Professional Documents
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WA800L 3 - Sn52001and Up
WA800L 3 - Sn52001and Up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice.
© 2004
All Rights Reserved
Printed in Japan 05-04 (01)
00-1
(1)
GENERAL
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
00-2 WA800L-3
(1)
LIST OF REVISED PAGES
WA800L-3 00-2-1
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LIST OF REVISED PAGES
00-2-2 WA800L-3
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LIST OF REVISED PAGES
Q 20-243 (1) Q 20-316 (1) Q 20-506 (1) Q 20-609 (1) Q 20-721 (1)
Q 20-244 (1) Q 20-317 (1) Q 20-507 (1) Q 20-610 (1) Q 20-722 (1)
Q 20-245 (1) Q 20-318 (1) Q 20-508 (1) Q 20-611 (1) Q 20-723 (1)
Q 20-246 (1) Q 20-319 (1) Q 20-509 (1) Q 20-612 (1) Q 20-724 (1)
Q 20-247 (1) Q 20-320 (1) Q 20-510 (1) Q 20-613 (1) Q 20-725 (1)
Q 20-248 (1) Q 20-321 (1) Q 20-511 (1) Q 20-614 (1) Q 20-726 (1)
Q 20-249 (1) Q 20-322 (1) Q 20-512 (1) Q 20-615 (1) Q 20-727 (1)
Q 20-250 (1) Q 20-323 (1) Q 20-513 (1) Q 20-616 (1) Q 20-728 (1)
Q 20-251 (1) Q 20-514 (1) Q 20-617 (1) Q 20-729 (1)
Q 20-252 (1) Q 20-401 (1) Q 20-515 (1) Q 20-618 (1) Q 20-730 (1)
Q 20-254 (1) Q 20-402 (1) Q 20-516 (1) Q 20-619 (1) Q 20-731 (1)
Q 20-255 (1) Q 20-404 (1) Q 20-517 (1) Q 20-620 (1)
Q 20-256 (1) Q 20-405 (1) Q 20-518 (1) Q 20-621 (1) Q 20-801 (1)
Q 20-257 (1) Q 20-406 (1) Q 20-519 (1) Q 20-622 (1) Q 20-802 (1)
Q 20-258 (1) Q 20-407 (1) Q 20-520 (1) Q 20-623 (1) Q 20-803 (1)
Q 20-259 (1) Q 20-408 (1) Q 20-521 (1) Q 20-624 (1) Q 20-804 (1)
Q 20-260 (1) Q 20-409 (1) Q 20-522 (1) Q 20-625 (1) Q 20-805 (1)
Q 20-261 (1) Q 20-410 (1) Q 20-523 (1) Q 20-626 (1) Q 20-806 (1)
Q 20-262 (1) Q 20-411 (1) Q 20-524 (1) Q 20-627 (1) Q 20-807 (1)
Q 20-263 (1) Q 20-412 (1) Q 20-525 (1) Q 20-808 (1)
Q 20-264 (1) Q 20-413 (1) Q 20-526 (1) Q 20-701 (1) Q 20-809 (1)
Q 20-265 (1) Q 20-414 (1) Q 20-527 (1) Q 20-702 (1) Q 20-810 (1)
Q 20-266 (1) Q 20-415 (1) Q 20-528 (1) Q 20-703 (1) Q 20-811 (1)
Q 20-267 (1) Q 20-416 (1) Q 20-529 (1) Q 20-704 (1) Q 20-812 (1)
Q 20-417 (1) Q 20-530 (1) Q 20-705 (1) Q 20-813 (1)
Q 20-301 (1) Q 20-418 (1) Q 20-531 (1) Q 20-706 (1) Q 20-814 (1)
Q 20-302 (1) Q 20-419 (1) Q 20-532 (1) Q 20-707 (1) Q 20-815 (1)
Q 20-303 (1) Q 20-420 (1) Q 20-533 (1) Q 20-708 (1) Q 20-816 (1)
Q 20-304 (1) Q 20-421 (1) Q 20-534 (1) Q 20-709 (1) Q 20-817 (1)
Q 20-305 (1) Q 20-422 (1) Q 20-535 (1) Q 20-710 (1) Q 20-818 (1)
Q 20-306 (1) Q 20-423 (1) Q 20-536 (1) Q 20-711 (1) Q 20-819 (1)
Q 20-307 (1) Q 20-424 (1) Q 20-712 (1) Q 20-820 (1)
Q 20-308 (1) Q 20-425 (1) Q 20-601 (1) Q 20-713 (1) Q 20-821 (1)
Q 20-309 (1) Q 20-426 (1) Q 20-602 (1) Q 20-714 (1)
Q 20-310 (1) Q 20-427 (1) Q 20-603 (1) Q 20-715 (1) Q 20-901 (1)
Q 20-311 (1) Q 20-604 (1) Q 20-716 (1) Q 20-902 (1)
Q 20-312 (1) Q 20-501 (1) Q 20-605 (1) Q 20-717 (1) Q 20-904 (1)
Q 20-313 (1) Q 20-502 (1) Q 20-606 (1) Q 20-718 (1) Q 20-905 (1)
Q 20-314 (1) Q 20-503 (1) Q 20-607 (1) Q 20-719 (1) Q 20-906 (1)
Q 20-315 (1) Q 20-504 (1) Q 20-608 (1) Q 20-720 (1) Q 20-907 (1)
WA800L-3 00-2-3
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LIST OF REVISED PAGES
00-2-4 WA800L-3
(1)
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
Sealing surface
mm mm Nm kgm
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
00-13
FOREWORD STANDARD TIGHTENING TORQUE
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
02 19 34 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
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
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
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
0 1 2 3 4 5 6 7 8 9
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 GENERAL
WA800L-3 01-1
GENERAL GENERAL ASSEMBLY DRAWING
01-2 WA800L-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Travel speed
REVERSE 1st km/h 7.1
REVERSE 2nd km/h 12.4
REVERSE 3rd km/h 28.3
Max. rimpull kN {kg} 588.4 {60,000}
Gradeability deg 25
Tread mm 3,350
Min. ground clearance mm 550
Height of bucket hinge pin mm 6,785
Dumping clearance (tip of tooth) mm 4,715
Dumping reach (tip of tooth) mm 2,375
Bucket dump angle deg 50 (Max. height)
Bucket tilt angle (SAE carrying position) deg 50
Digging depth (10° dump) (tip of tooth) mm 540
WA800L-3 01-3
GENERAL SPECIFICATIONS
Model SAA12V140ZE-2
4-cycle, water-cooled, V type,
Type 12-cylinder direct injection,
with 2-turbocharger, air-cooled after-cooler
No. of cylinders - bore x stroke mm 12 – 140 x 165
Piston displacement l {cc} 30.48 {30,480}
Flywheel horsepower kW/rpm {HP/rpm} 603/2,000 {808/2,000}
Engine
hydraulically actuated
Mounted on front axle input shaft, dry disc,
Parking brake
hydraulically release spring apply
01-4 WA800L-3
GENERAL SPECIFICATIONS
421
Torque converter, transmission pump l/min
(Gear type: SAR(4)112+SAR(3)100)
307
Steering pump l/min
(Fixed capacity piston pump: HPF76+71)
Hydraulic pump
405
Switch pump l/min
delivery
31.4 {320}
Steering demand valve MPa {kg/cm2}
(Fully hydraulic type)
3.7 {38}
PPC valve MPa {kg/cm2}
(2-lever type)
31.4 {320}
Main control valve MPa {kg/cm2}
(2-spool type)
Reciprocating piston
Steering cylinder No. - bore x stroke mm
2 – 160 x 503
Cylinder
Reciprocating piston
Boom cylinder No. - bore x stroke mm
2 – 260 x 1,368
Reciprocating piston
Bucket cylinder No. - bore x stroke mm
1 – 300 x 906
equipment
WA800L-3 01-5
GENERAL WEIGHT TABLE
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine 3,050
Radiator 1,200
Torque converter 590
Transmission 2,300
Damper 178
Upper drive shaft 58
Center drive shaft 204
Front drive shaft 186
Rear drive shaft 204
Center support 165
Front axle 8,190
Rear axle 7,700
Front differential assembly 1,226
Rear differential assembly 1,256
Planetary carrier assembly (each) 238
Planetary hub assembly (each) 600
Axle pivot (Rear axle) 286
Wheel (each) 874
Tire (each) 2,630
Steering demand valve 66
Steering cylinder (each) 206
Hydraulic tank 824
Work equipment pump 150
Parking brake assembly 185
Torque converter charging + PPC + brake pump 49
Switch pump 157
Steering pump 145
Fender and guard assembly 1,393
PPC valve 4
Main control valve (each) 95
Boom cylinder (each) 998
Bucket cylinder 1,210
110 (Top)
Engine hood
29 (Side)
Front frame 7,340
01-6 WA800L-3
GENERAL WEIGHT TABLE
Unit: kg
WA800L-3 01-7
GENERAL LIST OF LUBRICANT AND WATER
Note 1:
For axle oil, use only recommended oil as follows.
