Pa Carregadeira Avance (Wa 180)

CEBM005002
Shop
Manual
WA180-3MC
WHEEL LOADER
SERIAL NUMBERS WA180-3MC - A81001 and UP
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except
in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recom-
mended that customers contact their distributor for information on the latest revision.
November 2001 Copyright 2001 Komatsu

➁ DataKom Publishing Corporation
FOREWORD CONTENTS
12
00 CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2 WA180-3MC
PRODUCT PUBLICATIONS INFORMATION
Various product Parts and Service Publications are available to all KOMATSU construction equipment
owners, including operation and maintenance manuals, parts books and service manuals.
Special publications, such as service tool, air conditioning and turbocharger service manuals are also
available as well as selected Operation and Service manuals in foreign languages.
The Publications listed below are available for this particular machine(s).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB008500
PARTS BOOK - MICROFICHE:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BEPM008500
OPERATION AND MAINTENANCE MANUAL:

Chassis and Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM007500
SHOP MANUAL
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM005002
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SEBM010011
SAFETY MANUAL
Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WLT70-1
Parts and Service Publications can only be acquired by authorized KOMATSU distributors using the
Komatsu America International Company Parts Inventory Processing System (PIPS)or the Extranet
Literature Ording System.
If the PIPS system is not available at the distributor location, then the following Requisition for Technical
Service Publications and Service Forms can be used. Form KDC91E is shown on the reverse side of this
page.
WA180-3MC 11/6/01
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO ö DataKom Publishing Corporation
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
SHIP TO ö
ATTN.
STREET ADDRESS ORDER DATE

TYPE or PRINT CITY, STATE, ZIP CODE
ONLY ö
COUNTRY
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
PARTS BOOK
PUBLICATION
QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER
DESCRIPTION
M-Microfiche
KDC91E 072199 CURRENT PRICES WILL BE CHARGED

FOREWORD
The affected pages are indicated by using the following Mark Indication Action
marks. It is requested that necessary actions be taken to
these pages according to the table below. ❍ New page to be added Add
● Page to be replaced Replace
( ) Page to be deleted Discard
Mark Page Rev Mark Page Rev Mark Page Rev Mark Page Rev
● 00-1 2 01-4 10-15 10-43
00-2 01-5 10-16 10-44
● 00-2-1 2 01-6 10-17 10-45
● 00-2-2 2 01-7 10-18 10-46
● 00-2-3 2 01-8 10-19 10-47
● 00-2-4 2 ● 01-9 2 10-20 10-48
● 00-2-5 2 ● 01-10 2 10-21 10-49
● 00-2-6 2 01-11 10-22 10-50
00-3 01-12 10-23 10-51
00-4 01-13 10-24 10-52
00-5 01-14 10-25 10-53
00-6 01-15 10-26 10-54
00-7 01-16 10-27 10-55
00-8 10-28 10-56
00-9 10-1 10-29 10-57
00-10 10-2 10-30 10-58
00-11 10-3 10-31 10-59
00-12 10-4 10-32 10-60
00-13 10-5 10-33 10-61
00-14 10-6 10-34 10-62
00-15 10-7 10-35 10-63
00-16 10-8 10-36 10-64
00-17 10-9 10-37 10-65
00-18 10-10 10-38 10-66
10-11 10-39 10-67
● 01-1 2 10-12 10-40 10-68
● 01-2 2 10-13 10-41 10-69
01-3 10-14 10-42 10-70
WA180-3MC WA180-3MC 00-2-1 2

FOREWORD
10-71 10-104 10-137 20-1 1

10-72 10-105 10-138 ● 20-2 2
10-73 10-106 10-139 20-3 1
10-74 10-107 10-140 20-4 1

10-75 10-108 10-141 20-5 1
10-76 10-109 10-142 20-6 1
10-77 10-110 10-143 20-7 1

10-78 10-111 10-144 20-8 1
10-79 10-112 10-145 20-9 1
10-80 10-113 10-146 20-10 1
10-81 10-114 10-147 20-11 1

10-82 10-115 10-148 20-12 1
10-83 10-116 10-149 20-13 1
10-84 10-117 10-150 20-14 1

10-85 10-118 10-151 20-15 1
10-86 10-119 10-152 20-16 1
10-87 10-120 10-153 20-17 1

● 10-88 2 10-121 10-154 20-18 1
● 10-89 2 10-122 10-155 20-19 1
● 10-90 2 10-123 10-156 20-20 1

10-91 10-124 10-157 20-21 1
10-92 10-125 10-158 20-22 1
10-93 10-126 10-159 20-23 1

10-94 10-127 10-160 20-24 1
10-95 10-128 10-161 20-25 1
10-96 10-129 10-162 20-26 1

10-97 10-130 10-163 20-27 1
10-98 10-131 10-164 20-28 1
10-99 10-132 10-165 20-29 1

10-100 10-133 10-166 20-30 1
10-101 10-134 10-167 20-31 1
10-102 10-135 10-168 20-32 1

10-103 10-136 20-33 1
00-2-2 2 WA180-3MC
FOREWORD
20-34 1 20-118 1 ❍ 20-307 2 20-803 1

20-35 1 20-119 1 ❍ 20-308 2 20-804 1
20-36 1 ● 20-120 2 ❍ 20-309 2 20-805 1
20-37 1 ● 20-121 2 ❍ 20-310 2 20-806 1

20-38 1 20-122 1 ❍ 20-311 2 20-807 1
20-39 1 20-123 1 ❍ 20-312 2 20-808 1
20-40 1 20-124 1 ❍ 20-313 2 20-809 1

20-41 1 20-125 1 ❍ 20-314 2 20-810 1
20-42 1 20-126 1 ❍ 20-315 2 20-811 1
20-43 1 20-127 1 ❍ 20-316 2 20-812 1
20-44 1 20-128 1 ❍ 20-317 2 20-813 1

20-45 1 ❍ 20-318 2 20-814 1
20-46 1 ❍ 20-201 2 20-815 1
20-47 1 ❍ 20-202 2 ❍ 20-401 2 20-816 1

20-48 1 ❍ 20-203 2 ❍ 20-402 2 20-817 1
❍ 20-204 2 ❍ 20-403 2 20-818 1
20-101 1 ❍ 20-205 2 ❍ 20-404 2 20-819 1

20-102 1 ❍ 20-206 2 20-820 1
20-103 1 ❍ 20-207 2 ❍ 20-501 2
20-104 1 ❍ 20-208 2 ❍ 20-502 2 20-901 1

20-105 1 ❍ 20-209 2 ❍ 20-503 2 20-902 1
20-106 1 ❍ 20-210 2 ❍ 20-504 2 20-903 1
20-107 1 ❍ 20-211 2 ❍ 20-505 2 20-904 1

20-108 1 ❍ 20-212 2 ❍ 20-506 2 20-905 1
20-109 1 ❍ 20-213 2 ❍ 20-507 2 20-906 1
20-110 1 ❍ 20-214 2 ❍ 20-508 2 20-907 1

20-111 1 ❍ 20-509 2 20-908 1
20-112 1 ❍ 20-301 2 ❍ 20-510 2 20-909 1
20-113 1 ❍ 20-302 2 ❍ 20-511 2 20-910 1

20-114 1 ❍ 20-303 2 ❍ 20-512 2 20-911 1
20-115 1 ❍ 20-304 2 20-912 1
20-116 1 ❍ 20-305 2 20-801 1 20-913 1

20-117 1 ❍ 20-306 2 20-802 1 20-914 1
WA180-3MC 00-2-3 2
FOREWORD
20-915 1 20-1023 1 ❍ 30-17 2 ❍ 30-50 2
20-916 1 20-1024 1 ❍ 30-18 2 ❍ 30-51 2
20-917 1 20-1025 1 ❍ 30-19 2 ❍ 30-52 2
20-918 1 20-1026 1 ❍ 30-20 2 ❍ 30-53 2
20-919 1 20-1027 1 ❍ 30-21 2 ❍ 30-54 2
20-920 1 20-1028 1 ❍ 30-22 2 ❍ 30-55 2
20-921 1 20-1029 1 ❍ 30-23 2 ❍ 30-56 2
20-922 1 20-1030 1 ❍ 30-24 2 ❍ 30-57 2
20-923 1 20-1031 1 ❍ 30-25 2 ❍ 30-58 2
20-924 1 20-1032 1 ❍ 30-26 2 ❍ 30-59 2
20-1033 1 ❍ 30-27 2 ❍ 30-60 2
20-1001 1 20-1034 1 ❍ 30-28 2 ❍ 30-61 2
20-1002 1 20-1035 1 ❍ 30-29 2 ❍ 30-62 2
20-1003 1 20-1036 1 ❍ 30-30 2 ❍ 30-63 2
20-1004 1 20-1037 1 ❍ 30-31 2 ❍ 30-64 2
20-1005 1 20-1038 1 ❍ 30-32 2 ❍ 30-65 2
20-1006 1 ❍ 30-33 2 ❍ 30-66 2
20-1007 1 ❍ 30-1 2 ❍ 30-34 2 ❍ 30-67 2
20-1008 1 ❍ 30-2 2 ❍ 30-35 2 ❍ 30-68 2
20-1009 1 ❍ 30-3 2 ❍ 30-36 2 ❍ 30-69 2
20-1010 1 ❍ 30-4 2 ❍ 30-37 2 ❍ 30-70 2
20-1011 1 ❍ 30-5 2 ❍ 30-38 2 ❍ 30-71 2
20-1012 1 ❍ 30-6 2 ❍ 30-39 2 ❍ 30-72 2
20-1013 1 ❍ 30-7 2 ❍ 30-40 2 ❍ 30-73 2
20-1014 1 ❍ 30-8 2 ❍ 30-41 2 ❍ 30-74 2
20-1015 1 ❍ 30-9 2 ❍ 30-42 2 ❍ 30-75 2
20-1016 1 ❍ 30-10 2 ❍ 30-43 2 ❍ 30-76 2
20-1017 1 ❍ 30-11 2 ❍ 30-44 2 ❍ 30-77 2
20-1018 1 ❍ 30-12 2 ❍ 30-45 2 ❍ 30-78 2
20-1019 1 ❍ 30-13 2 ❍ 30-46 2 ❍ 30-79 2
20-1020 1 ❍ 30-14 2 ❍ 30-47 2 ❍ 30-80 2
20-1021 1 ❍ 30-15 2 ❍ 30-48 2 ❍ 30-81 2
20-1022 1 ❍ 30-16 2 ❍ 30-49 2 ❍ 30-82 2
00-2-4 2 WA180-3MC
FOREWORD
❍ 30-83 2 ❍ 30-116 2 ❍ 30-149 2 ❍ 30-182 2
❍ 30-84 2 ❍ 30-117 2 ❍ 30-150 2 ❍ 30-183 2
❍ 30-85 2 ❍ 30-118 2 ❍ 30-151 2 ❍ 30-184 2
❍ 30-86 2 ❍ 30-119 2 ❍ 30-152 2 ❍ 30-185 2
❍ 30-87 2 ❍ 30-120 2 ❍ 30-153 2 ❍ 30-186 2
❍ 30-88 2 ❍ 30-121 2 ❍ 30-154 2 ❍ 30-187 2
❍ 30-89 2 ❍ 30-122 2 ❍ 30-155 2 ❍ 30-188 2
❍ 30-90 2 ❍ 30-123 2 ❍ 30-156 2 ❍ 30-189 2
❍ 30-91 2 ❍ 30-124 2 ❍ 30-157 2 ❍ 30-190 2
❍ 30-92 2 ❍ 30-125 2 ❍ 30-158 2 ❍ 30-191 2
❍ 30-93 2 ❍ 30-126 2 ❍ 30-159 2 ❍ 30-192 2
❍ 30-94 2 ❍ 30-127 2 ❍ 30-160 2 ❍ 30-193 2
❍ 30-95 2 ❍ 30-128 2 ❍ 30-161 2 ❍ 30-194 2
❍ 30-96 2 ❍ 30-129 2 ❍ 30-162 2 ❍ 30-195 2
❍ 30-97 2 ❍ 30-130 2 ❍ 30-163 2 ❍ 30-196 2
❍ 30-98 2 ❍ 30-131 2 ❍ 30-164 2 ❍ 30-197 2
❍ 30-99 2 ❍ 30-132 2 ❍ 30-165 2 ❍ 30-198 2
❍ 30-100 2 ❍ 30-133 2 ❍ 30-166 2 ❍ 30-199 2
❍ 30-101 2 ❍ 30-134 2 ❍ 30-167 2 ❍ 30-200 2
❍ 30-102 2 ❍ 30-135 2 ❍ 30-168 2 ❍ 30-201 2
❍ 30-103 2 ❍ 30-136 2 ❍ 30-169 2 ❍ 30-202 2
❍ 30-104 2 ❍ 30-137 2 ❍ 30-170 2 ❍ 30-203 2
❍ 30-105 2 ❍ 30-138 2 ❍ 30-171 2 ❍ 30-204 2
❍ 30-106 2 ❍ 30-139 2 ❍ 30-172 2 ❍ 30-205 2
❍ 30-107 2 ❍ 30-140 2 ❍ 30-173 2 ❍ 30-206 2
❍ 30-108 2 ❍ 30-141 2 ❍ 30-174 2 ❍ 30-207 2
❍ 30-109 2 ❍ 30-142 2 ❍ 30-175 2 ❍ 30-208 2
❍ 30-110 2 ❍ 30-143 2 ❍ 30-176 2 ❍ 30-209 2
❍ 30-111 2 ❍ 30-144 2 ❍ 30-177 2 ❍ 30-210 2
❍ 30-112 2 ❍ 30-145 2 ❍ 30-178 2 ❍ 30-211 2
❍ 30-113 2 ❍ 30-146 2 ❍ 30-179 2 ❍ 30-212 2
❍ 30-114 2 ❍ 30-147 2 ❍ 30-180 2 ❍ 30-213 2
❍ 30-115 2 ❍ 30-148 2 ❍ 30-181 2 ❍ 30-214 2
WA180-3MC 00-2-5 2
FOREWORD
❍ 30-215 2 40-3 40-36

❍ 30-216 2 40-4 40-37 90-1
❍ 30-217 2 40-5 40-38 90-2
❍ 30-218 2 40-6 40-39 90-3

❍ 30-219 2 40-7 40-40 90-4
❍ 30-220 2 40-8 40-41 90-5
❍ 30-221 2 40-9 40-42 90-6

❍ 30-222 2 40-10 40-43 90-7
❍ 30-223 2 40-11 40-44 90-8
❍ 30-224 2 40-12 40-45 90-9
❍ 30-225 2 40-13 40-46 90-10

❍ 30-226 2 40-14 40-47 90-11
❍ 30-227 2 40-15 40-48 90-12
❍ 30-228 2 40-16 40-49

❍ 30-229 2 40-17 40-50
❍ 30-230 2 40-18 40-51
❍ 30-231 2 40-19 40-52

❍ 30-232 2 40-20 40-53
❍ 30-233 2 40-21 40-54
❍ 30-234 2 40-22 40-55

❍ 30-235 2 40-23 40-56
❍ 30-236 2 40-24 40-57
❍ 30-237 2 40-25 40-58

❍ 30-238 2 40-26 40-59
❍ 30-239 2 40-27 40-60
❍ 30-240 2 40-28 40-61

❍ 30-241 2 40-29 40-62
❍ 30-242 2 40-30 40-63
❍ 30-243 2 40-31 40-64

❍ 30-244 2 40-32 40-65
40-33 40-66
40-1 40-34 40-67

40-2 40-35 40-68
00-2-6 2 WA180-3MC
FOREWORD SAFETY
12
00 SAFETY
00 SAFETY NOTICE
00 IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accom-
panying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first con-
sider safety, and take the necessary actions to deal with the situation.
00 GENERAL PRECAUTIONS 00 PREPARATIONS FOR WORK

Mistakes in operation are extremely dangerous. Read the 1. Before adding oil or making repairs, park the machine
OPERATION & MAINTENANCE MANUAL carefully on hard, level ground, and block the wheels or tracks to
BEFORE operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all the 2. Before starting work, lower blade, ripper, bucket or any
precautions given on the decals which are fixed to the other work equipment to the ground. If this is not possi-
machine. ble, insert the safety pin or use blocks to prevent the
work equipment from falling. In addition, be sure to
2. When carrying out any operation, always wear safety lock all the control levers and hang warning signs on
shoes and helmet. Do not wear loose work clothes, or them.
clothes with buttons missing.
• Always wear safety glasses when hitting parts with a 3. When disassembling or assembling, support the
hammer. machine with blocks, jacks or stands before starting
• Always wear safety glasses when grinding parts with a work.
grinder, etc.
4. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
3. If welding repairs are needed, always have a trained,
handrails, ladders or steps when getting on or off the
experienced welder carry out the work. When carrying
machine. Never jump on or off the machine. If it is
out welding work, always wear welding gloves, apron,
impossible to use the handrails, ladders or steps, use a
glasses, cap and other clothes suited for welding work.
stand to provide safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure 00 PRECAUTIONS DURING WORK
before starting. Always inform your fellow workers 1. When removing the oil filler cap, drain plug or hydrau-
before starting any step of the operation. Before starting lic pressure measuring plugs, loosen them slowly to pre-
work, hang UNDER REPAIR signs on the controls in vent the oil from spurting out. Before disconnecting or
the operator's compartment. removing components of the oil, water or air circuits,
first remove the pressure completely from the circuit.
5. Keep all tools in good condition and learn the correct
way to use them. 2. The water and oil in the circuits are hot when the engine
is stopped, so be careful not to get burned. Wait for the
6. Decide a place in the repair workshop to keep tools and oil and water to cool before carrying out any work on
removed parts. Always keep the tools and parts in their the oil or water circuits.
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke 3. Before starting work, remove the leads from the battery.
only in the areas provided for smoking. Never smoke ALWAYS remove the lead from the negative (-) termi-
while working. nal first.
WA180-3MC 00-3
FOREWORD SAFETY
12
4. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or
crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by
the hoist or crane.
5. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in posi-
tion on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
6. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
7. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately.
Fuel or oil on the floor can cause you to slip, or can even start fires.
8. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing elec-
trical parts.
9. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts.
• When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine
is being operated.
10. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely
careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed.
11. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as
guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed cor-
rectly.
12. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
13. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measure-
ments.
14. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates
suddenly, so never let anyone stand at either end of the track.
00-4 WA180-3MC
FOREWORD GENERAL
12
00 GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate under-
standing of the product and by showing him the correct way to perform repairs and make judgements. Make sure you under-
stand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For
ease of understanding, the manual is divided into the following sections. These sections are further divided into each main
group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and
lubricant specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the
structure, but also serves as reference material for troubleshooting.
TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at comple-
tion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component,
as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
WA180-3MC 00-5
FOREWORD HOW TO READ THE SHOP MANUAL
12
00 HOW TO READ THE SHOP MANUAL
00 VOLUMES 00 REVISIONS
Shop manuals are issued as a guide to carrying out repairs. Revised pages are shown at the LIST OF REVISED PAGES
They are divided as follows: between the title page and SAFETY page.
Chassis volume: Issued for every machine model 00 SYMBOLS

Engine volume: Issued for each engine series
So that the shop manual can be of ample practical use,
Electrical volume: Each issued as one to cover all models
important places for safety and quality are marked with the
Attachment volume: Each issued as one to cover all models
following symbols.
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model, Symbol Item Remarks
it is necessary that chassis, engine, electrical and attachment
Special safety precautions are
be available.
Safety necessary when performing the
work.
00 DISTRIBUTION AND UPDATING
Special technical precautions or
other precautions for preserving
Any additions, amendments or other changes will be sent to ★ Caution
standards are necessary when
your distributors. Get the most up-to-date information before
performing the work.
you start any work.
Weight of parts or systems. Cau-
00 FILING METHOD Weight
tion necessary when selecting
hoisting wire or when working
1. See the page number on the bottom of the page. File the posture is important, etc.
pages in correct order. Places that require special atten-
2. Following examples show how to read the page number: Tightening
tion for tightening torque during
Example: torque
assembly.
10 - 3 Places to be coated with adhe-

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

When a manual is revised, an edition mark (123…) is
recorded on the bottom outside corner of the pages.
00-6 WA180-3MC
FOREWORD HOISTING INSTRUCTIONS
12
00 HOISTING INSTRUCTIONS
00 HOISTING can result. Hooks have maximum strength at the middle

portion.
WARNING! Heavy parts (25 kg or more)

must be lifted with a hoist etc. In
the DISASSEMBLY AND
ASSEMBLY section, every part
weighing 25 kg or more is indi-
cated clearly with the symbol
• If a part cannot be smoothly removed from the machine

by hoisting, the following checks should be made:
1. Check for removal of all bolts fastening the part to the 3. Do not sling a heavy load with one rope alone, but sling
relative parts. with two or more ropes symmetrically wound on to the
2. Check for existence of another part causing interface load.
with the part to be removed.
WARNING! Slinging with one rope may
00 WIRE ROPES cause turning of the load during
hoisting, untwisting of the rope,
or slipping of the rope from its
1. Use adequate ropes depending on the weight of parts to
original winding position on the
be hoisted, referring to the table below: load, which can result in a dan-
Wire ropes gerous accident
(Standard “Z” or “S” twist ropes without galvanizing)
4. Do not sling a heavy load with ropes forming a wide
Rope diameter Allowable load hanging angle from the hook. When hoisting a load with
two or more ropes, the force subjected to each rope will
mm kN tons
increase with the hanging angles. The table below
10 9.8 1.0 shows the variation of allowable load (kg) when hoist-
ing is made with two ropes, each of which is allowed to
11.2 13.7 1.4
sling up to 1000 kg vertically, at various hanging angles.
12.5 15.7 1.6 When two ropes sling a load vertically, up to 2000 kg of
total weight can be suspended. This weight becomes
14 21.6 2.2
1000 kg when two ropes make a 120° hanging angle. On
16 27.5 2.8 the other hand, two ropes are subject to an excessive
force as large as 4000 kg if they sling a 2000 kg load at a
18 35.3 3.6
lifting angle of 150°
20 43.1 4.4
22.4 54.9 5.6
30 98.1 10.0
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
★ The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.
2. Sling wire ropes from the middle portion of the hook.
Slinging near the edge of the hook may cause the rope to
slip off the hook during hoisting, and a serious accident
WA180-3MC 00-7
FOREWORD COATING MATERIALS
12
00 COATING MATERIALS
★ The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Quantity Container Main applications, features
• Used to prevent rubber gaskets, rubber
LT-1A 790-129-9030 150 g Tube
cushions and cork plugs from coming out
• Used in places requiring an immediately
effective, strong adhesive.
20 g Polyethylene • Used for plastics (except polyethylene,
LT-1B 790-129-9050
(2 pes.) container polypropylene, tetrafluoroethylene, and
vinyl chloride), rubber, metal and non-
metal.
• Features: Resistance to heat, chemicals
Polyethylene
LT-2 09940-00030 50 g • Used for anti-loosening and sealant pur-
container
poses for bolts and plugs.
Adhesive:
790-129-9060
1 kg
(Set of adhesive • Used as adhesive or sealant for metal, glass
LT-3 Hardening Can
and hardening or plastic.
agent:
agent)
500 g
Adhesives
Polyethylene
LT-4 790-129-9040 250 g • Used as sealant for machined holes.
container
Holtz • Used as heat-resisting sealant for repairing
790-126-9120 75 g Tube
MH 705 engine.
• Quick hardening type adhesive.
Three
Polyethylene • Cure time: within 5 sec. to 3 min.
bond 179-129-9140 2g
container • Used mainly for adhesion of metals, rub-
1735
bers, plastics and woods.
• Quick hardening type adhesive.
Aron- • Quick cure type (max. strength after 30
Polyethylene
alpha 790-129-9130 50 g minutes).
container
201 • Used mainly for adhesion of rubbers, plas-
tics and metals.
• Features: Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high tem-
648-50 container
perature.
• Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube
packing of power train case, etc.
• Features: Resistance to heat
Gasket • Used as sealant for flange surfaces and bolts
sealant at high temperature locations; used to pre-
LG-3 790-129-9070 1 kg Can vent seizure.
• Used as sealant for heat resistant gasket for
at high temperature locations such as engine
pre-combustion chamber, exhaust pipe.
00-8 WA180-3MC
FOREWORD COATING MATERIALS
Category Code Part No. Quantity Container Main applications, features

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

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

SYG2-400M Belows type • Used for places with heavy load.
case)
00-9 WA180-3MC
FOREWORD STANDARD TIGHTENING TORQUE
12
00 STANDARD TIGHTENING TORQUE
00 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in DISASSEMBLY AND
ASSEMBLY.
Thread diameter of bolt Width across flats
mm mm Nm kgm
6 10 13.2 ±1.4 1.35 ±0.15
8 13 31.4 ±2.9 3.20 ±0.3
10 17 65.7 ±6.8 6.70 ±0.7
12 19 112 ±9.8 11.5 ±1.0
14 22 177 ±19 18 ±2.0
16 24 279 ±29 28.5 ±3
18 27 383 ±39 39 ±4
20 30 549 ±58 56 ±6
22 32 745 ±78 76 ±8
24 36 927 ±98 94.5 ±10
27 41 1320 ±140 135 ±15
30 46 1720 ±190 175 ±20
33 50 2210 ±240 225 ±25
36 55 2750 ±290 280 ±30
39 60 3280 ±340 335 ±35
Thread diameter of bolt Width across flats
mm mm Nm kgm
6 10 7.85 ± 1.95 0.8 ± 0.2
8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8
00-10 WA180-3MC
FOREWORD STANDARD TIGHTENING TORQUE
12
TIGHTENING
00 TORQUE OF HOSE NUTS
Use these torques for hose nuts.
Thread diameter Width across flat Tightening torque
Nominal No.
mm mm Nm kgm
02 14 19 24.5 ± 4.9 2.5 ± 0.5
03 18 24 49 ± 19.6 5±2
04 22 27 78.5 ± 19.6 8±2
05 24 32 137.3 ± 29.4 14 ± 3
06 30 36 176.5 ± 29.4 18 ± 3
10 33 41 196.1 ± 49 20 ± 5
12 36 46 245.2 ± 49 25 ± 5
14 42 55 294.2 ± 49 30 ± 5
00 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.
mm mm Nm kgm
10 14 65.7 ± 6.8 6.7 ± 0.7
12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3
00 TIGHTENING TORQUE FOR FLARED NUTS

Use these torques for flared part of nut.

mm mm Nm kgm
14 19 24.5 ±4.9 2.5 ±0.5
18 24 49 ±19.6 5 ±2
22 27 78.5 ±19.6 8 ±2
24 32 137.3 ±29.4 14 ±3
30 36 176.5 ±29.4 18 ±3
33 41 196.1 ±49 20 ±5
36 46 245.2 ±49 25 ±5
42 55 294.2 ±49 30 ±5
00-11 WA180-3MC
FOREWORD ELECTRIC WIRE CODE
12
00 ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will
help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
00 CLASSIFICATION BY THICKNESS
Copper wire
Nominal num- Cable O.D. Current rat-
Number of Dia. Of strand Cross section Applicable circuit
ber (mm) ing (A)
strands (mm) (mm)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
00 CLASSIFICATION BY COLOR AND CODE

Circuits
Priority Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Primary
1
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2 White & Black & Red & Yellow & Green & Blue &
Color —
Red White White Red White White
Code WB — BY RB YB GR LR
3 White & Black & Yel- Yellow & Green &
Color — Red & Black Blue & Red
Black low Black Red
Code WL — BR RY YG GY LY
Auxiliary
4 White & Red & Yel- Yellow & Green & Blue & Yel-
Color — Black & Red
Blue low Green Yellow low
Code WG — — RG YL GB LB
5 White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6 Yellow & Green &
Color — — — Red & Blue —
White Blue
00-12 WA180-3MC
FOREWORD CONVERSION TABLES
12
00 CONVERSION TABLES
00 METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the
Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
A. Locate the number 50 in the vertical column at the left side, take this as 1, then draw a horizontal line from 1.
B. Locate the number 5 in the row across the top, take this as 2, then draw a perpendicular line down from 2.
C. Take the point where the two lines cross as 3. This point 3 gives the value when converting from millimeters to
inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.

A. The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to
55 mm.
B. Carry out the same procedure as above to convert 55 mm to 2.165 inches.
C. The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the
right) to return to the original value. This gives 550 mm = 21.65 inches.
2
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
3
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
1
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-13 WA180-3MC
12
Millimeters to Inches 1 mm = 0.03937 in

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

0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-14 WA180-3MC
12
Liter to U.S. Gallon 1 L = 0.2642 U.S. Gal

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

0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-15 WA180-3MC
12
kgm to ft. lb. 1 kgm = 7.233 ft. lb.

0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.63 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-16 WA180-3MC
12
kg/cm2 to lb/in2 1 kg/cm2 = 14.2233lb/in2

0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 19324 1949 1963 1977
140 1991 2005 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-17 WA180-3MC
12
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature
reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the
temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, con-
sider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column
at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8
-37.2 .35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-18 WA180-3MC
01 GENERAL
SPECIFICATION DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-2

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3
LIST OF LUBRICANT AND WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-8
ENGINE OIL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
NORMAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
ARCTIC OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-9
DIESEL FUEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
COOLANT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-10
ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-11
INHIBITORS/CONDITIONERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-12
WA180-3MC 01-1 2
GENERAL SPECIFICATION DRAWING
12
SPECIFICATION DRAWING
Unit: mm
01-2 2 WA180-3MC
GENERAL SPECIFICATIONS
12
SPECIFICATIONS
Machine model WA180-3MC Serial No. A81001 and up
Operating weight kg (lb) 9350 (20610)

Weight
Distribution (front) kg (lb) 3610 (7960)
Distribution (rear) kg (lb) 5740 (12650)
Bucket capacity (piled) m3 (yd3) 1.9 (2.49)
Rated load kg (lb) 3040 (6700)
Travel speed FORWARD 1st km/h (mph) 7.2 (4.5)
FORWARD 2nd km/h (mph) 12.0 (7.5)
FORWARD 3rd km/h (mph) 22.0 (13.7)
FORWARD 4th km/h (mph) 34.5 (21.4)

Performance
REVERSE 1st km/h (mph) 7.1 (4.8)
REVERSE 2nd km/h (mph) 12.3 (7.8)
REVERSE 3rd km/h (mph) 20.5 (14.2)
REVERSE 4th km/h (mph) 32.3 (21.7)
Max. rimpull FORWARD N (lbf) 81395 (18298)
Gradeability deg 25
Center of outside wheel mm (ft) 5490 (18)

Min. turning radius
Outside portion of chassis mm (ft) 4650 (15.25)
Overall length (with B.O.C.) mm (ft) 6510 (21.36)
Overall width (chassis) mm (ft) 2260 (7.41)
Bucket width cutting edge mm (ft) 2440 (8.00)
Overall height top of ROPS cab mm (ft) 3095 (10.15)
bucket raised mm (ft) 4830 (15.85)
Wheel base mm (ft) 2700 (8.85)

Dimensions
Tread mm (ft) 1820 (5.97)
Minimum ground clearance mm (ft) 425 (16.73)
Height of bucket hinge pin mm (ft) 3595 (11.79)
Dumping clearance (tip of edge) mm (ft) 2720 (8.92)
Dumping reach (tip of edge) mm (ft) 990 (3.25)
Bucket dump angle deg 46
Bucket tilt angle (travel position) deg 47
Digging depth (10° dump) mm (ft) 280 (0.92)
WA180-3MC 01-3
Model S6D102E-1
Direct Injection (Aspiration, Turbo

Type
charged)
No. of cylinders - bore x stroke 6 - 102 mm x 120 mm
Piston displacement L (in3) 5.88 (359)
Flywheel horsepower kW/rpm (HP/rpm) 89 (120)

Engine
Performance
Maximum torque (gross) Nm (lbf ft) 483 (357)
High idling speed rpm 2600
Low idling speed rpm 850
Starting motor 24 V 4.5 kW
Alternator 24 V 50 A
Battery 12 V 110 Ah x 2
3-element, 1-stage, single-phase

Torque converter
(Komatsu TCA30-6Z)
spur gear, constant-mesh multiple-

Transmission disc, hydraulic
Power train
actuated, modulation type
Reduction gear Single bevel gear
Straight bevel gear, torque propor-

Differential
tioning
Planetary gear, single

Final drive
reduction
Drive type Front / rear wheel drive
Front axle Fixed frame, semi-floating
Center pin support type,

Rear axle
semi-floating
Axle, wheel
Tire 17.5 - 25 x 12 pr (L2)
Wheel rim 25 x 13.00
Inflation pressure Front tire kPa (psi [lbf/in2]) 294 (42.64)
Rear tire kPa (psi [lbf/in2]) 294 (42.64)
Front/rear wheel independent wet-type sealed disc brakes with

Main brake
hydraulic booster
Brakes
Thrust shaft (transmission shaft) braking, wet-type disc brake,

Parking brake
mechanical type
01-4 WA180-3MC
Torque converter,
Liter/min (gal/min) 90.5 (23.9)
transmission pump
Hydraulic pump Steering pump Liter/min (gal/min) 106 (28.0)
delivery
PPC pump Liter/min (gal/min) 21 (5.5)
Work equipment pump Liter/min (gal/min) 144 (38.0)

Hydraulic system
Transmission valve kg/cm2 (lbf/in2) 23 / 327.1
Control valve set pressure Steering demand valve kg/cm2 (lbf/in2) Spool type 210 (2986.9)
Main control valve kg/cm2 (lbf/in2) Spool type 210 (2986.9)
Steering cylinder Reciprocating piston

mm
No. - bore x stroke 2 - 60 x 340
Boom cylinder Reciprocating piston

Cylinder mm
Bucket cylinder Reciprocating piston

mm
Link type Single Z bar link

equipment
Work
bucket edge type Flat edge with bolt on cutting edge
WA180-3MC 01-5
12
WARNING! This weight table is a guide for use when

transporting or handling components.
Unit: kg (lb)
Machine model WA180-3MC
Serial number A81001 and up
Engine (dry) (with air cleaner and muffler) 540 (1190.5)
Radiator (dry) 80 (176.37)
Torque converter (dry) 35 (77.16)
Transmission with torque converter (dry) 480 (1058.22)
Center drive shaft 11 (24.25)
Front drive shaft 12 (26.45)
Rear drive shaft 6 (13.22)
Axle pivot 69 (152.11)
Front axle 387 (853.18)
Rear axle 393 (866.41)
Wheel (each) 71 (156.52)
Tire (each) 106 (233.69)
Orbit-roll valve 8 (17.63)
Priority valve 6 (13.22)
Steering cylinder (each) 14 (30.86)
Hydraulic tank (dry) 53 (116.84)
Work equipment / steering pump 10 (22.04)
Brake booster 11 (24.25)
PPC valve 3.1 (6.8)
Main control valve 21 (46.29)
Boom (Lift) cylinder (each) 80 (175)
Bucket (Dump) cylinder 56 (123.45)
Engine hood with side panels 127 (279.98)
Front frame 750 (1653.44)
Rear frame 612 (1349.23)
Bucket link (with bushing) 17 (37.47)
Bellcrank (with bushing) 125 (275.57)
Boom (Lifting arm) (with bushing) 520 (1146.4)
Bucket with bolt on cutting edge 750 (1553)
01-6 WA180-3MC
Serial number A81001 and up
Counterweight 1210 (2667.59)
Fuel tank 80 (176.37)
Battery (each) 30 (66.13)
Cab assembly with floor 1060 (2336.9)
Cab (ROPS) 500 (1102.31)
Operator’s seat 40 (88.18)
Unit: kg (lb)
WA180-3MC 01-7
GENERAL LIST OF LUBRICANT AND WATER
12
LIST OF LUBRICANT AND WATER
Ambient Temperature Capacity

Kind of
Reservoir
fluid -22 -4 14 32 50 68 86 104 122°F
Specified Refill
-30 -20 -10 0 10 20 30 40 50°C
SAE 5W- 30
Engine oil 22 L 19.5 L
SAE 10W-30
pan 5.8 gal 5.1 gal
SAE 15W-40
1L 1L
Brake SAE 5W
0.26 gal 0.26 gal
Engine oil
Transmission 35 L 30 L
SAE 10W
case 9.2 gal 7.9 gal
Hydraulic 90 L 64 L
SAE 10W
system 23.8 gal 16.9 gal
Axle
17 L 17 L
(front & rear) Axle oil See Note 1
4.5 gal 4.5 gal
(each)
Pins Grease NLGI No. 2 --- ---
184 L
Fuel tank Diesel fuel ASTM D975 No. 2 ---
48.6 gal
*
Cooling Add Anti-freeze 25.5 L

Coolant ---
system Coolant 6.7 gal
* ASTM D975 No. 1
Other equipment will be necessary, when operating the machine at temperatures below -20o C (-4o F), therefore consult your
Komatsu distributor for your needs.
Note 1: For axle oil, use only the recommended oil as follows.
SHELL: DONAX TT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBIL 424
01-8 WA180-3MC
GENERAL ENGINE OIL SPECIFICATIONS
It is possible to substitute engine oil SAE 30 API classification CD for axle oil. Although increased brake noise may result,
durability is not affected.
ENGINE OIL SPECIFICATIONS

NORMAL OPERATION
Oil performance recommendations are as follows:
The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in
maintaining engine performance and durability.
SAE 15W-40 multi-viscosity oil meeting the American Petroleum Institute (API) performance classification of CF-4,
CF-4/SG, CG-4, CG-4/SH is recommended.
Remark
CC/CD or CD/SF oils may be used in areas where CE oil is not yet available but the oil change interval
must be reduced to one half the interval given in the maintenance schedule
A sulfated ash limit of 1.0 mass percent is suggested for optimum valve and piston deposit and oil consumption control. the
sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed on all engine
lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage and lead to exces-
sive oil consumption.
The API service symbol displays the appropriate oil categories; the lower half may contain words to describe oil energy con-
serving features. The center section identifies the SAE oil viscosity grade.
Oil viscosity recommendations are as follows:
The use of a multi-graded lubricating oil has been found to improve oil consumption control and improve engine cranking in
cold temperatures while maintaining lubrication at high operating temperatures.
While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previous chart for oil viscos-
ity recommendations for extreme climates.
Remark
Limited use of low viscosity oils, such as 10W-30 may be used for easier starting and providing sufficient
oil flow at ambient temperatures below -5° C (23° F). However, continuous use of low viscosity oil can
decrease engine life due to wear.
Single graded oils may be used if multi-graded oil is not available. But be sure to use oil that matches the temperature shown
in the table.
Special break-in lubricating oils are not recommended for a new or rebuilt engine. Use the same type of oil during the break-in
as specified for normal operation.
Additional information regarding lubricating oil availability throughout the world is available in the "E.M.A. Lubricating Oils
Data Book For Heavy Duty Automotive and Industrial Engines". The data book may be ordered from the Engine Manufactur-
ers Association, One Illinois Center, 111 East Wacker Drive,Chicago, Il U.S.A. 60601. The telephone number is
(312) 644-6610.
ARCTIC OPERATION
If an engine is operated in ambient temperatures consistently below -23° C (-10° F) and there are no provisions to keep the
engine warm when it is not in operation, use a synthetic API performance classification CE or CF-4 engine oil with adequate
low temperature properties such as SAE 5W-20 or 5W-30.
WA180-3MC 01-9 2
GENERAL DIESEL FUEL SPECIFICATIONS
The oil supplier must be responsible for meeting the performance service specifications.
IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals
can decrease engine life due to factors such as; corrosion, deposits and wear.
DIESEL FUEL SPECIFICATIONS
WARNING! Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.
★ Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of
dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and nozzles.
For normal service above -12° C (+10° F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number of 40
is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions.
Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent
misfires and excessive smoke.
At operating temperatures below -12° C (+10° F), use ASTM Grade No. 1-D diesel fuel. The use of lighter fuels can reduce
fuel economy.
Where a winterized blend of Grade No. 2-D and No. 1-D fuels is available, it may be substituted for Grade No. 1-D fuel.
However, it is the supplier's responsibility to provide the fuel for the anticipated ambient temperature.
Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel temperature. Cloud
point is the temperature at which crystals begin to form in the fuel. The viscosity of the fuel must be kept above 1.3 cSt to
provide adequate fuel system lubrication.
COOLANT SPECIFICATIONS
GENERAL
Selection and maintenance of the engine coolant is important to long engine life. The following information provides recom-
mendations for selecting the engine coolant and maintaining the coolant inhibitors.
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additives. Supple-
mental coolant additive recommendations are included in the section entitled Inhibitors Conditioners. The coolant mixture
must be drained and replaced at the specified service interval shown in the OPERATION & MAINTENANCE MANUAL, or
every two years of operation, whichever comes first.
WATER
Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited water must
meet the following standards:
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water con-
taining dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount will cause
scale deposits to develop in the engine.
Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits, scale
deposits, corrosion or a combination of these.
01-10 2 WA180-3MC
GENERAL COOLANT SPECIFICATIONS
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water
supplies meet these standards, water samples can be tested by water treatment laboratories. Softened water that is prepared
using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used.
★ Never use water alone in the cooling system because corrosion will occur.
ANTIFREEZE
In climates where the temperature is above -37° C (-34° F), use a coolant mixture that contains 50 percent antifreeze. Anti-
freeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by
raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is
required. Never use more than 68 percent antifreeze under any condition.
An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze concen-
trations between 68 and 100% actually have a higher freezing point than a 68% antifreeze concentration and should not be
used due to reduced heat transfer rates.
Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali
metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel formation can
occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive.
DO NOT use methanol or alcohol as an antifreeze because of its low boiling point.
Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to maintain corro-
sion protection.
Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system.
★ Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection against freezing.
Antifreeze containing sealer or anti-leak additives should NOT be used in this system. Sealer or anti-leak additives will
cause plugging problems in the cooling system.
Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient protection
against freezing.
The following table shows the approximate percentage of antifreeze solution required for various temperatures.
Approximate Freezing Point Percentage of Antifreeze Specific Gravity at 16°C (60°F)

Concentration by Volume
0°C (+32°F) 0 1.000

-7°C (+20°F) 15 1.025
-12°C (+10°F) 25 1.040
-18°C (0°F) 33 1.053
-23°C (-10°F) 40 1.062
-29°C (-20°F) 45 1.070
-34°C (-30°F) 48 1.074
-40°C (-40°F) 53 1.080
-46°C (-50°F) 56 1.083
-51°C (-60°F) 59 1.088
-57°C (-70°F) 62 1.092
-62°C (-80°F) 65 1.095
-68°C (-90°F) 67 1.097
-69°C (-92°F) 68 1.098
In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor DCA4, to protect the engine cooling
system.
WA180-3MC 01-11
12
INHIBITORS/CONDITIONERS
1. All cooling system inhibitors, including those in antifreeze solutions, become depleted through normal operation. If the
inhibitors in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and attacks and coats the metal-
lic surfaces of the cooling system which reduces heat transfer. Cooling system conditioners which contain these inhibitors
must be added to maintain corrosion protection.
2. Soluble oil is not recommended for use in this engine as its use will reduce heat transfer.
3. There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still the best
coolant.
4. DCA4 is recommended to inhibit corrosion in the cooling system for the following reasons:
• Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over concentration occurs.
• Provides engine protection in the following areas:
• Solder corrosion/bloom
• Copper corrosion/erosion/stress cracking
• Oil fouling
• Cylinder liner cavitation corrosion
• Aluminum cavitation corrosion
• Seal and gasket degradation
Maintenance of Cooling System Inhibitors
Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and corrosion.
New machines are delivered with antifreeze protection. Service at regular scheduled intervals specified in the OPERATION &
MAINTENANCE MANUAL with a service DCA4 filter.
Each time the coolant is drained and replaced, the coolant must be recharged with DCA4. New coolant can be correctly
charged with supplemental coolant additives by using DCA4 filters or DCA4 concentrate listed in the table entitled, DCA4
Unit Guide.
If coolant is added between drain intervals, additional DCA4 will be required.
Coolant Testing for Conditioner Concentration
When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The DCA4 con-
centration must not fall below 1.0 unit per 3.8 L (1 U.S. gal.) or exceed 2 units per 3.8 L (1 U.S. gal.) of coolant. The only
accurate method for testing chemical concentrations in coolant with mixed chemical compounds is a laboratory analysis. For
this reason, the coolant inhibitor should be maintained as shown in the OPERATION & MAINTENANCE MANUAL.
★ Inadequate concentration of the coolant additive can result in major corrosive damage to cooling system components.
Over concentration can cause formation of gel that can cause restriction, plugging of passages and overheating.
Replenishing Coolant Conditioner
Install a precharge DCA4 filter when the coolant is changed or a significant (more than 50%) coolant loss occurs. Install a ser-
vice DCA4 filter as specified in the OPERATION & MAINTENANCE MANUAL When antifreeze is added, add coolant con-
ditioner equal to 1.0 unit per 3.8 L (1 U.S. gal.) of antifreeze.
Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no test kit available
to measure concentration levels with mixed chemical solutions.
01-12 WA180-3MC
12
DCA4 Unit Maintenance Guide
Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion. Antifreeze
alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion protection must
be supplied through periodic additions of supplemental coolant additives to the coolant.
To protect against corrosion, a new coolant charge must be brought up to 0.26 DCA4 unit per liter (one unit per U.S. gal.) of
coolant (initial charge). Maintain the correct DCA4 concentration by changing the service coolant filter at each engine oil and
filter change interval.
Each time the coolant is drained and replaced, the coolant must be recharged with supplemental coolant additives. Use the
appropriate DCA4 spin-on filter listed in following table. The coolant mixture must be drained and replaced as defined under
General.
The amount of replacement inhibitor is determined by the length of the service interval and the cooling system capacity. Refer
to the DCA4 Unit Guide for the selection of the correct filter to replenish the DCA4.
If coolant is added between drain intervals, additional DCA4 will be required. Check the coolant DCA4 concentration level
anytime make-up coolant is added to the system. The DCA4 concentration must not fall below 0.13 units per liter or exceed
0.5 units per liter (0.5 units per U.S. gallon or exceed 2 units per U.S. gallon).
DCA4 Unit Guide
Fleetguard Part No. DCA4 Units

DCA4 Coolant Filter
WF-2070 2
WF-2071 4
WF-2072 6
WF-2073 8
WF-2074 12
WF-2075 15
WF-2076 23
WF-2077 0
DCA4 Liquid
DCA60L 4 (1 pint)
DCA80L 1,760 (55 U.S. gal.)
DCA4 Powder
DCA95 20
DCA4 Precharge and Service Filters
System Capacity Precharge Filter Service Filter

(See NOTE 1) (See NOTE 3)
Liters US Gallons
19 to 26 5 to 7 WF-2072 WF-2070
26 to 38 7 to 10 WF-2073 WF-2071
38 to 57 10 to 15 WF-2074 WF-2071
57 to 76 15 to 20 WF-2075 WF-2071
76 to 114 20 to 30 WF-2076 WF-2072
114 to 190 30 to 50 (See NOTE 2) WF-2073
WA180-3MC 01-13
NOTE 1 - After draining and replacing coolant, always precharge the cooling system to maintain the DCA4 concentration
between 1.0 and 2.0 units per 3.8 L (1 U.S. gal.).
★ When performing service which requires draining the cooling system, discard the coolant. Reusing coolant can introduce
contaminates or over concentrated chemicals, resulting in premature failure of cooling system components.
NOTE 2 - To precharge cooling systems larger than 114 L (30 U.S. gal.), do the following:
• Install appropriate service filter listed in the above table based on cooling system capacity.
Example: 360 L (95 U.S. gal.) cooling system capacity
-15 Units (1) WF-2075 Filter
80 Units
• The answer represents the additional units required to precharge the cooling system. Four bottles of powder, part
number DCA95, will provide a sufficient amount of DCA4 units (80) to precharge the example cooling system.
• Install the appropriate service filter at the next and subsequent maintenance intervals.
NOTE 3 - Change the coolant filter at every engine oil and filter change interval to protect the cooling system.
Maintain a nominal concentration of 1.0 DCA4 unit per 3.8 L (1 U.S. gal.) of coolant in the system. Less than 0.5 unit per 3.8
L (1 U.S. gal.) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8 L (1 U.S. gal.) indicates an over-
concentrated coolant solution.
To check the DCA4 concentration level, use the Fleet guard coolant test kit, CC2626. Instructions are included with the test
kit.
DCA4 Unit Concentration Guide
Number of Solution A Drops to Coolant Condition Action Required

Cause Color Change
Extremely under-concentrated - less than 0.4 DCA4 Initially charge the system to a minimum of 1.0 DCA4
0 to 10 Drops
units per 3.8 L (1 U.S. gal.) unit per 3.8 L (1 U.S. gal.)
Add DCA4 liquid units to maintain 1.0 DCA4 unit per

Marginally under-concentrated - 0.45 to 0.8 DCA4
11 to 16 Drops 3.8 L (1 U.S. gal.) minimum or change the DCA4 cool-
units per 3.8 L (1 U.S. gal.)
ant filter
Acceptable - 0.85 to 1.3 DCA4 units per 3.8 L (1 U.S.

17 to 25 Drops NONE
gal.)
Highly acceptable - 1.35 to 2.0 DCA4 units per 3.8 L

26 to 35 Drops NONE
(1 U.S. gal.)
Marginally over-concentrated - 2.1 to 3.3 DCA4 units

36 to 55 Drops Review maintenance practice
per 3.8 L (1 U.S. gal.)
Drain 50% of the coolant and replace with water anti-

Over 55 Drops Extremely over-concentrated freeze mixture. Retest the system for correct DCA4 unit
concentration.
01-14 WA180-3MC
The Fleetguard® Coolant Test Kit (available from your
Komatsu International Company distributor) is used to check
the coolant concentration of coolant additives in the cooling
system.
Part Number: CC-2626
1. Test strip bottles

2. Solution #1 bottle
3. Small plastic container
4. Large plastic cup
5. Syringe
WA180-3MC 01-15
12
MEMORANDUM
01-16 WA180-3MC
10 STRUCTURE AND FUNCTION
POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 10-5
POWER TRAIN SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 10-7
TORQUE CONVERTER, TRANSMISSION PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-8
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 10-8
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10
ENGINE LOW IDLING, DIRECTIONAL LEVER AT NEUTRAL, SPEED LEVER AT 2ND . . . . . . . . . 10-10
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11
ENGINE STOPPED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
TORQUE CONVERTER OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-14
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 10-16
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 10-18
REVERSE 1ST CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
FORWARD, 2ND CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
3RD, 4TH CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
FORWARD 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
FORWARD 2ND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
FORWARD 3RD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23
FORWARD 4TH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24
REVERSE 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
TRANSMISSION CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26
UPPER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
LOWER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28
TRANSMISSION SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-29
TORQUE CONVERTER OUTLET PORT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30
PILOT REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
TRANSMISSION SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-33
MAIN REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-34
QUICK RETURN VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-35
MODULATION FILL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-39
DIRECTIONAL SELECTOR SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
EMERGENCY MANUAL SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
OPERATION OF FORWARD 1ST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
ACCUMULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-46
TRANSMISSION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-48
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-51
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 10-52
REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
TORQUE PROPORTIONING DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-55
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56
AXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-58
WA180-3MC 10-1
STRUCTURE AND FUNCTION TABLE OF CONTENTS
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
STEERING PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
CUSHION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
STEERING VALVE (ORBIT-ROLL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-68
CONNECTION BETWEEN HAND PUMP AND SLEEVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
BRAKE PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-77
BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-78
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81
PARKING BRAKE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 10-86
HYDRAULIC PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
ENGINE LOW IDLING, WORK EQUIPMENT IN "HOLD" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-89
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-91
OIL FILTER BYPASS VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-92
BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
PPC RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101
FOR PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-101
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-102
2-SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 10-102
3-SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-104
RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
SAFETY VALVE (WITH SUCTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107
SUCTION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-108
BOOM AND BUCKET SPOOL AT NEUTRAL POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
BOOM SPOOL AT RAISE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
BOOM SPOOL AT LOWER POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
BOOM SPOOL AT FLOAT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112
BUCKET SPOOL AT TILT BACK POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-113
BUCKET SPOOL AT DUMP POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
WORK EQUIPMENT LVER LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
WORK EQUIPMENT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 10-118
BUCKET POSITIONER AND BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
PROXIMITY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121
ROPS CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
AIR CONDITIONER AND HEATER PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-124
ECSS (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-125
ECSS HYDRAULIC AND ELECTRICAL CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 10-127
CENTRAL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-128
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 10-129
ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
BRAKE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-129
ENGINE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
10-2 WA180-3MC
STRUCTURE AND FUNCTION TABLE OF CONTENTS
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131
ENGINE STARTING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131
ENGINE STOP CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-132
AUTOMATIC PREHEATING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-133
QUICK HEATING SYSTEM (QHS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-133
QHS CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
HEATER RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-135
RIBBON HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
QHS WATER TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
TRANSMISSION AUTO-SHIFT CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-138
SHIFT CONTROL SYSTEM FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
INPUT SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
OUTPUT SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
SHIFT CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141
SAFETY FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145
TRANSMISSION CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
CONNECTOR SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-146
COMBINATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-147
TRANSMISSION CUT-OFF FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-148
PARKING BRAKE FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
KICK-DOWN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
KICK-DOWN ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
KICK-DOWN SWITCH OPERATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-153
KICK-DOWN SWITCH ACTUATION - CANCELED (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-154
KICK-DOWN SWITCH ACTUATION - CANCELED (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-155
ELECTRICAL WIRING ILLUSTRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-157
ELECTRICAL WIRING DIAGRAM (1/5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-159
WA180-3MC 10-3
STRUCTURE AND FUNCTION
12
MEMORANDUM
10-4 WA180-3MC
STRUCTURE AND FUNCTION POWER TRAIN
12
POWER TRAIN
OUTLINE
The motive force from engine (3) passes through the engine flywheel and is transmitted to torque converter (2), which is con-
nected to the input shaft of transmission (1).
The transmission has six hydraulically actuated clutches, and these provide four speed ranges for both FORWARD and
REVERSE. The transmission speed ranges are selected manually.
The motive force from the output shaft of the transmission passes through center drive shaft (6), front drive shaft (5) and rear
drive shaft (7), and is then transmitted to front axle (4) and rear axle (8) to drive the wheels.
WA180-3MC 10-5
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
12
POWER TRAIN SYSTEM
10-6 WA180-3MC
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
12
1. Engine
2. Torque converter
3. Steering pump
4. Hydraulic pump
5. Torque converter charging pump
6. Transmission
7. Parking brake
8. Center drive shaft
9. Flange bearing
10. Front drive shaft
11. Front axle
12. Front differential
13. Front brake
14. Front final drive
15. Front tire
16. Rear drive shaft
17. Rear axle
18. Rear differential
19. Rear brake
20. Rear final drive
21. Rear tire
OUTLINE
The motive force from engine (1) passes through the flywheel and is transmitted to torque converter (2).
The torque converter uses oil as a medium. It converts the transmitted torque in accordance with the change in the load, and
transmits the motive force to the input shaft of the transmission.
In addition, the motive force of the engine passes through the pump drive gear of the torque converter, and is transmitted to
hydraulic, steering pump (4), (3) and torque converter charging pump (5) to drive each pump.
Transmission (6) operates the directional spool and speed spool of the transmission valve through the solenoid valves, and
actuates the six hydraulically actuated clutches to select one of the four FORWARD or REVERSE speeds.
The transmission speed range is selected manually.
The output shaft of transmission (6) transmits the power to the front and rear axles. At the front, the power is transmitted to
front axle (11) through center drive shaft (8), flange bearing (9), and front drive shaft (10). At the rear, the power is transmitted
to rear axle (17) through rear drive shaft (16).
The motive force transmitted to front axle (11) and rear axle (17) has its speed reduced by the bevel gear and pinion gear of
differentials (12) and (18), and is then transmitted to the sun gear shaft through the differential mechanism.
The motive force of the sun gear is reduced further by the planetary mechanism and is transmitted to the wheels through the
axle shaft.
WA180-3MC 10-7
STRUCTURE AND FUNCTION TORQUE CONVERTER, TRANSMISSION PIPING
12
TORQUE CONVERTER, TRANSMISSION PIPING
1. Transmission 4. Torque converter charging pump

2. Oil filter 5. Radiator
3. Torque converter 6. Oil cooler
OUTLINE
The oil from the torque converter charging pump passes through the oil filter and flows to the brake booster. From the brake
booster, it flows to the main regulator valve and is divided into three lines: the torque converter circuit, clutch circuit, and sole-
noid pilot circuit.
The oil flowing to the torque converter circuit enters the torque converter. The oil pressure is adjusted by the torque converter
outlet port valve, the oil is cooled by the oil cooler, lubricates the transmission and returns to the transmission case.
10-8 WA180-3MC
STRUCTURE AND FUNCTION TORQUE CONVERTER, TRANSMISSION PIPING
12
MEMORANDUM
WA180-3MC 10-9
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
12
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
ENGINE LOW IDLING, DIRECTIONAL LEVER AT NEUTRAL, SPEED LEVER

AT 2ND
10-10 WA180-3MC
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
ENGINE STOPPED
1. Transmission case 11. Transmission lubrication 21. Accumulator valve

2. Strainer 12. Pilot reducing valve 22. FORWARD clutch
3. Torque converter charging pump 13. Pilot oil filter 23. REVERSE clutch
4. Oil filter 14. Quick return valve 24. 4th clutch
5. Priority valve 15. Modulation fill valve 25. 3rd clutch
6. Main regulator valve 16. Accumulator 26. 2nd clutch
7. Torque converter 17. Solenoid valve 27. 1st clutch
8. Torque converter outlet valve 18. Speed spool 28. Brake booster
9. PTO lubrication 19. Directional spool
10. Oil cooler 20. Emergency manual spool
WA180-3MC 10-11
STRUCTURE AND FUNCTION TORQUE CONVERTER
12
TORQUE CONVERTER
1. Pilot 6. PTO gear (drive) Specifications

2. Turbine 7. Housing (transmission case) Model: TCA30-6A
3. Stator 8. Stator shaft Type: 3-element, 1-stage, 1-phase
4. Drive case Stall torque ratio: 2.84
5. Pump
10-12 WA180-3MC
STRUCTURE AND FUNCTION TORQUE CONVERTER
12
Path of motive force
The torque converter is installed between the engine and the transmission.
The motive force from the engine enters drive case (4) from flywheel.
Drive case (4), pump (5), and PTO gear (drive) (6) are each secured by
bolts and are rotated directly by the rotation of the engine. The motive
force of pump (5) uses oil as a medium to rotate turbine (2) and transmit
the motive force to transmission input shaft (11).
The motive force of drive case (4) is used as the motive force to drive the
gear pump through PTO gear (drive) (6).
Flow of oil
The oil supplied from the torque converter charging pump enters inlet port
A, passes through the oil passage of stator shaft (8), and flows to pump (5).
The oil is given centrifugal force by pump (5), enters turbine (2), and trans-
mits the energy of the oil to the turbine. Turbine (2) is fixed to transmission
input shaft (11), so the motive force is transmitted to the transmission input
shaft.
The oil from turbine (2) is sent to stator (3), and enters the pump again.
However, part of the oil is sent from the stator through outlet port B to the
cooler.
WA180-3MC 10-13
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
12
TORQUE CONVERTER OIL FILTER
1. Relief valve
2. Element
3. Center bolt
4. Drain plug
Specifications
Filter mesh size: 10 microns
Filtering area: 8900 cm²
Relief pressure: 3.5 kg/cm² (49.78 lbf/in2)
Operation
The oil from the torque converter charging pump enters filter inlet port A.
It is filtered from the outside of element (2) to the inside, and flows to out-
let port B.
If element (2) becomes clogged with dirt, or the oil temperature is low and
the pressure rises at inlet port A, the oil from inlet port A opens relief valve
(1) and flows directly to outlet port B in order to prevent damage to the
pump or element (2).
10-14 WA180-3MC
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
12
MEMORANDUM
WA180-3MC 10-15
STRUCTURE AND FUNCTION TRANSMISSION
12
TRANSMISSION
1. Transmission control valve 4. Transmission 7. 4th shaft

2. Oil filter 5. Parking brake lever 8. 4th gear (Teeth 45)
3. Accumulator valve 6. 4th gear (Teeth 33) 9. Strainer
10-16 WA180-3MC
12
10. Torque converter charging pump 16. Rear coupling 22. FORWARD, 2nd shaft
11. Input shaft 17. Output shaft 23. REVERSE, 1st shaft
12. Torque converter 18. Front coupling 24. 1st clutch
13. FORWARD clutch 19. Parking brake 25. REVERSE clutch
14. 4th clutch 20. 3rd clutch 26. Input gear (Teeth 34)
15. 3rd, 4th shaft 21. 2nd clutch
WA180-3MC 10-17
12
Outline
The motive force from the torque converter passes through the transmission input shaft and enters the transmission.
The transmission uses the combination of the forward or reverse clutches and the four speed clutches to shift to F1 - 4 or R1 -
4, and transmits the motive force from the input shaft to the output shaft.
CLUTCH
REVERSE 1ST CLUTCH
1. Spacer 7. REVERSE clutch disc (x9) a. REVERSE clutch oil port

2. Thrust washer 8. REVERSE gear (Teeth 45) b. 1st clutch oil port
3. 1st gear (Teeth 29) 9. REVERSE, 1st shaft c. Lubricating oil port
4. 1st clutch plate (x6) 10. REVERSE ring gear (Teeth: 59)
5. 1st clutch disc (x5) 11. 1st ring gear (Teeth: 59)
6. REVERSE clutch plate (x10)
10-18 WA180-3MC
12
FORWARD, 2ND CLUTCH
1. Spacer 6. FORWARD clutch disc (9) 11. 2nd gear (Teeth: 27, 49)
2. Thrust washer 7. FORWARD gear (teeth: 47) a. FORWARD clutch oil port
3. 2nd clutch plate (x6) 8. FORWARD 2nd shaft b. 2nd clutch oil port
4. 2nd clutch disc (x5) 9. FORWARD ring gear (teeth: 58) c. Lubricating oil port
5. FORWARD clutch plate (x10) 10. 2nd ring gear (Teeth: 58)
3RD, 4TH CLUTCH
1. Spacer 7. 4th gear (Teeth: 51) a. 4th clutch oil port

2. Thrust washer 8. 3rd, 4th sheaf b. 3rd clutch oil port
3. 3rd clutch plate (x6) 9. 4th ring gear (Teeth: 59) c. Lubricating oil port
4. 3rd clutch disc (x5) 10. 3rd ring gear (Teeth: 59)
5. 4th clutch plate (x6) 11. 3rd gear (Teeth: 40, 52)
6. 4th clutch disc (x5)
WA180-3MC 10-19
12
Operation of clutch
When operated
The oil sent from the transmission valve passes through the oil passage
inside shaft (1), and goes to the rear face of piston (6) to actuate the piston.
When piston (6) is actuated, separator plate (2) is pressed against clutch
disc (3) and forms shaft (1) and clutch gear (4) into one unit to transmit the
motive force.
Oil is drained from oil drain hole (5) at this time, but this does not affect
clutch operation since less oil is drained than supplied.
When not actuated

If the oil from the transmission valve is shut off, the pressure of the oil act-
ing on the rear face of piston (6) drops.
The piston is returned to its original position by wave spring (7), so shaft
(1) and clutch gear (4) are separated.
When the clutch is disengaged, the oil at the rear face of the piston is
drained by centrifugal force through oil drain hole (5), preventing the
clutch from remaining partially engaged.
10-20 WA180-3MC
12
FORWARD 1ST
Remark
Input gear (26) is always meshed with REVERSE gear (27) and FORWARD gear (28).
Operation
In the case of FORWARD 1st gear, FORWARD clutch (13) and 1st clutch (24) are connected by the oil pressure from the
transmission valve.
The power from the torque converter is transmitted from input shaft (11) and input gear (26) to FORWARD gear (28). FOR-
WARD clutch (13) is engaged, so the power is transmitted to REVERSE, 1st cylinder gear (29).
1st clutch (24) is engaged, so the rotation of REVERSE, 1st cylinder gear (29) rotates 1st gear (30) and is transmitted to 1st
driven gear (31).
1st driven gear (31) forms one unit with 2nd gear (32), so the power of 1st driven gear (31) passes through 2nd gear (32), is
transmitted to 3rd gear (33) and output gear (34), and is then transmitted to output shaft (17).
WA180-3MC 10-21
12
FORWARD 2ND
Remark
Operation
In the case of FORWARD 2nd gear, FORWARD clutch (13) and 2nd clutch (21) are connected by the oil pressure from the
transmission valve.
WARD clutch (13) is engaged, so the power is transmitted to FORWARD, 2nd cylinder gear (35).
2nd clutch (21) is engaged, so the rotation of FORWARD, 2nd cylinder gear (35) rotates 2nd gear (32) and is transmitted to 3rd
gear (33).
The power is transmitted from 3rd gear (33) and output gear (34) to output shaft (17).
10-22 WA180-3MC
12
FORWARD 3RD
Remark
Operation
In the case of FORWARD 3rd gear, FORWARD clutch (13) and 3rd clutch (20) are connected by the oil pressure from the
transmission valve.
WARD clutch (13) is engaged, so the power is transmitted to 3rd, 4th cylinder gear (36).
3rd clutch (20) is engaged, so the power of 3rd, 4th cylinder gear (36) is transmitted to 3rd gear (33). The power is then trans-
mitted through output gear (34) to output shaft (17).
WA180-3MC 10-23
12
FORWARD 4TH
Remark
Operation
In the case of FORWARD 4th gear, FORWARD clutch (13) and 4th clutch (14) are connected by the oil pressure from the
transmission valve.
WARD clutch (13) is engaged, so the power is transmitted to 3rd, 4th cylinder gear (36).
4th clutch (14) is engaged, so the power of 3rd, 4th cylinder gear (36) is transmitted to 4th gear (37). The power is then trans-
mitted to 4th gear (38), 4th shaft (39), and 4th gear (40).
The power of 4th gear (40) is transmitted to 4th gear (41), which forms one unit with 3rd gear (33), so the power passes
through 3rd gear (33), is transmitted to output gear (34) and output shaft (17).
10-24 WA180-3MC
12
REVERSE 1ST
Operation
In the case of REVERSE 1st gear, REVERSE clutch (25) and 1st clutch (24) are connected by the oil pressure from the trans-
mission valve.
The power from the torque converter is transmitted from input shaft (11) and input gear (26) to REVERSE gear (27).
REVERSE clutch (25) is engaged, so the power is transmitted to REVERSE, 1st cylinder gear (29).
1st clutch (24) is engaged, so the power of REVERSE, 1st cylinder gear (29) passes through 1st gear (30) and is transmitted to
1st driven gear (31).
1st driven gear (31) forms one unit with 2nd gear (32), so the power of 1st driven gear (31) passes through 2nd gear (32), is
transmitted to 3rd gear (33) and output gear (34), and is then transmitted to output shaft (17).
WA180-3MC 10-25
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
12
TRANSMISSION CONTROL VALVE
1. Lower valve a. Pilot oil pressure measurement port

2. Upper valve b. To oil cooler
3. Emergency manual spool c. From pump
4. Solenoid valve port d. Pump oil pressure measurement port
e. Clutch oil pressure measurement port
10-26 WA180-3MC
12
UPPER VALVE
1. Upper valve body 9. Check valve

2. Main regulator valve 10. Lower valve body
3. Pilot reducing valve 11. Torque converter outlet valve
4. Priority valve 12. FORWARD and REVERSE spool
5. Modulation fill valve pressure adjusting screw 13. HIGH and LOW spool
6. Modulation fill valve 14. Speed range spool
7. Accumulator 15. Solenoid valve
8. Quick return valve 16. Emergency manual spool
WA180-3MC 10-27
12
LOWER VALVE
Outline
The oil from the pump passes through the torque converter oil filter, enters the transmission valve, and is divided into the pilot
circuit and the clutch actuation circuit.
The priority valve gives priority to the oil sent to the pilot circuit, so the pilot pressure is always kept the same.
The pressure of the oil flowing to the clutch actuation circuit is adjusted by the modulation fill valve and actuates the clutch.
The oil which is relieved is sent to the torque converter.
The quick return and modulation fill valve are interconnected during gear shifting.
They act to raise the clutch oil pressure smoothly, thereby reducing the shock when shifting gear. During traveling, the clutch
pressure is kept the same.
The pressure of the oil which flows to the circuit is adjusted by the pilot reducing valve. During gear shifting, the oil flows in
accordance with ON-OFF position of the solenoid valves and actuates the FORWARD, REVERSE and speed spools.
By switching the FORWARD, REVERSE, and speed spools, the oil regulated by the modulation fill valve is sent to the
selected clutch to obtain the necessary gear combination.
10-28 WA180-3MC
12
TRANSMISSION SOLENOID VALVE
1. Connector 5. REVERSE solenoid valve

2. Valve body 6. FORWARD solenoid valve
3. 1st, 4th solenoid valve 7. Emergency manual spool
4. 3rd solenoid valve 8. Lock plate
STRUCTURE
The transmission solenoid valve is installed to the transmission
together with the transmission valve. When the directional lever
or speed control lever are operated, the solenoid valve is actuated
and moves the spool inside the transmission valve.
WA180-3MC 10-29
12
TORQUE CONVERTER OUTLET PORT VALVE
Function
The torque converter outlet port valve is installed in the outlet line of the torque converter and adjusts the maximum pressure
of the torque converter.
Operation
The oil at port a passes through the orifice in spool (1) and flows to port c.
When the pressure at port a rises, the pressure at port c also rises. This
overcomes the tension of spring (2) and moves spool (1) to the left in the
direction of the arrow to allow oil to flow from port a to port b.
If the pressure at port a becomes even higher, spool (1) is moved further to
the left in the direction of the arrow, and the oil flows from port a to port b
and drain port d. (Cold relief)
10-30 WA180-3MC
12
PILOT REDUCING VALVE
Function
The pilot reducing valve controls the pressure used to actuate the direc-
tional selector spool, H-L selector spool, range selector spool.
Operation
The oil from the pump enters port a, passes through port b of pilot reducing
spool (1), enters spool (2) in the lower valve, and fills the pilot circuit.
The oil at port b passes through the orifice (3)and flows to port c.
When the pressure in the pilot circuit rises, the pressure at port c also rises.
This overcomes the tension of spring (4) and moves pilot reducing spool
(1) to the right in the direction of the arrow.
For this reason, port a and port b are shut off, so the pressure at port c is
maintained.
WA180-3MC 10-31
12
Function
There are four solenoid valves installed to the transmission control valve. When the gear shift lever in the operator's compart-
ment is operated, the solenoid valves are switched ON/OFF, and the oil is drained to actuate the gear shift spool.
Operation
1. Solenoid valve OFF

The oil from pilot reducing valve (3) flows to ports a and b of gear
shift spools (1) and (2). The oil at ports a and b is stopped by solenoids
(4) and (5), and gear shift spools (1) and (2) move to the right in the
direction of the arrow. As a result, the oil from the pump flows to the
2nd clutch.
2. Solenoid valve ON
When the gear shift lever is operated, the drain port of solenoid valves
(4) and (5) opens.
The oil at ports a and b of gear shift spools (1) and (2) flows from
ports c and d to the drain circuit. Therefore, ports a and b become the
low pressure circuit, and the gear shift spool is moved to the left in the
direction of the arrow by the tension of spring (6).
As a result, the oil at port e flows to the 4th clutch and the clutch is
switched.
10-32 WA180-3MC
PRIORITY VALVE
Function
The priority valve gives priority to sending oil to the pilot circuit of the
lower valve. When the pressure in the circuit goes above the set pressure, it
acts as a main relief valve to protect the circuit.
Operation
The oil from the pump is divided into two lines. One oil flow enters port a,
passes around priority valve (2), goes through pilot reducing valve (1), and
flows to the pilot circuit of the lower valve. The other oil flow goes to pri-
ority valve (2).
The oil flowing to priority valve (2) passes through orifice (3) and flows to
port b.
As a result, it pushes priority valve (2) to the left in the direction of the
arrow against the force of spring (4), and flows to port c.
When the pressure at port b goes above the set pressure, priority valve (2)
is pushed further to the left in the direction of the arrow, and the oil is
drained from port d to protect the circuit. (The main relief function)
WA180-3MC 10-33
MAIN REGULATOR VALVE

Function
The main regulator valve controls the flow of oil to the clutch circuit and sends any excess oil to the torque converter circuit.
Operation
The oil from the pump enters port a of priority valve (1), and then passes
from port c through modulation fill valve (3) and main orifice (2), and
flows to the clutch circuit.
The oil passing through orifice (4) and entering port b moves the spool to
the left in the direction of the arrow against the force of spring (5), so the
oil passes through port c and flows to the torque converter circuit.
10-34 WA180-3MC
12
QUICK RETURN VALVE
Function
The pressure of the transmission clutch is raised smoothly by the modulat-
ing action. This reduces any shock when shifting gears and prevents the
generation of peak torque in the power train. Therefore, it reduces operator
fatigue and ensures a comfortable ride for the operator. At the same time, it
also increases the durability of the power train.
Operation
1. After starting engine, clutch fully engaged (clutch pressure at point A)

