN MOTOR

ASSEMBLY
REMOVAL 2. Remove the connector (5) and then remove
the backup buzzer (6).
3. Remove the connector (7) of the fan motor
solenoid.
4. Remove the motor cover (8).
1. Grille
1) Open the grille and sling it. Then, remove
the right and left dampers (1).
2) Remove the connectors (2) and (3) of the
working lamp and then remove the wiring
harness clamp. CPW10763
CPW10761
5. Disconnect the hydraulic hoses (9), (10) and

(11).
6. Remove the fan guards (12), (13), (14), and
(15).
3) Remove 4 pieces of the mounting bolt

and then remove the grille (4).
CPW10764
CPW10762
WA380-5 30-35
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
7. Sling the fan and fan motor assembly (16) REMOVAL AND INSTALLATION
and remove the right and left mounting bolts
to remove it. [*1] [*2] OF FUEL TANK ASSEMBLY
4 Fan and motor assembly: 45 kg REMOVAL
WARNING! Park the machine on a flat

stop the engine. Apply the parking
CPW10765 brake and put the block under the
wheels.
1. Drain fuel.
2. Disconnect the air bleeding hose (1) of the
fuel tank from the radiator.
3. Remove the engine oil drain valve (2) from
the fuel tank.
INSTALLATION
removal.
[*1] CPW10792
• Install the fan and fan motor assembly so
that the clearance between the fan out-
side diameter and the shroud inside
diameter become even all around.
[*2]
★ See the paragraph of "Bleeding Air of Fan
Motor Circuit" in Testing and Adjusting,
and bleed air of the fan motor circuit.
4. Disconnect the fuel sensor connector (3).
5. Remove the coolant drain valve (4) and the
hose clamp (5) from the fuel tank.
CPW10793
30-36 WA380-5
(10)
2
5
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
6. Remove the clamp (6) of the fuel tank air 11. Fuel tank assembly
bleeding hose (1) from the frame (7). 1) Support the front of the fuel tank (16)
7. Remove the clamps (8) and (9) of the fan from below with the transmission jack [1].
motor hose from the fuel tank. 2) Sling the rear part of the fuel tank (16).
★ Since the sling is apt to slip backward,
prevent it from slipping with bolts.
CPW10794
CPW10797
8. Remove the clamp (10) of the fan motor hose

from the fuel tank.
★ Around the center on the top of the fuel 3) Remove the left mounting bolt (17), the
tank. right mounting bolt (18) and the rear
9. Disconnect the fuel suction hose (11), return mounting bolt (19) of the fuel tank. [*1]
hose (12) and the spill hose (13) from the fuel
tank side.
CPW10798
CPW10795
10. Remove the left mounting bolt (14) and the

right mounting bolt (15) of the transmission
oil cooler from the fuel tank. CPW10799
★ Keep the cooler body as it is.
CPW10796
WA380-5 30-37
(9)
2
(7)
DISASSEMBLY AND ASSEMBLY REMOVAL AND INSTALLATION OF PARKING
PARKING BRAKEBRAKE DISC
DISC PLATE
4) Lower the transmission jack [1] and the REMOVAL AND INSTALLATION
crane at the same time, and remove the
fuel tank assembly (16).
OF PARKING BRAKE DISC
PLATE
4 Fuel tank dry weight: 180 kg
SPECIAL TOOL
New/Modified
Necessity
Quantity
Sketch
1 793T-607-1190 Bracket ● 1
CPW10800 K 2 722-14-13130 Plate ● 1
3 01011-62020 Bolt ● 1
REMOVAL
stop the engine. Put the blocks under
INSTALLATION the wheels.
• Carry out installation in the reverse order to 1. Drain transmission oil.

removal. 2. Remove the drive shaft (2). [*1]
[*1]
Fuel tank mounting bolt:

824 - 1,030 Nm {84 - 105 kgm}
CPW10766
3. Remove the bolt (3) and then remove the

washer (4), the retainer (5) and the
coupling (6). [*2]
CPW10767
30-38 WA380-5
(10)
2
DISC PLATE
4. Remove the mounting bolt (8) of the cage (7), 9. Attach 2 pieces of the bolt [3] to the piston (15)
and use the forcing screw [1] to remove the and pry the bolts with the bar [4] to remove
cage (7). [*3] the piston. [*4]
★ Check the thickness and the quantity of ★ Be careful so that the o-ring does not
the shims in advance. come off, because the piston will drop
5. Remove the level gauge cover (9). without the o-ring.
CPW10768
CPW10771
6. Loosen the mounting bolts (11) of the brake

cover (10) equally, and remove the cover (10) 10. Use the tools K1, K2, and K3 to push the
and the spring (12). brake disc and the plate inside and to remove
★ Since the mounting bolts are pressed the snap ring (16).
with the brake spring, loosen them ★ For the tools K2 and K3, the yoke mount-
equally. ing bolt and the retainer can be used.
CPW10772
7. Keep the guide bolt [2] attached to the hous- 11. Remove the hub (17) and then remove the
ing (13). plate (18), the spring (19) and the disc
8. Remove the bearing assembly (14). (20). [*5]
★ 10 plates, 9 springs, and 9 discs
CPW10770
CPW10773
WA380-5 30-39
(9)
2
(7)
DISC PLATE
INSTALLATION [*5]
★ Set the hub (17) first and then set the
• Carry out installation in the reverse order to plate (18), the spring (19) and the disc (20)
removal. in this order.
[*1] ★ Be careful so that the spring (19) is not
★ When installing the drive shaft, check that pinched between them.
the spider cap key is perfectly nested in
the key slot of the counter yoke, and then
tighten the bolt.
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
[*2]
Coupling mounting bolt:

Adhesive (LT-2)
Coupling mounting bolt:

490 - 608 Nm {50 - 62 kgm}
[*3]
★ Set the shim to where it was. • Oil supply
Supply transmission oil (the designated oil)
Mounting bolt: up to the specified level.
98 - 123 Nm {10 - 12.5 kgm}
Note: When replacing any parts other than the
[*4] disc and the plate, see the paragraph of
"Disassembly and Assembly of Parking
Brake Assembly".
Piston o-ring: Grease (G2-LI)
★ Bring the counter mark a of the piston to

the counter mark b of the housing, and
then install them.
CPW10774
30-40 WA380-5
(9)
2
5
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION
TORQUE CONVERTER ANDOFTRANSMISSION
TORQUE CONVERTER AND
ASSEMBLY
REMOVAL AND INSTALLATION OF TORQUE CONVERTER AND

TRANSMISSION ASSEMBLY
REMOVAL
7. Remove the drive shaft (2). [*3]
stop the engine. Put the blocks under
the wheels. CPW10766
1. Degas the air conditioner. [*1]

2. Drain oil from the transmission and the
hydraulic tank.
See Paragraph 2 of "Removal of Cylinder 8. Wiring and piping of emergency steering
Head Assembly" and remove the engine hood pump
assembly. 1) Disconnect the connector (3).
4. Bulkhead assembly 2) Disconnect the pump inlet hose (4) and
See Paragraph 4 of "Removal of Engine the outlet hose (5).
Assembly" to remove the bulkhead assembly.
5. See the Paragraph of "Removal of Cab and
Floor Frame Assembly" to remove the cab
and floor frame assembly.
6. Remove the universal joint assembly
(1). [*2]
CPW10777
CPW10776
3) Disconnect the motor wiring harness (6)

and the ground wiring harness (7).
CPW10778
WA380-5 30-41
(10)
2
(7)
DISASSEMBLY AND ASSEMBLYREMOVAL AND CONVERTER
TORQUE INSTALLATION OFTRANSMISSION
AND TORQUE CONVERTER AND
ASSEMBLY
9. Remove the oil filler port (8). 15. Pump outlet piping
10. Disconnect the hoses (9) and (10). 1) Remove the clamp (17) and disconnect
★ Disconnect the hose (9) because it the steering pump outlet pipe (18), switch
touches the transmission assembly when pump outlet pipe (19) and the work equip-
the assembly is lifted. ment pump outlet pipe (20).
11. Remove the cover (11).
CPW10782
CPW10779
2) Disconnect the steering pump outlet pipe

12. Piping of torque converter and transmission (18) and the switch pump outlet pipe (19)
1) Remove the clamp (12) of the wiring har- from the pump.
ness.
2) Disconnect the outlet hose (13) to the oil
cooler and the return hose (14) from the
cooler.
CPW10783
CPW10780
3) Remove the connector of the pressure

switch (21).
4) Remove the clamps (22) and (23) and then
remove the bracket (24) of the pipes (18)
13. Disconnect the steering, the switch and the and (19).
fan pump suction tube (15).
14. Disconnect the suction tube (16) of the work
equipment and the PPC pump.
CPW10784
CPW10781
30-42 WA380-5
(9)
2
5
DISASSEMBLY AND ASSEMBLYREMOVAL AND INSTALLATION
TORQUE CONVERTER ANDOF TRANSMISSION
TORQUE CONVERTER AND
ASSEMBLY
16. Pump piping 20. Torque converter and transmission assembly

1) Remove the clamp (25) and disconnect 1) Use a lever block to sling the torque con-
the pump outlet pipe (20) of the work verter and transmission assembly.
equipment. 2) Loosen the left mounting bolt (35) and the
2) Disconnect the PPC pump outlet hose right mounting bolt (36) of the engine.
(26). [*4]
3) Disconnect the fan pump control pressure
hose (27), the pump outlet hose (28), the
fan pump drain hose (29) and the fan
motor drain hose (30).
★ Before disconnecting them, place
counter marks on them. CPW10787
CPW10785
3) Remove the left mounting bolt (37) and

the right mounting bolt (38) of the trans-
mission and lift it a bit, then remove the
left bracket (39). [*5]
★ Do not loosen the adjustment bolt (43)
for positioning at the time of installa-
17. Disconnect the hose (31) from the transmis- tion.
sion filter, and remove the elbow (32).
18. Remove the clamp of the transmission wiring
harness (33).
19. Disconnect the strainer (34) from the bracket
and bring it to the frame side.
CPW10788
CPW10786
WA380-5 30-43
(9)
2
(7)
DISASSEMBLY AND ASSEMBLYREMOVAL AND CONVERTER
TORQUE INSTALLATION OFTRANSMISSION
AND TORQUE CONVERTER AND
ASSEMBLY
4) Lift the torque converter and transmission INSTALLATION

assembly (42) 100 mm or so, place the
block [1] between the engine flywheel • Carry out installation in the reverse order to
case and the rear axle and hold the removal.
engine rear portion. [*1]
• Fill the air conditioner with gas (R134a).
[*2] [*3]
★ When installing the coupling and the
drive shaft, check that the spider cap key
is perfectly nested in the key slot of the
counter yoke, and tighten the bolts.
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
[*4]
Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
5) Remove 12 pieces of the mounting bolts [*5]