SHELL: DONAX TD
MOBILE: MOBILFLUID 424
ESSO: TORQUE FLUID 56
It is possible to substitute engine oil CLASS-CD SAE30 for axle oil.
If noise comes from the brake, it is no problem of durability.
a In cold areas when the hydraulic oil temperature is low, if the steering wheel is turned and the machine is
stopped in that position, there may be a time lag before the machine turns and stops.
If this happens, turn the steering wheel slowly to the left and right (repeat for about 10 minutes) and the oil
inside the steering valve will be warmed up.
*1: [When working in particularly severe conditions, use a multi-purpose grease containing 3 – 5% molybde-
num.
*2: For machines equipped with an auto-grease system, if the machine is operated in temperatures below
–20°C, use lithium-based grease No. 0 for the grease.
REMARK
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
ASTM: American Society of Testing and Material API: American Petroleum Institute
SAE: Society of Automotive Engineers NLGI: National Lubricating Grease Institute
01-8 WA800L-3
GENERAL LIST OF LUBRICANT AND WATER
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 criti-
cal factors in maintaining engine performance and durability.
Komatsu Engine Oil or multi-viscosity engine oil meeting American Petroleum Institute (API) performance
classification CF-4, CG-4, CF-4/SG or CG-4/SH or MIL-L-2104D or E is recommended.
NOTICE:
Classification CD, CE, CD/SF or CE/SF oils may be used in areas where CF-4, CG-4, CF-4/SG or CG-
4/SH oil is not yet available. If API classification CC or CC/CD is used, reduce the engine oil change
interval by half.
A sulfated ash limit of 1.0 to 1.5 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 excessive oil consumption.
The API service symbol displays the following information. The upper half of the symbol displays the appro-
priate oil categories; the lower half may contain words to describe oil energy conserving features. The cen-
ter section identifies the SAE oil viscosity grade.
The use of a multi-grade 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
table for oil viscosity recommendations for extreme climates.
NOTICE:
Limited use of low viscosity oils, such as SAE 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 vis-
cosity oils can decrease engine life due to wear.
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 Automotive and Industrial Engines." The data book may be ordered from the
Engine Manufacturers Association, 401 North Michigan Ave., Chicago, II U.S.A. 60611. 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 engine oil API performance classification
CF-4, CG-4, CF-4/SG or CG-4/SH with adequate low temperature properties such as SAE 5W-20 or 5W-30.
The oil supplier must be responsible for meeting the performance service specifications.
NOTICE:
The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change inter-
vals can decrease engine life due to factors such as corrosion, deposits and wear.
WA800L-3 01-9
GENERAL LIST OF LUBRICANT AND WATER
Komatsu Engine Oil or engine oil meeting American Petroleum Institute (API) performance classification CF-4,
CG-4, CF-4/SG or CG-4/SH or MIL-L-2104D or E is recommended.
NOTICE:
Classification CD, CE, CD/SF or CE/SF oils may be used in areas where CF-4, CG-4, CF-4/SG or CG-4/SH
oil is not yet available.
k WARNING
Never mix gasoline, gasohol and/or alcohol with diesel fuel. This practice creates an extreme fire
hazard and under certain conditions an explosion which could result in personal injury or death.
k WARNING
Never remove the fuel tank filler cap or refill the fuel tank while the engine is running or when hot or
when the machine is indoors. Fumes are dangerous, a spark or flame could result in a fire or explo-
sion.
NOTICE:
The precise tolerances of diesel fuel injection systems demand that the fuel be kept clean and free of
contaminates or water. Contaminates or water in the system can cause severe damage to both the
injection pump and nozzles.
REMARK:
Below –12°C (+10°F) the paraffin in ASTM Grade No. 2-D diesel fuel will change to wax particles and
clog the fuel filters. For best results use Grade No. 1-D diesel fuel in cold weather.
For normal service above –10°C (+14°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 tempreatures below –10°C (+14°F) or extended engine idling, 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 tem-
perature. 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.
01-10 WA800L-3
GENERAL LIST OF LUBRICANT AND WATER
Optionally, the equivalent grades of recognized Federal Government specifications may be used; the latest revi-
sions of VV-F-800a.
COOLANT SPECIFICATIONS
GENERAL
Selection and maintenance of the engine coolant is important to long engine life. The following information pro-
vides recommendations for selecting the engine coolant and maintaining the supplemental coolant additives
(SCA).
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant
additives. The coolant mixture must be drained and replaced at the specified service interval or every two years
of operation, whichever comes first.
WATER
Use water which has a low mineral content. Water used 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 depos-
its. Water containig dissolved magnesium and calcium (the usual reason for water hard-
ness) 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.
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. Soft-
ened water that is prepared using common salt (sodium chloride) contains excessive amounts of chlorides and
should not be used.
NOTICE:
Never use water alone in the cooling system because rust, scale deposits and corrosion will occur.
ANTIFREEZE
Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant
freezing point and by raising its boiling point.
In climates where the temperature is above –34°C (–30°F), use a coolant mixture that contains 50 percent anti-
freeze. 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 concentrations 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.
Ethylene glycol, low silicate 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 sili-
cate antifreeze and/or supplemental coolant additive. DO NOT use methanol or alcohol, which has an unac-
ceptably low boiling point.
Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to
maintain corrosion protection.
Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system.
WA800L-3 01-11
GENERAL LIST OF LUBRICANT AND WATER
NOTICE:
Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protec-
tion against freezing. Antifreeze containing sealer or anti-leak additives should NOT be used in this sys-
tem. Sealer or anti-leak additives will cause plugging problems in the cooling system.
k WARNING
Use extreme caution when adding coolant to a hot radiator to avoid being burned. Wear gloves and
goggles and keep face away from the filler neck.
Check the solution periodically and at normal operating temperature, to be sure the cooling system has suffi-
cient protection against freezing. An antifreeze concentration greater than 68% will adversely affect antifreeze
protection and heat transfer rates. Antifreeze concentrations between 68% and 100% actually have a higher
freezing points than a 68% antifreeze concentration as well as reduced heat transfer rates and should not be
used.
REMARK:
Do not use a 100% antifreeze solution for freezing protection. This willl cause severe corrosion in the
cooling system and if not detected will cause radiator and oil cooler core damage. Use a water/anti-
freeze solution as described in the following table.
The following table shows the approximate percentage of antifreeze solution required for various temperatures.
Percentage of Antifreeze
Approximate Freezing Point 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 or supplemental cool-
ant additive (SCA), to protect the engine cooling system.
01-12 WA800L-3
GENERAL LIST OF LUBRICANT AND WATER
2. SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer and
allow internal engine damage.
3. There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is
still the best coolant.
4. A corrosion inhibitor/conditioner 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 oc-
curs.