(FORWARD 1st)
WA180-3MC 10-35
12
2. When shifting from FORWARD to REVERSE (clutch pressure at point B)
When the directional lever is moved from FORWARD to REVERSE, FORWARD solenoid (1) closes, REVERSE sole-
noid (2) opens, and directional spool (3) moves to the right in the direction of the arrow. FORWARD clutch (4) is con-
nected to the drain circuit and the oil is drained.
At the same time, the oil from the pump flows to REVERSE clutch (5), but while the oil is filling the clutch, the clutch
pressure is low. As a result, the oil pressure at port a of quick return valve (6) also drops, so check valve (7) opens and the
oil at port b flows to port a. At the same time, quick return valve (6) is moved to the left in the direction of the arrow by
the pressure of the accumulator, and the oil from accumulator (8) is suddenly drained from port c.
Accumulator (8) is returned fully to the left by the force of spring (9).
★ To reduce the shock when shifting gears, the pressure in the clutch circuit must be completely lowered and accumula-
tor (8) must move fully to the left.
10-36 WA180-3MC
12
3. Clutch pressure starting to rise (clutch pressure at point C)
The oil from the pump fills the REVERSE clutch and the pressure in the clutch circuit starts to rise. As a result, the pres-
sure at port a rises, so quick return valve (6) is moved to the right in the direction of the arrow, and closes drain port c.
WA180-3MC 10-37
12
4. Start of accumulator action, clutch completely engaged (clutch pressure at point D)
Because of the differential pressure created by modulation fill valve (11), a constant flow of oil passes through 1st orifice
(10) and enters accumulator (8). As this oil flows in, the accumulator piston gradually moves to the right in the direction
of the arrow, and spring (9) is compressed, so the accumulator pressure rises. As this accumulator pressure rises, it raises
the clutch pressure. Except in 1st, oil flows into the accumulator from 1st orifice + 2nd (3rd) orifice, so the modulating
time is shorter than for 1st.
When accumulator piston (8) moves to the end of its stroke, the rise in the pressure at port d finishes, so the specified pres-
sure is maintained and the REVERSE clutch is completely engaged.
When the gear shift spool is operated, the action is the same as above.
10-38 WA180-3MC
12
MODULATION FILL VALVE
Function
The modulation fill valve adjusts the pressure and controls the amount of
oil flowing to the accumulator while allowing the clutch pressure to rise.
Operation
1. Clutch completely engaged (point a)
2. Shifting from FORWARD to REVERSE

The oil inside the accumulator is drained by the quick return valve,
and accumulator piston (1) moves to the left. When this happens, the
pressure in chamber c and chamber d drops, and spring (2) moves
modulation fill valve (3) to the right to open port a.
WA180-3MC 10-39
12
3. Clutch pressure starting to rise (point c to point d)
When the oil from the pump fills the clutch piston, the pressure in the
clutch circuit starts to rise. When this happens, the drain circuit of the
quick return valve is closed.
When the drain circuit of the quick return valve closes, the oil passing
through port a enters chamber d and pressure P2 in chamber d starts to
rise. When the relationship between P1 and P2 becomes P2 > P1 + P3
(tension of spring (2)), the fill valve moves to the left, shuts off port a,
and prevents the clutch pressure from rising suddenly.
At the same time as the oil from port a flows to the directional spool,
the relationship is P2 > P1, so oil also passes through the orifice in the
quick return valve and flows into chamber c. P1 rises and P2 also rises
at the same time. This process is repeated while maintaining the rela-
tionship P2 = P1 + P3 (tension of spring (2)), and the clutch pressure
rises.
The oil from the torque converter outlet port circuit forms the pilot
pressure to the modulation fill valve and flows to port e. The pressure
at port e changes according to the engine speed. The relationship is P2
= P1 + P3 + P4 (changes according to engine speed), so if pressure P4
changes, pressure P2 also changes by the same amount. Therefore,
pressure P2 rises at the same time by the same amount that pressure P4
changes, so it is possible to create oil pressure characteristics that
matches the engine speed.
10-40 WA180-3MC
12
DIRECTIONAL SELECTOR SPOOL
Operation
1. When at neutral
Solenoid valves (4) and (5) are OFF and the drain port is closed. The
oil from the pilot circuit passes through the oil hole in the emergency
manual spool and fills ports a and b of the directional spool.
In this condition, P1 + spring force (1) = P2 + spring force (2), so the

balance is maintained. Therefore, the oil at port c does not go to the
FORWARD or REVERSE clutch.
2. When at FORWARD
When the directional lever is placed at the FORWARD position, sole-
noid valve (4) is switched ON and drain port d opens. The oil which is
filling port a is drained, so P1 + spring force (1) < P2 + spring force
(2). When this happens, the directional spool moves to the left, and the
oil at port c flows to port e and is supplied to the FORWARD clutch.
WA180-3MC 10-41
12
EMERGENCY MANUAL SPOOL
Function
If there should be any failure in the electrical circuit and the directional solenoid valve does not work, this spool can be
operated manually to engage the FORWARD or REVERSE clutch.
Operation
1. Emergency manual spool at neutral

The oil from the upper valve (pilot reducing valve) passes around
emergency manual spool (1), and is blocked by solenoid valves (2) and
(3).
When the operating condition is normal, the emergency manual spool

is at the neutral position.
2. Emergency manual spool actuated (FORWARD)

When emergency manual spool (1) is pushed in, port a and the drain
port are connected, so the oil in chamber b is drained. As a result,
directional spool (4) moves to the left in the direction of the arrow, and
the oil flows to the FORWARD clutch to engage the clutch.
10-42 WA180-3MC
12
MEMORANDUM
WA180-3MC 10-43
12
OPERATION OF FORWARD 1ST
10-44 WA180-3MC
12
The oil from pump (1) passes through priority valve (2) and is divided to the pilot circuit and clutch actuation circuit.
When the gear shift lever is operated to FORWARD 1st, FORWARD solenoid (3) and gear shift solenoid (6) are actuated. The
oil filling ports a and b is drained and directional spool (7) and gear shift spool (9) move to the left.
When directional spool (7) moves, the oil flows from clutch pressure port c to port d, and engages the FORWARD clutch.
Gear shift solenoid (5) is closed, and H-L spool (8) is pushed fully to the right, so the oil flows from clutch pressure port e to
port f, passes through spool (9) and engages the 1st clutch.
When the oil completely fills the clutch cylinder, the action of accumulator (10) and quick return valve (11) raises the oil pres-
sure gradually, and when it reaches the set pressure, the FORWARD and 1st clutches are completely engaged.
WA180-3MC 10-45
12
ACCUMULATOR VALVE
1. Piston (for 2nd clutch) 6. Stopper (for FORWARD clutch) 11. Stopper (for 1st clutch)
2. Piston (for 1st clutch) 7. Cover 12. Spring (for 1st clutch)
3. Body 8. Spacer (for FORWARD clutch) 13. Stopper (for 2nd clutch)
4. Piston (for FORWARD clutch) 9. Spacer (for 1st clutch) 14. Spring (for 2nd clutch)
5. Spring (for FORWARD clutch) 10. Spacer (for 2nd clutch)
Outline
The accumulator valve is installed in the FORWARD, 1st, 2nd clutch circuit. When the transmission shifts gear, the accumula-
tor valve slowly reduces the oil pressure to the clutch that was first engaged in order to prevent loss of torque and to reduce the
transmission shock when shifting gears. It temporarily stores the clutch oil pressure in order to allow gear shifting to be carried
out smoothly without any time lag.
(To make it possible to reduce the oil pressure to the clutch slowly, there are throttles installed in the directional spool, H-L
spool and range spool of the transmission control valve.)
10-46 WA180-3MC
12
Operation
1. Shifting down when digging (kick-down F2 ➞ Fl)

When the transmission is in F2, oil pressure is stored in the 2nd clutch
accumulator.
When the kick-down is operated, the Fl clutch is engaged, but the oil
pressure in the accumulator is maintained for the 2nd clutch until the
torque is transmitted to the 1st clutch. In this way, it is possible to shift
gear smoothly without losing the torque.
2. Moving out after digging (Fl ➞ R2)

When the transmission is in Fl, oil pressure is stored in the accumula-
tor for the FORWARD clutch and 1st clutch.
When shifting to R2 after completing digging operations, the R2
clutch is engaged, but the oil pressure for the FORWARD Clutch and
1st clutch is maintained in the accumulator. This makes it possible to
reduce the loss of torque due to the reaction force to the product being
handled, and to move back smoothly without shock.
WA180-3MC 10-47
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
12
TRANSMISSION CONTROL
1. Directional lever
2. Gear shift lever
3. Gear shift lever stopper
4. Turn indicator, lamp, dimmer switch
Outline
With the transmission control, an electrical signal is sent to the transmission solenoid valves when the directional and gear
shift levers are operated. This opens or closes the solenoid valves and moves the spool inside the transmission valve.
10-48 WA180-3MC
STRUCTURE AND FUNCTION DRIVE SHAFT
12
DRIVE SHAFT

2. Flange bearing
3. Center drive shaft
4. Rear drive shaft
Outline
The motive force from the engine passes through the torque converter and the transmission. Some of it is transmitted from rear
drive shaft (4) to the rear axle, while the rest goes from center drive shaft (3) through flange bearing (2) and front drive shaft
(1) to the front axle.
The drive shaft has the following purpose in addition to simply transmitting the power. The drive shaft has a universal joint
and sliding joint to enable it to respond to changes in the angle and length. This enables the drive shaft to transmit the motive
force when the machine is articulated and to protect the components from damage from shock when the machine is being oper-
ated or shock from the road surface when the machine is traveling.
WA180-3MC 10-49
STRUCTURE AND FUNCTION AXLE
AXLE
FRONT AXLE
10-50 WA180-3MC
FRONT DIFFERENTIAL
1. Side gear (No. of teeth: 12)

2. Pinion gear (No. of teeth: 9)
3. Shaft
4. Bevel gear (No. of teeth: 47)
5. Sun gear shaft
6. Bevel pinion (No. of teeth: 13)
WA180-3MC 10-51
12
REAR AXLE
1. Oil supply port

2. Differential
3. Differential housing
4. Wet-type single-disc brake
5. Final drive
6. Axle housing
7. Axle shaft
8. Drain plug
9. Brake inspection (level) plug
10-52 WA180-3MC
12
REAR DIFFERENTIAL
1. Side gear (No. of teeth: 12)

2. Pinion gear (No. of teeth: 9)
3. Shaft
4. Bevel gear (No. of teeth: 47)
5. Sun gear shaft
6. Bevel pinion (No. of teeth: 13)
WA180-3MC 10-53
12
Outline
The motive force from the engine is transmitted to the front and rear axles
via the torque converter, the transmission and the propeller shaft.
In the axle, the motive force is transmitted from pinion gear (1) to bevel
gear (5), shifted 90 and reduced, and transmitted to sun gear shaft (2) via
differential (4).
The motive force of the sun gear is further reduced by planetary gear-type
final drive, and transmitted to the axle shaft and wheel.
When moving straight forward

When moving straight forward, the speed of rotation of the left and right
wheels is equal, so pinion gear (4) in the differential assembly does not
rotate, and the motive force of carrier (6) is transmitted equally to the left
and right sun gear shafts (2) via the pinion gear (4) and side gear (3).
When slewing
When slewing, the speed of rotation of the left and right wheels is unequal,
so pinion gear (4) and side gear (3) in the differential assembly rotate
according to the difference in the left and right rotation speeds, and the
motive force of carrier (6) is transmitted to the sun gear shafts (2).
10-54 WA180-3MC
12
TORQUE PROPORTIONING DIFFERENTIAL
Function
Because of the nature of their work, 4-wheel drive loaders have to work in
places where the road surface is bad. In such places, if the tires slip, the
ability to work as a loader is reduced, and also the life of the tire is reduced.
The torque proportioning differential is installed to overcome this problem.
In structure it resembles the differential of an automobile, but differential

pinion gear (4) has an odd number of teeth. Because of the difference in the
resistance from the road surface, the position of meshing of pinion gear (4)
and side gear (3) changes, and this changes the traction of the left and right
tires.
Operation
When traveling straight (equal resistance from road surface to left and
right tires)
If the resistance from the road surface to the left and right wheels is the
same, the distance between pinion gear (4) and meshing point a of left side
gear (7) is the same as the distance between pinion gear (4) and meshing
point b of right side gear (3).
Therefore the left side traction TL and the right side traction TR are bal-
anced.
When traveling on soft ground (resistance from road surface to left

and right tires is different)
On soft ground, if the tire on one side slips, the side gear of the tire on the
side which has least resistance from the road surface tries to rotate forward.
Because of this rotation, the meshing of pinion gear (4) and side gear
changes.
If left side gear (7) rotates slightly forward, the distance between the pinion
gear and the meshing point a of the left side gear becomes longer than the
distance between the pinion gear and the meshing point b of the right side
gear. The position is balanced as follows.
a x TL = b x TR
The ratio between the distances to a and b can change to 1: 1.38.
Therefore when the ratio of the distances to a and b is less than 1: 1.38 (that
is, the difference between the resistance from the road surface to the left
and right tires is less than 38%), the pinion gear will not rotate freely, so
drive force will be given to both side gears, and the tires will not slip.
Because of this effect, the tire life can be increased by 20 - 30%, and at the
same the operating efficiency is also increased.
WA180-3MC 10-55
STRUCTURE AND FUNCTION FINAL DRIVE
12
FINAL DRIVE
1. Sun gear shaft (Teeth 15)

2. Ring gear (Teeth 69)
3. Planetary gear (Teeth 26)
4. Planetary carrier
5. Axle shaft
Outline
As the final function the final drive operates to reduce the rotative speed of the motive force from the engine and increases the
driving force.
Ring gear (2) is press-fitted in the axle housing and fixed in place by a pin.
The motive force transmitted from the differential to the sun gear shaft (1) is reduced using a planetary gear mechanism,
increasing the driving force. The increased driving force is transmitted to the tires via planetary carrier (4) and axle shaft (5).
10-56 WA180-3MC
STRUCTURE AND FUNCTION FINAL DRIVE
12
MEMORANDUM
WA180-3MC 10-57
STRUCTURE AND FUNCTION AXLE MOUNT
12
AXLE MOUNT
10-58 WA180-3MC
STRUCTURE AND FUNCTION AXLE MOUNT
12
1. Front axle 4. Rear axle

2. Front frame 5. Tension bolt
3. Rear frame 6. Pivot
FRONT AXLE
Front axle (1) receives the force directly during operations, so it is connected directly to front frame (2) by tension bolt (5).
REAR AXLE
The rear axle (4) has a structure which allows the center of the rear axle to float, so that all tires can be in contact with the
ground when traveling over soft ground.
WA180-3MC 10-59
STRUCTURE AND FUNCTION CENTER HINGE PIN
12
CENTER HINGE PIN
1. Front frame
2. Rear frame
3. Upper hinge pin
4. Lower hinge pin
Outline
The front frame (1) and rear frame (2) are connected through a bearing by the center hinge pin (3), (4). The steering cylinders
are connected to the left and right front and rear frames, so when the cylinders are operated, the frame bends at the middle to
give the desired angle, that is the desired turning radius.
10-60 WA180-3MC
STRUCTURE AND FUNCTION STEERING PIPING
12
STEERING PIPING
1. Main control valve

2. Steering valve (orbit-roll)
3. Hydraulic tank
4. Priority valve
5. Hydraulic pump
6. Steering pump
7. Cushion valve
8. Steering cylinder
WA180-3MC 10-61
STRUCTURE AND FUNCTION STEERING COLUMN
12
STEERING COLUMN
1. Steering wheel
2. Joint
3. Steering column
10-62 WA180-3MC
STRUCTURE AND FUNCTION PRIORITY VALVE
12
PRIORITY VALVE
1. Plug 6. Relief valve body 11. Screen A. To steering valve

2. Valve body 7. Spring seat B. To main control valve
3. Spool 8. Valve spring C. From steering valve
4. Return spring 9. Poppet D. Drain
5. Plug 10. Seat E. From pump
Outline
The priority valve is in the circuit between the steering pump and the steering valve. It acts to divide the flow of oil from the
steering pump and send it to the steering valve or oil cooler circuit. It also sets the oil pressure in the circuit from the priority
valve to the steering valve to 210 kg/cm2 (2986.9 lbf in2) to protect the circuit.
WA180-3MC 10-63
12
Operation
1. Steering wheel at neutral

When the engine is stopped, spool (3) is pushed fully to the left by the
tension of spring (4). In this condition, the circuits between ports M
and N are fully open, while the circuits between ports M and Q are
fully closed.
If the engine is started and the steering pump start to turn, the oil from
the pump goes from port M to port N, and then enters port A of the
steering valve.
The oil entering port A is throttled by orifice a, so the pressure in the

circuit rises.
When this happens, the oil passing through orifices m in spool (3)
enters port P. It then compresses spring (4), and moves spool (3) to the
right in the direction of the arrow. This stabilizes the condition so that
the circuits between ports M and Q are almost fully open and the cir-
cuits between ports M and N are almost fully closed. Therefore, the oil
from the steering pump almost all flows to the work equipment circuit.
2. Steering wheel turned to left

When the steering wheel is turned to the left, an angle variation is gen-
erated between the spool and sleeve of the steering valve, and the oil
flow is switched. (For details, see STEERING VALVE.)
The oil from the pump flows from port M to port N, and enters port A.
The degree of opening of the sleeve (port A) and spool (port B) of the
steering pump creates a difference between the pressure up to port A
and the pressure beyond port B. Some of the oil from port B flows to
the Girotor E, and then goes to the front right cylinder. The remaining
oil passes through orifice b, flows to port J, and then enters port R.
When this happens, spool (3) stabilizes at a position where the differ-
ential pressure between the circuit up to port A and circuit beyond port
B (pressure of port P - pressure of port R) and the load of spring (4)
are balanced. It adjusts the degree of opening from port M to ports N
and Q, and distributes the flow to both circuits. The ratio of this dis-
tributed flow is determined by the degree of opening of port A and port
B, in other words, the angle variation between the sleeve and spool of
the steering valve. This degree of opening is adjusted by the amount
the steering wheel is turned.
10-64 WA180-3MC
12
3. Steering cylinder at end of stroke
If the operator tries to turn the steering wheel further when the steering
cylinder has reached the end of its stroke, the circuit from port M
through port N to port S is kept open and the pressure rises.
When this pressure rises above 190 kg/cm² (2702.44 lbf in2), relief
valve (10) opens and the oil is relieved to the hydraulic tank. Because
of this flow of oil, a differential pressure is created on both sides of ori-
fice r. Therefore, the balance is lost between the load of spring (4), and
the pressure up to port A and the pressure beyond port B. As a result,
the pressure up to port A becomes relatively higher.
For this reason, the pressure at port P moves spool (3) even further to
the right from the condition in Item 2. It stabilizes the condition at a
position where the circuits between ports M and N are almost fully
closed, and the circuits between ports M and Q almost fully open.
WA180-3MC 10-65
STRUCTURE AND FUNCTION CUSHION VALVE
12
CUSHION VALVE
1. Valve seat 6. Plug 11. Poppet

2. Valve body 7. Spring L. Steering cylinder
3. Spring 8. Spool R. Steering cylinder
4. Poppet 9. Plug
5. Orifice 10. Spring
Outline
When there is a reaction to the sudden rise in the pressure of the steering cylinder, the cushion valve acts to prevent shock by
relieving the momentary high pressure oil to another line.
Function
If high pressure oil suddenly enters from port R, the high pressure oil compresses spring (3), and pushes open poppet (4). It
then passes through the center groove of spool (8), goes through poppet (11) of port L, and flows to port L.
At that time, the high pressure oil passes through orifice (5) and goes to the pressure chamber of plug (6). When it becomes
greater than the pressure at port L and force of spring (7), it pushes spool (8) fully to the left. This shuts off the flow of high
pressure oil from port R through poppet (4) to port L. This temporary flow of oil has a cushion effect. The valve is not actuated
any further, so there is no effect on the steering, and the steering operates as normal.
When the pressure rises slowly and there is no need for any cushion effect, spool (8) closes more quickly than poppet (4) opens
so there is no unnecessary cushion action.
10-66 WA180-3MC
STRUCTURE AND FUNCTION CUSHION VALVE
12
MEMORANDUM
WA180-3MC 10-67
STRUCTURE AND FUNCTION STEERING VALVE (ORBIT-ROLL)
12
STEERING VALVE (ORBIT-ROLL)
10-68 WA180-3MC
12
Outline
The steering valve is connected directly to the shaft of the steering wheel. It
switches the flow of oil from the steering pump to the left and right steering
cylinders to determine the direction of travel of the machine.
The steering valve, broadly speaking, consists of the following compo-

nents: rotary type spool (3) and sleeve (5), which have the function of
selecting the direction, and the Girotor set (a combination of rotor (8) and
stator (9)), which acts as a hydraulic motor during normal steering opera-
tions, and as a hand pump (in fact, the operating force of the steering wheel
is too high, so it cannot be operated) when the steering pump or engine has
failed and the supply of oil has stopped.
Structure
Spool (3) is directly connected to the drive shaft of the steering wheel, and
is connected to sleeve (5) by center pin (4) (it does not contact the spool
when the steering wheel is at neutral) and centering spring (12).
The top of drive shaft (6) is meshed with center pin (4), and forms one unit
with sleeve (5), while the bottom of the drive shaft is meshed with the
spline of rotor (8) of the Girotor.
There are four ports in valve body (2), and they are connected to the pump
circuit, tank circuit, and the circuits at the head end and bottom end of the
steering cylinders. The pump port and tank port are connected by the check
valve inside the body. If the pump or engine fail, the oil can be sucked in
directly from the tank by this check valve.
WA180-3MC 10-69
12
OPERATION
1. Steering wheel at neutral.
10-70 WA180-3MC
12
• When the steering wheel is at neutral, centering spring (12) makes

spool (3) and sleeve (5) stop at a position where center pin (4) is at
the center of the oblong hole in spool (3).
At this point, pump port A of the sleeve and ports E, F, and G to

the steering cylinder and Girotor, and vertical grooves B, C, and D
of the spool are shut off.
However, orifice a of pump port A is connected to orifice d (con-

nected to drain port H) of the spool.
Orifice b of port J from the priority valve is connected to vertical

groove B of the spool.
In addition, port K of the sleeve is connected to drain port L of the

spool and vertical groove B.
• By shutting off and connecting these ports and grooves, the oil
from the pump passes from port A through orifices a and d, and is
drained to the hydraulic tank.
In addition, the oil which forms the pilot pressure of the priority
valve passes from port J through orifice b, then through vertical
groove B and port K, and is returned to the hydraulic tank from
port L.
WA180-3MC 10-71
12
2. Steering wheel turned (turning to left)
10-72 WA180-3MC
12
• When the steering wheel is turned to the left, spool (3), which is connected by the spline of the steering shaft, also
turns to the left. The spool and sleeve (5) are interconnected by centering spring (12), so the spool compresses the
centering spring.
Therefore, a difference in the angle of rotation (angle variation) is generated between the spool and sleeve equal to
the amount that the centering spring is compressed.
When this happens, first, port A and vertical groove B are connected. Then vertical groove B and port E to the Giro-
tor, and port E from the Girotor to vertical groove C are connected. Finally, vertical groove C and port G to the head
end of the right cylinder are connected.
In addition, vertical groove B is kept connected to orifice b of port J to the priority valve, but port K of the sleeve
gradually closes the connection of vertical groove B and port L.
Port F from the head end of the left cylinder is connected to vertical groove D (connected to drain port H) at the same
time as port A and vertical groove B are connected.
• By shutting off and connecting the above ports and grooves, the oil from the pump enters vertical groove B from port
A, then flows to port E to the Girotor, and turns the Girotor. The oil discharged from the Girotor enters vertical
groove C from port E, and flows from port G to the head end of the right cylinder.
The oil entering vertical groove B passes through orifice b and flows to port J. From port J, it becomes the pilot pres-
sure of the priority valve.
The oil from the head end of the left cylinder enters vertical groove D from port F and is drained to the hydraulic
tank.
3. Steering wheel stopped

When the operation of the steering wheel is stopped, the difference in rotation between the spool and sleeve is returned to
the neutral condition by the reaction of centering spring (12).
WA180-3MC 10-73
12
CONNECTION BETWEEN HAND PUMP AND SLEEVE
• The diagrams above show the connections with the sleeve ports
used to connect the suction and discharge ports of the Girotor.
• If the steering wheel has been turned to the right, ports a, c, e, g, i

and k are connected by the vertical grooves in the spool to the
pump side. At the same time, ports b, d, f, h, j, and I are con-
nected to the head end of the left steering cylinder in the same
way. In the condition in Fig. 1, ports 1, 2, and 3 are the discharge
ports of the Girotor set. They are connected to ports l, b, and d, so
the oil is sent to the cylinder.
Ports 5, 6, and 7 are connected and the oil flows in from the pump.
If the steering wheel is turned 90°, the condition changes to the

condition shown in Fig. 2. In this case, ports 1, 2, and 3 are the
suction ports, and are connected to ports i, k, and c. Ports 5, 6, and
7 are the discharge ports, and are connected to ports d, f, and h.
10-74 WA180-3MC
12 • In this way, the ports acting as the discharge ports of the Girotor
are connected to the ports going to the steering cylinder, while the
ports acting as the suction ports are connected to the pump circuit.
• Adjustment of discharge according to amount steering wheel is

turned.
For each 1/7 turn of the steering wheel, the inside teeth of the
Girotor advance one tooth, and the oil from the pump is dis-
charged in an amount that matches this movement. Therefore, the
amount of oil discharged is directly proportional to the amount the
steering wheel is turned.
Role of centering spring
• Centering spring (12) consists of four X-Shaped leaf springs and

two flat leaf springs. It is assembled between spool (3) and sleeve
(5) as shown in the diagram on the right. When the steering wheel
is turned, the spool compresses the spring, and a difference (angle
variation) is generated in the turning angle of the spool and sleeve.
As a result, the port of the spool and sleeve is connected and oil is
sent to the cylinder.
However, when the rotation of the steering wheel is stopped, the

rotation of the Girotor also stops, so no more oil is sent to the cyl-
inder, and the oil pressure rises.
To prevent this, when the turning of the steering wheel is stopped,

the action of the centering spring only allows it to turn by an
amount equal to the difference in angle of rotation (angle varia-
tion) of the sleeve and spool, so the steering wheel returns to the
NEUTRAL position.
WA180-3MC 10-75
STRUCTURE AND FUNCTION BRAKE
12
BRAKE
BRAKE PIPING
1. Front axle 4. Rear axle 7. Brake booster

2. Right brake pedal 5. Brake oil tank 8. Transmission cut-off switch
3. Left brake pedal 6. Rear brake 9. Front brake
Outline
Brake booster (7) consists of a hydraulically actuated boosting mechanism. It is designed to reduce the operating force of the
pedal, and to ensure a powerful braking force.
When the brake pedal is depressed, the oil sent from the pump shuts off the transmission circuit inside the valve and actuates
the piston to apply the front and rear brakes.
A relief valve is installed in the circuit to protect the circuit from damage if any abnormal pressure should be generated in the
oil sent from the pump.
10-76 WA180-3MC
12
BRAKE CONTROL
WA180-3MC 10-77
12
BRAKE BOOSTER
1. Dust cover 4. Cylinder cover 7. Return spring (for connector) 10. Reaction piston
2. Spool 5. Power piston 8. Connector 11. Secondary piston
3. Relief valve 6. Return spring (for power piston) 9. Reaction spring 12. Primary piston
Outline
The brake booster is a boosting system to increase the braking force. It
increases the pressure in the master cylinder in proportion to the operating
force by using the oil pressure delivered from the oil pump.
Operation
Brake OFF
When the push rod connected to the brake pedal is returned, spool (2), con-
nector (8), and power piston (5) are returned towards cylinder cover (4) by
return springs (6) and (7).
Therefore, primary piston assembly (12) and secondary piston assembly (11) of the master cylinder are each in their respective
neutral positions. The respective pressures in the chambers E and F (the chambers connected to the discharge port) pass
through the relief port and are released to atmospheric pressure chambers C and D in the reservoir.
The oil from the pump flows from port A to port B and then flows into the transmission circuit.
In addition, the oil in the master cylinder is connected to the front and rear axles.
10-78 WA180-3MC
12
Hydraulic pressure starting to rise
When the brake pedal is depressed, the push rod connected to the pedal
compresses reaction spring (9) and moves spool (2) forward. Connector (8)
is pushed towards the power piston by return spring (7), so the passage
between power piston (5) and spool (2) is restricted. A difference in pres-
sure is generated between the front and rear walls of the power piston, so
the power piston moves forward, pushes connector (8), and actuates sec-
ondary piston assembly (11) of the master cylinder.
Hydraulic force rising

When secondary piston (11) moves forward and primary cup (13) closes
relief port (14), pressure is generated in chamber E. Reaction piston (10)
(piston with small diameter) built into secondary piston (11) moves to the
rear and is in continuous contact with the tip of spool (2). The pressure gen-
erated in the master cylinder and bearing on the area of reaction piston (10)
passes through push rod (16) and is transmitted to the pedal as the operat-
ing force.
The pressure generated at chamber E of secondary piston (11) of the master

cylinder is also generated at the same time in chamber F of primary piston
(12).
In addition, when the brake pedal is depressed, power piston (5) moves to
the right, and the pressure of the oil in chamber E and chamber F rises, so
the braking force of the front brake and rear brake is also increased.
Relief valve
When the brake is being operated, if the pressure inside the power cylinder
(port A) goes above the specified level, relief valve (3) is actuated. The oil
is relieved to the transmission circuit to prevent abnormal pressure in the
brake system.
If there should be any failure in the hydraulic pump sending oil to the
power cylinder, the operating force of the pedal is transmitted through
spool (2) and connector (8), so the piston in the master cylinder can be
actuated. However, when this happens, the operating force of the brake
pedal is heavier than usual.
WA180-3MC 10-79
12
Brake actuated (oil leaking from front brake)
The brake oil tanks from independent systems, so if there is any leakage of
oil in either the front or rear brake systems, only one of the brakes (front or
rear) will be applied.
This increases the safety and ensures that the machine can always be
stopped.
Brake pedal released

When the pedal is released, spool (2) is returned by reaction spring (9), so
the passage between spool (2) and power piston (5) is restricted. It is
released to the same conditions as when not actuated (brake OFF), and the
difference in pressure between front and rear chambers of power piston (5)
is removed, so the power piston and connector (8) are returned by return
springs (6) and (7). Following this, the pistons of the master cylinders are
also returned to the neutral position by their respective return springs. The
relief ports are connected to the reservoir, and the pressure returns to atmo-
spheric pressure.
10-80 WA180-3MC
12
BRAKE
1. Differential housing 4. Disc 7. Axle housing

2. Piston 5. Outer ring 8. Sun gear shaft
3. Inner ring 6. Bearing carrier
Function
The brake is a wet-type, single disc brake. It consists of piston (2), inner ring (3), disc (4), and outer ring (5).
The brake cylinder consists of differential housing (1) and bearing carrier (6). Piston (2) is assembled inside the brake cylinder.
Inner ring (3) is installed to the notched part of bearing carrier (6). Outer ring (5) is secured to axle housing (7) by pin.
Disc (4) has a lining stuck on both faces. It is assembled between inner ring (3) and outer ring (5). It is connected by the spline
of the sun gear shaft.
WA180-3MC 10-81
12
Operation
Brake applied
When the brake pedal is depressed, the rod of the master cylinder is
pushed. Oil pressure P is generated, and this acts on the piston inside the
brake cylinder to slide piston (6) slightly.
Therefore, the rotation of disc (4), which is between inner ring (3) and
outer ring (5), is stopped, and the brakes are applied to stop the machine.
Brake released
When the oil pressure is released, piston (6) moves back slightly
because of the return force of piston O-ring (9). A gap is created between
inner ring (3) and outer ring (5), so disc (4) is free.
Grooves are cut in a lattice pattern on the lining stuck to disc (4).
When the disc is rotating, oil flows in these grooves to cool the lining.
10-82 WA180-3MC
12
PARKING BRAKE CONTROL
1. Parking brake pedal 2. Parking brake release lever 3. Control cable 4. Parking brake lever 5. Transmission
Outline
When parking brake pedal (1) is depressed, control cable (3) pulls brake lever (4) up and actuates the multiple disc brake
installed to the output shaft of the transmission.
To release the parking brake, pull parking brake release lever (2).
When the parking brake is applied, the neutralizer relay acts to shut off the electric current to the transmission solenoid valv e
and keep the transmission at neutral.
WA180-3MC 10-83
12
PARKING BRAKE
1. Transmission 4. Plate 7. Cover

2. Parking brake lever 5. Transmission output shaft 8. Piston
3. Disc 6. Ball
Outline
The parking brake is a mechanically operated wet type multiple disc brake which applies braking force to transmission output
shaft (5).
Lever (2) is connected to the control cable, and when the lever is pulled, ball (6), which is between cover (7) and piston (8)
connected to the lever, moves on the slope of the piston groove. The piston pushes the discs and plates together, and applies
braking force to output shaft (5).
10-84 WA180-3MC
12
MEMORANDUM
WA180-3MC 10-85
STRUCTURE AND FUNCTION HYDRAULIC
12
HYDRAULIC
HYDRAULIC PIPING
1. Bucket cylinder 4. Hydraulic tank 7. Steering pump

2. Boom cylinder (R.H.) 5. Priority valve 8. Main control valve
3. Steering valve 6. Hydraulic pump 9. Boom cylinder (L.H.)
10-86 WA180-3MC
12
Outline
The hydraulic system consists of the work equipment circuit and the steering circuit. The work equipment circuit controls the
operation of the boom, bucket, or other attachments.
The oil from the hydraulic tank (4) is sent from the hydraulic (6)and steering pump (7) to the priority valve (5). The amount of
oil flow is controlled and sent to main control valve (8). If the bucket and boom spools of main control valve are at neutral, the
oil passes through the drain circuit of the main control valve, is filtered by the filter inside hydraulic tank (4), and returns to the
tank.
When the work equipment control lever is operated, the bucket or boom spool of main control valve (8) move, oil flows from
main control valve (8) to the boom cylinders (2) and (9) or to bucket cylinder (1), and operates the boom or bucket.
The maximum pressure of the hydraulic circuit is controlled by priority valve (5) and the relief valve inside the main control
valve. A safety valve (with suction) is installed in the bucket cylinder circuit to protect the circuit.
Hydraulic tank (4) is a pressurized sealed typed and has a breather with a relief valve. It pressurizes the inside of the tank and
also prevents negative pressure in order to prevent cavitation of the pump.
WA180-3MC 10-87
12
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
ENGINE LOW IDLING, WORK EQUIPMENT IN "HOLD"
10-88 2 WA180-3MC
12
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WA180-3MC 10-89 2
1. Hydraulic tank 10. Cushion valve 19. PPC pump

2. Filter 11. Relief valve 20. Pilot oil filter
3. Steering pump 12. Safety valve (with suction) 21. Check valve
4. Work equipment pump 13. Bucket spool 22. Accumulator
5. Breather 14. Boom spool 23. Relief valve
6. Priority valve 15. Suction valve 24. PPC valve
7. Steering valve 16. Bucket cylinder 25. 2-way restrictor valve
8. Overload valve 17. Boom cylinder
9. Steering cylinder 18. Not used
10-90 2 WA180-3MC
12
HYDRAULIC TANK
1. Cap breather
2. Air bleed plug
3. Oil filter bypass valve
4. Oil filer
5. Oil level gauge
6. Drain plug
Outline
The oil from the hydraulic tank is sent from the pump through the priority valve and main control valve to each cylinder. It
merges in the return circuit with the oil from various parts, is filtered by the oil filter, and returns to the tank.
The oil filter filters the whole oil flow in the circuit. When the oil filter becomes clogged, the bypass valve is actuated to allow
the oil to return directly to the tank and prevent damage to the filter.
WA180-3MC 10-91
12
OIL FILTER BYPASS VALVE
When the filter is clogged
By-pass valve (1) opens and the oil returns directly to the tank without
passing through the filter (2).
By-pass valve set pressure: 1.5 kg/cm ² (21.33 lbf/in2)
When negative pressure is formed in the return circuit.

By-pass valve (1) moves up and acts check valve.
Check valve set pressure: 0.24 kg/cm² (3.41 lbf/in2)
10-92 WA180-3MC
12
BREATHER
1. Cover
2. Sleeve
3. Spring
4. Spring
5. Poppet
6. Filter element
Preventing negative pressure inside tank

The tank is a pressurized sealed type, so if the oil level inside the hydraulic
tank goes down, there will be negative pressure in the tank. If this happens,
a sleeve (2) is opened by the difference between the pressure inside the
tank and the atmospheric pressure, and air is let in to prevent negative pres-
sure from forming inside the tank.
Preventing rise in pressure inside tank

If the pressure in the circuit rises above the set pressure during operations
because of the change in the oil level in the hydraulic cylinders or the rise
in the temperature, the poppet (5) is actuated to release the pressure inside
the hydraulic tank.
WA180-3MC 10-93
12
PPC VALVE
P From PPC pump P3 To boom raise spool of main valve

P1 To bucket tilt spool of main valve P4 To boom lower and float of main valve
P2 To bucket dump spool of main valve T Drain to hydraulic tank
10-94 WA180-3MC
PPC Valve Main Parts
1. Spool 6. Solenoid 11. Plate
2. Metering spring 7. Rod 12. Retainer
3. Centering spring 8. Disk 13. Piston
4. Spring 9. Nut 14. Body
5. Retainer 10. Joint
WA180-3MC 10-95
12
OPERATION
1. NEUTRAL POSITION
A. PPC Valve for Bucket

Each port for the bucket control valve PA, PB and the PPC valve
P1, P2 drain into cavity (D) through fine control hole (f) in spool
(1).
B. PPC Valve Boom

Each port for the boom control valve PA, PB and the PPC valve
P3, P4 drain into cavity (D) through fine control hole (f) in spool
(1).
10-96 WA180-3MC
12
2. FINE CONTROL POSITION
(NEUTRAL -> FINE CONTROL)
When rod (7) and piston (13) begin to be pushed by disk (5), spool (1)
is pushed by metering spring (2) and moves downwards.
As a result of this movement, the fine control hole (f) becomes isolated
from the drain cavity (D) and connects with the pressurized cavity
(PP). Pressurized fluid from the control pump flows to the PB port
from the P1 port through the fine control hole (f).
When the pressure at the P1 port rises, spool (1) is forced back. This
causes the fine control hole (f) to become isolated from the pressurized
cavity (PP) and to connect the pressurized P1 port to the drain cavity
(D).
This action causes spool (1) to move up and down to match the meter-
ing spring (2) force with the P1 port pressure.
The fine control hole (f) is at the mid-point between the drain hole (D)
and the pressurized cavity (PP). the position of spool (1) and body
(14) do not change until retainer (12) strikes the spool.
The metering spring (2) compresses in proportion to the operating

lever stroke. This results in a pressure rise at the P1 port. The operat-
ing valve spool moves to a position where the return spring force
matches with pressure in the PB cavity (The same as the P1 port pres-
sure.)
WA180-3MC 10-97
12
3. FINE CONTROL POSITION
(OPERATING LEVER -> SPOOL RETURNS)
As disk (5) returns upward, force from the centering spring (3) and
from P1 port pressure causes spool (1) to be pushed upward.
This action causes the fine control hole (f) to connect with the drain
cavity (D) and to reduce the fluid pressure in the P1 port.
When the P1 port pressure is lowered too much, spool (1) is pushed
downward by the metering spring (2). As a result, the fine control hole
(f) disconnects from the drain cavity (D) and connects with the pres-
surized cavity (PP). This increases the P1 port pressure to correspond
with that related to the lever position.
When the spool of the operating valve returns, fluid from the drain
cavity (D) oil flow out through the control hole (f1) on the side of the
stationary valve. Fluid is supplied to the PA cavity through the P2
port.
4. FULL STROKE
When pushing disk (5), rod (7) and piston (13) are pushed down,
retainer (12) and spool (1) are lowered. The fine control hole (f)
becomes isolated from the drain cavity (D) and connects with the pres-
surized cavity (PP).
Pressurized fluid from the control pump flows to the PB cavity from
P1 port through the fine control hole (f) and pushes the operating valve
spool.
The returning fluid from the PA cavity flows into the drain cavity (D)
from P2 port through the fine control hole (f1).
10-98 WA180-3MC
12
5. BOOM (FLOATING) OPERATION
Disk (5) pushes on rod (7) causing it to descend and open port P4. As
the rod descends, its protruded part (a) touches pole (15), initiating the
detent operation. When rod (7) is pushed further in, ball (15) pushes up
on collar (16), which is held with the detent spring (17) and escapes as
it passes over the protruded part of rod (a). At the same time, on the
opposite side, rod (71) is pushed to its uppermost level by spring (4)
When the solenoid is energized, if rod (71) is pushed further upward,

retainer (5) is held by solenoid (6). Rod (71) is therefore held at its
fully raised position, resulting in a floating operation, which is main-
tained even if the operator removes his hand from the control lever.
The operating valve moves to floating position and remains there.
6. BLADE (FLOATING) RELEASE

Disk (5) is returned from its float position location by pushing down
with sufficient force to separate the retainer (5) from solenoid (6).
Alternatively if the solenoid is de-energized by turning off the power,

the magnetic field collapses, causing the lever to return to neutral and
canceling the float position.
Remark
The boom ascending and bucket tilting functions operate in
the same way.
WA180-3MC 10-99
12
PPC RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
FUNCTION
The PPC relief valve is between the PPC pump and the PPC valve. When
the PPC pump is not actuated, or when any abnormal pressure is generated,
the oil from the PPC pump is relieved from this valve to prevent any dam-
age to the pump or circuit.
OPERATION
Port A is connected to the pump circuit and port C is connected to the drain
circuit. The oil passes through the orifice in main valve (1) and fills port B.
In addition, pilot poppet (3) is seated in valve seat (2).
If the pressure at port A and port B reaches the set pressure, the pilot pop-
pet (3) opens and the oil pressure at port B escapes from port D to port C to
lower the pressure at port B.
When the pressure at port B drops, a difference in pressure is generated at

ports A and B by the orifice of main valve (1). The main valve (1) is
pushed open by the pressure at port A and the oil at port A is drained to
port C to relieve the circuit.
The set pressure can be changed by adjusting the tension of pilot poppet
spring (4). To change the set pressure, remove the cap nut, loosen the lock-
nut, then turn adjustment screw (5) to adjust the set pressure as follows:
TIGHTEN to INCREASE pressure

LOOSEN to DECREASE pressure
10-100 WA180-3MC
12
ACCUMULATOR
FOR PPC VALVE
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Gas used: Nitrogen gas

Gas amount: 500 cc (16.9 fluid oz)
Max. actuation pressure: 38 kg/cm2 (540 psi)
Min. actuation pressure: 12 kg/cm2 (172 psi)
FUNCTION
The accumulator is installed between the hydraulic pump and the PPC
valve. Even if the engine stops when the boom is raised, it is possible to
lower the boom and bucket under their own weight by using the pressure of
the nitrogen gas compressed inside the accumulator to send the pilot oil
pressure to the main control valve to actuate it.
OPERATION
After the engine stops, if the PPC valve is at hold, chamber A inside the
bladder is compressed by the oil pressure in chamber B.
When the PPC valve is operated, the oil pressure in chamber B goes below
38 kg/cm2 (541 psi). When this happens, the bladder is expanded by the
pressure of the nitrogen gas in chamber A, and the oil inside chamber B is
used as the pilot pressure to actuate the main control valve.
WA180-3MC 10-101
12
MAIN CONTROL VALVE
2-SPOOL
1. Main relief valve A. To bucket cylinder rod side

2. Bucket spool B. To bucket cylinder bottom
3. Boom spool C. To boom cylinder rod side
4. Check valve D. To boom cylinder bottom
5. Suction valve P. Pump port -- IN
6. Safety valve (with suction), Type A T. Drain port (to hydraulic tank) -- OUT
7. Safety valve (with suction), Type B
10-102 WA180-3MC
12
WA180-3MC 10-103
12
3-SPOOL
1. Main relief valve A. To service cylinder

2. Service spool B. To service cylinder
3. Bucket spool C. To bucket cylinder rod side
4. Boom spool D. To bucket cylinder bottom
5. Boom magnet E. To boom cylinder rod side
6. Bucket magnet F. To boom cylinder bottom
7. Check valve P. Pump port -- IN
8. Suction valve T. Drain port (to tank) -- OUT
9. Safety valve (with suction)
10-104 WA180-3MC
12
WA180-3MC 10-105
12
RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
Function
The relief valve is installed to the inlet portion of the main control valve. If
the oil goes above the set pressure, the relief valve drains the oil to the tank
to set the maximum pressure for the work equipment circuit, and to protect
the circuit.
Operation
Port A is connected to the pump circuit and port C is connected to the drain
circuit. The oil passes through the orifice in main valve (1), and fills port B.
Pilot poppet (3) is seated in valve seat (2).
If the pressure inside ports A and B reaches the set pressure of pilot poppet
spring (4), pilot poppet (3) opens and the oil pressure at port B escapes
from port D to port C, so the pressure at port B drops.
When the pressure at port B drops, a difference in pressure between ports A

and B is created by the orifice of main valve (1). The main valve is pushed
open and the oil at port A passes through port C, and the abnormal pressure
is released to the drain circuit.
The set pressure can be changed by adjusting the tension of pilot poppet
spring (4). To change the set pressure, remove the cap nut, loosen the lock-
nut, then turn adjustment screw (5) to adjust the set pressure as follows.
TIGHTEN (clockwise) to INCREASE pressure

LOOSEN (counter clockwise) to DECREASE pressure
10-106 WA180-3MC
12
SAFETY VALVE (WITH SUCTION)
1. Suction valve
2. Main valve
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
Function
The safety valve is in the bucket cylinder circuit inside the main control
valve. If any abnormal pressure is generated by any shock to the cylinder
when the main control valve is at the neutral position, this valve relieves
the abnormal pressure to prevent damage to the cylinder.
Operation
Operation as safety valve
Port A is connected to the cylinder circuit and port B is connected to the
drain circuit. The oil pressure at port A is sent to port D from the hole in
pilot piston (4). It is also sent to port C by the orifice formed from main
valve (2) and pilot piston (4).
Pilot piston (4) is secured to the safety valve, and the size of the cross-sec-
tional surface (cross-sectional area) has the following relationship: d2 > d1
> d3 > d4.
If abnormal pressure is created at port A, suction valve (1) is not actuated

because of relationship d2 > d1, but relationship between port A and port
C is d3 > d4, so main valve (2) receives oil pressure equivalent to the dif-
ference between the areas of d3 and d4. If the oil pressure reaches the force
(set pressure) of main valve spring (3), main valve (2) is actuated, and the
oil from port A flows to port B.
WA180-3MC 10-107
12
Operation as suction valve
If any negative pressure is generated at port A, port D is connected with
port A, so there is also negative pressure at port D. The tank pressure of
port B is applied to port E, so the suction valve (1) receives oil pressure a,
which is equal to the difference in the area of d2 and d1 because of the tank
pressure at port E. Therefore, oil pressure e moves the valve in the direc-
tion of opening, and oil pressure a acts to move suction valve (1) in the
direction of closing.
When the pressure at port A drops (and comes close to negative pressure),
it becomes lower than hydraulic pressure e. The relationship becomes oil
pressure e > oil pressure a + force of valve spring (5), and suction valve (1)
opens to let the oil from port B flow into port A and prevent any negative
pressure from forming at port A.
SUCTION VALVE
1. Main poppet
2. Sleeve
3. Spring
Function
This valve acts to prevent any negative pressure from forming in the cir-
cuit.
Operation
If any negative pressure is generated at port A (boom cylinder rod end)
(when a pressure lower than tank circuit port B is generated), main poppet
(1) is opened because of the difference in area between d1 and d2, and oil
flows from port B at the tank end to port A at the cylinder port end.
10-108 WA180-3MC
12
BOOM AND BUCKET SPOOL AT NEUTRAL POSITION
Operation
The oil from the switch pump which has passed through the cut-off valve and the work equipment pump's oil enters port A and
the maximum pressure is regulated by relief valve (1).
Since the bucket spool (2) is at the neutral position, the bypass circuit is open, and the oil at port A passes around the spool and
flows to port B. The boom spool (3) is also at the neutral position, so the bypass circuit is open, the oil at port B passes around
the spool and returns to the tank from the drain circuit.
The oil from the PPC pump enters PPC valve port L, but since the boom and bucket levers are at the neutral position, the oil
returns to the tank from the PPC relief valve.
WA180-3MC 10-109
12
BOOM SPOOL AT RAISE POSITION
Operation
When operator lever (4) is pulled, oil flows from the PPC valve port L to port N and port S. The oil at port T passes through
port M and flows to the drain circuit. The oil pressure at port S presses the boom spool (3) and sets it to the RAISE position.
Oil from the pump passes through the bucket spool (2) bypass circuit and flows to the boom spool (3) bypass circuit. The
bypass circuit is closed by boom spool (3), so the oil pushes open check valve (5). The oil from check valve (5) flows to port D
and to the cylinder bottom side.
The oil on the cylinder rod side enters drain port F from port E and returns to the tank, thereby raising the boom.
10-110 WA180-3MC
12
BOOM SPOOL AT LOWER POSITION
Operation
When equipment lever (4) is pushed, oil flows from PPC valve port L to port M and port T, and the oil at port S flows to the
drain circuit. The oil pressure at port T pushes boom spool (3) and sets it to the LOWER position.
The oil from the pump passes through the bucket spool (2) bypass circuit and flows to the boom spool (3) bypass circuit. The
bypass circuit is closed by boom spool (3), so the oil pushes open check valve (5). The oil from check valve (5) flows to port E
and to the cylinder rod side.
The oil on the cylinder bottom side enters drain port F from port D and returns to the tank, thereby lowering the boom.
WA180-3MC 10-111
12
BOOM SPOOL AT FLOAT POSITION
Operation
When the lever (4) is pressed in further from the LOWER position (to the FLOAT position), the boom spool (3) moves further
from the LOWER position and is set to the FLOAT position.
The oil from the pump passes through the bucket spool (2) bypass circuit and flows to the boom spool (3) bypass circuit. The
boom spool (3) causes the oil in the bypass circuit to flow to the drain circuit, so the check valve (5) cannot be pushed open. In
addition, the boom cylinder raise circuit D and lower circuit E are both connected to the drain circuit, so the boom lowers
under its own weight.
When the bucket is touching the ground, it can move up and down in accordance with the ground surface contour.
10-112 WA180-3MC
12
BUCKET SPOOL AT TILT BACK POSITION
Operation
When the operator lever (6) is pulled, the oil pressure at PPC valve port L is released from port P to port R, and the oil at port
V flows to the drain circuit. The oil pressure at port R sets bucket spool (2) to the TILT position.
Since the bypass circuit is closed by bucket spool (2), the oil at port A pushes open check valve (7).
The oil from port A passes from check valve (7) through port G and to the bottom side of the bucket cylinder.
The oil on the bucket cylinder's rod side flows from port H to drain port F and returns to the tank, causing the bucket to tilt.
WA180-3MC 10-113
12
BUCKET SPOOL AT DUMP POSITION
Operation
When operator lever (6) is pushed, the oil pressure at PPC valve port L is released from port Q to port V, and the oil at port R
flows to the drain circuit. The oil pressure at port V sets bucket spool (2) to the DUMP position.
Since the bypass circuit is closed by bucket spool (2), the oil at port A pushes open check valve (7). The oil from port A passes
from check valve (7) through port H and to the rod side of the bucket cylinder.
The oil on the bucket cylinder's bottom side flows from port G to drain port F and returns to the tank, causing the bucket to
dump.
10-114 WA180-3MC
STRUCTURE AND FUNCTION WORK EQUIPMENT
12
WORK EQUIPMENT
WORK EQUIPMENT LVER LINKAGE
1. Main control valve 3. Kick-down switch

2. Work equipment control lever 4. Lock lever
WA180-3MC 10-115
12
WORK EQUIPMENT LINKAGE
1. Bellcrank 4. Boom
2. Bucket cylinder 5. Bucket link
3. Boom cylinder 6. Bucket
10-116 WA180-3MC
WA180-3MC 10-117
12
BUCKET
1. Bucket 1.9 m3 (2.48 yd3)

2. Bolt-on cutting edge (BOC)
10-118 WA180-3MC
12
BUCKET POSITIONER AND BOOM KICK-OUT
1. Bucket cylinder rod

2. Lever
3. Proximity switch
4. Proximity switch
WA180-3MC 10-119
12
BUCKET POSITIONER
The bucket positioner is an electrically actuated system which is used to set
the bucket to the desired angle when the bucket is moved from the DUMP
position to the TILT position. When the bucket reaches the desired posi-
tion, the bucket control lever is returned from the TILT position to the
HOLD position, and the bucket is automatically set to the suitable digging
angle.
Lever (2) is secured to the bucket cylinder rod (1) by bolts. In addition,
proximity switch (3) is fixed to the cylinder by bolts.
When the bucket is moved from the DUMP position to the TILT position,
the bucket cylinder rod moves to the left, and at the same time, lever (2)
also moves to the left. Proximity switch (3) separates from lever (2) at
the desired position, and the bucket control lever is returned to neutral.
BOOM KICK-OUT
The boom kick-out is an electrically actuated system. It acts to move the
boom control lever to the HOLD position and stop the boom at the desired
position before the boom reaches the maximum height.
Plate is fixed to the boom. In addition, proximity switch (4) is fixed to the
frame. When the boom is moved from the LOWER position to the RAISE
position, the boom rises, and when it reaches the desired position, the prox-
imity switch and lever come together and the system is actuated to return
the boom control lever to the HOLD position.
10-120 WA180-3MC
PROXIMITY SWITCH
Operation
The proximity switches are installed to the boom and bucket cylinders by a support. In accordance with the operating condi-
tion, a pulse is generated from the sensor at the desired point when moving to the boom RAISE position and bucket TILT
BACK position. This electric current is transmitted to a magnet, and the boom and bucket control lever is returned to neutral.
Therefore, the main control valve also returns to neutral and the movement of the boom and bucket are stopped.
WA180-3MC 10-121
12
OPERATION OF THE PROXIMITY SWITCH
Bucket TILT BACK switch

If the bucket is dumped beyond the set position for the bucket positioner, the detector (plate) is above the detector surface of
the bucket proximity switch, so the proximity switch sends the battery current to the magnet switch coil.
When the bucket lever is operated to the TILT BACK position, the bucket spool is held at the TILT BACK position by the
magnet at the bucket spool detent of the main control valve, and the bucket is tilted back.
When the bucket tilts back and reaches the set position for the bucket positioner, the detector (plate) separates from the prox-
imity switch detector surface. When this happens, the proximity switch cuts the electric current to the magnet coil. The bucket
spool is then returned to the neutral position by the return spring.
Boom RAISE switch

When the boom is lowered below the set position for the boom kick-out, the detector (plate) is above the detector surface of
the boom proximity switch, so the proximity switch sends the battery current to the magnet switch coil.
Now when the boom lever is operated to the RAISE position, the boom spool is held at the RAISE position by the boom spool
detent magnet of the main control valve, and the boom rises.
When the boom rises and reaches the set position for the boom kick-out, the detector (plate) separates from the proximity
switch detector surface. When this happens, the proximity switch cuts the electric current to the magnet coil. The boom spool
is then returned to the neutral position by the return spring.
ACTION OF THE PROXIMITY SWITCH
POSITION
Proximity switch When detector is positioned at detection surface When detector is separated from detection
of proximity switch. surface of proximity switch.
Boom, Bucket Proximity switch sends electric current to Proximity switch cuts electric current to magnet
Proximity Switch magnet coil. (Magnet is actuated.) coil. (Magnet is not actuated.)
10-122 WA180-3MC
STRUCTURE AND FUNCTION ROPS CAB
12
ROPS CAB
WA180-3MC 10-123
STRUCTURE AND FUNCTION AIR CONDITIONER
12
AIR CONDITIONER
AIR CONDITIONER AND HEATER PIPING
1. Vent 3. Compressor 6. Dry receiver
2. Air conditioner unit 4. Hot water inlet port 7. Air conditioner condenser
5. Hot water outlet port
10-124 WA180-3MC
STRUCTURE AND FUNCTION ECSS
12
ECSS
(ELECTRONIC CONTROLLED SUSPENSION SYSTEM)
1. Accumulator
2. Charge valve
3. Control valve
Outline
The E.C.S.S. is a system to suppress the travel vibration when traveling on unpaved surfaces, snow, or other rough road
surfaces at high speed, or when traveling loaded. It is effective in reducing the vibration of the chassis and makes it possible to
carry out stable travel operations.
WA180-3MC 10-125
12
ECSS HYDRAULIC AND ELECTRICAL CIRCUIT DIAGRAM
System actuation table

Boom cylinder bottom pressure Solenoid
E.C.S.S. switch
System Function
(system ON - OFF)
kgf/cm2 (lbf/in2) SOL1 SOL2
OFF 0 - 210 (0 - 2986.9) OFF ON Not working
0 - 150 (0 - 2133.5) ON OFF Working

ON
150 - 210 (2133.5 - 2986.9) OFF ON Not working
10-126 WA180-3MC
12
OPERATION
The ECSS uses the hydraulic spring effect of the hydraulic accumulator installed to the circuit at the lift cylinder bottom to
absorb the vibration of the chassis by using the damper to provide the most effective absorption of the travel vibration both
when traveling empty and when traveling loaded. This enables the machine to travel smoothly at high speed.
When the ECSS switch is turned ON, the solenoid valve (SOL1) opens at the boom cylinder pressure 0 - 150 kgf/cm2 (2133.5
lbf/in2), the circuit at the left cylinder bottom is connected with the hydraulic accumulator and the ECSS is actuated. When the
ECSS switch is turned OFF, the solenoid valve (SOL1) closes, the circuit at the left cylinder bottom is shut off from the
hydraulic accumulator and the ECSS is not actuated.
For details of the system, refer to the ECSS System Chart on the previous page.
WA180-3MC 10-127
STRUCTURE AND FUNCTION CENTRAL PANEL
12
CENTRAL PANEL
(CLUSTER GAUGE)
1. Service meter 8. Brake oil level caution pilot lamp 15. Transmission cut-off pilot lamp
16. Emergency steering normal pilot lamp

2. Fuel gauge 9. Working lamp pilot lamp
(Blue)
3. Speedometer 10. Preheating pilot lamp 17. Brake boost pressure caution pilot lamp
18. Transmission auto-shift / manual pilot

4. High beam pilot lamp 11. Working lamp switch
lamp
5. Turn signal pilot lamp 12. Parking brake pilot lamp 19. Transmission cut-off switch
6. Engine water temperature gauge 13. Engine oil pressure caution pilot lamp 20. Ground driven steering pilot lamp
7. Torque converter oil temperature gauge 14. Battery charge caution pilot lamp
10-128 WA180-3MC
STRUCTURE AND FUNCTION SENSORS
12
SENSORS
ENGINE OIL PRESSURE
Function
The engine oil pressure sensor is installed to the engine block and detects the oil pressure. If the oil pressure goes below the
specified pressure, it lights up the engine oil pressure warning pilot lamp on the cluster gauge to warn the operator of the
abnormality.
BRAKE OIL LEVEL
1. Cap
2. Ring
3. Float
4. Connector
5. Tank
6. Diaphragm
Function
The brake oil level sensor is installed to the top of the brake oil tank. When
the brake oil goes below the specified level, the float goes down and the
switch is turned on. This lights up the brake oil level lamp on the cluster
gauge to warn the operator of the abnormality.
WA180-3MC 10-129
STRUCTURE AND FUNCTION SENSORS
12
ENGINE SPEED SENSOR
1. Magnet 4. Boot
2. Terminal 5. Connector
3. Case
Function
The engine speed sensor is installed to the ring gear portion of the flywheel housing. A pulse voltage is generated by the rota-
tion of the gear teeth and a signal is sent to the controller and monitor panel.
10-130 WA180-3MC
STRUCTURE AND FUNCTION ENGINE
12
ENGINE
ENGINE STARTING CIRCUIT
Function
A neutral safety circuit is used to prevent the engine from starting if the directional lever is not at the N position. This ensures
safety when starting the engine.
Operation
When the directional lever is placed at the N position, the N contacts of the directional lever switch are closed.
When the starting switch is turned to the ON position, Electric current flows from battery (+) ➞ starting switch terminal B -
BR ➞ battery relay. The battery relay is closed, so current flows in the following circuit: (1) battery(+) ➞ slow blow fuse
directional switch terminal N ➞ neutral relay terminals 1 - 2 ➞ ground, and the relay coil is excited. When this happens, neu-
tral relay terminals 3 - 5 are closed.
In addition, electric current flows from switch terminal ACC ➞ Fuel shut-off solenoid ➞ ground, and then releases the stop
lever of the fuel injection pump to the FULL position to set the operating condition.
If the starting switch is turned to the START position, current flows from starting switch terminals B - C ➞ neutral relay ter-
minals 5 - 3 ➞ starting motor terminal S ➞ ground, and a circuit is also formed from the battery ➞ battery relay ➞ starting
motor terminal B, so the engine starts.
If the directional lever is not at the N position, circuit (1) is not formed, so the engine does not start.
WA180-3MC 10-131
STRUCTURE AND FUNCTION ENGINE
12
ENGINE STOP CIRCUIT
Function
The system is equipped with an electrical fuel cut device (Fuel shut-off solenoid) which makes it possible to start the engine by
turning the switch ON or OFF. This improves the ease of operation.
Operation
When the starting switch is turned OFF, starting switch terminals B and ACC are opened.
The current in the Fuel shut-off solenoid is shut off by the starting switch, so the coil is not excited. Therefore, the stop lever of
fuel injection pump is released to the stop position and shuts off the fuel supply to the injection pump, causing the engine to
stop.
10-132 WA180-3MC
STRUCTURE AND FUNCTION AUTOMATIC PREHEATING CIRCUIT
12
AUTOMATIC PREHEATING CIRCUIT
QUICK HEATING SYSTEM (QHS)
OUTLINE
To make it easier to start the engine in cold weather, a Q.H.S. (Quick Heating System) automatic preheating system is
installed. This consist of a controller, a water temperature sensor, and a large capacity ribbon heater.
The Q.H.S. automatically sets the preheating time to match the coolant temperature simply by turning the starting switch ON.
It also acts to reduce the preheating time.
When the starting switch is turned to the ON position, the preheating pilot lamp lights up, and the ribbon heater carries out pre-
heating while the lamp is lit up. The water temperature sensor detects the water temperature and the preheating time is set by
the controller.
While the preheating pilot lamp is lit up, preheating is being carried out, so keep the starting switch at the ON position. When
the engine reaches a temperature which makes it possible to start the engine, the preheating pilot lamp goes out, so the engine
can be started.
When the starting switch is turned to the START position while preheating, it assumes the engine has started and immediately
stops the preheating.
Operation
When the starting switch is turned to the ON position, a signal flows from the starting switch terminal ACC to Q.H.S. control-
ler terminal 4. The controller instantaneously detects the water temperature and determines the length of time for lighting up
the preheating pilot lamp and the preheating time for the ribbon heater.
Controller terminal 5 is connected to the ground, and lights up the preheating pilot lamp. At the same time, it sends a signal
from terminal 2 to the heater relay to actuate the heater relay and make the ribbon heater red hot.
When the preheating end signal is sent from the controller, the heater relay is turned OFF and preheating is completed.
WA180-3MC 10-133
The diagrams on the right show the actuation sequence. (Fig. 1, Fig. 2)
The diagrams on the right show lighting up time T1 for the preheating
lamp and preheating/post heating time T2 according to the water tempera-
ture. (Fig. 3, Fig. 4)
10-134 WA180-3MC
12
QHS CONTROLLER
1. Q.H.S. controller body

2. Lead wire
3. Connector
HEATER RELAY
WA180-3MC 10-135
12
RIBBON HEATER
QHS WATER TEMPERATURE SENSOR
10-136 WA180-3MC
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL
12
TRANSMISSION AUTO-SHIFT CONTROL
Function
1 Electrical control is used to actuate the transmission solenoid and select the F, R, or N position.
If the directional lever is not at the N position, the engine will not start even if the staring switch is
2 Directional lever turned to the START position. This is to prevent any accident if the machine should start suddenly.
(For details, see ENGINE STARTING CIRCUIT).
3 When traveling in reverse, it lights up the backup lamp to warn people in the surrounding area.
4 Gear shift lever Electrical control is used to actuate the transmission solenoid and select the speed range.
Transmission cut-off This is used to select between actuation and non-actuation of the transmission cut-off function.
5
selector switch
Transmission cut-off When the left brake pedal is pressed, the transmission is returned to neutral and the normal brake is
6
switch actuated (transmission cut-off function).
To prevent seizure of the parking brake, the transmission is returned to neutral when the parking
7 Parking brake switch
brake is applied.
When traveling in F2, it is possible to operate the switch to shift down to F1 with-out moving the
8 Kick-down switch gear shift lever. If the gear shift lever is moved to the R or N position, the speed range is automati-
cally returned to the original 2nd position.
WA180-3MC 10-137
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
12
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
System
No. Input No. Output
1 Directional Switch Signal D➔ D➔ 1 F Solenoid
2 Speed Range Switch Signal D➔ D➔ 2 R Solenoid
3 Transmission Cut-Off Signal D➔ D➔ 3 HL Solenoid
4 Kick-Down Switch Signal D➔ D➔ 4 SP Solenoid
D➔ 5 Alarm Buzzer Signal

Transmission
6 Neutralizer Relay Signal D➔
Controller
7 Travelling Speed Signal P➔
8 Engine Speed Signal P➔
9 Model (Engine) Select Signal D➔ D: Digital Signal
10 Manual Switch Signal D➔ P: Pulse Signal
11 Tire Select Signal D➔
Control Function
Outline
With the auto-shift control system, the position signals from the directional lever and speed lever, the engine speed signal,
travel speed signal and signals from other switches are received. The transmission controller then drives the speed solenoid
valve and automatically carries out the shift control to select the optimum speed range for the transmission.
10-138 WA180-3MC
12
SHIFT CONTROL SYSTEM FUNCTION
INPUT SIGNALS
1. Directional lever
This selects F (FORWARD), R (REVERSE), and N (Neutral).
2. Speed lever
This selects the optimum speed range when using auto-shift FORWARD or REVERSE. Normally, if the speed lever is at
position 2 or above, the transmission will be set to 2nd when the machine starts.
When Auto-shift is used and the gear shift lever is moved 4 ➔ 3 ➔ 2 ➔ 1 when the machine is travelling with the trans-
mission in 4th, the transmission will also shift down immediately 4 ➔ 3 ➔ 2 ➔ 1.
(Priority given to speed lever)
3. Engine speed sensor

When the engine is running at low speed (less than 1,450 rpm), the auto-shift is stopped. When shifting between forward
and reverse or when coasting, the present speed range is maintained and the shift shock is reduced. When the machine is
traveling in 2nd, and the engine speed changes from low speed (less than 1,450 rpm) to high speed (more than 1,450 rpm),
the speed range is kept at 2nd to allow the machine to accelerate more easily.
4. Travel speed sensor

The speed range is determined according to the travel speed. In addition, the change in speed is determined from the pulse
count to decide whether to shift up or down.
5. Neutralizer relay
The parking brake actuation signal is input to the controller and the transmission is shifted to neutral.
6. Transmission cut-off signal

When the controller receives the transmission cut-off signal, it shifts the transmission to neutral. After the signal is can-
celed, it selects a speed range that matches the travel speed at that point.
WA180-3MC 10-139
12
OUTPUT SIGNALS
1. Transmission solenoid output

The F and R solenoids correspond to the F and R positions of the directional lever. Positions 1 to 4 of the speed lever actu-
ate the HL solenoid and SP solenoid to select the clutches to give the 1st to 4th transmission speeds. This combination is
then output to the transmission (Table 1, below).
Table 1: Transmission Solenoid Output

Solenoid Clutch
Speed Range
F R HL SP F R 1 2 3 4
N O
F 1 O O O O
F 2 O O O
F 3 O O O O
F 4 O O O O O
R 1 O O O O
R 2 O O O
R 3 O O O O
R 4 O O O O O
2. Kick-down function
The operator can override all the automatic conditions and deliberately downshift into 1st (when traveling below 12.0
km/h (7.5 mi/h) in 4th or 3rd, or when traveling at any speed in 2nd (see Table 2, item 7). When the travel speed increases,
the transmission is shifted up in accordance with the auto-shift-up conditions, or it is shifted to 2nd when the direction is
shifted between forward and reverse.
10-140 WA180-3MC
12
SHIFT CHARACTERISTICS
1. Auto shift (see Table 2, Items 1 and 2)

When the engine speed is above 1,450 rpm, the transmission is shifted as follows according to the travel speed.
A. FORWARD (see Table 2, Item 1) Directional lever at F, speed lever at 4.
Shift up
i. When starting, the transmission is set to the F2 torque converter range.
ii. When the accelerator pedal is depressed, the engine speed rises and the machine travels faster. If the engine
speed continues to rise and the travel speed reaches 10.0 km/h (10.5 km/h) [6.2 mi/h {6.5mi/h}], the transmission
is up shifted to F3. If there is insufficient acceleration, the transmission up shifts when the travel speed reaches
the figure shown
in () {}.
iii. Immediately after the transmission up shifts, the engine speed will drop momentarily. But if the machine contin-
ues to travel faster and the travel speed reaches 17.5 km/h [10.8 mi/h], the transmission upshifts to F4.
Shift down
i. If the machine is traveling in F4 and the load increases, the transmission will down shift to F3 if the travel speed
drops below 15.5 km/h [9.6 mi/h].
ii. If the travel speed drops further to 10.5 km/h [6.5 mi/h], the transmission is down shifted to F2. If there is insuf-
ficient deceleration, the transmission down shifts when the travel speed reaches the figure shown in () [].
With auto-shift, the transmission does not downshift to 1st even if the travel speed drops. Normally, the transmis-
sion shifts to 1st only if the speed lever is placed at 1st or if the kick-down switch is pressed.
B. REVERSE (see Table 2, Item 2)

Directional lever at R, speed lever at 4. The transmission range is shifted according to the travel speed in the same
way as for FORWARD.
WA180-3MC 10-141
12
2. Changing direction (switching between forward and reverse)
(When the directional lever is shifted to the opposite direction from the direction of travel)
If the travel speed and engine speed are in area I in Fig. 2, the transmission output shifts to 2nd speed in the same direction
as the directional lever regardless of the speed range. Following this, the transmission shifts up to match the travel speed.
(See Table 2, item 8)
Example:
Directional lever: F ➔ N ➔ R
Transmission output: F4 ➔ N ➔ R2 ➔ R3 ➔ R4
In area II in Fig. 2, the transmission output reverses, but the speed range downshifts to 2nd in accordance with the travel
speed. Then, after the actual direction of travel of the machine changes to the same direction as the directional lever, the
transmission upshifts in accordance with the travel speed (to prevent damage to the clutch) (See Table 2, items 9 and 10).
However, when the hold function is ON, the transmission does not down shift.
Example:
Directional lever: F ➔ N ➔ R
Transmission output: F4 ➔ N ➔ R4 ➔ R3 ➔ R2
(The transmission downshifts while the machine is coasting in forward) R2 ➔ R3 ➔ R4
(The machine upshifts when traveling in reverse)
However, if the speed lever is at 1, the transmission remains in 1st.
3. Switching F - N - F (R - N - R) (lever returned)

A speed range that matches the speed is selected. (See Table 2, items 11 and 12)
4. Skip shift
When the machine is coasting in 3rd or 4th (engine speed below 1,450 rpm), and the accelerator pedal is depressed
(engine speed above 1,450 rpm), the speed range is held if the travel speed is more than 8 km/h (5 mi/h). If the travel
speed is less than 8 km/h (5 mi/h), the transmission is shifted down to 2nd to make it easier to accelerate.
(See Table 2, item 4)
A time lag is specially provided when shifting down 4 ➔ 2 or 3 ➔ 2.
10-142 WA180-3MC
12
5. No-shift time
This is the time that the speed range is held after shifting. The
speed cannot be shifted until this time has elapsed (to prevent
"shift-hunting"). The no-shift time differs according to the shift
conditions (see Table 2 on next page).
WA180-3MC 10-143
Table 2: Gear Shift Characteristics
Shift Speed Shift Speed No-Shift Time
Item Shift
(km/h) (mi/h) (seconds)
5.0 3.1
1➔2
(5.2) (3.2)
2.0
10.0 6.2
2➔3
1. Normal gear shift (10.5) (6.5)
Directional lever: F 3➔4 17.5 10.8
1.0
4➔3 15.5 9.6
10.5 6.5
3➔2 2.0
(10.0) (6.2)
5.0 3.1
1➔2
(5.2) (3.2)
2.0
10.0 6.2
2➔3
2. Normal gear shift (10.5) (6.5)
Directional lever: R 3➔4 18.0 11.1
1.0
4➔3 16.0 9.9
10.5 6.5
3➔2 2.0
(10.0) (6.2)
4➔2
3. Engine speed less than 1,450 rpm 1.0 0.6 0.0
3➔2
4. Engine speed less than 4➔2
8.0 4.9 See *1
1,450 rpm‘ more than 1,450 rpm 3➔2
1➔2 5.0 3.1
5. When hold switch is ON
2➔3 10.0 6.2 0.0
Directional lever: F
3➔4 17.5 10.8
1➔2 5.0 3.1
6. When hold switch is ON
2➔3 10.0 6.2 0.0
Directional lever: R
3➔4 18.0 11.1
2➔1 Whole range Whole range
7. Kick-down: ON 3➔1 5.0
12.0 7.4
4➔1
8. Directional lever switched 4➔2 See *1 See *1
(Area I) (F➔) N➔ R 3➔2 --- --- 2.0
(R➔) N➔ F 1➔2 --- ---
18.0 11.1
9. Directional lever switched ➔4
16.0 - 18.0 9.9 - 11.1 0.0
(Area II) (F➔) N➔ R
➔3 See *2 See *2
17.5 10.8
10. Directional lever switched ➔4
16.0 - 17.5 9.9 - 10.8 0.0
(Area II) (R➔) N➔ F
➔3 See *3 See *3
➔4 17.5 10.8
11. Directional lever switched
➔3 10.0 - 17.5 6.2 - 10.8 0.0
(F➔) N➔ F
➔2 10.0 6.2
➔4 18.0 11.1
12. Directional lever switched
➔3 10.0 - 18.0 6.2 - 11.1 0.0
(R➔) N➔ R
➔2 10.0 6.2
*1: Engine speed less than 2,000 rpm and travel speed between 13 km/h (8.0 mi/h) and 16 km/h (9.9 mi/h).
*2: Engine speed more than 2,000 rpm - 3 has travel speed less than 13 km/h (8.0 mi/h) ~ 18.0 km/h (11.1 mi/h).
*3: Engine speed more than 2,000 rpm - 3 has travel speed less than 13 km/h (8.0 mi/h) ~ 17.5 km/h (10.8 mi/h);
for Area I and Area II, see Figure 2.
No-shift time before No-shift time after

shifting shifting
4th ➔ 2nd
1.2 seconds 2.0 seconds
3rd ➔ 2nd
10-144 WA180-3MC
SAFETY FUNCTION
1. Alarm buzzer
The alarm buzzer will sound to prevent damage to the clutch if
the direction of travel is switched between forward and reverse
in area III in of Fig. 3 (travel speed above 13 km/h or 8 mi/h
and engine speed is above 1,800 rpm, or travel speed is above
14 km/h or 9 mi/h),
2. N priority for directional lever