(41) of the flywheel case (40) and on the Mounting bolt:
torque converter side. 490 - 608 Nm {50 - 62 kgm}
★ In order to position the transmission, tighten
the mounting bolts so that the clearance a
with the adjustment screw becomes even.
CPW10790
DJW05922
6) Pull out and remove the torque converter

and transmission assembly (42) from the
flywheel. [*6]
4 mission assembly:
Torque converter and trans- [*6]
910 kg ★ Check that an o-ring is set in the torque
converter housing.
★ Adjust the height carefully so that the
pilot cover enters the flywheel hole
smoothly, and never assemble them by
force.
CPW10791
BLEEDING AIR OF BRAKE CIRCUIT
• After completing the installation, see the
paragraph of "Bleeding Air of Brake Circuit" in
Inspection and Adjustment to bleed air of the
brake circuit.
• Oil supply
Supply hydraulic oil (the designated one) up
to the specified level. Supply transmission oil
(the designated oil) up to the specified level.
30-44 WA380-5
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF TRANSMISSION
TRANSMISSION ASSEM-
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION ASSEMBLY

SPECIAL TOOL
5) Sling the pump assembly (6) and remove
New/Modified
Necessity
2 pieces of the mounting bolt (7).
Quantity
Sketch
793T-607-1210 Lifting tool ● 2 {

F 2
793-607-1230 Pin ● 2
DISASSEMBLY CPW10802
1. Transmission, work equipment and PPC

pump assembly
1) Set the torque converter and transmission
assembly (1) on the blocks [1] and [2].
2) Disconnect the suction tube (2).
3) Disconnect the hoses (3) and (4) and the
breather hose (5).
4) Remove the retainer (10). 2. Steering, switch and fan pump
Sling the pump assembly (8) and remove 2
pieces of the mounting bolt (9).
CPW10801
CPW10803
WA380-5 30-45
(10)
2
(7)
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY TRANSMISSION
OF TRANSMISSION ASSEM-
ASSEMBLY
3. Emergency steering pump assembly 6. Filter and brake hose

Remove the plate mounting bolt and then 1) Disconnect the hose (21) and remove the
remove the emergency steering pump filter (22).
assembly (11). 2) Disconnect the brake hose (23).
CPW10804 CPW10807
4. Pipes 7. Valve assembly

1) Remove the connector (12) and then 1) Remove 16 sets of the connector (24) and
remove the block (13).
then remove the wiring harness assembly
2) Disconnect the hose (14) and remove the
flow control valve (15). (25).
3) Disconnect the tube (16) and remove the ★ Before removing the connectors,
nipple (17). check their numbers.
2) Use the eyebolt [3] and the shackle [4] to
sling the valve assembly (26), and remove
10 pieces of the mounting bolt (where is
blacked without bolt).
CPW10805
CPW10808
5. Transmission mount and level gauge

1) Remove the left transmission mount (18).
2) Remove the level gauge (19).
★ Fix the upper and lower holders (20)
with a wrench so that they do not
rotate, then remove the bolt.
CPW10806
30-46 WA380-5
(9)
2
TRANSMISSION ASSEM-
ASSEMBLY
8. Speed sensor and oil temperature sensor 10. Torque converter assembly
Remove the speed sensor (27) and the trans- 1) Face the torque converter side down and
mission oil temperature sensor (28). lift the rear case assembly (31). Then, set
the block [7] below the torque converter
assembly (32).
★ Keep the case upright.
2) Remove the stator shaft mounting bolt
(33) and lift the rear case to remove the
torque converter (32) assembly.
CPW10809
9. Torque converter and rear case assembly

1) Turn the torque converter and the trans-
mission assembly (29) to show the torque
converter side up and set it on the block
[5].
2) Remove 20 pieces of the case mounting
bolt (30).
CPW10813
CPW10810
11. PTO gear (for transmission and work equip-

ment PPC pump)
3) Use a lever block to sling the torque con- 1) Remove the snap ring (34).
verter and rear case assembly (31), and
disconnect and remove the transmission
case with the forcing screw [6].
CPW10814
CPW10811
WA380-5 30-47
(9)
2
(7)
ASSEMBLY
2) Face the PTO side up and set the rear case ★ Repeat the same procedures to
to the block. remove the PTO gear on the opposite
3) Remove the snap ring (37), the plate (38) side.
and the woodruff thrust plate (39).
CPW10815
12. Clutch pack assembly

1) Remove the seal ring (44) from the shaft.
CPW10816
CPW10819
4) Pull out the shaft (40) and remove the

PTO gear (41).
2) Use the tool F2 to lift and remove the 1st
speed and 4th speed clutch assembly (45)
and the 2nd speed and 3rd speed clutch
assembly (46) at the same time.
5) Remove the snap ring (35) and the plate