• Provides engine protection in the following areas:
- Solder corrosion/bloom
- Oil fouling
- Aluminum caviation/corrosion
- Copper corrosion/erosion/stress cracking
- Cylinder liner caviation corrosion
- Seal and gasket degradation
New machines are delivered with antifreeze protection. Service at a regular scheduled interval specified in the
Operation and Maintenance Manual.
Each time the coolant is drained and replaced, the coolant must be recharged with supplemental coolant addi-
tives. New coolant can be correctly charged with coolant additives by using a replacement coolant filter and/or
concentrate.
If coolant is added between drain intervals, additional coolant additives may be required.
NOTICE:
Inadequate concentration of the coolant additive can result in major corrosive damage to cooling sys-
tem components. Over-concentration can cause formation of gel that can cause restriction, plugging of
passages and overheating.
NOTICE:
Mixing of DCA4 and other supplemental coolant additives is not recommended because there is cur-
rently no test kit available to measure concentration levels with mixed chemical solutions.
WA800L-3 01-13
GENERAL LIST OF LUBRICANT AND WATER
To protect against corrosion, a new coolant charge must be brought up to 0.26 SCA unit per liter [one unit per
U.S. gallon] of coolant (initial charge). Maintain the correct SCA concentration by changing the service coolant
filter at each engine oil and filter change interval.
Each time the coolant is drained and replace, the coolant must be recharged with supplemental coolant addi-
tives. Use the appropriate replacement coolant filter listed in following tables. The coolant mixture must be
drained and replaced as defined under "General."
The amout of a 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 SCA.
If coolant is added between drain intervals, additional SCA will be required. Check the coolant DCA concentra-
tion level anytime make up coolant is added to the system. The SCA concentration must not fall below 0.13
units per liter or exceed 0.5 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].
NOTE 1: After draining and replacing coolant, always precharge the cooling system to maintain the SCA con-
centration between 1.0 and 2.0 units per 3.8 liters (1 US gal).
01-14 WA800L-3
GENERAL LIST OF LUBRICANT AND WATER
NOTICE:
When performing service which requires draining the cooling system, discard the coolant. Reusing
coolant can introduce contaminants or over-concentrated chemicals and result in premature failure of
cooling system components.
NOTE 2: To precharge cooling systems larger than 114 liters (30 gal) do the following:
• Install appropriate service filter listed in the above table based on cooling system capacity.
Example: 95 gal (360 liter) 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 SCA units (80) to precharge the ex-
ample 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 SCA concentration of 1.0 unit per 3.8 liters (1 US gal) of coolant in the system. Less than 0.5
units per 3.8 liters (1 US gal) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8 liters
(1 US gal) indicates an over-concentrated coolant solution.
To check the SCA concentration level, use Coolant Test Kit CC-2626. Instructions are included with the test kit.
WA800L-3 01-15
10 STRUCTURE AND FUNCTION
WA800L-3 10-1
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
OUTLINE
• The power from engine (16) is transmitted from • The output shaft of transmission (10) transmits
the flywheel to damper (15) through the ring the power to the output shaft of transfer (9)
gear. The damper alleviates the torsional vibra- through the gear. The power from the output
tion caused by the variation of the engine torque shaft of the transfer is transmitted to both the
and transmits the power to torque converter (11) front axle (5) and the rear axle (21).
through upper drive shaft (14). The torque con- In the front section of the chassis, the power is
verter converts the delivered torque according to transmitted to front axle (5) through center drive
the variation in load on the oil used as the medi- shaft (7) and front drive shaft (6).
um, and transmits the power to the input shaft of In the rear section, the power is transmitted to
transmission (10). Then, the engine power is rear axle (21) through rear drive shaft (24).
transmitted to steering pump (12), main pump • The power transmitted to front axle (5) and rear
(13), switch pump (17), and torque converter axle (21) is reduced through pinion and ring
charging pump + PPC pump + brake pump (18) gears in differential (22) and (1), and is transmit-
through the pump driving gear in torque convert- ted to the axle shafts.
er (11), thereby driving the pumps. • The power from the axle shafts is reduced
• In transmission (10), the five hydraulically-oper- through final drive (19) and (3) and transmitted
ated clutches are operated by the forward-re- to wheel (20) and (4) through the planetary carri-
verse spool and the speed change spools in the er.
transmission valves, which are themselves acti-
vated by solenoid valves. Thus, the desired trav-
el speed can be selected from among the 3
forward and 3 reverse gear speeds.
10-2 WA800L-3
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
WA800L-3 10-3
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
1. Accelerator pedal
2. Harness
OUTLINE
1. Engine speed is controlled electronically. The 2. An engine low idling selection feature is used,
foot pedal contains an electronic sensor which and when the selection switch is operated, the
signals to the engine control module. One cir- engine low idling speed can be switched in two
cuit signal indicates whether the pedal is at idle stages.
(released) position or not. The other circuit pro- 1) The engine low idling speed is set to
vides voltage signal that corresponds to the approximately 650 rpm. Use for normal
pedal's angular position. operations such as when waiting for a dump
truck at low idling speed o OFF.
2) The engine low idling speed is set to
approximately 900 rpm. Used on busy job
sites where it is needed to reduce the cycle
time o ON.
10-4 WA800L-3
STRUCTURE AND FUNCTION RADIATOR AND COOLER
10-6 WA800L-3
STRUCTURE AND FUNCTION RADIATOR AND COOLER
WA800L-3 10-7
STRUCTURE AND FUNCTION DAMPER
DAMPER
1. Shaft FUNCTION
2. Breather • The damper reduces the torsional vibration
3. Rubber cushion caused by changes in the engine torque, and
4. Inner body acts to protect the units of the power train be-
5. Outer body yond the engine from the effects of torsional vi-
bration.
OPERATION
• The power of the engine is transmitted from the
flywheel to outer body (5). The torsional vibra-
tion of the engine is absorbed by rubber cushion
(3), passes through inner body (4) and shaft (1),
and is transmitted to the upper drive shaft be-
tween the torque converter.
10-8 WA800L-3
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRNSMISSION PIPING
WA800L-3 10-9
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
A. To PPC valve
B. To brake line
C. From hydraulic tank
D. From brake oil tank
10-10 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
WA800L-3 10-11
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
10-12 WA800L-3
STRUCTURE AND FUNCTION TORQUE CONVERTER
9. Turbine SPECIFICATIONS
10. Stator Model: TCA51-1A
11. PTO gear (Teeth 86) Type: 3-element, single stage, single phase
12. Housing Stall torque ratio: 2.84
13. Gear (Teeth 81)
14. Pump
15. Transmission input shaft
16. Gear (Teeth 81)
WA800L-3 10-13
STRUCTURE AND FUNCTION TORQUE CONVERTER
Flow of oil
• The oil pressure is adjusted by the torque con-
verter relief valve and then enters inlet port A,
passes through the oil passage in housing (12)
and flows to pump (14). In pump (14) centrifugal
force is applied. The oil enters turbine (9) and
the energy of the oil is transmitted to the turbine.
Turbine (9) is fixed to transmission input shaft
(15), so the motive force is transmitted to the
transmission input shaft (15).
The oil from turbine (9) is sent to stator (10) and
again enters the pump. However, part of the oil
passes from the stator through outlet port B and
is sent to regulator valve (1).
The oil sent to regulator valve (1) passes
through the oil cooler to be cooled, and is then
used to lubricate the transmission.
10-14 WA800L-3
STRUCTURE AND FUNCTION TORQUE CONVERTER
OUTLINE
• The torque converter relief valve is inside the
transmission valve, and acts to keep the oil en-
tering the torque converter at a constant pres-
sure. If the specified pressure is exceeded, it
drains the oil.
FUNCTION
• The oil from the pump passes through transmis-
sion main relief valve (1), enters port A, and
then flows to the torque converter.