The controller is equipped with an interlock function which
always gives the neutral output when the lever is at N.
3. Neutral safety
When the directional lever is at any position other than N, the
transmission is set to neutral to prevent unexpected movement
of the machine when the engine is started and the machine does not start even if the starting switch is turned ON. This
condition is canceled if the directional lever is returned to the N position. The engine can then be started.
4. Speed lever priority

If the speed lever is shifted down when traveling downhill, the transmission shifts down immediately to use the braking
force of the engine.
5. Manual shift
If there should be any disconnection in the travel speed sensor or any other failures and the input of the travel speed stops,
the lever operation switches to manual shift.
Example:
Directional lever F, speed lever 4 ➔ F4
Directional lever R, speed lever 2 ➔ R2
TROUBLESHOOTING
The controller always observes if the electronic devices (the solenoids which receive the controller output signals, and the
engine speed sensor and travel speed sensor from which the controller takes in the signals) are functioning normally. If there is
any abnormality in any of these devices, the controller judges the condition and informs the operator of the result with the
alarm buzzer.
WA180-3MC 10-145
12
TRANSMISSION CONTROLLER
CONNECTOR SIGNALS
CN1 CN2 CN3

1 — 1 Directional switch F 1 —
2 — 2 Speed range switch 2 2 —
4 — 4 Neutralizer relay signal 4 Travel speed signal (+)
5 — 5 Manual switch 5 Engine speed signal
6 — 6 Model (engine) selector 2 6 —
7 — 7 Model (engine) selector 1 7 —
8 Power source input (+24 V) 8 Engine selector 8 Manual signal output
9 GND 9 Signal GND output 9 —
10 HL, Sol 10 — 10 —
11 SP, Sol 11 Directional switch N 11 —
Travel speed signal (-)
12 — 12 Directional switch R 12
Engine speed signal (-)
13 Sensor power (+24 V) 13 Speed range switch 1 13 —
15 — 15 Tire selector 15 Buzzer signal output
16 — 16 Transmission cut-off switch 16 —
17 Sol, power source input (+24 V) 17 Kick-down switch
18 Power source input (+24 V) 18 —
19 GND 19 —
20 R, Sol 20 —
21 F, Sol
10-146 WA180-3MC
12
COMBINATION SWITCH
Outline
The directional lever has three positions and the speed lever switch has four positions. As an individual part, the switch does
not have a detent mechanism; the detent mechanism is in the combination switch. Each switch is positioned by two pins, and is
secured to the body by three screws. When each lever is operated to the desired position, the switch, which is interconnected
by a shaft, acts to allow electric current to flow to that circuit only.
General locations, function
1 Directional lever switch Switches between F, R, and N
2 Speed lever switch Selects speed range
Stopper used to prevent speed lever from entering 3rd or 4th during
3 Speed lever stopper
operations
4 Turn signal indicators Direction indicator lamps used when turning left or right
Turn signal indicator lever automatically returns to central position

5 Self cancel
after machines turns left or right
6 Turn signal indicators Switches on clearance lamp, head lamp, parking lamp, etc.
7 Dimmer switch Selects high beam for travel and low beam for passing
Makes both left and right turn signal indicator lamps flash at the same
8 Hazard switch
time
9 Emergency flashing pilot lamp Flashes at the same time as the emergency flashing lamp flashes
WA180-3MC 10-147
12
TRANSMISSION CUT-OFF FUNCTION
Outline
If the transmission cut-off selector switch on the cluster gauge is turned ON (pilot lamp lights up), the transmission cut-off
switch installed to the left brake pedal is actuated. When the left brake is operated, the brake is applied and the transmission is
also shifted to neutral at the same time.
If the transmission cut-off selector switch is turned OFF (pilot lamp goes out), the transmission is not shifted to neutral and the
left brake operates in the same way as the right brake
When terminal 16 of the transmission controller is disconnected from ground, the transmission is cut-off.
Operation
1. Transmission cut-off selector switch ON

If the transmission cut-off selector switch is turned ON, the transmission cut-off relay opens and terminal 16 is connected
to ground, energizing transmission control valve solenoids R and F.
When the left brake pedal is depressed, the contacts on the transmission cut-off switch open and the power is shut off to
terminal 16 on the transmission controller. At the same time the power is shut off to terminal 20 (R) and terminal 21 (F) on
the transmission controller, shifting the transmission to neutral and actuating the brake.
10-148 WA180-3MC
12
2. Transmission cut-off selector switch OFF

If the transmission cut-off selector switch is turned OFF, the transmission cut-off relay is excited and the solenoid closes.
Terminal 16 is connected to the ground through the transmission cut-off selector switch. In this condition, voltage is
applied to transmission solenoids R and F regardless of the position of the brake-actuated transmission cut-off switch. As
a result, when the left brake pedal is depressed, the transmission does not shift to neutral.
WA180-3MC 10-149
12
PARKING BRAKE FUNCTION
Outline
When the parking brake is applied, the transmission is kept at neutral. This means that even when the engine is run at full
throttle, there is no load on the parking brake, and this prevents any dragging caused by mistaken operation.
Operation
When the parking brake pedal is depressed, the parking brake switch is turned ON, an electric current flows from the
neutralizer relay coil to the parking brake switch ➞ ground, and the neutralizer relay coil is excited.
As a result, the neutralizer relay is actuated, so the circuit is cut. No electric current flows to the FORWARD relay or
REVERSE relay and the transmission is placed in neutral.
10-150 WA180-3MC
12
KICK-DOWN SWITCH
Operation
The kick-down (shifting down from 2nd ➞ 1st) is actuated only when traveling in F2.
When traveling in F2, if it is desired to shift down to 1st without operating the speed lever, operate the kick-down switch on
the boom lever to ON to shift down to F1.
After this, even if the kick-down switch is pressed, the transmission is kept at F1.
Cancellation (or not actuated)
When directional lever is at N
When directional lever is at R
When speed lever is not at 2nd
When starting switch is OFF
WA180-3MC 10-151
12
KICK-DOWN ELECTRICAL CIRCUIT
Normal operation
Solenoid actuation table

F1 F2 F3 F4 N R1 R2 R3 R4
1 O ● O O
2 O O O O
3 O O O O
4 O O O O
Directional lever set to F

When the directional lever is operated to the F position, electric current flows from the battery positive terminal to directional
lever switch terminals 1 and 2 and to FORWARD transmission controller terminal 1. As a result, a signal from terminal 21
activates the FORWARD solenoid relay (1)
During release of the parking brake, the parking brake switch is connected as current flows from the battery positive terminal
to neutralizer relay terminals 1 and 2 and to ground, causing neutralizer terminal 3 and 5 to connect.
Speed lever set to 2nd

When the gear shift lever is at the 2nd position, no electric current flows to solenoids (2), (3), or (4). In this condition, the
transmission valve is set to F2 by the action of solenoid (1). Unless the kick-down switch is depressed, the kick down relay is
not actuated and the transmission is held in F2.
10-152 WA180-3MC
12
KICK-DOWN SWITCH OPERATED
(During operation or during travel when gear shift lever is at F2)

F1 F2 F3 F4 N R1 R2 R3 R4
1 ● O O O
2 O O O O
3 O O O O
4 ● O O O
Kickdown switch pushed to ON position

When the kick-down switch is depressed, the kick-down circuit is activated within the controller. Current flows from terminals
21 and 11 to FORWARD solenoid (1) as well as to speed solenoid (4). The solenoid valves are actuated and the transmission is
set to F1.
The kick-down circuit continues to be actuated and the transmission stays in F1 when the kick-down switch is released. (There
is a self-hold circuit in the kick-down relay.)
In this way, if the kick-down switch is pressed when the speed lever is at F2, the transmission will shift to F1. As well, it wi ll
continue to be held in F1, by the self-hold function of the kick-down relay, when the kick-down switch is released.
WA180-3MC 10-153
12
KICK-DOWN SWITCH ACTUATION - CANCELED (1)
(Directional lever at N or R)

F1 F2 F3 F4 N R1 R2 R3 R4
1 O O O O
2 O ● O O
3 O O O O
4 O O O O
When the directional lever is moved to the R position, the F terminal contacts are turned OFF. Current stops flowing from the
battery positive terminal to speed lever switch terminals 1 and 2 and tot he transmission controller.
The transmission controller FORWARD circuit is opened and the current stops flowing. As a result, the self-hold circuit of the
kick-down relay is cancelled and solenoid (4) is no longer actuated.
When the directional lever is moved to the N position, the actuation is the same as above and the kick-down relay is canceled.
In addition, the FORWARD circuit is opened and solenoid (1) is no longer actuated.
When the directional lever is moved to the R position, current flows from the battery positive terminal 12 on the REVERSE
transmission controller. It then flows to the REVERSE circuit output signal terminal 20 to REVERSE solenoid (2) to ground,
activating the REVERSE solenoid valve. Therefore, only the REVERSE solenoid (2) is actuated and the transmission is set to
the R2 position.
10-154 WA180-3MC
12
KICK-DOWN SWITCH ACTUATION - CANCELED (2)
(Gear shift lever at position other than 2nd)

F1 F2 F3 F4 N R1 R2 R3 R4
1 O O ● O
2 O O O O
3 ● O O O
4 O O O O
When the speed lever is moved to any position other than 2, the terminal connection at the lever is turned OFF and current no
longer flows from the battery positive terminal to speed lever switch connections 1 and 6 and to the transmission controller.
Therefore, the kick-down circuit, which is connected with the speed 2 circuit, is shut off within the transmission controller nd
solenoid (4) is no longer actuated.
When the speed lever is moved to 3, solenoid (3) is actuated. In addition, with the directional lever at the F position, solenoid
(1) is actuated. Therefore, solenoids (1) and (3) are actuated and the transmission is set to F3.
WA180-3MC 10-155
12
MEMORANDUM
10-156 WA180-3MC
STRUCTURE AND FUNCTION ELECTRICAL WIRING ILLUSTRATION
12
ELECTRICAL WIRING ILLUSTRATION
1. Central panel 9. Slow blow fuse 17. Battery relay

2. Bucket positioner proximity switch 10. Alternator 18. Transmission solenoid valve
3. Head lamp 11. Water temperature sensor 19. Directional lever
4. Transmission cut-off switch 12. Working lamp 20. Gear shift lever
5. Staring switch 13. License lamp 21. Wiper switch
6. Combination switch 14. Rear combination lamp 22. Horn
7. Fuse box 15. Battery 23. Boom kick-out proximity
8. Parking brake switch 16. Fuel level sensor switch
WA180-3MC 10-157
STRUCTURE AND FUNCTION ELECTRICAL WIRING ILLUSTRATION
12
MEMORANDUM
10-158 WA180-3MC
STRUCTURE AND FUNCTION ELECTRICAL WIRING DIAGRAM (1/5)
12
ELECTRICAL WIRING DIAGRAM (1/5)
Refer to FOLDOUT 10-159 at the end of this manual.

If desired, replace this page with the foldout.
WA180-3MC 10-159
12
MEMORANDUM
10-160 WA180-3MC
12

WA180-3MC 10-161
12
MEMORANDUM
10-162 WA180-3MC
12

WA180-3MC 10-163
12
MEMORANDUM
10-164 WA180-3MC
12

WA180-3MC 10-165
12
MEMORANDUM
10-166 WA180-3MC
12

WA180-3MC 10-167
12
MEMORANDUM
10-168 WA180-3MC
WA180-3MC 10-169
20 TESTING, ADJUSTING AND
TROUBLESHOOTING
STANDARD VALUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5

ENGINE TABLE - IN CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5
CHASSIS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
SERVICE TOOLS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
ADJUSTING ENGINE STOP MOTOR CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-14
ADJUSTING ENGINE STOP SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
MEASURING AND ADJUSTING VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
MEASURING BLOW-BY PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
MEASURING COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-14
MEASURING COOLANT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
MEASURING ENGINE LUBRICATING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
MEASURING ENGINE SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
MEASURING EXHAUST COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
MEASURING EXHAUST GAS TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
MEASURING FUEL FILTER INLET RESTRICTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
TEST AND ADJUSTING FAN BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
TEST AND ADJUSTING FUEL INJECTION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-14
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
OPERATING ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16
SPEED LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-17
OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-17
TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-17
STALL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
TORQUE CONVERTER STALL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-18
HYDRAULIC STALL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-19
FULL STALL SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-19
TORQUE CONVERTER OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20
TRANSMISSION OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20
EMERGENCY MANUAL SPOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 20-22
STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . 20-24
OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24
OPERATING TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
STEERING OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
METHOD OF MEASURING MAIN RELIEF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
METHOD OF ADJUSTING MAIN RELIEF PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
OPERATING FORCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . 20-28
BRAKE PEDAL LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-29
BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-31
WA180-3MC 20-1 1
TESTING AND ADJUSTING
BRAKE OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32
BRAKE DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-33
BLEEDING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35
PARKING BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35
PARKING BRAKE LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
DISC WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
MEASURING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
WORK EQUIPMENT HYDRAULIC PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
WORK EQUIPMENT MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-44
HYDRAULIC DRIFT WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-45
BUCKET POSITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-46
BOOM KICK-OUT (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
PROXIMITY SWITCH ACTUATION PILOT LAMP (RED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48
TROUBLESHOOTING GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101

TROUBLESHOOTING SYSTEMS OF:
A MODE - TRANSMISSION CONTROLLER SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-301
D MODE - ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM). . . . . . . . . . . . . . . . 20-401
E MODE - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-501
S MODE - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-801
T MODE - HYDRAULIC AND MECHANICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-901
AIR CONDITIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1001
20-2 2 WA180-3MC
12
★ See ENGINE SHOP MANUAL.
★ When using the standard value tables to make judgement for testing, adjusting, and troubleshooting, the following precau-
tions are necessary:
1. The standard values in the tables are the values for a new machine and are given as reference values for the time when the
machine is shipped from the factory. These values should be used as a guide when estimating wear after the machine is
operated, and when carrying out repairs.
2. The permissible values given in the tables are values estimated based on the results of various tests carried out on the
machines shipped from the factory, so they should be used together with the information on the repair condition and other
information such as the operating history of the machine when judging the condition of the machine.
3. These standard values do not form a basis for judging claims.
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on level
ground and use the safety pins and blocks to prevent the machine from moving
WARNING! When carrying out work together with co- workers, always use signals and do not let
unauthorized people near the machine.
WARNING! When checking the coolant level, always wait for the coolant to cool down. If the radiator
cap is removed when the coolant is still hot, the coolant will spurt out and cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
WA180-3MC 20-3 1
12
MEMORANDUM
20-4 1 WA180-3MC
TESTING AND ADJUSTING STANDARD VALUE TABLE
12
STANDARD VALUE TABLE
ENGINE TABLE - IN CHASSIS
Engine model Komatsu S6D102E-1
Standard value for new

Item Measurement condition Unit Service limit value
machine
High idle 2650 ± 50 2650 ± 50

Engine speeds rpm
Low idle 850 ± 100 850 ± 100
Engine rating Rated gross power / rated speed kW / rpm 95.5 / 2400 95.5 / 2400
Intake manifold At T.C. stall and W.O.T (Wide

mm Hg 900 - 1000 800 - 1100
pressure Open Throttle)
At T.C. stall and W.O.T. at New element: 380

Intake air restriction mm H2O Max. 635
restriction indicator port Used Element: 635
kgf/cm2 0.70 0.70

Lubricating oil pressure Minimum at low idle
(lbf/in2) (10.15) (10.15)
with SAE 15W-40 oil &
coolant temperature in
kgf/cm2 2.81 2.81
operating range Minimum at rated speed & load
(lbf/in2) (40.03) (40.03)
Fuel filter inlet

Maximum restriction at high idle mm Hg 100 200
restriction
Coolant temperature in operating

range:
• Service Tool orifice size:
Blow-by pressure mm H2O 180 360
5.613 mm
• At T.C. stall and W.O.T.
• With SAE 15W-40 oil
Exhaust back Maximum at T.C. stall and

mm Hg 77 77
pressure W.O.T.
Maximum operating °C 100 100

Coolant temperature
temperature (° F) (212) (212)
Engine cold:
Valve clearance Intake valves mm 0.25 0.25
Exhaust valves 0.51 0.51
Engine stall speeds: • Coolant temperature in

operating range
Torque
converter • Torque converter oil
2500 ±100 2500 ± 200
temperature in operat- rpm
Hydraulic ing range 2500 ± 100 2500 ± 200
• Hydraulic oil at normal
Full 1950 ± 200 1950 ± 300
operating temperature
★ For further detailed information, refer to the Engine Shop Manual.
WA180-3MC 20-5 1
12
CHASSIS TABLE
Cate Standard value for Service limit
Item Measurement Condition Unit
gory new machine value
49 - 98 147
Operating Force N (lbf)
(11 - 22) (33)
Accelerator pedal
∠1 48 ± 3 ---
Operating
deg.
Angle
∠2 31 ± 2 ---
Stopper Height L1 mm 48 ± 5 ---
5.9 +4.9
-2.9
N-FORWARD 13.7 (3.07)
(1.3 +1.1
-0.65 )
Directional lever
Operating
Force N (lbf)
5.9 +4.9
-2.9
N-REVERSE 13.7 (3.07)
(1.3 +1.1
-0.65 )
N-FORWARD 40 ± 10 40 ± 20
Travel mm
N-REVERSE 40 ± 10 40 ± 20
• Engine stopped 5.9 +4.9

-2.9
1st-2nd • Torque converter oil tem- 13.7 (3.07)
(1.3 +1.1
-0.65)
perature: 60-80°C (140-
176°F)
Operating 5.9 +4.9
-2.9
2nd-3rd N (lbf) 13.7 (3.07)
Force (1.3 +1.1
-0.65)
Speed lever
5.9 +4.9
-2.9
3rd-4th 13.7 (3.07)
(1.3 +1.1
-0.65)
1st-2nd 40 ± 10 40 ± 20
Travel 2nd-3rd mm 40 ± 10 40 ± 20
3rd-4th 40 ± 10 40 ± 20
23 ± 2 23 ± 2
Priority valve pressure
(327 ± 28.4) (327 ± 28.4)
Transmission valve
10+1,-2
• Torque converter oil tem- 10 ± 1
Pilot reducing valve pressure (142 +14.2,
perature: 60-80°C (140- kgf/cm2 (142 ± 14.2)
- 28.4)
176°F)
(lbf/in2)
• Engine speed: High idling 23 ± 2 23 +3, -4
Clutch pressure
(327 ± 28.4) (327 +42, -56)
Torque converter outlet port pres- 3.9 ± 0.5 3.9 ± 1.0

sure (55.4 ± 7.1) (55.4 ± 14.2)
20-6 1 WA180-3MC
Cate Standard value for Service limit

gory new machine value
Play • Engine speed: Low idling mm 20 ± 20 0 - 120

• Machine facing straight to
Steering wheel
front .8.8 - 11.8 Max. 21.6

Operating Force N (lbf)
• Flat, horizontal, straight, dry (1.97 - 42.44) (Max. 4.85)
paved road surface
Low idle Max. 3.9 Max. 6.0
Operating time • Hydraulic oil temperature: Sec.
High idle 45-55°C (113-131°F) Max. 3.2 Max. 4.5
Steering valve
• Engine speed: High idle 210 +7, -11

kgf/cm2 210 ± 7
Relief pressure • Hydraulic oil temperature: +99.5
(lbf/in2) (2987 ± 99.5) (2987 156.4)
45-55° C (113-131° F)
∠1 • Brake pedal operating force: 53 ---

206 N (46.3 lbf)
∠2
Operating
deg.
angle
16 ± 4 16 ± 6
• Flat, horizontal, straight, dry

Brakes
paved road surface

• Speed when applying brake:
• 20 km/h, braking delay: 0.1
Performance sec. m Max. 4.0 Max. 4.0
• Brake pedal operating force:
490 N (40 kg)
• Tire inflation pressure:
Specified pressure
42 kgf/cm2 (lbf/in2) in 5 min. kgf/cm2 Max. 3.5 Max. 3.5

Drop in hydraulic pressure 2
(lbf/in ) (Max. 49.7) (Max. 49.7)
Wear of disc Thickness of disc mm 1.08 ± 0.06 Min. 0.7
WA180-3MC 20-7 1
Cate Standard value Service limit

gory for new machine value
• Tire inflation pressure:
Specified pressure
• Flat paved road with 1/5
Performance (11°20') grade --- Stopped Stopped
• Dry road surface
Machine at operating
condition
Parking brake
Piston stroke (X) mm 1.85 ± 0.28 Min. 3.5
• Parking brake ON: a

• Parking brake OFF: b
• X=a-b
20-8 1 WA180-3MC
12
Cate Standard value Service limit

gory for new machine value
Max. 17.6 Max. 26.4

Hold to Raise
(Max. 4.0) (Max. 6.0)
Max. 27.4 Max. 44.1

Raise to Detent
(Max. 6.16) (Max. 9.25)
Max. 15.2 Max. 22.8

Boom Hold to Lower
(Max. 3.42) (Max. 5.13)
Lower to Hold --- ---

Operating effort
Max. 21.5 Max. 32.3

Lower to Float
N (Max. 4.84) (Max. 7.25)
(lbf)
Work equipment control lever
Max. 21.6 Max. 32.4

Float to Hold
(Max. 4.86) (Max. 7.29)
• Engine speed:
Low idle Max. 19.8 Max. 29.7
Hold to Dump
(Max. 4.45) (Max. 6.68)
• Hydraulic oil
temperature: 45 - 55° C Max. 29.4 Max. 34.3
Hold to Tilt
(113-131° F) (Max. 6.60) (Max. 7.71)
Bucket
Max. 28.3 Max. 42.5
Tilt to Detent
(Max. 6.37) (Max. 9.56)
Max. 21.5 Max. 32.3

Tilt Detent to Hold
(Max. 4.84) (Max. 7.25)
Hold to Raise with

60 ± 15 60 ± 20
Detent
Boom
Hold to Lower 46 ± 15 46 ± 20
Travel
mm
Lower to Float (in) 14 ± 15 14 ± 20
Hold to Dump 60 ± 15 60 ± 20
Bucket
Hold to Tilt with
60 ± 15 60 ± 20
Detent
WA180-3MC 20-9 1
12
Cate
Item Measurement Conditions Unit Standard Value Permissible Value
gory
21 +4
-2 22 +8
-4
Boom Raise Relief
(298.6 +56.8
-28.4 ) (312.9 +113.7
-56.8 )
Boom Raise Detent 35 ± 3.5 35 ± 7

(497.8 ± 49.7) (497.8 ± 99.5)
16 +2
-1.5 16 +4
-3
Relief pressure
Boom Lower Relief • Hydraulic oil

PPC Valve
(227.57 +28.4
-21.3 ) (227.57 +56.8
-42.6 )
temperature: 45 - 55° C kgf/cm2
(113 - 131° F)
(lbf/in2) 35 ± 3.5 35 ± 7
Boom Lower Float • Engine speed: Low idle
(497.8 ± 49.7) (497.8 ± 99.5)
21 +4
-2 21 +8
-4
Bucket Tilt Relief
(298.6 +56.8
-28.4 ) (298.6 +113.7
-56.8 )
21 +4
-2 21 +8
-4
Bucket Dump Relief
(298.6 +56.8
-28.4 ) (298.6 +113.7
-56.8 )
Main control valve
• Hydraulic oil 210 +4 210 +4

temperature: 45 - 55° C kgf/cm2 -5 -15
Relief pressure
• Engine speed: High idle (lbf/in2) (2987 +56
-72
) (2987 +56 )
-213
20-10 1 WA180-3MC
Cate
Item Measurement Conditions Unit Standard Value Permissible Value
gory
Boom lifting time 5.6 ± 0.3 Max. 6.3
Boom lowering time 3.4 ± 0.5 Max. 5.1
Bucket dumping time • Hydraulic oil temp: 1.3 ± 0.3 Max. 1.9
• 45 - 55° C (113 - 131° F)
Speed
At full stroke • Engine speed: High idle Sec.

Standard • Steering valve: Neutral 1.5 ± 0.3 Max. 2.1
Bucket cylinder • No load
Work equipment
tilting
time Bucket horizontal
Standard 1.2 ± 0.3 Max. 1.8
cylinder
Retraction of boom cylinder • Hydraulic oil temp:

45 - 55° C (113 - 131° F) Max. 17 Max. 20
rod
• Leave for 5 minutes after
Hydraulic drift
stopping engine then

measure for next 15 mm
Retraction of bucket cylinder minutes
Max. 17 Max. 25
rod • Bucket empty, boom,
bucket horizontal
• No load
Clearance of bucket positioner switch 3-5 ---

Proximity
switch
• Hydraulic oil temp:

45 - 55° C (113 - 131° F) mm
Clearance of boom kick-out switch 3-5 ---
WA180-3MC 20-11 1
TESTING AND ADJUSTING SERVICE TOOLS TABLE
12
SERVICE TOOLS TABLE
Check or measurement item Symbol Tool Number Tool Description Remarks
Digital display (799-203-

1 799-203- 8001 Multi-tachometer 9000) L: 60-2000 rpm
R: 60-19999 rpm
Engine speeds A
2 6142-82-5112 Adapter See engine shop manual
3 795-790-2500 Adapter assembly See engine shop manual
Coolant & oil temperatures B 799-101-1502 Digital temperature gauge -99.9 - 1299° C
Pressure gauge
799-101-5002 Analog hydraulic tester 2.45, 5.88, 39.2, 58.8 Mpa
1 (25, 60, 400, 600 kgf/cm2)
Pressure gauge 0 - 68.6 Mpa

799-261-1203 Digital hydraulic tester
(0 - 700 kgf/cm2)
Oil pressure C
Pressure gauge 1.0 Mpa (10
2 790-401-2320 Hydraulic gauge
kgf/cm2)
790-261-1311 ---
3 Adapter
790-261-1321 ---
1 795-502-1590 Compression gauge 0 - 69 MPa (0-70 kgf/cm2)

Compression pressure D Kit part#: 799-502-1205
2 795-502-1370 Adapter ---
1 799-201-1511 Tool
2 799-201-1541 Gauge
3 799-201-1571 Tube
Kit part#: 799-201-1504
Blow-by pressure E 4 799-201-1411 Adapter
5 799-201-1460 Plug
6 799-201-1450 Adapter
7 795-790-1950 Nozzle 5.613 mm dia
Commercially
F Feeler Gauge ---
Valve clearance available
F1 795-799-1130 Gear ---
1 799-201-9000 Handy smoke detector Discoloration

Exhaust color G Commercially 0-70% w/ standard color
2 Smoke meter % x 1/10 Bosch index
available
Troubleshooting of wiring harness

H 799-601-7400 T-adapter kit ---
and sensors
Commercially
Operating Force I Push-pull scale ---
available
20-12 1 WA180-3MC
TESTING AND ADJUSTING SERVICE TOOLS TABLE
Check or measurement item Symbol Tool Number Tool Description Remarks
Commercially
Pushing force J Push gauge ---
available
Commercially
Stroke, hydraulic drift K Scale ---
available
1 793-605-1001 Brake test kit 6.9 Mpa (70 kgf/cm2)

Brake oil pressure L
2 790-101-1430 Coupler ---
Commercially
Measuring clearance O Feeler gauge ---
available
Commercially
Speed P Stop watch ---
available
Boom holding Q 793-463-1100 Stopper ---
Commercially
Pushing angle R Angle gauge ---
available
Commercially
Length measurement S Slide calipers ---
available
WA180-3MC 20-13 1
TESTING AND ADJUSTING ENGINE COMPONENTS
12
ENGINE COMPONENTS
Remark
To tune, test and troubleshoot the following procedures you must refer to ENGINE SHOP MANUAL for tools and
proper procedure.
ADJUSTING ENGINE STOP MOTOR CABLE
ADJUSTING ENGINE STOP SOLENOID
MEASURING AND ADJUSTING VALVE CLEARANCE
MEASURING BLOW-BY PRESSURE
MEASURING COMPRESSION PRESSURE
MEASURING COOLANT TEMPERATURE
MEASURING ENGINE LUBRICATING OIL PRESSURE
MEASURING ENGINE SPEEDS
MEASURING EXHAUST COLOR
MEASURING EXHAUST GAS TEMPERATURE
MEASURING FUEL FILTER INLET RESTRICTION
TEST AND ADJUSTING FAN BELT TENSION
TEST AND ADJUSTING FUEL INJECTION TIMING
20-14 1 WA180-3MC
TESTING AND ADJUSTING ACCELERATOR PEDAL
12
ACCELERATOR PEDAL
OPERATING FORCE
1. Measuring
A. Set push-pull scale I at a position 150 mm from pedal fulcrum a.

★ Put the center of the push-pull scale I in contact with a point
150 mm from the pedal fulcrum.
B. Start the engine then measure the maximum value when the pedal
is moved from the pushed position (low idling) to the end of its
travel (high idling).
2. Testing
A. Stop the engine.
B. Disconnect the cable (1) at the bottom of the accelerator pedal,

and check that the plate (2) and ball joint (3) at the bottom of the
pedal move smoothly.
★ Carry out the above inspection, and adjust or replace parts if
necessary. Then carry out the measurement of the operating
force again to check that it is within the standard value.
WA180-3MC 20-15 1
TESTING AND ADJUSTING ACCELERATOR PEDAL
12
OPERATING ANGLE
1. Measuring
A. Stop the engine.
B. Put angle gauge R in contact with the accelerator pedal, and

measure operating angle ∠ (∠∠ =∠∠ 1-∠
∠2) when the pedal is
operated from low idle position ∠1 to high idle position ∠ 2.
2. Adjusting
A. Open the inspection cover of the engine hood.
B. Set accelerator (1) to the FREE condition (lever (2) in contact

with U-bolt (3)), adjust cable (5) so that the governor lever (4) is
at the low idle position, then tighten nuts (6) and (7).
Locknuts (6), (7): 46.6 ± 12.3 Nm (34.3 ± 9.0 lbf ft)
Locknut (9): 3.9 ± 1.0 Nm (2.8 ± 0.73 lbf ft)
Mount nut (10): 13.2 ± 1.5 Nm (9.7 ± 1.1 lbf ft)
C. Keep accelerator pedal (1) depressed, then adjust stopper bolt (8)
so that the governor lever (4) is at the high idle position.
★ Screw in ball joint (3) at least 8 mm.
20-16 1 WA180-3MC
TESTING AND ADJUSTING SPEED LEVER
12
SPEED LEVER
★ Measurement conditions
Toque converter oil temperature: 60 - 80° C (140 - 176° F)
WARNING! Block the tires securely.
OPERATING FORCE
1. Stop the engine.
2. Install push-pull scale I or a spring balance to center of the control

lever knob, and measure the operating force when the lever is pulled in
the direction of operation.
★ Carry out the measurement for each speed range.
TRAVEL
1. Stop the engine.
2. Make mark a at the center of the control lever knob, and measure the
travel when the lever is operated in the direction of operation.
WA180-3MC 20-17 1
TESTING AND ADJUSTING STALL SPEEDS
12
STALL SPEEDS
• Engine water temperature: Within the white operating range on
the engine water temperature gauge.
• Hydraulic oil temperature: 45 - 55° C (113 - 131° F)
• Engine speed: High idle
• Torque converter oil temperature: 60 - 80° C (140 - 176° F)
WARNING! Apply the parking brakes and block the

tires
WARNING! When measuring each stall speed be

careful not touch any rotating part or parts
that are extremely hot.
★ Check that the low idle and high idle are the standard values.
★ Before measuring each stall speed, remove cover (1) from the
pickup port, install adapter A2 of tachometer A1, then connect the
tachometer A1 and the adapter with a cable.
★ Check that the engine speed is the standard value. If it is not

within the standard range, check for loose linkage or play.
TORQUE CONVERTER STALL SPEED

★ Before starting the operation, check that the tires are chocked and
release the parking brake.
1. Start the engine and run at low idle.
2. Place direction lever (4) at FORWARD OR REVERSE, and set speed

lever (3) to the highest position.
3. Use the brakes to stop the machine, then use multi-tachometer A1 to

measure the speed when the engine is at high idle.
★ Turn transmission cut-off selector switch (2) OFF and use the left
brake. (Check that the pilot lamp goes out.)
★ Do not keep the stall condition for more than 20 seconds. Make
sure that the torque converter oil temperature does not exceed
120° C (248° F).
20-18 1 WA180-3MC
TESTING AND ADJUSTING STALL SPEEDS
12
HYDRAULIC STALL SPEED
1. Start the engine and run at high idle.
2. Operate the bucket or boom lever (4), set the cylinder to the stroke
end, and activate the work equipment valve relief.
3. Use multi-tachometer A1 To measure the engine

★ Do not keep the stall condition for more than 20 seconds. Operate
the control lever quickly.
FULL STALL SPEED

• Measure the engine speed when the torque converter stall and the
hydraulic stall are both carried out at the same time.
★ Before measuring the full stall, check that the torque converter
stall and hydraulic stall speeds are normal. If either of the stall
speeds are abnormal, correct the problem and measure again.
WA180-3MC 20-19 1
TESTING AND ADJUSTING TORQUE CONVERTER OIL PRESSURE
12
TORQUE CONVERTER OIL PRESSURE
TRANSMISSION OIL PRESSURE

Remark
Torque converter/transmission oil pressure are the same.
• Engine water temperature: within white range on engine water
temperature gauge
• Torque converter oil temperature: 60 - 80° C (140 - 176° F)
WARNING! Apply the parking brake and put blocks

under the tires.
Preparatory Work
★ The following preparatory work is necessary when measuring all oil

pressures.
★ Before starting the operation, check that there are blocks under the
tires, then release the parking brake.
• Remove cover (1) on the left side of the rear frame.

• Turn transmission cut-off selector switch (2) OFF and use the left
brake. (Check that the pilot lamp is OFF.)
• Remove the plug from the measurement port of the transmission
valve.
• Install hydraulic tester kit C1 to the measurement port, extend the
gauge to the operator's compartment, then start the engine and
measure the pressure.
★ Check that no oil is leaking from any connection.

★ After removing the measurement plug, always coat the plug with
adhesive.
Plug: Sealing agent (LG-1)
20-20 1 WA180-3MC
TESTING AND ADJUSTING TRANSMISSION OIL PRESSURE
12
Measuring pilot pressure
1. Measurement port: 1
2. Start the engine and measure the pressure at high idling.
Measuring priority pressure
Measuring all clutch pressure
Measuring torque converter outlet port pressure
2. Start the engine and measure the pressure at torque converter stall.
Adjusting modulating time

Turn screw (A) to make the modulating time shorter or longer.
A. TIGHTEN screw to give PATTERN 1).
B. LOOSEN screw to give PATTERN 2).
★ The standard length is 6.75 mm (return fully, then screw in 4 1/2 turns).
★ Do not adjust excessively. After adjusting, always check that there is no abnormality in the pressure.
★ Keep the range of adjustment to within ± 1 turn.
WA180-3MC 20-21 1
TESTING AND ADJUSTING EMERGENCY MANUAL SPOOL
12
EMERGENCY MANUAL SPOOL
OPERATION
Outline
The transmission valve is controlled electrically, but if there should be any

failure in the electrical system, or if there is any failure in the solenoid
valve or spool and the machine cannot move, it is possible to operate the
emergency manual spool to move the machine.
WARNING! This operation of the spool is designed

only for use if the machine cannot be
moved because of a failure in the
transmission control, and it is necessary
to move the machine from a dangerous
working area to a safe place where
repairs can be carried out. This spool
must not be operated except when there
has been a failure.
WARNING! When carrying out this operation, keep

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

lower the bucket to the ground, apply the
parking brake, and put blocks under the
tires.
WARNING! Always stop the engine before operating

the spool.
1. Remove cover (1) from the left side of the rear frame.
2. Remove lock plate (2) from emergency manual spool (3) of the
transmission valve.
★ The lock plate can be removed simply by loosening the
mounting bolts.
3. Operate emergency spool (3) to the operating position according

to the direction of movement of the machine (forward or reverse).
★ FORWARD: Push in the spool until it enters the detent.
a = Approximately 8 mm
★ REVERSE: Pull the spool until it enters the detent.
b = Approximately 8 mm
4. Check that the area around the machine is safe, then remove the
blocks from under the tires.
20-22 1 WA180-3MC
TESTING AND ADJUSTING EMERGENCY MANUAL SPOOL
12
5. Sit in the operator’s seat and depress the left brake pedal (4) fully.
6. Start the engine, then release the parking brake and slowly let the
brake pedal out to start the machine.
WARNING! When the engine is started, the transmis-

sion is also engaged and the machine will
start, so always check carefully that the
area around the machine and in the
direction of travel is safe, and keep the
brake pedal depressed fully when starting
the engine.
7. After moving the machine, stop the engine, then apply the parking
brake and put blocks under the tires.
8. Return the manual spool to the neutral position and install the lock
plate.
WA180-3MC 20-23 1
TESTING AND ADJUSTING STEERING WHEEL
12
STEERING WHEEL
PLAY
Measuring steering wheel play
• Engine: Stopped.
• Vehicle posture: Facing straight.
Measuring procedure
1. Turn the steering wheel lightly clockwise and counterclockwise two or

three times to check that the steering mechanism is in neutral, then put
a mark "a" on the outer frame of the vehicle monitor.
2. Turn the steering wheel lightly clockwise, align the position where it
stops with mark "a", and place mark "b" on the steering wheel.
3. Turn the steering wheel lightly counterclockwise, align the position

where it stops with mark "a", and place mark "c" on the steering
wheel. Measure the straight distance "d" between mark "c" and the
position marked in step 2.
OPERATING FORCE
• Road surface: Flat, horizontal, dry paved surface
• Engine water temperature: within green range on engine water
temperature gauge
• Hydraulic oil temperature: 45 - 55° C (113-131° F)
• Tire inflation pressure: Specified pressure
• Engine speed: Low idling (bucket empty)
Measurement method.
1. Install push-pull scale I to the steering wheel knob.
2. Start the engine.

★ After starting the engine, raise the bucket approximately 400 mm
and remove the safety bar.
3. Pull push-pull scale I in the tangential direction and measure the value
when the steering wheel moves smoothly.
★ Avoid measuring when the steering wheel starts to move.
20-24 1 WA180-3MC
TESTING AND ADJUSTING STEERING WHEEL
12
OPERATING TIME

• Engine water temperature: Within green range on engine water
temperature gauge
• Hydraulic oil temperature: 45 - 55° C (113-131° F)
• Engine speed: Low and high idle
Measurement method

★ After starting the engine, raise the bucket approximately 400 mm
and remove the safety bar.
2. Operate the steering wheel (1) to the end of its stroke to turn the
machine to the left or right.
3. Measure the time taken to operate the steering wheel to the end of the
stroke to the right (left).
★ Operate the steering wheel as quickly as possible without using

force.
★ Carry out the measurements both at low idling and high idling,
and to both the left and right.
WA180-3MC 20-25 1
TESTING AND ADJUSTING STEERING OIL PRESSURE
12
STEERING OIL PRESSURE
Measurement conditions
• Hydraulic oil: 45 - 55° C (113 - 131° F)

• Engine speed: High idling
METHOD OF MEASURING MAIN RELIEF

PRESSURE
WARNING! Loosen the oil filler cap to release the

pressure inside the hydraulic tank, then
turn the steering wheel several times to
release the remaining pressure inside the
piping.
1. Fit safety bar (1) to the frame.
2. Remove cover (3) at the bottom right of floor frame (2).
3. Remove measurement plug (4) for the right turn steering circuit.
4. Install hydraulic tester kit A1 to the measurement port.
5. Start the engine, run the engine at high idle, then turn the steering
wheel to the right and measure the pressure when the relief valve is
actuated.
★ To measure the pressure when turning the steering wheel to the

left, remove the plug (5)for the left turn steering circuit.
20-26 1 WA180-3MC
TESTING AND ADJUSTING STEERING OIL PRESSURE
12
METHOD OF ADJUSTING MAIN RELIEF
PRESSURE
WARNING! Always stop the engine before adjusting

the pressure.
1. Stop the engine.
2. Remove hose (2) and fitting (3) connected to port T of the priority
valve (1).
3. Remove double screw (4).
4. Then turn adjustment screw (5) to adjust

★ Pressure adjustment for one turn of adjustment screw:
Approximately 70 kgf/cm2 (995.6 lbf/in2)
★ Turn the adjustment screw to adjust the set pressure as follows.
TIGHTEN to INCREASE pressure.
LOOSEN to DECREASE pressure.
★ Tool 1 for adjusting adjustment screw: Size 7/32 inch, hexagonal.
★ Do not carry out any adjustment if the relief pressure cannot be
measured accurately.
Adjustment screw (5): 4.5 ± 2.3 Nm (3.31 ± 1.69 lbf ft)
Double screw (4): 14.7 ± 2 Nm (10.8 ± 1.47 lbf ft)
WA180-3MC 20-27 1
TESTING AND ADJUSTING BRAKE
12
BRAKE
BRAKE PEDAL
• Engine water temperature: Within white range on engine water
temperature gauge
• Engine speed: Low idle
OPERATING FORCE
1. Install push gauge J to the operator's foot.
2. Align the center of the push gauge with a point 150 mm from
the fulcrum of the pedal.
3. Start the engine, run at low idle, and measure the operating effort when
the pedal is depressed
TRAVEL
1. Install push gauge J to the operator's foot.

★ Align the center of the push gauge "a" with a point 150 mm from
the fulcrum of the pedal.
2. Start the engine and measure the pedal angle when running at low idle
with a pedal depressed with a force of 206 N (46.31 lbf).
3. Next, place angle meter R on the pedal and measure angle "∠∠"with a
pushing a force of 206 N (46.31 lbf).
It is also possible to measure ∠1 and ∠2 and calculate ∠ = ∠1 - ∠2
20-28 1 WA180-3MC
12
BRAKE PEDAL LINKAGE
TESTING
1. Check for play in linkage mounting pin (1), pin hole of lever (2), and
lever bushing.
2. Measure length "X1" of rod and check that it is within the standard
value.
★ Standard length of rod "X1": 206 mm
★ Measure the length from the center of pin (1) to the center of ball
joint (6a).
3. Measure the distance of movement of rod (8) and check that clearance
"a" is within the standard value.
★ Standard clearance "a": 0 - 0.7 mm
★ When doing this, check that the brake pedal is in contact with the
stopper.
ADJUSTING
1. Adjusting link "X1"
A. Remove pin (1) and ball joint (6a), remove rod and loosen locknut
(5), then turn yoke (6) and ball joint (6a) to adjust the length.
B. After adjusting the length of rod "X1", connect it to the brake

pedal.
WA180-3MC 20-29 1
12
2. Adjusting rod "X2"
A. Loosen locknut (7), turn rod (8) so that tip C of rod contacts the
master cylinder piston, then turn rod (8) back 1/4 turn.
★ Standard length of rod "X2": 154.3
★ Movement for ½ turn of rod: 0.75 mm
B. Tighten locknut (7) to hold in position.
3. Adjusting transmission cut-off switches (left pedal)
A. Loosen mounting screw of switch (9) and adjust switch (9) so that
protrusion of the tip of the switch from the end face of the trans-
mission cut-off switch plate is dimension "b".
★ Dimension "b": 1.1 - 1.9 mm
★ When doing this, check that the switch is ON.
B. To adjust the cut-off timing, adjust plate (10) so that the dimen-
sion "d" from the center of the stopper bolt of plate (10) to the end
face of plate (10) is 24 mm.
★ When doing this, check that plate (10) contacts portion "e" of
the switch plate.
★ Adjust with the pedal in the FREE condition.
4. Adjusting Stop lamp switch (right pedal)

Adjust with mount nut (11) of stop lamp switch (12).
Adjust with nuts (11) so that the tip of the switch is dimension: "f".
★ Dimension "f": 3.5 - 5.0 mm
When doing this, check that the switch is OFF.
Adjust with the pedal in the FREE condition.
20-30 1 WA180-3MC
12
BRAKE PERFORMANCE
• Travel speed: 20 km/h (12.4 mi/h) when brakes are applied
• Delay in applying brakes: 0.1 sec.
Measurement method
1. Start the engine and move the machine.
2. Set the speed lever to the highest speed position and drive the machine.
3. When the travel speed reaches 20 km/h (12.4 mi/h), depress the left brake pedal with the specified operating force.
Specified operating force: 294 N (66.09 lbf)
★ Before carrying out this operation, determine the run-up path and the point for applying the brakes, then apply the
brakes when the machine reaches that point.
4. Measure the distance from the point where the brakes were applied to the point where the machine stopped.
★ Repeat this measurement three times and take the average.
WA180-3MC 20-31 1
12
BRAKE OIL PRESSURE
temperature gauge
• Brake pressure: 42 kgf/cm2 (597.38 lbf/in2)

under the tires.
Measuring
1. Raise the boom, set support 1A or tool Q in position, then remove

front cover (1).
2. Stop the engine.

★ When leaving the operator's seat, apply the lock to the work
equipment control levers securely.
3. Remove brake tube (2) on the side to be measured, then remove

adapter (3).
4. After removing the adapter, install tool L1, L2.

★ Connect the quick coupler of tool L1, L2.
5. Loosen bleeder screw (4) and bleed the air.

★ Operate pump 2 to bleed the air.
6. Tighten the bladder screw, operate pump 2, raise the pressure to 42

kgf/cm2 (597.38 lbf/in2), then tighten stop valve 3.
7. After applying the pressure, leave for 5 minutes and measure the drop
in the pressure.
★ If the hose is moved while measuring the pressure, the pressure

will change, so do not move the hose.
★ When removing hydraulic test kit L1, L2 after testing, operate
pump 2 to lower the pressure of L1, L2, then remove it.
★ After completing the operation, install the brake tube, then bleed
the air from the brake circuit.
20-32 1 WA180-3MC
12
BRAKE DISC WEAR
WARNING! Apply the parking brake and chocks

under the tires.
Measuring
1. Loosen drain plug (1) and drain the axle oil.
Axle oil: 14 L (3.69 gal)
2. Install measuring plug (2).
3. Lightly press the brake pedal.

★ Check that plate (4) and plate (5) are in tight contact with disc (3).
Insert feeler gauge O between disc (3) and plate (4), and measure the
clearance.
4. Fasten the drain plug and supply axle oil to the specified level through
the oil supply port.
WA180-3MC 20-33 1
12
BLEEDING AIR
under the tires.
Procedure
1. Raise the boom, set support 1A or boom drop prevention stopper Q in

position, then remove front cover (1).
2. Remove cap (2) of the bleeder screw, insert vinyl hose (3) into the
screw, and insert the other end in a container.
4. Depress the brake pedal, then loosen the bleeder screw and bleed the
air. Keep the brake pedal depressed, tighten the bleeder screw, then
release the brake pedal slowly.
★ Add brake oil when necessary during the operation to keep brake
oil tank full.
5. Repeat this operation, and when no more bubbles come out with the
fluid from the hose, depress the pedal fully and tighten the bleeder
screw while the oil is still flowing.
★ Repeat the operation to bleed the air from the other cylinders, and
after completing the operation, check the level in the oil tank and
add more oil if necessary.
★ To bleed the air completely, bleed the air first from the cylinder
which is farthest from the brake pedal.
★ After bleeding the air, carry out a brake performance test then
bleed the air again and check that there is no air in the circuit.
20-34 1 WA180-3MC
TESTING AND ADJUSTING PARKING BRAKE
12
PARKING BRAKE
PARKING BRAKE PERFORMANCE

• Road surface: Flat, dry paved road surface with slope of 1/5 grade
(11° 20').
• Machine: Operating condition
• Operating effort: 392.3 N (88.19 lbf)
Measurement method
1. Start the engine, set the machine facing in a straight line, then drive the
machine up a 1/5 grade slope with the bucket empty.
2. Depress the brake, stop the machine, set the directional lever to the
neutral position, then stop the engine.
3. Depress the parking brake pedal, then gradually release the brake
pedal and check that the machine is held in position.
★ Carry out the measurement in two ways: Once with the machine
facing uphill, and once more with the machine facing downhill.
WA180-3MC 20-35 1
12
PARKING BRAKE LINKAGE

under the tires.
Testing
Depress the parking brake pedal with a force of approximately 294 N
(66.13 lbf). If the travel of brake pedal is more than 13 clicks, check for
looseness of the control cable mount (pedal end and brake end). If any
looseness is found, tighten and then adjust as follows.
Adjusting linkage
1. Pull release lever (1) and release the parking brake.
2. Loosen locknut (2) and remove clevis pin (4).
3. Set lever (5) at the parking brake end in the release position.
★ With lever (5) at the FREE position, move the link up by the
amount of play.
4. Screw in clevis (3), align the hole with the pin hole in lever (5) at the
parking brake end, then assemble clevis pin (4) and tighten locknut
(2).
5. After adjusting, depress parking brake pedal (6) with a force of

approximately 294 N (66.13 lbf), and check that the travel of the pedal
is 7 - 11 clicks.
If it is impossible to adjust only at parking brake end
6. Loosen locknut (7) at pedal (6) end, then remove clevis pin (9).
7. Screw in clevis (8) and adjust so that the mounting dimension is "X".
★ Standard dimension "X": 148 mm
Adjusting parking brake switch
1. Adjust with nut (11) so that the mounting dimension at the tip of park-
ing brake switch (10) is "c".
★ Mounting dimension "c" of switch: 4 - 6 mm
★ When doing this, check that the parking brake switch is OFF.
20-36 1 WA180-3MC
12
DISC WEAR
WARNING! Stop the machine on level ground, install
the safety bar to the frame, lower the
bucket to the ground, stop the engine,
then apply the parking brake and put
blocks under the wheels.
★ Check that there are blocks under the tires.
★ Carry out this operation with the drive shaft still installed.
TESTING
1. Check that the parking brake is applied.
2. Remove plug (1).

• Width across flats of hexagon wrench: 6 mm
3. Insert calipers S into the measurement port (2) and measure

dimension "a" from end face "c" of the cover (3) to the piston (4).
4. Release the parking brake.
5. Insert calipers S into the measurement port (2), and measure

dimension "b" from end "c" face of the cover (3) to the piston (4).
• Piston stroke X = "a" - "b"
If X is 3.5 mm, the brake disc is worn and must be replaced.
★ For details of method of replacing the brake disc, see
DISASSEMBLY AND ASSEMBLY OF TRANSMISSION.
★ After measuring, check the transmission oil level.
WA180-3MC 20-37 1
12
WARNING! Put blocks under the tires.
★ If the braking effect is poor, or if the transmission has been over-

hauled, measure the wear of the parking brake disc.
★ For details of method disassembling and assembling the parking brake
see DISASSEMBLY AND ASSEMBLY OF TRANSMISSION.
MEASURING
To measure the thickness of brake disc (1), check that dimension "w" is
greater than the value given below.
★ Dimension "w": Min. 1.97 mm
★ For details of the procedure for adjusting the parking brake linkage,
see PARKING BRAKE PEDAL, TESTING AND ADJUSTING.
20-38 1 WA180-3MC
TESTING AND ADJUSTING WORK EQUIPMENT
12
WORK EQUIPMENT
CONTROL LEVER
• Engine water temperature: Within green range on engine water
temperature gauge.
• Engine speed: Low idling.
WARNING! Install the safety bar to the frame.
Measurement method
1. Operating effort
Install tool I to the work equipment control lever and measure the
operating force.
★ Install tool I to the center of the knob.
★ Operate the control lever at the same speed as for normal
operations, and measure the minimum value for the force needed
to operate the knob.
2. Travel
Measure travel at each position when operating the work equipment
control lever.
★ Mark the lever knob and use scale to measure.
★ If the travel is not within the standard valve, check for play of the linkage and wear of the bushing.
WA180-3MC 20-39 1
12
PPC VALVE
MEASURING PRESSURE
• Engine coolant temperature: Within engine coolant temperature
gauge green range
• Hydraulic oil temperature: 45° - 55° C (113° - 131° F)
WARNING! Apply the parking brake and chock the

tires.
Measuring
1. Raise boom (1), set boom prop (2), set the bucket to an angle of
approximately 45° (not to maximum dump position) and remove front
cover (3).
WARNING! Set the boom support securely.
2. Stop the engine, loosen the oil supply cap, release the pressure inside
the hydraulic tank, then stroke the bucket control lever between the tilt
and neutral positions at least 40 times to completely release the accu-
mulator pressure.
★ Be sure to stop the engine before operating the lever.
★ After the accumulator pressure is completely released, set the
bucket lever to the dump position and check that the bucket does
not dump.
3. Remove the work equipment dump cylinder circuit pressure

measurement hose.
4. Install the hydraulic test kit C to the measuring port.

• Connect the hose after installing the hydraulic test kit 90° elbow
to the measuring port.
• Check that there is no oil leakage from any joints.
• Use a hose which is long enough to reach the operator’s seat.
5. Start the engine, raise the boom 400 mm (15.75 in), tilt back the
bucket using the control lever and measure the pressure when the relief
valve is activated.
• Be careful not to apply any sudden pressure to the pressure gauge.
WARNING! When removing the hydraulic pressure gauge, release the pressure inside the circuit in
the same way as when installed.
20-40 1 WA180-3MC
12
Adjusting
WARNING! If it is impossible to measure the relief

pressure accurately, DO NOT try to adjust
the pressure.
WARNING! Always stop the engine before adjusting

the hydraulic pressure.
1. Stop the engine and remove the covers.
2. Remove the cap nut (2) of the relief valve.
3. Loosen the locknut (3), then turn the adjustment screw (4) to adjust.
A. One turn of the adjustment screw changes the pressure by about

9.8 kgf/cm2 (139.3 lbf in).
B. Turn the adjustment screw to adjust as follow:

To INCREASE pressure, TIGHTEN SCREW.
To DECREASE pressure, LOOSEN screw.
WA180-3MC 20-41 1
12
WORK EQUIPMENT HYDRAULIC PRESSURE
temperature gauge
• Engine speed: High idling
Work equipment relief valve pressure measuring procedure
WARNING! Loosen the oil filler cap slowly to release

the pressure inside the hydraulic tank.
Then operate the control levers several
times to release the remaining pressure in
the hydraulic piping.
1. Remove plug (1) for measuring the hydraulic pressure in the

bucket cylinder circuit.
2. Install tool C1 400 kgf/cm2 (5689.34 lbf/in2) to the

measurement port.
★ Check that there is no oil leakage from any joints.
★ Use a hose which is long enough to reach the operator’s compartment.
3. Start the engine, raise the boom about 400 mm (15.75 in), run the engine at high idling, then operate the control lever to
tilt back the bucket, and measure the pressure when the relief valve is actuated.
★ Be careful not to apply any sudden pressure to the pressure gauge.
WARNING! When removing the hydraulic pressure gauge, release the pressure inside the circuit in
the same way as when it was installed.
20-42 1 WA180-3MC
12
Adjusting
WARNING! Always stop the engine when adjusting

the oil pressure.

under the tires.
1. Raise the boom, set support 1A or tool Q in position, then remove

front cover (1).
2. Remove cap nut (2) at control valve (3).
3. Loosen lock nut (4), then turn adjust screw (5) to adjust.
★ Pressure adjustment for one turn of adjustment screw:
Approximately 24.8 kgf/cm2 (352.7 lbf/in2)
★ Turn the adjustment screw to adjust the set pressure as
follows.
TIGHTEN to INCREASE pressure
LOOSEN to DECREASE pressure
★ Do not carry out any adjustment if the relief pressure cannot be
measured accurately.
WA180-3MC 20-43 1
12
WORK EQUIPMENT MEASUREMENT
temperature gauge
• Steering position: Neutral
• No load
Measurement method
1. Boom RAISE time

Set the bucket at the lowest position from the ground with the bucket
tilted back fully, then raise it and measure the time taken for the bucket
to reach the maximum boom height.
2. Boom LOWER time

Set the bucket horizontal, then lower the boom from the maximum
height and measure the time taken for the bucket to reach the lowest
position from the ground.
3. Bucket DUMP time

Raise the boom to the maximum height, and measure the time taken to
move the bucket from the tilt position (bucket fully tilted back) to the
dump position (bucket fully tipped forward).
4. Bucket TILT time
A. Raise the boom to the maximum height, and measure the time
taken to move the bucket to the tilt position (bucket fully tilted
back).
B. Set the bucket horizontal to the ground and measure the time
taken to move the bucket from the horizontal position to the tilt
position (bucket fully tilted back).
20-44 1 WA180-3MC
12
HYDRAULIC DRIFT WORK EQUIPMENT
• Engine water temperature: Within white range on engine water temperature gauge.
• Stop the engine, leave for 5 minutes, then measure for 15 minutes.
• Boom: Horizontal
• Bucket: Horizontal
• No load
WARNING! Apply the safety lock to the work equip-

ment control levers.
WARNING! Never go under the work equipment.
Measurement method
1. Set the boom and bucket in a horizontal position, then stop the engine.
2. Leave for 5 minutes, then start the measurement.
3. Wait for 15 minutes, then measure retraction amount A of the bucket

cylinder rod and retraction amount B of the boom cylinder rod.
A: Retraction amount of bucket cylinder rod

B: Retraction amount of boom cylinder rod
WA180-3MC 20-45 1
12
BUCKET POSITIONER
temperature gauge.
TESTING
1. With the engine stopped, check that clearance between switch (1) and
bar (2) is the standard value.
2. Start the engine, run at high idle and check the actuation position.
(Check three times and take the average value.)
ADJUSTING
1. Lower the bucket to the ground, operate the bucket to the desired
digging angle, then return the lever to HOLD and stop the engine.
2. Adjust so that clearance between bracket (3) and detection bar (2) is
"a", then secure in position.
★ Clearance "a": 0.5 - 2.0 mm (0.19 - 0.078 in)
3. Secure support (4) to bucket cylinder bracket so the tip of detection bar
(2) is in line with the center of the switch sensing surface.
4. Adjust the switch so the clearance between the switch sensing surface
and detection bar (2) is "b" then secure in position.
Switch mount nut: 17.7 ± 2 Nm (13.05 ± 1.47 lbf ft)
★ Clearance: "b" 3 - 7 mm (0.118 - 0.275 in)

(The clearance must be less than 7 mm, and there must be no
interference between the switch and detection bar (plate)
★ After adjusting, operate the bucket lever and check that the bucket
positioner is actuated at the desired position.
20-46 1 WA180-3MC
12
BOOM KICK-OUT (IF EQUIPPED)
temperature gauge.
TESTING
1. Stop the engine, and check that the clearance between switch (1) and
plate (2) is the stand value.
2. Start the engine, run at high idle, and check the actuation position.
(Check three times and take the average value.)
ADJUSTING
1. Raise the boom the desired position and mark it at the position where
the center of the switch is at lower end of the plate.
2. Adjust the position of the plate so that the center of the switch (1) is in
line with the bottom of plate (2), then secure in position.
Plate mount nut: 88.3 ± 34.3 Nm (65.12 ± 25.29 lbf ft)
3. Adjust the switch (1) so that the clearance "a" between the switch
(1) sensing surface and plate (2) is the standard value, then secure the
switch in that position.
WA180-3MC 20-47 1
12
PROXIMITY SWITCH ACTUATION PILOT
LAMP (RED)
The proximity switch is equipped with a pilot lamp which shows when it is
being actuated, so use this when adjusting.
20-48 1 WA180-3MC
TROUBLESHOOTING
GENERAL
POINTS TO REMEMBER WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-103

SEQUENCE OF EVENTS IN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-105
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-106
HANDLING CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . 20-112
CHECKS BEFORE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-114
JUDGEMENT OF POWER TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-115
PRECAUTIONS WHEN TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
METHODS FOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-116
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING
PARTS DURING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-118
PREVENTING RECURRENCE OF TROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
HYDRAULIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
OIL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
CLEANING FRAGMENTS OF DAMAGED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-119
METHOD OF USING TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
CATEGORY OF TROUBLESHOOTING CODE NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH
TROUBLESHOOTING MODE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120
METHOD OF USING MATRIX TROUBLESHOOTING TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-122
METHOD OF USING ENGINE RELATED CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-124
WA180-3MC 20-101 1
TROUBLESHOOTING
12
MEMORANDUM
20-102 1 WA180-3MC
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
12
POINTS TO REMEMBER WHEN TROUBLESHOOTING
WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking brake
are securely fitted.
WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, water or
air, always release the internal pressure first. When installing measuring equipment, be
sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence
of the failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However, a
short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure
that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled
immediately after a failure occurs:
• Parts that have no connection with the failure or other unnecessary parts will be disassembled.
• It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of the
user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out a thorough prior
investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator.
A. Have any other problems occurred apart from the problem that has been reported?
B. Was there anything strange about the machine before the failure occurred?
C. Did the failure occur suddenly, or were there problems with the machine condition before this?
D. Under what conditions did the failure occur?
E. Had any repairs been carried out before the failure? When were these repairs carried out?
F. Has the same kind of failure occurred before?
3. Check before troubleshooting.
WA180-3MC 20-103 1
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
A. Check the oil level.
B. Check for any external leakage of oil from the piping or hydraulic equipment.
C. Check the travel of the control levers.
D. Check the stroke of the control valve spool.
E. Other maintenance items can be checked externally, so check any item that is considered to be necessary.
4. Confirming the failure.
A. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the
method of operation, etc.
★ When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or
measurement that may make the problem worse.
5. Troubleshooting
A. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the
troubleshooting flowchart to locate the position of the failure exactly.
B. The basic procedure for troubleshooting is as follows.
i. Start from the simple points.
ii. Start from the most likely points.
iii. Investigate other related parts or information.
6. Measures to remove root cause of failure.
A. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again.
B. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
20-104 1 WA180-3MC
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
12
SEQUENCE OF EVENTS IN TROUBLESHOOTING
WA180-3MC 20-105 1
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
12
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to pre-
vent failures or other troubles before they occur, correct operation, mainte-
nance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mecha-
tronics and is aimed at improving the quality of repairs. For this purpose, it
gives sections on 'Handling electric equipment' and 'Handling hydraulic
equipment' (particularly hydraulic oil).
PRECAUTIONS WHEN HANDLING ELECTRIC

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

(faulty contact between male and female).
Problems with faulty contact are likely to occur because the male
connector is not properly inserted into the female connector, or
because one or both of the connectors is deformed or the position
is not correctly aligned, or because there is corrosion or oxidation
of the contact surfaces.
B. Defective compression or soldering of connectors

The pins of the male and female connectors are in contact at the
compressed terminal or soldered portion, but there is excessive
force on the wiring, and the plating peels to cause improper
connection or breakage.
20-106 1 WA180-3MC
12
C. Disconnections in wiring
If the wiring is held and tugged and the connectors are pulled
apart, or components are lifted with a crane with the wiring still
connected, or a heavy object hits the wiring, the crimping
compression of the connectors to the wire may be loosened, or the
soldering may be damaged, or the wiring may be broken.
D. High pressure water entering a connector

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

If oil or grease are stuck to the connector and an oil film is formed
on the mating surface between the male and female pins, the oil
will not let the electricity pass, and this will cause a defective
contact.
If there is oil or grease or dirt stuck to the connector, wipe it off
with a dry cloth or blow dry with air, and spray it with a contact
restorer.
★ When wiping the mating portion of the connector, be careful
not to use excessive force or deform the pins.
★ If there is water or oil present, it will increase the
contamination of the points, so clean with air until all water
and oil has been removed.
WA180-3MC 20-107 1
12
3. Removing, installing, and drying connectors and wiring harnesses.
A. Disconnecting connectors
i. Hold the connectors when disconnecting.

When disconnecting the connectors, hold the connectors and
not the wires. For connectors held by a screw, loosen the
screw fully, then hold the male and female connectors in each
hand and pull apart. For connectors which have a lock
stopper, press down the stopper with your thumb and pull the
connectors apart.
ii. When removing the connectors from the clips, pull the
connector in a parallel direction to the clip.
★ If the connector is twisted to the left and right or up and
down, the housing may break.
iii. When disconnecting male and female connectors, release the

lock and pull in parallel with both hands.
★ Never try to pull apart with one hand.
20-108 1 WA180-3MC
12
iv. Action to take after removing connectors.
After removing any connector, cover it with a vinyl bag to
prevent any dust, dirt, oil, or water from getting in the
connector portion.
B. Connecting connectors
i. Check the connector visually.

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

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

the wiring harness.
For connectors fitted with boots, correct any protrusion or the
boot. In addition, if the wiring harness is misaligned, or the
clamp is out of position, adjust it to its correct position.
★ When blowing with dry air, there is danger that the oil in
the air may cause improper contact, so clean with prop-
erly filtered air.
WA180-3MC 20-109 1
12
iv. When the wiring harness clamp of the connector has been
removed, always return it to its original condition and check
that there is no looseness of the clamp.
C. Drying wiring harness

If there is any oil or dirt on the wiring harness, wipe it off with a
dry cloth. Avoid washing it in water or using steam. If the
connector must be washed in water, do not use high pressure
water or steam directly on the wiring harness. If water gets
directly on the connector, do as follows:
i. Disconnect the connector and wipe off the water with a dry
cloth.
★ If the connector is blown dry with air, there is the risk that
oil in the air may cause a faulty contact, so avoid
blowing with air.
ii. Dry the inside of the connector with a dryer.

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

After drying, leave the wiring harness disconnected and carry
out a continuity test to check for any short circuits between
pins caused by water.
★ After completely drying the connector, spray it with con-

tact restorer and reassemble.
20-110 1 WA180-3MC
12
HANDLING CONTROL BOX
1. The control box contains a microcomputer and electronic control
circuits.
This controls all of the electronic circuits on the machine, so be
extremely careful when handling the control box.
2. Do not open the cover of the control box unless necessary.
3. Do not place objects on top of the control box.
4. Cover the control connectors with tape or a vinyl bag.
5. Do not leave the control box in a place where it is exposed to rain.
6. Do not place the control box on oil, water, or soil, or in any hot place,
even for a short time.
(Place it on a suitable dry stand)
7. Precautions when carrying out arc welding

When carrying out arc welding on the body, disconnect all wiring har-
ness connectors connected to the control box. Fit an arc welding
ground close to the welding point.
WA180-3MC 20-111 1
12
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the
most common cause of failure is dirt (foreign material) in the hydraulic
circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

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

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

After any piping or equipment is removed, the openings should be
sealed with caps, tape, or vinyl bags to prevent any dirt or dust from
entering. Never leave any openings opened or blocked with a rag, this
could cause particles or dirt to get into the system.
Drain all oil into a container and not unto the ground and be sure to
follow the proper environmental regulation for any disposal of oil.
4. Do not let any dirt, or dust get in during refilling operations.

Be careful not to let any dirt or dust get in when refilling with
hydraulic oil. Always keep the oil filler and the area around it clean,
and also use clean pumps and oil containers. If an oil cleaning device
is used, it is possible to filter out the dirt that has collected during
storage, so this is an even more effective method.
20-112 1 WA180-3MC
12
5. Change hydraulic oil when the temperature is high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the
sludge can also be drained out easily from the circuit together with the
oil, so it is best to change the oil when it is still warm. When changing
the oil, as much as possible of the old hydraulic oil must be drained
out. (Do not drain the oil from the hydraulic tank; but drain the oil
from the filter and from the drain plug in the circuit.) If any old oil is
left, the contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6. Flushing operations
After disassembling and assembling the equipment, or changing the
oil, use flushing oil to remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary flushing is carried out
with flushing oil, and secondary flushing is carried out with the
specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump, control valve, etc.) or
when running the machine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove the ultra fine (about 3µ)
particles that the filter built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
WA180-3MC 20-113 1
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
12
CHECKS BEFORE TROUBLESHOOTING
Item Judgement Remedy

standard
1. Check fuel level, type of fuel - Add fuel
Lubricating oil, cooling water
2. Check for impurities in fuel - Clean, drain

3. Check hydraulic oil level - Add oil
4. Check hydraulic filter (Torque converter, transmission oil) - Replace
5. Check brake oil level - Add oil
6. Check engine oil level - Add oil
7. Check coolant level - Add coolant
8. Check dust indicator for clogging - Clean or replace
9. Check for looseness, corrosion of battery terminal, wiring - Tighten or replace
equipment
Electrical
10. Check for looseness, corrosion of alternator terminal, wiring - Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, wiring - Repair or replace
12. Check operation of instruments - Repair or replace
13. Check for abnormal noise, smell - Repair
mechanical
Hydraulic,
equipment
14. Check for oil leakage - Repair

15. Carry out air bleeding - Bleed air
16. Check effect of parking brake, wheel brake - Adjust, repair or

replace
17. Check battery voltage (engine stopped) 23 - 26 V Repair or replace
18. Check battery electrolyte level - Add or replace
19. Check for discolored, burnt, exposed wiring - Repair or replace
Electrical equipment
20. Check for missing wiring clamps, hanging wire - Repair

21. Check for water leaking on wiring (pay particular attention to Disconnect
water leaking on connectors or terminals) - connector and dry
22. Check for blown, corroded fuses - Replace
23. Check alternator voltage (engine running at 1/2 throttle or above)
(If the battery charge is low, the voltage may be approximately. 25V Check, repair or
27.5 - 29.5 V replace
immediately after charging
24. Sound of actuation of battery relay
(when starting switch is turned ON, OFF - Replace
20-114 1 WA180-3MC
TROUBLESHOOTING JUDGEMENT OF POWER TRAIN
12
JUDGEMENT OF POWER TRAIN
To judge if any abnormality in the power train is in the electrical system of the transmission or in the transmission itself, use
the following judgement flow chart. If the abnormality is in the electrical system, carry out troubleshooting for E-5, and if the
abnormality is in the transmission system, go to troubleshooting T-1 - T-4.
Testing transmission solenoid
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower
the bucket to the ground and stop the engine. Then apply the parking brake and
put blocks under the wheels to prevent the machine from moving.
1. Install a T-adapter checker to connector CNFT1, and check the voltage between the connector pins and the chassis ground.
2. Turn the start switch ON.

★ Do not start the engine under any circumstances.
3. Turn the parking brake switch ON ➞ OFF (release).
4. When using the foot brake, press the right brake so that the transmission cut-off is not turned off.
WA180-3MC 20-115 1
TROUBLESHOOTING PRECAUTIONS WHEN TROUBLESHOOTING
12
PRECAUTIONS WHEN TROUBLESHOOTING
SAFETY
WARNING! Stop the machine on level ground, and check that the safety pins and parking brake are
correctly applied, and that the tires are blocked.
WARNING! When working in groups, use agreed upon signals and do not allow unauthorized per-
sons near machine.
WARNING! Be careful not to get burned by hot parts or get caught in rotating parts.
WARNING! Always disconnect the cable from the negative (-) terminals of the battery before discon-
necting any wiring.
WARNING! Always release the pressure before removing the plugs or caps of any place under
hydraulic or air pressure, and connect all measuring tools correctly.
METHODS FOR TROUBLESHOOTING

★ Just because a failure occurs, do not immediately start to disassemble the machine.
• The machine may be disassembled in such a way that the problem cannot be located, so the cause of the problem will be
unknown.
As a result,
• The customer and operator will lose confidence in you.
• Time will be wasted, and unnecessary costs will be incurred for excess parts and greasing.
To avoid these problems, use the following procedure when troubleshooting.
1. Ask the customer and operator the following questions about the breakdown.
A. Was there anything unusual before the machine broke down?
B. Have there been any other problems apart from the one reported?
C. Did the breakdown occur suddenly, or had there been signs of trouble before?
D. What was the machine doing when break down occurred?
E. Had the machine been repaired before the breakdown? If so, who carried out the repair, and when?
F. Had the same kind of failure occurred before?
2. Check the following items which can be checked simply by visual checks etc.
A. Check oil level.
B. Check for leakage of oil from piping or hydraulic equipment.
C. Check travel of control levers.
D. Check stroke of spool in control valves.
20-116 1 WA180-3MC
3. Reenact the failure and check the condition of the machine (particular conditions at the time of failure).
A. Ask the user or operator if the decision about the failure was made based on measured values, or by comparison, or
by feeling.
B. Compare extent of failure with standard values.
C. Check safety before carrying out any check.
D. Did not make any check or measurement that will make the condition worse.
4. Try to locate the possible causes for the failure.

The transmission system consists of the transmission itself, the transmission control valve, and the transmission electrical
control.
In particular, when trouble occurs in the transmission system, the probable location of the failure can be divided as
follows;
• Transmission itself, or transmission control valve.
• Transmission electric control.
• To decide which of the two is the location of the failure, refer to “JUDGMENT ON POWER TRAIN”.
5. Carry out troubleshooting using the troubleshooting charts.