(36) from the shaft (40).
6) Remove the bearing (43) and the inner
race (59) from the shaft (40).
3) Use the eyebolt [11] to lift and remove the
forward-reverse clutch assembly (47).
30-48 WA380-5
(9)
2
TRANSMISSION ASSEM-
ASSEMBLY
13. Yoke 15. Bearing (on the 1st speed clutch side)
Remove the yoke (48). Remove the bearing (54).
16. Cover (on the 2nd speed clutch side)
1) Remove the cover (55).
CPW10821
CPW10824
14. Reverse idle gear

1) Remove the bolt (49) and the plate (50).
2) Use a forcing screw to remove the cover
(56).
★ Check the thickness and the quantity
of the shims (57) in advance.
CPW10822
CPW10825
2) Use the puller [12] to remove the gear (51)

and the bearing (52).
3) Remove the bearing (52) and the plate
(53).
3) Remove the outer race (58) from the cover
(56).
WA380-5 30-49
(9)
2
(7)
ASSEMBLY
ASSEMBLY 3. Reverse idle gear

1) Attach the plate (53).
1. Cover (on the 2nd speed clutch side) 2) Use the push-tool to attach the bearing
1) Attach the outer race (58) to the cover (52) with the counter mark B.
(56). 3) Attach the outer race (52-1) to the gear
(51).
2) Set the removed shim (57) in the cover

(56) and tack-weld the cover. 4) Set the spacer (52-2) and attach the gear
★ In order to adjust the shim here after (51).
the clutch assembly is assembled. 5) Use the push-tool to attach the bearing
(52) with the counter mark A.
2. Bearing (on the 1st speed clutch side)
Use the push-tool to attach the bearing (54) to
the housing.
CPW10827
6) Attach the plate (50) and tighten the bolt

(49).
Bolt: Adhesive (LT-2)
Bolt:
98 - 123 Nm {10 - 12.5 kgm}
CPW10822
30-50 WA380-5
(10)
2
TRANSMISSION ASSEM-
ASSEMBLY
4. Yoke 4) Attach the seal ring (44) to the shaft.

Attach the yoke (48).
5. Clutch assembly Seal Ring: Grease (G2-LI)
1) Face the brake side down and set the
front case on the block.
2) Use the eyebolt [11] to attach the forward-
reverse clutch assembly (47).
CPW10819
CPW10821
6. PTO gear (for transmission, work equipment

and PPC pump)
1) Attach the bearing (60) to the rear case
3) Use the tool F2 to combine the 1st speed (31).
and 4th speed clutch assembly (45) and ★ The snap ring is mounted on the
the 2nd speed and 3rd speed clutch steering, the switch and the fan pump
assembly (46) and attach them at the sides.
same time.
★ When it is difficult to set the roller
bearing on the 1st speed clutch side,
remove the bearing and set it to the
shaft side to attach it.
2) Use the push-tool to attach the inner race

(59) and the bearing (43) to the shaft (40).
3) Attach the plate (36) and the snap ring
(35).
WA380-5 30-51
(9)
2
(7)
ASSEMBLY
4) Set the PTO gear (41) to the case and 6) Attach the snap ring (34).
attach the shaft (40). ★ Repeat the same procedures to attach
the PTO gear on the opposite side.
CPW10814
5) Attach the woodruff thrust plate (39), and

plate (38) and the snap ring (37) to the 7. Torque converter assembly
shaft. 1) Set the torque converter assembly (32) on
the block [7], and attach 1 piece of the
guide bolt [8].
2) Lift the rear case (31), meet respective
bolt holes with each other and attach the
rear case to the torque converter.
CPW10816
CPW10831
CPW10815 3) Tighten 6 pieces of the stator shaft

mounting bolt (33).
Bolt: Adhesive (LT-2)
Bolt:
98 - 123 Nm {10 - 12.5 kgm}
CPW10813
30-52 WA380-5
(9)
2
TRANSMISSION ASSEM-
ASSEMBLY
8. Rear case assembly 9. Adjusting procedures of taper roller bearing

1) For each clutch assembly, make the shim of 2nd speed and 3rd speed clutch
extension of the seal ring from the shaft assembly
equal. 1) Face the parking brake side up and set the
2) Attach the guide bolt [9] to the front case. transmission assembly on the block.
3) Use the lever block to lift the rear case 2) Pull the brake piston with the bolt (63) to
assembly (31) and to attach it to the shaft release the parking brake.
of the clutch assembly.
Case mating face:

Gasket sealant (LG-4)
• For the applying procedures, see the

illustration DJW05923. CPW10838
CPW10832
3) Pull out the shim temporarily set in the

paragraph of 1-2) of Assembly, attach the
cover (56) and tighten all mounting bolts
by applying the torque of 9.8 ± 0.98 Nm
{1.0 ± 0.1 kgm}.
4) Use the hole on the end face of the shaft
(64) or the output shaft coupling to give
the shaft 20 turns, and check bolt torques.
★ When bolt torques are different,
repeat 3) and 4).
DJW05923 5) When bolt torques become equal, mea-
sure the clearances at four places (circular
equal division) (3-place equal division is
also acceptable) to find the average clear-
ance.
★ To check if the bearing is not inclined,
however, check if the bearing is set
properly or if there is any other rea-
son where measured values differ
more than 0.15 mm. Take a proper
4) Tighten 20 pieces of the mounting bolt measure so that the bearing is not
(30). inclined.
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
CPW10839
CPW10833
WA380-5 30-53
(9)
2
(7)
ASSEMBLY
6) A shim increases measured clearances by 11. Speed sensor