WA800L-3 10-15
STRUCTURE AND FUNCTION TORQUE CONVERTER
1. Valve body
2. Spring
3. Spool
OPERATION
• The oil from the torque converter flows from port
A to port B. However, the hydraulic pressure at
port B is lower than the tension of spring (2), so
spool (3) does not move.
10-16 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
1. Transmission
2. Transmission control valve
3. Transfer
4. Oil filler
5. Transfer output coupling
6. Drain plug
7. Transfer output coupling
WA800L-3 10-17
STRUCTURE AND FUNCTION TRANSMISSION
10-18 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION
1. Input shaft
2. Reverse sun gear (Teeth 26)
3. Reverse ring gear (Teeth 90)
4. Gear (Teeth 90)
5. Reverse clutch
6. Planetary gear (Teeth 30)
7. Ring gear (Teeth 86)
8. Forward sun gear (Teeth 38)
9. Forward clutch
10. Planetary gear (Teeth 26)
11. Forward ring gear (Teeth 90)
12. Sun gear (Teeth 38)
13. Planetary gear (Teeth 26)
14. Ring gear (Teeth 140)
15. Ring gear (Teeth 90)
16. 2nd clutch
17. Planetary gear (Teeth 31)
18. 2nd ring gear (Teeth 140)
19. 2nd sun gear (Teeth 27)
20. Gear (Teeth 89)
21. 1st clutch
22. 1st sun gear (Teeth 27)
23. 1st ring gear (Teeth 89)
24. Planetary gear (Teeth 31)
25. 3rd clutch
26. Hub (Teeth 112)
27. Idle shaft
28. Output shaft
29. 1st carrier
30. 2nd carrier
31. Forward carrier
32. Reverse carrier
WA800L-3 10-19
STRUCTURE AND FUNCTION TRANSMISSION
CLUTCH
OUTLINE
• The transmission consists of a 3-FORWARD, 3-
Speed range Clutch combination
REVERSE speed planetary gear transmission,
transfer, and transmission control valve. F1 F, 1st
• In the transmission, the motive force of the input F2 F, 2nd
shaft is changed by the combination of Forward F3 F, 3rd
or Reverse clutch with 1st, 2nd, 3rd clutch to
give FORWARD 1 – 3 or REVERSE 1 – 3 R1 R, 1st
speed, and is transmitted to the output shaft. R2 R, 2nd
R3 R, 3rd
OPERATION OF CLUTCH
Engaged
The oil sent from the transmission control valve
passes through the oil passage inside the transmis-
sion. When it reaches the rear of piston (2), it moves
piston (2).
When piston (2) moves, disc (4) and plate (5) are
pressed together. Ring gear (6) is meshed with disc
(4), so the rotation is stopped.
Disengaged
When the supply of oil from the transmission control
valve is shut off, the pressure of the oil acting on the
rear of piston (2) is reduced. The piston is then
pushed back to the right by return spring (3), and
disc (4) and plate (5) are separated. Ring gear (6)
then rotates freely, and no motive force is transmit-
ted.
10-20 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 1st
1 8 9 10 11 12 13 15 21 22 23 24 27 28
31 29
SEW01343
• In the case of FORWARD 1st, FORWARD • Ring gear (15) is being held in position, so the
clutch (9) and 1st clutch (21) are engaged. The rotation of carrier (31) is transmitted through
power from the torque converter transmitted to planet gear (13) to sun gear (12). It is also trans-
input shaft (1) is transmitted to output shaft (28). mitted through intermediate shaft (27) to sun
• FORWARD clutch (9) is actuated by the hydrau- gear (22).
lic pressure applied to the clutch piston and • Ring gear (23) is being held in position by 1st
holds ring gear (11) in position. 1st clutch (21) is clutch (21). For this reason, the rotation of sun
actuated by the hydraulic pressure applied to gear (22) is transmitted from carrier (29) through
the clutch piston and holds ring gear (23) in po- planet gear (24) to output shaft (28).
sition.
• The power from the torque converter is transmit-
ted to input shaft (1). The rotation of the input
shaft is transmitted through sun gear (8) to plan-
et gear (10). Ring gear (11) is being held in posi-
tion by FORWARD clutch (9), so the rotation of
planet gear (10) rotates carrier (31).
WA800L-3 10-21
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 2nd
1 8 9 10 11 12 13 15 16 17 18 19 22 23 24 27 28
31 30 29
SEW01344
• In the case of FORWARD 2nd, FORWARD • Ring gear (15) is being held in position, so the
clutch (9) and 2nd clutch (16) are engaged. The rotation of carrier (31) is transmitted through
power from the torque converter transmitted to planet gear (13) to sun gear (12).
input shaft (1) is transmitted to output shaft (28). • It is also transmitted through intermediate shaft
• FORWARD clutch (9) is actuated by the hydrau- (27) to sun gears (19) and (22). Ring gear (18) is
lic pressure applied to the clutch piston and being held in position by 2nd clutch (16). For this
holds ring gear (11) in position. 2nd clutch (16) reason, the rotation of sun gear (19) is transmit-
is actuated by the hydraulic pressure applied to ted through planet gear (17) to carrier (30). It is
the clutch piston and holds ring gear (18) in po- then transmitted to ring gear (23).
sition. • The rotation of ring gear (23) and the rotation of
• The power from the torque converter is transmit- sun gear (22) passes through planet gear (24)
ted to input shaft (1). The rotation of the input and is transmitted to carrier (29). It is then trans-
shaft is transmitted through sun gear (8) to plan- mitted to output shaft (28).
et gear (10).
• Ring gear (11) is being held in position by FOR-
WARD clutch (9), so the rotation of planet gear
(10) rotates carrier (31).
10-22 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 3rd
1 8 9 10 11 12 13 15 25 26 27 28
31
SEW01345
• In the case of FORWARD 3rd, FORWARD • Ring gear (15) is being held in position, so the
clutch (9) and 3rd clutch (25) are engaged. The rotation of carrier (31) is transmitted through
power from the torque converter transmitted to planet gear (13) and goes from sun gear (12) to
input shaft (1) is transmitted to output shaft (28). intermediate shaft (27).
• FORWARD clutch (9) is actuated by the hydrau- • Intermediate shaft (27) and output shaft (28) are
lic pressure applied to the clutch piston and formed into one unit by 3rd clutch (25). For this
holds ring gear (11) in position. 3rd clutch (25) is reason, the rotation of intermediate shaft (27) is
actuated by the hydraulic pressure applied to transmitted to output shaft (28).
the clutch piston and engages output shaft (28)
and hub (26).
• The power from the torque converter is transmit-
ted to input shaft (1). The rotation of the input
shaft is transmitted through sun gear (8) to plan-
et gear (10).
• Ring gear (11) is being held in position by FOR-
WARD clutch (9), so the rotation of planet gear
(10) rotates carrier (31).
WA800L-3 10-23
STRUCTURE AND FUNCTION TRANSMISSION
REVERSE 1st
1 2 5 6 7 12 15 21 22 23 24 27 28
32 31 29
SEW01346
• In the case of REVERSE 1st, REVERSE clutch • Carrier (32) is being held in position by RE-
(5) and 1st clutch (21) are engaged. The power VERSE clutch (5), so the rotation of planet gear
from the torque converter transmitted to input (6) rotates ring gear (7). The direction of rotation
shaft (1) is transmitted to output shaft (28). of ring gear (7) is the opposite of the rotation of
• REVERSE clutch (5) is actuated by the hydrau- the engine.
lic pressure applied to the clutch piston and • The rotation of ring gear (7) is transmitted to car-
holds carrier (32) in position. 1st clutch (21) is rier (31). Ring gear (15) is being held in position,
actuated by the hydraulic pressure applied to so the rotation of carrier (31) is transmitted
the clutch piston and holds ring gear (23) in po- through sun gear (12) to intermediate shaft (27).
sition. Ring gear (23) is being held in position by 1st
• The power from the torque converter is transmit- clutch (21). For this reason, the rotation of sun
ted to input shaft (1). The rotation of the input gear (22) is transmitted from carrier (29) through
shaft is transmitted through sun gear (2) to plan- planet gear (24) to output shaft (28).
et gear (6).