There are the following two types of troubleshooting charts.
A. TROUBLESHOOTING TABLE
POWER TRAIN
STEERING SYSTEM
BRAKE AND AIR SYSTEM
WORK EQUIPMENT SYSTEM
B. TROUBLESHOOTING FLOW CHART

ELECTRICAL SYSTEM
The troubleshooting charts consist of:
i. Items which can be checked easily.
ii. Items which are likely to be the cause of such failures.
Follow theses charts to carry out troubleshooting. At the same time, do not forget the following points.
• Check related items.
• Check that there are no other failures or breakdowns.
6. Investigate causes of breakdown

• Even if the breakdown is repaired, if the original cause of the problem is not removed, the same breakdown will occur
again. To investigate and remove the original cause, see "Actions to take to prevent failures from occurring again".
WA180-3MC 20-117 1
12
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR
ASSEMBLING PARTS DURING TROUBLESHOOTING
Carry out the various testing and adjusting while observing the items on quality control given in "Testing and Adjusting".
When removing parts, check their condition of mounting, and distinguish between front and rear, left and right, and top and
bottom.
Check the match marks, or make match marks to prevent mistakes when installing.
If part cannot be removed even when the nuts and bolts have been removed, do not use excessive force to remove it. Check the
part to see if there is any problem with it and remove the problem before trying to disassemble the part.
When installing or assembling, clean off all dust and dirt and repair any scratches or dents. Remove all grease or oil before
coating with gasket sealant.
20-118 1 WA180-3MC
TROUBLESHOOTING PREVENTING RECURRENCE OF TROUBLE
12
PREVENTING RECURRENCE OF TROUBLE
• The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of equipment.
However, it is not able to establish the root cause of the damage or failure.
• Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not mention
what action should be taken to prevent a recurrence of the root cause.
• In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause while refer-
ring to the following items.
• Regarding the method of checking and adjusting each part or piece of equipment, refer to "Testing and Adjusting" in the
Shop Manual.
HYDRAULIC EQUIPMENT
OIL CHECKS
The fundamental cause of almost all faults occurring in hydraulic equipment is the inclusion of water, air or other foreign
matter in the oil. Accordingly, it is necessary to check the oil to see whether or not it contains any of the above substances, and
then take appropriate action.
1. Oil checks
• Check for water contamination.
Check the oil for possible water contamination by means of a diesel engine oil checker or a hot plate.
• Check for contamination of other foreign matter. Remove the drain plug and filter, then check the bottom of the tank
and also the filter to see if any foreign matter has collected there. Check the degree of contamination by means of a
contamination checker.
• Viscosity check
Check the viscosity of the oil using a viscometer in order to confirm whether or not the oil is satisfactory.
2. Check of contamination point

If, as a result of the above checks, it is discovered that the oil is contaminated by water or other foreign matter, it is
necessary to find out where the contamination is occurring and also to take steps to prevent it.
Water: Oil storage tank, breather, etc.
Sand: Oil replenishing or replacing method, etc.
Rubber: Cylinder packing, etc.
Metal: Wear or damage to hydraulic equipment such as pump and motor, as well as transmission
and torque converter, etc.
3. Oil cleaning and replacement

If a large amount of metal particles or other foreign matter is discovered in the oil, either wash the oil using an oil
refresher or replace it.
★ If the oil is contaminated by water, it is not possible to remove the water by means of an oil refresher.
★ When washing the oil, also wash or replace the strainer and replace the filter.
CLEANING FRAGMENTS OF DAMAGED PARTS

If a part becomes damaged, fragments may pass into the oil line. It is thus necessary to wash the oil.
In addition, disassemble and wash such parts as valves and cylinders which are liable to collect metal fragments and other
foreign matter, thus helping to prevent a recurrence of faults due to such fragments becoming lodged in various parts of the
engine or hydraulic equipment.
WA180-3MC 20-119 1
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING
12
METHOD OF USING TROUBLESHOOTING CHARTS
CATEGORY OF TROUBLESHOOTING CODE NUMBER
Troubleshooting code No. Component
A - 00 Troubleshooting of Transmission Controller System
D - 00 Troubleshooting of ECSS (Electronically Controlled Suspension System)
E - 00 Troubleshooting of Electrical System
S - 00 Troubleshooting of Engine System
T - 00 Troubleshooting of Hydraulic & Mechanical System
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH

TROUBLESHOOTING MODE.
1. Troubleshooting code number and problem.
The title of the troubleshooting chart gives the troubleshooting code, service code and failure mode (problem with the
machine). (See Example (1)).
2. Distinguishing conditions.
Even with the same failure mode (problem), the method of troubleshooting may differ according to the model,
component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small
letters (for example, (a)), so go to the appropriate section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start the troubleshooting from the first check item in the failure
mode. (See Example (2)).
3. Method of following troubleshooting chart.

• Check or measure the item inside , and according to the answer, follow either the YES line or the NO line to
go to the next condition box. (Note: The number at the top right corner of the condition box is an index
number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause
column. Check the cause and take the action given in the Remedy column on the right. (See Example (3))
• Below the condition box, there are the methods for inspection or measurement, and the judgement values.
If the judgement values below the condition box are correct or the answer to the question inside the
condition box is YES, follow the YES line. If the judgement value is not correct, or the answer to the question in NO,
then follow the NO line.
• Below the condition box is given the preparatory work needed for inspection and measurement, and the
judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is
the danger that it may cause mistaken judgement or the equipment may be damaged. Therefore, before starting
inspection or measurement, always read the instructions carefully, and start the work in order from the first item 1.
4. General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all the items are given at the
top of the page and marked with a !.(See Example (4)).
The precautions marked ! are not given in the condition box, but must always be followed when carrying out the
check inside the condition box.
20-120 2 WA180-3MC
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING
12
5. Troubleshooting tools
When carrying out troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING,
ADJUSTING AND TROUBLESHOOTING.
6. Installation position, pin number.

A diagram or chart is given for the connector type, installation position, and connector pin number connection. When
carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and
measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode
(problem).
< Example >

(1) M-15 Abnormality in buzzer
(2) (a) Buzzer does not sound when starting switch is turned ON (during self-check)
(3)
(4)
! Before carrying out troubleshooting, check that all the related connectors are properly inserted.
! Always connect any disconnected connectors before going on to the next step.
WA180-3MC 20-121 2
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES
12
METHOD OF USING MATRIX TROUBLESHOOTING TABLES
The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the causes of fail-
ures in the machine. The troubleshooting tables are divided broadly into categories for the main components, such as the steer-
ing system and work equipment hydraulic system. Follow the procedure given below and carry out troubleshooting to locate
the problems accurately and swiftly.
Step 1. Questioning the operator 1. Steering does not work Symptom [Example]
The questions to ask the operator are given below the
failure symptom. If the answers to the questions match the Ask the operator about the following points.
information given, follow the arrow to reach the probable • Did the steering suddenly stop working? ➛ Breakage in
cause of the failure. steering equipment
Consider the contents of the questions and consult the table • Did the steering gradually become heavy? ➛ Internal wear
while proceeding to Steps 2 and 3 to grasp the true cause. of steering equipment, defective seal.
Checks before starting [Example]

Step 2. Checks before troubleshooting • Is the oil level in the hydraulic tank correct?
Before starting the main troubleshooting and measuring the • Is the type of oil correct?
hydraulic pressure, first check the Checks before Starting • Are there any oil leaks from the steering control valve?
items, and check for oil leaks and loose bolts. These checks • Has the safety bar been removed from the frame?
may avoid time wasted on unnecessary troubleshooting.
The items given under Checks before Starting are items [Example 1]
which must be considered particularly for that symptom
before starting troubleshooting. No. Problem Remedy
1 Steering does work to the left or right.
Step 3. Using cross-reference table 2 Same as item 1, but abnormality in actuation of
work equipment.
3 Steering can only be operated to one side.
A. Operate the machine to carry out the checks in the
troubleshooting item column. 4 Steering wheel is heavy and cannot be turned.
Mark the items where the results match the
symptom. [Example 2]
★ It is not necessary to follow the troubleshoot-
ing checks in order; follow an order which is
easiest to carry out troubleshooting.
Causes
B. Find the appropriate cause from the cause column.

a b c d e
If the symptom appears, the O, marks on that line
Problems Remedy
indicate the possible causes. (For item No. 2 in the X C A X
X
table on the right, the possible causes are c or e.)
If there is only one O: 1 O O O O
Carry out the other troubleshooting items (where 2 ● ●
the same cause is marked with check if the symp- 3 O O
tom appears, then repair. 4 O O
If there are two O: 5 O O
Go on to Step 3) to narrow down the possible
causes.
20-122 1 WA180-3MC
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES
12
3) Operate the machine and check the troubleshooting items
other than those in 1).
Operate the machine and check the items in the same way
Causes
as in 1) and if the symptom appears, mark that item. (In
the chart on the right, the symptom appears again for item
a b c d e
5).
Remedy
X C X A X
Problems
4) Find the appropriate cause from the cause column. In the
1 O O O O
same way as in Step 2), if the symptom appears, the O
2 O ●
marks on that line indicate the possible causes. (For item
3 O O
No.5 in the table on the right, the possible causes are b or
4 O O
e.)
5 ● ●
5) Narrow down the possible causes.
There is one common cause among the causes located in Applicable troubleshooting item located in Step 3).
Applicable troubleshooting item located in Step 1).
Steps 2) and 4). (One cause marked O, appears on the line
for both items.) This cause is common to both the
symptoms in troubleshooting Steps 1) and 3).
Ignore these causes
★ The causes which are not common to both
troubleshooting items (items which are not marked O
for both symptoms) are unlikely causes, so ignore them.
Causes
Common causes
(In the example given on the right, the causes for
Troubleshooting Item 2 are c or e, and the causes for a b c d e
Troubleshooting Item 5 are b or e, so cause e is Remedy
common to both.) X C X A X
Problems
1 O O O O
6) Repeat the operations in Steps 3), 4) and 5) until one 2 ● ●
cause (one common cause) remains. 3 O O
★ If the causes cannot be narrowed down to one cause, 4 O O
narrow the causes down as far as possible. 5 ● ●
7) Remedy
If the causes are narrowed down to one common cause,
take the action given in the remedy column.
Causes
The symbols given in the remedy column indicate the

following:
a b c d e Action to take
X: Replace Remedy
: Repair X C X A X
Problems
A: Adjust 1 O O O O
C: Clean 2 O ●
3 O O
4 O O
5 O ●
WA180-3MC 20-123 1
TROUBLESHOOTING METHOD OF USING ENGINE RELATED CHARTS
12
METHOD OF USING ENGINE RELATED CHARTS
Using troubleshooting charts for engine-related failure
This troubleshooting chart is divided into three sections:

questions, check items, and troubleshooting.
The questions and check items are used to pinpoint high
probability causes that can be located from the failure
symptoms or simple inspection without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are used to
check the high probability causes to make final confirmation.
[Questions]
Sections (A) + (B) in the chart on the right corresponds to the
items where answers can be obtained from the user. The items
in (B) are items that can be obtained from the user, depending
on the user’ level.
[Check items]
The serviceman carries out simple inspection to narrow down
the causes. The items under (C) in the chart on the right
correspond to this.
The service man 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 order of probability, starting
with the causes that have been marked with having the highest
probability from information gained from [Questions] and
[Check items]
Causes
(1) (2) (3)
(A) (a)
Ques-
tions
(b)
(c)
(B) (d) O
(C) (e) O
Check items
i ●
Trouble-
shooting
ii ●
iii ●
20-124 1 WA180-3MC
12
The basic method of using the troubleshooting chart is as follows.
Items listed for [Questions] and [Check items] that have a
relationship with the Cause items are marked with O, and these,
causes that have high probability are marked with a .
Check each of the [Questions] and [Check items] in turn and mark
the O or the 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
ake final confirmation of the cause.
❇1. For [Confirm recent repair history] in the
[Questions Section, ask the user, and mark the Cause
column with to use as reference for locating the
cause of the failure. However, do not use this when
making calculations to narrow down the causes.
❇2. Use the in the Cause column as reference for
[Degree of use (operated for long period)] in the
[Questions] section as reference.As a rule do not use
it when calculating the points for locating the cause,
but it can be included if necessary to determine the
order for troubleshooting.
Causes
Defective injection pump (excessive injection)

Seized turbocharger, interference
Clogged seized injection nozzle

Clogged air cleaner element
Worn piston ring, cylinder
Improper injection timing

❇1 Confirm recent repair history
❇2 Degree of use Operated for long period
WA180-3MC 20-125 1
12• Example of troubleshooting when exhaust gas is black
Let assume that [Clogged air cleaner] is taken to be the cause of the black 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 pin point the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)
General causes why exhaust gas is black
• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel
Causes
Defective injection pump (rack, plunger seized)

Air leaks between turbo charger and head

Defective contact of valve, valve seat
Clogged seized injection nozzle

improper valve clearance

Crushed clogged muffler
Legend
O: Possible causes (judging from questions and check items)
: Most probable causes (judging from questions and check items)
: Possible causes do to length of use (used for a long period)
●: Items to confirm the cause
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black O O
Color of exhaust gas Gradually became black O O
Questions
Blue under light load

Engine oil must be added more frequently
Power was lost

Suddenly O O O
Gradually O O O O
Non-specified fuel has been used O O
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 O O O O O
Check items
When exhaust manifold is touched immediately after starting engine, temperature of

some cylinders is low O
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 O O
Muffler is crushed
Air leaks between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy ●
When air cleaner is inspected, it is found to be clogged ●
Troubleshooting
When compression pressure is measured, it is found to be low ● ●

Speed of some cylinder does not change when operating on reduced cylinders ●
When check is made using delivery method, timing found to be incorrect ●
Injection pump test shows that injection amount is incorrect ●
When valve clearance is checked, 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
Adjust
Adjust
Adjust
Repair
Remedy
Clean
20-126 1 WA180-3MC
12
Five causes
Step 1
Clarify the relationship between the three symptoms

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

tal lines for the three symptoms and the vertical col-
umns for the causes intersect.
(1) Clogged air cleaner element:----------------- O
(2) Air leaks between turbocharger and head:--O O
(3) Clogged, seized injection nozzle:------------O
(4) Defective contact of valve, valve seat:------O
(5) Worn piston ring, cylinder:-------------------O
Step 3
The calculation in Step 2 show that the closet relation-

ship 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.
WA180-3MC 20-127 1
12
MEMORANDUM
20-128 1 WA180-3MC
TROUBLESHOOTING
ELECTRICAL CONNECTORS
CONNECTOR TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-204
ELECTRICAL CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-213
ENGINE START, STOP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-213
PREHEATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-214
WA180-3MC 20-201 2
TROUBLESHOOTING CONNECTOR TYPES
12
CONNECTOR TYPES Connector
Type
No.
Description
No. Pins
Connector No.
Type Description CNE8 1 Safety relay - C
No. Pins
CN61PT 1 Grd bucket sw relay CNE9 1 Grd
CN8 1 JRB CNER2 8 Intermediate connector
CNAL2 2 Intermediate AC connector CNER3 8 Intermediate connector
CNB3 1 License lamp CNER4 1 Glow plug
CNB4 1 License lamp grd CNF1 3 Head lamp - RH
CNC01 6 Front wiper motor CNF10 3 Head lamp - LH
CNC03 2 Front working lamp CNF16 1 Grd - Frt combination RH
CNC04 2 Front working lamp LH CNF17 1 Grd - Frt combination LH
CNC05 4 Warning lamp sw CNF2 1 Turn signal - Frt combination RH
CNC06 2 Room lamp CNF3 1 Side lamp - Frt combination RH
CNC07 4 Rear wiper motor CNF4 3 Bucket proximity sw
CNC1 10 Wiper switch CNF5 3 Boom proximity sw
CNC2 12 Intermediate connector CNF6 1 Horn
CNC3 3 Washer tank CNF7 1 Horn
CNC4 6 Wiper relay CNF8 1 Fuse normal 24V
CNCL1 12 Intermediate connector CNF8 1 Turn signal - Frt combination LH
CNDF 1 Fuse key on 24V CNF9 1 Side lamp - Frt combination LH
CNDF 1 Window defroster CNFL1 10 Intermediate connector
CNE08 1 Heater relay CNFL2 2 Intermediate connector
CNE1 1 Engine oil pressure sensor CNFS1 4 Fuse connector
CNE10 1 Alternator - E CNFS2 2 Fuse connector
CNE11 1 Alternator - R CNFS3 6 Fuse connector
CNE12 1 Alternator - B CNFS4 6 Fuse connector
CNE13 2 Intermediate connector - S & R CNFS5 2 Key on 24V
CNE14 1 Slow blow fuse 80A CNFS6 2 Fuse key on 24V
CNE15 2 Fuel level sensor CNFS7 6 Fuse connector
CNE16 2 Diode CNFS9 1 Fuse key on 24V
CNE21 2 Engine RPM sensor CNG1 2 Working lamp RH
CNE3 1 Ribbon heater CNG2 2 Working lamp LH
CNE4 1 Water temp sensor F/auto pre-heat CNG3 1 Back up buzzer
CNE5 1 Water temp sensor CNG4 1 Grd
CNE6 1 Water temp sensor grd CNG5 6 Rear combination RH
CNE7 3 Fuel cut-off solenoid CNG7 6 Rear combination lamp LH
20-202 ➁ WA180-3MC
Connector No. Connector No.

Type Description Type Description
No. Pins No. Pins
CNGR1 3 Intermediate connector Emergency steering abnormal

CNL38 1
(opt)
CNGR2 6 Intermediate connector
T/M combination sw - lighting
CNL1 10 Monitor panel CNL4 6
side lamp & HL
CNL11 6 Working lamp connector CNL40 5 T/M cut-off relay
CNL12 1 Additional working lamp (opt) CNL41 2 Diode
CNL13 1 Intermediate F working sw CNL42 2 Diode
CNL14 1 Intermediate F working sw CNL43 1 Tachograph lighting (opt)
CNL14 4 Working lamp sw T/M combination sw - turn &
CNL5 6
hazard
CNL15 4 T/M cut-off selector sw
CNL50 21 T/M controller
CNL16 1 T/M cut-off sw
CNL17 1 T/M cut-off sw
CNL18 1 Stop lamp sw
CNL53 4 Manual sw
CNL19 1 Stop lamp sw
CNL54 1 Caution buzzer
CNL2 12 Monitor panel
CNL55 1 Grd caution buzzer
CNL20 2 Brake oil level sensor
CNL56 1 Machine select
CNL21 1 Parking brake sw
CNL6 3 Turn unit
CNL22 1 Parking brake sw
CNL60 5 Boom proximity sw relay
CNL23 1 Grd
CNL60PT 1 Grd boom sw relay
Starting sw
1=B CNL60Z 1 Grd boom sw relay
CNL24 4 2 = BR
3=C CNL61 5 Bucket proximity sw relay
4 = ACC
CNL61Z 1 Grd Bucket relay
CNL25 1 Horn
CNL62 1 Suspension seat
CNL26 6 Working lamp relay
CNL63 1 Grd
CNL27 5 Hazard relay
CNL7 8 Air intake heater relay controller
CNL28 5 Neutralizer relay
CNLR2 10 Intermediate connector
CNL29 5 Neutral relay
CNLR3 2 Key on 24V
T/M combination sw - FR & 1, 2,
CNL3 14 CNLR4 2 Key on 24V
3, 4
CNL30 6 Alternator relay CNLR5 6 Intermediate connector
CNL32 5 Reverse relay CNLR6 8 Intermediate connector
CNL34 2 Kick-down sw CNLR7 1 Key on 24V
CNL35 2 Diode CNOP1 1 Spare
CNL36 2 Diode CNR1 2 Diode
Emergency steering abnormal CNR2 2 Diode

CNL37 1
(opt)
WA180-3MC 20-203 2
Connector No. Connector No.

Type Description Type Description
No. Pins No. Pins
CNR4 1 Heater relay to ribbon heater CNT1 2 Washer tank - front
CNR4 1 Slow blow fuse 20A CNT2 2 Transmission shift R
CNR5 3 Intermediate connection CNT2 2 Washer tank - rear
CNR6 1 Grd CNT3 2 Transmission HI-LO
CNRES3 2 CNT4 2 Transmission SPEED
CNS1 2 Bucket solenoid CNT5 1 Grd
CNS2 2 Boom float solenoid CNT6 2 T/C oil temp sensor
CNS3 2 Boom kick-out solenoid CNT7 2 Speed sensor
CNT1 2 Transmission shift F
20-204 ➁ WA180-3MC
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR
12
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
★ The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion
of the housing.
WA180-3MC 20-205 2
12
20-206 2 WA180-3MC
12
WA180-3MC 20-207 2
12
20-208 2 WA180-3MC
12
WA180-3MC 20-209 2
12
20-210 2 WA180-3MC
WA180-3MC 20-211 2
12
20-212 2 WA180-3MC
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS
12
ELECTRICAL CIRCUIT DIAGRAMS
ENGINE START, STOP SYSTEM
WA180-3MC 20-213 2
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS
PREHEATING SYSTEM
20-214 2 WA180-3MC
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM (A-MODE)
OUTLINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-302
FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-302
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-302
FAILURE CODE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-302
TABLE OF TROUBLESHOOTING MODES AND CAUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-303
A-1 TROUBLESHOOTING CODE [12] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-304
F SOLENOID SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-304
R SOLENOID SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-305
ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-306
ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-307
ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-308
ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-309
ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-310
ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-311
A-10 KICK-DOWN SWITCH SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-312
A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-313
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-314
A-13 BUZZER SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-315
A-15 CONTROLLER POWER SOURCE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-316
WA180-3MC 20-301 2
TESTING AND ADJUSTING OUTLINE
12
OUTLINE
FUNCTION
The control mechanism of the transmission controller consists of the controller, sensors, input switch, solenoid output and
buzzer output. The contoller receives the input signal, processes it, and carries out the auto-shift control by controlling the
solenoid to a transmission range that matches the travel speed.
TROUBLESHOOTING
The controller has a troubleshooting function and when a failure is detected, the alarm buzzer alerts the operator while the
display shows the failure code on the main monitor. Failure codes A-9 through A-16, abnormalities in the control, will not
display in the display area.
FAILURE CODE TABLE
No. Failure code Failure or abnormality in the No. Failure code Failure or abnormality in the
following following
A-1 12 F solenoid signal system A-9 --- Not used
A-2 13 R solenoid signal system A-10 --- Kick-down switch signal system
A-3 14 H-L solenoid signal system A-11 --- Transmission cut-off signal system
A-4 16 Speed solenoid signal system A-12 -- Neutralizer signal system
A-5 20 Directional lever signal system A-13 -- Alarm buzzer signal system
A-6 21 Speed lever signal system A-14 -- Network signal system
A-7 22 Travel sensor signal system A-15 -- Controller power source voltage
A-8 23 Engine speed sensor signal system A-16 -- Model selection harness
20-302 2 WA180-3MC
TESTING AND ADJUSTING OUTLINE
12
TABLE OF TROUBLESHOOTING MODES AND CAUSES
Related equipment
Troubleshooting code when no abnormality is display is given

Controller power source voltage system
Engine speed sensor signal system
Travel speed sensor signal system
Neutralizer relay signal system

Directional lever signal system
Alarm buzzer signal system

Transmission cut-off signal
Hold switch signal system
Speed lever signal system
Kick-down signal system
Network signal system

Speed solenoid system
Cause of failure
H-L solenoid system

R solenoid system
F solenoid system
Failure mode
Main monitor display failure code 12 13 14 16 20 21 22 23 -- -- -- -- -- -- -- --

Impossible to travel O O O O O O H-1
Auto-shift does not work O O O O --
Position of directional lever and direction of travel do --
O
not match
Machine travels forward when directional lever is not at
O --
F position
Machine travels in reverse when directional lever is not
O --
at R position
Transmission doesn’t shift down with travel speed O O O --
Transmission doesn’t shift up with travel speed O O --
Transmission stays in same range as speed lever
O H-2
regardless of travel speed
Excessive shock when shifting gear O H-3
Shift hunting when traveling O --
Shift hunting when shifting gear O --
Transmission range can’t be controlled with speed lever O --
Shift cannot be held O A-9
Kick-down switch doesn’t shift transmission to 1st O A-10
No power for scooping operations when kick-down
O A-10
switch is ON
Transmission is not cut off when left brake is operated O A-11
Machine can travel when parking brake is applied O A-12
Alarm buzzer does not sound when travel direction is
switched between forward and reverse while traveling O A-13
at high speed
Alarm buzzer does not stop O A-13
Main monitor does not display transmission controller
O A-14
data (alarm buzzer, failure code, etc.)
Troubleshooting code when error code is displayed A-1 A-2 A-3 A-4 A-5 A-6 A-7 A-8 -- -- -- -- -- -- -- --
WA180-3MC 20-303 2
TESTING AND ADJUSTING A-1
12
A-1 TROUBLESHOOTING CODE [12]
F SOLENOID SIGNAL SYSTEM
★ Before troubleshooting, check that all related connectors are in good condition and properly connected before going to the
next step.
★ Before troubleshooting, check that all related connectors are properly inserted.
★ Turn the starting switch OFF before disengaging connectors, as when connecting the T-adapter or socket adapter.
Cause Remedy
1 Yes
Defective controller Replace
Is resistance between
CNL50 (female) (21)
and (19) normal? Yes
• Disconnected wiring
1) 46 - 58Ω.
2) Turn starting switch between CNL50
OFF. 2 (female) (21) - CNT1
3) Disconnect CNL50.
(female) (1), faulty
Is resistance between Inspect,
CNT1 (male) (1) and connections or shorted repair or
No (2) normal? to ground replace
1) 46 - 58Ω. • Disconnected wiring
2) Turn starting switch between T1 (female)
OFF.
3) Disconnect CNT1. (2) and chassis
Defective F solenoid Replace

No
20-304 2 WA180-3MC
12
R SOLENOID SIGNAL SYSTEM
★ Before troubleshooting, check that all related connectors are in good condition and properly connected before going to the
next step.
★ Before troubleshooting, check that all related connectors are properly inserted.
Cause Remedy
1 Yes
Is resistance between
CNL50 (female) (20)
and (19) normal? Yes • Disconnected wiring
1) 46 - 58Ω. between CNL50
2) Turn starting switch (female) (20) - CNT2
OFF. 2
3) Disconnect CNL50. (female) (1), faulty
Is resistance between connections or shorted Inspect,
CNT2 (male) (1) and to ground repair or
No (2) normal? replace
• Disconnected wiring
1) 46 - 58Ω.
2) Turn starting switch between CNT2
OFF. (female) (2) and
3) Disconnect CNT2. chassis
Defective R solenoid Replace

No
WA180-3MC 20-305 2
12
ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM
★ Before troubleshooting, check that all related connectors are in good condition and properly connected.
★ Restore disconnected connectors before proceeding to the next step.
Cause Remedy
Yes
1 Yes Wiring harness between CNL50 (female) (10)

Is resistance between - CNET1 (male) (3), CNL05 (female) (13) Repair wiring
3 short circuiting with chassis ground or discon- harness or replace
CNL50 (female) (10) nection, defective contact
and (19) normal.? Yes Is resistance between
CNET1 (female) (3)
1) Turn starting switch and chassis normal?
OFF.
2) 46 - 58 Ω 1) Turn starting switch • Wiring harness between CNET1
3) Disconnect CNL50. 2 OFF. (female) (3) short circuiting with
2) Disconnect chassis ground or disconnection with
Is resistance between CNET1. Repair wiring
CNT3 (male) (1) and 3) 46 - 58 Ω chassis ground or disconnection,
harness or replace
No (2) normal? No defective contact.
• Disconnection in wiring harness
1) Turn starting switch between CNT3 (female) (2) and chassis
OFF.
2) Disconnect CNT3.
3) 46 - 58 Ω.
Defective H-L solenoid Replace

No
20-306 2 WA180-3MC
12
ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM
Cause Remedy
Yes
1 Yes Wiring harness between CNL50 (female) (11)

Is resistance between - CNET1 (male) (4), CNL05 (female) (12) Repair wiring
3 short circuiting with chassis ground or discon- harness or replace
CNL50 (female) (11) nection, defective contact
and (19) normal.? Yes Is resistance between
CNET1 (female) (4)
1) Turn starting switch and chassis normal?
OFF.
2) Disconnect CNL50. 1) Turn starting switch • Wiring harness between CNET1
3) 46 - 58Ω 2 OFF. (female) (4) and CNT4 (female) (1)
2) Disconnect short circuiting with chassis ground or
Is resistance between CNET1. Repair wiring
CNT4 (male) (1) and 3) 46 - 58Ω disconnection with chassis ground or
harness or replace
No (2) normal? No disconnection, defective contact.
• Disconnection in wiring harness
1) Turn starting switch between CNT4 (female) (2) and chassis
OFF.
2) Disconnect CNT4.
3) 46 - 58Ω
Defective speed solenoid Replace

No
WA180-3MC 20-307 2
12
ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM
★ Check that the combination switch for directional and speed levers is in good condition.
★ Turn starting switch OFF before disengaging connectors, when connecting the T-adapter or socket adapter.
Cause Remedy
Yes
3
Yes Is voltage between • Wiring harness between CNL51
CNL51 (12) and (9) (female) (12) - CNL03(4) - directional,
normal?
speed lever switch short circuiting with
1) Directional lever chassis ground or disconnection,
at R: 20 - 30 V Repair wiring
Other than R: 0 No defective contact harness or replace
2
V • Wiring harness between CNL51
Yes Is voltage between 2) Turn starting
CNL51 (1) and (9) switch ON. (female) (1) and CNL32 (female) (8)
normal? short circuiting with chassis ground
1) Directional lever at • Wiring harness between CNL51
F: 20 - 30 V (female) (1) - CNL03(2) - directional
Other than F: 0 V
2) Turn starting switch speed lever switch short circuiting with
1 ON. chassis ground or disconnection, Repair wiring
defective contact harness or replace
Is voltage between No
CNL51 (11) and (9) • Wiring harness between CNL51
normal? (female) (1) and CNL40 (female) (7)
1) Directional lever at N: short circuiting with chassis ground
20 - 30 V
Other than N: 0 V • Wiring harness between CNL51
2) Turn starting switch
ON. (female) (11) - CNl03(3) - directional
speed lever switch short circuiting with
chassis ground or disconnection, Repair wiring
defective contact harness or replace
No
• Wiring harness between CNL51
(female) (11) and CNL29 (female) (8)
short circuiting with chassis ground
20-308 2 WA180-3MC
12
ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM
Cause Remedy
4 Yes
Yes Is voltage between
CNL51 (3) and (9)
normal? Wiring harness between
CNL51 (female) (3) - Repair
3 1) Speed lever 4th: CNL03(8) - directional
20 - 30 V. speed lever switch short wiring
Other than 4th: 0 V. No circuiting with chassis harness
Yes Is voltage between or replace
CNL51 (14) and (9) 2) Turn starting switch ground or disconnection,
normal? ON. defective contact
2 1) Speed lever 3rd: Wiring harness between

20 - 30 V. CNL51 (female) (14) -
Other than 3rd: 0 V. Repair
Yes Is voltage between CNL03(7) - directional wiring
CNL51 (2) and (9) 2) Turn starting switch speed lever switch short
normal? ON. No circuiting with chassis harness
ground or disconnection, or replace
1) Speed lever 2nd: defective contact
20 - 30 V.
1 Other than 2nd: 0 Wiring harness between
V. CNL51 (female) (2) -
2) Turn starting switch CNL03(6) - directional Repair
Is voltage between ON. speed lever switch short wiring
CNL51 (13) and (9) No circuiting with chassis harness
normal? ground or disconnection, or replace
defective contact
1) Speed lever 1st:
20 - 30 V. Wiring harness between
Other than 1st: 0 V. CNL51 (female) (13) - Repair
2) Turn starting switch CNL03(5) - directional wiring
ON. speed lever switch short harness
circuiting with chassis or replace
No ground or disconnection,
defective contact
WA180-3MC 20-309 2
12
ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM
Cause Remedy
Yes
1
Is resistance between Yes Disconnect wiring Repair
CNL52 (female) (4) and between CNL52 (female) wiring
(12) normal? (4), (12) - CNT7 (female) harness
2 or faulty connection or replace
1) Turn starting switch Is resistance between
OFF. CNT7 (male) (1) and
2) Disconnect CNL52. No (2) normal? Yes Wiring between CNL52 Repair
3) 0.5 - 1.0 kΩ (female) (4), (12) - CNT7 wiring
1) Turn starting switch 3 (female) shorted to ground harness
OFF. or short circuited or replace
2) Disconnect CNT7. Is insulation between
3) 0.5 - 1.0 kΩ CNL52 (female) (4),
(12) and chassis
No normal?
Defective speed sensor Replace
1) Turn starting switch No
OFF.
2) Disconnect CNL07,
CNL52 and CNT7.
3) Min. 1MΩ.
20-310 2 WA180-3MC
12
ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM
Cause Remedy
2 Yes
Yes Is continuity between
CNL52 (female) (5)
1 and (12) normal?
Is insulation between OFF. Disconnected wiring between CNL52 (female) Repair wiring
CNL52 (female) (5), 2) Disconnect CNL52, No (5) - CNE21 (female) (1) or faulty connection harness or replace
(12) and chassis CNE21 and CNL07.
normal? 3) Between CNE21
(female) (1) and (2)
1) Turn starting switch short to ground.
OFF. Wiring harness between CNL52 (female) (5),
2) Disconnect CNL52, No (12) - CNL07 (female) (3), (2), between CNL52 Repair wiring
CNE21, and (female) (5), (12) - CNE21 (female) (1), (2) harness or replace
CNL07. short circuiting with chassis ground
3) Min. 1 MΩ.
WA180-3MC 20-311 2
12
A-10 KICK-DOWN SWITCH SYSTEM
Cause Remedy
Yes
1
Is continuity between
CNL51 (female) (17) Wiring harness between
and chassis normal? CNL51 (female) (17) and Repair
2 Yes CNL34 (female) (1) short wiring
circuiting with chassis harness
1) Disconnect CNL51. Is continuity between ground or disconnection, or replace
2) Hold switch CNL34 (male) (1) and (2) defective contact.
ON: Max. 1Ω No normal?
OFF: Min. 1 MΩ
1) Disconnect CN34.
2) Hold switch Defective kick-down Replace
ON: Max. 1Ω No switch
OFF: Min. 1 MΩ
20-312 2 WA180-3MC
12
A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM
Cause Remedy
Yes
1
CNL51 (male) (16) and • Wiring harness between CNL51
chassis normal? (female) (16) - CNL15 (female) short
Repair wiring harness
1) Turn starting switch circuiting with chassis ground or or replace
Yes
OFF. disconnection, defective contact
2) Disconnect CNL51. 2 • Wiring harness between CNL51
3) Transmission cut-
off switch (female) (16) - short circuiting with Replace
ON: Max. 1 Ω CNL15 (male) - CNL40 chassis ground
OFF: MAX 1 MΩ No (female) normal?
OFF. Defective transmission cut-off switch Replace
2) Disconnect CNL15, No
CNL40.
3) Transmission cut-off
switch
ON: Max. 1 Ω
OFF: MAX 1 MΩ
WA180-3MC 20-313 2
12
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM
★ Check that the parking brake works properly.
Cause Remedy
Yes
4 Yes
Defective neutralizer relay Replace
1 Yes Is continuity
between CNL73
Is voltage CNL51 (4) (female) (13) and
and (9) Defective contact or
CNL51 (female) (4) disconnection in wiring
normal? 3 normal? Repair
harness between CNL73 wiring
1) Insert T-adapter. Is voltage between 1) Tun starting switch No (female) (13) - CNL28 harness
2) Turn starting switch Yes CNL28 (female) (1) OFF. (female) (5), CNL28 or replace
ON. and chassis normal? 2) Disconnect CNL73, (female) (3) - CNL51
3) Turn parking brake CNL51 and (female) (4)
2
switch ON ⇒ OFF. CNL28.
4) 20 - 30 V. 1) Disconnect CNL28. 3) Short circuit
Is continuity 2) Turn starting switch
between CNL28 CNL28 (3) & (5).
ON. 4) Max. 1 Ω.
(female) (2) and 3) 20 - 30 V. Disconnected wiring Repair
No chassis normal? between L28 (female) (1) wiring
and CNFS3 (female) (9) or harness
1) Turn starting No faulty connection or replace
switch OFF.
2) Disconnect
CNL28.
3) Parking brake 5 Yes
switch: ON ⇒ Defective parking brake
OFF. Is resistance between switch or wrong place for Replace
or repair
4) Max. 1 Ω. CNL21 (male) and switch to be installed
No chassis normal?
OFF. Disconnected wiring Repair
2) Disconnect CNL21. No between CNL21 (male) wiring
3) Max. 1Ω. and CNR8 or faulty harness
connection or replace
20-314 2 WA180-3MC
12
A-13 BUZZER SIGNAL SYSTEM
★ Check that the main monitor and alarm buzzer work properly.
Cause Remedy
Yes
2
Yes
CNL52 (female) (15)
and chassis normal?
1 Disconnected wiring Repair
Is insulation between 1) Disconnect CNL52, No between CNL52 (female) wiring
CNL52 (female) (15) CNL08. (15) - CNL08 (female) (6) harness
and chassis normal? 2) Short circuit CNL08 or faulty connection or replace
(female) (6) - chassis.
1) Turn starting switch 3) Max. 1 Ω.
OFF.
2) Disconnect CNL52. Wiring between CNL52 Repair
3) Min. 1 MΩ. (female) (15) - CNL08 wiring
No (female) (6) shorted to harness
ground or replace
WA180-3MC 20-315 2
12
A-15 CONTROLLER POWER SOURCE SYSTEM
★ Check that the fuse for the transmission controller is intact (not blown).
Cause Remedy
Yes
1
Is voltage between Disconnect wiring

CNL50 (female)(8), between CNL50 (female) Repair or
(17), (18) - (9), (19) Yes (8) (17) (18) - CNFS2 replace
normal? (female) (8), faulty con- wiring
2 nection or shorted to harness
1) Disconnect CNL50. Is continuity between ground
2) Turn starting switch CNL50 (female)(9),
ON. No (19) and chassis
3) 20-30 V. normal?
1) Turn starting switch Disconnected wiring Repair or
between CNL50 (female) replace
OFF. wiring
Νο (9) (19) and chassis harness
2) Disconnect CNL50.
3) Max. 1 Ω.
20-316 2 WA180-3MC
TROUBLESHOOTING ELECTRONICALLY
CONTROLLED SUSPENSION SYSTEM
D MODE - (ECSS)
ECSS - ELECTRICAL / HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
ECSS - WORKING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
ECSS CIRCUIT - REMAINING
PRESSURE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-403
INSPECTION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-403
WA180-3MC 20-401 2
TROUBLESHOOTING ECSS - ELECTRICAL / HYDRAULIC SCHE-
12
ECSS - ELECTRICAL / HYDRAULIC SCHEMATIC
ECSS - WORKING CHART

ECSS SWITCH LIFT CYLINDER PRESSURE SOLENOID SYSTEM
SOL 1 SOL 2
(SYSTEM ON - OFF) kgf/cm2 (lbf/in2) FUNCTION
(ECSS VALVE) (CHARGING VALVE)
OFF 0 - 210 (0 - 2986.9) X O
0 - 150 (0 - 2133.5) O X➞O

ON
150 - 210 (2133.5 - 2986.9) X O
X = OFF
O = ON
20-402 2 WA180-3MC
TROUBLESHOOTING ECSS CIRCUIT - REMAINING PRESSURE
12
ECSS CIRCUIT - REMAINING
PRESSURE REMOVAL
INSPECTION / ADJUSTMENT
★ When removing ECSS circuit piping and the ECSS valve, use the
following the procedure to extract the accumulator pressure.
1. Loosen lock nut (2) on ECSS valve (1).
2. Loosen adjusting screw (3) by turning 1/2 to 1 turns at a time to

extract the accumulator pressure.
★ The lock nut (2) and the adjustment screw (3) are painted red.
3. After extracting the remaining pressure, return adjustment screw

(3) to its original position, then tighten with lock nut (2).
Lock nut torque: 12.7 ± 0.6 Nm (9.36 ± 0.44 lbf ft)
WA180-3MC 20-403 2
TROUBLESHOOTING ECSS CIRCUIT - REMAINING PRESSURE
12
MEMORANDUM
20-404 2 WA180-3MC
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E-MODE)
E-1 ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-502

A. STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START . 20-502
B. CHECK FUEL SHUT-OFF SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-504
E-2 ENGINE DOES NOT STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-505
E-4 TRANSMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED
(TRANSMISSION CUT-OFF IS NORMAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-506
E-10 PREHEATING IS NOT CARRIED OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-508
E-11 PREHEATING REMAINS ACTUATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
WA180-3MC 20-501 2
TESTING AND ADJUSTING E-1
12
E-1 ENGINE DOES NOT START
★ Check that the fuse is normal before starting troubleshooting.
★ Set the speed lever to neutral.
★ To prevent failures, always turn the starting switch OFF when connecting or disconnecting connectors in order to connect
the T-adapter (or socket adapter) or short circuit connector when carrying out checks.
★ When connecting the T-adapter (or socket adapter), connect to the connector specified in CN - O ().
★ After checking, disconnect the T-adapter and connect the disconnected connectors immediately before going on to the
next step, unless otherwise specified.
• Refer to electrical wiring diagram on page 20-213, ENGINE START, STOP SYSTEM.
A. STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS

TURNED TO START
Yes a
3 Yes b
Yes Is there sound of c
starting motor
pinion engaging? Yes
1) Turn starting
switch to START. 4 6
When neutral relay Yes Is voltage between

No is interchanged, starting motor
does condition terminal C and
become normal? chassis normal?
1) Turn starting 1)Turn starting d

switch to START. 5 switch to START.
2)20 - 30 V.
No
Is voltage between
No starting switch
terminal C and
chassis normal?
2
Yes When starting switch 1) Turn starting switch
to START.
is turned OFF, is 2) 20 - 30 V. e
sound heard from
battery relay? No
to ON - OFF.
10
Yes Is resistance of Yes f
wiring harness
between starting
switch BR and g
1 9 battery relay BR
normal?
Yes Is there continuity No
Is voltage and between starting
specific gravity of switch terminal B
battery normal? 1) Between starting.switch BR and battery
and BR? relay Max 1Ω.
8 2) Between wiring harness and chassis: Min.
1) 20 - 30 V. Is voltage of 1) Turn starting 1 MΩ.
2) Specific gravity: starting switch switch ON. 3) Disconnect both starting switch and bat-
Min. 1.26. No terminal B normal? 2) Remove tery relay ends.
terminal B.
1) Connect (-) end of
tester to battery
terminal (-). h
2) 20 - 30 V
No i
No j
No
20-502 2 WA180-3MC
12
Cause Remedy
a
Defective starting motor Repair or
replace
b
Defective neutral relay Replace
7 Yes Defective contact of wiring harness between battery relay Repair or

c Is voltage between and starting motor, or defective starting motor replace
alternator
terminal R and
chassis normal? Defective alternator safety relay Replace
1) Turn starting No
switch ON.
d 2) Max. 1 V. Defective contact or disconnection in wiring harness
between starting motor terminal C - CNL09(3) - Repair or
CNL34(5), (3) - CNLR2(4) - CNR11, CNR12(2), (1) - replace
CNE13(1) - safety relay terminal S, or defective safety
relay
e
Defective starting switch Replace
11 Yes Defective battery relay or defective contact or Repair or

disconnection in wiring harness between battery relay replace
f Is there continuity terminal E - CNR7(3) - CNR8
between battery
relay terminal (-) Defective contact of wiring harness between battery relay Repair or
and frame ground terminal (-) and frame ground replace
connections? No
g 1) Turn starting
switch OFF. Defective contact or disconnection in wiring harness
between starting switch terminal BR - CNL09(2) - Repair or
CNLR2(7) - CNR1(2), (1) - CNR7(1) - battery relay replace
terminal BR
h
Defective starting switch (between B and BR) Replace
i Defective contact or disconnection in wiring harness

between battery terminal (+) - CNR7(2) - CNLR3(1) - Charge or
CNFS3(6) - fuse - CNFS3(4) - CNL09(1) - starting switch replace
terminal B
j Repair or
Defective battery replace
WA180-3MC 20-503 2
12
B. CHECK FUEL SHUT-OFF SOLENOID
★ Set the speed lever to neutral.
★ When connecting the T-adapter (or socket adapter), connect to the connector specified in CN - O ().
next step, unless otherwise specified.
Cause Remedy
Yes Defective adjustment
between fuel shut-off Adjust
solenoid and engine stop
lever
1 3 Yes Defective fuel shut-off Replace
solenoid or repair
Is fuel shut-off solenoid Yes Is resistance value
actuated? between fuel shut-off
solenoid terminal A or
C and chassis normal? Defective contact or
1) Turn starting switch 2 disconnection in wiring
ON - OFF and check harness between fuel Replace
visually. Is voltage between 1) Turn starting switch No shut-off solenoid CNE7(d) or repair
CNE7(A) and OFF. and chassis ground CNE9
No chassis 20 - 30 V? 2) Disconnect CNE7.
3) Refer to "Engine Shop
1) Turn starting switch Manual". Defective contact or
ON. disconnection in wiring
4 Yes harness between starting Inspect,
switch ACC - CNL09(4) - repair or
CNLR5(9) - CNLR2 replace
Is voltage between (11)(12) - fuel shut-off
starting switch terminal solenoid CNE7(A)
ACC and chassis 20 -
No 30 V?
Defective starting switch Replace
1) Turn starting switch No
ON.
20-504 2 WA180-3MC
12
E-2 ENGINE DOES NOT STOP
★ When connecting the T-adapter (or socket adapter), connect to the connector specified in CNO ( ).
next step unless otherwise specified.
Cause Remedy
1 Yes Defective adjustment
between fuel shut-off Adjust
solenoid and engine stop
Is fuel shut-off solenoid lever
actuated?
2 Yes Defective fuel shut-off
solenoid Replace
1) Turn starting Is voltage between
switch ON - OFF fuel shut-off sole-
and check visually No noid and chassis less Defective circuit or con-
than 1 V? 3 Yes tact between battery (+24 Inspect
V) and ACC - CNL09(4) - repair or
1) Turn starting CNLR5(9) -
switch OFF. Is voltage between CNER2(11)(12) - fuel replace
starting switch shut-off solenoid CNE7
terminal ACC and
No chassis less than 1
V? Defective starting switch Replace
No (Between ACC and B)

OFF.
2) Disconnect terminal
ACC.
WA180-3MC 20-505 2
12
E-4 TRANSMISSION IS NOT SET TO NEUTRAL WHEN PARKING
BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NORMAL)
★ When connecting the T-adapter (or socket adapter), connect to the connector specified in CNO ().
Cause Remedy
1 Yes
Defective neutralizer relay Replace
Is problem corrected
when relay is replaced? 2 Yes
Defective parking brake Adjust or
switch or defective mount replace
Is voltage between CNL28 position of switch
1) Interchange No (female) and CNL13
neutralizer relay (male) 20 - 30 V?
(CNL33) and
back-up lamp relay Contact of chassis with wiring After
(CNL35). 1) Depress parking brake No harness between CNL33(2) - inspection,
2) Turn starting pedal. CNL28 (female) - CNL72(1) repair or
switch ON. 2) Turn starting switch ON. replace
20-506 2 WA180-3MC
12
MEMORANDUM
WA180-3MC 20-507 2
12
E-10 PREHEATING IS NOT CARRIED OUT
★ Check that the water temperature is 0° C (32° F) or below.
• Refer to electrical wiring diagram on page 20-213, PREHEAT SYSTEM.
Yes
a
Yes
b
6
2 Yes Is problem
removed when
Yes Is voltage between relay is replaced?
heater relay output 1) Replace
terminal R4 and preheating
chassis 20 - 30 V? relay
5
(CNL41) with c
1) Turn starting Yes Is voltage between horn relay No
switch ON. (CNL42).
CNL41(1) (female) 2) Turn starting
and chassis 20 - 30 switch ON.
V?
4 1) Disconnect CNL41.
Yes Is voltage between ON.
CNL41(5) (female) d
1 No
and chassis 20 -30
V?
Is voltage between 1) Disconnect

starting switch CNL41.
terminal BR and 2) Turn starting e
chassis 20 - 30 V? 3 switch ON.
No
Is voltage between
1) Turn starting No heater relay input
switch ON. terminal R3 and
chassis 20 - 30 V?
1) Turn starting
switch ON.
f
No
g
No
20-508 2 WA180-3MC
12
Cause Remedy
Defective contact or After

a disconnection in wiring inspec-
harness between heater tion,
relay terminal CNR4 and repair or
electrical intake air heater replace
terminal CNE3
b Defective heater relay Replace
10 Yes Defective QHS water

temperature sensor Replace
9 Yes When CNE4 is
Is voltage between disconnected, does
Yes
heater relay voltage between
CNR9(1) (female) CNL06(4) and No Defective QHS controller Replace
and chassis 20 - 30 chassis ground inside monitor
8 V? become 0 V?
Yes 1) Disconnect CNR9. 1) Disconnect CNE4.

Is voltage between 2) Turn starting switch 2) Turn starting switch
CNL07(10) (female) ON. ON. Defective contact or After
and chassis 20 - 30 disconnection in wiring inspec-
V? harness between tion,
7
CNL41(3) - CNR5(7) - repair or
1) Disconnect CNL07. No CNR9 replace
c Is there continuity 2) Turn starting switch
between ON.
CNL41(2)
(female) and
CNL06(4) Defective contact or After
(female)? disconnection in wiring inspec-
No harness between starting tion,
switch terminal BR - repair or
1) Turn starting CNL09(2) - CNL07(10) replace
switch OFF.
2) Disconnect After
CNL41. Defective contact or inspec-
3) Disconnect No disconnection in wiring tion,
CNL06. harness between repair or
CNL41(2) and CNL06(4) replace

disconnection in wiring inspec-
d harness between tion,
CNL41(1) - CNFS2(7) repair or
replace

e disconnection in wiring inspec-
harness between tion,
CNL41(5) - CNFS2(7) - repair or
CNFS1(2) - CNLR4(1) - replace
CNR5
f disconnection in wiring inspec-
harness between battery tion,
relay terminal M and repair or
heater relay terminal replace
CNR3
Defective contact or
disconnection in wiring After
harness between battery - inspec-
g battery relay - CNR7(2) - tion,
CNLR3(1) - CNFS3(6), repair or
(4) - CNL09(1) - starting replace
switch terminal B, or
defective starting switch
WA180-3MC 20-509 2
12
E-11 PREHEATING REMAINS ACTUATED
• Refer to electrical wiring diagram on page 20-214, PREHEAT SYSTEM.
Yes
a
Yes
b
1 4
Is voltage between Yes Is problem when Yes

CNR9 (female) and relay is replaced? c
chassis ground 3 5
normal? 1) Replace pre-
Yes Is resistance of Is there continuity
QHS water heating relay
1) Disconnect temperature sensor (CNL41) with No between CNL05(7)
CNR9. as shown in Table horn relay (female) and
2) Turn starting 1, below? (CNL42). chassis ground?
2 2) Turn starting
switch ON.
3) Approx. 2 1) Turn starting switch ON. 1) Turn starting
minutes after Is voltage between switch OFF. switch OFF. d
turning No CNR9 (female) and 2) Remove QHS 2) Disconnect No
starting switch chassis ground 0 V? water CNL05
ON: Max. 1 V. temperature
sensor.
1) Disconnect
CNR9. e
2) Disconnect No
CNL41.
3) Turn starting
switch ON. f
No
Table 1 (Reference)
Temperature Resistance value

5° C (41° F) Approx. 4 kΩ
25° C (77° F) Approx. 2 kΩ
20-510 2 WA180-3MC
12
Cause Remedy
a Defective heater relay Replace
b Defective preheating relay Replace
c Defective QHS controller inside monitor After inspection, repair

or replace
d Defective contact or disconnection in

wiring harness between CNL05(7) - CNE4 After inspection, repair
- QHS water temperature sensor terminal or replace
e Defective QHS water temperature sensor Replace
f Abnormal contact of +24 V wiring harness After inspection, repair

with wiring harness between CNR9 (1) - or replace
CNLR5(7) and CHL41(3)
WA180-3MC 20-511 2
12
MEMORANDUM
20-512 2 WA180-3MC
TROUBLESHOOTING OF
ENGINE SYSTEM (S-MODE)
S1 STARTING PERFORMANCE IS POOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-803

S2 ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-804
(1) ENGINE DOES NOT TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-804
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-805
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . 20-806
S-3 ENGINE DOES NOT PICK UP SMOOTHLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-807
S-4 ENGINE STOPS DURING OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-808
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-809
S-6 ENGINE LACKS OUTPUT (NO POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-810
S-7 EXHAUST GAS IS BLACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-811
S-8 OIL CONSUMPTION IS EXCESSIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-812
S-9 OIL BECOMES CONTAMINATED QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-813
S-10 FUEL CONSUMPTION IS EXCESSIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-814
S-11 OIL IN COOLING WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
S-12 OIL PRESSURE LAMP LIGHTS UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-816
S-13 OIL LEVEL RISES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-817
S-14 WATER TEMPERATURE BECOMES TOO HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-818
S-15 ABNORMAL NOISE IS MADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-819
S-16 VIBRATION IS EXCESSIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-820
WA180-3MC 20-801 1
TROUBLESHOOTING
12
MEMORANDUM
20-802 1 WA180-3MC
TROUBLESHOOTING S1 STARTING PERFORMANCE IS POOR
12
S1 STARTING PERFORMANCE IS POOR
(Starting always takes time)
General causes why starting performance is poor
Defective electrical system - Insufficient supply of fuel - Insufficient intake of air - Improper selection of fuel
(At ambient temperature of -10°C (-14°F) or below, use ASTM D975
No. 1, and -10°C (-14°F) or above, use ASTM D975 No. 2 diesel fuel.)
★ Battery charge table
Ambient Percent of full charge
temperature 100% 90% 80% 75% 70%
20°C (68°F) 1.28 1.26 1.24 1.23 1.22
0°C (32°F) 1.29 1.27 1.25 1.24 1.23
-10°C (-14°F) 1.30 1.28 1.26 1.25 1.24
• The specific gravity should exceed the values for 70% in the above table.
• In cold weather the specific gravity must exceed the values for 75% in the table above
Causes
Defective injection pump, (rack, plunger stuck)

Leakage, clogging, air in fuel system

Clogged fuel tank air breather hole
Defective or deteriorated battery
Clogged feed pump strainer

Clogged fuel filter, strainer
Defective air intake heater

Defective injection nozzle

Defective injection timing
Defective feed pump

Defective alternator
Defective regulator
Legend
Ease of starting
Gradually became worse O O O
Starts when warm
Questions
Preheating indicator lamp does not light up

Replacement of filters has been carried out according to operation manual O O
Non-specified fuel has been used O O O O
Battery charge lamp is ON
Starter 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 O O
Check items
Blow by gas is excessive

Mud is stuck to fuel tank cap O
When cranking engine with starter motor, little fuel comes out, even if injection pump sleeve nut is loosened
When cranking engine with starter motor, little fuel comes out, even when fuel filter air bleed plug is loosened
Leakage from fuel piping O
There is hunting from engine (rotation is irregular) O O O
When compression pressure is measured, it is found too be low ● ●
When air element is inspected, it is found to be clogged ●
When fuel filter, strainer are inspected, they are found to be clogged ● ●
When feed pump, strainer is inspected, it is found to be clogged ●
●
Troubleshooting
Heater mount does not become warm

Voltage is 26 - 30V between alternator terminal B and terminal E with engine at Yes ●
low idle No ●
Either specific gravity of electrolyte or voltage of battery is low ●
Stop fuel injection to one cylinder at a time. If there is no change in engine speed, that cylinder is not working ●
When check fuel injection timing, injection timing is found to be incorrect -------❇ ●
When control rack is pushed, it is found to be heavy or does not return (when blind plug at rear of pump is
removed, it can be seen that plunger control sleeve does not move) ●
When fuel cap is inspected directly, it is found to be clogged ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
❇ Refer to TESTING AND ADJUSTING Remedy

Clean
Clean
Clean
WA180-3MC 20-803 1
TROUBLESHOOTING S2 ENGINE DOES NOT START
12
S2 ENGINE DOES NOT START
(1) ENGINE DOES NOT TURN
General causes why engine does not turn
• Internal parts of engine are seized
★ If the internal parts of the engine are seized, carry out troubleshooting for "Engine stops during operations"
• Failure in power train
• Defective electrical system
Causes
Defective safety relay or safety switch
Defective battery terminal connection

Defective wiring of starting circuit
Defective fuel cut-off solenoid

Defective starting switch
Defective starting motor
Defective battery relay

Broken ring gear
Legend
Questions

Horn does not sound O O
Condition of horn when starting switch is turned ON
Horn sound level is low
Rotating speed is slow
Makes grating noise
When starter switch is turned to START, pinion moves out, but Soon disengages again
Makes rattling noise and
Check items
does not return O O O
When starter switch is turned to START, pinion does not move out O O
Carry out troubleshooting for defective wiring of starting circuit
When starter switch is turned to ON, there is no clicking sound O

Battery terminal is loose
When stater switch is turned to ON, solenoid linkage does not move
When battery is check, battery electrolytes 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 at ON
1) When terminal B and terminal C of starter switch are connected, engine starts ●
Troubleshooting
2) Even when terminal B and terminal C of starter motor are connected, engine start ●
3) When terminal B and terminal C of safety relay are connected, engine starts ●
4) When terminal of safety switch and terminal B of starter motor are connected, engine starts ●
5) There is no 24V voltage between battery relay terminal B and terminal E ❇ ●
When ring gear is inspected, tooth surface is found to be chipped ●
Does not move even when fuel cut-off solenoid linkage is disconnected ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace

-
20-804 1 WA180-3MC
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT

(Fuel is not being injected)
General causes why engine turns but no exhaust gas comes out
• Supply of fuel impossible
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
Standards for use of fuel
Type of Ambient temperature
fuel -22 -4 14 32 50 68 86 104°F 122°F
-30 -20 -10 0 10 20 30 40°C 50°C
ASTM D975 No.2

Diesel
ASTM
D975 No. 1
Causes
Defective injection pump (seized plunger, rack)

Broken injection pump drive shaft, key
Seized, broken feed pump (gear, shaft)

Defective fuel shut-off solenoid
Clogged, leaking fuel piping
Clogged fuel filter strainer
Improper fuel used

Legend
Lack of fuel
Exhaust gas suddenly (when starting again) stops coming out
Questions
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
Mud is stuck to fuel cap
When starting switch is turned ON, solenoid does not move
When fuel filter is drained, fuel does not come out
Check items
When engine is cranked with starter motor,

1) Injection pump coupling does not rotate
2) No fuel comes out even when fuel filter air bleed plug is loosened O O O
3) No fuel spurts out even when injection pipe sleeve nut is loosened
Rust and water are found when fuel is drained O O
Inspect injection pump ●
Troubleshooting
Inspect feed pump ●

When fuel filter, strainer are inspected, they are found to be clogged ● ●
When feed pump strainer is inspected, it is found to be clogged ●
When fuel cap is inspected, it is found to be clogged ●
Does not move even when when fuel shut-off solenoid is disconnected ●
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Remedy
Add
WA180-3MC 20-805 1
12
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START
(Fuel is being injected)
Causes
General causes why exhaust gas comes out but engine does not start
Defective, broken valve system (valve, rocker lever, etc.)

• Lack of rotating force due to defective electrical system
• Insufficient supply of fuel
Defective injection pump (rack plunger, stuck)

Clogged injection nozzle, defective spray

• Improper selection of fuel
Leakage, clogging air in fuel system

Defective air intake heater

Improper fuel used

Legend
Suddenly failed to start
When engine is cranked, abnormal noise is heard from around head
Questions

Rust is found when fuel is drained
Indicator lamp does not light up
Starer motor cranks engine slowly
Mud is stuck to fuel tank cap O
When fuel lever is placed at FULL position, it does not contact stopper O
Check items
When engine is cranked with starter motor,

1) Little fuel comes out even when injection pump sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened O
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 ●
When compression pressure is measured it is found to be low ●
When fuel filter, stainer are inspected, they are found to be clogged ● ●
Troubleshooting

Heater mount does become warm ●
Either or specific gravity of electrolyte or voltage of battery is low ●
When feed pump is operated, there is no response, or pump is heavy ●
Stop fuel injection to one cylinder at a time, if there is no change in engine speed, that cylinder is not working ●
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Clean
Clean
Clean
Remedy
20-806 1 WA180-3MC
TROUBLESHOOTING S-3 ENGINE DOES NOT PICK UP SMOOTHLY
12
S-3 ENGINE DOES NOT PICK UP SMOOTHLY
(FOLLOW-UP IS POOR)
Causes
General causes why engine doe not pick up smoothly


Clogged, fuel tank air breather hole

Seized injection pump plunger
• Improper fuel used


Worn piston ring cylinder
Improper valve clearance

Legend
Questions
Non-specified fuel has been used

Rust and water are found when fuel is drained
Engine pick-up suddenly became poor O O O
Color of gas
Black O
Check items

High idle speed is normal, but speed suddenly drops when load is applied O
There is hunting from engine (rotation is irregular) O O O
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low O
When fuel filter, stainer are inspected, they are found to be clogged ●
Troubleshooting
Stop fuel injection to one cylinder at a time, if there is no change in engine speed, that cylinder is not working ●
When control rack is pushed, it is found to be heavy, or does not return ●
When compression pressure is measured it is found to be low ● ●
When feed pump is operated, operation is too light or too heavy ●
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
WA180-3MC 20-807 1
TROUBLESHOOTING S-4 ENGINE STOPS DURING OPERATIONS
12
S-4 ENGINE STOPS DURING OPERATIONS
General causes why engine stops during operations
• Seized parts inside engine Causes
Defective injection pump (rack, plunger stuck)

Broken valve system (valve, rocker lever, etc.)
• Overheating
★ If there is an overheating and insufficient output, carry
Broken, seized piston connecting rod

out troubleshooting for overheating
Broken, pump auxiliary equipment

Broken, seized crank shaft bearing
Broken fuel pump drive shaft, key

• Failure in power train
Failure in chassis power train

★ If the engine stops because of failure in power train, carry
Broken, seized gear, shaft

Broken, seized gear train
out troubleshooting for chassis
Legend
Lack of fuel
Abnormal noise was heard and engine
stopped suddenly O O
Condition when engine stopped Engine overheated and stopped O O

Questions
Engine stopped slowly O O

There was hunting and engine stopped O O O
Fuel gauge lamp lights up
Non-specified fuel has been used O O O O
When feed pump is operated, there is no response or it is heavy O O
Engine turns but stops when transmission control lever is operated
Check items
Does not turn at all

Turns in opposite direction
Try to turn by hand using barring tool
Moves amount of backlash
Carry out trubleshooting in chassis volume

Shaft does not turn
Rust and water are found when fuel is drained
Metal particles are found when oil is drained O O
Remove oil pan and check ● ●
Troubleshooting
When gear train is inspected, it does no turn ●

Turns when pump auxiliary equipment is removed ●
Check feed pump ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Clean
Clean
Clean
Remedy
-
Add
20-808 1 WA180-3MC
TROUBLESHOOTING S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
12
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
General causes why engine does not rotate smoothly
• Air in fuel system
• Defective governor mechanism
Causes
Clogged, air in circuit between fuel tank and feed pump

Defective operation of governor (defective adjustment)
Clogged, air in circuit between feed pump and nozzle

Defective sliding of governor (solenoid spool)
Defective operation of control rack

Low speed too low
Legend
Lack of fuel
Occurs at certain speed range O
Occurs at low idle O O O O O O
Questions
Condition of hunting
Occurs even when speed is raised O O
Occurs on slopes
Rust is found when fuel is drained O O
Leakage from fuel piping
When feed pump is operated,
Check items
1) No response, light, return is quick

2) No response, light, return is normal
Engine speed sometimes rises too high
Engine is sometimes difficult to stop
Governor lever (solenoid plunger) is stiff ● ● ●
Troubleshooting
Spool valve is stiff ●

When control rack is pushed, it is found to be heavy, or does not return ●
When fuel cap is inspected it is found to be clogged ● ●
When feed pump strainer is inspected it is found to be clogged ●
When fuel filter, strainer are inspected they are found to be clogged ●
Adjust
Adjust
Adjust
Adjust
Repair
Repair
Clean
Clean
Clean
Remedy
Add
WA180-3MC 20-809 1
TROUBLESHOOTING S-6 ENGINE LACKS OUTPUT (NO POWER)
12
S-6 ENGINE LACKS OUTPUT (NO POWER)
Causes
General causes why engine lacks output
Bent fuel lever linkage, defective adjustment




• Improper fuel used
Seized injection pump plunger

(If non-specified fuel is used, output drops)


• Lack of output due to overheating

Clogged fuel filter, stainer

★ If there is overheating and insufficient output, carry out trouble-
shooting for overheating.
Legend
Suddenly
Power was lost
Questions
Gradually O O O O O O
Non-specified fuel has been used
Black
Color of exhaust gas
Engine pickup is poor and combustion is irregular O O O
Check items
High idle speed under no load is normal, but speed suddenly drops when load is applied O
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low O
There is hunting from engine (rotation is irregular) O O O O

High idle speed of engine is low O
Leakage from fuel piping
Troubleshooting

Stop fuel injection to one cylinder at a time, if there is no change in engine speed, that cyl- ●
inder is not working
When lever is placed at FULL position, it does not contact stopper ●
When feed pump is operated, operation is too light or too heavy ●
Replace
Replace
Replace
Replace
Adjust
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
20-810 1 WA180-3MC
TROUBLESHOOTING S-7 EXHAUST GAS IS BLACK
12
S-7 EXHAUST GAS IS BLACK
(Incomplete combustion)
General why exhaust gas is black Causes


Leakage of air between turbocharger and head


Clogged, seized injection nozzle

Crushed, clogged muffler

Legend
Suddenly became black O O
Color of gas Gradually became black O O
Questions

Suddenly O O O
Power was lost
Gradually O O O O
Non-specified fuel has bee used O O
Engine pickup is poor and combustion is irregular O O O O O
When exhaust manifold is touched immediately after starting engine, temperature
Check items
of some cylinders is low O

Exhaust noise is abnormal O O
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
Troubleshooting
Stop fuel injection to one cylinder at a time, if there is no change in engine speed, ●
that cylinder is not working
When check is made using delivery method, injection timing is found to be incor- ●
rect -------❇
When muffler is removed, exhaust is returns to normal ●
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
WA180-3MC 20-811 1
TROUBLESHOOTING S-8 OIL CONSUMPTION IS EXCESSIVE
12
S-8 OIL CONSUMPTION IS EXCESSIVE
(OR EXHAUST GAS IS BLUE)
★ Do not run the engine at idle for more than 20 minutes continuously. (Both low and high idle)
General causes why oil consumption is excessive Causes

• Abnormal combustion of oil
Turbocharger
• External leakage of oil
• Wear of lubrication system
★ Judge the oil consumption by comparing it to the fuel
consumption during the same period.
Leakage from oil pan, cylinder head, etc.