+ 0.25 - + 0.3 mm. 1) Screw the sensor (27) in until it touches
7) Set the selected shim (57) in and attach the outside surface of the gear (61).
the cover (56). ★ Before attaching the sensor, make
sure that the gear is at the most out-
Mounting bolt: side of the mounting face.
98 - 123 Nm {10 - 12.5 kgm} ★ When you screw the sensor in with a
8) Attach the cover (55). wrench, stop screwing just before the
gear then let the sensor touch the
gear by hand.
2) After the sensor (27) touched the gear
(61), give the sensor a half to a turn in
reverse and fix it with the locknut (62).
★ When fixing the sensor with the lock-
CPW10840 nut, fix the other nut with a wrench
and tighten the locknut.
Sensor threaded portion:

Gasket sealant (LG-5)
Sensor locknut:
58.8 - 78.4 Nm {6 - 8 kgm}
10. Speed sensor and oil temperature sensor

1) Attach the oil temperature sensor (28).
Oil temperature sensor:

Gasket sealant (LG-5) DJW05924
Oil temperature sensor:
29.4 - 49 Nm {3 - 5 kgm}
CPW10834 12. Valve assembly

1) Attach 2 pieces of the guide bolt [10] to
the case.
2) Use the eyebolt [3] and the shackle [4] to
lift and install the valve assembly (26).
2 pieces of mounting bolt a:

44.1 - 53.9 Nm {4.5 - 5.5 kgm}
8 pieces of other bolts:

58.8 - 73.5 Nm {6 - 7.5 kgm}
30-54 WA380-5
(9)
2
TRANSMISSION ASSEM-
ASSEMBLY
3) Attach the wiring harness assembly (25) 15. Pipes

and connect 16 sets of the connector (24). 1) Attach the nipple (17) and connect the
tube (16).
Mounting bolt:
9.8 - 12.7 Nm {1.0 - 1.3 kgm}
2) Attach the front control valve (15) and

CPW10835 connect the hose (14).
Mounting bolt:
Adhesive (LT-2)
Mounting bolt:
29.4 - 39.2 Nm {3 - 4 kgm}
3) Attach the block (13), and connect the

13. Filter and brake hose mounting connector (12).
1) Connect the brake hose (23).
2) Attach the filter (22) and connect the hose
(21).
CPW10805
CPW10807
16. Emergency steering pump assembly

Install the emergency steering pump assem-
bly (11).
14. Transmission mount and level gauge
1) Attach the level gauge (19).
★ Fix the upper and lower holders (20)
with a wrench so that they do not
rotate, and tighten the bolts.
Mounting bolt: CPW10804

12.7 - 13.7 Nm {1.3 - 1.4 kgm}
2) Attach the left transmission mount (18).
CPW10806
WA380-5 30-55
(9)
2
(7)
ASSEMBLY
17. Steering, switch and fan pump assembly 3) Connect the hoses (4) and (3) and the
Lift and install the pump assembly (8), and breather hose (5).
tighten 2 pieces for the mounting bolt (9). 4) Connect the suction tube (2).
CPW10803 CPW10801
18. Transmission, work equipment and PPC

pump assembly
1) Lift and install the pump assembly (6),
and tighten 2 pieces of the mounting bolt
(7).
CPW10802
2) Attach the strainer (10).
30-56 WA380-5
(9)
2
WA380-
5 TRANSMISSION
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND OFCLUTCH
ASSEMBLY CYLINDER PACK
TRANSMISSION CLUTCH
HEAD ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION CLUTCH PACK

ASSEMBLY
SPECIAL TOOLS
2. Forward gear
1) Remove spacer (1) and thrust washer (4)
Simplified Drawing
New/Revised
and dismount forward gear (2).
Necessity
Quantity
Part
Symbol Number Part Name 2) Dismount needle bearing (5) from the for-
ward gear.
1 790-201-2170 Plate ■ 1
2 790-201-2730 Spacer ■ 1
C2
3 796-465-1120 Push tool ■ 1
4 790-201-2740 Spacer ■ 1
1 793-607-1110 Seal holder ■ 1 N

C3
2 793-607-1120 Seal holder ■ 1 N
C12 799-301-1500 Oil leak tester kit ■ 1
DISASSEMBLY
WARNING! When loading the clutch

pack on the block, take care so that the
clutch pack may not slip from your
hands with oil and so that your finger
may not get caught between the block 3. End plate
and clutch pack. 1) Use C clamp [3] or the like to press end
plate (6) and to dismount snap ring (7).
2) Dismount end plate (6).
DISASSEMBLY OF FORWARD AND
REVERSE CLUTCH PACKS
[FORWARD CLUTCH SIDE]
1. Bearing
Mount bearing race puller [1] on bearing (3)
and push the shaft with a press, then dis- cpw10573
mount bearing (3).
★ When the bearing is dismounted, the
clutch assembly drops. So catch the
clutch assembly by a cushion seat.
cpw10972
WA380-5 30-57
(9)
2
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH
TRANSMISSION TRANSMISSION CLUTCH
PACK ASSEMBLY
4. Clutch plate
1) Dismount spring plate (8) from the hous-
ing.
cpw10577
cpw10574
★ If the piston is tilted and will not dismount,

push the piston again.
★ If the piston is dismounted by force, note that
the inside surface of the cylinder is damaged.
2) Dismount plate (9), disc (10) and spring
(11).
[REVERSE CLUTCH SIDE]
6. Bearing
Mount bearing race puller [4] on reverse gear
(16) and use hydraulic cylinder [5] to dis-
mount bearing (15).
cpw10575
Dismount thrust washer (12). cpw10974
3) Dismount thrust washer (12).
5. Piston
Make air blow into the forward side oil hole of
the shaft and dismount piston (14).
cpw10576
30-58 WA380-5
(9)
2
TRANSMISSION
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OFCLUTCH PACK ASSEMBLY
TRANSMISSION CLUTCH
7. Reverse gear 2. 1st gear