10-24 WA800L-3
STRUCTURE AND FUNCTION TRANSFER
TRANSFER
WA800L-3 10-25
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
10-26 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
STRUCTURE
• The transmission solenoid valve is installed to Actuation table for solenoid valve and clutch
the transmission together with the transmission
F R 1 2 3 4
valve. When the directional lever or speed con-
trol lever are operated, the solenoid valve is ac- F1 Q Q
tuated and moves the spool inside the F2 Q Q
transmission valve. F3 Q Q
N
R1 Q Q
R2 Q Q
R3 Q Q
WA800L-3 10-27
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
LOWER VALVE
10-28 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
UPPER VALVE
OUTLINE
• The oil from the torque converter charging pump • The other oil line flows to modulating valve (17)
enters port A of main relief valve, and passes and quick return valve (14). The action of modu-
through priority valve (11) via by main relief lating valve (17) and quick return valve (14) rais-
valve. It is then divided into three lines; there es the clutch pressure smoothly. This reduces
are; to the clutch pistons, to pilot reducing valve the shock when actuating the FORWARD, RE-
(16) and main relief valve. Priority valve (11) VERSE and 1st, 2nd and 3rd speed clutches to
acts to control the three lines so that pilot reduc- change gear.
ing valve (16) is the priority circuit. • Lubrication valve (15) controls the lubrication oil
• The oil flowing to pilot reducing valve (16) con- inside the transmission.
trols the pilot pressure used to actuate the direc-
tional and speed spools. The oil regulated by
pilot reducing valve (16) presses through the or-
ifice in each spool and fills the spool.
WA800L-3 10-29
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
10-30 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
FUNCTION
• The main relief valve acts to supply the neces-
sary oil to the clutch when shifting gear. When
the gears are not being shifted, it sends all of the
oil directly to the torque converter.
OPERATION
• The oil from the pump passes through the oil fil-
ter and enters port A of main relief valve (1).
• Until the specified pressure is reached, the oil
flows to the priority valve.
WA800L-3 10-31
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
FUNCTION
• The pilot reducing valve acts to control the pres-
sure needed to actuate the transmission spools.
OPERATION
• The oil from the pump passes through the pilot
filter and enters port A of pilot reducing valve
(1). The oil passes through port B and enters
through the orifice of transmission spool (2) to fill
the inside of port C.
10-32 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
FUNCTION
• There is one solenoid valve installed for each di-
rectional and speed spool in the transmission
valve.
When the directional lever and speed control
levers in the operator’s compartment are oper-
ated, the solenoid valve is actuated, and oil is
drained to actuate the directional and speed
spools.
OPERATION
1) Solenoid valve OFF
The oil of spool (2) enters port A. However,
valve (1) shuts off the oil, so directional and
speed spool (2) does not move.
2) Solenoid valve ON
When the directional and gear shift lever are
operated, the solenoid valve is pulled up.
The oil from directional and speed spool (2)
enters port A and flows from port B to the drain
circuit. Therefore, port C becomes the high pres-
sure circuit and port A becomes the low pres-
sure circuit, and directional and speed spool (2)
is moved to the left, and the oil from the quick
return valve flows to the clutch.
WA800L-3 10-33
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
PRIORITY VALVE
FUNCTION
• Priority valve (1) controls the minimum pressure
of pilot reducing valve (2). In addition, priority
valve (1) gives the oil flow to pilot reducing valve
(2) priority over the other circuit.
OPERATION
• The oil from the pump flows to port A of priority
valve (1) and port B of pilot reducing valve (2).
10-34 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
FUNCTION
The modulating valve, and quick return valve act
together to raise the transmission clutch pressure
smoothly. This reduces shock when shifting speed
range, and prevents the generation of peak torque in
the power train. Therefore, operator fatigue is
reduced to give better operating comfort, and at the
same time, the durability of the power train is
increased.
OPERATION
1. Immediately after shifting gear (point A)
When the gear shift lever is operated to engage
the clutch, the passage from the pump to the
clutch cylinder is opened and oil flows to the
clutch cylinder.
Using the force of this flow, quick return valve (2)
moves to the right in the direction of the arrow,
and connects port E and port G. When the back
pressure of piston (3) is removed, the tension of
springs (4) and (5) move modulating valve (1) to
the right in the direction of the arrow. At the
same time, piston (3) is returned to the left in the
direction of the arrow.
WA800L-3 10-35
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
10-36 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
REDUCING VALVE
FUNCTION
• The reducing valve is in the circuit between the
quick return valve and the 3rd speed spool. It
acts to protect the 3rd clutch by reducing the hy-
draulic pressure acting on the 3rd clutch.
The maximum pressure of the oil in the circuit is
set by the transmission main relief pressure.
WA800L-3 10-37
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
FUNCTION
• If there is any failure in the electrical circuit of
the transmission control system, and the sole-
noid valve does not work, the emergency manu-
al spool is used. This spool is attached to each
directional and speed spool and is used to oper-
ate the transmission valve mechanically. (It is
used to drive the machine to a place where it
can be repaired.)
a Particular attention must be paid for when
using this spool.
OPERATION
1. When solenoid valve is normal:
(Emergency manual spool is at normal posi-
tion)
When the solenoid valve is working normally,
the spool is maintained in this position.Oil from
directional and speed spool (1) enters port A,
but it is shut off by solenoid valve (2).
10-38 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
FUNCTION
• The transmission lubrication valve protects the
transmission lubrication circuit from abnormally
high pressure.
OPERATION
• The oil from the oil cooler and torque converter
relief valve passes from port A and lubricates
the transmission. The oil entering port A passes
through orifice a and enters port B.
WA800L-3 10-39
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
FORWARD 1ST
A. To PPC valve
B. To brake line
C. From hydraulic tank
D. From brake oil tank
10-40 WA800L-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
OPERATION
• When the directional and speed control levers • The other oil line flows from priority valve (13) to
are moved to FORWARD 1st, solenoid valves quick return valve (14). It then flows through ori-
(1) and (2) are opened. fice a, and directional and speed spools (11)
• The oil from pumps (3) and (4) is divided into and (12), and flows to the FORWARD clutch
three lines, but when the gears are being and 1st clutch. When it starts to flow to the
changed, the oil flows mainly to each clutch. clutch, it passes through orifice a and creates a
• In one of the three lines, the oil passes from difference in pressure between port C and port
main relief valve (5) through torque converter D. Quick return valve (14) moves to the right,
(6). It then lubricates the transmission and re- and the oil at the rear of modulating valve piston
turns to the transfer case. (17) flows to drain circuit E. When each clutch is
• One of the two oil lines flows from pilot reducing filled with oil, the difference in pressure between
valve (10) through the orifice of each speed port C and port D disappears. The valve is
spool to the solenoid valve. However, solenoid pushed back to the left by the difference in area
valves (1) and (2) of FORWARD spool (11) and of the valves, and drain circuit E is closed.
1st spool (12) are open, so the oil passing At this point, each clutch is filled with oil, but the
through the orifice flows to the drain circuit. As a oil has not reached the specified pressure. The
result, a difference in pressure is created be- oil at port D flows through orifice b and reaches
tween port A and port B, and this overcomes the the back of modulating piston (17). Piston (17)
force of springs. The port to the clutch is then moves to the right and the clutch pressure rises
connected. slowly. When the modulating piston reaches the
end of its stroke, the clutch pressure reaches
the specified level, and the clutch is completely
engaged.