More than 0.5%: Check the engine
Worn valve (stem, guide), broken seal

Worn broken rear seal, seal surface
Dust sucked in from intake system
More than 1.0%: There is abnormality
Clogged breather or breather hose

Leakage from oil filter, oil cooler
Worn piston ring, cylinder liner
Leakage from oil drain plug
Worn seal at turbine end

Leakage from oil piping
Worn seal at blower end

Broken piston ring
Broken oil cooler

Legend
Questions
Oil consumption suddenly increased O

Engine oil must be added more frequently O
Engine oil becomes contaminated quickly O O
Exhaust is blue under light load
Abnormally excessive O O
Amount of blow-by gas
None
Check items
Area around engine is dirty with oil

There is oil in engine coolant water
When exhaust pipe is removed, inside is found to be dirty with oil O
Inside turbocharger intake pipe is dirty with oil
Oil level in clutch or TORQFLOW transmission damper chamber rises
Clamps for intake system are loose
When breather element is inspected, it is found to be clogged with dirty oil ●
Troubleshooting
There is external leakage of oil from engine ● ● ● ●

Pressure-tightness test of oil cooler shows there is leakage ●
Excessive play of turbocharger shaft ● ●
Check rear seal directly ●
When intake manifoldid removed, dust is found inside ●
When intake manifold is removed, inside is found to be dirty with oil ●
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Clean
Remedy
20-812 1 WA180-3MC
TROUBLESHOOTING S-9 OIL BECOMES CONTAMINATED QUICKLY
12
S-9 OIL BECOMES CONTAMINATED QUICKLY
General causes why oil becomes contaminated quickly Causes

• Intake of exhaust gas due to internal wear
Defective seat at turbocharger turbine end

• Clogging of lubrication passage
• Improper combustion
Clogged turbocharger drain pipe

Clogged breather, breather tube
• Improper oil used
• Operation under excessive load
Worn valve, valve guide
Defective safety valve

Exhaust gas is black
Clogged oil cooler
Clogged oil filter
Legend
Questions

Non-specified fuel has been used O
Black
Abnormally excessive O O O
Check items
Amount of blow-by gas
Carry out troubleshooting for "Exhaust black"

None
Oil filter caution lamp stays ON even when oil pressure rises O
When oil filter is inspected, metal particles are found O O
When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly
When breather element is inspected, it is found to clogged with dirty oil or hose is ●
Troubleshooting
broken
When oil filter is inspected, it is found to be clogged ●
When oil cooler is inspected, it found to be clogged ●
Turbocharger drain tube is clogged ●
Excessive play of turbocharger shaft ●
When safety valve is inspected, it is found to be catching or broken ●
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
WA180-3MC 20-813 1
TROUBLESHOOTING S-10 FUEL CONSUMPTION IS EXCESSIVE
12
S-10 FUEL CONSUMPTION IS EXCESSIVE
General causes why fuel consumption is excessive Causes

• Leakage of fuel
External leakage from fuel piping, fuel filter
Defective oil seal inside feed pump (piston)

Defective adjustment of fuel lever linkage

Leakage of fuel inside head cover

Defective injective pump plunger
Defective injection nozzle spray
Improper fuel injection timing

Legend
Questions
More than for other machines of same

O
model
Condition of fuel consumption Gradually increased O O
Suddenly increased O O
Black O O O
Exhaust gas color
White O
There is irregular combustion
Check items
When exhaust manifold is touched immediately after starting engine, temperature O

of some cylinders is low
Match marks on injection pump is misaligned
There is external leakage of fuel from engine
Engine oil level rises and smells of diesel fuel O
Engine low idle speed is high O
Injection pump test shows that injection amount is excessive ●
Stop fuel injection to one cylinder at a time, if there is no change in engine speed, ●
Troubleshooting

When control rack is pushed, it found to be heavy or does not return ●
When checking fuel injection timing, injection timing is found to be incorrect--- ❇ ●
Remove feed pump and check ●
When engine speed is measured, low idling speed is found to be high ●
Replace
Replace
Adjust
Adjust
Adjust
Repair
Repair
Repair
20-814 1 WA180-3MC
TROUBLESHOOTING S-11 OIL IN COOLING WATER
12
S-11 OIL IN COOLING WATER
WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
General causes why oil is in coolant water Causes
• Internal leakage in lubrication system
Broken liner O-ring, holes caused by pitting

• Internal leakage in cooling system
Broken oil cooler for power train
Internal cracks in cylinder block

Broken oil cooler core, O-ring
Insufficient protrusion of liner

Broken head, head gasket
Broken water pump

Legend
Questions

Suddenly increased O O O
Oil level
Gradually increased O O
Hard water is being used as coolant water O O
Check items
Engine oil level has risen, oil is cloudy white O O O

Excessive air bubbles inside radiator, spurts back
Hydraulic oil, torque converter / transmission oil is cloudy white
When hydraulic oil, torque converter / transmission oil is drained, water is found
Pressure-tightness test of oil cooler shows there is leakage ● ●
Troubleshooting
Pressure-tightness test of cylinder head shows there is leakage ●

Remove cylinder head and check ●
Remove oil pan and check ● ●
Check water seal and oil seal of water pump ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
WA180-3MC 20-815 1
TROUBLESHOOTING S-12 OIL PRESSURE LAMP LIGHTS UP
12
S-12 OIL PRESSURE LAMP LIGHTS UP
(DROP IN OIL PRESSURE)
General causes why oil pressure lamp lights up
★ Standards for use of oil
• Leakage clogging, wear of lubricating system Selection of oil SAE number
according to ambient temperature
• Defective oil pressure control Type of oil
-22 -4 14 32 50 68 86 104°F
• Improper oil used (improper viscosity) -30 -20 -10 0 10 20 30 40°C
• Deterioration of oil due to overheating SAE 30
SAE 10W
Engine oil
SAE 10W-30
SAE 15W-40
Causes
Clogged, broken oil pipe inside oil pan
Leaking, crushed hydraulic piping

Clogged strainer inside oil pan
Defective oil pressure sensor

Broken suction pipe brazing
Defective oil level sensor

Insufficient oil in oil pan
Defective regular valve
Defective relief valve
Worn bearing journal
Defective oil pump
Clogged oil cooler

Water, fuel in fuel
Clogged oil filter
Legend
Questions
Replacement of filter has not been carried out according to operation manual
Caution lamp lights up O
Lights up at low idle O O
Condition when oil pressure lamp lights Lights up at low, high idle O O O O
up Lights up on slopes
Sometimes lights up O O
Check items
There is clogging, leakage from hydraulic from hydraulic piping (external)

Oil level sensor lamp lights up
When oil level in oil pan is checked, it is found to be low
Metal particles are found when oil is drained
Metal particles are stuck to oil filter element O
Oil is cloudy white or smells of diesel oil
When oil filter is inspected it is found to be clogged ● ●
Carry out troubleshooting for"Oil
Remove oil pan and inspect ● ● ●

Troubleshooting
Oil pump rotation is heavy, there is play ●

level rises"
There is catching of relief valve or regular valve, spring, or valve guide is broken ● ●
When oil level sensor is replaced, oil pressure sensor lamp goes out ●
When oil pressure is measured, it is found to be within standard value ●
When oil cooler is inspected, it is found to be clogged ●

Replace
Replace
Replace
Adjust-
replace
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
-
Add
20-816 1 WA180-3MC
TROUBLESHOOTING S-13 OIL LEVEL RISES
12
S-13 OIL LEVEL RISES
★ If there is oil in the coolant water, carry out troubleshooting for "Oil is in coolant water".
General causes why oil level rises Causes

• Water in oil (cloudy white)
Defective part inside injection pump (flange type)

Clogged water pump breather hole, defective seal
Defective seal of pump or auxiliary equipment

• Fuel in oil (diluted, and smells of diesel fuel)
Leakage of fuel form piping inside head cover
Damage liner O-ring, holes made by pitting

• Entry of oil from other components
Worn, damaged rear seal surface

Broken oil l cooler core, O-ring
Defective nozzle holder sleeve
Cracks inside cylinder block

Defective thermostat seat

Legend
Questions

There is oil in radiator coolant water O O O O
Exhaust gas white O O
When engine is first started, drops of water come from muffler
Leave radiator cap open. When engine is idling, an abnormal number of bubbles
O
appear, or water spurts back
Check items
Water pump breather hole is clogged with mud

When water pump breather hole is cleaned, water comes out
Oil level goes down in clutch, torque converter, transmission, or damper chamber
Oil level goes down in hydraulic tank
Engine oil smells of diesel fuel
Fuel is added more frequently
Pressure-tightness test of oil cooler shows there is leakage ●
Pressure-tightness test of cylinder head shows there is leakage ●
When compression pressure is measured, it is found to below ●
Troubleshooting
Remove water pump and inspect ●

Check rear seal ●
When pump auxiliary equipment is removed, seal is found to be broken ●
Remove head cover and inspect ●
Remove injection pump and inspect ●
There is improper contact of thermostat seat valve ●
Remove oil pan and inspect ● ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
WA180-3MC 20-817 1
TROUBLESHOOTING S-14 WATER TEMPERATURE BECOMES TOO HIGH
12
S-14 WATER TEMPERATURE BECOMES TOO HIGH
(OVERHEATING)
★ Check that maintenance monitor panel coolant level caution lamp is not lit up
★ When maintenance monitor panel water temperature gauge is normal, go to troubleshooting of machine monitor system
(M-mode)
General causes why water temperature become too high Causes
• Lack of coolant water (deformation, damage of fan)
• Drop in heat dissipation efficiency
Rise in torque converter oil temperature

Defective thermostat (does not open)
• Defective cooling circulation system
Defective water temperature gauge
Fan belt slipping, worn fan pulley

• Rise in oil temperature of power train
Clogged, crushed radiator fin

★ Carry out troubleshooting for chassis.
Clogged broken oil cooler

Insufficient coolant water
Defective pressure valve

Clogged radiator core
Broken water pump
Legend
Suddenly overheated O O
Questions
Condition of overheating
Always tends to overheat O O
Rises quickly O
Water temperature 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 coolant water
Coolant water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Check items
Engine oil level has risen, oil is cloudy white O

There is play when fan pulley is rotated
Radiator shroud, inside of underguard is clogged with dirt or mud
When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hoses or loose clamps
Belt tension is found to be slack
Power train oil temperature enters red range before engine water temperature
Temperature difference between top and bottom radiator tank is excessive ●
Temperature difference between top and bottom radiator tank is slight ● Carry out troubleshooting for chassis
When water filler port is inspected, the core is found to be clogged ●
Troubleshooting
When function test is carried out on the thermostat, it does not open even at the ●
cracking temperature
When water temperature is measured, it is found to be normal ●
When oil cooler is inspected, it is found to be clogged ●
When measurement is made with radiator cap tester, set pressure is found to be low ●
When compression pressure is measured, it is found to be low ●
Remove oil pan and inspect
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
-
Add
20-818 1 WA180-3MC
TROUBLESHOOTING S-15 ABNORMAL NOISE IS MADE
12
S-15 ABNORMAL NOISE IS MADE
Causes
Defect inside of muffler (dividing board out of position)

★ Determine if the noise is an internal noise or external noise.
General causes why abnormal noises are made

Broken valve system (valve, rocker lever, etc.)
Leakage of air between turbocharger and head

• Abnormality due to defective parts
• Abnormal combustion noise
Improper adjustment of valve clearance

Deformed fan, interference of fan belt
• Air sucked in from intake system
Clogged, seized injection nozzle

Worn piston ring, cylinder liner
Improper gear train backlash

Missing, seized bushing
Legend
Questions
Gradually occurred O O
Condition of abnormal noise
Suddenly occurred O O O
Black O O
Metal particles are found in oil filter
Check items
Engine pickup is poor and combustion is irregular

When exhaust manifold is touch immediately after starting engine, temperature of O
some cylinder is low
Abnormal noise is loud when accelerating engine O O O O O O
Leakage of air between turbocharger and head, loose clamp
Vibrating noise is heard from around muffler
When compression pressure is measured, it found to be low ●
Remove gear cover and inspect ● ●
Troubleshooting
Stop fuel injection to one cylinder at a time. If there is no change in engine speed, ●
Injection pump test show that injection amount is incorrect ●
Fan is deformed, or belt is loose ●
When valve clearance is inspected, it is found to be outside standard value ●
Remove cylinder head cover and inspect ●
When muffler is removed, abnormal noise goes away ●
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Repair
Repair
Repair
Remedy
WA180-3MC 20-819 1
TROUBLESHOOTING S-16 VIBRATION IS EXCESSIVE
12
S-16 VIBRATION IS EXCESSIVE
Causes
★ If there is abnormal noise together with the vibration,

Misalignment between engine and power train
Loose engine mounting bolts, broken cushion
carry out troubleshooting for "Abnormal noise is made"
Valve system (valve, rocker lever, etc.) stuck

General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
Broken inside output shaft (damper)

Worn connecting rod, main bearing
• Improper alignment
Improper gear train backlash

Worn balancer, cam bushing
• Abnormal combustion
Worn support pilot

Legend
Questions

Suddenly increased O O
Condition of vibration
Gradually increased O O O O
Metal particles are found in oil filter
Metal particles are found when oil is drained
Check items
Oil pressure is low at low idle O O

Vibration occurs at mid-range speed O O
Vibration follows engine speed O O O O O
Exhaust gas is black O
Remove oil pan and inspect ●
Remove side cover and inspect ●
Check for worn support pilot, play ●
Troubleshooting
Inspect for loose engine mounting bolts, broken cushion ●

Inspect inside of output shaft (damper) ●
When radial runout, face runout are measured, they are found to be outside stan- ●
dard value
Remove front cover and inspect ●
Remove head cover and inspect ●
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
Remedy
20-820 1 WA180-3MC
TROUBLESHOOTING OF HYDRAULIC &
MECHANICAL SYSTEMS (T-MODE)
POWER TRAIN
T-1 MACHINE DOES NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-903
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES . . . . . . 20-904
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR . . . . . . . . . . . . . . . . . . . . 20-906
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR . . . . . . . . . . . . . . . . . 20-907
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-908
STEERING SYSTEM
T-6 STEERING WHEEL DOES NOT TURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-909
T-7 STEERING IS HEAVY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-910
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-911
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING . . . . . . . . . . . . . . . . . . . . 20-911
T10 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . 20-912
T11 EXCESSIVE SHOCK TO MACHINE WHEN STEERING WHEEL IS TURNED
FULLY TO LEFT OR RIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-912
BRAKE SYSTEM
T-12 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-913
T-13 BRAKE IS NOT RELEASED, BRAKE DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-914
WORK EQUIPMENT
T-14 BOOM DOES NOT RISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-915
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER . . . . . . . . . . . . . . . . . . . . . . . 20-916
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT . . . . . . . . . . . . . . . . . . . 20-917
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) . . . . . . . . . . . . . . 20-917
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-917
T-19 BOOM SHAKES DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-918
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM
HOLD TO RAISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 20-918
T-21 BUCKET DOES NOT TILT BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-919
T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER . . . . . . . . . . . . . . . . . . . . . . . . . 20-920
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION . . . . . . . . . . . . . . . 20-921
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-921
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-921
T-26 BUCKET SHAKES DURING LOADING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-922
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM
HOLD TO TILT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-922
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY . . . . . . . . 20-923
Explanation of symbols in Table

The following symbols are used on the Cause column to show the action to be taken to remove the cause.
X: Replace, : Correct, A: Adjust, C: Clean
WA180-3MC 20-901 1
TROUBLESHOOTING
MEMORANDUM
20-902 1 WA180-3MC
TROUBLESHOOTING T-1 MACHINE DOES NOT START
12
POWER TRAIN
T-1 MACHINE DOES NOT START
Ask the operator the following questions.
• Did the problem suddenly start?
Yes = Internal part seized or broken
• Was there any abnormal noise when this happened?
Yes = Component broken.
Checks before troubleshooting Causes

• Does the machine monitor function properly?
Excessive leakage of oil from transmission clutch shaft seal portion (worn, broken)
Defective operation inside transmission clutch (seized, worn, oil leakage, broken)
Defective operation of clutch pressure regulator valve of control valve
• Is the transmission oil level correct?
Breakage inside accumulator valve (abnormal wear of spool portion)

Breakage inside torque converter (bearing, turbine, pump, stator, seal, etc.)
• Is the type of oil correct?
Defective operation of control valve (dirt caught, scuffing, etc.)

• Is the transmission filter or strainer clogged?
• Does the electrical circuit of the transmission
Breakage inside transmission (bearing, gear, housing)

control work properly?
Defective operation of torque converter relief valve

• Is the transmission oil deteriorated?
• Does the oil smell of burning? No drive for charging pump (defective PTO)
Air sucked in at charging pump suction end
Breakage inside transmission control valve

• Is there any damage or leakage of oil that can be
Defective transmission solenoid valve

Defective operation of solenoid valve
Defective transmission cut-off switch

seen externally?
Clogged orifice of control valve
Defective parking brake switch

• Is the drive shaft broken?
• Is the wheel brake or parking brake locked?
Defective charging pump
Torque Accumulator Electrical

Charging pump Converter Transmission control valve Transmission valve system
Remedy C
X X X X X X X X X X X X X X X
No. Problems a b c d e f g h i j k l m n o p q
1 Does not start in any transmission range ● ● ● ● ● ● ● ● ● ● ● ● ● ●
2 Does not start in certain transmission ranges ● ● ● ● ● ● ●
3 Does not start when oil temperature rises ● ● ●
4 Torque converter stall speed does not go down to specified ● ● ● ● ●
speed in any transmission range
5 Torque converter stall speed does not go down to specified
● ● ●
speed in certain transmission ranges
6 Torque converter charging pressure does not rise ● ● ● ● ●
7 Transmission clutch pressure does not rise in any speed range ● ● ● ● ● ●
8 Transmission clutch pressure does not rise in certain speed
● ● ● ●
ranges
9 Metal particles (aluminium, copper, iron etc.) stuck to filter or
● ● ● ●
strainer
Legend: X: Replace : Correct A: Adjust C: Clean
WA180-3MC 20-903 1
TROUBLESHOOTING T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK,
12
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK,
LACKS POWER ON SLOPES
Checking for abnormalities
• Measure digging operations and speed when traveling on level ground and on slopes, and check if there is actually an
abnormality or whether it is just the feeling of the operator
20-904 1 WA180-3MC
TROUBLESHOOTING T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK,
12

• Is there any oil leaking from the joints of the
piping or valves?
• Is there any dragging of the wheel brake or
parking brake?
• Is the tire inflation pressure and tread pattern
Oil leakage inside torque converter (seal ring, bushing, snap ring, bearing, etc.)
normal?
Leakage of oil from seal of shaft in work equipment & steering circuit pump
• Is the method of operation correct?
Defect inside transmission control valve (wear, scratches on spool, etc.)

Defective operation of clutch pressure regulator valve of control valve
Breakage inside torque converter (bearing, turbine, pump, stator, etc.)
Breakage inside accumulator valve (abnormal wear of spool portion)

Leakage of oil from seal ring of transmission clutch pack shaft
Leakage of oil from transmission clutch piston seal
Clogged torque converter cooler circuit

Defective torque converter relief valve
Clogged orifice of control valve
Clogged transmission breather

Breakage inside transmission
Defect in engine related part

Transmis-
Charging Torque sion Control Torque converter / Accumula- Others
pump converter control valve transmission circuit tor valve
valve
C C
Remedy
X X X X X X X X X X X X X
No. Problems a b c d e f g h i j k l m n o p
1 Abnormality in all transmission ranges ● ● ● ● ● ● ● ● ● ● ●
2 Abnormality in certain transmission ranges ● ● ● ● ●
3 When oil temperature is low, abnormal noise comes from ●
charging pump
4 Torque converter oil overheats ● ● ● ● ● ● ● ●
5 Abnormality in high idling and low idling speeds ● ● ●
6 Abnormality in each stall engine speed ● ● ● ● ●
7 Torque converter relief pressure is low ● ● ● ● ● ●
8 Transmission clutch pressure: Low in every transmission ● ● ● ● ●
range
9 Transmission clutch pressure: Low in certain transmission
● ● ● ● ●
ranges
10 Transmission clutch pressure: Indicator is unstable and fluctu- ●
ates violently
11 Transmission oil level changes ● ● ●
12 Metal particles stuck to transmission strainer or torque con- ● ● ●
verter filter
WA180-3MC 20-905 1
TROUBLESHOOTING T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING
12
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING
GEARS
It is difficult to measure if the shock is excessive or normal, so judge that the shock is excessive in the following cases.
• When it is clear that the shock has become greater than before.
• When the machine is compared with another machine of the same class and the shock is found to be greater.

• Is the engine idling speed too high?
Clogged oil drain hole around circumference of clutch pack cylinder

Defective operation of transmission clutch pressure regulator valve
• Is there play in any of the drive shafts?
Defective piston return due to broken or flattened return spring of
Defective operation of accumulator valve

Defective operation of quick return valve
Defective operation of modulation valve
Stuck accumulator piston
clutch pack
Accumulator
Control valve Transmission valve
C
Remedy
X X X X X X
No. Problems a b c d e f g
1 Shock is excessive in every transmission range ● ● ● ●
2 Shock is excessive in certain transmission ranges ● ● ●
3 Clutch pressure is too high ●
20-906 1 WA180-3MC
TROUBLESHOOTING T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFT-
12
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR
SHIFTING GEARS
• Was there excessive time lag? Was there any abnormality in the travel speed or thrusting force? Was there any lack of
power when traveling up slopes?
Yes = Go to T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes

Breakage inside accumulator valve (broken spring, worn spool)

Leakage of oil from transmission clutch pack, shaft seal ring
Leakage of oil from joint of transmission housing and valve

Leakage of oil from transmission clutch pack, piston seal
• Is there any oil leaking from the joints of the
piping or valves?
Leakage of oil due to wear of piston, spool or bore

Defective operation of quick return valve
Defective operation of accumulator
Clogged orifice
Transmission control Accumulator

Transmission
valve valve
C
Remedy
X X X X X X X
No. Problems a b c d e f g h
1 Time lag is excessive in every transmission range ● ● ● ●
2 Time lag is excessive in certain transmission ranges ● ●
3 Clutch pressure is low in every transmission range ● ●
4 Clutch oil pressure is low in transmission ranges where time
● ● ●
lag is excessive
WA180-3MC 20-907 1
TROUBLESHOOTING T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH
12
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH

• Does oil temperature rise during torque converter stall and go down when there is no load?
Yes = Selection of transmission range
• Does oil temperature rise only when carrying out scooping work?
Yes = Improvement in method of operation

• Are the radiator water level and fan belt tension
Breakage inside torque converter (bearing, pump, turbine, stator, etc.)
Leakage of oil from seal of shaft in work equipment circuit and steer-
Leakage of oil inside torque converter (seal ring, bushing, snap ring,
correct?
Defective bleeding of air from torque converter cooler or clogged

Defective transmission clutch pressure regulator valve

• Measure the torque converter oil temperature.
Is it actually high?
Defective torque converter relief valve

No = Defective oil transmission gauge
Clogged transmission breather

Breakage inside transmission
Defect in engine related part

ing circuit pump

bearing, etc.)
circuit
Charging Torque Torque converter /
Transmission Others
pump converter transmission circuit
C
Remedy
X X X X X X X X X X
No. Problems a b c d e f g h i j k
1 When oil temperature is low, abnormal noise comes from ●

charging pump
2 Abnormality in high idling and low idling speeds ● ● ● ●
3 Abnormality in each stall engine speed ● ● ● ● ●
4 Abnormality in travel speed, thrusting force and grade ability ● ● ● ● ● ● ● ● ● ●
in all transmission ranges
5 Abnormality in travel speed, thrusting force and grade ability
●
in certain transmission ranges
6 Torque converter relief pressure is low ● ● ● ● ●
7 Transmission clutch pressure: Low in every range ● ● ● ●
8 Transmission clutch pressure: Low in certain ranges ●
9 Transmission clutch pressure: Indicator is unstable and
●
fluctuates violently
10 Transmission oil level changes ● ● ●
11 Metal particles stuck to transmission strainer or torque con- ● ● ●
verter filter
20-908 1 WA180-3MC
TROUBLESHOOTING T-6 STEERING WHEEL DOES NOT TURN
12
STEERING SYSTEM
★ There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the
steering, check the operation of the work equipment also.
T-6 STEERING WHEEL DOES NOT TURN

Yes = Steering equipment damaged or broken
• Was there previously any symptom, such as heavy steering?
Yes = Wear of internal parts of steering equipment, defective seal

• Is the hydraulic oil level correct?
Defective inside steering cylinder (oil leakage from piston seal)

• Has the safety bar been removed from the frame?
Defective inside priority valve (relief valve, plunger)

Defective steering pump, work equipment pump
Defective inside orbital

Defective pump PTO
Pump Valves Others
Remedy
X X X X X
No. Problems a b c d e
1 Steering wheel does not turn either to left or to right ● ● ● ●
2 In Item 1, movement of work equipment is abnormal ● ●
3 Steering wheel turns only to one side (left or right) ●
4 Steering wheel is heavy and cannot be turned ● ● ●
5 Oil pressure in steering circuit does not rise at all ● ●
6 Steering wheel turns, but steering does not turn ● ●
WA180-3MC 20-909 1
TROUBLESHOOTING T-7 STEERING IS HEAVY
T-7 STEERING IS HEAVY

Yes = Steering equipment damaged or broken
• Was there previously any symptom, such as heavy steering?
Yes = Wear of internal parts of steering equipment, defective seal
Checks before troubleshooting. Causes

• Is the hydraulic oil level correct? Is the type of
Clogged filter at hydraulic oil return side, faulty bypass valve

Defect inside steering cylinder (oil leakage from piston seal)
oil correct?
• Is there any leakage of oil from the
hydraulic hoses, valves, or cylinders?
Defect inside priority valve (relief valve, plunger)

Defective steering pump, work equipment pump
• Is there any scuffing of the center hinge pin
bearing or steering cylinder pin or bushing?
• Is the tire inflation pressure correct?
Checking for abnormalities.
• Measure the operating force of the steering
wheel and the time taken to turn the steering,
and check the values in the Standard Value
Defect inside orbitrol
Clogged oil cooler

Table to see if there is really any abnormality.
Pump Valves Others
Remedy A C C
X X X
X X X
1 Steering is heavy when turned in either direction (left or right) ● ● ● ●
2 Steering is heavy when turned in one direction (left or right) ● ●
3 Steering is particularly heavy when engine is at low speed ● ● ●
4 Boom lifting speed is slow when engine is running at full
●
throttle
5 Steering is heavy and steering wheel jerks ● ●
6 Oil pressure in steering circuit is low ● ● ●
7 Oil pressure rises in return piping for steering cylinder ●
8 Hydraulic oil overheats ●
20-910 1 WA180-3MC
TROUBLESHOOTING T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK
12
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK

• Is the hydraulic oil level correct? Is the type of
Defective inside steering cylinder (inside surface of cylinder, piston

oil correct?
• Is there any play in the center hinge pin
bearing or steering cylinder pin or bushing?
• Is there any variation in the tire inflation
pressure?
• Is the steering wheel play correct?
• Operate at a safe place and check how the
steering wheel shakes and under what conditions.
★ In cases where the steering wheel is heavy
but does not shake, go to "T-7 Steering is heavy."
Defective cushion valve

Defect inside orbitrol
seal, nut, bolt)

Valves Cylinder Valves
Remedy
X X X
No. Problems a b c d
1 Chassis shakes when traveling on rough road surface ● ● ●
2 Shakes when steering is suddenly turned during operation or ● ● ●
travel
3 Chassis shakes when accelerating during travel operations ● ● ●
4 Chassis shakes when engine is started ●
5 Excessive shock when steering wheel is turned back ●
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN

TRAVELING
Causes: Defective steering

• Defect inside of Orbit-Roll valve
• Oil leakage inside steering cylinder
• Variation in tire inflation pressure
WA180-3MC 20-911 1
TROUBLESHOOTINGT-10 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT
12
T-10 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND
RIGHT
Cause
• Defective cylinder piston packing
• Defect inside Orbit-roll
T-11 EXCESSIVE SHOCK TO MACHINE WHEN STEERING WHEEL

IS TURNED FULLY TO LEFT OR RIGHT
Cause
• Deteriorated, damaged or missing front frame bumper
20-912 1 WA180-3MC
TROUBLESHOOTING T-12 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR
12
BRAKE SYSTEM
T-12 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR
Ask the operator the following questions
Yes = Brake equipment broken
• Did the problem gradually appear?
Yes = Deterioration of seal, wear of lining, disc

• Is the brake oil level correct?
Internal damage of master cylinder (damaged piston cup or scuffed

• Is the brake pedal play correct?
Contact with metal portion due to complete wear of brake lining

• Is there any leakage of oil from the brake tube
or connector?
• Is there any deformation of the tube?
Wear or other abnormality of brake lining inside axle

• Is the tire inflation pressure and tread pattern
Defective operation of brake piston inside axle

normal?
Defective brake piston seal inside axle

• Measure the braking force and compare with
Defective brake portion inside axle

the Standard Value Table to check if the
braking effect is poor
Defective brake booster
Air in brake circuit

Defective pump
inside axle
piston)
Booster Inside axle Pump
Remedy
X X X X X X X X
No. Problems a b c d e f g h i
1 Resistance is low when brake pedal is depressed ● ● ●
2 Brake pedal is heavy when it is depressed ● ● ●
3 Abnormal operating force is needed to obtain specified ● ● ● ● ●
braking force
4 Abnormal noises is heard from axle brake is applied ● ●
5 Machine cannot travel (lacks rimpull) ● ● ●
6 Jack up four wheels and set axles on stand. In F1, when brakes ● ● ● ● ●
are applied, only certain wheels rotate quickly
7 Air can be seen flowing out when air is bled from brake cir- ●
cuit. Returns to normal after air is bled
8 Abnormal oil leakage is found when checking leakage of oil
●
inside axle.
9 Many metal particles are found in axle oil ●
WA180-3MC 20-913 1
TROUBLESHOOTING T-13 BRAKE IS NOT RELEASED, BRAKE DRAGS
12
T-13 BRAKE IS NOT RELEASED, BRAKE DRAGS

• Is the play of the brake pedal correct?
Defect inside brake booster (spring, power piston, spool scuffing)

Defect inside master cylinder (clogged oil port, piston scuffing)
• Does the machine travel smoothly under
inertia on flat ground?
• Jack up the four wheels and check the
rotating resistance of the tires.
Defect in brake inside axle (liner lining, etc.)

Defect return of brake piston inside axle
Booster Axle
brake brake
Remedy
X X X X
No. Problems a b c d
1 When oil is drained from air bleed plug in brake high pressure ● ●
circuit, circuit pressure drops and brake is released circuit
2 When four wheels are jacked up, axles are put on stands,
engine is stopped, parking brake is released and tires are ● ●
rotated by hand, certain wheels are heavy turning
3 When four wheels are jacked up, axles are put on stands,
engine is stopped, parking brake is released, transmission is
●
set to neutral and tires are rotated by hand, wheels rotate
smoothly, but become heavy when engine is started
20-914 1 WA180-3MC
TROUBLESHOOTING T-14 BOOM DOES NOT RISE
WORK EQUIPMENT
T-14 BOOM DOES NOT RISE

Yes = Equipment seized, damaged Was there any abnormal noise when this happened? (from where?)
• Was there previously any symptom, such as the speed becoming slow?
Yes = Wear of internal parts, deterioration in spring

• Is the hydraulic oil level correct?
Clogged suction port of pump or excessive air in oil

• Is the travel of the boom control lever and
Defective hydraulic pump and steering pump

spool properly adjusted?
Breakage inside valve body (boom spool)

Defective operation of main relief valve
Damaged boom cylinder piston seal

No PTO drive for pump
Main control
Tank - pump Cylinder
valve
Remedy C
X X X X X X
No. Problems a b c d e f
1 Bucket cannot be operated and boom cannot be raised ● ● ● ●
2 Chassis can be raised with boom, but boom cannot be raised ● ●
or bucket can be operated, but boom cannot be raised
3 Boom can be raised when there is no load, but cannot be ● ● ●
raised when there is a load
4 Abnormal noise comes from hydraulic pump ● ●
5 Excessive hydraulic drift of boom cylinder ● ●
WA180-3MC 20-915 1
TROUBLESHOOTINGT-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POW-
12
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING
POWER

• Is the travel of the boom control lever and
Defective operation or defective adjustment of main relief valve

main control valve spool properly adjusted?
• Is there any seizure of the work equipment
linkage? (Is there any abnormal noise?)
Breakage or wear inside valve body (boom spool)

• There is a strong connection between
Clogged suction port of pump, or air in oil

lifting power and speed, so this problem
first appears as a lack of lifting speed.
Damaged boom cylinder piston seal

Measure the boom lifting speed when the
bucket is loaded and use the Standard Value
Defective hydraulic pump

Table to judge if there is any abnormality.
Defective steering pump

Main control
Tank - pump Cylinder
valve
C A
Remedy
X X X X X X
No. Problems a b c d e f
1 Bucket tilting power and speed are abnormal and boom lifting ● ● ● ●
speed is slow
2 Bucket tilting power and speed are normal, but boom lifting
● ●
speed is slow
3 As in Item 1, but lifting speed is particularly slow when oil ● ● ● ●
temperature rises
4 Abnormal noise comes from hydraulic pump ● ● ●
5 Excessive hydraulic drift of cylinder ● ●
6 Relief pressure of relief valve in main control valve is low. ● ● ●
20-916 1 WA180-3MC
TROUBLESHOOTING T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN
12
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A
CERTAIN HEIGHT
Checks before troubleshooting
• Can any deformation be seen in the boom cylinder?
Cause
• Swelling or internal damage to boom cylinder tube
★ For other abnormalities when the boom is raised, go to "T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS
LIFTING POWER."
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER

(BUCKET FLOATS)
See "T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER."

• Is the oil level in the hydraulic tank correct?
• Is the stroke of the boom spool in the main control valve properly adjusted?
Cause
• Defective seating of suction valve at boom cylinder rod end of main control valve
• Oil leakage from boom cylinder piston seal
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM

Yes = Dirt caught in valve, broken part
Yes = Worn parts

• Is the type and level of oil in the hydraulic tank correct?
• Is the boom spool at the HOLD position?
Yes = Seized link bushing, defect in spool detent
Troubleshooting and Cause

• When measuring the hydraulic drift, is there any sound of oil leakage from inside the boom cylinder?
Yes = Defective cylinder packing
WA180-3MC 20-917 1
TROUBLESHOOTING T-19 BOOM SHAKES DURING OPERATION
12
T-19 BOOM SHAKES DURING OPERATION
When digging or leveling operations are carried out with the boom control lever at HOLD, the bucket and boom move up and
down to follow the shape of the ground.
Troubleshooting and Cause

Measure the hydraulic drift of the boom and check if it is possible to lift the chassis with the boom cylinder.
1. If the hydraulic drift of the boom cylinder is outside the standard value, go to "T-18 EXCESSIVE HYDRAULIC DRIFT
OF BOOM."
2. If the chassis cannot be raised with the boom cylinder, go to "T-17 BUCKET CANNOT BE PUSHED WITH BOOM
CYLINDER."
3. If the hydraulic drift of the boom is normal, operate the boom several times, and operate the boom cylinder to the end of
its stroke. Is it now possible to raise the chassis with the boom cylinder?
Yes = Vacuum had formed inside cylinder
★ However, if this problem appears frequently, the suction valve at the boom cylinder rod end is defective.
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS

OPERATED FROM HOLD TO RAISE
Checking problem
• When the engine is run at low idling and the boom control lever is operated slowly from HOLD to RAISE, the boom goes
down under its own weight. When the lever is operated fully to the RAISE position, the condition returns to normal.
Cause
• Defective seating of check valve for boom spool in main control valve
20-918 1 WA180-3MC
TROUBLESHOOTING T-21 BUCKET DOES NOT TILT BACK
12
T-21 BUCKET DOES NOT TILT BACK
Yes = Equipment seized, damaged Was there any abnormal noise when this happened? (from where?)
• Was there previously any symptom, such as the speed becoming slow?
Yes = Wear of internal parts, deterioration in spring

• Is the travel of the bucket control lever and
Defective operation of safety valve (with suction valve) at bucket cyl-

spool properly adjusted?
Clogged suction port of pump or excessive air in oil
Defective hydraulic pump and steering pump
Breakage inside valve body (bucket spool)

Defective operation of main relief valve
Damaged bucket cylinder piston seal

No PTO drive for pump
inder bottom end

Tank - pump Main control valve Cylinder
Remedy C A
X X X X X X X
1 Boom cannot be operated and bucket cannot be tilted back ● ● ● ●
2 Chassis can be raised with bucket, but bucket cannot be tilted
back; or boom can be operated, but bucket cannot be tilted ● ● ●
back
3 Bucket can be tilted back when there is no load, but cannot be
● ● ● ●
tilted back during digging or scooping operations
4 Abnormal noise comes from hydraulic pump ● ●
5 Excessive hydraulic drift of bucket cylinder ● ● ●
WA180-3MC 20-919 1
TROUBLESHOOTINGT-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER
12
T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS
POWER

• Is the travel of the bucket control lever and
Defective operation of safety valve (with suction valve) at bucket cyl-

main control valve spool properly adjusted?
Defective operation or defective adjustment of main relief valve

• Is there any seizure of the work equipment
linkage? (Is there any abnormal noise?)
Breakage or wear inside valve body (bucket spool)

• Check if there is lack of tilt-back power
during actual operations.
Clogged suction port of pump or air in oil

• Measure the operating speed of the bucket
and use the Standard Value Table to check if
Damaged bucket cylinder piston seal

there is any abnormality
Defective hydraulic pump

Defective steering pump
inder bottom end

Tank - pump Main control valve Cylinder
C
Remedy A
X X X X X X
X
1 Boom lifting power and speed are abnormal and bucket ● ● ● ●

tilt-back power or speed are abnormal
2 Boom lifting power and speed are normal, but bucket tilt-back ● ● ●
power or speed are abnormal
3 As in Item 1, but problem is particularly bad when oil
● ●
temperature rises
4 Abnormal noise comes from hydraulic pump ● ● ●
5 Excessive hydraulic drift of bucket cylinder ● ● ●
6 Relief pressure of relief valve in main control valve is low ● ● ● ●
7 Discharge from hydraulic is low ● ●
20-920 1 WA180-3MC
TROUBLESHOOTING T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK
12
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK
OPERATION
• Can any deformation be seen in the bucket cylinder?
Cause
• Swelling or internal damage to bucket cylinder tube
• For other abnormalities when the bucket is operated, go to "T-22 BUCKET MOVEMENT IS SLOW OR TILT BACK
LACKS POWER."
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER

See "T-22 BUCKET MOVEMENT IS SLOW OR TILT BACK LACKS POWER."

• Is the stroke of the bucket spool in the main control valve properly adjusted?
Cause
• Defective seating of safety valve (with suction valve) at bucket cylinder rod end of main control valve
• Oil leakage from bucket cylinder piston seal
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET

Yes = Dirt caught in valve, broken part
Yes = Worn parts

• Is the bucket spool at the neutral position?
Yes = Seized link bushing, defect in spool detent

• Use the Standard Value Table to check if the hydraulic drift of the bucket is actually excessive.
Cause
• Oil leakage inside bucket cylinder
• Defective seating of safety valve (with suction valve) at bottom end
• Defective oil tightness of bucket spool
WA180-3MC 20-921 1
TROUBLESHOOTING T-26 BUCKET SHAKES DURING LOADING OPERATION
12
T-26 BUCKET SHAKES DURING LOADING OPERATION
(Main control valve at HOLD)

• Is there play in the work equipment linkage pin, bushing? (Is there any abnormal noise?)
Cause
• Defective bucket cylinder piston seal
• Defective operation of safety valve (with suction valve) at bucket cylinder rod end. If any other problem occurs at the
same time, carry out troubleshooting according to the nature of the problem.
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS

OPERATED FROM HOLD TO TILT
Checking problem
• When the engine is run at low idling and the bucket control lever is operated slowly from HOLD to TILT, the bucket
dumps momentarily under its own weight. When the lever is operated fully to the TILT position, the condition returns to
normal.
Cause
• Defective seating of check valve for bucket spool in main control valve
20-922 1 WA180-3MC
TROUBLESHOOTING T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DOES
12
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DOES
NOT MOVE SMOOTHLY
Checking for abnormalities Causes

• Compare operating force of the lever with
Deformation of valve body due to uneven tightening of valve mount

the value in the Standard Value Table to see if it
Defective out-of-roundness of main control valve body and spool

Defective clearance between main control valve body and spool
is actually excessive.
Seizure, stiffness of rotating portion of control lever, link
Catching of main control valve spool detent
Dirt caught in main control valve spool

Bent main control valve spool
Lever bolts Main control valve
Remedy
1 Levers are heavy when there is a load and oil pressure is high ● ● ●
2 Levers become heavy as oil temperature changes ● ● ●
3 Levers become heavy at places during operation regardless of
●
oil pressure or temperature
4 Levers are always heavy during operation regardless of oil ● ● ● ●
pressure or temperature
5 Levers are still heavy after control lever link is disconnected ●
at valve connection
WA180-3MC 20-923 1
TROUBLESHOOTING T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DOES
12
MEMORANDUM
20-924 1 WA180-3MC
TESTING, ADJUSTING AND
TROUBLESHOOTING AIR CONDITIONER
SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 20-1003

GAUGE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1003
STRUCTURE AND HANDLING OF GAUGE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1004
CHARGING HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1006
GAS LEAK DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1007
HALIDE TORCH LEAK DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1007
ELECTRIC LEAK TESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1009
VALVE FOR SERVICE CANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1011
MAINTENANCE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1012
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1012
PROHIBITED WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1012
OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1012
BLEEDING AIR FROM REFRIGERATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1014
PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1014
CONNECTING GAUGE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1014
EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1015
AIR-TIGHTNESS CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1015
GAS-LEAK CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1016
EVACUATION (REPEATING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1016
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . 20-1017
CHARGING FROM THE HIGH-PRESSURE SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1017
CHARGING FROM THE LOW PRESSURE SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1018
WHEN THE AMBIENT TEMPERATURE IS LOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1019
WHEN THE AMBIENT TEMPERATURE IS HIGH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1019
REPLACING SERVICE CANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1020
CHECKING THE AMOUNT OF REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1020
REMOVAL OF GAUGE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1022
DISCHARGING THE REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1022
DAILY CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1023
CHECK REFRIGERANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1023
CLEANING THE CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1023
CHECKING THE V-BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1023
CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1024
PROCEDURE FOR CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1024
PROCEDURE FOR CHECKING OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1024
ADDING AND REMOVING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1025
ADDING OIL BY EVACUATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1025
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1026
VISUAL AND ACOUSTICAL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1026
DEFECTIVE COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1027
TROUBLESHOOTING TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1029
DEFECTIVE HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1031
TROUBLESHOOTING USING GAUGE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1032
PREPARATIONS BEFORE MEASURING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1032
INSUFFICIENT REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1032
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER . . . . . . . . . . . 20-1033
AIR INSIDE REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1034
WA180-3MC 20-1001 1
TROUBLESHOOTING
MOISTURE IN REFRIGERATING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1035
REFRIGERANT DOES NOT CIRCULATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1036
FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING
OF HEAT SENSING TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1037
DEFECTIVE COMPRESSION BY COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1038
20-1002 1 WA180-3MC
TROUBLESHOOTING SERVICE TOOLS
12
SERVICE TOOLS
GAUGE MANIFOLD
The gauge manifold is used not only for evacuation and charging refrigerant, but also for troubleshooting. The dials on the
front of the gauge manifold are used to open and close the valves. LO indicates “Low pressure valve”, and HI indicates “High
pressure valve”. Each valve can be opened and closed by turning the respective dial.
1. Low pressure valve

2. Low pressure gauge
3. High pressure gauge
4. High pressure valve
5. Red hose
6. Green hose
7. Blue hose
Fig. 1
WA180-3MC 20-1003 1
STRUCTURE AND HANDLING OF GAUGE MANIFOLD

The following four circuits (A to D) can be structured by opening or closing the high and low pressure valves.
1. Low pressure gauge 1. Valve operation knob

2. High pressure gauge 2. Valve plate
3. High pressure valve (HI) 3. Spring
4. Low pressure valve (LO) 4. Seat
5. Built-in valve (Also called schrader valve)
A. When both low pressure valve (LO) and high pressure valve (HI)
are closed.
20-1004 1 WA180-3MC
12
B. When low pressure valve (LO) is open, and high pressure valve
(HI) is closed.
C. When low pressure valve (LO) is closed, and high pressure valve
(HI) is open.
D. When both low pressure (LO) and high pressure valve (HI) are
open.
WA180-3MC 20-1005 1
12
CHARGING HOSES
The three charging hoses are blue, green, and red. The blue one
is connected to the low pressure side, the green one to the
adapter at the center, and the red one to the high pressure side.
When storing the gauge manifold, connect each charging hose
to an empty adapter as shown in Fig. 1 (on page 20-1003) to
prevent dust and water from entering the manifold.
Since the pin which opens the core type valve is built into the
nut on the bent adapter (45°) at the end of the hose, it is not
necessary to install an adapter (joint to open the core type
valve) when connecting with another core type valve.
1. Pin
2. Packing
3. 45° swivel
4. Nut
WARNING! For the above reason, be sure to connect the straight end to the gauge manifold, and the
bent end to the mate side (service valve or charge valve of the compressor).
Since there is a packing in the nut at the end of the hose, it can be connected to the mate side by tightening it lightly by han d.
(It is not necessary to tighten it with pliers.) Although the core type valve can be opened and closed with the pin, the valve can-
not be adjusted with a valve plunger as in service valves (a stem type valve opened and closed with a ratchet wrench).
★ If the needle of the gauge fluctuates, tighten nut (4) a little more
20-1006 1 WA180-3MC
12
GAS LEAK DETECTOR
A tester that can detect the leak of refrigerant gas is called a gas leak detector. To find the place from which gas is leaking, look
for it patiently. Even if a highly accurate detector is used, a gas leak may be missed if you do not look carefully. Especially, 10
days or so after the gas has been charged, if the operator feels that the cooling capacity might have decreased because of a gas
leak, check all connections, rotating parts, welded zones (including fusible plug of liquid tank) carefully.
There are two types of gas leak detectors:
1. Halide torch leak detector - it can detect any gas leak which causes a significant drop in cooling capacity any time during
one season.
2. Electric leak tester - can detect l/15 of the amount of gas that a halide torch type can detect.
HALIDE TORCH LEAK DETECTOR

The main components of the halide torch leak
detector are a bin (l), valve (2), intake pipe (3)
nozzle (6), torch (7), and combustion cylinder (11).
1. Bin
2. Valve
3. Intake pipe and hose
4. Strainer
5. Holder (set screw for combustion cylinder)
6. Nozzle
7. Torch
8. Ignition window
9. Set screw for copper plate
10. Copper plate
11. Combustion cylinder
12. Cap
13. Wrench for nozzle
14. Handle
15. Adjustment line for flame length (upper limit)
16. Adjustment line for flame length (lower limit)
17. Core type valve (for bin)
18. Nozzle cleaner
19. Wrench for bin valve
WA180-3MC 20-1007 1
12
When air containing the refrigerant gas is inhaled from the intake pipe, it will contact the heated copper plate (10). Copper
halide will be produced to change the color of the flame. A gas leak can be detected with this change in color of the flame.
WARNING! In the halide torch gas leak detector, an open flame is used. Since it can ignite a combus-
tible gas, make sure that there are no flammable substances before using the detector.
WARNING! Do not breathe the vapor coming out of the detector. Although freon gas is not poisonous
by itself, it can form poisonous phosgene gas, hydrochloric acid, or fluoride when it con-
tacts the flame. Therefore, never breathe the vapor coming out of the gas leak detector.
How to detect gas leak
1. Confirm that propane gas is charged in the bin. Connect the bin to the valve, and turn the valve fully clockwise. The core
type valve (inside valve) of the bin will open, and the gas will be ready to flow out. If the valve handle is turned counter-
clockwise, the gas will flow out.
2. To ignite the gas, insert a match or lighter through the ignition window of the combustion cylinder, and turn the handle
counterclockwise.
3. Use the valve to adjust the flame length between the upper limit line (15) and the lower limit line (16).
If the flame is too long, it can only overheat the combustion cylinder. It cannot detect slight leaks of the refrigerant. The
shorter the flame, the more sensitive the detector.
4. After adjusting the flame length, slowly bring the end of the intake pipe to possible leaking places (connections of the pip-
ing) and observe the color of the flame. Always keep the detector in the upright position.
5. When the leak detector is not in use, remove the bin. Replace the bin when empty.
20-1008 1 WA180-3MC
12
ELECTRIC LEAK TESTER
The electric tester utilizes the cations discharged from metals at high temperature. This tester uses a platinum wire as the heat-
ing electrode. It is based on the principle that many cations are discharged when halide gas or air containing halides comes into
contact with the heated platinum. The detector electrodes are made of double cylinders; the inside positive electrode heated to
approximately 800° C (1472° F) and the outside negative electrode. A voltage of 200 V is applied between these two elec-
trodes. If air containing halide gas flows between the electrodes, the cation current flows from the positive to the negative elec-
trode. This current is amplified to turn on the lamp and buzzer to indicate a gas leak. The electric leak tester can detect a gas
leak as low as 10-4mmHg.L/sec.
WARNING! The detectors electrode is heated to 800° C (1472° F), which can ignite a combustible
gas. Therefore, confirm that there are no combustible substances around the work area.
How to detect gas leak
1. Connect the detector cable to the metal plug socket at the rear of the amplifier.
2. Connect the power cables.
A. For HGT-112 model, connect the power cable to an automobile battery (12 V), the red clip to the positive (+) termi-
nal, and the black clip to the negative (-) terminal.
★ If the cables are connected in reverse, the tester will break down.
B. For HGT-200 model, connect the power cable to the AC power source (AC l00V, 50/60 Hz).
3. Set the “SELECTOR” knob to “STANDBY” and turn the power switch “ON”. Wait for about ten minutes until the elec-
trode heater is warmed up.
4. Set the “SELECTOR” knob to “CHECK”. Using the check leak liquid, check the operation of the buzzer and alarm lamp
in a place where there is no halide gas. Unscrew the leak valve of the check leak liquid one turn with a screw driver, and
bring the intake pipe of the tester near the leak valve. If the buzzer and alarm lamp operate, the tester is normal. If they do
not operate, or readjustment is necessary, set the “ALARM SET” knob to the point where the buzzer and the alarm lamp
start to operate.
★ If the “ALARM SET” knob is turned by a large angle at one time, its sensitivity is not stable, and will cause misoper-
ation. Wait for about 20 seconds after turning the knob one scale.
5. Set the “SELECTOR” knob to “LEAK TEST-l” (buzzer and alarm lamp operate) or “LEAK TEST-2” (alarm lamp only
operate).
6. Slowly bring the end of the intake pipe of the tester to possible leaking places (connections of the piping). When the
buzzer or alarm lamp operate at a certain place, gas is leaking from there.
7. When stopping use of the tester for a short time, set the “SELECTOR” knob to “STANDBY”.
8. Although the sensitivity of the electrodes gradually decrease, they have long lives. Adjust the sensitivity with the
“ALARM SET” knob until adjustment is no longer possible. When adjustment is no longer possible, replace the
electrodes with new ones.
WA180-3MC 20-1009 1
12
WARNING! The electrode of the tester is heated to 800° C (1472° F) while the tester is in use. Never
use it in a place where there are combustible gases (city gas, propane gas, thinner, gas-
oline, etc.).
WARNING! If the tester is used for a long time, the end of the detector (intake pipe and electrode
housing) will be heated to approximately 60 ° C (140° F). Never touch it.
WARNING! A highly dense halide gas (gas from a freon gas bin) can damage the electrode of the
tester, or deteriorate the performance. Never let it flow into the tester.
WARNING! Note that the tester will not operate correctly if there are halide gases in the ambient air
(gasoline, thinner, cigarette smoke, etc.).
WARNING! Be sure to close the leak valve of the check leak liquid after using.
WARNING! When the humidity of the ambient air is very high or water vapor is inhaled, the buzzer
may continue to operate even if the “ALARM SET” knob is set to “0”. This is not a failure.
After the vapor has cleared, the tester will operate correctly.
WARNING! Always keep the intake pipe and filter clean. A clogged filter can cause insufficient sensi-
tivity, instability, incorrect responses, etc.
WARNING! If the intake pipe is blocked or bent, or the opening of a vent for the fan is blocked, the fan
motor will overheat and damage may occur.
WARNING! When the tester is not in use for short periods, set the “SELECTOR” knob to “STANDBY”.
When the tester is not in use for long periods of time set the power switch to “OFF”. Note
that the detector is heated to 70 to 80° C (158 to 176° F) while in “STANDBY”.
WARNING! Never apply a strong shock to the detector and amplifier.
20-1010 1 WA180-3MC
12
VALVE FOR SERVICE CANS
The valve for the service cans is used when charging refrigerating system. Handle it as follows:
1. Before using the service can, confirm that a packing can be used on it. Then, turn the handle fully counterclockwise to lift
the needle. Lift the disc (circular nut) at this time.
2. Screw the valve into the service can, and tighten the disc. Take care not to tighten it so much that the service can is
damaged.
3. Connect the green charging hose of the gauge manifold to the valve.
4. Turn the handle of the valve clockwise to lower the needle and make a hole on the blind cap of the service can.
5. Turn the handle counterclockwise to lift the needle. Then, the refrigerant will flow into the refrigerating system through
the valve. To stop the gas, turn the handle fully clockwise to lower the needle.
WARNING! Never reuse an empty can.
1. Adapter for charging hose

2. Handle
3. Needle
4. Packing
5. Service can
6. Disc
WA180-3MC 20-1011 1
TROUBLESHOOTING MAINTENANCE PROCEDURE
12
MAINTENANCE PROCEDURE
PRECAUTIONS WHEN REMOVING OR

INSTALLING PIPING
PROHIBITED WORK
The following operations are prohibited:
1. Never allow moisture, dirt, or air to get into the air conditioner parts.
If moisture, dirt, or air does enter into the air conditioner parts, it will
become completely impossible for the air conditioner to work prop-
erly, so be particularly careful when carrying out operations.
For this reason, never work outside, and avoid working on rainy days.
2. Never leave the air conditioner parts with the blind plug removed.
To prevent rust and the entry of dust, dirt, or moisture, the air condi-
tioner parts are all carefully dried, and parts such as the compressor are
filled with gas and completely sealed with blind plugs. Therefore, do
not remove the blind plugs until immediately before connecting the
piping, and after removing the plugs, complete the work quickly.
In particular, if the receiver is left open, the desiccant (drying agent)

inside will completely lose its effect.
WARNING! Never let moisture or dirt get into the parts

of the cooler.
WARNING! Never leave the parts of the cooler with

the blind plugs removes.
3. Never run the compressor in the refrigeration cycle without any refrig-
erant.
If the compressor is run without any refrigerant, the oil will not lubri-
cate properly and this may lead to seizure.
OTHER PRECAUTIONS
1. When trying to bend a stiff pipe, never heat it with a burner.

If a burner is used on the pipe, an oxidized film will be formed inside,
and this will cause the same kind of problem as dirt.
If it is necessary to clean the inside of the pipe, use Freon, never use
compressed air because it contains moisture.
20-1012 1 WA180-3MC
12
2. Be careful not to connect the receiver in reverse.

There is an “IN” mark at the refrigerant inlet side of the receiver sight
glass, so be careful not to connect the inlet and outlet sides in reverse
when connecting the piping.
If the ports are connected in reverse, it will lead to such troubles as
overcharging with refrigerant and defective cooling.
★ When removing the piping, replace the receiver.
3. When connecting the piping, coat with oil. When connecting the pip-
ing, coat the O-ring with compressor oil before tightening.
Always use two spanner wrenches when tightening.
When tightening, turn only the spanner on the flared nut, keep the
other nut in position and do not let it turn.
4. Tighten the piping connections to the specified tightening torque.

When connecting the piping, if the pipe connection nut is tightened too
much, damage to the flared part and cause the nut to fall off. With O-
ring type nuts the seal may be deformed, leading to gas leakage.
On the other hand, if the connections are not tight enough, the gas will
leak, so always tighten to the standard torques given in the table below.
Standard torques for piping connection nuts
Type of tightening nut Tightening torque
3/8 in (9.5 mm) 104.2 - 130.1 lbf in (11.7 - 14.6 Nm)
1/2 in (12.7 mm) 173.6 - 216.9 lbf in (19.6 - 24.5 Nm)
5/8 in (15.8 mm) 260.4 - 303.7 lbf in (29.4 - 34.3 Nm)
WA180-3MC 20-1013 1
12
BLEEDING AIR FROM REFRIGERATION CIRCUIT
PURPOSE
Extreme care should be taken during handling, to prevent moisture from entering the air conditioner. Since the refrigerant
does not dissolve easily in water, small amounts of water remaining inside the circuit may become frozen in the small orifice
of the expansion valve, and cause rusting of the compressor valves. This can impair the operation of the air conditioner in var-
ious ways. Thus, it is necessary to remove all moisture from the air conditioner before charging it with refrigerant.
To remove the moisture from the air conditioner, the water is evaporated by evacuation. To obtain a good vacuum, a high per-
formance vacuum pump must be used. Otherwise, a long time is required for evacuation. Moisture in the air conditioner can be
removed by a “repeating vacuum method” in a relatively short period of time.
CONNECTING GAUGE MANIFOLD
1. Close high-pressure (HI) and low-pressure (LO) valves at the

gauge manifold.
2. Connect charging hoses (red and blue) to the compressor service

valves.
Red hose.. . . . . . . .to high pressure side (D side)
Blue hose. . . . . . . . . to low pressure side (S side)
WARNING! The “L” shaped ends of the charging

hoses should be connected to the
compressor service valves. Otherwise,
the valve core will not open. Each
charging hose should be connected to
the correct (high or low pressure) side.
3. With the engine stopped, open the high pressure valve of the
gauge manifold and the valve for the service can. Charge approximately 4/5 of the amount of refrigerant.
20-1014 1 WA180-3MC
EVACUATION
1. Open both the high-pressure valve (HI) and the low pressure valve
(LO) at the gauge manifold.
2. Switch on the vacuum pump and allow it to run for approximately

15 minutes.
3. When the negative pressure (degree of vacuum) reading of the low

pressure gauge is 750 mmhg or more, turn off the vacuum pump
switch and close the high and low pressure valves.
AIR-TIGHTNESS CHECK
1. Maintain this vacuum (keep the high and low pressure valves closed)
for 5 minutes or more. Then, make sure that the needle of the gauges
does not move back to zero.
2. If the needle moves toward the zero mark, it indicates a leak. If this
happens, retighten or repair the piping connections and perform the
evacuation again until it is confirmed that no air is leaking.
WA180-3MC 20-1015 1
12
GAS-LEAK CHECK
1. Reconnect the charging hose (green), which has been connected

to the vacuum pump, to a service can.
★ For method of installing the service can. See VALVE FOR
SERVICE CANS on page 20-1011.
2. Open the service can valve, keeping the nut on the gauge manifold
side of the charging hose (green) in the open position. Thus, the
air in the charging hose is bled out under pressure of the
refrigerant. (when a “Whoosh” sound is heard, retighten the hose.)
3. Open the high pressure valve at the gauge manifold and charge
with refrigerant until the low pressure gauge reads 1 kg/cm 2.
After charging, close the high pressure valve.
4. Carefully check the refrigeration circuit for gas leaks, using a gas
leak detector.
5. If a leak is detected, retighten or repair it.
WARNING! Before checking for gas leaks, make

sure there are no flammable sub-
stances (such as fuel) in the vicinity. If
the refrigerant comes into contact with a
naked flame, a poisonous gas
(phosgene) will be given off.
EVACUATION (REPEATING)
1. Close the service can valve and disconnect the green charging
hose from the service can, then connect it to the vacuum pump.
★ Both the high and low pressure valves at the gauge manifold
should be kept closed.
2. Repeat the evacuation procedure described on page 20-1015

(EVACUATION) until the low- pressure gauge reads 750 mmHg
or higher, for 15 minutes or more.
3. After evacuation, close the high and low pressure valves at the
gauge manifold.
WARNING! Evacuation should be repeated at least

two times. Particularly in rainy or humid
weather.
20-1016 1 WA180-3MC
12
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT
After evacuation, charge the refrigeration circuit with refrigerant in the following manner:
CHARGING FROM THE HIGH-PRESSURE SIDE
1. Disconnect green charging hose from the vacuum pump, then connect it
to the service can
2. Open the service can valve, keeping the nut on the gauge manifold side
of the charging hose open, to bleed the air out of the charging hose under
the pressure of the refrigerant.
★ When a ‘whoosh” sound is heard, retighten the nut.
WA180-3MC 20-1017 1
12
3. Open the high-pressure valve at the gauge manifold and the
service can valve, with the engine stopped. Charge specified
amount of refrigerant.
WARNING! While charging with refrigerant, do not

operate the compressor. If the com-
pressor is operated, the refrigerant will
flow back into the service can and
hoses, causing them to burst.
WARNING! If the compressor is operated without

refrigerant in the refrigeration cycle, it
will burst or seize up.
WARNING! The low pressure valve at the gauge

manifold must not be opened (to pre-
vent compression of the liquid refriger-
ant).
4. Close both the high pressure valve at the gauge manifold and the service
can valve.
CHARGING FROM THE LOW PRESSURE SIDE

(REPLENISHING THE REFRIGERATION CIRCUIT)
1. Make sure that the high pressure valve at the gauge manifold is closed.
2. Start the engine and open all the doors of the cab.
3. Turn on the air conditioner switch.

Thermal control lever. . . . . . set to “COLDEST”
Blower switch . . . . . . . . . . . . . . . . . . set to “HI”
4. Set the engine speed to 1300 - 1500 rpm.
WARNING! If valve is opened the service can will be

broken off, causing serious injury.
20-1018 1 WA180-3MC
12
5. Open the low pressure valve at the gauge manifold and the service
can valve. Then, charge the circuit with refrigerant until air bub-
bles in the sight glass at the liquid tank disappear.
Gauge manifold indications:

High pressure side . . . . . 12 to 17 kg/cm2 (ambient temperature 30° C)
Low pressure side . . . . . 1.5 to 2 kg/cm 2 (ambient temperature 30° C)
6. After charging the refrigeration circuit with refrigerant, close the

low pressure valve at the gauge manifold and the service can
valve.
Then, stop the engine.
7. Using a gas leak detector, make sure there are no gas leaks.
WARNING! Do not open the high pressure valve

(HI) at the gauge manifold. If the high
pressure valve is open, the gas will flow
into the service can and charging
hoses, causing them to burst.
WARNING! Keep the service can right side up while

charging the air conditioner with refrig-
erant. (When charging with the engine
running). If the service can is turned
upside down, the liquid refrigerant will
be drawn into the compressor, causing
damage to the compressor valves and
packing. Set or hold the service can
upright and charge the circuit with gas-
eous refrigerant.
WHEN THE AMBIENT TEMPERATURE IS LOW

Where the refrigerant is not flowing into the refrigeration circuit
easily, warm the service can in warm (40°C or below) water to raise
the pressure in the service can.
If the service can is heated in hot water or by direct flame, it will burst.
When warming a service can in warm water, make sure the water temperature is not higher than 40° C.
WHEN THE AMBIENT TEMPERATURE IS HIGH

If the ambient temperature is high, to speed the flow of the refrigerant into the circuit, cool the condenser by using a fan.
WA180-3MC 20-1019 1
12
REPLACING SERVICE CANS
If the service can is emptied before the circuit is completely charged,
replace it with a new can in the following manner:
1. Close the high and low pressure valves at the gauge manifold.
2. Raise the needle and disc of the service can valve.
3. Install the service can valve into a new service can.
4. Bleed the air from the charging hose as follows:
A. Tighten the service can valve, then loosen it slightly.
B. Slightly open the low pressure valve at the gauge manifold.
C. When the refrigerant flows out between the service can valve,
making a “whoosh” sound, immediately close the service can
valve and the low pressure valve at the gauge manifold.
WARNING! Be careful not to let the refrigerant contact

your skin.
5. Screw the service can valve handle into the can to provide a hole and
continue charging with refrigerant.
CHECKING THE AMOUNT OF REFRIGERANT

After charging the refrigeration circuit with refrigerant, check the amount
as follows:
1. Disconnect the lead wire to the magnetic clutch and reconnect it so

the power is directly from the battery.
2. Open all doors and start the engine. Run the engine speed at 1300 to
1500 rpm.
3. Connect the magnetic clutch lead wire directly to the battery. Turn
the blower switch to the “HI” position. (Set the thermal control lever
coldest position.)
4. Maintain a pressure of 13 to 15 kg/cm2 on the high pressure side for

approximately 5 minutes, or until the refrigeration circuit is stabi-
lized.
20-1020 1 WA180-3MC
12
5. After the refrigeration circuit is stabilized, turn off the blower switch,
so that only the compressor is running. The pressure on the low pres-
sure side will gradually decrease. If the pressure on the high pressure
side is kept between 13 to 15 kg/cm2, the amount of refrigerant
charged can be measured in the following manner:
A. Too little refrigerant charged

At a pressure of 1.01 kg/cm2 or above on the low pressure side,
bubbles pass continuously through the sight glass.
B. Proper amount of refrigerant charged.

At a pressure of 1.0 to 0.6 kg/cm2 on the low pressure side, bub-
bles pass continuously through the sight glass.
C. Too much refrigerant charged.

At a pressure of 0.6 kg/cm2 or less on the low pressure side, bub-
bles may or may not be observed in the sight glass at all.
6. If there is too little refrigerant, add some from the low pressure side
as described on page 20-1018 (see CHARGING FROM THE LOW
PRESSURE SIDE.)
7. If there too much refrigerant, discharge some gradually from the low
pressure side until the amount is decreased to the proper level.
8. After making sure the refrigeration circuit contains the proper amount
of refrigerant, turn on the blower switch and confirm that, at a pres-
sure of 1.01 kg/cm2 or more on the low pressure side, no air bubbles
appear in the sight glass. Turn off the blower switch and confirm that,
at a pressure of 1.0 to 0.6 kg/cm2, air bubbles pass through the sight
glass. Repeat these checks two or three more times.
9. Stop the engine, and reconnect the magnetic clutch lead wire as it was
before.
10. Disconnect the charging hoses and remove the gauge manifold (SEE
REMOVAL OF GAUGE MANIFOLD - page 20-1022).
WA180-3MC 20-1021 1
REMOVAL OF GAUGE MANIFOLD

1. After charging the refrigeration circuit with refrigerant remove the
charging hoses from the compressor as follows:
2. Push the “L” shaped fitting on the low pressure charging hose (blue)
against the compressor service valve to prevent leakage. Then, loosen
the flared nut.
3. As soon as the flared nut is removed, disconnect the charging hose

from the service valve.
4. Leave the charging unit connected to the refrigeration circuit until the
high pressure gauge shows the lowest possible reading (10 kg/cm2).
5. Disconnect the high pressure hose (red) in the same manner as the
low pressure charging hose.
WARNING! Disconnect charging hoses from compressor as quickly as possible to minimize loss of
refrigerant. Particularly on the high pressure side, compressor oil may sometimes gush
out together with refrigerant. Therefore, wait for the gauge to drop to its lowest reading
and remove the hose quickly.
WARNING! Be careful not to get any refrigerant on your skin. Use safety goggles to protect your eyes
from the refrigerant.
DISCHARGING THE REFRIGERANT

If the coolant is discharged during the refrigerating cycle, always use the
charging valve and discharge the refrigerant gradually from the high
pressure side.
WARNING! If the piping connection is removed

immediately, the refrigerant will get in
your eyes.
WARNING! If all the refrigerant is discharged at one

time, the compressor oil will leak out, so
be sure to discharge the refrigeration
circuit gradually.
20-1022 1 WA180-3MC
12
DAILY CHECKS
When carrying out the daily maintenance checks before operating the machine, also check the following items:
CHECK REFRIGERANT LEVEL

Start the engine and check the following:
1. Turn the air conditioner switch ON, and run the engine at the standard speed (generally at 2000 rpm).
2. Run the blower motor at maximum speed.
3. Set the temperature control lever at maximum cooling.
4. Check the sight glass.

Look at the sight glass at the top of the receiver and dryer, and check
the flow of the refrigerant in the refrigerating cycle. If there are bub-
bles in the flow as shown in the figure, the refrigerant is low. If there
are no bubbles, the refrigerant is at the correct level. However, even if
the refrigerant level is too high, there are no bubbles, so in this case,
check the temperature of the suction hose (low pressure piping) con-
nected to the compressor. If it is warm, the refrigerant level is too high.
CLEANING THE CONDENSER

Direct tap water on the condenser installed at the front of the machine to
wash off any dirt or mud stuck to the condenser.
If the is excessive dirt, use a soft haired brush while applying the water. A
hard haired brush may damage or bend the fins, so do not use a hard haired
brush. Repair any crushed fins with a screwdriver blade or electrical pliers.
CHECKING THE V-BELT

If the V-belt is loose, it will slip and cause the compressor speed to drop.
As a result, it will be impossible to obtain the specified cooling capacity,
and cooling will be defective, so check the V-belt in the following manner.
Push the V-belt with a finger midway between the pulleys. The V-belt
should deflect about 10 mm, but this varies according to the machine model. For details of the V-belt tension, see the operating
manual for that machine.
Do not use any deteriorated V-belt. Replace it with the same size and type of V-belt.
WA180-3MC 20-1023 1
12
CHECKING OIL LEVEL
PROCEDURE FOR CHECKING
(Unnecessary if oil is normal)
Before checking the oil level, run the refrigerating cycle at low speed (approximately 1000 rpm) for 5 to 6 minutes. This circu-
lates the refrigerant. In addition, the compressor oil which circulates in the refrigeration cycle and remains at each functional
part is collected as far as possible in the compressor. Next, discharge the refrigerant inside the refrigerating system. Depending
on the type of compressor, it may be impossible to check the oil level. However, for those models where the oil level can be
checked, check per PROCEDURE FOR CHECKING OIL LEVEL. (Only check if there is any abnormality, such as defective
cooling or leakage of oil from the refrigeration system.)
PROCEDURE FOR CHECKING OIL LEVEL

Use a dipstick to check the oil level. There are various types of compres-
sors. In some, the end of the oil plug acts as the gauge, and in others, there
is only an oil plug. For compressors with only the oil plug, insert a dipstick
(95456-02020). When doing this, measure with the handle end of the dip-
stick in close contact with the crankshaft case. Pull out the dipstick and
check that the oil level is between the top and bottom lines on the gauge.
This range indicates that the oil is at the correct level.
If the oil is not between the top and bottom lines, correct the oil level.
For compressors with a dipstick built into the oil plug, the procedure for
measuring is the same. However, there is already oil on the dipstick, so
wipe off that oil before measuring. When doing this, bring the threaded part
of the oil plug into contact with the crankcase. Do not screw it in.
20-1024 1 WA180-3MC
12
ADDING AND REMOVING OIL
If there is any failure in the functional parts during the operation of the refrigeration system, some compressor oil will remain
in the refrigerating system. If trouble had occurred in the evaporator or condenser, and these are replaced with new parts, it is
necessary to add an amount of oil equal to the oil which would have remained in those parts. On the other hand, when replac-
ing the compressor, the oil level inside the new compressor must be the same as the oil level remaining in the failed compres-
sor. (Remove any excess oil.)
Amount of compressor oil to add (when replacing functional parts). Amount of oil to add or remove
Replaced part 2M110 Series, 2M126 Series
Condenser replaced as individual part 30 cc
Adding Evaporator replace as individual part 60 cc
Receiver replaced as individual part 10 cc
Remove enough oil to give the same volume of
Removing Compressor replaced as an individual part
oil as in the removed compressor
NOTE: The values in the above table show the oil remaining after running for 5 to 6 minutes at an engine speed of 1000 rpm.
ADDING OIL BY EVACUATION

If the structure of the refrigerating system is kept intact, oil must be added by
evacuation.
First, use a measuring cylinder to prepare slightly more compressor oil than is
needed for adding to the refrigerating system.
As shown in the figure, connect the service valve at the high pressure side of
the compressor with the valve at the high pressure side of the gauge manifold.
Connect a vacuum pump to the connection port at the center of the gauge
manifold.
Connect a charging hose to the service valve at the low pressure side of the
compressor, and put the other end into the compressor oil prepared in the
measuring cylinder.
When the vacuum pump is started, the oil will be sucked from the low pres-
sure side of the compressor and will go into the compressor. When the speci-
fied amount of oil has been sucked into the compressor, stop the vacuum
pump.
WA180-3MC 20-1025 1
TROUBLESHOOTING TROUBLESHOOTING
12
TROUBLESHOOTING
Before the hot season sets in, make a systematic check on each functional part in the refrigeration system. This will make it
possible to find those problems which customers are seldom aware of. The early discovery and prompt repair will contribute to
a longer service life of the air conditioner system.
VISUAL AND ACOUSTICAL CHECKS

1. V-belt
If the V-belt is too loose, it will be torn off because of slippage. To prevent such problems, keep the belt tight. Replace a
torn belt with a new one.
2. Noise around the compressor

Check the compressor mounting bolts and the bracket mounting bolts for looseness and tighten as necessary.
3. Noise from inside the compressor

This may indicate that either a delivery or suction valve has been damaged, or that the connecting rod has come loose.
Dismount the compressor and repair or replace it.
4. Mud and dirt on the condenser fins

If the condenser and fins are fouled with mud or dust, the cooling effect of the condenser will decline, and the cooling
capacity of the air conditioner will also be reduced. Be sure to wash the mud and dust off the condenser. Use a soft haired
brush, if the condenser fins are washed with a hard hair brush, they will be scratched or bent. Therefore, clean them very
carefully.
5. Clogged air filter

If an air filter is clogged, the air flow will be significantly reduced, deteriorating the cooling capacity. Remove and clean
all air filters.
6. Dirty connections and portions with oil

The presence of oil indicates that the refrigerant is leaking. The compressor oil contained in the refrigerating gas escapes
from the system together with the leaking refrigerant. Consequently, the gas leaking portions get fouled with oil.
If any place has gotten dirty with oil, retighten the connections or replace the related parts to prevent gas leakage. Oil
stains are frequently found in the compressor gaskets and piping connections, so check these areas carefully.
7. Noise around the blower

Run the blower motor at low (Lo), medium (Med), and high (Hi) speeds. If you notice any abnormal operating noise or
unsatisfactory rotation, replace the blower motor. But before replacing the blower motor, check to see if the noise is
caused by foreign matter stuck in the motor, or if the motor is running unsatisfactorily because of loose parts.
8. Checking the quantity of refrigerant through the sight glass

When many air bubbles are seen through the sight glass, it indicated a lack of refrigerant. Therefore, add refrigerant to its
proper level. In this case, see if there are any oil stains (step 6) and confirm that the refrigerant is not leaking from any
point. If no air bubbles are seen through the sight glass even when the condenser is cooled with water, it indicates that too
much refrigerant has been charged into the condenser. In this case, carefully drain the refrigerant through a low pressure
service valve a little at a time, until the proper level is obtained. Otherwise, too much refrigerant will drain out or the com-
pressor oil will spurt out.
20-1026 1 WA180-3MC
12
DEFECTIVE COOLING
YES Possible Cause
Pressure normal
Air in system
Pressure at high
pressure end too Too much refrigerant
YES high
YES
Is compressor rota- Is pressure normal? Condenser covered with
tion normal? dirt or dust
Refrigerant low
Compressor delivery valve

Pressure at high broken
pressure end and too
NO low
Gasket broken (compres-
sor)
Low pressure in piping

(crushed/clogged
Expansion valve open too

far
Is air flow normal?
Pressure at low pres-
sure end to high Defective contact of heat
sensing tube
Refrigerant too much
Refrigerant not enough
Gas leaking from heat

sensing tube
Pressure at low pres-

sure end too low Frost on evaporator
Low pressure piping

abnormal
Expansion valve clogged
Pressure at high
pressure and low Refrigerant too much
pressure ends too
high
Pressure at high Refrigerant not enough

B pressure and low
pressure ends too
low
See "B", next page
NO
Other
See "Other", next page

A NO
See "A", next page
WA180-3MC 20-1027 1
Possible Cause
Drop in battery voltage
Abnormality of Interference between rotor

internal parts of and stator
compressor
B
Broken, disconnected wir-
NO ing
See "B", previous page Magnetic clutch
Failure or defective adjust-
ment in relay
Belt slipping Layer short in coil
Defective grounding
Disconnection in coil
Outside air entering

through ventilator to win-
Other dow
See "Other", previous Temperature control func-

page tion defective
Heater is on
Obstruction near suction

port
Frost on evaporator
YES
Filter clogged
A
Air duct clogged or dis-
connected
See "A", previous Are blower & motor
page NO normal?
Defective switch
Defective resistor
Blower & motor
NO related parts
Battery voltage low
Blown fuse
Defective or disconnected
C NO wiring
See "C", next page Defective contact of brush
20-1028 1 WA180-3MC
Possible Cause
Defective tightening of
C blower
See "C", previous page Blower system Contact between blower

NO and heater case
Deformation of blower
TROUBLESHOOTING TABLE
Problem Location Condition Possible cause Remedy

When compressor is 1. Gasket, O-ring broken
stopped, high and low 2. High, low pressure valve reed
Compressor related parts Replace compressor
pressure immediately broken
becomes the same 3. Dirt or dust stuck in reed valve
Suction pressure (pressure at Area around low
1. Valve open to far
low pressure side) abnormally Expansion valve related pressure hose, low 2. Defective contact (disconnection)
1. Replace valve
high (more than parts pressure service valve 2. Securely fix heat sensing tube
of heat sensing tube
2 abnormally cold
approximately 3 kg/cm )
Pressure at high pressure
side also high; suction Bleed from compressor schrader
Refrigerating system Too much refrigerant in refrigeration
pressure drops after valve (high pressure side) to adjust
related parts system
forced cooling of con- to correct amount.
denser
Poor suction of air by
1. Defective motor 1. Replace motor
Condenser related parts condenser cooling fan
2. Condenser fins clogged with dirt 2. Clean fins (wash with water)
(insufficient cooling air)
1. Insufficient cooling water, oil
1. Add to correct level
2. Ignition timing incorrect
2. Adjust timing
Engine related parts Engine tends to overheat 3. Defective water pump, insufficient
3. Replace or repair
capacity
4. Clean fins (wash with water)
4. Radiator fins clogged with dirt
Delivery pressure (pressure at
1. Outside temperature extremely high
high pressure side) 1. Improve cooling of condenser
Others Heat load too high 2. Source of heat inside machine
abnormally high (more than 2. Turn off heater, etc.
(heater, etc.)
approximately 20 kg/cm2) Even when condenser is
Bleed from compressor schrader
cooled by water no
Too much refrigerant valve (high pressure side) to adjust
bubbles are seen in sight
to correct amount
Refrigerating system glass
related parts Immediately after com-
pressor is stopped, Discharge all refrigerant and evac-
pressure drops suddenly Air in refrigeration system uate, then refill to correct level
about 2 kg/cm2
Cooling is poor, many
bubbles can be seen in Insufficient refrigerant Add to correct level
Refrigerating system sight glass
related parts Receiver and dryer
abnormally cold (con- Receiver and dryer clogged Replace (evacuate completely
Suction pressure (pressure at densation, etc.)
low pressure) abnormally low 1. Valve clogged (defective
(less than approximately 0.5 adjustment, entry of dirt or dust) 1. Replace valve
No condensation at
kg/cm2) 2. Gas lost from heat sensing tube 2. Replace valve
valve, piping at low pres-
Expansion valve related 3. Temporary clogging caused by 3. After replacing valve and
sure end not cold
parts freezing of valve (trouble caused by receiver, evacuate completely
entry of water)
Valve tends to clog (defective
Frost on valve Replace valve
adjustment or dirt in valve)
WA180-3MC 20-1029 1
Problem Location Condition Possible cause Remedy

Suction pressure (pressure at Wind discharge
low pressure) abnormally low temperature low, no Frost on evaporator Check, adjust thermostat
Others
(less than approximately 0.5 wind
kg/cm2) Heat load is too low Outside temperature extremely low ---
When compressor is 1. Gasket, O-ring broken
stopped, high and low 2. High, low pressure valve reed
Compressor related parts Replace compressor
pressure immediately broken
becomes the same 3. Dirt or dust stuck in reed valve
Delivery pressure (pressure at Refrigerating system Cooling is poor, many
high pressure side) bubbles can be seen in Insufficient refrigerant Add to correct level
related parts
abnormally low (less than sight glass
1. Valve clogged (defective
approximately 10 kg/cm2) No condensation at
adjustment, entry of dirt or dust) 1. Replace valve
valve, piping at low
Expansion valve related 2. Gas lost from heat sensing tube 2. Replace valve
pressure end not cold
parts 3. Temporary clogging caused by 3. After replacing valve and
(may become negative
freezing of valve (trouble caused by receiver, evacuate completely
pressure)
entry of water)
Area around shaft seal
Compressor related parts dirty with oil, gas level Gas leaking from shaft seal Replace shaft seal
reduced
Gas leakage, oil leakage
Area around piping
Refrigerating system 1. tighten connection
connections dirty with Gas leaking from piping connection
related parts 2. Replace piping
oil, gas level reduced
Cooler switch ON Disconnection in coil Replace
Defective wiring or connections
Reconnect or replace parts
(ground, fuse)
No attraction even when
Defective contact or switch related
cooling switch is ON
No attraction for magnetic parts (thermostat, stabilizer relay, Repair or service
Clutch
clutch cooler switch)
When switch is turned
ON, rotor shows Excessive clearance between rotor
Repair or replace
movement and is and stator
attracted when pushed
Battery voltage low Charge battery
Clutch slips during
Magnetic clutch slips Clutch Oil on clutch face Remove oil
rotation
Layer short in coil Replace
20-1030 1 WA180-3MC
12
DEFECTIVE HEATING
Cause
Water valve clogged
YES
Piping clogged or bent
YES
Is cooling water Air in hot water circuit
temperature normal?
Insufficient level of
cooling water
NO
Defective engine radiator
thermostat
Obstruction near suction

port
Frost on evaporator
YES
Is air flow normal?
Filter clogged
Air duct clogged or

disconnected
Are blower and Defective switch

NO motor normal?
Defective resistor
Battery low voltage
Blown fuse
Defective or disconnected
1. Blower & motor wiring
related parts
NO 2. blower system
Defective contact of brush
Defective tightening of
blower
Contact between blower

and heater case
Deformation of blower
WA180-3MC 20-1031 1
12
TROUBLESHOOTING USING GAUGE MANIFOLD
In this method, the gauge manifold is used to indicate on its gauges the pressure at the high pressure and the low pressure sides
of the refrigerating system, to locate problems and to repair them.
PREPARATIONS BEFORE MEASURING

Precautions
1. Close the valves firmly on the high pressure and low pressure sides of the gauge manifold, then connect the charging
hoses (red high side, blue low side) to the service valves of the compressor. When doing this, always set the valve plunger
type service valve at the intermediate seat position (if the indicator moves, this means the back seat) so that measurement
can be carried out with the gauge.
★ When measuring, remove the air inside the charging hoses from
the connection port at the gauge manifold end using the pressure
of the refrigerant in the air conditioning system.
2. Generally speaking, when the refrigerating system is working nor-

mally, (and under the following conditions: Air temperature at cooler
suction port: 30 to 35° C; Engine speed: 2000 rpm; Maximum cool-
ing, blower running at maximum speed) the gauge manifold readings
are as follows:
• Low pressure side: approximately 1.5 - 2.0 kg/cm2.
• High pressure side: approximately 14.5 - l 5 kg/cm 2.
3. If the outside temperature is low for machines mounting the EPR, at

around 1.8 kg/cm 2, the pressure at the low pressure side continuously
alternates between high pressure and low pressure.
★ The gauge manifold readings given in the diagrams are all for the
same conditions (Air temperature at cooler suction port: 30 to 35° C; Engine speed: 2000 rpm; Maximum cooling: Blower
running at maximum speed), but the actual gauge reading will vary slightly according to the surrounding air conditions.
INSUFFICIENT REFRIGERANT
Conditions
1. Cooling effect is poor.
Symptoms in refrigerating system
1. Pressure low at both low and high pressure ends.
2. Bubbles seen in sight glass.
3. Air coming from cooler vents only slightly cold.
Cause
1. Gas leakage somewhere in the refrigerating system.
20-1032 1 WA180-3MC
12
Judgement
1. Insufficient refrigerant in system - refrigerant leaking.
Remedy
1. Check for leakage with leak tester, repair.
2. Add refrigerant to correct level.
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER

Conditions
1. Very little cooling effect
1. Pressure high at both low and high pressure ends.
Cause
1. There is excessive refrigerant in the system, so the capacity is not

being fully displayed.
Judgement
1. Excessive refrigerant in system - too much refrigerant.
2. Defective cooling of condenser - clogged condenser fins or loose fan

belt.
Remedy
1. Clean condenser (with water).
2. Correct tension of fan belt.
3. Replace condenser fan motor.
4. If items l, 2 and 3 are normal, check the amount of refrigerant.
For details, see page 20-1023, “Check refrigerant level”.