1) Dismount spacer (17), thrust washer (18) 1) Remove snap ring (32) and dismount
and reverse gear (16). thrust washer (33) and 1st gear (34).
2) Dismount needle bearing (19) from the
reverse gear.
cpw10586
cpw10579

1st gear.
8. End plate
9. Clutch plate
10. Piston
★ Disassemble procedures 8. - 10. In the
same manner as the procedures 3. - 5. at
the reverse clutch side.
cpw10587
DISASSEMBLY OF 1ST AND 4TH
CLUTCH PACK
[1ST CLUTCH SIDE]
1. Idler gear
Use puller [7] to dismount inner race (30) and
idler gear (31).
3. End plate
1) Use C clamp [8] or the like to press end
plate (36) and dismount snap ring (37).
cpw10585
cpw10588
WA380-5 30-59
(9)
2
PACK ASSEMBLY
4. Clutch plate [4TH CLUTCH SIDE]

(40) from the housing. 6. Bearing
Use puller [9] to pull out 4th gear (46) and dis-
mount bearing (43).
cpw10589
cpw10975
2) Dismount thrust washer (41).
5. Piston
7. 4th gear
Make air blow into the reverse side oil hole of
1) Dismount spacer (44), thrust washer (45)
the shaft and dismount piston (42).
and 4th gear (46).
4th gear.
cpw10590
cpw10593
8. End plate
9. Clutch plate
10. Piston
cpw10591
★ Disassemble procedures 8. - 10. in the
same manner as the procedures 3. - 5. at
the 1st clutch side.
★ If the piston is tilted and will not dismount,

push the piston again.
★ If the piston is dismounted by force, note that
the inside surface of the cylinder is damaged.
30-60 WA380-5
(10)
2
TRANSMISSION
TRANSMISSION CLUTCH
DISASSEMBLY OF 2ND AND 3RD 3. End plate

CLUTCH PACK 1) Use C clamp [11] or the like to press end
plate (54) and dismount snap ring (55).
[3RD CLUTCH SIDE]
1. Bearing
1) Apply puller [10] to 3rd gear (53) and dis-
mount bearing (49) and 4th gear (50).
cpw10598
cpw10976
4. Clutch plate
(58) from the housing.
2. 3rd gear
1) Dismount thrust washer (52) and 3rd gear
(53).
cpw10599
cpw10596
2) Dismount thrust washer (58a).
2) Dismount needle bearing (53a) from 3rd

gear (53).
cww10977
WA380-5 30-61
(10)
2
PACK ASSEMBLY
5. Piston 7. 2nd gear

Make air blow into the 3rd clutch side oil hole 1) Dismount thrust washer (62) and 2nd gear
of the shaft and dismount piston (59). (63).
cpw10600 cpw10979
2) Dismount needle bearing (64) from 2nd

gear (63).
cpw10602
cpw10605
★ If the piston is tilted and will not dis-

mount, push the piston again.
★ If the piston is dismounted by force, note
that the inside surface of the cylinder is
damaged. 8. End plate
9. Clutch plate
10. Piston
[2ND CLUTCH SIDE]
★ Disassemble procedures 8. - 10. in the
6. Bearing same manner as the procedures 3. - 5. at
1) Use forcing screw [12] to pull out output the 3rd clutch side.
gear (60) and dismount bearing (60a).
2) Remove output gear (60).
cpw10978
30-62 WA380-5
(10)
2
TRANSMISSION
TRANSMISSION CLUTCH
ASSEMBLY 3. Clutch plate

ASSEMBLY OF THE FORWARD AND 1) Alternately assemble plate (68), disc (69)
and spring (70) in this order.
REVERSE CLUTCH PACKS ★ Assemble disc (69) after having
[REVERSE CLUTCH SIDE] immersed it in clean transmission oil
for two minutes or more.
1. Piston seal ★ Take care so that spring (70) and disc
Assemble piston seal (66) in piston (65). (69) will not overlap.
★ When assembling a new piston seal, use ★ Carefully assemble the plate and the
tool C3-1 to assemble it after the seal spring so that they will not bite into
the ring groove of the clutch housing.
having run in (it takes two or three min-
utes).
★ If the seal is assembled in the cylinder
without making the seal run in, note that
the seal is damaged.
Tool C3-1 inside surface:
Transmission oil cpw10608
cww10606
2) Mount spring plate (71)
★ Mount it facing identification mark U
upward.
2. Reverse side piston

1) Mount reverse side piston (65). cpw10609
★ Take care so that the piston seal will
not be damaged.
Piston sliding surface:

Transmission oil
2) Mount thrust washer (67).