WA800L-3 10-41
STRUCTURE AND FUNCTION torque converter oil cooler
10-42 WA800L-3
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
OUTLINE
• The motive force from the engine passes • When the body is articulated, or when there is
through the damper, upper drive shaft (5), shock from the road surface during traveling, or
torque converter, transmission and transfer. Part when there is shock during operations, the axle
of this motive force passes through rear drive in front and behind the engine and transmission
shaft (4) and goes to the rear axle; the rest of change position.
the motive force passes through center drive To allow the motive force to be transmitted with-
shaft (3), center support (2) and front drive shaft out damage to parts of the machine when there
(1) and is sent to the front axle. In addition to is shock or when the components move posi-
transmitting the motive force, the drive shafts tion, the drive shafts have a universal joint and a
have the following purposes. sliding joint. This allows them to handle changes
in angle and length.
WA800L-3 10-43
STRUCTURE AND FUNCTION CENTER SUPPORT
CENTER SUPPORT
10-44 WA800L-3
STRUCTURE AND FUNCTION AXLE
AXLE
FRONT AXLE
1. Front differential
2. Drain plug
3. Front axle
4. Brake
5. Final drive
6. Parking brake
7. Spring cylinder
WA800L-3 10-45
STRUCTURE AND FUNCTION AXLE
REAR AXLE
1. Rear differential
2. Rear axle
3. Brake
4. Final drive
5. Drain plug
10-46 WA800L-3
STRUCTURE AND FUNCTION DIFFERENTIAL
DIFFERENTIAL
FRONT DIFFERENTIAL
WA800L-3 10-47
STRUCTURE AND FUNCTION DIFFERENTIAL
REAR DIFFERENTIAL
10-48 WA800L-3
STRUCTURE AND FUNCTION DIFFERENTIAL
OUTLINE
• The motive force from the drive shaft passes
through bevel pinion (1) and is transmitted to
bevel gear (5). The bevel gear changes the di-
rection of the motive force by 90¡, and at the
same time reduces the speed. It then transmits
the motive force through differential (4) to axle
shaft (2).
1
2
3
4
5
SEW00077
3
2
4
SEW00078
When turning
• When turning, the rotating speed of the left and
right wheels is different, so pinion gear (4) and 6
side gear (3) inside the differential assembly ro-
tate in accordance with the difference between
the rotating speed of the left and right wheels.
The motive force of carrier (6) is then transmit-
ted to axle shafts (2).
3
2
4
SEW00079
WA800L-3 10-49
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
10-50 WA800L-3
STRUCTURE AND FUNCTION CENTER HINGE PIN
WA800L-3 10-51
STRUCTURE AND FUNCTION AXLE MOUNT
AXLE MOUNT
10-52 WA800L-3
STRUCTURE AND FUNCTION AXLE MOUNT
WA800L-3 10-53
STRUCTURE AND FUNCTION TIRE AND WHEEL
1. Tire OUTLINE
2. Rim • The tires act to absorb the shock that the ma-
3. Valve chine receives from the road surface, and at the
4. Lock ring same time, they provide drive force by rotating
5. Side ring in contact with the ground.
• Depending on the purpose of use, there are var-
ious types of tire available, so it is important to
select the correct tire to match the type of work
and bucket capacity.
SPECIFICATIONS
Tire type: 45/65-45-46PR
TRA code: L5
Nominal wheel: 36.00 x 45WTB
Normal inflation pressure:
515 kPa {5.25 kg/cm2}
10-54 WA800L-3
STRUCTURE AND FUNCTION STEERING PIPING
STEERING PIPING
WA800L-3 10-55
STRUCTURE AND FUNCTION JOYSTICK steering LINKAGE
10-56 WA800L-3
STRUCTURE AND FUNCTION STEERING PUMP
STEERING PUMP
10-58 WA800L-3
STRUCTURE AND FUNCTION STEERING PUMP
WA800L-3 10-59
STRUCTURE AND FUNCTION SWITCH PUMP
SWITCH PUMP
10-60 WA800L-3
STRUCTURE AND FUNCTION SWITCH PUMP
WA800L-3 10-61
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
A. To steering cylinder
B. To steering cylinder
P1. From steering pump
P2. From switch pump
PB. To main control valve
T. To hydraulic tank
(through hydraulic oil cooler)
10-62 WA800L-3
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
FUNCTION
• The overload relief valve is installed in the cylin-
der circuit of the steering demand valve. When
the demand valve is at neutral and any impact is
applied to the steering cylinder and abnormal
pressure is generated, this valve functions as
a safety valve to relieve the circuit to prevent
breakage of the cylinder or hydraulic piping.
It also functions to prevent any vacuum if any
negative pressure is generated at the cylinder
end.
OPERATION
1. Operation of relief valve
• Port A is connected to the cylinder circuit and
port B is connected to the drain circuit. The oil
passes through the hole in poppet (1) and acts
on the area of diameters d1 and d2. Check
valve poppet (3) and relief valve poppet (2) are
securely seated.
WA800L-3 10-63
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
10-64 WA800L-3
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
FUNCTION
• The main relief valve of the steering demand
valve is inside the valve and sets the maximum
pressure in the steering circuit when it is operat-
ed. In other words, when the valve is being op-
erated and the steering circuit goes above the
set pressure of this valve, it relieves the oil and
actuates the flow control spool of the demand
valve to drain the oil to the steering circuit.
WA800L-3 10-65
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
• When the pressure in the circuit rises and reach- • When demand spool (4) moves, the oil from the
es the pressure set by spring (2) and adjustment steering pump is drained and the oil from the
screw (1), pilot poppet (3) opens and drains the switch pump is relieved to the main control
oil. valve, so the steering circuit pressure is prevent-
• When this happens, the balance of the pressure ed from going above the set value.
in pressure receiving chamber ( ) and pressure
receiving chamber ( ) is lost, and demand
spool (4) moves to the left.
10-66 WA800L-3
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
• The oil from the steering pump enters port A • When the pressure in pressure receiving cham-
and the oil from the switch pump enters port B. ber ( ) reaches a certain value (set by spring
• When steering spool (2) is at the neutral posi- (3)), notch f opens and the oil from the steering
tion, pressure receiving pressure chamber ( ) is pump goes to the drain circuit. Notch g is
connected to the drain circuit through orifice b, closed, so the oil from the switch pump all flows
and notch c is closed. to the main control valve.
• Notch c is closed, so the pressure of the oil at
port A and port B rises. This pressure passes
through orifice a, goes to pressure receiving
chamber ( ) and moves demand spool (1) to the
left.
WA800L-3 10-67
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
• When the steering is operated, oil flows from the • The merged oil passes through notches c and d,
rotary valve to steering spool (2) and pushes pushes load check valve (5), and flows to the
steering spool (2) to the right. The circuit be- cylinder. The return oil from the cylinder passes
tween pressure receiving chamber ( ) and the through notch e and flows to the drain circuit.
drain circuit is shut off, and at the same time, • When this happens, the pressure before
notch c opens. passing through notch c is sent to pressure re-
• As a result, the pressure in pressure receiving ceiving chamber ( ) and the pressure after
chamber ( ) rises, and demand spool (1) passing through notch c is sent to pressure re-
moves to the right until notch h closes. ceiving chamber ( ). Demand spool (1) is ac-
• The passage from port B to the main control tuated so that the difference in pressure on
valve is shut off, so the oil from the switch pump both sides of notch c is kept constant. There-
pushes up pump merge-divider check valve (4) fore, an oil flow corresponding to the opening of
and merges with the oil from the steering pump notch c is supplied to the cylinder port. These
at port A. pressure differences (control pressure) are set
by spring (3).
10-68 WA800L-3
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
• There is no need for supply of extra oil from the • The oil from the steering pump passes through
switch pump, so the steering pump pressure ris- notches c and d, pushes load check valve (5),
es until notch g closes and shuts off the merge and flows to the cylinder. The return oil from the
passage from port B. cylinder passes through notch e and flows to the
• The pressure difference on both sides of notch c drain circuit.
is controlled only by notch f, and the excess oil • Notch g is closed, so the oil from the switch
from the steering pump is drained from notch f pump all flows from port B and is sent to the
to the drain circuit. (At this point, notch g is main control valve.
completely closed.)