When discharging the refrigerant, push the schrader valve on the low pressure side of the gauge manifold and discharge the
refrigerant gradually.
WA180-3MC 20-1033 1
12
AIR INSIDE REFRIGERATION SYSTEM
Condition
1. Cooling effect is insufficient.
1. Pressure high at both low and high pressure ends.
2. Piping at low pressure end does not feel cold.
Cause
1. Air in refrigerating system.
Judgement
1. Air in refrigerating system - incomplete evacuation.
Remedy
1. Replace receiver and dryer.
2. Check compressor oil level, check for dirt in compressor oil.
3. Evacuate, then charge with new refrigerant
20-1034 1 WA180-3MC
12
MOISTURE IN REFRIGERATING SYSTEM
Conditions
1. The cooler repeats a cycle of cooling and non-cooling.
2. During operation, the pressure at the low pressure end sometimes

changes between negative pressure and normal pressure.
Cause
1. The moisture in the refrigerant of the refrigerating system is freezing

at the orifice in the expansion valve, so the system is temporarily
shut-off. After a short time, the ice melts and the system returns to the
normal condition.
Judgement
1. The dryer is oversaturated the moisture in the refrigerating system is freezing at the orifice in the expansion valve and
preventing the refrigerant from circulating.
Remedy
1. Replace receiver and dryer.
2. To remove the moisture in the system, carry out repeated evacuation of the system.
3. Add new refrigerant to the correct level.
WA180-3MC 20-1035 1
12
REFRIGERANT DOES NOT CIRCULATE
Conditions
1. No cooling effect (there may be cooling occasionally).
1. The pressure on the low pressure side indicates negative pressure and
the pressure on the high pressure side is extremely low.
2. There is frost or condensation on the piping on both sides of the

expansion valve or the receiver and dryer.
Cause
1. Water or dirt in the refrigerating system is freezing or sticking at the

orifice of the expansion valve and preventing the flow of refrigerant.
2. Gas leakage from the heat sensing tube of the expansion valve is pre-
venting the flow of refrigerant.
Judgement
1. Orifice of the expansion valve is closed - refrigerant does not circulate.
Remedy
Leave for a short time, then start operation again to judge if the problem is caused by water or by dirt.
1. If the problem is caused by water, carry out the action given in "MOISTURE IN REGRIGERATING SYSTEM".
2. If the problem is caused by dirt:

• Remove the expansion valve and blow out the dirt with compressed air. If the dirt can not be removed, replace the
expansion valve.
• Replace the receiver and dryer.
• Evacuate the refrigeration system, then add new refrigerant to the correct level.
3. If the problem is gas leakage from the heat sensing tube, replace the expansion valve.
20-1036 1 WA180-3MC
12
FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT
SENSING TUBE
Conditions
1. Cooling effect is poor.
1. Pressure high at both low and high pressure end.
2. Frost or excessive condensation on piping at low pressure end.
Cause
1. Failure of expansion valve or defective mounting of heat sensing

tube.
2. Flow control is not being carried out properly.
Judgement
1. Excessive liquid refrigerant inside piping at low pressure end.
2. Expansion valve open too far.
Remedy
1. Check mounting of heat sensing tube.
2. If there is no abnormality in l), test the expansion valve as an individual part and adjust it. If it can not be adjusted, replace
it.
WA180-3MC 20-1037 1
12
DEFECTIVE COMPRESSION BY COMPRESSOR
Conditions
1. No cooling.
Symptoms in refrigeration system
1. Pressure at low pressure end too high.
2. Pressure at high pressure end too low.
Cause
1. Leakage inside compressor.
Judgement
1. Defective compression by compressor - leakage from valve, damage,

damage to sliding parts (piston, cylinder, gasket, connecting rod,
etc.).
Remedy
1. Replace compressor as assembly.
20-1038 1 WA180-3MC
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5

PRECAUTIONS DURING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
PRECAUTIONS WHEN COMPLETING THE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
OTHER PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-8
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-9
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
ALTERNATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
ENGINE OIL COOLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
FUEL INJECTION PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
NOZZLE HOLDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
STARTING MOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
THERMOSTAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
TURBOCHARGER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
WATER PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-11
COVERS AND LADDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-13
ENGINE HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-27
EXHAUST MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
TORQUE CONVERTER CHARGING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
TORQUE CONVERTER, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
DISASSEMBLY OF PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-53
WA180-3MC 30-1 2
ASSEMBLY OF PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
TRANSMISSION CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
1ST, REVERSE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70
FORWARD, 2ND CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-72
3RD, 4TH CLUTCH PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-74
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
1ST, REVERSE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-76
FORWARD, 2ND CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-81
3RD, 4TH CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-85
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-90
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-94
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
TRANSMISSION SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-99
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-100
TRANSMISSION ACCUMULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-101
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-102
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-103
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-105
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-107
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-111
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-120
AXLE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-130
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-135
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-143
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-151
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-160
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-161
STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-162
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-162
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-164
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-165
DISASSEMBLY OF ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-165
DISASSEMBLY OF CONTROL SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-166
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-168
ASSEMBLY OF CONTROL SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-168
ASSEMBLY OF ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-170
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-173
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-173
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-175
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-176
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-178
30-2 2 WA180-3MC
PPC VALVE TO MAIN CONTROL VALVE HYDRAULIC LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180
PPC VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-183
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-186
BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-187
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-187
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-189
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-190
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-193
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-198
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-198
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-200
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-202
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203
HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-204
STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206
BUCKET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-209
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-210
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-213
ECSS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-216
ECSS CIRCUIT - REMAINING PRESSURE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-216
ECSS SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-217
ECSS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-218
WORK EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-219
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-222
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-225
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-225
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-226
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227
REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227
INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227
REMOVAL OF REAR COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-227
INSTALLATION OF REAR COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-228
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-229
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-229
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-229
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
AIR CONDITIONER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
WA180-3MC 30-3 2
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-230
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-236
AIR CONDITIONER CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-237
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-237
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-238
DRYER RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-240
AIR CONDITIONER COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-242
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-242
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-243
30-4 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
12
METHOD OF USING MANUAL
1. When removing or installing unit assemblies
A. When removing or installing a unit assembly, the order of work and techniques used are given for the removal opera-
tion; the order of work for the installation operation is not given.
B. Any special techniques applying only to the installation procedure are marked , and the same mark is placed
after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to.
Example Explanation
(COMPONENT) REMOVAL Title of operation
WARNING! Safety precautions to observe when performing an operation
1. XXX Text of or name of procedural step
A. Text of procedural step if 1 was procedural name

★ Technique or important point
Reference to a special technique during assembly or installation (note that

this symbol is right-aligned).
(COMPONENT) INSTALLATION Title of operation
• Installation is the reverse of removal. Overall directive
Special technique during assembly or installation (note that this symbol is

left-aligned).
(Component/assembly) Specification
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as
PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when performing out
the operation.
3. Listing of special tools

For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the operation procedure, see
the SPECIAL TOOL LIST later in this section.
WA180-3MC 30-5 2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS DURING OPERATION
PRECAUTIONS DURING OPERATION

12
Be sure to follow the general precautions given below when carrying out removal or installation (disassembly or assembly) of
units.
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 disconnecting the con-
nectors.
• Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
• Check the number and 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 alternately.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after
removal.
★ Precautions when handling piping during disassembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
A. Hoses and tubes using sleeve nuts
Nominal Sleeve nut (elbow end) Use the two items

Plug (nut end)
number below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
B. 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
30-6 2 WA180-3MC
12 3) If the part is not under hydraulic pressure, the following corks can be used:
Dimensions
Nominal
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
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 pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two or three
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 water, then connect securely.
• When using eye bolts, check that there is no deformation or deterioration, screw them fully, and align the direction of the
hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
★ After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and installing any hydrau-
lic cylinder, hydraulic pump or any other hydraulic equipment or work equipment piping, always bleed the air as follows
after completion of installation.
A. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5 times without
going to the end of this stroke. (Stop approximate 100 mm before the end of the stroke.)
B. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the engine and bleed
the air from the plugs at the top of the hydraulic tank filter.
C. Raise the engine speed and repeat Step B. to bleed the air. Repeat this procedure until no more air comes out from the
plugs.
WA180-3MC 30-7 2
D. After completing bleeding the air, tighten the plugs.
Plug: 11.3 ± 1.5 Nm (8.33 ± 1.10 lbf ft)
★ If the engine is run at high speed from the start, or the cylinders are operated to the end of this stroke, the air
inside the cylinder will cause damage to the piston packing.
★ After repair or long storage, follow the same procedure.
PRECAUTIONS WHEN COMPLETING THE OPERATIONS

• If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate
the coolant through the system. Then check the coolant level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to
circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, bleed
air from the system after reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.
OTHER PRECAUTIONS
• To maintain the performance of the machine and to prevent failures, it is particularly important to pay attention to the
degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing the oil, or when replacing the filters,
check that the oil container and area around the filler of the hydraulic tank are clean.
• To keep the hydraulic circuits clean and to protect the hydraulic equipment, be careful of the following points when disas-
sembling or assembling.
• Before disassembling, wash the machine. Be particularly careful to completely clean the area that is to be disassembled.
• Do not let dirt or dust get into the hydraulic circuits when disassembling or assembling.
• Carry out thorough flushing of the parts, and be particularly careful to do this thoroughly for the circuits or parts that have
failed.
• When disassembling or after flushing, always mask the openings of the piping or hydraulic equipment completely.
• Do not use seal tape for the thread of the plug mounts or connections.
• If any internal part of the hydraulic equipment breaks, disassemble and clean all the hydraulic equipment and circuits to
remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disassembled and assembled, also carry
out thorough flushing of the hydraulic circuits.
• When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping, always bleed the
air before starting the engine to prevent seizure of the pump. For details, see TESTING AND ADJUSTING, Bleeding air
from piston pump.
30-8 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL
12
TOOL LIST
Nature of work Symbol Part no. Part Name Qty. Remarks
Removal, installation of rear

1 793-305-1600 Lifting tool 2
Disassembly, assembly of housing
A
transmission assembly Removal, installation of clutch
2 793-310-2100 Lifting tool 1
assembly
1 793-310-1300 Stand 1
2 793-310-1330 Plate 1
B 3 793-310-1360 Bar 1 Removal, installation of end plate

Disassembly, assembly of
4 793-310-1370 Pin 5
transmission clutch pack
assembly 5 01541-01260 Nut 2
Jig for setting

1 793-415-1110 Lifting tool 1 F-R
C piston seal
2 793-415-1120 Lifting tool 1 1st - 4th
Positioning bearing of
D 793-510-1600 Mandrel 1
differential pinion
793-520-2202 Installer 1
793-520-2110 • Plate 5
E Insertion of brake piston
Disassembly, assembly of 01010-31640 • Bolt 5
differential assembly
01010-31680 • Bolt 5
793-605-1001 Brake tester 1
F 799-101-5002 Hydraulic tester kit 1 Checking for oil leaks
790-101-1102 Pump assembly 1
G 790-101-3100 Puller assembly 1
Disassembly, assembly of axle 1 790-101-3110 • Puller 1set

housing H 2 790-101-3120 • Bolt 2
3 790-101-3130 • Nut 2
1 793-520-2730 Seal support 2

Holder for oil seal when press
I 2 793-520-2740 Bolt 4
Assembly of axle housing fitting oil seal
3 01016-30840 Adjustment bolt 6
J 793-510-1500 Holder 1 For adjusting shim
WA180-3MC 30-9 2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Nature of work Symbol Part no. Part Name Qty. Remarks
790-502-1003
or Cylinder repair stand 1
K 790-502-2000
790-101-1102 Pump 1
Boom, Removal,
790-102-3820 Wrench assembly 1
L Bucket Installation of
790-330-1100 Wrench assembly 1 Steering round head
Socket (width across

790-102-1320 1 Bucket
flats: 70 mm)
Removal,
Socket (width across
M 790-302-1290 1 Boom installation of
flats: 60 mm)
piston nylon nut
Commercially Socket (width across
1 Steering
available flats: 46 mm)
790-101-5021 Grip 1 Press fitting of coil bushing kit

01010-50816 Bolt 1 P/N 790-201-1702
N 790-201-1811 Push tool 1 Boom
Hydraulic cylinder 790-201-1781 Push tool 1 Bucket
790-201-1741 Push tool 1 Steering
790-101-5021 Grip 1 Press fitting of dust seal kit

01010-50816 Bolt 1 P/N 790-201-1500
O 790-201-1620 Plate 1 Boom
790-201-1590 Plate 1 Bucket
790-201-1550 Plate 1 Steering
Removal, installation of piston

1 790-702-1000 Expander 1
ring
796-720-1660 Ring 1 Boom,

07281-01159 Clamp 1 Bucket
P
796-720-1630 Ring 1
2 Steering
07281-00709 Clamp 1
796-720-1670 Ring 1
Bucket
07281-01279 Clamp 1
Remark
As for special tool of disassembly and assembly of engine components (engine oil cooler, fuel injection pump, turbo-
charger, nozzle holder, thermostats, cylinder head etc.) Refer to ENGINE SHOP MANUAL.
30-10 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY ENGINE COMPONENTS
12
ENGINE COMPONENTS
Remark
As for the removal, installation, disassembly and assembly of engine components (see the following list). Refer to the
ENGINE SHOP MANUAL.
ALTERNATOR ASSEMBLY
CYLINDER HEAD ASSEMBLY
ENGINE OIL COOLER ASSEMBLY
FUEL INJECTION PUMP ASSEMBLY
NOZZLE HOLDER ASSEMBLY
STARTING MOTOR ASSEMBLY
THERMOSTAT ASSEMBLY
TURBOCHARGER ASSEMBLY
WATER PUMP ASSEMBLY
WA180-3MC 30-11 2
DISASSEMBLY AND ASSEMBLY COVERS AND LADDER
12
COVERS AND LADDER
WARNING! Stop the machine on level ground and

install the safety bar on the frame. Lower
the bucket to the ground and stop the
engine. Then apply the parking brake and
put blocks under the wheels to prevent
the machine from moving.
WARNING! Disconnect the cable from the negative (-)

terminal of the battery.
REMOVAL
1. Covers, ladder
A. Remove hood covers (4) and (5).
B. Remove rear frame inspection cover (6).
C. Remove covers (7) and (8) under cab.
D. Remove ladder fender assembly (9).
E. Remove ladder fender assembly (10).
F. Remove covers (11) and (12) under cab.
G. Remove rear frame inspection cover (13).
30-12 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY COVERS AND LADDER
12
H. Remove hood covers (14) and (15), then remove grease gun (16).
★ Loosen the mount bolts of grease gun clamp (17).
INSTALLATION
• Carry out installation in the reverse order of removal.
★ Determine the position, then tighten fully
WA180-3MC 30-13 2
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
12
ENGINE HOOD
REMOVAL


1. Remove pre-cleaner assembly (1) from hood, cap opening of air

cleaner to prevent dirt from entering.
2. Install lifting eyes (A) and chain (B) on top of hood (2).
3. Remove overflow hose (3) for radiator sub-tank at radiator neck.
4. Open engine hood side covers and radiator grille and lock in position.
Remove six engine hood mount bolts (4) and four fender mount bolts
(5).
30-14 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
12
5. Disconnect wiring connectors (6) and (7) from engine hood.
6. Disconnect negative (-) and positive (+) battery cables (8) and (9), and
Unclip crossover light harness (10).
7. Remove the grease gun inside the left side of the engine compartment,
then remove the clips (11).
8. Lift engine hood (2) approximately 6 in. (150 mm), check that there is
no interference, then lift off slowly.
★ Be careful not to hit the cab or rear wiper arm.
Engine hood: 68 lb (150 kg)
INSTALLATION
★ Install engine hood in reverse order of removal.
WA180-3MC 30-15 2
DISASSEMBLY AND ASSEMBLY RADIATOR
12
RADIATOR

WARNING! Loosen the oil cap slowly to release the

pressure inside the hydraulic tank. Then
operate the control levers several times to
release the remaining pressure in the
hydraulic piping.
REMOVAL
1. Engine hood and side covers.
Refer to "ENGINE HOOD, REMOVAL".
2. Draining coolant
Loosen radiator cap (1) to release internal pressure, and open drain
valve (2) and drain coolant from system.
★ When system is drained close the drain valve.
★ If the coolant contains antifreeze, dispose of it properly.
Coolant: 35 liter (9.2 gal)
3. Fan guards.
Remove left fan guard (3) and right fan guard (3A).
★ Be careful not to damage radiator fins.
4. Rear cover.
Remove cover (4) at the bottom rear of the radiator.
30-16 2 WA180-3MC
12
5. Removal of cooling lines.
A. Close petcock (5) to shut off heater hose, remove lower radiator
outlet tube (6) with hoses.
B. Disconnect engine vent line (7), remove radiator inlet tube (8),
and disconnect roading transmission cooler line (9) from
thermostat housing.
C. Disconnect torque converter cooler hoses (10) and (11) from radi-
ator bottom tank.
★ Radiator fan shroud may have to be disconnected from radia-
tor and pushed aside to disconnect hoses (10) and (11).
6. Radiator removal.
A. Disconnect radiator stay rod (12) at radiator, loosen at frame and

rotate forward.
WA180-3MC 30-17 2
12
B. Install lifting eyes (13) and hook up hoist, remove radiator mount
bolts and rubber mounts (14), and lift radiator assembly from
machine.
Radiator: 110 lb (50 kg)
30-18 2 WA180-3MC
12
INSTALLATION
★ Install radiator in reverse order of removal.
★ Be careful not to damage the fins on the radiator assembly.
★ Adjust so that the clearance between the shroud and fan is uniform.
★ Install so that the clearance between fan and fan guard is uniform
★ Temporarily tighten the mount bolts and fix the position, then tighten fully.
★ When installing the radiator, the difference in the clearance between the fan and radiator on the left and right must be
within 3 mm (0.118 in).
★ Install so that the clearance between the radiator fins and the front face of the fan is uniform at the top, bottom, left, and
right.
★ The difference between the left and right in the position of the radiator in the front-to-rear direction must be within 5 mm
(0.197 in).
★ Tighten hoses without twisting.
Radiator mount bolts: 112.8 ± 9.8 Nm (82 ± 8 lbf ft)
Radiator support mount bolts: 112.8 ± 9.8 Nm

(82 ± 8 lbf ft)
Torque converter cooler hoses: 76.4 ± 29.4 Nm

(130 ± 22 lbf ft)
WA180-3MC 30-19 2
DISASSEMBLY AND ASSEMBLY ENGINE
12
ENGINE

WARNING! Loosen the oil cap slowly to release the

pressure inside the hydraulic tank. Then
operate the control levers several times to
release the remaining pressure in the
hydraulic piping.

REMOVAL
2. Radiator and piping.

Refer to "RADIATOR, REMOVAL".
3. Machines with Air Conditioning.
Remark
There are shims (A) and (B) at bottom mount bolt between welded
spacer and compressor. When removing keep shims as they were
removed.
A. Disconnect wire (1) from harness at top of compressor, loosen

lower mount bolt (2) and adjusting bolt (3) allowing for removal
of compressor belt (4).
B. Unclip compressor lines (5) at air cleaner, and cut tie straps (6).
C. Remove hardware (2) and (7), keeping in mind the shims and
position the compressor out of way.
30-20 2 WA180-3MC
12
4. Right side of engine.
A. Disconnect fuel inlet hose (8) and fuel outlet hose (9) and remove
muffler drain tube (10).
B. Disconnect the fuel cut-off sensor (11), oil pressure switch (12),
and coolant lead (13). Unclamp harness at clamp (14).
C. Remove slow-blow fuse (15) from mount bracket (16), open side
door of fuse and disconnect harness lead (17). Replace screw,
close door, and place fuse back in mount bracket.
D. At intake manifold, disconnect heat switch cable (18) and

unclamp at air cleaner bracket (19), and remove cable from frame
relay (20).
WA180-3MC 30-21 2
12
E. Unclip engine harness from floor harness (21).
F. Unclip harness and cranking motor cable at throttle bracket (22) at

rear of engine (23), and shut off petcock (24), and disconnect
heater hose (25).
G. Disconnect throttle linkage rod at fuel pump lever (26), remove

throttle bracket (22) and position assembly out of way.
H. Remove remote engine oil drain bracket (27) from trunnion.
30-22 2 WA180-3MC
12
5. Left side of engine.
A. Disconnect fuel sending unit (28), remove output (29), ground

(30) leads from back of alternator, and water temperature switch
(31).
B. Disconnect harness ground cable (32), remove starter relay and

bracket (33) from engine block.
C. Cut tie straps (34), remove mount bolts from washer tank and
bracket (35), and position out of way. Disconnect cranking motor
leads (36) and (37).
D. Slide harness connector (38) from flywheel housing bracket and

disconnect and remove engine harness. Disconnect cranking
motor ground cable (39) at frame.
WA180-3MC 30-23 2
12
E. Remove air conditioning dryer and bracket (40) from frame and
position out of way.
F. Disconnect heater hose (41) pass through clips (42) and position
out of way.
6. Top of engine.
A. Remove turbocharger shield (43), and loosen muffler clamp (44)

at turbocharger.
B. Remove band (45), remove center mount bolts (46), and lift off
exhaust muffler (47).
30-24 2 WA180-3MC
12
C. Loosen clamps (48) on hose between air cleaner and
turbocharger, remove bands (49), and lift off air cleaner (50).
7. Engine assembly.
A. Set jack stand (51) under transmission (52) and adjust the height
properly and set the stand into position.
B. Hook hoist to rear lifting eye (53), to front lifting eye (54), and to
air conditioning compressor mount bracket (55).
C. Remove torque converter housing to flywheel housing bolts (56).
WA180-3MC 30-25 2
12
D. Remove rear engine mount bolts (57) from each side.
E. Using hoist, guide the engine rearward to clear the torque

converter housing and lift from the machine.
★ Be careful not to damage the fuel tank breather tube and the
engine oil drain hose when removing the engine.
Engine assembly: 1190 lb (540 kg)
30-26 2 WA180-3MC
12
INSTALLATION
1. Install the engine assembly in reverse order of removal.
★ Check that there is an o-ring installed to the mating face of the torque converter.
Lubricate the outside circumference of O-ring: Soapy water
★ When connecting the engine and torque converter, adjust the height so that the torque converter pilot goes in
smoothly. Never use force when connecting.
★ When assembling rear engine mount bolts never use grease, oil, or soapy water on the rubber mounts.
Mount bolt: 745 ± 83 Nm (550 ± 61 lbf ft) (Width across flats: 32 mm)
2. Installation of radiator, refer to "RADIATOR, REMOVAL AND INSTALLATION".
3. Installation of engine hood, refer to "ENGINE HOOD, REMOVAL AND INSTALLATION".
4. Refilling with oils and coolant.

★ Tighten radiator drain valve and open the two heater hose petcocks on the engine, and add the engine coolant through
the radiator filler neck to the specified level.
★ Check and if necessary add transmission oil through the oil filler neck on the transmission to the specified level.
★ Check and if necessary add engine oil through the oil filler neck on the engine to the specified level.
★ Run the engine (to operating temperature) and heater to circulate the oil and engine coolant through the system. Then
check the engine coolant and oil, and the transmission oil levels again. Add oil or coolant if required.
WA180-3MC 30-27 2
DISASSEMBLY AND ASSEMBLY EXHAUST MUFFLER
12
EXHAUST MUFFLER


REMOVAL
2. Exhaust muffler.
A. Remove turbocharger shield (1), and loosen muffler clamp (2) at

turbocharger.
B. Remove band (3), remove center mount bolts (4), and lift off exhaust muffler (5).
INSTALLATION
1. Install the exhaust muffler in reverse order of removal.
30-28 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY AIR CLEANER
12
AIR CLEANER


REMOVAL
2. Air cleaner.
Loosen clamps (1) on hose between air cleaner and turbocharger, remove bands (2), and lift off air cleaner (3).
INSTALLATION
1. Install the air cleaner assembly in reverse order of removal.
WA180-3MC 30-29 2
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP
12
TORQUE CONVERTER CHARGING
PUMP
REMOVAL

1. Cover, wiring
A. Remove cover (1) under left center fender.
B. Remove clamp and wiring clamp (2) of air conditioner hose.
2. Hydraulic piping
A. Disconnect hose (3) between transmission strainer and torque

converter charging pump from torque converter charging pump.
B. Disconnect tube (4) between torque converter charging pump and

filter from torque converter charging pump.
3. Torque converter charging pump

Remove mount bolts, then remove torque converter charging pump
(5).
INSTALLATION
★ Carry out installation in reverse order to removal.
Tube flange mount bolt: 66.2 ± 7.4 Nm (48.8 ± 5.4 lbf ft)
Tube flange mount bolt: 30.9 ± 3.4 Nm (22.7 ± 2.5 lbf ft)
Mount bolt: 66.2 ± 7.4 Nm (48.8 ± 5.4 lbf ft)
★ Be careful not to get the O-ring caught when installing.
30-30 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
12
TORQUE CONVERTER,
TRANSMISSION
REMOVAL

★ Remove cover (1) at the top of the hydraulic tank on the right side,
then remove covers (2) on the left and right under the floor.

★ Loosen plug (3) to prevent the oil inside the hydraulic tank from
flowing out.
★ Disconnect the cable from the negative (-) terminal of the battery.
★ Machines equipped with air conditioner, capture and re-use the Freon.
WARNING! DO NOT let Freon escape into the

atmosphere.
1. Draining oil
Loosen drain plug (3-1) and drain transmission oil.
Transmission oil: 28.0 L (7.39 gal)
2. Cover
A. Sling left ladder rail (4), then remove mount bolts, and lift off
together with center fender (5).
★ Carry out the operation in the same way on the right side.
★ When lifting off the ladder, be careful of the center of gravity.
★ Be careful not to damage the cab glass.
WA180-3MC 30-31 2
12
B. Disconnect connector for left brake oil level sensor.
C. Remove brake oil tank mount bracket (8) together with oil tank
(7) from under floor.
★ Leave the oil hose installed to the brake oil tank and tie it to
the top surface of the rear frame with wire.
★ For machines equipped with an air conditioner, it can be
placed on top of the condenser.
★ When carrying out this operation, do not disconnect the brake
oil hose. Move it to the side and tie it temporarily with wire.
3. Electric wiring
Fit tags to identify the wiring.
• Disconnect following electric wiring from connector.
• Disconnect front wiring (9) and rear wiring (10) from connectors
(11), (12), (13), (14), (15), (16), and (17).
• For machines with cab, disconnect wiring for cab from connector.
• Disconnect ground wiring (18) from rear frame.
• Disconnect transmission cut-off switch (19) and wiring connector
(20).
• Remove wiring clamp and bracket (21) from rear frame (22).
4. Brake booster
A. Remove locknut of ball joint (24) and brake linkage (23), and pull
out linkage rod.
B. Set block under brake booster (25), then remove mount bolts (26).
30-32 2 WA180-3MC
12
5. Fuel control cable
Remove bracket (28) together with control cable.
★ For machines equipped with cab
• Disconnect the washer hose from the tank, then coil up and
bend the end of the hose.
• After removing the hose, fit a blind plug in the washer tank.
6. Transmission valve wiring

Disconnect connectors (33) of transmission valve wiring.
★ Fit tags to identify the wiring.
7. Work equipment control cable

Disconnect work equipment control cables (34) at valve end.
★ Fit tags to the cables before disconnecting.
★ Remove the cable clamp.
WA180-3MC 30-33 2
12
8. Parking brake cable
A. Disconnect parking brake cable (38) from lever, and remove

bracket (40) from front face of transmission (39).
★ After removing the cable, tie it temporarily to the bottom

surface of the floor with wire.
B. Disconnect speedometer cable (41).
C. Remove transmission oil filler tube (42).
9. Steering piping
A. Remove hoses (44) and (45) from steering valve (43).
B. Disconnect hoses (47), (48), and (49) between steering valve (43)
and priority valve.
C. Remove hose (50) between steering valve and hydraulic tank.

★ Fit blind plugs after disconnecting the hoses.
30-34 2 WA180-3MC
12
10. Floor frame, cab assembly
Sling floor frame and cab assembly (51), then remove mount bolts,
and lift off.
★ When raising the floor frame and cab assembly, pull the brake
booster out gradually from the mount bracket, and lift the cab
slowly.
★ The brake hose is not disconnected, so be careful not to catch the
brake booster.
★ When raising the floor frame and cab assembly, lift slowly for
approximate 40-50 mm (1.5 - 2 in), stop and check that there is no
interference, then continue to lift.
Floor frame, cab assembly: 680 kg (1499.14 lb)
Floor frame assembly: 155 kg (341.71 lb)
11. Drive shafts
A. Disconnect center drive shaft (52) at transmission end.
B. Remove rear drive shaft (53).
12. Hydraulic, steering pump
A. Disconnect hose (55) between hydraulic, steering pump and

priority valve at priority valve end.
B. Loosen clamp of hose (56) between hydraulic tank and hydraulic,

steering pump, then disconnect at tank end.
★ Remove hose clamp (56-1) between the main control valve and the
hydraulic tank first.
C. Remove mount bolts of hydraulic, steering pump (57), then remove.
WA180-3MC 30-35 2
12
13. Hydraulic piping
A. Disconnect drain hose (60) of brake booster at transmission end.
B. Disconnect hose (61) between priority valve and main control

valve, then remove hose support bracket (62) from rear frame.
C. Disconnect hose (58) between main control valve and hydraulic

tank, then disconnect hose clamp (59).
14. Torque converter, transmission
A. Disconnect hose (63) between transmission valve and cooler from

transmission valve (64).
B. Disconnect hose (65) between transmission and cooler from

elbow under rear housing of transmission (68).
C. Remove oil filler tube (66) from transmission.
30-36 2 WA180-3MC
12
D. Set hydraulic jack ➀ under engine.
★ Adjust the height properly and support the engine.
E. Remove left and right transmission mount bolts (67) and (67-1).
F. Sling torque converter and transmission (68), and remove bolt

connecting to engine (69).
★ Sling at two points.
G. Lift off torque converter and transmission (68).
★ Check that there is no interference from the hoses and wiring,

then lift off.
★ Be extremely careful that the torque converter and
transmission does not hit the rear frame when lifting off.
Torque converter, transmission: 480 kg(1058.22 lb)
WA180-3MC 30-37 2
12
INSTALLATION
• Carry out installation in the reverse order to removal.
★ Bend the cotter pin securely.
★ Adjust the parking brake. For details, see TESTING AND ADJUSTING, Adjusting parking brake.
Mount bolt: 277 ± 32 Nm (204.3 ± 23.6 lbf ft)
★ Be careful of the direction of the yoke, and align the pilot portion correctly to install.
★ Install the hoses without twisting or interference.
★ To position the transmission, adjust with the adjustment screw to

make clearance "a" the specified value, then tighten the mount
bolts.
★ When assembling the rubber, never use grease, oil, or soapy
water.
Clearance "a": 1 - 2 mm
Mount bolt: 745 ± 83.4 Nm (549.4 ± 61.5 lbf ft)

(Width across flats: 32 mm)
★ Check that the O-ring is inserted securely in the mating surface of the torque converter.
Outside circumference of O-ring: Soapy water
★ When connecting the engine and torque converter, adjust the height so that the torque converter pilot goes in
smoothly. Never use force when connecting.
★ Tighten the mount bolts a little at a time on the left and right, and be careful not to damage the O-ring.
30-38 2 WA180-3MC
12
• Refilling with oil
A. Tighten drain plug and add transmission oil through oil filler to the specified level.
Transmission oil: 28 L (7.39 gal)
B. Tighten plug and add hydraulic oil through oil filler to the specified level.
Hydraulic oil: 80 L (21.1 gal)
★ Run the engine to circulate the oil through the system. Then check the oil level again.
WA180-3MC 30-39 2
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
12
TORQUE CONVERTER
DISASSEMBLY
1. Turbine case assembly
A. Remove stator shaft and pump assembly (2) from turbine and case
assembly (3).
B. Disassemble turbine and case assembly as follows.
i. Remove pilot (4).
ii. Remove snap ring (5).
iii. Push boss portion of turbine (6) and remove from case (7).
iv. Remove bearing (8) from case.
30-40 2 WA180-3MC
12
2. Stator
A. Remove snap ring (9).
B. Remove stator (10).
3. Stator shaft
Using forcing screws ➀, push from stator shaft (11) end, and
disconnect from pump assembly (12).
4. Gear
Remove gear (13) from pump (14).
5. Bearing
Remove bearing (15) from gear (13).
WA180-3MC 30-41 2
12
ASSEMBLY
1. Bearing
Install bearing (15) to gear (13).
2. Gear
Install gear (13) to pump (14).
3. Stator shaft
A. Install seal ring (16) to stator shaft (11).
Seal ring: Grease (G2-LI)

Make the extension of the seal ring uniform.
B. Push inner race end of bearing, and install pump assembly (12) to
stator shaft (11).
4. Stator
A. Install stator (10).
B. Install snap ring (9).
5. Turbine, case assembly
A. Assemble turbine and case assembly as follows.
i. Install bearing (8) to case.

★ Press fit until the ring contacts the case.
ii. Push inner race of bearing and install turbine (6) to case (7).
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12
iii. Install snap ring (5).
iv. Install pilot (4).
Mount bolt: Thread tightener (LT-2)
B. Install stator shaft and pump assembly (2) to turbine and case
assembly (3).
WA180-3MC 30-43 2
DISASSEMBLY AND ASSEMBLY TRANSMISSION
12
TRANSMISSION
DISASSEMBLY
• After removing transmission assembly (9) from the chassis, remove
the left and right mount brackets first.
• Remove the PTO lubrication tube.
1. Hydraulic piping
Disconnect hoses (1) and (2), and each tube.
★ Be careful not to crush tube (3) during the operation.
★ After removing the tubes, fit a cover to protect the thread.
2. Oil filter
A. After removing each hose, remove mount bracket (5) of filter (4)
with filter still installed.
B. Remove O-ring (8), cover (7), and speedometer pickup port

assembly (6) of idler countershaft portion.
★ After removing the speedometer pickup port assembly, be
careful not to damage the gear portion of the idler
countershaft.
30-44 2 WA180-3MC
12
C. Raise transmission assembly (9), and install to assembly stand.
i. After installing the transmission assembly to the assembly

stand, turn over, then set a support under the REVERSE and
last side. (To keep it parallel)
3. Strainer, rear coupling
A. Pull out rear coupling (10).

★ Fit a cover to prevent dirt or dust from entering.
B. Remove hose and tube (11) between strainer and pump.
4. Charging pump
After removing hoses, remove charging pump assembly (12) and
O-ring.
5. Transmission control valve
A. Remove accumulator valve (13).
B. Sling transmission control valve (14), then remove mount bolts

and lift off.
★ After removing the mount bolts, fit 2 guide bolts in the bolt
holes.
Transmission control valve: 46 kg (101.4 lb)
WA180-3MC 30-45 2
12
6. Rear housing
A. Install tool A to rear housing (15), then sling.

★ Install tool A securely to prevent it from coming off.
B. Using forcing screws, raise rear housing(15), then use tool A to

lift off.
★ Remove slowly and be careful not to damage the seal ring.
★ When removing, install guide bolts to front housing (16) and
lift off horizontally.
Rear housing, torque converter assembly:

160 kg (352.7 lb)
7. Torque converter
Lift off torque converter (17) from rear housing (15).
★ Before removing, make match marks on the housing and torque
converter mating face with a felt pen.
★ When turning over the rear housing, remove pilot cap (18) or set
the housing on blocks.
Torque converter: 35 kg (77.2 lb)
30-46 2 WA180-3MC
12
8. Pump (torque converter, work equipment)
A. Remove snap ring (19) at torque converter pump mount.
B. Turn over rear housing (15), and remove snap ring (21) of pump
gear (20), then remove ring washer (22) and split spacer (23).
C. Insert screwdriver into stepped portion between rear housing (15)

and shaft (24), then lever with screwdriver, push shaft down and
pull it out.
WA180-3MC 30-47 2
12
D. Remove bearing (25) from shaft (24).
★ Carry out the operation in the same way at the work
equipment hydraulic pump end.
9. Seal ring
A. Remove seal ring (26) from each clutch shaft.
B. Remove input shaft (27).
10. REVERSE, 1st clutch assembly
A. Install tool B to REVERSE and lst clutch assembly (28).
B. Using tool B, lift off REVERSE and lst clutch assembly (28).
★ Be careful not to hit the other gears when removing.
REVERSE, lst clutch assembly: 30 kg (66.2 lb)
11. FORWARD, 2nd clutch assembly
A. Install tool B to FORWARD and 2nd clutch assembly (29).
30-48 2 WA180-3MC
12
B. Using tool B, lift off FORWARD and 2nd clutch assembly (29).
★ When doing this, 3rd, 4th clutch assembly (30) and the gear
are engaged, so pull up each part in turn to a point where the
bearing comes out from the front housing.
FORWARD, 2nd clutch assembly: 37 kg (81.6 lb)
C. When bearing of 3rd, 4th clutch assembly (30) comes out from
housing, pull to output shaft end and tie with wire.
WARNING! Be careful not to get your fingers caught

between the gear and housing when
carrying out this operation.
12. 3rd, 4th clutch assembly
A. Install tool B to 3rd and 4th clutch assembly (30).

★ Install the lifting tool before removing the wire.
B. Using tool B, lift off 3rd and 4th clutch assembly (30).
3rd, 4th clutch assembly: 42 kg (92.6 lb)
13. Idler countershaft assembly
A. Remove idler countershaft (31) from front housing (16).
WA180-3MC 30-49 2
12
B. Remove bearings (32) and (33), and gears (34) and (35) from
shaft (31).
★ If speedometer worm gear (36) is installed, remove it before
carrying out the operation.
14. Rear dust seal, oil seal

Remove dust seal (37) and oil seal (38).
15. Coupling
Remove mount bolts, then remove front coupling (39), holder (40),
and O-ring.
16. Parking brake assembly
A. Turn over front housing (16), and set support stand under housing.
B. Remove plug of portion "a" at parking brake front housing end,

and be sure to assemble set bolt ➂ for securing piston.
Set bolt for securing piston:
P = 1.25, M = 8, L = 35
Washer: 01643-30825
C. Remove housing mount bolts (42).

★ Install a guide bolt to prevent the housing from failing.
★ Before removing the parking brake assembly, sling the output
gear to prevent the output shaft bearing cone from coming out
from the bearing cup.
30-50 2 WA180-3MC
12
D. Tighten 2 forcing screws in forcing screw hole, and remove
housing and piston assembly (43).
★ Check that a set bolt is installed to hold the part in position.
★ Using housing mount bolts as forcing screws.
E. Loosen mount bolts of parking brake retainer assembly (44), and

pull out left and right shims (45).
★ For reference when installing, check the number and
thickness of the shims.
F. Remove hub spline (46), then remove parking brake retainer

assembly (44).
17. Output shaft gear
A. Loosen mount bolts of gear cover (47) and leave them fitted
temporarily, then turn over front housing (16).
WA180-3MC 30-51 2
12
B. Remove mount bolt (48), then remove gear cover (47) from
bottom of housing.

between the gear and housing.
C. Hold spline portion of output shaft gear assembly (49) and pull
up.
WARNING! Be extremely careful not to get your

fingers caught between the gear and
housing (16) when removing.
★ Clearance (one side) between gear and housing:

Approximately 20 mm
★ If there is oil on the output shaft spline, wipe it off completely
and be extremely careful when removing.
D. Remove bearing cone (51), snap ring (52), gear (53), and bearing
cone (54) from shaft (50) in order.
18. Bearing cup

Remove bearing cup of front housing with puller.
★ Do not remove unless necessary.
30-52 2 WA180-3MC
12
DISASSEMBLY OF PARKING BRAKE
1. Plate, disc
A. Remove holder bolts (6) from retainer assembly (44).
B. Remove separator plate (7), wave spring (8), and disc (9).
2. End plate
Remove end plate (10), then remove hub spline (11).
3. Retainer
Turn over retainer (4), and remove bearing cup (12) with puller.
WA180-3MC 30-53 2
12
4. Housing
Remove 2 set bolts ➂ for securing piston, then remove piston (13) and
balls (14).
★ If it is necessary to disassemble the lever portion, remove lock
bolt (15), check the match marks on inner lever (16) and outer
lever (17), then pull out the inner lever, and remove bearings (18)
and oil seal (19).
30-54 2 WA180-3MC
12
ASSEMBLY OF PARKING BRAKE
1. Housing
A. Press fit oil seal (20) and dust seal (21) to housing (5).
Press-fitting dimension "a": 25.8 ± 1.0 mm
Press-fitting dimension "b": 18.3 ± 1.0 mm
Lip of oil seal: Grease (G2-LI)
★ Coat with grease when assembling the housing.
B. Press fit needle bearing (18) and oil seal (19) to housing (5) to
specified dimensions.
Needle bearing press-fitting dimension "c": 38.5 ± 0.15 mm
(lst).
Needle bearing press-fitting dimension "d": 18.0 ± 0.5 mm
(2nd).
Oil seal press-fitting dimension "e": 7.5 ± 0.3 mm.
C. Insert outside lever (17) from oil seal end.

★ Clean and remove all oil and grease from the bolt hole of the
outside lever.
D. Align with match mark and assemble inside lever (16).
E. Tighten lock bolt (15).

★ Clean and remove all oil and grease from lock bolt and bolt
hole.
★ Be sure to assemble the washer.
Lock bolt: Thread tightener (LT-2)
Lock bolt: 30.9 ± 3.4 Nm (22.8 ± 2.5 lbf ft)
WA180-3MC 30-55 2
12
F. Fit balls (14) in groove of housing (5), install piston (13) from top,
then temporarily tighten 2 set bolts (3), for securing piston.
★ Assemble temporarily to prevent the piston from failing out
during assembly.
★ Set bolt for securing piston:
P = 1.25, M = 8, L = 35
2. Retainer
Press fit bearing cup (12) to retainer (4).
★ After press fitting the cup, check that there is no clearance at
portion "a".
3. End plate
Turn over retainer and assemble end plate (10), then assemble hub
spline (11) to center.
★ Use the hub spline as a guide when assembling the disc.
30-56 2 WA180-3MC
12
4. Separator plate, disc
A. Assemble separator plate (7), wave spring (8), and disc (9) in
order in turn.
★ Soak disc (9) in clean transmission oil for at least 2 minutes
before assembling.
★ Use one spring.
★ Insert pins (22) into the guide of the separator plate spline.
B. Tighten holder bolt (6) of separator plate (7) to retainer (4).

★ Remove all oil and grease from the bolt thread and bolt hole.
Holder bolt: Thread tightener (LT-2)
Holder bolt: 53.9± 19.6 Nm
5. Brake housing, retainer

Assemble temporarily parking brake retainer assembly (44) and
parking brake housing and piston (43).
★ When assembling housing and piston (43), do not remove the 2
set bolts (3) for holding the piston.
WA180-3MC 30-57 2
12
ASSEMBLY
★ Press fit the oil seal and dust seal before assembling each clutch
assembly.
★ Press fit the bearing cup fully to the stepped portion of the housing so
that there is no clearance.
★ Keep the front housing horizontal.
1. Bearing cup
Press fit bearing cup (55) to front housing (16).
2. Output shaft gear
A. Press fit bearing cone (54) to shaft (50), assemble gear (53) and
snap ring (52), then press fit bearing cone (51).
★ To prevent improper adjustment of the end play, press fit the
cone securely up to the shoulder of the shaft.
★ Fit the snap ring securely in the shaft groove.
B. Assemble output shaft and gear assembly (49)to bearing cup

portion of front housing (16).

★ Clearance (one side) between gear and housing: Approxi-

mately 20 mm.
★ If there is oil on the output shaft spline, wipe it off completely
and be extremely careful when assembling.
C. Insert gear cover (47) from under housing, rotate gear cover a half
turn and align mount bolt holes.

30-58 2 WA180-3MC
12
D. Remove all oil and grease from mount bolt (48) and bolt hole,
coat thread of mount bolt of gear cover (47) with gasket
sealant, then tighten.
3. Adjusting rotating torque of bearing
A. Assemble O-ring (44-1) to parking brake retainer assembly (44),

and coat outside circumference thinly with grease.
O-ring outside circumference: Grease G2-LI
B. Turn over front housing (16), and install guide bolt, align with
guide bolt, assemble brake retainer assembly (44), and
temporarily assemble mount bolts.
★ When doing this, check that the bearing cone is properly
fitted inside bearing cup "a", then assemble.
C. Insert desired shim (45) from left and right of parking brake
retainer assembly (44), then tighten mount bolts.
★ Do not install the hub spline until Step F.
WA180-3MC 30-59 2
12 ★ To settle the bearing, rotate the shaft while tightening. After
tightening, hit the end face of the shaft several times with a
plastic hammer.
★ Coat the bearing thoroughly with oil.
★ Standard shim thickness "a": 0.85 ± 0.83 mm
Bearing: Transmission oil
D. Tighten coupling mount bolts to shaft (50), then measure

rotating torque.
Rotating torque: 0.10 - 1.0 Nm (0.073 - 0.737 lbf ft)
★ If no small torque wrench is available, it is also possible to

measure as follows.
★ Fit measurement plate (56) to shaft (50), tighten the coupling
mount bolts, then install a push-pull scale to the tip of plate
(56), and carry out the measurement.
• Plate length: 100 mm
• Push-pull scale reading:
1.0 - 9.8 Nm (0.224 - 2.203 lbf))
★ When measuring the rotating torque, do not measure at the
beginning of the movement. Measure the torque when the
shaft is rotating.
★ If the rotating torque is not within the standard value, add or
remove shims to adjust again.
★ If the rotating torque is within the standard value, check that
the end plate is "0".
E. Insert selected shim (45) from left and right of parking brake
retainer assembly (44), then tighten mount bolts uniformly.
★ Insert the thin shims in the middle, and the thick shims on the
outside when assembling.
F. Align with parking brake disc spline, and assemble hub spline (46) to output shaft (50).
★ Use a Pry Bar to align the disc spline.
★ If the spline is not aligned, rotate lightly while assembling. Never push with force.
30-60 2 WA180-3MC
12
4. Parking brake assembly
A. Assemble new gasket to surface "b" for housing and piston

assembly on parking brake retainer assembly (44).
B. Align housing and piston assembly (43) with guide bolt and
assemble.
★ Check that the lock set bolt is assembled.
★ When assembling, be careful not to damage the oil seal lip.
C. Tighten mount bolts (42) of housing and piston assembly (43) on

diametrically opposite sides.
D. Remove lock set bolt and install plugs (41-1).
WA180-3MC 30-61 2
12
5. Coupling
Coat oil seal lip portion thinly with grease, assemble coupling (39),
then tighten O-ring (57), holder (40), and mount bolt (58).
★ Slide the coupling several times to prevent the oil seal lip from
turning over.
★ Insert the O-ring into the shaft groove, and be careful not to get it
caught.
★ Check that the lock set bolt has been removed and the plug has
been assembled in its place.
6. Rear oil seal, dust seal

Turn over front housing (16), then press fit oil seal (38) and dust seal
(37).
Press-fitting dimension "a": 29 ± 1 mm

Press-fitting dimension "b": 21.5 ± 1.0 mm
7. Idler countershaft
A. Assemble to shaft (31) so that oil groove of gear (34) is on inside,

then press fit bearing (32).
B. Assemble to shaft (31) so that oil groove of gear (35) is on inside,

then press fit bearing (33).
★ Press fit the bearing securely to the face of the gear.
C. Assemble speedometer worm gear (36) to spline of shaft (31),

then tighten mount bolt (59).
★ Remove all oil and grease from the mount bolts and bolt
holes.
30-62 2 WA180-3MC
12
D. Assemble idler countershaft (31) to front housing (16).
★ When assembling, be careful not to damage the speedometer
worm gear.
8. 3rd, 4th clutch assembly

Using tool B, assemble 3rd and 4th clutch assembly (30) to housing,
then move it towards output shaft end.
★ Secure with wire in the same way as when disassembling.
★ Do not fit the bearing at the bottom of the clutch into position.
9. FORWARD, 2nd clutch assembly
A. Using tool B, raise FORWARD and 2nd clutch assembly (29).

★ Be careful that the stopper pin does not come out.
B. Mesh gear of 3rd, 4th clutch assembly (30) with gear of

FORWARD, 2nd clutch assembly (29), then lower slowly.
★ Do not fit the bearing at the bottom of the clutch into
position.

in the gear.
C. After checking that each gear is engaged, press fit bearing at

bottom of 3rd, 4th clutch assembly (30) to front housing.
★ Check the meshing of each gear when press fitting the
bearing.
★ When doing this, the 3rd, 4th clutch gear and FORWARD,
2nd clutch gear must be meshed.
WA180-3MC 30-63 2
12
D. Press fit bottom bearing of FORWARD and 2nd clutch assembly
(29) to front housing portion.
★ Coat the bearing press-fitting portion of the front housing
thinly with transmission oil.
Bearing press-fitting portion: Transmission oil
10. REVERSE, 1st clutch assembly

Using tool B, press fit bottom bearing of REVERSE and 1st clutch
assembly (28) to front housing.

in the gear.
11. Seal ring
A. Press fit bearing (60) to input shaft (27), assemble gear (61) so
that oil groove of gear is on bearing side, then secure with snap
ring (62).
B. Press fit bearing (63) to input shaft (27).
Bearing press-fitting portion: Transmission oil
★ Fit the snap ring securely in the groove.
C. Assemble input shaft (27) to front housing (16).
30-64 2 WA180-3MC
12
D. Install seal rings (26) to each clutch.
★ Coat the seal ring thoroughly with oil, then install, and check
that it rotates lightly by hand.
Seal ring: Oil (transmission oil)
12. Pump (torque converter, work equipment)
A. Press fit bearing (25) to shaft (24).

★ Press fit so that there is no clearance at the stepped portion of
the shaft.
B. Assemble gear (20) and snap ring (21) inside rear housing (15),
and insert shaft (24) from pump mount end.
★ Install the gear so that the oil groove of the gear is on the
pump mount side.
C. Assemble ring washer (22) and split spacer (23) to stepped portion
of shaft (24), then install snap ring (21).
WA180-3MC 30-65 2
12
D. Turn over rear housing (15), and assemble snap ring (19) at pump
mount end.
★ Carry out the operation in the same way at the work

equipment pump end.
13. Torque converter

Using eyebolts, raise rear housing (15), set to mount of torque
converter, then tighten mount bolts (64).
★ Install guide pins to the torque converter.
★ Align the mount bolt hole properly, and be careful of the meshing
with the pump gear when installing.
★ When installing, align the match marks made during assembly.
14. Rear housing
A. Using tool A, raise rear housing (15), and assemble to front

housing (16).
★ Install guide bolts (M = 10, P = 1.5, 150 mm) to the front
housing.
Mating surface of housing:

Gasket sealant (Three Bond 1207B)
★ Be careful not to coat with too much gasket sealant, and be

sure that the gasket sealant is not squeezed out to the inside of
the case.
30-66 2 WA180-3MC
12 ★ When inserting the input shaft, be careful not to let the tip of
the shaft contact portion "a" of the housing.
★ Lower slowly until it meshes with the spline of the input
shaft.
★ Mesh the spline of the input shaft securely.
★ Be careful not to damage the seal rings of each shaft.
Housing mount bolt: 112.8± 4.9 Nm (83.19 ± 3.61 lbf ft)
B. Install pilot cap (18).

Remove all oil and grease from the mount bolts and bolt holes.
Cap mount bolt: Thread tightener (LT-2)
Pilot cap mount bolt: 66.2 ± 7.4 Nm (48.8 ± 5.45 lbf ft)
Remove tool A from rear housing (15).
15. Transmission control valve
A. Install guide bolt to mount of control valve(14).

★ Clean and remove all oil and grease from the mount bolt
thread and mount bolt hole of the control valve.
B. Align with guide bolt, assemble gasket, then fit control valve (14)
temporarily.
★ Use a new part for the gasket.
C. Coat mount bolts of control valve (14) with thread tightener, and
tighten.
★ Tighten the mount bolts on diametrically opposite sides, and
be careful not to tighten too much.
★ The length of the mount bolts is different, so be careful when
using them.
➀: L = 120 mm ➁: L = 130 mm
➂: L = 135 mm ④: L = 115 mm
➄: L = 100 mm
WA180-3MC 30-67 2
12
D. Assemble O-ring to accumulator valve (13), and install to
transmission.
holes.
16. Charging pump

Assemble O-ring to charging pump (12), and install to transmission.
★ Be careful not to get the O-ring caught.
17. Strainer, rear coupling
A. Install hose and tube (11) between strainer and pump.

B. Align center line of key groove to align rear coupling (10) with
front coupling.
★ Coat the oil seal lip portion thinly with grease.
★ Slide the coupling to prevent the oil seal lip from turning
over.
30-68 2 WA180-3MC
12
18. Oil filter
A. Sling transmission assembly (9), and lift off from assembly stand.
★ When standing the transmission assembly, be careful of the
center of gravity (lift off slowly).
B. Install O-ring (8) to idler countershaft portion, then install

speedometer pickup port assembly (6) and cover (7).
★ Do not use force to mesh the gears.
C. Install oil filter (4) and bracket (5).
Mount bolt: 112.8 ± 9.8 Nm

Install hoses (1) and (2) and tube.
★ Be careful not to crush tube (3) during the operation.
★ Install the hoses without twisting, and be careful not to get the
O-rings caught.
• Connect PTO lubrication tube.
• Install mount brackets to left and right of transmission
assembly (9).
• Wipe the bracket mount surface clean.
WA180-3MC 30-69 2
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
12
TRANSMISSION CLUTCH PACK
DISASSEMBLY
1ST, REVERSE CLUTCH
WARNING! When setting the clutch pack on the
stand, be careful not to let your hands slip
because of oil, and be extremely careful
not to get your fingers caught between the
stand and the clutch pack
★ Set with the lst side facing up, and set on tool D1.
1. Bearing
Remove bearing (1) with puller.
2. Remove spacer (2), thrust washer (3), gear (4), needle bearing (5), and
thrust washer (6).
3. End plate
A. Install tools D2 and D3, tighten nut D5, and remove ring (7).
★ Set the spacer in position and push in the end plate.
★ After removing the ring, remove tools D2 and D3.
30-70 2 WA180-3MC
12
B. Remove end plate (8).
4. Clutch plate
Remove plate (9), disc (10), and spring (11) from housing.
5. Piston
Blow air in through oil hole at 1st end of shaft and remove piston (12).
★ If the piston is at an angle and does not come out, push the piston
in and try again.
★ If force is used to remove the piston, the inside circumference of
the cylinder will be damaged.
6. Bearing
★ Set with the REVERSE side facing up, and set on tool D1.
7. REVERSE gear
Remove spacer (15), thrust washer (16), needle bearing (17),
REVERSE gear (18), and thrust washer (19).
★ Disassemble the REVERSE gear in the same way as in Steps 3 - 5
for the 1st gear.
WA180-3MC 30-71 2
12
FORWARD, 2ND CLUTCH PACK
Set with the 2nd side facing up, and set on tool D1.
1. Bearing
Using puller, remove 2nd gear (37) together with bearing (35).
2. 2nd gear
Remove spacer (39) and thrust washers (36), then remove needle
bearings (38) from 2nd gear (37).
★ Remove the inside thrust washer after removing the clutch plate.
3. End plate
A. Install tools D2 and D3, tighten nut D5, then remove ring (40).
30-72 2 WA180-3MC
12
4. Clutch plate
Remove plate (42), disc (43), and spring (44) from housing.
5. Piston
Blow air in through oil hole at 2nd end of shaft and remove piston
(45).
in and try again.
6. Bearing
★ Set with the FORWARD side facing up, and set on tool D1.
★ When installing the puller, put the center in contact with the plate.
7. FORWARD gear
Remove spacer (47), thrust washer (48), needle bearing (49), FOR-
WARD gear (50), and thrust washer (51).
★ Disassemble the FORWARD gear in the same way as in Steps 3 -
5 for the 2nd gear.
WA180-3MC 30-73 2
12
3RD, 4TH CLUTCH PACK
★ Set with the 3rd side facing up, and set on tool D1.
1. Bearing
Fit puller to bearing (53), then remove bearing (53).
2. 3rd gear
★ Remove spacer (54), thrust washer (55), 3rd gear (56), and needle
bearings (57).
Remove the inside thrust washer at Step 4-B).
3. End plate
A. Install tools D2 and D3, tighten nut D5, then remove ring (58).
30-74 2 WA180-3MC
12
4. Clutch plate
A. Remove plate (60), disc (61), and spring (62) from housing.
B. Remove inside thrust washer (71).
5. Piston
Blow air in through oil hole at 3rd end of shaft and remove piston (63).
in and try again.
6. Bearing
Set with the 4th side facing up, and set on tool D1.
Using puller, remove bearing (64) and 3rd gear (65).
7. 4th gear
Remove spacer (66), thrust washer (67), needle bearing (68), 4th gear
(69), and thrust washer (70).
★ Disassemble the 4th gear in the same way as in Steps 3 - 5 for the
3rd gear.
WA180-3MC 30-75 2
12
ASSEMBLY
1ST, REVERSE CLUTCH
stand and the clutch pack.
★ Set with the REVERSE side facing up, and set the shaft and housing
assembly on tool D1.
1. Piston seal
Assemble piston seal (71-1) to piston (71).
★ When assembling a new piston seal, use seal shaping jig E1 or E2
for approximately 2 - 3 minutes, then assemble the piston seal.
★ If the seal is installed to the piston without being shaped, the seal
will be damaged.
Inside surface of shaping jig: Oil (transmission oil)
2. REVERSE piston
Assemble REVERSE piston (71).
★ Be careful not to damage the piston seal.
Sliding surface of piston seal: Oil (transmission oil)
3. Clutch plate
Insert tool D4 in housing, then assemble plate (72), disc (73), and
spring (74) in turn.
before assembling.
★ Be careful not to let spring (74) and plate (72) rest on top of each
other.
★ Be careful not to let the plate or spring get caught in the ring
groove of the clutch housing when assembling.
★ A3 x 85 mm nail can also be used for tool D4.
30-76 2 WA180-3MC
12
4. End plate
Install tools D2 and D3, tighten nut D5 to push in end plate (76), then
remove tool D4.
A. Assemble ring (77), then remove tools D2 and D3.

★ Check that ring (77) is fitted securely in the groove.
★ Check that the disc rotates smoothly by hand.
5. Thrust washer
Install thrust washer (19).
6. REVERSE gear
Use a screwdriver to align the spline on the inside of the plate, and
assemble REVERSE gear (18).
★ If the gear spline is not aligned, rotate lightly while assembling.
Never push with force.
7. Bearing
Assemble needle bearing (17), thrust washer (16), and spacer (15).
★ Check that the end face of thrust washer (16) is level with or
below the stepped portion of the shaft.
WA180-3MC 30-77 2
12
8. Bearing
Press fit bearing (13).
★ Press fit completely so that spacer (15) is in tight contact with the
stepped portion of the shaft and bearing (13).
★ After press fitting the bearing, check that clearance "a" between
thrust washer (16) and spacer (15) is within the specified
range."a" = 0.07 - 0.93 mm
9. 1st piston
A. Turn over clutch pack.
WARNING! When turning over the clutch pack, be

careful not to get your fingers caught
between the stand and clutch pack.
B. Assemble piston (12) in same way as for REVERSE piston.
10. Clutch plate

Insert tool D4 in housing and assemble plate (9), disc (10), and spring
(11) in turn.
★ A 3 x 85 mm beta pin (nail) can also be used for tool D4.
★ Assemble in the same way as for REVERSE.
30-78 2 WA180-3MC
12
11. End plate
A. Install tools D2 and D3, tighten nut D5 to push in end plate (8),
then remove tool D4.
★ Set a spacer in position and push in the end plate.
B. Assemble ring (7) and remove tools D2 and D3.

12. Thrust washer

13. lst gear

Assemble 1st gear (2).
14. Bearing
Assemble needle bearing (5).
15. Thrust washer, spacer

Assemble thrust washer (4) and spacer (3).
★ Check that the end face of thrust washer (4) is level with or below
the stepped portion of the shaft.
WA180-3MC 30-79 2
12
16. Bearing
★ Press fit completely so that the spacer is in tight contact with
the stepped portion of the shaft and bearing (1).
★ After press fitting the bearing, check that clearance "b" between
thrust washer (4) and spacer (3) is within the specified range.
b = 0.04 - 1.16 mm
17. Clutch pack operating test

Blow in compressed air through oil hole of shaft and check if each
clutch is actuated.
★ If the gear at the point where the air is blown in is held in position,
the clutch is working normally.
30-80 2 WA180-3MC
12
FORWARD, 2ND CLUTCH
★ Set with the FORWARD side facing up, and set the shaft and housing
assembly on tool D1.
1. Piston seal
★ When assembling a new piston seal, use seal shaping jig El or E2
will be damaged.
2. FORWARD piston
Assemble FORWARD piston (83).
3. Clutch plate
before assembling.
★ Be careful not to let spring (80) and plate (78) rest on top of
each other.
★ A 3 x 85 mm nail can also be used for tool D4.
WA180-3MC 30-81 2
12
4. End plate
B. Assemble ring (82) and remove tools D2 and D3

5. Thrust washer
6. FORWARD gear
Assemble FORWARD gear (50), then assemble needle bearing (49).
7. Thrust washer
Assemble thrust washer (48).
★ Check that the end face of the thrust washer is level with or below
the stepped portion of the shaft.
8. Bearing
Assemble spacer (47), then press fit bearing (46).
★ After press fitting the bearing, check that clearance "e" between
e = 0.07 - 0.93 mm
30-82 2 WA180-3MC
12
9. 2nd piston

B. Assemble piston (45) in same way as for FORWARD piston.
10. Clutch plate

(44) in turn.
★ Assemble in the same way as for FORWARD.
11. End plate
B. Assemble ring (40), then remove tools D2 and D3.

12. Thrust washer

WA180-3MC 30-83 2
12
13. 2nd gear
Assemble 2nd gear (37), then assemble needle bearings (38).

Assemble thrust washer (36) and spacer (34).
15. Bearing
★ After press fitting the bearing, check that clearance "f" between
f = 0.04 - 1.16 mm

Blow in compressed air through oil hole at 2nd end and check if each
clutch is actuated.
30-84 2 WA180-3MC
12
3RD, 4TH CLUTCH
★ Set with the 4th side facing up, and set the shaft and housing assembly
on tool D1.
1. Piston seal
★ When assembling a new piston seal, use seal shaping jig E1 or E2
will be damaged.
2. 4th piston
Assemble 4th piston (84).
3. Clutch plate
before assembling.
★ Be careful not to let spring (87) and plate (85) rest on top of each
other.
WA180-3MC 30-85 2
12
4. End plate

5. Thrust washer
6. 4th gear
Assemble 4th gear (69), then assemble needle bearing (68).
7. Thrust washer, bearing

Assemble thrust washer (67), and spacer (66), then insert bearing (64)
to shaft.
.
below the stepped portion of the shaft
30-86 2 WA180-3MC
12
8. Bearing
★ After press fitting the bearing, check that clearance "g" between
"g" = 0.07 - 0.93 mm
9. 3rd piston

B. Assemble piston (63) in same way as for 4th piston.
10. Thrust washer

★ Assemble 3rd inside thrust washer (71) before assembling the
clutch plate.
WA180-3MC 30-87 2
12
11. Clutch plate
(62) in turn.
★ Assemble in the same way as for 4th.
12. End plate

13. 3rd gear

Assemble 3rd gear (56), then assemble needle bearings (57).

Install thrust washer (55), then assemble space (54).
30-88 2 WA180-3MC
12
15. Bearing
★ After press fitting the bearing, check that clearance "h" between
h = 0.04 - 1.16 mm

Blow in compressed air through oil hole at 3rd end and check if each
clutch is actuated.
WA180-3MC 30-89 2
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
12
REMOVAL

• Remove inspection cover (1) of the left side of the rear frame.
• Remove cover (2) at the left side of the floor.
1. Electric wiring
A. Disconnect connectors (3), (4), (5), and (6) and wiring for
transmission solenoid valve.
B. Disconnect torque converter oil temperature sensor connector (7).

★ When disconnecting the wiring connectors, fit tags to identify
the connectors.
2. Hydraulic piping
A. Disconnect hose (8) between brake booster and transmission

valve
B. Disconnect hose (9) between transmission valve and oil cooler
C. Disconnect hose (10) between torque converter oil filter and brake
booster, and remove hose clamp.
3. Downshift switch
WARNING! The working space is confined, so be

extremely careful.
A. Disconnect downshift switch (A).
30-90 2 WA180-3MC
12
4. Transmission valve
Sling transmission valve (12) and remove mount bolts, then lower
under machine.

extremely careful.
★ To prevent the valve from falling, remove 2 mount bolts, then

install guide bolts and insert wooden blocks.
★ Remove the valve with a upper valve and lower valve assembled.
Disassemble the upper and lower valve after removing.
★ When fitting a lifting tool, avoid the connectors and fit the tool securely to the valve body.
Transmission valve: 46 kg (101.4 lb)

upper: 15.5 kg (34.2 lb)
lower: 30.5 kg (67.2 lb)
WA180-3MC 30-91 2
12
INSTALLATION

extremely careful.
★ Connect the wiring connector securely.
Nut of hose mouthpiece:

176.5 ± 29.4 Nm (130.2 ± 21.6 lbf ft)
★ Width across flats of hose mouth piece nut: 36 mm

★ When installing the transmission valve, replace the gasket with a
new part.
★ When installing the transmission valve, use guide bolts to prevent
it from falling.
★ Secure with upper and lower valve set bolts (13) and (14).
★ Remove all oil and grease from the valve mount bolts and mount
bolt holes.
★ The length of the mount bolts is different, so be careful when
using them.
(1) L = 120 mm (2) L = 130 mm (3) L = 135 mm
(4) L = 115 mm (5) L = 100 mm (6) L = 100 mm
★ To prevent distortion of the valve, tighten the transmission valve

mount bolts in the order shown in the diagram.
30-92 2 WA180-3MC
12
MEMORANDUM
WA180-3MC 30-93 2
12
DISASSEMBLY
30-94 2 WA180-3MC
12
1. Disconnection
Remove mount bolts, and disconnect upper valve (1) and lower valve (2), then remove gasket (3).
2. Disassembly of upper valve
A. Remove mount bolts, remove cover (4), then remove gasket (5), pilot valve (6), priority spring (7), quick return valve
assembly (8), accumulator piston (9), and spring (10).
B. Remove sleeve (11) from quick return valve assembly, then remove spring (12) and ball (13).
C. Remove plug (14) from sleeve (11).
D. Remove mount bolts, remove cover (15), then remove gasket (16), main regulator valve (17), spring (18), priority
valve (19), modulating valve assembly (20), accumulator shaft (21), and springs (22) and (23).
E. Remove load pistons (24) and (25) from main regulator valve (17) and priority valve (19).
F. Remove plug (26) from modulating valve assembly (20), then remove retainer (27), springs (28) and (29), sleeve
(30), and O-rings (31).
G. Remove nut (32) and washer (33) from cover (15), then remove adjustment screw (34) and O-ring (35).
H. Remove plug (36) and main orifice (37) from upper valve (1).
3. Disassembly of lower valve
A. Remove mount bolts, remove solenoid valve assembly (38), then remove spring (39), retainer (40), spring (41), and
sleeve (42).
B. Remove mount bolts, remove cover (43), then remove gasket (44), torque converter regulator valve (45), shim, (46),
spring (41A), sleeve (42A), F-R selector valve (47), H-L selector valve (48), range selector valve (49), springs (50),
and spacers (51).
C. Remove mount bolts, then remove pilot filter (52) and O-rings (53).
D. Remove plug (54) from F-R selector valve (47).
E. Remove plugs (55) from lower valve (2) and cover (43).
F. Remove orifices (56) from lower valve (2).
WA180-3MC 30-95 2
12
ASSEMBLY
30-96 2 WA180-3MC
12
1. Assembly of lower valve
A. Install orifices (56) to lower valve (2).