4. End plate
1) Mount end plate (72).
plate (72).
3) Mount snap ring (73).
cpw10607
cpw10610
WA380-5 30-63
(9)
2
PACK ASSEMBLY
5. Reverse gear, bearing [FORWARD CLUTCH SIDE]

1) Assemble needle bearing (19) in the
reverse gear (16) and mount it fitting the 6. Forward side piston
internal gear of the disc. 1) Make the piston seal run in the same
2) Mount thrust washer (18), spacer (17) and manner as the reverse clutch side and
assemble it in piston (14).
bearing (15) in this order. 2) Assemble piston (14) in the same manner
as the reverse side piston.

Transmission oil
cpw10579
cpw10576
3) The clearance a between spacer (17) and

thrust washer (18) is within a standard
value.
Standard value a: 0.3 - 0.7 mm.
★ Measure the clearance a using a dial
gauge or clearance gauge. 7. Clutch plate
1) Alternately assemble plate (9), disk (10)
and spring (11) in this order.
★ Assemble them in the same manner
as the reverse clutch side.
cww10980
cpw10575
2) Mount spring plate (8)

★ Mount it facing identification mark U
sideways.
cpw10574
30-64 WA380-5
(9)
2
PACK ASSEMBLY
8. End plate 10. Clutch pack operation test

1) Mount end plate (6). Use tool C12 to make compressed air blow in
2) Use C clamp [3] or the like to press needle the oil hole of the shaft and each clutch oper-
plate (6) and mount snap ring (7). ates.
★ If the gear at the side where air blew in is
secured, the clutch operates normally.
cpw10573
cww10982
9. Reverse gear, bearing

1) Assemble needle bearing (5) in the for-
ward gear (2) and mount it fitting the
ASSEMBLY OF 1ST AND 4TH
internal gear of the disc.
2) Mount thrust washer (4) and spacer (1). CLUTCH PACK
[4TH CLUTCH SIDE]
1. Piston seal
Assemble piston seal (76) in piston (75).
★ When assembling a new piston seal, use
tool C3-2 to assemble it after the seal
having run in (it takes two or three min-
cww10973
utes).
★ If the seal is assembled in the cylinder

Transmission oil
3) Press-fit bearing (3) and check that the

clearance b between spacer (1) and thrust
washer (4) is within a standard value.
Standard value b: 0.24 - 0.76 mm
cww10617
cww10981
★ Measure the clearance b using a dial

gauge or clearance gauge.
WA380-5 30-65
(9)2
PACK ASSEMBLY
2. 4th side piston 4. End plate

1) Mount 4th side piston (75). 1) Mount end plate (82).
★ Take care not to damage the piston seal. 2) Use C clamp [14] or the like to press end
plate (82) and mount snap ring (83).
Contact surface of piston seal: ★ Check that snap ring (83) is correctly
Transmission oil inserted in the groove.
cpw10620
cpw10618
5. 4th gear, bearing

1) Assemble needle bearing (47) in the 4th
3. Clutch plate gear (46) and mount it fitting the internal
Alternately assemble plate (79), disc (80) and gear of the disc.
spring (81) in this order. 2) Mount thrust washer (45) and spacer (44),
★ Assemble disc (80) after having then use tools C2-1 and C2-2 to press-fit
immersed it in clean transmission oil bearing (43).
for two minutes or more.
★ Take care so that spring (81) and disc
(80) will not overlap.
★ Carefully assemble the plate (79) and
the spring (81) so that they will not
bite into the ring groove of the clutch
housing.
cpw10593
cpw10619
30-66 WA380-5
(10)
2
PACK ASSEMBLY
3) Check that the clearance c between 7. Clutch plate

spacer (44) and thrust washer (45) is Alternately assemble plate (38), disc (39) and
within a standard value. spring (40) in the housing.
Standard value c: 0.28 - 0.72 mm ★ Assemble them in the same manner as
★ Measure the clearance c using a dial the 4th side.
cpw10589
8. End plate
[1ST CLUTCH SIDE] plate (36) and mount snap ring (37).
6. 1st side piston
1) Make the piston seal run in the same
manner as the 4th clutch side and assem-
ble piston (42).
2) Assemble piston (42) in the same manner
as the 4th clutch side piston.
cpw10588
Transmission oil
9. 1st gear
1) Assemble needle bearing (35) in 1st gear
(34).
cpw10590 2) Mount the 1st gear fitting the internal
gear of the disc.
cpw10587
WA380-5 30-67
(10)
2
PACK ASSEMBLY
3) Assemble thrust washer (33) and snap 2) Check that the clearance d between idler
ring (32). gear (31) and thrust washer (33) is within
a standard value.
Standard value d: 0.26 - 0.74 mm
★ Measure the clearance d using a dial
cpw10586
10. Idler gear

1) Assemble idler gear (31) and use tools
C2-1 and C2-2 to press-fit inner race (30).
11. Clutch pack operation test

Use tool C12 to make compressed air blow in
the oil hole of the shaft and each clutch oper-
ates.
★ If the gear at the side where air blew in is
secured, the clutch operates normally.
cpw10624
30-68 WA380-5
(9)
2
TRANSMISSION
TRANSMISSION CLUTCH
ASSEMBLY OF 2ND AND 3RD 3. Clutch plate

CLUTCH PACK Alternately assemble plate (88), disc (89) and
spring (90) in this order.
[2ND CLUTCH SIDE]
★ Assemble disc (89) after having
1. Piston seal immersed it in clean transmission oil
Assemble piston seal (86) in piston (85). for two minutes or more.
★ When assembling a new piston seal, use ★ Take care so that spring (90) and disc
tool C3-2 to assemble it after the seal (88) will not overlap.
having run in (it takes two or three min- ★ Carefully assemble the plate and the
utes). spring so that they will not bite into
★ If the seal is assembled in the cylinder the ring groove of the clutch housing.