WA800L-3 10-69
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
Neutral
• The steering is not being operated, so steering • When the pressure at ports A and B rises, de-
spool (2) does not move. mand spool (1) moves to the left, so the oil from
• The oil from the steering pump enters port A. the steering pump passes through port C of the
The oil from the switch pump enters port B. spool and is drained.
The oil from the switch pump passes through
port D and all flows to the main control valve.
10-70 WA800L-3
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
Turning right
• When the steering is turned to the right, the rota- inder to turn the machine to the right. The oil
ry valve is operated and steering spool (2) from the left and right cylinders passes through
moves to the left. load check valve (5) of the steering spool and is
The oil from the steering pump enters port A, drained. The oil from the switch pump enters
then flows to steering spool (2) through demand port B, goes through demand spool (1), pushes
spool (1). The oil pushes open load check valve open check valve (4), and is merged with the oil
(6) of the spool, and flows to the bottom end of from the steering pump.
the left cylinder and the rod end of the right cyl-
WA800L-3 10-71
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
Turning left
• When the steering is turned to the left, the rotary inder to turn the machine to the left. The oil
valve is operated and steering spool (2) moves from the left and right cylinders passes through
to the right. load check valve (6) of the steering spool and is
The oil from the steering pump enters port A, drained. The oil from the switch pump enters
then flows to steering spool (2) through demand port B, goes through demand spool (1), pushes
spool (1). The oil pushes open load check valve open check valve (4), and is merged with the oil
(5) of the spool, and flows to the rod end of the from the steering pump.
left cylinder and the bottom end of the right cyl-
10-72 WA800L-3
STRUCTURE AND FUNCTION EPC VALVE
EPC VALVE
WA800L-3 10-73
STRUCTURE AND FUNCTION ROTARY VALVE
ROTARY VALVE
a. To hydraulic tank
b. To port Pb of steering demand valve
c. To port Pa of steering demand valve
d. From PPC pump
10-74 WA800L-3
STRUCTURE AND FUNCTION ROTARY VALVE
OUTLINE
• The steering lever is connected to the top of the
rotary valve. The direction of the oil sent from
the PPC pump through the EPC valve to this
valve is changed with the steering lever to move
the spool of the steering demand valve. As a re-
sult, the steering cylinder is operated to set the
steering direction of the machine.
• The link installed to the front frame is connected
to the bottom of the rotary valve to feed back the
steering angle of the machine. Accordingly, the
position of the steering lever is matched to the
steering angle of the machine.
STRUCTURE
• Spool (4) is connected through pin (10) (which is
not in contact with the spool while the steering
lever is in "neutral") and neutral position spring
(1) to sleeve (5).
• The top and bottom of drive shaft (9) are en-
gaged with pin (10) and assembled into one unit
together with sleeve (5) and feedback sleeve
(7).
• Feedback spool (6) is connected through pin
(10) (which is not in contact with the spool while
the steering lever is in "neutral") and loose
spring (8) to feedback sleeve (7).
• Valve body (2) has four ports, which are con-
nected to the pump circuit, tank circuit, and pilot
circuit of the steering demand valve respective-
ly.
OPERATION
• If the steering lever is operated, spool (4) rotates
along sleeve (5), against neutral position spring
(1).
By this rotation, the port of spool (4) is matched
to that of sleeve (5) to form an oil passage, then
the oil flows in the steering demand valve.
If the steering lever is operated more than the
allowable displacement of neutral position
spring (1), loose spring (8) absorbs the displace-
ment through drive shaft (9).
• If the oil flows in the steering cylinder and steer-
ing operation starts, the link installed to the front
frame turns sleeve (5) through feedback spool
(6) and drive shaft (9) so that the deviation of
sleeve (5) from spool (4) will be offset.
If the machine is steered to the position matched
to the operating distance of the steering lever,
deviation of spool (4) from sleeve (5) is elimi-
nated and the oil passage is closed.
WA800L-3 10-75
STRUCTURE AND FUNCTION TWO-WAY RESTRICTOR VALVE
1. Poppet
2. Spring
3. Body
FUNCTION
• To reduce the shock caused by the inertia of the
machine when the steering is operated, an ori-
fice is installed in the oil line of the return circuit
from the cylinder. This applies pressure to the
returning oil, and regulates the movement of the
cylinder piston.
OPERATION
• When the oil is flowing to arrow o, it pushes
spring (2) and flows through the orifice, and be-
tween poppet (1) and the poppet seat.
10-76 WA800L-3
STRUCTURE AND FUNCTION DIVERTER VALVE
DIVERTER VALVE
WA800L-3 10-77
STRUCTURE AND FUNCTION DIVERTER VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
FUNCTION
Compared to the steering valve relief pressure of
31.4 MPa {320 kg/cm 2}, the rated pressure of the
emergency steering pump and diverter valve are
both 20.6 MPa {210 kg/cm 2}. Therefore, to protect
the emergency steering pump and diverter valve,
there is a relief valve in the piping from the diverter
valve to the steering valve. When the emergency
steering is being operated, and the hydraulic pres-
sure generated by the steering exceeds 20.6 MPa
{210 kg/cm2}, the relief valve is actuated.
OPERATION
• Port A is connected to the pump circuit, and port
C is connected to the drain circuit. The oil pass-
es through the orifice in main valve (1) and fills
port B. Pilot poppet (3) is in contact with valve
seat (2).
10-78 WA800L-3
STRUCTURE AND FUNCTION DIVERTER VALVE
WA800L-3 10-79
STRUCTURE AND FUNCTION DIVERTER VALVE
10-80 WA800L-3
STRUCTURE AND FUNCTION BRAKE PIPING
BRAKE PIPING
WA800L-3 10-81
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
10-82 WA800L-3
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
WA800L-3 10-83
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
BRAKE VALVE (RIGHT)
1. Brake pedal (Right and left brake valves) A. Pilot port (Right brake valve)
2. Rod (Right brake valve) B. To front brake (Right brake valve)
3. Pilot piston (Right brake valve) C. To rear brake (Right brake valve)
4. Spool (Right brake valve) D. Drain (Right and left brakes valves)
5. Upper cylinder (Right brake valve) E. From brake pump (Right and left brakes valves)
6. Spool (Right brake valve) F. To pilot port (Left brake valve)
7. Lower cylinder (Right brake valve)
8. Rod (Left brake valve)
9. Spool (Left brake valve)
10. Cylinder (Left brake valve)
10-84 WA800L-3
STRUCTURE AND FUNCTION BRAKE VALVE
OUTLINE
• There are two brake valves installed in parallel
under the front of the operator’s cab, and these
are actuated by depressing the pedal.
• When the right pedal is depressed, oil is sent to
the brake cylinder to apply the brakes.
• When the left pedal is depressed, oil is sent to
the right pedal to apply the brakes in the same
way as when the right pedal is depressed.
In addition, the left brake pedal operates the
transmission cut-off switch to actuate the trans-
mission solenoid valve electrically and set the
transmission to neutral.
WA800L-3 10-85
STRUCTURE AND FUNCTION BRAKE VALVE
OPERATION
Lower portion
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
spool (5) is also pushed down by plunger (6).
When this happens, drain port b is closed, and
the oil from the pump and accumulator flows
from port B to port D and actuates the rear
brake cylinders.
10-86 WA800L-3
STRUCTURE AND FUNCTION BRAKE VALVE
Lower portion
• When spool (3) in the upper portion moves up
and the circuit between port A and port C is shut
off, oil also fills the rear brake cylinder at the
same time, so the pressure in the circuit be-
tween port B and port D rises. The oil entering
port J from orifice f of spool (5) pushes up spool
(5) by the same amount that spool (3) moves,
and shuts off port B and port D. Drain port b is
closed, so the oil entering the brake cylinder is
held, and the brake is applied.