★ Screw in the orifice at least 2 mm from the valve body.
B. Install plugs (55) to lower valve (2) and cover(43).
Plug: Sealant (LG-1 or LG-5)
C. Install plug (54) to F-R selector valve (47).
D. Install O-rings (53) to pilot filter (52), then set in mounted position and tighten the mount bolts.
E. Install H-L selector valve (48), range selector valve (49), spacers (51), springs (50), F-R selector valve (47), sleeve
(42A), spring (41A), shim (46), and torque converter regulator valve (45), then set gasket (44) in position, and install
cover (43).
F. Install sleeve (42), spring (41), retainer (40), and spring (39), then set gasket mount, and install solenoid valve
assembly (38) to lower valve (2).
2. Assembly of upper valve
A. Install plug (36) and main orifice (37) to upper valve (2).
i. Screw in the orifice at least 2 mm from the valve body.
B. Fit O-ring (35) to adjustment screw (34), then set cover (15) in mounted position, and secure washer (33) and
nut (32).
★ For details of the adjustment procedure, see TESTING AND ADJUSTING.
C. Fit plug (26) to modulating valve (20), then assemble O-rings (31) to sleeve (30), and install springs (28) and (29) and
retainer (27).
D. Install load pistons (24) and (25) to main regulator valve (27) and priority valve (19).
E. Assemble springs (22) and (23), accumulator shaft (21), modulating valve assembly (20), priority valve (19), spring
(18), and main regulator valve (17), then set gasket (16) to mount, and install cover (15).
F. Assemble plug (14) to sleeve (11), then set ball (13) and spring (12) to quick return valve (8), and assemble
sleeve (11).
WA180-3MC 30-97 2
G. Assemble spring (10), accumulator piston (9), quick return valve assembly (8), priority spring (7), and pilot valve (6),
then set gasket (5) to mount, and install cover (4).
3. Connection
Set gasket (3) to mount, then connect lower valve (2) and upper valve (1).
30-98 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY TRANSMISSION SOLENOID VALVE
12
DISASSEMBLY
1. Remove mount bolts from solenoid valve body (1), then remove solenoids (2) and O-rings (4).
★ Remove the connector from the plate.
2. Remove plate (3) from valve body (1).
3. Remove lock plate (5), then remove emergency manual spool (6) and O-ring (7).
A. Remove orifice (8) from emergency manual spool (6).
B. Remove plate (9).
4. Remove plugs (10) from solenoid valve body (1).
WA180-3MC 30-99 2
DISASSEMBLY AND ASSEMBLY TRANSMISSION SOLENOID VALVE
12
ASSEMBLY
1. Install plugs (10) to solenoid valve body (1).
2. Install orifice (8) and O-ring (7) to emergency manual spool (6), then
secure with lock plate (5), and install plate (9).
3. Install plate (3) to valve body (1).
4. Assemble O-rings (4) to solenoid valve (2), and tighten bolts.

30-100 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
12
TRANSMISSION ACCUMULATOR
VALVE
DISASSEMBLY
1. Remove accumulator valve (4) from transmission assembly (3).
2. Remove O-rings (1) and (2) from accumulator valve (4).
3. Using pads, set accumulator valve body (9) in vice.
4. Remove mount bolts (5) and (6), and assemble guide bolts A.
• M = 10, P = 1.5, L = Approximately 40 mm
5. Remove bolts (7) and (8), then remove cover (10) together with guide
bolts A.
★ The internal parts will come off together with the cover, so be
extremely careful not to damage them when removing.
6. Pull out valves (11), springs (12) and (14), stoppers (13) and (15), and
spacers (16) and (17) from cover (10).
★ Fit tags to each spring, stopper, spacer, and use for reference when
assembling.
★ Reference
Spring Stopper Spacer
FWD L = 145 L = 95 L = 40
1ST L = 145 L = 95 L = 40
2ND L = 145 L = 95 L = 50
WA180-3MC 30-101 2
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
12
7. Remove plugs (19) and (20) from cover (10).
• Plug: 5 mm (width across flats)
★ Do not remove the plugs unless necessary.
★ If plugs (19) and (20) have been removed, coat the thread with
thread tightener as shown in the diagram below, then tighten the
plugs.
★ Be careful not to let the thread tightener drip on to the hatched
portion when coating with thread tightener.
Plug: Thread tightener (LG-1)
ASSEMBLY
1. Using pads, set accumulator valve cover (10) in vice.
★ Be careful not to tighten the vice on the cover with excessive force.
2. Assemble spacers (17) and (16), stoppers (15) and (13), and springs
(14) and (12) to accumulator valve cover (10), then insert valves (11)
from top of each spring.
3. Fit O-rings (22) and (21) in each groove of accumulator valve body
(9).
★ Assemble the O-ring securely in the body groove.
4. Assemble accumulator valve body (9) perpendicularly from above

cover (10), then temporarily install with guide bolts.
★ Assemble the body carefully and be sure that the O-ring does not
fall out.
5. Push in accumulator valve body (9), and remove guide bolts, then
secure with standard bolt.

Mount bolt: 8 mm (width across flats)
30-102 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
12
DRIVE SHAFT
DISASSEMBLY
A. Shaft slip spline is permanently lubricated, and should not be

disassembled.
B. Loosen bolt (2), then remove coupling (3) and retainer.

★ Make match marks to prevent the coupling from being
installed in a different direction.
C. Using a press, remove flange bearing (4).
2. Center drive shaft, rear drive shaft

Shaft slip spline is permanently lubricated, and should not be
disassembled.
3. Spider, bearing
Remove bolts (6) of spider and bearing assembly (5), and tap with
plastic hammer to remove.
WA180-3MC 30-103 2
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
12
ASSEMBLY
1. Spider, bearing
A. Assemble so that the grease nipples face in the same direction.

★ Repeat the same procedure for the front, center and rear drive shafts.
B. Set spider and bearing assembly (5) to drive shaft mount, and lock
with bolts (6).
Bearing cap: Grease (G2-LI)
Mount bolt: 54 ± 3 Nm (40 ± 2 lbf ft)
A. Press fit flange bearing (4).

★ Do not hit the flange bearing directly with a hammer.
B. Align match marks, and tighten coupling (3) and retainer (9) with
mount bolt (2).
★ Tighten the bolt to the specified tightening torque after
installing to the machine.
Spline portion: Grease (G2-LI)
30-104 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY FRONT AXLE
12
FRONT AXLE
REMOVAL

the work equipment to the ground and
stop the engine. Then apply the parking
brake and put blocks under the wheels to
prevent the machine from moving.
1. Jacking up the machine

Put block ➀ under front frame, and hold up machine.
★ Raise the front frame with the bucket, and set blocks ➀ in
position with the tires raised slightly from the ground.
2. Tire, wheel
Sling tire and wheel (1), remove mount bolts, then lift off.
Tire, wheel: 180 kg (397 lb)
3. Drive shaft
Disconnect front drive shaft (2).
4. Axle
A. Disconnect brake tube (3).
WA180-3MC 30-105 2
DISASSEMBLY AND ASSEMBLY FRONT AXLE
12
B. Using jack and hoist, sling axle (4), remove mount bolts (5), then
lift off.
★ Adjust the height of the jack when removing the mount bolts.
Axle: 387 kg (853.2 lb)
C. Pull out axle from machine.

★ Use a hoist and jack to remove the axle.
INSTALLATION
★ Raise the front frame slightly with the bucket, and remove
block ➀.

Drive shaft: 65.7 ± 6.9 Nm (48.4 ± 5.0 lbf ft)
★ Be careful not to tighten the tube nut too far.
Tube nut: 11.8 ± 2.9 Nm (8.7 ± 2.1 lbf ft)
★ When installing the axle, use the mount bolts as a guide and align the mount position.

• Bleeding air from brake system

Bleed the air. For details, see TESTING AND ADJUSTING.
30-106 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY REAR AXLE
12
REAR AXLE
REMOVAL

put blocks under the wheels to
WARNING! Open the side inspection cover and apply

the lock.
★ Loosen drain valve (1) and drain fuel.
1. Fuel tank
A. Disconnect fuel hose (2), fuel return hose (3), and fuel gauge
wiring connector (4).
B. Remove return hose (5) from fuel filter.

★ Remove the clamp of breather tube (5-1).
C. Remove inside cover (7), outside cover (8) and rubber of fuel oil
filler port (6) at left side of rear frame.
D. Set transmission jack under fuel tank, and support fuel tank (9)
lightly.
E. Remove mount bolts, then lower transmission jack slowly and

remove.
★ When there is a clearance of approx. 50 mm (2 in) from the
rear frame, stop and check that there is no interference.
★ The oil filler tube will hit the rear frame so move to the right
and remove carefully.
Fuel tank (dry): 70 kg (154.3 lb)
F. Pull out fuel tank (9) to right side of chassis.
WA180-3MC 30-107 2
12
2. Jacking up chassis
A. Remove engine oil drain valve (11) from rear axle pivot (10).
B. Set block ➀ between left and right rear axles and rear frame.
C. Jack up chassis and put support stand ➁ under rear frame.

★ Raise the rear frame with a garage jack, and when the tires
come slightly off the ground, set stand in position.
3. Tire, wheel
Fit sling around tire and wheel (12), then remove mount bolts and lift
off.
Tire, wheel: 180 kg (396.8 lb)
4. Drive shaft
Remove rear drive shaft (13).
★ Make match marks to show the mount position.
30-108 2 WA180-3MC
12
5. Brake, grease tube
A. Disconnect brake hose (14).
B. Remove grease tube (15) from rear axle pivot.
6. Axle
A. Secure pivot (10) to axle with chain or wire.

★ Fix securely so that the pivot does not move.
B. Sling one end of axle (16), set garage jack under axle housing at
other end, then remove mount bolts.
★ Adjust the height of the garage jack when removing.
★ The pivot end will go down, so be extremely careful when
removing the axle.
Rear axle, pivot: 462 kg (1018.5 lb)
C. Pull out axle assembly from chassis.

★ Use a hoist and jack to pull out the axle assembly.
★ After pulling the axle assembly out from the chassis,
remove the chain or wire.
7. Rear pivot
A. Remove trunnion cap (16-1).

★ Before removing the cap, remove the grease tube.
★ If there are shims installed, check the number and thickness
of the shims and use for reference when assembling.
B. Remove thrust plate (17).
WA180-3MC 30-109 2
12
C. Lift off rear pivot (18).
★ Be careful that the hanging tool does not slip when lifting off
the rear pivot.
Rear pivot: 75 kg (165.3 lb)
D. Remove O-ring (19) and bushing (20) from pivot (18).
8. Front pivot
Remove O-rings (22) and bushing (23) from pivot (21).
30-110 2 WA180-3MC
12
INSTALLATION
1. Front pivot
Assemble O-rings (22) and bushing (23) to pivot (21).
★ Assemble so that the chamfered side of the bushing is on the axle
housing side.
★ Set with the join of the bushing at the side.
O-ring, bushing: Grease (G2-LI)
2. Rear pivot
A. Assemble O-ring (19) and bushing (20) to pivot (18).

★ Set with the join of the bushing at the side.
O-ring, bushing: Grease (G2-LI)
B. Raise pivot (18), and insert to mount portion of axle.

C. Install thrust plate (17) to mount portion of axle.

★ Wipe the mating surface of the thrust plate clean.
★ Assemble so that the 5 hole of thrust plate (17) is at the top.
Outside circumference of pivot mount: Grease (G2-LI)
WA180-3MC 30-111 2
12
D. To make axle and pivot parallel, turn over trunnion cap (16-1) and
tighten down with 8 bolts uniformly.
★ Check that the clearance between the pivot and trunnion cap
is uniform.
★ Set on the mount on the machine body with the cap still
reversed.
3. Axle
Raise axle (16) with jack and hoist, set in mount position and tighten
mount bolts.
★ Use the bolts as guides when setting in the mount position.
★ When tightening the mount bolts, do not tighten in one pass.
Tighten the mount bolts in three stages.
★ After installing the axle assembly, remove the wire.

4. Adjusting shim at rear pivot
A. Using depth micrometer ➀, measure dimension "a" of trunnion

cap (16-1). Measure at 4 places at 90° angles and take the average.
★ Clean the probe contact surface before measuring.
• Standard value "a": 12.2 - 12.33 mm
B. Assemble thrust washer (17) at rear pivot. Using depth microme-

ter (1), measure dimension "b" at 4 places at 90° angles and take
the average.
★ Clean the contact surfaces of the thrust plate.
★ Clean the probe contact surface before measuring.
• Reference value "b": 12.10 - 12.30 mm
★ Insert a feeler gauge around circumference "c" and at the joint
of the thrust plate, and check that there is no clearance.
30-112 2 WA180-3MC
★ Joint rear pivot and trunnion cap
• Standard clearance "d": 0.1 - 0.29 mm.
• "a" - "b" - (0.1 - 0.29) = t (shim thickness)
★ Shim size = 0.2 mm
C. Assemble selected shims between rear pivot (10) and trunnion cap
(16-1), then install the mount bolts.
★ Fill the trunnion cap with grease before installing.
Trunnion cap: Grease (G2-LI)
5. Brake, grease tube
A. Secure grease tube (15) with mount clamp.
B. Connect brake hose (14).

★ Be careful not to tighten the brake hose too much.
WA180-3MC 30-113 2
12
C. Install engine oil drain valve (11) in axle pivot (10).
6. Drive shaft
Install rear drive shaft (13).
★ Align the pilot correctly and install with the yoke facing in the
correct direction.
Mount bolt: 31.4 ± 2.9 Nm m(23.6 ± 2.13 lbf ft)
7. Tire, wheel
Sling tire and wheel (12), set in mount position, and tighten mount
bolts.
Mount bolts: 927 ± 103 Nm (683.7 ± 75.9 lbf ft)

8. Lowering machine
A. Pull out block ➁ from under rear frame and lower machine to
ground.
★ Raise the rear frame with a garage jack, and remove blocks ➁
when the frame is raised slightly.
B. Remove block ➀ between left and right rear axles and rear frame.
30-114 2 WA180-3MC
12
9. Fuel tank
A. Pull in fuel tank (9) under chassis.

★ Pull in from the right side of the rear frame.
B. Operate transmission jack and raise fuel tank (9) slowly, then set
in mount position, and fit mount bolts temporarily.
★ When setting to the mount, move from the right to the left,
raise, and stop at a point where the oil filler passes the rear
frame, then check that there is no interference.
C. Position and tighten mount bolt firmly.
D. Install inside cover (7), outside cover (8), and rubber of fuel filler
port (6) at left side of rear frame.
E. Install return hose (5) from fuel filter.
F. Install breather tube (5-1) and clamp.
G. Connect fuel hose (2), fuel return hose (3), and fuel gauge wiring
connector (4).
H. Close drain valve (1).
I. Bleeding air from brake system

Bleed air. For details, see TESTING AND ADJUSTING.
WA180-3MC 30-115 2
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
12
DIFFERENTIAL
DISASSEMBLY
1. Brake tube
Remove brake tube (1).
2. Differential cover
Remove bleeder screw (2), then remove differential cover (3).
★ Install the differential assembly in a stand.
★ Remove the axle housing.
3. Cage
A. Screw in a forcing screw, then using guide bolt (4), remove cage
(5).
★ Check the number and thickness of the shims, and keep them
in a safe place.
★ Loosen mount bolts of coupling, and temporarily install the
cage.
Cage: 17 kg (37.5 lb)
B. Remove O-ring from cage.
4. Brake piston
Screw in forcing screws (3 places) to raise evenly, then remove piston
(6).
★ If the O-ring of the piston is not damaged, it is possible to install
the bleeder screw and blow in air to remove the piston.
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12
5. Bearing carrier
Screw in forcing screws to raise bearing carrier evenly, and remove
bearing carrier (7). Remove angle ring.
★ Check the number and thickness of the shims, and keep them in a
safe place.
★ Mark the left and right bearing carriers to avoid confusing them.
6. Differential carrier
A. Lift off differential carrier assembly (9) from differential housing

(8).
★ When removing the assembly, be careful that the lifting tool
does not slip.
Differential carrier assembly: 30 kg (66.2 lb)
B. Remove bevel gear (10), then remove bearing (11) from bevel
gear.
C. Remove thrust washer (13) from differential carrier (12), then

remove side gear (14).
WA180-3MC 30-117 2
12
D. Remove lock pins (15), pull out shaft (16), then remove pinion
gears (17).
E. Remove side gear (18).
7. Coupling
A. Remove mount bolt (20), then remove holder (21), coupling (22)
and O-ring (23).
★ Do not remove the protector press fitted to the coupling
unless necessary.
B. Remove oil seal (24).
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12
C. Using a press, remove pinion gear (25) from cage, then remove
bearing (26).
D. Remove spacer (27) and bearing (28) from pinion gear (25).
E. Remove bearing cups (29) and (30) from cage (5).
WA180-3MC 30-119 2
12
ASSEMBLY
1. Pinion gear
A. Press fit bearing cone (28) in pinion gear (25), then assemble
spacer (27).
★ There must be no clearance at the contact faces of any parts.
B. Press fit bearing cups (29) and (30) in cage (5).
C. Assemble pinion gear (25) in cage (5), then press fit bearing cone
(26).
★ Apply pressure to the bearing at the specified load, and rotate
the case to settle the bearing.
★ Press load: 49 kN (5 ton)
Bearing: Oil (axle oil)
★ When rotating the case at the specified load, rotate lightly by

hand. If the rotation is not smooth, replace the bearing and
spacer, and again rotate lightly by hand.
30-120 2 WA180-3MC
12
D. Press fit oil seal (24) in cage (5).
★ Assemble oil seal (24) evenly so that it has the specified
depth "t".
t = 6 ± 0.5 mm
Oil seal lip: Grease (G2-LI)
Pinion gear shaft: Grease (G2-LI)
2. Coupling
Install coupling (22), O-ring (23) and holder (21) to pinion gear (25),
then tighten mount bolts.
★ Tighten the mount bolts partially. Tighten them fully after the
completion of assembly.
★ When inserting the coupling, be careful not to damage the seal.
3. Differential carrier assembly
A. Install side gear (18) to differential carrier (12).
B. Install pinion gears (17) and shaft (16) to differential carrier (12),
then insert lock pins (15).
Gears, shafts: Oil (axle oil)
WA180-3MC 30-121 2
12
C. Assemble side gear (14) and thrust washer (13).
Sliding surface of thrust washer: Oil (axle oil)
D. Press fit bearing (11) on bevel gear (10).
E. Assemble bevel gear (10) in differential carrier (12), then tighten

mount bolts.
Mount bolts: Thread tightener (LT-2)
Mount bolts: 279 ± 29 Nm (206 ± 21 lbf ft)
★ Coat the thrust washer with grease and stick it to the bevel
gear to prevent it from falling off during installation.
★ Align the lock of the washer correctly with the groove in the
bevel gear.
4. Adjusting shim of cage
A. Assemble cage (5) without shims in differential housing (8).
Mount bolts: 112.8 ± 9.8 Nm (83 ± 7 lbf ft)
B. Insert measuring tool A in differential (8), and measure distance

between end face of bevel pinion gear and tool A with an inside
micrometer or a cylinder gauge.
★ When inserting tool A in the differential housing, coat thinly
with oil, and insert straight without twisting.
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12
C. Selecting shims
t = C - (L + D/2)
t: Shim thickness A: 157.5
C: (A + a) - (B + b) B: 50.68
L: Actual value a: Error for distance A
D: Diameter of tool A b: Error for distance B
★ Use the actual value for distance D
★ Shim thickness "t" must be within 0.5 -1.9 mm.

The end face of the pinion gear is marked with an electric pen
as follows.
MD +0.10 [Distance "a" mm]
(-0.01) [Distance "b" mm]
★ Always use the bevel pinion gear and bevel gear in a set with
the same number.
D. Remove cage.
5. Bearing carrier
Press fit bearing cups (32) and (33) in bearing carriers (7) and (31).
Press-fitting portion of bearing cup: Oil (axle oil)
6. Adjusting bearing carrier shims
A. Raise differential carrier assembly (9), set in mounted position,

then install left and right bearing carriers (7) temporarily.
★ Assemble the differential carrier assembly with the bevel gear
on the right as seen from the cage mount.
★ Assemble the bearing carrier and adjust without the angle
ring and shim.
WA180-3MC 30-123 2
12
B. Tighten carrier (31) at differential carrier end to specified
tightening torque.
Mount bolts: 113 ± 9.8 Nm (83 ± 7 lbf ft)
C. Tighten 4 mount bolts of carrier (7) at bevel gear end.

★ Rotate the bevel gear and coat the bearing with oil.
Bearing: Oil (axle oil)
★ To settle all the parts, rotate the bevel gear when tightening.
Mount bolts: 11.8 Nm (9 lbf ft)
D. Loosen 4 mount bolts at bevel gear end until there is end play at
bearing.
E. Tighten 4 mount bolts uniformly again.
Mount bolts: 3.9 Nm (3 lbf ft)
★ When doing this, check that there is end play at the bearing,
and rotate the bevel gear when tightening.
F. Using a feeler gauge at 2 places in groove of bearing carrier (7) at

bevel gear end, measure clearances T1 and T2
G. Selecting shims
Shim thickness = (T1 + T2)/2 ± 0.035 mm
★ Combine the following shims to give the necessary shim
thickness. 0.07 mm, 0.20 mm, 0.30 mm, 0.80 mm
30-124 2 WA180-3MC
12
H. Remove left and right bearing carriers (7),and assemble selected
shims (32).
★ Rotate the bevel gear and tighten the mount bolts of the
bearing carrier uniformly.
I. Using a spring balance, measure preload of bevel gear and check

that it is within specified range.
★ Preload: 7.8 - 25.5 Nm (6 - 19 lbf ft)
[Target: 25.5 Nm (19 lbf ft)]
★ If the preload is not within the specified range, change the
shim thickness to adjust.
7. Cage
A. Assemble O-ring (34) in bearing cage.
O-ring: Oil (axle oil)
B. Install guide bolt, assemble shims (35) selected in Step 4, and

install cage (5).
WA180-3MC 30-125 2
12
8. Adjusting backlash
A. Measure backlash of bevel gear with a dial gauge.

★ First, measure with all the shims inserted at the bevel gear
end.
★ Measure the backlash at 3 places around the circumference of
the bevel gear. The variation between the measurement must
be within 0.1 mm.
B. To obtain backlash within specified range, move some of the

shims from bevel gear side to opposite side.
★ When moving the shims, do not change the total shim
thickness. The total shim thickness on the left and right must
remain the same.
★ Adjust the backlash as follows.
If backlash is too LARGE, move shims from B to A
If backlash is too SMALL, move shims from A to B
30-126 2 WA180-3MC
12
9. Adjusting tooth contact
Coat face of 7 or 8 teeth of bevel gear lightly with red lead. Hold the bevel gear by hand to act as a brake, rotate the pinion
gear forward and backward and inspect the pattern left on the teeth.
Tooth contact Cause Procedure for adjustment
Correct contact
The tooth contact pattern should start
Adjust the bevel pinion by adjusting the shims at the bevel
from about 5 mm from the toe of the
pinion cage.
bevel gear and cover about 50% of the
Adjust the bevel gear in the same way as when adjusting
length of the tooth.
backlash.
It should be in the center of the tooth
height.
1. Reduce shims at bevel

pinion to bring closer to
bevel gear.
Bevel pinion is too far from bevel gear. 2. Move bevel gear further
away from bevel pinion
and adjust backlash
correctly.
1. Increase shims at bevel

pinion to move away from
bevel gear.
Bevel pinion is too close to bevel gear. 2. Move bevel gear closer to
bevel pinion and adjust
backlash correctly.
1. Reduce shims at bevel

pinion to bring closer to
bevel gear.
Bevel gear is too close to bevel pinion 2. Move bevel gear further
away from bevel pinion
and adjust backlash
correctly.
1. Increase shims at bevel

pinion to move away from
bevel gear.
Bevel gear is too far from bevel pinion. 2. Move bevel gear closer to
bevel pinion and adjust
backlash correctly.
★ When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between the left
and right. Always keep the same total thickness of shims.
WA180-3MC 30-127 2
12
10. Bearing carrier
Remove bearing carrier (7), assemble angle ring (36) together with
adjusted shims.
★ Coat the angle ring with grease, and be careful not to drop it when
installing.
★ When installing bearing carrier (7), the angle ring may come out,
so do not use a hammer to install the bearing carrier.
Angle ring: Grease (G2-LI)
Mount bolt: 113 ± 9.8 Nm (83 ± 7 lbf ft)
11. Brake piston
A. Assemble O-rings (37) and (38) securely in grooves of brake

piston (6) and bearing carrier (7).
★ Coat the brake piston and piston mount with grease to prevent
the O-ring from twisting or breaking.
Piston and piston mount face: Oil (axle oil)
B. Install piston press fit tool B on housing, and tighten screws (39)
evenly to press fit.
★ Press fit the piston completely until it contacts the housing.
★ The O-ring and piston will be damaged if a plastic hammer is
used to press fit the piston.
12. Brake oil leakage test
A. Install bleeder screw.
B. Tighten screw (39) of piston press-fitting tool B completely, then

loosen one turn.
C. Install hose of tool C to brake tube mount port (44), and bleed air
from inside cylinder.
D. Operate pump and raise pressure to 14 kg/cm2 (199.1 lbf/in2).

When the pressure is 14 kg/cm2 (199.1 lbf/in2), leave for 5
minutes. The drop in pressure should be less than 3.5 kg/cm2
(49.7 lbf/in2).
30-128 2 WA180-3MC
12
E. If the test shows that there is no air leakage, raise pressure to 42
kg/cm2 (597.3 lbf/in2).
★ When the pressure is 42 kg/cm2 (597.3 lbf/in2), leave for 5
minutes. The drop in pressure should be less than
3.5 kg/c m2 (49.7 lbf/in2).
★ If there is any oil leakage, remove the brake piston, check the
O-ring for damage, then assemble again.
After checking for brake oil leakage, insert the piston fully.
13. Coupling
Tighten mount bolts of coupling (22) fully.
Mount bolts: 279 ± 29 Nm (206 ± 21 lbf ft)
A. Install differential cover (3) to housing.

★ Use a guide bolt when installing to prevent thread tightener
from entering the mount hole of the bleeder screw.
Cover contact surface: Gasket sealant (Loctite 515)
B. Remove guide bolt, install bleeder screw (2).

★ Check that there is no thread tightener stuck to the bleeder
screw hole before installing.
WA180-3MC 30-129 2
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
12
AXLE HOUSING
DISASSEMBLY
1. Draining oil
Loosen drain valve (1) and drain oil
A. Remove bleeder screw (2), then using forcing screw, remove dif-
ferential cover (3).
B. Install axle assembly to stand.
3. Axle housing assembly
A. Sling axle housing (4), then remove housing mount bolts.

★ Put match marks on the housings to distinguish the left and
right housings.
B. Disconnect axle housing, and remove shaft (5), brake disc (6) and
brake ring.
★ Be careful not to damage the surface of the brake disc.
Axle housing: 88 kg (194 lb)
30-130 2 WA180-3MC
12
4. Brake outer ring
Remove brake outer ring (7) and pin (8).
★ Be careful not to damage the surface in contact with the brake
disc.
A. Remove axle shaft mount bolt, then remove planetary carrier (9).
B. Remove shims.
★ Check the number and thickness of the shims, and keep them
in a safe place.
6. Axle shaft
A. Stand housing and shaft assembly upright, then sling housing

(10).
B. Tap end face of axle shaft (11) with a copper hammer to remove
the shaft.
WA180-3MC 30-131 2
12 ★ When the axle shaft has been pulled out a little way, pull out
portion "a" of oil seal (12) with a screwdriver to prevent the
oil seal from being damaged by bearing (13).
C. Remove bearing (13) and seal (12) from shaft (11)

★ Never apply heat or use gas cutting to remove the bearing.
(This will affect the hardening of the shaft and reduce the
strength.)
★ Remove the bearing as follows.
D. When removing bearing (13) of shaft (11), use a screwdriver at

point "b" of oil seal and sleeve (12), and push towards flange uni-
formly around circumference.
E. Make clearance "c" in order to fit claws of puller to connection of

bearing (13) and sleeve (12A).
F. Install bolt (30) (5/8 - 18 UNF, L = approx. 60 mm) at point "d" to

bearing puller A1.
★ Screw in the bolt thread fully.
30-132 2 WA180-3MC
12
G. Set bearing puller A1 to clearance "c" between bearing (13) and
sleeve (12A), then assemble bolt A2 and nut A3.
★ When doing this, fix securely to prevent any play in the
bearing puller.
H. Insert washer between bolt (30) and flange surface, turn in

direction to loosen bolt (30), and remove bearing (13).
★ The puller has only a small grip on the bearing, so be
extremely careful not to let it come off the bearing.
★ If the length of the thread of bolt (30) is too short, add extra
washers to the flange surface to adjust the height of bolt (30),
and remove bearing (13).
★ Replace the oil seal and sleeve assembly with new parts.
7. Ring gear
Using a puller, raise ring gear (14) evenly and remove.
8. Axle housing
Remove bearing cups (15) and (16) from axle housing (10).
WA180-3MC 30-133 2
12
A. Drive in spring pin (17).

★ Be careful not to drive in the spring too far.
B. Using a press, remove shaft (18).
C. Remove spring pin (17) from shaft (18).
D. Remove pinion gear (19) from planetary carrier (9), then remove
bearing cone (20), spacer (21) and shims.
30-134 2 WA180-3MC
12
ASSEMBLY
1. Axle housing
Press fit bearing cups (15) and (16) in axle housing (10).
★ After press fitting the cups, check that there is no clearance at
portion "a".
2. Ring gear
Press fit ring gear (14) in axle housing (10), then insert pins (17).
★ Cool ring gear (14) in dry ice to a temperature of about
-30° C (-22° F) before press fitting.
★ Align the pin holes of the housing and ring gear when assembling.
★ Press fit the ring gear horizontally and be careful not to fit it at an
angle.
3. Axle shaft
A. Using a press on axle shaft (11), press fit oil seal (12).
★ Do not use a hammer as it may cause deformation.
★ Coat the press-fitting portion of the sleeve surface "a" thinly
with oil.
Press-fitting portion of sleeve: Axle oil
WA180-3MC 30-135 2
12
B. Set bearing (13) on press stand, and press fit axle shaft (11).
★ Be careful not to fit the bearing at an angle.
Press-fitting portion of bearing: Axle oil
4. Housing, shaft
A. Stand shaft (11) upright and install tool B1.

★ Using the adjustment bolt, adjust the height of the seal sup-
port. Set the top surface of tool B1 lightly in contact with seal
(12) and make the clearance uniform.
★ Secure tool B1 with tool B2 so that it does not come out of
position.
B. Raise housing (10) horizontally, and insert carefully on shaft.

★ Stop housing (10) before press fitting the oil seal.
C. Align housing (10) with press-fitting portion for oil seal, then
lower housing slowly.
★ Use the weight of the housing to insert it.
30-136 2 WA180-3MC
12
D. Remove tool B1.
E. Press fit bearing (13) on shaft (11). Rotate housing by hand and
press fit until end play is 0.3 mm.
★ Do not make the end play 0 mm.
Press-fitting portion of bearing cone: Axle oil
★ Press force: Approximately 19.6 kN (4406.25 lbf)

★ After assembling the housing, the face of the seal must be
level with the housing face. If there is any clearance "b" at
part "a", it must be uniform and within the standard range.
Standard range
Clearance "b": 0.21 - 1.91 mm
5. Adjusting end play
A. Stand axle shaft and housing assembly (22) upright, and hold
flange "a".
WA180-3MC 30-137 2
12
B. Install planetary carrier (9) to spline of axle shaft (11), then
assemble shim adjustment tool C to portion "c" of planetary
carrier, and install mount bolts.
★ Assemble planetary carrier (9) without the gear.
★ Remove all thread tightener from the mount bolts and the bolt
holes of the axle shaft.
C. Rotate axle housing (10) and tighten mount bolt (26) of retainer.
Bolt: 55 Nm (41 lbf ft)
D. Using a depth micrometer, measure distance H from shim

adjustment tool to end face of axle shaft.
• Shim thickness X = (H - t)+0.15
+0.10
★ When selecting the shims take the nearest value to X + 0.10.
30-138 2 WA180-3MC
12
E. After selecting shims, loosen bolts, and remove planetary carrier
(9).
A. Assemble bearing cone (20) on gear (19), then set spacer (21) and
pinion gear (19) in carrier (9).
★ Insert spacer (21) in the planetary carrier before assembling.
★ There is no need to adjust with shims.
★ Reference value for end play: 0 - 0.17mm
WA180-3MC 30-139 2
12
B. Check alignment of shaft hole of gear and planetary carrier again,
then press fit shaft(18).
★ Align the hole of spring pin (17) and shaft (18), then drive in
the spring pin until it is level with the face of the carrier.
★ Press force: 49 kN (11015.6 lbf)
Shaft: Axle oil
C. Tap end face of shaft (18) and differential side of gear (19) to push
back bearing (20) and allow gear to rotate smoothly.
★ The gear must rotate smoothly.
A. Assemble shims (24) selected in Step 5 in planetary carrier (9) at

axle shaft end face, then install mount bolts.
mount holes of the axle shaft.
★ Clean the end face of the shaft and the planetary carrier spline
before installing.
WARNING! When installing the planetary carrier, be

careful not to get your fingers caught.
30-140 2 WA180-3MC
12
B. After settling bearing (23) fully, check "X" at drill hole "b" of axle
housing (10).
★ Reference value
• Rotation force "X": Approximately 26.5 N (5.95 lbf) or less
C. Install stand of dial gauge to axle housing, and measure end play
of planetary carrier at end face of planetary carrier.
• End play of planetary carrier: 0 - 0.098 mm
★ If the end play is more than 0.098 mm, repeat Step 5 and
adjust again.
8. Brake outer ring

Assemble brake outer ring (7) in axle housing.
★ Align pin and pin hole of outer ring to assemble.
★ Be careful not to damage the surface of the brake outer ring.
9. Axle housing assembly
A. Assemble brake ring (27), brake disc (6) and shaft (5) in differen-
tial housing.
★ Be careful not to damage the surface of the brake ring when
assembling.
★ Soak the brake disc for 2 to 3 minutes in clean axle oil before
assembling.
WA180-3MC 30-141 2
12
B. Raise axle housing (10) horizontally, align spline groove and hole
of pin (28), then assemble carefully.
★ When assembling, be careful not to let the brake ring or disc
come out of place.
★ Remove all oil and grease, and clean the mount surface to the
differential housing and axle housing, then coat with an
unbroken film of gasket sealant.
Contact face of housing: Gasket sealant (Loctite 515)
Mount bolt of housing: 279 ± 29 Nm (206 ± 22 lbf ft)
A. Install differential cover (3) to differential housing.

★ Coat with an unbroken film of gasket sealant.
★ Be careful not to let the gasket sealant enter the mount hole of
the bleeder screw when assembling.
Contact face of cover: Gasket sealant (Loctite 515)
Mount bolt of cover: 113 ± 9.8 Nm (83 ± 7 lbf ft)
B. Install bleeder screw (2).
11. Refilling with oil

Tighten drain plug and add engine oil through oil filler and gauge (29)
to the specified level.
30-142 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
12
CENTER HINGE PIN
REMOVAL

★ Before starting the operation, set a pallet under the bucket.

then remove covers (2) on the left and right under the floor.

• Loosen plug (3) to prevent the oil inside the hydraulic tank from
flowing out.
WARNING! Machines equipped with air conditioner;

make sure to re-capture gas. DO NOT let
gas escape to the atmosphere.
★ Disconnect the cable from the negative terminal of the battery.
1. Cover
A. Sling left side ladder rail (4), remove mount bolts, then lift off
together with center fender (5).
★ When lifting off the ladder, be careful of the center of gravity.
B. Disconnect connector for left brake oil level sensor.
C. Remove brake oil tank mount bracket (8) together with oil tank
(7) from under floor.
★ Leave the oil hose installed to the brake oil tank and tie it to
the top surface of the rear frame with wire.
• For machines equipped with an air conditioner, it can be
placed on top of the condenser.
WA180-3MC 30-143 2
12
2. Electric wiring
Disconnect following electric wiring from connector.
• Connectors (11), (12), (13), (14), (15), (16), and (17) of front
wiring (9) and rear wiring (10).
★ For machines with cab, disconnect wiring for cab from connector.
• Disconnect ground wiring (18) from rear frame.
• Disconnect transmission cut-off switch (19) and wiring connector
(20).
• Remove wiring clamp and bracket (21) from rear frame (22).
3. Brake booster
A. Remove locknut of ball joint (24) of brake linkage rod (23), and
pull out linkage rod.
B. Set block under brake booster (25), then remove mount bolts (26).

Disconnect fuel control cable (27) at engine end, then remove bracket
(28) together with control cable.
★ For machines equipped with cab
• Disconnect the washer hose from the tank, then coil up and bend
the end of the hose.
• After removing the hose, fit a blind plug in the washer tank.
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12
Disconnect each connectors (33) from transmission valve wiring.

Disconnect work equipment control cables (34) at valve end.
★ Fit tags to the cables before disconnecting.
★ Remove the cable clamp.
A. Disconnect parking brake cable (38) from lever, and remove

bracket (40) from front face of transmission (39).
★ Check that there are blocks under the tires.
★ After disconnecting the cable, tie it temporarily to the bottom
surface of the floor with wire.
B. Disconnect speedometer cable (41).
C. Remove transmission oil filler tube (42).
WA180-3MC 30-145 2
12
8. Steering piping
A. Remove hoses (44) and (45) from steering valve (43).
B. Disconnect hoses (47), (48), and (49) between steering valve (43)
and priority valve.
C. Remove hose (50) between steering valve and hydraulic tank.

★ Fit blind plugs after disconnecting the hoses.

Sling floor frame and cab assembly (51), then remove mount bolts
(51-1) and lift off.
★ When raising the floor frame and cab assembly, pull the brake
booster out gradually from the mount bracket, and raise the cab
slowly.
★ The brake hose is not disconnected, so be careful not to catch the
brake booster.
★ When raising the floor frame and cab assembly, lift slowly for
approx. 40 - 50 mm, stop and check that there is no interference,
then continue to lift.
Floor frame, cab assembly: 680 kg (1499 lb)
Floor frame assembly: 155 kg (342 lb)
★ Eyebolts for removing cab assembly (M = 16 mm, P = 2.0 mm) (4

bolts)
30-146 2 WA180-3MC
12
A. Disconnect hoses (52) and (53) between steering valve and

steering cylinder from connection with tube.
★ Disconnect both the left and right hoses.
B. Remove bottom lock bolt of steering cylinder, then remove pin

(54).
11. Drive shaft

Disconnect center drive shaft (55) at transmission end.
★ When removing the drive shaft, set a block between the rear frame
and the drive shaft to prevent the grease fitting from being
crushed.
12. Electric wiring

Remove clamp mount bolts (56) and (56-1) of front frame wiring.
13. Brake tube

Remove clamp of brake hose and tube (57) for front axle from frame.
WA180-3MC 30-147 2
12
Remove mount bolts of dump and lift cylinder hose clamp brackets
(60) and (60-1) for front frame (58) and rear frame (59) from frame.
15. Jacking up chassis
A. Adjust height of rear frame and set block ➀ in position.
B. Adjust height of front frame on left and right, and set block ➂ in
position.
★ Be extremely careful when adjusting the height of the frame.
C. Set support stand ➁ to counterweight.
16. Lower hinge pin

Remove lock bolt, then pull out lower hinge pin (61).
30-148 2 WA180-3MC
12
17. Upper hinge pin
A. Remove locknut (62) and washer (63).
B. Remove pin mount bolts, then pull out upper hinge pin (64).
★ There are shims between the retainer and frame, so check the
number and thickness of the shims, and keep in a safe place.
18. Disconnection of frame
A. Remove safety bar, jack up front differential and palleter under

bucket, then pull out to front of front frame.
★ Carry out this operation with two workers and rotate the tires
uniformly on the left and right.
★ Be extremely careful to maintain the balance when carrying
out this operation.
★ Be careful not to let the spacer at the bottom of the upper
hinge get caught in the rear frame, and insert a bar between
the rear frame and front frame to raise the front frame while
disconnecting.
B. After disconnecting frame, remove spacer (65).
19. Lower hinge
A. Remove washer (66).
B. Remove snap rings (67) and (68), then pull out bearing (69).
WA180-3MC 30-149 2
12
20. Upper hinge
A. Remove spacer (70).
B. Remove mount bolt, then remove retainer (71).

★ There are shims between the retainer and frame, so check the
number and thickness of the shims, and keep in a safe place.
C. Remove dust seal (73) from retainer (72).
D. Remove bearing (74) and spacer (75) from front frame.
30-150 2 WA180-3MC
12
INSTALLATION
1. Upper hinge
A. Press fit bearing (74) and spacer (75) on front frame.

★ The clearance between the bearing and spacer is adjusted, so
do not change the combination. When replacing the bearing
and spacer, replace as a set.
★ When press fitting the bearing, press fit correctly and make
sure that there is no clearance from the contact surface of the
frame.
Bearing: Grease (G2-LI)
B. Install dust seal (76) and spacer (70) from under front frame.
★ Be careful not to damage the seal lip, and install with the lip
on the outside.
★ Outside circumference of dust seal: Thread tightener (Loctite
601)
Seal lip: Grease (G2-LI)
Inside circumference of spacer: Grease (G2-LI)
C. Press fit dust seal (73) on retainer (72).

★ When press fitting the dust seal, fit with the lip on the outside.
Seal lip: Grease (G2-LI)
D. Tighten retainer (72) with 4 mount bolts, then insert shims so that
clearance "a" between retainer and frame is standard value.
Clearance "a": 0.1 - 0.2 mm
Mount bolt (when adjusting shim):

4.9 ± 0.98 Nm (4 ± 1 lbf ft))
Mount bolt: 66.7 ± 6.9 Nm (49 ± 5)
WA180-3MC 30-151 2
12
2. Lower hinge
A. Install snap ring (68), and press fit bearing (69).
B. Install snap ring (67), and install washer (66).
3. Connecting frame
Jack up front differential, move front frame towards rear frame and
align pin holes.
WARNING! Use a bar to align the pin holes. Never

use your fingers.
★ Be careful not to bite into the lower spacer (65) of the upper hinge
when connecting the frames.
★ Align the pin holes correctly.
★ Install the safety bar.
30-152 2 WA180-3MC
12
4. Upper hinge pin
A. Insert upper hinge pin (64).
B. Fit washer (63) and tighten lock nut (62) to specified tightening
torque. Select shims to give standard value for clearance "b"
between rear frame and pin.
★ Temporarily tighten the mount bolt to act as a stopper when
tightening the lock nut.
★ Clearance "b": Max. 0.4 mm
Lock nut: 559 ± 49 Nm (412 ± 36 lbf ft))
C. Assemble selected shims, and tighten mount bolts of pin.

★ Before tightening the mount bolts, tighten the lock nut to the
specified torque again.
5. Lower hinge pin

Insert lower hinge pin (61), and secure with lock bolt.
Outside circumference of hinge pin: Grease (G2-LI)
WA180-3MC 30-153 2
12
6. Lowering chassis
Remove blocks ➀ and ➂ from front and rear frame and support stand
➁ from counterweight, then lower chassis.
7. Hydraulic piping
Install mount bolts of dump and lift cylinder hose clamp brackets (60)
and (60-1) for front frame (58) and rear frame (59) to frame.
8. Brake tube
Connect front axle brake hose (57) to tube.
9. Electric wiring
Install clamp mount bolts (56) and (56-1) for front frame wiring.
30-154 2 WA180-3MC
12
10. Drive shaft
Connect center drive shaft (55) to transmission.
★ Be careful of the direction of the yoke, and align the pilot portion
correctly to install.
Mount bolt: 65.7 ± 6.9 Nm. (49 ± 5 lbf ft)
A. Install pin (54) to bottom of steering cylinder, and secure with

lock bolt.
B. Connect hoses (52) and (53) between steering valve and steering
cylinder.
A. Raise floor frame and cab assembly (51), stop approx. 100 mm
from mount, assemble mount bracket (77) to brake booster (76),
and keep suspended.
B. Check mounted condition of brake booster, then install cab

assembly (51) to rear frame.
★ Tighten floor mount bolts (51-1) unIformly at left, right,
front, and rear.
★ Check that there is no interference with any hoses or wiring
when installing.
Mount bolt: 274.6 ± 29.4 Nm (203 ± 22 lbf ft)
WA180-3MC 30-155 2
12
13. Steering piping
A. Connect hose (50) between steering valve and hydraulic tank.
B. Connect hoses (47), (48), and (49) between steering valve (43)
and priority valve.
C. Connect hoses (44) and (45) to steering valve (43).

A. Install bracket (40) of parking brake cable (38) to front face of

transmission, and connect parking brake cable (38) to lever.
B. Connect speedometer cable (41).
C. Install transmission oil filler tube (42).
D. Adjust the parking brake. For details, see TESTING AND

ADJUSTING.

Connect work equipment control cables (34) to each spool of valve.
★ Install the clamp of the cable.
30-156 2 WA180-3MC
12
Connect each transmission valve wiring connectors (33).
★ When connecting, check the tags used to identify the wiring

Connect fuel control cable (27) to engine end, and install bracket (28)
to engine.
★ For machines with cab
• Connect the washer hose to the tank end.
18. Brake booster
A. Remove block under brake booster (25), and install mount

bolts (26).
★ Tighten the mount bolts uniformly and be careful not to
tighten them too much.
B. Insert brake linkage rod (23) in boot portion of brake booster (25),
and connect to linkage lever.
C. Connect ball joint (24) and tighten locknut.
Locknut: 29.4 ± 4.9 Nm (22 ± 4 lbf ft)
WA180-3MC 30-157 2
12
19. Electric wiring
Connect connectors to following electric wiring.
★ When connecting, check the tags used to identify the wiring
A. Connectors (11), (12), (13), (14), (15), and (16) of front wiring (9)
and rear wiring (10).
B. Connector (17) of cab wiring
C. Connect ground wiring (18) to rear frame.
D. Connect transmission cut-off switch (19) and wiring connector

(20).
E. Install wiring clamp and bracket (21) to rear frame (22).
20. Cover
A. Install brake oil tank mount bracket (8) together with oil tank (7)
to bottom of floor.
B. Connect connector for left brake oil level sensor.
C. Sling left ladder rail (4), then raise together with center fender (5)
and install.
★ When raising the ladder to install it, be careful of the center of
gravity.
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12
21. Refilling with oil
Tighten drain plug and add hydraulic oil through oil filler to the specified level.
Hydraulic oil: Add oil
22. Bleeding air from brake system

• If the hose has been disconnected from the brake booster, bleed the air from the brake system.
★ For details of the procedure for bleeding air, see TESTING AND ADJUSTING.
23. Install cover (1) at the top of the hydraulic tank on the right side, and
covers (2) on the left and right under the floor.
WA180-3MC 30-159 2
DISASSEMBLY AND ASSEMBLY PRIORITY VALVE
12
PRIORITY VALVE
REMOVAL

★ Turn the steering wheel to the left to articulate the chassis.

then remove covers (1-1) on the left and right under the floor.

flowing out.
1. Hydraulic piping
Disconnect following piping.

• Hose (3) between hydraulic pump and priority valve.
★ Remove rear right inspection cover (2-1), disconnect
hydraulic pump, and remove hose (2-3) while still installed to
the priority valve.
★ This operation can also be carried out by removing connector
mount bracket (2-2) connecting the front wiring and rear
wiring.
★ To prevent damage to the mount bolts, remove hose (2-3)
after removing the priority valve.
• Hose (4) between priority valve and main control valve
• Hose (5) between steering valve and priority valve
• Hose (6) between priority valve and hydraulic tank
• Hose (7) between priority valve and steering valve
★ Remove hose (7) after removing the priority valve.
30-160 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY PRIORITY VALVE
12
2. Priority valve
Remove mount bolts (8), then remove priority valve (9).

★ Remove hose (7) after removing the priority valve.
INSTALLATION
Hose (4) mouthpiece:

176.5 ± 29.4 Nm (130 ± 22 lbf ft)
Hose (7) mouthpiece: 78.5± 19.6 Nm (58 ± 14 lbf ft)

★ Install to the rear frame after installing hose (3) to the priority
valve.
Hose mouthpiece: 176.5 ± 29.4 Nm (30 ± 22 lbf ft)

Mount bolt (8): 31.4 Nm (23 lbf ft)
★ If the mount plate had to be removed, assemble as shown in the

diagram on the right.
WA180-3MC 30-161 2
DISASSEMBLY AND ASSEMBLY STEERING VALVE
12
STEERING VALVE
REMOVAL

then remove covers (1-1) on the left and right under the floor.

flowing out.
1. Column cover
Remove steering column cover (4), then remove plugs (3) of bottom
boot (5), and roll up.
2. Hydraulic piping
Disconnect following hydraulic piping.

★ Fit tags to identify the piping.
• Hose (7) between priority valve and steering valve
• Tubes (8) and (9) between steering valve and steering cylinder
• Hose (11) between steering valve and hydraulic tank
30-162 2 WA180-3MC
12
3. Steering valve
★ Carry out the steering valve removal operation with 2 workers,
give signals to each other, and be extremely careful when
removing the steering valve.
A. Remove lock bolt (12) of spline connecting portion at steering

column end.
★ Be sure to remove lock bolt (12). If it is not removed, the lock
bolt will catch in the column shaft lock groove, and the
steering valve will not come out.
B. Support from below, and remove bracket mount bolt (14).
C. Remove steering valve (15).
★ Remove the steering valve together with bracket (13).
D. Remove lock bolt (12-1) from steering valve (15), remove

coupling (16) and mount bolts (17), then remove bracket (13) and
column assembly (18).
★ Make match marks before removing column assembly (18)
from the steering valve.
WA180-3MC 30-163 2
12
INSTALLATION
★ Carry out the steering valve installation operation with 2 workers,
give signals to each other, and be extremely careful when
installing the steering valve.

★ Hoses (7), (8), (9), (11)

Width across flats of hose mouthpiece: 27 mm
★ When assembling the lock bolt, align with the column shaft groove
and screw in.
Lock bolt (12): 25 ± 5 Nm
Column shaft spline: Grease (G2-LI)
★ When assembling the lock bolt, align with the column shaft
groove and screw in.
Lock bolt (12-1): 28.4 ± 3.9 Nm (18 ± 3 lbf ft)
★ Tighten mount bolts (17) on diametrically opposite sides.
Mount bolt (17): 41.7 ± 17.2 Nm (31 ± 13 lbf ft)
★ If the oil seal of the column assembly has been replaced, coat the
oil seal lip with grease.

Tighten drain plug and add hydraulic oil through oil filler to the
specified level.
★ Run the engine to circulate the oil through the system. Then check
the oil level again.
30-164 2 WA180-3MC
12
DISASSEMBLY
★ Use a wire brush to remove all the dirt and dust stuck to the joint
around the outside circumference of the unit.
★ Carry out the operation in a clean place to prevent dirt or dust from
sticking to the valve.
★ As far as possible, hold the valve in a vice when disassembling.
DISASSEMBLY OF ROTOR
1. Put a copper plate in contact with the vice and be careful not to tighten
the vice too hard.
2. Set rotor side facing up, and hold mount flange lightly in vice (1).
3. Remove screw (1), then remove end cap (2).
4. Remove O-ring (3) from end cap (2).
5. Pull out rotor set (4), then remove O-ring (5).

★ Be careful not to drop the star inside the rotor set.
6. Remove spacer (6).
WA180-3MC 30-165 2
12
7. Remove drive shaft (7).
8. Remove spacer plate (8).
9. Remove O-ring (9) from housing (10).
DISASSEMBLY OF CONTROL SIDE
1. Remove housing (10) from vice, and place on a clean cloth. Be careful
not to damage the finished surface.
2. Raise tip of snap ring (11) with screwdriver, and remove from housing.
3. Turn spool and sleeve to place pin in a horizontal position, then push
in spool and sleeve with your thumb, and remove bushing (12) from
housing.
4. Remove X-ring seal (13) from bushing (12).
5. Remove dust seal (14) from bushing (12) with screwdriver.

★ Be careful not to damage the bushing.
30-166 2 WA180-3MC
12
6. Remove 2 bearing races (15) and thrust needle (16) from spool and
sleeve.
7. Pull out spool and sleeve assembly (17) from housing (10) in the
direction of the arrow.
★ To prevent the spool and sleeve assembly from catching in the
housing, rotate the spool and sleeve assembly slowly to the left
and right when pulling out from the housing.
8. Pull out pin (18) from spool and sleeve assembly (17).
9. Push spool (20) inside sleeve (19) slightly to front, and remove 6
centering springs (21) from spool (20) carefully by hand.
10. Turn spool (20) slowly and pull out from rear of sleeve (19) (in the
direction of the arrow).
11. Remove O-ring (22) from housing.
12. Remove set screw (23) from housing.
13. Screw a threaded bar into check sheet (24), and pull out check sheet
(24).
14. Remove O-rings (25) and (26) from check sheet (24).
15. Tap housing, and remove ball (27) and retainer (28).
WA180-3MC 30-167 2
12
ASSEMBLY
★ Check all parts for damage or burrs.
★ Wash all metal parts in clean solvent and blow dry with air.
★ Do not use a file or polish any part with rough sandpaper.
★ Coat the O-rings with clean grease. (No need to put grease on
new X-ring seals)
★ Coat the O-ring for the rotor set with a small amount of grease.
ASSEMBLY OF CONTROL SIDE
1. Insert retainer (28) in housing with tweezers.

★ Check that the retainer is not inserted at an angle.
2. Insert ball (27).
3. Fit O-rings (26) and (25) in check sheet (24), and push check sheet
(24) into housing.
★ Be careful to set the top and bottom of the check sheet facing in
the correct direction.
4. Install set screw (23).

★ Check that the set screw is set in slightly from the end face of
the housing.
Set screw: Adhesive (LT-2)
Set screw: 11.8 Nm (9 lbf ft)
5. Assemble spool (20) and sleeve (19) so that spring groove is on same
side.
★ Rotate the spool and slide it in.
★ Grip the splined portion of the spool lightly and check that the
spool rotates smoothly inside the sleeve.
★ If there are match marks, check that the match marks are aligned.
30-168 2 WA180-3MC
12
6. Align spring groove positions of spool (20) and sleeve (19), and set on
flat plate, then insert spring (21) in spring groove.
★ Set so that the notches at both ends are at the bottom.
7. Insert pin (18) in spool and sleeve assembly (17).
8. Insert spool and sleeve assembly (17) in housing (10) in the direction
of the arrow.
A. Keep pin horizontal and rotate to left and right a little at a time to
insert.
★ Be extremely careful not to get it caught.
B. Make the spool and sleeve assembly flush with the rear end face
of the housing.
★ If it is inserted beyond the end face, the pin will fall out.
C. Check that spool and sleeve rotate smoothly inside housing.
9. Install O-ring (22) to housing (10).
10. Fit 2 bearing races (15) and thrust needle (16) in case (10).
WA180-3MC 30-169 2
12
11. Insert dust seal (14) in bushing (12).
12. Insert X-ring seal (13) in bushing (12).
13. Insert bushing (12) in spool, and rotate to install.

• Tap with a plastic hammer to assemble to the specified position.
• It must be in contact horizontally with the bearing race.
14. Fit snap ring (11) in housing.
ASSEMBLY OF ROTOR
1. Hold flange of housing lightly in vice.

★ Be careful not to tighten the vice too hard.
★ Check that the spool and sleeve are set in slightly from the
housing surface with fourteen holes.
2. Insert O-ring (9) in housing.
3. Put on spacer plate (8), and align positions of bolt hole and tap hole of
housing.
30-170 2 WA180-3MC
12
4. Turn spool and sleeve assembly to make pin (18) and port surface of
housing parallel, then mesh pin and yoke of drive shaft (7).
★ To position accurately, draw a line on the end face of the drive
shaft spline.
5. Insert O-ring (5) in rotor set (4).
6. Make O-ring (5) end of rotor set to spacer plate end, then align insert
portion of star of rotor (4) with drive.
A. Check that lines A, B, C, and D are all parallel.
B. Without removing joint of drive shaft (7), position bolt holes of

rotor set.
★ This procedure is very important for determining the valve
timing of unit.
7. Insert spacer (6) inside rotor set.
8. Set end cap (2) on rotor set, and align bolt hole.
WA180-3MC 30-171 2
12
9. Coat thread of screw with grease, and tighten end cap.
★ Install the handle to the spool, and check that the spool rotates.
End cap mount screw

First step: 14.7 Nm (10.8 lbf ft)
Second step: 27.0 ± 1.5 Nm (20 ± 1 lbf ft)
30-172 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
12
MAIN CONTROL VALVE
REMOVAL

★ Raise the boom, set stand (1A) of boom holding stopper (Q) in
position, then remove front cover (1).
★ Remove cover (2) at the top of the hydraulic tank on the right side.

• Loosen plug (3) at the top of the hydraulic tank filter to prevent the oil
inside the hydraulic tank from flowing out.
1. Drive shaft
Disconnect drive shaft (4) at front axle end.
★ After disconnecting the drive shaft, move it to the left and secure
it with wire.
2. Electric wiring
Disconnect electric wiring connectors (5) and (6) for main control
valve.
★ Fit tags with numbers to identify the wiring.
WA180-3MC 30-173 2
12
3. Control cable
Pull out snap pin and remove pins (7), then remove control cables (8)
from spools (9).
★ Fit tags with numbers to identify the wiring.
4. Hydraulic piping
Disconnect following hydraulic piping.

• Tubes (10) and (11) between main control valve and boom
cylinder
• Hoses (12) and (13) between main control valve and the pilot
solenoid valve for the tilt cylinders.
• Hose (14) between hydraulic pump and main control valve
• Hose (15) between main control valve and hydraulic tank
• Between main control valve and oil return hose (16)
5. Main control valve
A. Install eyebolt ➀ to front frame boss.

★ Install the eyebolt to the boss portion securely.
• M = 12, P = 1.75
B. Using eyebolt installed to front frame, fit lifting tool and sling
main control valve (18).
C. Remove mount bolts (19) on top of mount bracket of main control

valve (18), then remove main control valve.
Main control valve: 21 kg (46.3 lb)
★ Loosen bottom bracket mount bolts (20).

★ When removing the main control valve, remove the top
mount bolts and lift off.
30-174 2 WA180-3MC
12
INSTALLATION
★ Install the snap pin securely.
Tube mouthpiece: 265 ± 29.4 Nm (195 ± 22 lbf ft)


★ Align with the bottom bracket mount bolts and install the main control valve.
★ Be sure to tighten all of the bottom bracket mount bolts.

★ Tighten drain plug and add hydraulic oil through oil filler to the specified level.
WA180-3MC 30-175 2
12
DISASSEMBLY
30-176 2 WA180-3MC
12
1. Spool assembly
A. Remove mount bolt (2) and plug (3) of detent assembly (1).
B. Holding spool (4) from moving, loosen bolt (5) inside detent assembly (1), then
remove detent assembly (1).
★ Remove joint (6) from spool (4).
C. Remove retainer (7), spring (8), retainer (9), oil seal (10) and plate (11).
D. Remove plate (12), then remove oil seal (10) and spool (4).
2. Main relief valve assembly
A. Remove main relief valve assembly (13).
B. Loosen nut (14), and screw out holder (15), then remove retainer (16), spring
(17), poppet (18), seat (19) and spring (20).
C. Remove plug (21), then remove valve (22) from sleeve (23).
★ Valve (22) and sleeve (23) are not available as individual parts, so replace
them as a set.
3. Remove safety valve assembly (25) with suction valve and suction valve assembly
(24).
4. Remove plug (26), then remove spring (27) and valve (28).
WA180-3MC 30-177 2
12
ASSEMBLY
30-178 2 WA180-3MC
12
1. Assemble valve (28) and spring (27) in body (29), and fit O-ring and tighten plug
(26).
Plug: 107.8 ± 14.7 Nm (80 ± 11 lbf ft))
2. Fit O-rings and install suction valve assembly (24) and safety valve assembly (25)
with suction valve.
Safety valve (with suction):

142.2 ± 19.6 Nm (105 ± 14 lbf ft)
Suction valve: 142.2 ± 19.6 Nm (105 ± 14 lbf ft)
3. Main relief valve assembly
A. Assemble valve (22) in sleeve (23), then tighten plug (21).
B. Assemble spring (20), seat (19), poppet (18), spring (17) and retainer (16) in
sleeve.
C. Screw nut (14) into holder (15), fit O-ring on holder, then install the holder into
sleeve (23) and tighten nut (14).
D. Fit O-ring and backup ring and install main relief valve assembly (13).
Main relief valve: 83.4 ± 14.7 Nm (62 ± 11 lbf ft)
4. Spool assembly
A. Assemble spool (4) in body, then install oil seal (10) and plate (12).
B. Pull out spool slightly, then assemble retainer (11), oil seal (10), retainer (9),
spring (8), and retainer (7).
C. Holding spool from moving, turn bolt inside detent assembly (1), and install joint (6) to spool (4).
Joint: 14.7 ± 4.9 Nm (11 ± 4 lbf ft)
D. Tighten bolt (5), then install detent assembly (1).
E. Tighten plug (3).
Plug: 13.7 ± 3.9 Nm (10 ± 3 lbf ft)
WA180-3MC 30-179 2
DISASSEMBLY AND ASSEMBLY PPC VALVE TO MAIN CONTROL VALVE HY-
12
PPC VALVE TO MAIN CONTROL VALVE HYDRAULIC LINES
30-180 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY PPC VALVE TO MAIN CONTROL VALVE HY-
12
MEMORANDUM
WA180-3MC 30-181 2
DISASSEMBLY AND ASSEMBLY PPC VALVE
12
PPC VALVE
REMOVAL

engine. then apply the parking brake and
• Loosen the plug on top of the hydraulic tank filter to prevent the oil
inside the tank from flowing out.

Then operate the steering wheel and con-
trol levers several times to release the
remaining pressure in the hydraulic
piping.
★ The working space is confined so be careful when carrying out the

operation
1. Covers
Remove console box cover (1).
2. Hydraulic piping
Disconnect the following hydraulic piping from PPC valve.
★ Fit tags to distinguish the hoses.
A. Hose (2) between accumulator and PPC valve.
B. Hose (3) between PPC valve and hydraulic tank.
C. Hoses P2 (4) and P3 (5) for boom spool.
D. Hoses P4 (6) and P1 (7) from bucket spool.

.
30-182 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY PPC VALVE
12
3. Wiring
Remove the three electrical connectors (A), (B), and (C)
4. PPC valve
A. Loosen nut (2) from handle (1) and remove handle.

★ Be careful while disconnecting the two switches in the
handle. Tag the switches.
B. Pull out boot (3) out from Right Hand Console.
C. Remove mount bolts (6), then remove PPC valve (8) from under
the right console box.
INSTALLATION
WA180-3MC 30-183 2
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
12
STEERING CYLINDER
REMOVAL

• Remove cover (1-1) on the right under the floor.

Loosen plug (1) to prevent the oil inside the hydraulic tank from flowing
out.
1. Hydraulic piping
A. Disconnect steering cylinder rod hose (2) from steering cylinder

tube.
B. Disconnect steering cylinder bottom hose (3) from steering

cylinder tube.
2. Cylinder
A. Remove lock bolt at rod end, then remove pin (4).
30-184 2 WA180-3MC
12
B. Remove lock bolt at bottom end, remove pin (5), then remove
cylinder (6).
★ Be careful not to damage the rod plating.
WA180-3MC 30-185 2
12
INSTALLATION
★ Align the rod pin hole and assemble the shims so that clearance
"b" between the cylinder and the frame is the specified value, then
lock pin (4) with the mount bolt.
WARNING! Always use a bar when aligning the pin

holes. Never insert your fingers.
Clearance "b" = Max. 1.0 mm
★ Align the bottom pin hole and assemble the shims so that
clearance "a" between the cylinder and the frame is the specified
value, then lock pin (5) with the mount bolt.
WARNING! Always use a bar when aligning the pin

holes. Never insert your fingers.
Clearance "a" = Max. 1.0 mm
• Add hydraulic oil through oil filler to the specified level.

30-186 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY BRAKE BOOSTER
12
BRAKE BOOSTER
REMOVAL

• Turn the steering wheel to the right to articulate the chassis.
1. Covers
A. Remove cover (1) under cab or on left and right sides of floor.
B. Remove cover (2) at left side of rear frame.
2. Machines equipped with air conditioner
A. Remove left ladder rail (3).

★ Be careful not to catch the brake hose when removing the
ladder rail.
B. Remove condenser front cover (4).

★ Remove the hose clamp.
C. Remove condenser mount brackets (5), and open condenser (6)

to rear.
WA180-3MC 30-187 2
12
3. Brake piping
A. Disconnect hose (7) between brake booster and torque converter

filter from brake booster.
B. Disconnect hose (8) between brake booster and transmission

valve from brake booster.
C. Disconnect hoses (9) and (10) between brake oil tank and brake
booster from brake booster.
D. Disconnect tubes (11) and (12) between brake booster and front
and rear brake from brake booster.
E. Disconnect hose (13) between brake booster and transmission oil

filler tube from brake booster.
4. Brake booster
A. Pull out ball joint (15) of brake linkage (14).
B. Remove 4 mount bolts (16), then remove brake booster (17).
30-188 2 WA180-3MC
12
INSTALLATION
★ Be careful not to catch the brake hose when installing the ladder rail.

★ Be careful to assemble correctly when connecting the hoses between the brake booster and transmission.
Tube nut between front and rear brakes:

11.3 ± 3.4 Nm (8.3 ± 2.5 lbf ft)
Hose clamp between brake oil tanks:

3.3 ± 0.5 Nm (2.4 ± 0.36 lbf ft)
★ Check that the cylinder rod is inserted in the brake booster piston groove.
Ball joint nut: 29.4 ± 4.9 Nm (21.6 ± 3.6 lbf ft)
Rod locknut: 110.3 ± 12.3 Nm (81.3 ± 9.0 lbf ft)
Mount bolt (16): 110.3 ± 12.3 Nm (81.3 ± 9.0 lbf ft)
• Bleeding air
Bleed the air from the brake system.
★ For details, see TESTING AND ADJUSTING.
• Adjusting rod
Adjust the rod. For details, see TESTING AND ADJUSTING.
WA180-3MC 30-189 2
12
DISASSEMBLY
1. Power master cylinder
A. Remove linkage rod (2) and dust cover from power master
cylinder (1).
★ Mask the tip of the piston of the linkage rod to protect it from
damage.
B. Disconnect power cylinder (3) and master cylinder (4).
2. Piston assembly
A. Remove snap ring (5) from body (4), then remove secondary
piston (6).
B. Remove stopper bolt (7), then hold brake oil hole (8) and stopper
bolt hole (9) with finger. Blow in oil through brake oil hole (10)
and remove primary piston (11).
★ The piston may fly out, so do not blow the air in strongly.
30-190 2 WA180-3MC
12
C. Remove spring (12) from inside body (4).
★ When removing the piston, be careful not to damage the
inside diameter of the body or the sliding surface on the
outside of the piston.
★ If there is any problem with the primary or secondary pistons,
replace the pistons as an assembly.
3. Fine disassembly of power cylinder
A. Remove dust cover (13).

★ Remove the elbow first.
B. Push in cylinder cover (14), remove snap ring (15), then remove
power piston (16), connector assembly (17), spring seat (18), and
springs (19) and (20).
WARNING! When removing the spring, the cylinder

cover is pushed out by the spring, so
remove carefully.
★ Remove power piston (16) from connector assembly (17).
C. Remove snap ring (21), disconnect spool (22) and connector, then
remove thrust washer (23) and spring (24).
WA180-3MC 30-191 2
12
4. Relief valve
Remove plug (25), then remove spring (26) and spool (27).
5. Power piston
Remove seal ring (28) from piston (16).
30-192 2 WA180-3MC
12Remove seal ring (28) from piston (16).
ASSEMBLY
1. Elbow
Install elbow (29) to power cylinder body (3).
2. Relief valve
Insert spring (26) in spool (27), assemble in power body, then install
plug (25).
3. Fine assembly of power cylinder
A. Assemble spring (24) in connector (31).
B. Insert spool (22) in connector (31), and assemble thrust washer

(23), then secure with snap ring (21).
WA180-3MC 30-193 2
12
C. Set body (3) on block.
D. Insert springs (19) and (20), and spring seat (18) inside body (3).
E. Assemble connector assembly (17).
F. Assemble O-rings (32) and seal (33) in cylinder cover (14).
Seal: Oil (brake oil)
G. Assemble seal ring (28) in power piston (16).
Seal ring: Oil (brake oil)
30-194 2 WA180-3MC
12
H. Assemble power piston (16) and cylinder cover (14) to spool (22),
then set guide shaft "a" in position.
★ To prevent power piston (16) and cylinder cover (14) from
dropping inside the body, stop them at the top of the body.
I. Push in guide shaft "a" with a press, bend springs (19) and (20),
and keep in position.
★ Keep snap ring (15) until the completion of assembly.
J. Lower power piston (16) only, and push in evenly on the left and
right with both thumbs.
★ When assembling the power piston, do not hit it in with a
hammer.
★ When assembling the power piston (16), apply the force
evenly. Never use excessive force.
K. Check that there is no damage to O-ring of power piston (16), then

assemble cylinder cover (14).
L. Secure cylinder cover (14) with snap ring (15).
WA180-3MC 30-195 2
12
M. Install dust cover (13).
4. Fine assembly of master cylinder
A. Insert primary piston (11) in body (4).

★ Insert the piston carefully to prevent damage to the seal cup.
Never force it into position.
Body and piston: Oil (brake oil)
B. Push piston (13) and tighten stopper bolt (7) by hand.

★ After tightening as far as possible by hand, tighten fully.
Stopper bolt: 10.8 ± 2.0 Nm (8 ± 1 lbf ft)
C. Insert secondary piston (6) in body (4).
Body and piston: Oil (brake oil)
★ When assembling the piston, be careful not to damage the

inside diameter of the body and the outside diameter of the
piston.
D. Push in secondary piston (6), then install C-ring (5).

★ Fit the C-ring properly in the groove.
30-196 2 WA180-3MC
12
5. Power master cylinder
A. Connect power master cylinder (3) and master cylinder (4).

★ Use a new O-ring for the connection of the master cylinder.
Connecting bolt (34): 31.9 ± 2.5 Nm (24 ± 2 lbf ft)
B. Assemble linkage rod (2) to power master cylinder (1).

★ For details of adjusting the brake linkage, see TESTING
AND ADJUSTING.
WA180-3MC 30-197 2
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
12
PARKING BRAKE
REMOVAL

★ If further disassembly is necessary, see DISASSEMBLY AND

ASSEMBLY OF TRANSMISSION
★ After putting blocks under the tires, release the parking brake.
• Loosen the plug of the transmission and drain the oil.
1. Drive shaft
A. Disconnect drive shaft (1) from transmission end.
★ Set block ➀ to the rear frame.
B. Using hexagonal wrench, remove 2 plugs on opposite sides, then

install 2 piston lock set bolts ➁.
★ Width across flats of hexagonal wrench:6 mm

★ Piston lock set bolt: p = 1.25, M = 8, L = 35
2. Coupling
Remove mount bolt (7), then remove holder (4), O-ring (5), and
coupling (6).
★ Make match marks on the coupling.
3. Parking brake housing

Disconnect cable (9) from parking brake lever (8).
★ Check that there are blocks under the tires, then disconnect the
cable.
★ Disconnect the cable with the parking brake released.
30-198 2 WA180-3MC
12
4. Parking brake
A. Remove all mount bolts (10) of parking brake housing (11).
B. Tighten 2 forcing screws ➂ in forcing screw hole and remove

parking brake housing (11).
★ Use the housing mount bolts as forcing screws.

★ Do not remove bolts (20) used for installing retainer
assembly (19).
★ The working posture is poor and the housing is removed with
the piston installed to the housing, so be extremely careful
when removing.
★ Install guide bolt ④ to prevent the housing from failing.
★ Be careful not to let the oil seal lip hit the shaft when
removing.
Parking brake housing: 15 kg (33.0 lb)
5. End plate
A. Remove separator plate bolt (14).
B. Remove separator plate (13), wave spring (15), and disc (16) in
turn, then remove end plate (17).
★ If it is necessary to remove hub spline (18), remove it as it is.
WA180-3MC 30-199 2
12
INSTALLATION
★ Remove 2 piston lock set bolts and install the plug.

★ Align with the coupling match mark, and assemble so that there is no misalignment of the front and rear couplings in
the circumferential direction.
★ After connecting the parking brake cable, bend the cotter pin securely.
★ The working posture is poor, so be extremely careful when installing the parking brake housing.
★ Install a guide bolt to prevent the housing from falling.
★ Use a new gasket.
★ Be careful not to let the oil seal lip hit the shaft when installing.
★ Remove all oil and grease from the separator bolt thread and bolt hole.
★ Tighten the separator bolts uniformly in turn.
Bolt: Thread tightener (LT-2)
Bolt: 53.9 ± 19.6 Nm (40 ± 14 lbf ft)
★ Soak the disc in clean transmission oil for at least 2 minutes before assembling.
★ Use one spring.
★ When assembling the separator plate, be careful that the hub spline does not rise up.
30-200 2 WA180-3MC
★ Install drain plug and add engine oil through oil filler to the specified level.
★ If it is necessary to adjust the parking brake cable, see TESTING AND ADJUSTING.
WA180-3MC 30-201 2
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
12
HYDRAULIC TANK
REMOVAL


• Loosen plug (1) at the top of the hydraulic tank filter to prevent the oil
inside the hydraulic tank from flowing out.
• Remove covers (2) at the side first.
1. Ladder rail
Lift off right ladder rail (3).
Ladder rail: 22 kg (48.5 lb)
2. Hydraulic piping
A. Loosen clamp of hose (4) between hydraulic tank and pump, and
disconnect when removing hydraulic tank.
B. Disconnect hose (5) between main control valve and hydraulic

tank from hydraulic tank.
★ Width across flats of hose mouthpiece (5): 36 mm
C. Disconnect hose (6) between steering valve and hydraulic tank

and hose (7) between main control valve and hydraulic tank.
★ Width across flats of hose mouthpiece (6): 27 mm
3. Hydraulic tank
A. Set palleter ➀ and stand ➁ under hydraulic tank (8).
B. Raise palleter ➀ slowly to support hydraulic tank (8).
30-202 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
12
C. Remove mount bolts of hydraulic tank (8).
★ Be sure to remove all the mount bolts.
D. Pull out palleter ➀ and pull out hose between pumps while
removing hydraulic tank (8).
★ When removing the hydraulic tank, tip it to the outside and
disconnect the hose.
Hydraulic tank (dry): 53 kg (116.8 lb)
INSTALLATION
• Carry out installation in the reverse order to removal

Add hydraulic oil through oil filler to the specified level.
WA180-3MC 30-203 2
DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER
12
HYDRAULIC FILTER
REMOVAL
• Loosen the oil filler cap slowly to release the pressure inside the
hydraulic tank.
1. Hydraulic piping
Disconnect hydraulic hoses (1) and (2).
• Width across flats of hose mouthpiece (1):36 mm

• Width across flats of hose mouthpiece (2):27 mm
2. Cover
Remove mount bolts, then remove cover (3).
WARNING! The cover is under the tension of a spring,

so be careful when removing it.
★ Be careful not to damage the mating surface of the cover and the
tank and O-ring (4).
3. Filter
Remove spring (5) and bypass valve (6), then remove filter (7).
INSTALLATION
★ Replace the O-ring with a new part.