Transmission oil
cpw10631
4. End plate
plate (91) and mount snap ring (92).
2. 2nd side piston

1) Mount 2nd side piston (85).
★ Take care so that the piston seal may
not be damaged.
Piston seal sliding surface:

Transmission oil
cpw10632
5. 2nd gear
1) Assemble needle bearing (64) in 2nd gear
cpw10630
(63) and mount it fitting the internal gear
of the disc.
★ If the internal gear of the disc is not fit,
assemble needle bearing gently turn-
ing the disc. Take care never to press
it strongly.
WA380-5 30-69
(10)
2
PACK ASSEMBLY
2) Mount thrust washer (62). 3) Check that the clearance e between idler
gear (60) and thrust washer (62) is within
a standard value.
Standard value e: 0.28 - 0.72 mm
★ Measure the clearance e using a dial
cpw10605
cpw10979 [3RD CLUTCH SIDE]

7. 3rd side piston
1) Make the piston seal run in the same
manner as the 2nd clutch side and assem-
ble piston (59).
2) Assemble piston (59) in the same manner
as the 2nd clutch side piston.
6. Idler gear, bearing Piston sliding surface:

1) Mount idler gear (60). Transmission oil
3) Mount thrust washer (58a).
cpw10633
cwp10600
2) Use tool C2-3 to press-fit bearing (60a).
30-70 WA380-5
(10)
2
TRANSMISSION
TRANSMISSION CLUTCH
8. Clutch plate 11. 4th gear, bearing

Alternately assemble plate (56), disc (57) and 1) Assemble 4th gear (50).
spring (58) in the housing. 2) Use tools C2-4 to press-fit bearing (49).
★ Assemble them in the same manner as
the 2nd side.
cpw10599
3) Check that the clearance f between 4th

gear (50) and thrust washer (52) is within
a standard value.
9. End plate Standard value f: 0.28 - 0.72 mm
Use C clamp [11] or the like to press end plate ★ Measure the clearance f using a dial
(54) and dismount snap ring (55). gauge or clearance gauge.
cpw10598
12. Clutch pack operation test

10. 3rd gear Use tool C12 to make compressed air blow in
1) Assemble needle bearing (53a) in 3rd the oil hole of the shaft and each clutch oper-
gear (53) and mount it fitting the internal ates.
gear of the disc. ★ If the gear at the side where air blew in is
2) Mount thrust washer (52). secured, the clutch operates normally.
WA380-5 30-71
(10)
2

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TROUBLESHOOTING H-17

Inspection before diagnosis

Inspection before diagnosis

H-19 Hydraulic drifts of the Lift arm occur often

Ask the operator about the following:

Inspection before diagnosis

Diagnosis and Cause

H-20 The Lift arm wobbles during operation

Diagnosis and Cause

H-22 The bucket does not tilt back

Ask the operator about the following: Cause

Clogging of pump suction port or mixing of much air in oil

The hydraulic pump and the switch pump are defective

Breakage inside valve body (Bucket spool)

Damage of bucket cylinder piston seal

The relief valve is defective

The spool is defective

When the engine is at full throttle, the steering operation is heavy

H-23 The bucket moves slowly or the tilting-back force is insufficient

Inspection before diagnosis Cause

Defective operation or improper adjustment of main relief valve

Defective operation or improper adjustment of cutoff valve

The hydraulic pump and the switch pump are defective

Wear or breakage inside valve body (Bucket spool)

Damage of bucket cylinder piston seal

Defective operation of relief valve

Defective operation of spool

H-24 The bucket comes to operate slowly in the midst of tilting-back

Inspection before diagnosis

H-25 The bucket cylinder cannot hold down the bucket

Inspection before diagnosis

H-26 Hydraulic drifts of the bucket occur often

Ask the operator about the following:

Inspection before diagnosis

Inspection before diagnosis

Check of Abnormality Cause

Strain of valve body due to uneven tightening of valve mounting bolt

Improper roundness between work equipment valve body and spool

Foreign matter pinched in work equipment valve spool

The work equipment valve spool is bent

The levers totally come not to move smoothly during operation

E.C.S.S.: Electronically controlled suspension system

• Did the problem gradually appear?

Checks before troubleshooting

Defective seal, leakage of gas from high-pressure accumulator

Defective actuation of solenoid valve (SOL1)

Defective actuation of controller

Defective speed sensor

2 E.C.S.S. does not work when traveling loaded Q Q

Connector types and mounting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-903

CONNECTOR TYPES AND MOUNTING LOCATIONS

1.PS DT-T 2 Transmission 1st clutch solenoid AJ-4 M-8

Outside temperature sensor (Vehicle with automatic air

AL1 M 6 Intermediate connector (Air conditioner relay) U-2

C01 Yazaki 2 AM/FM radio C-9

C47 AMP1720 16 A/C control AMP P-1

PB.PS DT-T 2 Parking brake solenoid AJ-3 P-8

R39 DT-T 2 Battery level sensor L-5 T-7