★ Fit the O-ring securely in the groove and be careful not to get it
caught when assembling.
★ After installing the hydraulic tank and connecting the hose, bleed
the air from the hydraulic tank.
30-204 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY STEERING PUMP
12
STEERING PUMP
REMOVAL

engine. Then apply the parking brake
and put blocks under the wheels to
★ Disconnect the cable from the negative(-) terminal of the battery.
1. Cover, wiring
A. Remove cover (1) under right center fender.
B. Remove covers (3) and (4) top of hydraulic tank.

★ Remove the wiring clamps.

flowing out.
C. Remove connector mount bracket (7) connecting front wiring (5)

and rear wiring (6), then move to side.
★ Do not disconnect the connector at this point.
2. Hydraulic piping
A. Disconnect tube (8) between hydraulic tank and hydraulic,

steering pump at hydraulic and steering pump end.
B. Disconnect hose (9) between hydraulic, steering pump and

priority valve at hydraulic and steering pump end.
3. Pump
Remove mount bolts, then remove hydraulic and steering pump (10).

extremely careful when removing.
WA180-3MC 30-205 2
DISASSEMBLY AND ASSEMBLY STEERING PUMP
12
INSTALLATION
★ Be careful not to get the O-ring caught when installing the tube.

★ Be careful not to get the O-ring caught when installing.
Be careful not to get the O-ring caught when installing.

Tighten the mount bolts uniformly at the top and bottom.

Run the engine to circulate the oil through the system. Then check
30-206 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
12
BUCKET CYLINDER
WARNING! Stop the machine on level ground and install the safety bar on the frame. Lower the
bucket to the ground and stop the engine. Then apply the parking brake and put blocks
under the wheels to prevent the machine from moving.
WARNING! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then
operate the control levers several times to release the remaining pressure in the
hydraulic piping.
REMOVAL
1. Bucket positioner
Disconnect connector (1).
2. Rod pin
Sling cylinder (7), then remove lock bolt, and remove pin (2).
★ Sling at 2 points, and be careful of the center of gravity.
3. Hydraulic piping
A. Disconnect rod hose (3) from cylinder.

• Width across flats of hose (3) mouthpiece:36 mm
B. Disconnect bottom tube (4) at connection with hose (5)

• Width across flats of hose (3) mouthpiece:36 mm
WA180-3MC 30-207 2
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
12
4. Bucket cylinder
A. Remove lock bolt, then remove bottom pin (6).

★ If there are shims installed, check the number and thickness
of the shims, and keep in a safe place.
B. Lift off bucket cylinder (7).

★ Be careful not to damage the cylinder rod portion.
Bucket cylinder: 56 kg (123.5 lb)
INSTALLATION
WARNING! When aligning the position of the pin hole,

use a bar. NEVER insert your fingers in
the pin hole.
• Bucket positioner
★ For details of adjusting the bucket positioner, see TESTING AND ADJUSTING.

the pin hole.
★ Align the pin hole at the cylinder bottom, assemble shims so that
the total for clearance "a" between the cylinder and frame is
within the standard value, then assemble pin (6) and lock with
bolt.
Clearance "a": Max. 1.5 mm
30-208 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
12
BOOM CYLINDER

Remark
Set the support stand under the tip of the boom.
REMOVAL
1. Rod pin
A. Sling boom cylinder (1), then remove lock bolt, and remove
pin (2).
★ If there shims installed, check the number and thickness of
the shims, and keep in a safe place.
B. Start the engine, and use the control lever to retract cylinder rod
on side that was removed.
★ Retract the rod to a point 20 mm before the end of the stroke.
2. Hydraulic piping
A. Disconnect rod tube (3) from connection of hose (4).
B. Disconnect bottom tube (5) from connection of hose (6).

★ Do not forget to relieve the pressure in the hydraulic system
before disconnecting tubes and hoses.
★ After disconnecting the tubes and hoses, fit plugs to prevent
the entry of dirt or dust.
WA180-3MC 30-209 2
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
3. Boom cylinder
A. Remove lock bolt, then remove bottom pin (7).

B. Lift off boom cylinder (1).

★ Be careful of the center of gravity, and lift off slowly.
★ Be careful not to damage the cylinder rod portion.
Boom cylinder: 62 kg (136.7 lb)
INSTALLATION

the pin hole.
★ Start the engine, operate the control levers, extend the rod. Align
the pin holes and assemble shims so that clearance "b" is within
the standard value, then assemble pin (2) and lock with the bolt.
Clearance "b": Max. 2 mm

the pin hole.
★ Align the pin hole at the cylinder bottom, assemble shims so that
the total for clearance "a" between the cylinder and frame is
within the standard value, then assemble pin (7) and lock with
bolt.
30-210 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
12
HYDRAULIC CYLINDER
DISASSEMBLY
1. Set cylinder assembly (1) to tool A.
2. Raise lock portion of cylinder head (2), then using tool B, remove
cylinder head (2) from cylinder.
3. Pull out cylinder head and piston rod assembly (3) from cylinder (4),
and lift off.
★ Oil will flow out when the piston rod assembly is removed from
the cylinder, so place a container under the cylinder to catch the
oil.
4. Remove cylinder (4) from tool A.
5. Set cylinder head and piston rod assembly to tool A, then using tool C,
loosen nut (5).
Cylinder Width across flats (mm)
Boom 60
Bucket 70
Steering 46
6. Remove nut (5), then remove piston assembly (6), and retainer and
cylinder head assembly (8) from rod (9).
★ The retainer is for the steering cylinder only.
WA180-3MC 30-211 2
12
7. Disassembly of piston assembly
A. Remove wear ring (11).
B. Remove piston ring (12) from piston (13).
8. Disassembly of cylinder head assembly
A. Remove snap ring (14), then remove dust seal (15).
B. Remove rod packing (16).
C. Remove bushing (17) from cylinder head (18).
D. Remove O-ring (19) and backup ring (20).
30-212 2 WA180-3MC
12
ASSEMBLY
★ Clean all parts, and check for dirt or damage. Coat the sliding surfaces
of all parts with engine oil before installing. Be careful not to damage
the rod packing, dust seals or O-rings when assembling.
1. Assembly of cylinder head assembly
A. Using tool D, press fit bushing (17) to cylinder head (18).

★ Be extremely careful not to deform the bushing when press
fitting.
B. Install rod packing (16).

★ Be sure to install the rod packing facing in the correct
direction.
C. Using tool E, Install dust seal(15) to head (18).
D. Install snap ring (14).
E. Install backup ring (20) and O-ring (19).

★ Do not try to force the backup ring into position. Warm it in
warm water 50 - 60° C (122 - 140° F) before fitting it.
2. Assembly of piston assembly
A. Using tool F1, expand piston ring (12).

★ Set the piston ring on the expander and turn the handle 8 - 10
times to expand the ring.
B. Remove piston ring (12) from tool F1, then assemble to

piston (13).
C. Using tool F2, compress piston ring (12).
D. Assemble wear ring (11).
WA180-3MC 30-213 2
12
3. Set piston rod (9) to tool A.
4. Assemble cylinder head assembly (8) and retainer and piston assembly
(6), and install nut (5).
★ The retainer is for the steering cylinder only.
5. Using tool C, tighten nut (5).
Rod thread: Thread tightener (LT-2)
Nut: See chart below.
Cylinder Width across flats Torque

(mm) Nm (lbf ft)
1765 ± 176
Boom 60 mm
(1302 ± 129)
2599 ± 259
Bucket 70 mm
(1917 ± 191)
784 ± 78
Steering 46 mm
(578 ± 57)
6. Remove piston rod and head assembly from tool A, then set cylinder
(4) to tool A.
7. Raise piston rod and head assembly (3), and assemble to cylinder (4).
30-214 2 WA180-3MC
12Using tool B, tighten cylinder head nut (2).
8. Using tool B, tighten cylinder head nut (2).
Cylinder head nut: See chart below.
Cylinder Torque Nm (lbf ft)
Boom 932 ± 93 (687 ± 68)
Bucket 980 ± 98 (722 ± 72)
Steering 441 ± 44 (325 ± 32)
9. Bend lock into notch at cylinder end.
10. Remove cylinder assembly (1) from tool A.
WA180-3MC 30-215 2
DISASSEMBLY AND ASSEMBLY ECSS SYSTEM
12
ECSS SYSTEM
(ELECTRONICALLY CONTROLED SUSPENSION SYSTEM)
ECSS CIRCUIT - REMAINING PRESSURE REMOVAL

★ When removing ECSS circuit piping and the ECSS valve, use the
following the procedure to extract the accumulator pressure.
1. Loosen lock nut (2) on ECSS valve (1).
2. Loosen adjusting screw (3) by turning 1/2 to 1 turns at a time to

extract the accumulator pressure.
★ The lock nut (2) and the adjustment screw (3) are painted red.
3. After extracting the remaining pressure, return adjustment screw

(3) to its original position, then tighten with lock nut (2).
Lock nut torque: 12.7 ± 0.6 Nm (9.36 ± 0.44 lbf ft)
30-216 2 WA180-3MC
12
ECSS SOLENOID VALVE

the machine from moving
WARNING! Relieve ECSS circuit pressure before

removal of solenoid valve - see ECSS
CIRCUIT - REMAINING PRESSURE
REMOVAL.
REMOVAL
1. Raise boom and set support ➀ or tool G in position, then remove front
cover (1).
2. Relieve ECSS circuit pressure.
3. Disconnect connector CND08 (2).
4. Disconnect the two hydraulic hoses (3) and (4).
5. Remove the two mount bolts (5) and (6).
INSTALLATION
Hose nut (3): 58.8 - 98.0 Nm (43 - 72 lbf ft)
Hose nut (4): 107.8 - 166.7 Nm (80 - 123 lbf ft)
WA180-3MC 30-217 2
12
ECSS CONTROL VALVE

install the safety bar on the frame. Then
apply the parking brake and put blocks
under the wheels to prevent the machine
from moving
WARNING! Relieve ECSS circuit pressure before

removal of solenoid valve - see ECSS
CIRCUIT - REMAINING PRESSURE
REMOVAL.
REMOVAL
1. Raise boom and set support ➀ or tool G in position, then remove front
cover (1).
2. Disconnect the hydraulic lines from the ECSS control valve.
3. Disconnect the electrical connectors CND06 (6) and CND07 (7).
4. Disconnect hydraulic hoses (3), (4) and (5).
5. Remove the four mount bolts (8) and (9).

• Bolts (10) and (11) are not depicted.
INSTALLATION
Hose nut (5): 58.8 - 98.0 Nm (43 - 72 lbf ft)
Hose nut (2): 107.8 - 166.7 Nm (80 - 123 lbf ft)
30-218 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
12
WORK EQUIPMENT
REMOVAL

1. Bucket link
A. Remove bucket link mount pin (1).

★ Tie the bucket link to the tilt lever with wire.
B. Remove left and right bucket hinge mount pins (2).
WARNING! NEVER insert your fingers in the pin hole.
C. Drive machine in reverse and disconnect the bucket.
Bucket (BOC): 710 kg (1565.3 lb)
2. Bucket cylinder mount pin

Sling bucket cylinder (3), remove pin mount (4), then disconnect
cylinder rod and bellcrank.
★ Set block ➀ between cylinder bottom and frame
Bucket cylinder: 56 kg (123.5 lb)
3. Boom cylinder pin

Sling boom cylinder (5), then remove mount pin (6).
★ Put support under the tip of the boom.
★ Insert block ➁ on top of the axle, then lower the cylinder.
★ If shims are inserted, check number and size of shims, and put in a
safe place.
Boom cylinder: 62 kg (136.7 lb)
WA180-3MC 30-219 2
12
4. Boom, bellcrank, bucket link
A. Remove bracket (7-1) of boom kick-out switch (7).
B. Sling boom, bellcrank, and bucket link (8), then remove mount
pins (9) of boom, then lift off the boom.
Boom, bellcrank, bucket link: 662 kg (1459.5 lb)

5. Bellcrank, bucket link
A. Remove mount pin (11) of bucket link (10), and remove from
bellcrank.
Bucket link: 17 kg (37.5 lb)
★ Remove the wire holding the bucket to the bellcrank.
WARNING! When the pin is removed, the bellcrank

will move up suddenly, so keep your head
and other parts away.

B. Sling bellcrank (12), remove mount pin (13), then lift off from
boom.
Bellcrank: 125 kg (275.6 lb)
30-220 2 WA180-3MC
12
6. Dust seal, bushing
A. Remove dust seal (15) and bushing (16) from boom (14).
B. Remove dust seal (17) and bushings (18) from bellcrank (12).
C. Remove dust seal (19) and bushing (20) from bucket (10).
WA180-3MC 30-221 2
12
INSTALLATION

the pin hole.
1. Dust seal, bushing

Press fit bushings (16) to bucket link, bellcrank, and boom with press,
and assemble dust seals (15).
Bushing: Grease (G2-LI)
2. Bellcrank, bucket link
A. Align hole of boom (14) and bellcrank (12), and assemble shims
so that clearance "d" is specified value, then assemble mount pin
(13), and lock with bolt.
Clearance "d": Max. 2.0 mm
B. Align hole of bellcrank (12) and bucket link (10), and assemble
shims so that clearance "e" is specified value, assemble mount pin
(11), and lock with bolt.
Clearance "e": Max. 2.0 mm
★ Secure the bucket link to the bellcrank with wire.
30-222 2 WA180-3MC
12
3. Boom, bellcrank, bucket link
A. Raise boom, bellcrank, and bucket link (8) and set in mount
position, align front frame and boom mount hole so that clearance
"a" is specified value, then assemble mount pin (9) and lock with
bolt.
★ After assembling the pins, set a stand under the tip of the
boom.
B. Install bracket (7-1) of boom kick-out switch (7).
4. Boom cylinder
Sling boom cylinder (5), start engine, align cylinder rod with boom
mount hole, insert shims so that clearance "f" is specified value, then
assemble mount pin (6) and lock with bolt.
Clearance "f": Max.2.0 mm
WARNING! When starting the engine, check that the

directional lever is at neutral and that the
parking brake is applied.
★ Remove the block after assembling the mount pins.
5. Bucket cylinder
Sling bucket cylinder (3), adjust control lever and align pin hole, then
assemble mount pin (4), and lock with bolt.
★ Remove the block after assembling the mount pin.
WA180-3MC 30-223 2
12
6. Bucket
Operate control lever and align hole of bucket mount pin (2). Insert
shims to make clearance "b" uniform on the left and right, then install
mount pin (2) and lock with bolt.
Clearance "b":Max. 1.5 mm
7. Bucket link
Align hole of mount pin (1) of bucket link (10). Insert shims to make
clearance "c" uniform on the left and right, then install mount pin (1)
and lock with bolt.
Clearance "c": Max. 2.5 mm
8. Greasing
Grease all pins
30-224 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY FUEL TANK
12
FUEL TANK
REMOVAL


1. Open the side inspection cover and apply the lock, and open rear grill.
2. Loosen drain valve (1) and drain fuel.
3. Disconnect fuel hose (2), fuel return hose (3), and fuel gauge wiring
connector (4).
4. Remove return hose (5) from fuel filter.
★ Remove clamp of breather tube (5-1).
5. Remove cover (6).
6. Remove outer cover (8), inner cover (7), and rubber at oil filler port (6)
on left side of rear frame.
WA180-3MC 30-225 2
DISASSEMBLY AND ASSEMBLY FUEL TANK
12
7. Fuel tank
A. Set transmission jack under fuel tank, and support fuel tank (9)
lightly.
B. Remove mount bolts, then lower transmission jack slowly and

remove.
★ When there is a clearance of approx. 50 mm from the rear
frame, stop and check that there is no interference.
★ The oil filler tube will hit the rear frame, so move to the right
and remove carefully.
Fuel tank (dry): 80 kg (176.4 lb)
C. Pull out fuel tank (9) to right side of chassis.
INSTALLATION
★ Be sure to assemble the fuel hoses correctly.
★ When raising the transmission jack, maintain the balance, keep

the fuel tank horizontal, and set in the mount position.
★ Tighten the bolts in turn on the left and right.
• Refilling with fuel

Tighten drain plug and add fuel through fuel filler.
30-226 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
12
COUNTERWEIGHT

REMOVAL OF LEFT AND RIGHT

COUNTERWEIGHTS
1. Remove left (1) and right (2) counterweights.
A. Sling counterweights.
B. Remove mount bolts.
Counterweight left: 100 kg (220.5 lb)

Counterweight right: 170 kg (374.8 lb)
INSTALLATION OF LEFT AND RIGHT

COUNTERWEIGHTS
★ Install left and right in reverse order of removal.
Mount bolt (A): 549 ± 59 Nm (405 ± 44 lbf ft))
Mount bolt (B): 279 ± 29 Nm (206 ± 21 lbf ft))
REMOVAL OF REAR COUNTERWEIGHT

1. Removal of radiator grill.
A. Disconnect battery cables at the battery (3).
B. Disconnect electrical connections (4).
C. Disconnect backup warning horn (power and ground wires) (5).
2. Connect hoist (6) to radiator guard cover.
A. Disconnect gas spring cylinders at the frame (7).
B. Disconnect top mount bracket.
3. TILT radiator guard cover from machine and set to the side.
WA180-3MC 30-227 2
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
12
4. Rear counterweight.
Counterweight: 850 kg (1874 lb)
A. Using proper size hook and chain, hoist counter weight (to relieve
pressure on mount bolts).
B. Remove four (4) mount bolts.
WARNING! Rear counterweight may swing out from

machine when the last bolt is removed.
C. Rest rear counterweight on a pallet (8).
INSTALLATION OF REAR COUNTERWEIGHT

• Install rear counterweight in reverse order of removal.
30-228 2 WA180-3MC
DISASSEMBLY AND ASSEMBLY INSTRUMENT PANEL
12
INSTRUMENT PANEL
REMOVAL

★ Disconnect the cable from the negative (-) terminal of the battery.
1. Instrument panel
Remove mount bolts, then remove panel assembly (2) from instrument
panel mount guard (1), and pull up.
2. Tachometer cable
Disconnect tachometer cable (4) from housing (3).
★ Remove the clip of the tachometer from the left side under the
floor frame.
3. Electric wiring
Disconnect following electric wiring connectors.

• Connectors (5) and (6)
★ Remove the wiring from the clamp.
4. Panel
A. Remove panel assembly (2).
B. Remove each gauge from housing (3).
INSTALLATION
★ After inserting the connectors, arrange the wiring so that there is

no strain.
WA180-3MC 30-229 2
DISASSEMBLY AND ASSEMBLY AIR CONDITIONING
12
AIR CONDITIONING
AIR CONDITIONER UNIT

REMOVAL
bucket to the ground and stop the engine. Then apply the parking brake and block the
wheels to prevent the machine from moving.
WARNING! Disconnect the cable from the negative terminal of the battery.
WARNING! Remove the cover under the cab.
WARNING! Carry out the oil return operation for the compressor, then use a manifold gauge and
capture the refrigerant slowly from the core of the compressor high-pressure and low
pressure valves.
When carrying out the oil return operation, set the fan switch to the maximum position,
run the engine at low idling, and operate the air conditioner for five minutes.
WARNING! The refrigerant can cause blindness. Wear protective goggles when working on the air
conditioning system.
1. Remove hood cover (1 -1), then disconnect heater hose (1 -2) from
intermediate joint.
2. Remove covers (2) and (3) at rear of cab.
A. Slide the operator's seat to the front, then tip it over.
B. Remove blind cap (3-1).
C. Remove two bolts and loosen six bolts.
30-230 2 WA180-3MC
12
3. Remove five mount bolts of cover (4), remove cover.
4. Remove seat support cover (5).
5. Remove cool and hot box assembly (6) mount bolts (7), then remove
cool and hot box assembly.
6. Remove fuse box assembly bracket (8) from right console box.
WA180-3MC 30-231 2
12
7. Remove connectors (9), (10), (11), (12), (13), and (14) from fuse box
assembly bracket, and put fuse box assembly on right console box
temporarily.
• Label the connectors with tags to identify them when installing.
8. Disconnect floor wiring connectors (15), (16), and (17) from air
conditioner unit wiring, then disconnect air conditioner relay wiring
connector (18).
9. Remove left console box cover (19).
10. Remove left console box mount bolts (20) and (21), then remove left
console box (22).
30-232 2 WA180-3MC
12
11. Remove mount bolts (24) of air conditioner unit (23).
12. Remove mount bolts (26) of air conditioner unit (23) and air
conditioner damper (25).
• Loosen mount bolt (27).
• Loosen the four mount bolts at the cab end.
13. Disconnect air conditioner tubes (28) and (29) from air conditioner
unit.
★ Check that the pressure has been reduced.
14. Remove cover (30) at rear right of cab
WA180-3MC 30-233 2
12
15. Remove air conditioner filter (31), then remove duct mount bolts.
16. Remove connecting bolts (33) of air conditioner unit (23) and air
conditioner damper (25).
17. Remove clamp bolt (34) of air conditioner wiring connector (16).
18. Disconnect heater hoses (35) and (36) from air conditioner unit, then
remove air conditioner unit (23).
Air conditioner unit assembly: 38 kg (83.7 lb)
30-234 2 WA180-3MC
12
19. Disconnect air conditioner damper wiring connector (37) from floor
wiring, then remove air conditioner damper (25).
★ After disconnecting, take steps to prevent the entry of dust or
water.
WA180-3MC 30-235 2
12
INSTALLATION
• Installation is the reverse of the removal procedure.
Tube mount bolt: 9.8 ± 2 Nm (7 ± 2 lbf ft)
★ Coat the O-ring with compressor oil ND-OIL8.
★ Pass the air conditioner drain hose through the floor support grommet.
• Fill the air conditioner with new refrigerant.

★ Precautions when filling air conditioner line with new refrigerant:
i. Keep the temperature inside the room at above 3° C (37.4° F). (If the temperature is below 3° C (37.4° F), the
system will not work.)
ii. Use R134a as the refrigerant.
iii. When filling with refrigerant, always use the repeat vacuum method to completely evacuate.
(Vacuum: Min. 750 mm (29.5 in) Hg)
iv. Charge with 1.5 - 1.6 kg (3.3 - 3.5 lb) of refrigerant.
WARNING! Do not use the can of refrigerant upside down. Follow the refrigerant manufacturer's
recommendations. Be careful not to let liquid freon get into the refrigerating system.
WARNING! Do not operate the compressor before charging with refrigerant
★ Check the oil level in the compressor. (Specified oil level: 150 +14
0 cc ND-OIL8)
30-236 2 WA180-3MC
12
AIR CONDITIONER CONDENSER
REMOVAL
1. Oil return operation

Carry out oil return operation for compressor, then use a manifold
gauge and release refrigerant slowly from compressor high-pressure
and low-pressure valves.
• Procedure for oil return operation:
Set fan switch to maximum position, run engine at low idling, and
operate air conditioner for five minutes.
2. Covers
Remove covers (1) and (2) from hood.
• Open the hood door and top inspection cover.
3. Air conditioner condenser, bracket

• After disconnecting the hoses, fit covers to prevent dirt or water
from entering.
A. Disconnect connectors (3), (4), (5), and (6) of electric wiring.
B. Disconnect air conditioner hose (7) from condenser.
C. Disconnect air conditioner hose (8) from dryer receiver.
D. Remove air conditioner hose clamp bolt (9) from bracket (10).
E. Sling condenser and bracket assembly, remove mount bolts of

bracket (10), then lift off condenser bracket assembly (11) from
hood.
F. Install eye bolts in the bracket bolt holes.
WA180-3MC 30-237 2
12
G. Remove mount bolts, then remove air conditioner condenser (12)
from bracket (10). Disconnect the air conditioner hose. After
disconnecting the hose, cover the openings to prevent dirt or water
from entering the joint.
INSTALLATION
Connect the wiring connectors securely.
Do not remove the covers from the hoses until immediately before installing.
To prevent the hose from twisting, hold the hose securely with two wrenches when tightening.
Dryer receiver hose bolt: 5.4 ± 1.5 Nm (4 ± 1 lbf ft)
Condenser hose: 13.2 ± 1.5 Nm (10 ± 1 lbf ft)

(condenser outlet port)
Condenser hose: 22.1 ± 2.5 Nm (1 6 ± 2 lbf ft)

(condenser inlet port)
Thread of hose joint: Compressor oil
30-238 2 WA180-3MC
12
• Filling with freon
WARNING! Do not use the can of refrigerant upside down. Follow refrigerant manufacturer's
recommendations. Be careful not to let liquid freon get into the refrigerating system.
A. Before filling with refrigerant, always use the repeat vacuum method to completely evacuate.
B. Do not operate the compressor before charging with refrigerant.
C. Fill the air conditioner with freon. (R134a)
D. Check that the refrigerant level is correct.
E. Check the oil level in the compressor. (Specified oil level: 150 +14
0 cc ND-OIL8)
★ Checks after assembly

Amount of bubbles in receiver sight glass Remedy
Almost completely transparent; even it there are bubbles,

Correct ---
becomes transparent when engine speed is raised or lowered
Connect charging hose to compressor, then add

Low Continuous stream of bubbles passes
refrigerant until condition becomes normal.
WA180-3MC 30-239 2
12
DRYER RECEIVER
REMOVAL
1. Carry out oil return operation for compressor, then use a gauge manifold and release refrigerant slowly from compressor
high-pressure and low-pressure valves.
• Procedure for oil return operation
Set fan switch to maximum position, run engine at low idling, and operate air conditioner for five minutes.
2. Disconnect hoses (1) and (2).
Remark
After disconnecting the hoses, fit covers to the joint.
3. Remove mount U-bolts (3), then remove dryer receiver (4) from
bracket.
INSTALLATION
Hose mount bolt: 6.4 ± 1.5 Nm (4 ± 1 lbf ft)
Remark
To prevent dirt, dust, or water from entering, do not remove the covers from the air conditioner hoses until immedi-
ately before installing.
Hose joint: Compressor oil
U-bolt: 18.6 ± 7.8 Nm (14 ± 6 lbf ft)
Remark
Be careful not to over-tighten the U-bolts.
30-240 2 WA180-3MC
12
WARNING! Do not use the can of refrigerant upside down. Follow refrigerant manufacturer's recom-
mendations. Be careful not to let liquid freon get into the refrigerating system.
0 cc ND-OIL8)


Correct ---

WA180-3MC 30-241 2
12
AIR CONDITIONER COMPRESSOR
REMOVAL
WARNING! Perform the oil return operation for the air conditioner compressor (set the fan switch to
the maximum position, run the engine at low idling, and operate the air conditioner for five
minutes). Then use a manifold gauge and release the refrigerant slowly from the valve of
the compressor.
WARNING! Disconnect the cable from the negative terminal of the battery.
1. Disconnect electric wiring connector (1).
2. Disconnect hoses (3) and (4) from air conditioner compressor.

• Remove the hose clamps.
• After disconnecting the hose, cover the openings to prevent dirt or
water from entering the joint.
3. Remove air conditioner compressor mount bolts, then remove air

conditioner compressor (5) and V-belt.
30-242 2 WA180-3MC
12
INSTALLATION
Connect the wiring connectors securely.

Remark
To prevent dirt or water from entering, do not remove the cover from the hose until immediately before installing.
Hose joint, O-ring portion: Compressor oil
Hose mount bolt: 9.8 ± 2.0 Nm (7 ± 2 lbf ft)
Procedure for adjusting V-belt.
WARNING! Do not use the can of refrigerant upside

down. Follow refrigerant manufacturer's
recommendations. Be careful not to let
liquid freon get into the refrigerating
system.
0 cc ND-OIL8)


Correct ---

WA180-3MC 30-243 2
12
MEMORANDUM
30-244 2 WA180-3MC
40 MAINTENANCE STANDARD
ENGINE MOUNT, TRANSMISSION MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2

TORQUE CONVERTER CHARGING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
TORQUE CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-6
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 40-8
TRANSMISSION (1/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-8
TRANSMISSION (2/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-12
TRANSMISSION (3/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-16
REVERSE, 1ST CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-18
FORWARD, 2ND CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20
3RD, 4TH CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-22
UPPER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-24
LOWER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-26
SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-28
ACCUMULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30
DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-32
DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-34
DIFERENTIAL (1/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-34
DIFFERENTIAL (2/2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-36
FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-38
AXLE MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40
ADDITIONAL COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-42
CENTER HINGE PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-44
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-46
PRIORITY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-48
STEERING CYLINDER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-49
BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-52
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-53
HYDRAULIC PUMP (SAL40+14+8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-54
MAIN CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-55
2-SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-55
3-SPOOL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-58
HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-61
WORK EQUIPMENT LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-62
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-64
BUCKET POSITIONER AND BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-66
WA180-3MC 40-1
MAINTENANCE STANDARD ENGINE MOUNT, TRANSMISSION MOUNT
12
ENGINE MOUNT, TRANSMISSION MOUNT
40-2 WA180-3MC
MAINTENANCE STANDARD ENGINE MOUNT, TRANSMISSION MOUNT
12
Item Nm Torque lbf ft Torque
1 Bolt 745 ± 83 549.48 ± 61.21
2 Bolt 110.5 ± 12.5 81.50 ± 9.21
3 Bolt 745 ± 83 549.48 ± 61.21
4 Bolt 277 ± 31.9 204.30 ± 23.52
5 Bolt 110.5 ± 12.5 81.50 ± 9.21
6 Bolt 277 ± 31.9 204.30 ± 23.52
WA180-3MC 40-3
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP
12
TORQUE CONVERTER CHARGING PUMP
[LAL(1)-32]
Unit: mm
No Check item Criteria Remedy
Standard clearance Clearance limit

1 Side clearance
0.05 - 0.10 0.15
Clearance between inside
diameter of plain bearing
2 and outside of diameter
0.060 - 0.119 0.200
of gear shaft
Replace
Standard size Tolerance
Depth for knocking
3
in pin 10 0
-0.5
Rotating torque of
4 2.0 - 4.9 Nm (1.47 - 3.61 lbf ft)
spline shaft
Standard Delivery
Discharge amount Rotating Delivery
delivery amount
Oil: EO10-CD speed pressure
amount limit
--- Oil temperature: ---
45 - 55° C 30 kg/cm2 94 L/min 86 L/min
113 - 131° F 3000 rpm
426.7 lbf/in2 24.8 gal/min 22.7 gal/min
Nm Torque lbf ft Torque
5 Bolt 64.7 ± 5.9 47.72 ± 4.35
40-4 WA180-3MC
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP
MEMORANDUM
WA180-3MC 40-5
MAINTENANCE STANDARD TORQUE CONVERTER
12
TORQUE CONVERTER
40-6 WA180-3MC
MAINTENANCE STANDARD TORQUE CONVERTER
12
Unit: mm
No. Check item Criteria Remedy
Standard size Tolerance Repair limit

1 Outside diameter of pilot Repair
42 -0.009 41.75
chrome
-0.034
plating or
Inside diameter of retainer seal ring contact 100 +0.035 100.5 replace
2
surface 0
Width 3 -0.01 2.7

Wear stator shaft seal -0.03
3
ring
Thickness 4 ± 0.1 3.6 Replace
Backlash between PTO drive gear and 0.15 - 0.42

4
drive gear
5 Bolt 66.2 ± 7.4 48.82 ± 5.45
6 Bolt 30.9 ± 3.4 22.79 ± 2.50
7 Bolt 66.2 ± 7.4 48.82 ± 5.45
WA180-3MC 40-7
MAINTENANCE STANDARD TRANSMISSION
12Tr
TRANSMISSION
TRANSMISSION (1/3)
40-8 WA180-3MC
12
Unit: mm
No Check item Criteria Remdy
Standard Tolerance Standard Clearance

Clearance between 4th shaft and size Shaft Hole clearance limit
1
bearing (R)
0 +0.021 -0.008 -
30 ---
-0.012 -0.008 0.033
Clearance between 4th shaft 0 +0.018 -0.012 -

2 72 ---
bearing (R) and housing -0.013 -0.012 0.031
Clearance between 4th shaft and 0 +0.021 0.008 -

3 30 ---
bearing (F) -0.012 +0.008 0.033
Clearance between 4th shaft 0 +0.018 -0.012 - Replace

4 72 ---
bearing (F) and housing -0.013 -0.012 0.031
Clearance between pump drive +0.025 0 -0.037 -

5 50 ---
shaft and bearing +0.009 -0.012 0.009
Clearance between pump drive 0 +0.022 -0.013 -

6 90 ---
shaft bearing and housing -0.015 -0.013 0.037
Clearance between pump drive -0.009 +0.041 0.034 -

7 35 ---
shaft and bearing -0.025 +0.025 0.066
Clearance between pump drive 0 +0.014 -0.011 -

8 47 ---
9 Bolt 110 ± 12.3 81.13 ± 9.0
10 Bolt 66.2 ± 7.4 48.82 ± 5.45
11 Bolt 11.3 ± 1.5 8.33 ± 1.10
12 Bolt 66.2 ± 7.4 48.82 ± 5.45
13 Bolt 110 ± 12.3 81.13 ± 9.0
14 Bolt 11.3 ± 1.5 8.33 ± 1.10
15 Bolt 176.5 ± 29.4 130.18 ± 21.68
16 Bolt 34.3 ± 4.9 25.29 ± 3.61
17 Bolt 53.9 ± 19.6 39.75 ± 14.4
18 Bolt 30.9 ± 3.4 22.79 ± 2.50
19 Bolt 66.2 ± 7.4 48.82 ± 5.45
20 Bolt 66.2 ± 7.4 48.82 ± 5.45
21 Bolt 235.4 ± 39.2 173.62 ± 28.91
22 Bolt 68.9 ± 9.8 50.81 ± 7.22
23 Bolt 110 ± 12.3 81.13 ± 9.0
24 Bolt 110 ± 12.3 81.13 ± 9.0
WA180-3MC 40-9
25 Bolt 110 ± 12.3 81.13 ± 9.0
26 Bolt 30.9 ± 3.4 22.79 ± 2.50
27 Bolt 299.1 ± 93.2 220.60 ± 68.74
40-10 WA180-3MC
12
MEMORANDUM
WA180-3MC 40-11
12
TRANSMISSION (2/3)
40-12 WA180-3MC
12 Unit : mm

size clearance limit
Shaft Hole
1 Clearance between pump drive +0.025 0 -0.037 - ---

50
shaft and bearing -0.009 -0.012 -0.009
2 Clearance between pump drive 0 +0.018 -0.012 - ---

80
Clearance between pump drive -0.009 +0.041 0.034 - ---

3 35
shaft and bearing -0.025 +0.025 0.066
Clearance between pump drive 0 +0.014 -0.011 - ---

4 47
Clearance between input shaft and +0.009 0 -0.037 - ---

5 35
bearing +0.025 -0.012 -0.009
Clearance between input shaft 72 0 +0.018 -0.012 - ---

6
bearing and housing earing -0.013 -0.012 0.031
Clearance between input shaft and 50 -0.009 0 0.037 - ---

7
bearing -0.025 -0.012 -0.009 Replace
Clearance between input shaft 90 0 +0.022 -0.013 - ---
8
bearing and housing -0.0151 -0.013 0.037
Clearance between REVERSE, 90 0 +0.022 -0.013 - ---

9
1st clutch bearing (F) and housing -0.015 -0.013 0.037
Clearance between REVERSE, 0 +0.022 -0.013 - ---

10 90
1st clutch bearing (R) and housing -0.015 -0.013 0.037
Clearance between FORWARD, 0 +0.022 -0.013 - ---

11 2nd cl;utch clutch bearing (F) and 110 -0.015 -0.013 0.037
housing
12 Clearance between FORWARD, 0 +0.022 -0.013 - ---

2nd clutch bearing (R) and 90 -0.015 -0.013 0.037
housing
13 Clearance between 3rd, 4th clutch 0 +0.026 -0.014 - ---

130
bearing housing (F) and housing -0.018 -0.014 0.044
14 Clearance between 3rd, 4th clutch 0 0 -0.013 - ---

90
bearing (R) and housing -0.015 -0.015 0.037
15 Bolt 110 ± 12.3 81.13 ± 9.0
16 Bolt 110 ± 12.3 81.13 ± 9.0
17 Bolt 30.9 ± 3.4 22.79 ± 2.50
18 Bolt 277 ± 31.9 204.30 ± 23.52
19 Bolt 53.9 ± 19.6 39.75 ± 14.4
WA180-3MC 40-13
20 Bolt 110 ± 12.3 81.13 ± 9.0
21 Bolt 68.6 ± 9.8 50.81 ± 7.22
40-14 WA180-3MC
12
MEMORANDUM
WA180-3MC 40-15
12
TRANSMISSION (3/3)
40-16 WA180-3MC
12 Unit: mm

size Shaft Hole clearance limit
1 Clearance between output shaft +0.031 0 -0.043 -

50 ---
and bearing (F) +0.015 -0.012 -0.015
2 Clearance between output shaft 0 -0.015

90 -0.040 - 0 ---
bearing (F) and housing -0.015 -0.040
3 Clearance between output shaft +0.031 0 -0.043 -

50 ---
and bearing (R) +0.015 -0.012 0.015
4 Clearance between output shaft 0 -0.015

90 -0.040 - 0 ---
bearing (R) and housing -0.015 -0.040
5 Clearance between output shaft +0.170 +0.054 -0.170 -

90 ---
oil seal (F) and housing +0.080 0 -0.026
6 Clearance between output shaft +0.170 +0.054 -0.170 -

90 ---
oil seal (R) and housing +0.080 0 -0.026

Replace
Inside diameter of housing seal +0.05 0.05
50
ring contact surface 0 (Amount of wear)
+0.076
Width of shaft seal ring grove 3.2 3.5
0
7
0
Width of seal ring 3.0 2.6
-0.13
0
Thickness of seal ring 2.29 2.1
-0.1
Outside diameter of sliding 0 0.05

8 65
portion of coupling oil seal (F) -0.074 (Amount of wear)
Outside diameter of sliding 0 0.05

9 65
portion of coupling oil seal (R) -0.074 (Amount of wear)
Standard size Standard clearance clearance limit
Clearance between parking brake

10 0.85 0.02 - 1.68 ---
housing and case
Free rotation torque of output Adjust shim

11 0.10 - 1.0 Nm (0.073 - 0.737 lbf ft)
shaft
WA180-3MC 40-17
12
REVERSE, 1ST CLUTCH
Unit: mm

+0.102 +0.28
REVERSE
Clearance Inside 85 0.048 - 0.19 0.24

-0.090 +0.15
1 between piston
and cylinder -0.350 +0.08
Outside 118 0.300 - 0.480 0.53
-0.040 -0.05
+0.102 +0.28
Clearance Inside 85 0.048 - 0.190 0.24
+0.090 +0.15
1ST
2 between piston Replace

and cylinder -0300 +0.13
Outside 140 0.048 - 0.190 0.53
-0.350 0
Clearance at bearing press fitting +0.025 0

3 50 -0.009 - -0.037 ---
portion of REVERSE clutch shaft +0.009 -0.012
Clearance at bearing press fitting +0.025 0

4 50 -0.009 - -0.037 ---
portion of 1st clutch shaft +0.009 -0.012
Clearance at spacer press fitting

+0.025 0
5 portion of REVERSE, 1st clutch 51 -0.055 - -0.009 ---
+0.009 -0.012
shaft
40-18 WA180-3MC
12
Unit: mm
Thickness of separator plate 1.8 ± 0.06 1.7

6
Distortion of separator plate --- 0.05 0.15
+0.05
Thickness of friction plate 3.0 2.65
7 -0.10
Distortion of friction plate --- 0.07 0.14
902 N (202.77 lbf)

8 Load of wave spring Height: 2.975 mm ± 902 N (± 20.27 lbf) 731 N (164.33 lbf) Replace
(Height: 0.117126 in)
Thickness of REVERSE, 1st

9 5.0 ± 0.05 ---
clutch spacer
Thickness of REVERSE, 1st

10 3.0 ± 0.1 2.7
clutch thrust washer
11 End play of REVERSE gear 0.07 - 0.93
12 End play of 1st gear 0.04 - 1.16
WA180-3MC 40-19
12
FORWARD, 2ND CLUTCH
Unit: mm

size clearance limit
Shaft Hole
Clearance +0.102 +0.28 0.048 -

FORWARD
Inside 85 0.24
between +0.090 +0.15 0.19
1 piston and
cylinder -0.35 +0.08 0.30 -
Outside 118 0.53
-0.40 -0.05 0.48
Clearance +0.102 +0.28 0.048 -

Inside 85 0.24
between +0.090 +0.15 0.19
2ND
2 Replace
piston and -0.30 +0.13 0.030 -
cylinder Outside 140 0.53
-0.35 0 0.48
3 Clearance at bearing press fitting +0.025 0 -0.037 -

50 ---
portion of FORWARD clutch shaft +0.009 -0.012 -0.009
4 Clearance at bearing press fitting +0.025 0 -0.037 -

50 ---
portion of 2nd clutch shaft +0.009 0.012 -0.009
5 Clearance at spacer press fitting

+0.025 0 -0.055 -
portion of FORWARD, 2nd clutch 51 ---
+0.009 -0.03 -0.009
shaft
40-20 WA180-3MC
12
Unit: mm
Thickness of FORWARD, 2nd

6 .03 ±0.1 2.7
clutch thrust washer
Thickness of separator plate 1.8 ±0.06 1.7

7
+0.05
Thickness of friction plate 3.0 2.65
8 -0.10
Distortion of friction plate --- 0.07 0.14 Replace
902 N (202.77 lbf)

9 Load of wave spring Height: 2.975 mm ± 902 N (± 20.27 lbf) 731 N (164.33 lbf)
(Height: 0.117126 in)
Thickness of FORWARD, 2nd

10 5.0 ±0.05 ---
clutch spacer
11 End play of FORWARD gear 0.07 - 0.93
12 End play of 2nd gear 0.04 - 1.16
WA180-3MC 40-21
12
3RD, 4TH CLUTCH
Unit: mm

+0.102
Inside 85 +0.28 0.048 - 0.19 0.24
Clearance between +0.090
1
piston and cylinder -030 +0.13
Outside 140 0.30 - 0.48 0.53
-0.35 0
Clearance at outside diameter of

+0.025 0 -0.037 -
2 bearing press-fitting portion of 4th 50 ---
+0.009 -0.012 -0.009
clutch shaft
Clearance at outside diameter of Replace

+0.030 0 -0.045 -
3 bearing press-fitting portion of 3rd 60 ---
+0.011 -0.015 -0.011
clutch shaft
Clearance at spacer press-fitting +0.025 0 -0.055 -

4 51 ---
portion of 4th clutch shaft +0.009 -0.03 -0.009
Clearance at spacer press-fitting 0.030 0 -0.060 -

5 61 ---
portion of 3rd clutch shaft +0.011 -0.03 -0.011
Thickness of separator plate 1.8 ±0.06 1.70

6
40-22 WA180-3MC
3.0 +0.05 2.65

Thickness of friction plate
7 -0.10
Distortion of friction plate --- 0.07 0.14 Replace
902 N (202.77 lbf)

± 902 N (± 20.27
8 Load of wave spring Height: 2.975 mm 731 N (164.33 lbf)
lbf)
(Height: 0.117126 in)
Standard size Standard clearance Clearance limit
9 Thickness of 4th clutch thrust washer 3.0 ±0.1 2.7
10 Thickness of 3rd clutch thrust washer 3.0 ±0.1 2.7
11 Thickness of 4th clutch spacer 5.0 ±0.05 --- Replace
12 Thickness of 3rd clutch spacer 5.0 ±0.05 ---
13 End play of 4th gear 0.07 - 0.93
14 End play of 3rd gear 0.04 - 1.16
WA180-3MC 40-23
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
12
UPPER VALVE
40-24 WA180-3MC
12 Unit: mm
Standard Tolerance Standard Clearance limit

size clearance
Shaft Hole
1 Clearance between pilot valve and 19 -0.02 +0.013 0.020 - 0.050

body -0.03 0 0.043
2 Clearance between main regulator 19 -0.02 +0.013 0.020 - 0.050

valve and body -0.03 0 0.043
3 Clearance between main regulator 13.5 -0.02 +0.018 0.020 - 0.055

valve and load piston -0.03 0 0.048
4 Clearance between priority valve 19 -0.02 +0.013 0.020 - 0.050

and body -0.03 0 0.043
5 Clearance between priority valve 12.5 -0.02 +0.018 0.020 - 0.055

and load piston -0.03 0 0.048
6 Clearance between quick return 28 -0.020 +0.013 0.020 - 0.044

7 Clearance between modulation 28 -0.02 +0.013 0.020 - 0.050

fill valve and body -0.03 0 0.043

fill valve and sleeve -0.03 +0.020 0.066

fill valve and sleeve -0.05 +0.025 0.091
Replace
10 Clearance between sleeve and 41 -0.050 +0.025 0.050 - 0.110
body -0.075 0 0.100
11 Clearance between accumulator 28 -0.02 +0.013 0.020 - 0.050

Standard size Repair limit
Free Installed Installed load Free length Installed load

length length
230 ± 11.5 N 79.3 207 N

12 Main regulator valve spring 82.55 62.6
(51.70 l± 2.58 lbf) (46.53 lbf)
254 ± 12.7 N 66.7 228 N

13 Priority valve spring 69.5 52.6
(57.10 ± 2.85 lbf) (51.25 lbf)
0.8 ± 0.04 N 46.1 0.7 N

14 Quick return valve spring 48.0 41.0
(0.179 ± 0.00089 lbf) (0.1573 lbf)
Modulation fill valve spring 24.1 ± 1.2 N 40.1 21.7 N

15 41.8 40.0
(inner) (5.41 ± 0.269 lbf) (4.87 lbf)
Modulation fill valve spring 138 ± 7 N 41.9 125 N

16 43.6 24.3
(outer) (31.02 ± 1.57 lbf) (28.10 lbf)
17 Accumulator spring (outer) 99.6 99.6 0 95.6 ---
18 Accumulator spring (inner 1) 35.6 35.6 0 34.2 ---
19 Accumulator spring (inner 2) 40.8 40.8 0 39.2 ---
WA180-3MC 40-25
20 Bolt 66.2 ± 7.4 48.82 ± 5.45
21 Bolt 66.2 ± 7.4 48.82 ± 5.45
22 Bolt 49.0 ± 4.9 36.14 ± 3.61
LOWER VALVE
40-26 WA180-3MC
Unit: mm

1 Clearance between torque converter -0.02 +0.013 0.020 -

19 0.050
regulator valve and body -0.03 0 0.043
2 Clearance between F-R selector -0.02 +0.013 0.020 -

19 0.050
spool and body -0.03 0 0.043
3 Clearance between H-L selector -0.02 +0.013 0.020 -

19 0.050
spool and body -0.03 0 0.043
4 Clearance between range selector -0.02 +0.013 0.020 -

19 0.050
spool and body -0.03 0 0.043 Replace
Free Installed Installed

Installed load Free length
length length load
5 Torque converter regulator valve 55.7 ± 2.7 N 50 N

70.3 66.1 67.5
spring (12.52 ± 0.606 lbf) (11.24 lbf)
6 F-R selector spool spring 83.4 ± 4.2 N 75.5 N

48.8 36 46.8
(18.74 ± 0.0966 lbf) (16.97 lbf)
7 H-L range selector spool return 69.8 ± 3.5 N 62.8 N

48.0 36.7 46.1
spring (15.69 ± 0.7868 lbf) (14.11 lbf)
8 Bolt 66.2 ± 7.4 48.82 ± 5.45
9 Bolt 66.2 ± 7.4 48.82 ± 5.45
WA180-3MC 40-27
SOLENOID VALVE
40-28 WA180-3MC
12
Unit: mm
Stanard Tolerance Standard Clearance

Replace
1 Clearance between emergency -0.02 +0.013
14 0.020 - 0.043 0.050
manual spool and body -0.03 0
2 Bolt 30.9 ± 3.4 22.79 ± 2.50
3 Nut 12.5 ± 4.6 9.21 ± 3.39
4 Screw 1.6 ± .15 1.18 ± 0.11
WA180-3MC 40-29
MAINTENANCE STANDARD ACCUMULATOR VALVE
12
ACCUMULATOR VALVE
40-30 WA180-3MC
MAINTENANCE STANDARD ACCUMULATOR VALVE
12
Unit: mm

Clearance between piston and -0.035 +0.025

1 32 0.035 - 0.070 0.08
body -0.045 0
Free Installed Installed

Installed load Free length Replace
length height load
FORWARD clutch accumulator 158 N

2 184.8 175 177.4 ---
spring (35.51 lbf)
78.8 N
3 1st clutch accumulator spring 145 135 139.2 ---
(17.71 lbf)
157.9 N
4 2nd clutch accumulator spring 145 125 139.2 ---
(35.49 lbf)
5 Bolt 53.9 ± 19.6 39.75 ± 14.45
WA180-3MC 40-31
MAINTENANCE STANDARD DRIVE SHAFT
12
DRIVE SHAFT
40-32 WA180-3MC
MAINTENANCE STANDARD DRIVE SHAFT
12
MEMORANDUM
WA180-3MC 40-33
MAINTENANCE STANDARD DIFFERENTIAL
12
DIFFERENTIAL
DIFERENTIAL (1/2)
40-34 WA180-3MC
12
Unit: mm
1 Bevel gear free rotating torque 1.2 -3.9 Nm (0.885 - 2.876 lbf ft)
Thickness of shim at differential

2 0.085 - 1.295
side bearing carrier (one side)
Replace
Thickness of shim for differential
3 0.5 - 1.55
housing and gauge assembly
4 Protrusion of pin 12
5 Bolt 279.5 ± 29.4 206.14 ± 21.68
6 Bolt 112.8 ± 9.8 83.19 ± 7.22
7 Bolt 112.8 ± 14.7 83.19 ± 10.84
8 Bolt 181.4 ± 53.9 133.79 ± 39.75
9 Bolt 132.4 ± 39.2 97.65 ± 28.91
10 Bolt 5.4 ± 1.5 3.98 ± 1.10
11 Bolt 279.5 ± 29.4 206.14 ± 21.68
12 Bolt 112.8 ± 9.8 83.19 ± 7.22
13 Bolt 112.8 ± 9.8 8.19 ± 7.22
WA180-3MC 40-35
12
DIFFERENTIAL (2/2)
40-36 WA180-3MC
12 Unit: mm

Outer 0 -0.024
Clearance at 105 -0.059 - -0.004 ---
race -0.020 -0.059
1 differential side
bearing Inner +0.051 0
65 -0.066 - -0.032 ---
race +0.032 -0.015
Outer 0 -0.041
Clearance of bearing 110 -0.076 - -0.026 ---
race -0.015 -0.076
2 and pinion shaft gear
end Inner +0.039 0
50 -0.051 - -0.025 ---
race +0.025 -0.015
Outer 0 -0.040
Clearance of bearing 90 -0.075 - -0.025 ---
race -0.015 -0.075
3 and pinion shaft
coupling Inner +0.037 0
40 -0.049 - -0.026 ---
race -0.026 -0.012
4 Clearance between pinion gear -0.180 +0.02

25.18 0.16 - 0.213 0.3
and spider -0.193 -0.02
Assembly portion of piston of

-0.250 +0.05 Replace
5 differential housing (housing and 260.4 0.20 - 0.50 ---
-0.450 -0.05
piston)
Assembly portion of piston of -0.250 +0.05

6 215.95 0.20 - 0.50 ---
bearing carrier (piston, carrier) -0.450 -0.05
7 Backlash of bevel gear 0.15 - 0.30
8 Backlash of differential gear 0.15 - 0.35
9 End play of pinion gear Max. 0.172
10 Thickness of side gear washer 1.55 ± 0.05 1.35
Wear of outside diameter of lock 0

11 8 ---
pin - 0.09
Height of spacer between pinion

12 51.90 ± 0.025 ---
shaft bearings
Outside diameter of axle mount - 0.043

13 150 149.6
(rear differential) - 0.106
- 0.043
14 Axle mount (rear differential) 150 149.6
- 0.106
WA180-3MC 40-37
MAINTENANCE STANDARD FINAL DRIVE
12
FINAL DRIVE
40-38 WA180-3MC
MAINTENANCE STANDARD FINAL DRIVE
12 Unit: mm

Clearance between axle housing and +0.100 +0.100

1 276 -0.100 - 0.07 ---
ring gear +0.030 0
Clearance of guide pin +0.025 +0.187

2 12 0.100 - 0.180 ---
+0.007 +0.125
Outer +0.077 -0.038

Clearance at axle 112.661 -0.077 - -0.014 ---
race +0.052 0
3 housing bearing
press-fitted section Inner +0.050 -0.013
69.85 -0.050 - -0.016 ---
race +0.025 0
Outer +0.025 -0.013

Clearance at axle 127 -0.076 - -0.013 ---
race 0 -0.051 Replace
4 housing bearing
press-fitted section Inner +0.063 +0.025
77.788 -0.063 - -0.013 ---
race +0.038 0
+0.063
Housing 130 --- --- ---
Axle shaft press-fitted 0
5
section 0
Shaft 93.5 --- --- ---
-0.054
Clearance between pinion gear +0.025 +0.013

6 33.338 -0.025 - 0 ---
bearing and shaft +0.013 0
7 End play of axle shaft Max. 0.98
Clearance between oil seal and

8 0.21 - 1.91
housing
9 Bolt 279.5 ± 29.4 206.14 ± 21.68
10 Bolt 132.4 ± 32.9 97.65 ± 24.26
11 Bolt 926.7 ± 103.0 683.49 ± 75.96
12 Bolt 279.5 ± 29.4 206.14 ± 21.68
WA180-3MC 40-39
MAINTENANCE STANDARD AXLE MOUNT
12
AXLE MOUNT
40-40 WA180-3MC
MAINTENANCE STANDARD AXLE MOUNT
12 Unit: mm
+0.1
1 Thickness of thrust plate 12.2 ±0.1
-0.5

size Shaft Hole clearance limit Replace
Clearance between hole and shaft -0.043 +0.550

2 150 0.093 - 0.656 ---
at front support end -0.106 +0.050
Clearance between hole and shaft -0.043 +0.550

3 150 0.093 - 0.656 ---
at rear support end -0.106 +0.050
4 Thickness of axle mount shim 0.2 (each) ---
5 Bolt 549.2 ± 58.8 406.06 ± 43.36
6 Bolt 112.8 ± 9.8 83.19 ± 7.22
7 Bolt 112.8 ± 9.8 83.19 ± 7.22
8 Bolt 740.4 ± 73.6 546.09 ± 54.28
WA180-3MC 40-41
MAINTENANCE STANDARD ADDITIONAL COUNTERWEIGHT
12
ADDITIONAL COUNTERWEIGHT
1 Bolt 490 - 608 361.4 - 448.4
2 Bolt 490 - 608 361.4 - 448.4
3 Bolt 245 - 309 180.7 - 227.9
40-42 WA180-3MC
MAINTENANCE STANDARD ADDITIONAL COUNTERWEIGHT
12
MEMORANDUM
WA180-3MC 40-43
MAINTENANCE STANDARD CENTER HINGE PIN
12
CENTER HINGE PIN
40-44 WA180-3MC
MAINTENANCE STANDARD CENTER HINGE PIN
12 Unit: mm

Clearance between upper hinge -0.073 +0.05

1 66 0.023 - 0.153 ---
pin and rear frame -0.103 -0.05

2 50 0.038 - 0.168 ---
pin and rear frame -0.068 0
Clearance between upper hinge -0.038 0

3 50 0.026 - 0.068 ---
and bearing -0.068 -0.012

4 50 0.038 - 0.318 ---
and spacer (top) -0.068 0

5 50 0.038 - 0.318 ---
and spacer (bottom) -0.068 0
Clearance between front frame 0 -0.02 Replace

6 105 -0.120 - -0.005 ---
and upper hinge bearing -0.015 -0.12
Clearance between lower hinge -0.05 +0.05

7 69.85 0 - 0.11 ---
pin and rear frame -0.06 -0.05
Clearance between front frame 0 +0.05

8 88.9 -0.05 - 0.07 ---
and bearing -0.020 -0.05
Clearance between bearing and -0.050 +0.050

9 69.85 0.078 - 0.113 ---
hinge pin -0.060 +0.028
Wear of oil seal contact surface of 0

10 63.45
upper hinge spacer -0.20
Height (top), (bottom) of upper

11 23 ± 0.1
hinge spacer
Standard size Standard clearance Clearance limit
Clearance when adjusting shims

12 1.3 0.1 - 0.2 ---
at upper hinge
Adjust
Thickness of shim between upper
13 hinge and retainer (rear frame 0.8 Max. 0.4 ---
portion)
14 Bolt 112.8 ± 9.8 83.19 ± 7.22
15 Bolt 65.7 ± 6.9 48.45 ± 5.08
16 Bolt 559.0 ± 49.0 412.29 ± 36.14
WA180-3MC 40-45
MAINTENANCE STANDARD STEERING COLUMN
12
STEERING COLUMN
40-46 WA180-3MC
MAINTENANCE STANDARD STEERING COLUMN
12
Item Nm Torque lbf ft Torque
1 Bolt 18.6 ± 7.9 13.71 ± 5.82
2 Bolt 29.4 ± 2.9 21.68 ± 2.13
3 Bolt 110.3 ± 12.3 81.35 ± 9.07
4 Bolt 28.4 ± 3.9 20.94 ± 2.87
5 Bolt 51.5 ± 7.4 37.98 ± 5.45
WA180-3MC 40-47
MAINTENANCE STANDARD PRIORITY VALVE
12
PRIORITY VALVE
Unit: mm
Free Installed Installed load Free length Installed load

length height Replace
218.7 N 175.5 N
1 Return spring 63.4 45 62 ± 1
(49.16 lbf) (39.45 lbf)
2 Bolt 20.6 15.19
3 Bolt 44.1 32.52
4 Bolt 44.1 32.52
40-48 WA180-3MC
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
12
STEERING CYLINDER MOUNT
Unit: mm

Tolerance Standard
Standard size Clearance limit
Shaft Hole clearance
1 Clearance between mounting pin and
-0.050 +0.142
bushing at connection of steering 35 0.130 - 0.222 1.0
-0.080 +0.080
cylinder rod and frame
2 Clearance between mounting pin and
-0.050 +0.142 Replace
bushing at connection of steering 35 0.130 - 0.222 1.0
-0.080 +0.080
cylinder bottom and frame
Standard clearance
Width of boss Width of hinge
(clearance a + b)
Connection between steering Max. 1.0
3 45+ 0.8
0 48 ± 1.5
cylinder and front frame (after adjusting with shim)
4 Connection between steering cylinder Max. 1.0
45+ 0.8
0 48 ± 1.0
and rear frame (after adjusting with shim)
WA180-3MC 40-49
MAINTENANCE STANDARD BRAKE BOOSTER
12
BRAKE BOOSTER
Unit: mm
40-50 WA180-3MC
MAINTENANCE STANDARD BRAKE BOOSTER
12 Unit: mm

size clearance
Shaft Hole
Clearance between primary -0.025 +0.062

1 33.34 0.025 - 0.126 0.15
piston and body -0.064 0
Clearance between secondary pis- 0.025 +0.062

2 33.34 0.025 - 0.126 0.15
ton and body 0.064 0
Clearance between power piston -0.060 +0.074
3 70 0.060 - 0.180 0.20
and body -0.106 0
Free Installed
Installed load Free length Installed load Replace
length height
85.3 N 85.3 ± 12.7 N
4 Primary piston spring 57.1 35.1 ---
(19.1 lbf) (19.1 ± 2.8 lbf)
129.4 N 129.4 ± 18.6

5 Secondary piston spring 72.8 48.3 ---
(29.0 lbf) (29.0 ± 4.1 lbf)
294 N 294 ± 44.1 N
6 Spring 199.2 86 ---
(66.0 lbf) (66.0 ± 9.9 lbf)
196 N 196 ± 29.4 N
7 Spring 143.75 80.25 ---
(44.0 lbf) (44.0 ± 6.6 lbf)
98 N 98 ± 18.6 N
8 Reaction spring 48 40 ---
(22.0 lbf) (22.0 ± 4.1 lbf)
9 Bolt 26.5 ± 12.8 19.5 ± 9.4
10 Bolt 26.5 ± 12.8 19.5 ± 9.4
11 Bolt 32.4 ± 2.0 23.8 ± 1.4
12 Bolt 10.8 ± 2.0 7.9 ± 1.4
WA180-3MC 40-51
MAINTENANCE STANDARD BRAKE
12
BRAKE
Unit: mm
0
1 Thickness of inner ring 6.6 5.8
-0.05
Thickness of brake disc 8.697 ± 0.063 7.4

Replace
2 Depth of lining groove 0.838 ± 0.2 0.4
Thickness of lining 1.08 0.89 (min.) ---
3 Thickness of outer ring 19.5 ± 0.12 0.3
40-52 WA180-3MC
MAINTENANCE STANDARD PARKING BRAKE
12
PARKING BRAKE
Unit: mm
Thickness 1.7 ± 0.05 1.6

1 Plate
Distortion --- 0.1 0.1
Thickness 2.2 ± 0.08 1.97
Depth of lin- +0.175 Replace

0.45 0.3
2 Brake disk ing groove 0
Lining
0.5 ± 0.075 ---
thickness
3 Wave spring load 1010 N

± 98 N 814 N
(Height: 2.2 mm)
WA180-3MC 40-53
MAINTENANCE STANDARD HYDRAULIC PUMP (SAL40+14+8)
12
HYDRAULIC PUMP (SAL40+14+8)
Torque values
Item lbf ft Nm
a 44 - 55 59 - 74
b 20 - 25 27 - 34
Pump Specification
Pump model SA (2) SB (1) SB (1) ---

Theoretical displacement cm3/rev 40.2 14.2 8.0 ---
Max discharge pressure 210kg/cm2 (2986.9 lbf/in2)
Max Speed rpm 3000
Temperature range ° C (° F) -30 ∼ 120 (-22 ∼ 248)
Oil temperature ° C (° F) 50 (122) 80 (176) 50 (122) 80 (176) 50 (122) 80 (176) ---
3000 92% 90% 90% 88% 88% 82% Volumetric

80% 80% 76% 76% efficiency per
1500 84% 64%
Speed rpm cent at max
60% 60% 52% 52% discharge
750 68% 28%
pressure
Remark: Hydraulic oil E010-CD
40-54 WA180-3MC
MAINTENANCE STANDARD MAIN CONTROL VALVE
12
MAIN CONTROL VALVE
2-SPOOL VALVE
WA180-3MC 40-55
12
40-56 WA180-3MC
12 Unit: mm
No. Criteria Remedy
Free Installed Installed Free

load Installed load Replace
length length length
41.1 mm 32.6 mm 258.9 N 39.4 mm 206.9 N

1 Relief valve spring
(1.618 in) (1.28 in) (58 lbf) (1.55 in) (47 lbf)
Torque
Item lbf ft Nm
a 51 - 72 69 - 98
b 51 ± 7 68.6 ± 10
c 43 - 58 59 - 78
d 65 - 90 88 - 123
e 36 - 44 49 - 59
f 87 - 119 118 - 162
g 4-6 5-8
h 123 ± 7 167 ± 10
j 43 ± 7 59 ± 10
k 7 - 11 12 - 15
WA180-3MC 40-57
12
3-SPOOL VALVE
40-58 WA180-3MC
12
WA180-3MC 40-59
12 Unit: mm
No. Criteria Remedy
Free Installed Installed Free

load Installed load Replace
length length length
41.1 mm 32.6 mm 258.9 N 39.4 mm 206.9 N

1 Relief valve spring
(1.618 in) (1.28 in) (58 lbf) (1.55 in) (47 lbf)
Torq
Item lbf ft Nm
a 51 - 72 69 - 98
b 51 ± 7 68.6 ± 10
c 43 - 58 59 - 78
d 65 - 90 88 - 123
e 36 - 44 49 - 59
f 87 - 119 118 - 162
g 4-6 5-8
h 123 ± 7 167 ± 10
j 43 ± 7 59 ± 10
k 7 - 11 12 - 15
40-60 WA180-3MC
MAINTENANCE STANDARD HYDRAULIC CYLINDER
12
HYDRAULIC CYLINDER
Unit: mm

size clearance
Shaft Hole
-0.030 +0.271
Boom 70 0.105 - 0.375 0.675
-0.104 +0.075
Clearance Replace
between -0.030 +0.271
1 Bucket 70 0.105 - 0.375 0.675
piston rod and -0.104 +0.075
bushing
-0.025 +0.132
Steering 40 0.031 - 0.219 0.519
-0.087 +0.006
Boom 932 ± 93.2 687.4 ± 68.7
2 Cylinder head Bucket 981 ± 98.1 723.5 ± 72.3
Steering 785 ± 78.5 578.9 ± 57.8
Boom 1765 ± 176.5 1301.8 ± 130.1
3 Nut Bucket 2599 ± 259.9 1916.9 ± 191.6
Steering 785 ± 78.5 578.9 ± 57.8
WA180-3MC 40-61
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
12
WORK EQUIPMENT LINKAGE
40-62 WA180-3MC
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
12 Unit: mm
size clearance
Shaft Hole
Clearance between pin and -0.025 +0.142
1 50 0.105 - 0.206 1.0
bushing at both ends of bucket link -0.064 +0.080
Clearance between pin and
-0.025 +0.142
2 bushing at connection of boom and 50 0.105 - 0.206 1.0
-0.064 +0.080
bucket
-0.030 +0.142
3 bushing at connection of and boom 60 0.110 - 0.218 1.0
-0.076 +0.080
and frame
Clearance between pin and Replace
-0.030 +0.142
4 bushing at connection of bucket 60 0.110 - 0.206 1.0 (Replace also if
-0.076 +0.080
cylinder bottom and frame there is scuffing of
Clearance between pin and pin)
-0.025 +0.142
5 bushing at connection of bucket 50 0.105 - 0.218 1.0
-0.076 +0.080
cylinder rod and bellcrank
-0.030 +0.174
6 bushing at connection of bellcrank 65 0.130 - 0.250 1.0
-0.076 +0.100
and boom
7 Clearance between pin and
-0.030 +0.174
bushing at connection of boom 60 0.130 - 0.250 1.0
-0.076 +0.100
cylinder bottom and frame
8 Clearance between pin and
-0.030 +0.174
bushing at connection of boom 60 0.130 - 0.250 1.0
-0.076 +0.100
cylinder rod and boom
Standard clearance
Width of boss Width of hinge
(Clearance a + b)
9 Connection of boom and bucket 85 ± 1.8 83 +3

0 1.2 - 7.8 Insert shims on both
sides so that clear-
Connection of bucket link and
10 83 +2.2
-0.6 88 ± 1.5 1.3 - 7.1 ance is less than 0.5
bucket mm on both left and
Connection of bellcrank and bucket right
11 83 +2.2
-0.6 88 ± 1.5 0.7 - 4.5
link
12 Connection of bellcrank and boom 200 ± 0.5 204 ± 1.5 2.0 - 6.0
Connection of bucket cylinder and
13 80 +0.8
0 83 ± 1.5 0.7 - 4.5
frame
Connection of boom cylinder and Clearance less than
14 85 +0.8
0
88 +3
0 2.2 - 6.0 1.5 mm
frame
15 Connection of boom and frame 85 +0.8

0
88 +3
0 1.2 - 7.8
Connection of boom and boom Clearance less than

16 85 +0.8
0 89 ± 0.8 1.4 - 6.6
cylinder 2.0 mm
Connection of bucket cylinder and
17 85 +0.8
0 88 ± 1.5 0.7 - 4.5 Replace
bellcrank
WA180-3MC 40-63
MAINTENANCE STANDARD BUCKET
12
BUCKET
Unit: mm

Replace
1 Wear of cutting edge 22 15.5
2 Nut 460.9 ± 68.6 339.9 ± 50.5
40-64 WA180-3MC
MAINTENANCE STANDARD BUCKET
12
MEMORANDUM
WA180-3MC 40-65
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-
12
BUCKET POSITIONER AND BOOM KICK-OUT
40-66 WA180-3MC
12 Unit: mm
1 Clearance at bucket positioner switch

3 - 7 mm (There must be no interference)
2 Clearance at boom kick-out switch Adjust
3 Clearance between lever and guide 0.5 - 2.0 mm
4 Bolt 110.3 ± 12.3 81.3 ± 9.0
5 Bolt 17.7 ± 2.0 13.0 ± 1.4
6 Bolt 17.7 ± 2.0 13.0 ± 1.4
7 Bolt 110.3 ± 12.3 81.3 ± 9.0
WA180-3MC 40-67
12
MEMORANDUM
40-68 WA180-3MC
90 OTHERS
ELECTRICAL WIRING DIAGRAM (1/5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-3

ELECTRICAL WIRING DIAGRAM (5/5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-11
WA180-3MC 90-1
OTHERS
12
MEMORANDUM
90-2 WA180-3MC
OTHERS FOLDOUT 10-159
12
WA180-3MC 90-3
OTHERS MEMORANDUM
MEMORANDUM
90-4 WA180-3MC
12
WA180-3MC 90-5
OTHERS MEMORANDUM
MEMORANDUM
90-6 WA180-3MC
12
WA180-3MC 90-7
OTHERS MEMORANDUM
MEMORANDUM
90-8 WA180-3MC
12
WA180-3MC 90-9
OTHERS MEMORANDUM
MEMORANDUM
90-10 WA180-3MC
12
WA180-3MC 90-11
OTHERS MEMORANDUM
MEMORANDUM
90-12 WA180-3MC
DataKom Publishing Corporation
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications PROPOSAL FOR MANUAL OR CSS REVISION
Fax No. (847) 970-4186
DATE: FOR INTERNAL USE ONLY -- No. PMR
P NAME OF COMPANY: CITY:

R
O STATE OR PROVINCE::
P
O DEPARTMENT: COUNTRY:
S
E
NAME: FAX NO:
R
MANUAL DESCRIPTION: CSS PROGRAM - e.g: Lookup, Parts or Service
MANUAL OR CSS CD NO: CSS PROGRAM RELEASE VERSION:
MANUAL OR CSS CD ISSUE DATE: CSS BOOK PUBLISHER:
BOOK DESCRIPTION
MACHINE MODEL & S/N:
MANUAL SECTION/PAGE NUMBERS OR CSS REFERENCE & PAGE NUMBERS:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PROPFREV.WPD 012100

Pa Carregadeira Avance (Wa 180)

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Pa Carregadeira Avance (Wa 180)

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CEBM005002

SERIAL NUMBERS WA180-3MC - A81001 and UP

November 2001 Copyright 2001 Komatsu

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING, ADJUSTING AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:

PARTS BOOK - MICROFICHE:

OPERATION AND MAINTENANCE MANUAL:

Machine specific . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WLT70-1

STREET ADDRESS ORDER DATE

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

KDC91E 072199 CURRENT PRICES WILL BE CHARGED

● Page to be replaced Replace

( ) Page to be deleted Discard

● 00-1 2 01-4 10-15 10-43

00-2 01-5 10-16 10-44

● 00-2-1 2 01-6 10-17 10-45

● 00-2-2 2 01-7 10-18 10-46

● 00-2-3 2 01-8 10-19 10-47

● 00-2-4 2 ● 01-9 2 10-20 10-48

● 00-2-5 2 ● 01-10 2 10-21 10-49

● 00-2-6 2 01-11 10-22 10-50

00-3 01-12 10-23 10-51

00-4 01-13 10-24 10-52

00-5 01-14 10-25 10-53

00-6 01-15 10-26 10-54

00-7 01-16 10-27 10-55

00-8 10-28 10-56

00-9 10-1 10-29 10-57

00-10 10-2 10-30 10-58

00-11 10-3 10-31 10-59

00-12 10-4 10-32 10-60

00-13 10-5 10-33 10-61

00-14 10-6 10-34 10-62

00-15 10-7 10-35 10-63

00-16 10-8 10-36 10-64

00-17 10-9 10-37 10-65

00-18 10-10 10-38 10-66

10-11 10-39 10-67

● 01-1 2 10-12 10-40 10-68

● 01-2 2 10-13 10-41 10-69

01-3 10-14 10-42 10-70

WA180-3MC WA180-3MC 00-2-1 2

10-71 10-104 10-137 20-1 1

10-73 10-106 10-139 20-3 1

10-74 10-107 10-140 20-4 1

10-76 10-109 10-142 20-6 1

10-77 10-110 10-143 20-7 1

10-79 10-112 10-145 20-9 1

10-80 10-113 10-146 20-10 1

10-81 10-114 10-147 20-11 1

10-83 10-116 10-149 20-13 1

10-84 10-117 10-150 20-14 1

10-86 10-119 10-152 20-16 1

10-87 10-120 10-153 20-17 1

● 10-89 2 10-122 10-155 20-19 1

● 10-90 2 10-123 10-156 20-20 1

10-92 10-125 10-158 20-22 1

10-93 10-126 10-159 20-23 1

10-95 10-128 10-161 20-25 1

10-96 10-129 10-162 20-26 1