• The pressure in the space in the upper portion is
balanced with the operating force of the pedal,
and the pressure in the space in the lower por-
tion is balanced with the pressure in the space
in the upper portion. When spools (3) and (5)
move to the end of their stroke, the circuits be-
tween ports A and C and between ports B and D
are fully opened, so the pressure in the space in
the upper and lower portions and the pressure in
the left and right brake cylinders is the same as
the pressure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the
brake can be adjusted by the amount that the
pedal is depressed.
WA800L-3 10-87
STRUCTURE AND FUNCTION BRAKE VALVE
Lower portion
• When the pedal is released, spool (3) in the up-
per portion moves up. At the same time, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (5)
up. Drain port b is opened and the oil from the
brake cylinder flows to the hydraulic tank return
circuit to release the rear brake.
10-88 WA800L-3
STRUCTURE AND FUNCTION CHARGE VALVE
CHARGE VALVE
WA800L-3 10-89
STRUCTURE AND FUNCTION CHARGE VALVE
1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. PPC relief valve (R2)
5. Relief valve (H1)
6. Filter
10-90 WA800L-3
STRUCTURE AND FUNCTION CHARGE VALVE
OPERATION
1. When no oil if being supplied to accumulator
(cut-off condition)
• The pressure at port B is higher than the set
pressure of the relief valve (R1), so piston (8) is
forcibly pushed up by the oil pressure at port B.
Poppet (6) is opened, so port C and port T are
short circuited.
• The spring chamber at the right end of spool
(15) is connected to port C of the relief valve
(R1), so the pressure becomes the brake oil
tank pressure. The oil from the pump enters port
P, pushes spool (15) to the right at a low pres-
sure equivalent to the load on spring (14), and
flows from port A to brake oil tank. At the same
time, it also passes through orifices (17), (18),
and (16), and flows to the brake oil tank.
WA800L-3 10-91
STRUCTURE AND FUNCTION CHARGE VALVE
10-92 WA800L-3
STRUCTURE AND FUNCTION ACCUMULATOR (For brake)
4 1. Valve
2. Top cover
3. Cylinder
SEW00120
4. Free piston
FUNCTION SPECIFICATIONS
• The accumulator is installed between the charge Gas used: Nitrogen gas
valve and the brake valve. It is charged with ni- Charge amount: 6,000 cc
trogen gas between cylinder (3) and free piston Charging pressure: 3.43 MPa {35 kg/cm2} (at 50°C)
(4), and uses the compressibility of the gas to
absorb the pulse of the hydraulic pump or to
maintain the braking force and to make it possi-
ble to operate the machine if the engine should
stop.
WA800L-3 10-93
STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
1. Piston SPECIFICATIONS
2. Cylinder Maximum available pressure: 5.88 MPa {60 kg/cm2}
3. Check valve Normal pressure: 4.61 MPa {47 kg/cm2}
4. Spring Check valve cracking pressure:
5. Bleeder 1.09 MPa {11.1 kg/cm2}
10-94 WA800L-3
STRUCTURE AND FUNCTION SLACK ADJUSTER
OPERATION
1. Brake pedal depressed
The oil pumped out from brake valve (9) flows in from port P of the slack adjuster. From port P the oil is
divided and sent to left and right cylinders (2) and moves piston (4) a distance of stroke S to the right or left.
Because of this, an amount of oil corresponding to stroke S flows from port C to brake cylinder (7). When
this happens, the clearance between the brake piston and disc becomes 0, so no braking force is gener-
ated.
WA800L-3 10-95
STRUCTURE AND FUNCTION SLACK ADJUSTER
If the oil pressure in brake valve (9) goes above a certain specified pressure, check valve (3) opens and the
oil flows through pilot circuit D and applies pressure to port C. This gives the braking force.
As a result, there is a constant time lag when the brake is applied.
10-96 WA800L-3
STRUCTURE AND FUNCTION BRAKE
BRAKE
WA800L-3 10-97
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
10-98 WA800L-3
STRUCTURE AND FUNCTION PARKING BRAKE
OPERATION
Parking
• When the parking brake switch is turned ON, the
solenoid valve is actuated and the oil pressure
from the brake pump is shut off by the solenoid
valve. The oil inside spring cylinder (1) is
drained to the brake oil tank from the solenoid
valve port.
Therefore, the piston and rod of spring cylinder
(1) are pushed by the force of the spring, so
lever (2) rotates and the parking brake is
applied.
• Lever (2) rotates piston shaft (3) and moves pis-
ton (4) in the axial direction, so the pad is
pushed against the disc, and the parking brake
is applied.
Traveling
• When the parking brake switch is turned OFF,
the solenoid valve is actuated and the valve
opens the drain port.
At the same time, the oil pressure from the
brake pump enters the bottom of the piston of
spring cylinder (1). It overcomes the force of the
spring and pushes the piston to rotate lever (2).
This rotates piston shaft (3), moves piston (4),
and releases the parking brake.
Therefore, hydraulic pressure is applied to the
spring cylinder and the parking brake is kept
released.
WA800L-3 10-99
STRUCTURE AND FUNCTION SPRING CYLINDER
SPRING CYLINDER
10-100 WA800L-3
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
WA800L-3 10-101
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
10-102 WA800L-3
STRUCTURE AND FUNCTION HYDRAULIC PIPING
1. Bucket cylinder
2. PPC valve
3. Accumulator
4. Main piston pump
5. Hydraulic oil cooler
6. 4th gear pump
(Torque converter charging (x 2) + PPC + brake)
7. Switch piston pump
8. Transmission
9. Boom cylinder
10. Main control valve (x 2)
WA800L-3 10-103
STRUCTURE AND FUNCTION HYDRAULIC PIPING
10-104 WA800L-3
STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
1. Kick-down switch
2. Hold switch
3. Boom lever
4. Bucket lever
5. Safety lever
6. Solenoid valve for bucket lever
7. Solenoid valve for boom lever
8. PPC valve
WA800L-3 10-105
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
10-106 WA800L-3
STRUCTURE AND FUNCTION HYDRAULIC TANK
WA800L-3 10-107
STRUCTURE AND FUNCTION HYDRAULIC TANK
BREATHER
1. Body
2. Filter element
3. Poppet
SEW00141
4. Sleeve
FUNCTION
10-108 WA800L-3
STRUCTURE AND FUNCTION MAIN PISTON PUMP
WA800L-3 10-109
STRUCTURE AND FUNCTION MAIN PISTON PUMP
PISTON PUMP
10-110 WA800L-3
STRUCTURE AND FUNCTION MAIN PISTON PUMP
WA800L-3 10-111
STRUCTURE AND FUNCTION MAIN PISTON PUMP
FUNCTION STRUCTURE
• The engine rotation and torque transmitted to • Cylinder block (7) is supported to shaft (1) by a
the pump shaft is converted into hydraulic ener- spline, and shaft (1) is supported by the front
gy, and pressurized oil is discharged according and rear bearings.
to the load. • The tip of piston (6) is spherical, and shoe (5) is
• It is possible to change the delivery amount by caulked to it to form one unit. Piston (6) and
changing the swash plate angle. shoe (5) form a spherical bearing.
• Rocker cam (4) has plane surface A, and shoe
(5) is always pressed against this surface while
sliding in a circular movement.
Rocker cam (4) brings high pressure oil at cylin-
drical surface B with cradle (2), which is secured
to the case, and forms a static pressure bearing
when it slides.
• Piston (6) carries out relative movement in the
axial direction inside each cylinder chamber of
cylinder block (7).
• Cylinder block (7) seals the pressure oil to valve
plate (8) and carries out relative rotation. This
surface is designed so that the oil pressure bal-
ance is maintained at a suitable level. The oil in-
side each cylinder chamber of cylinder block (7)
is sucked in and discharged through valve plate
(8).
• Impeller (9) is connected to shaft (1) through the
spline boss (10) and rotates together with the
shaft. The oil sucked in through the suction port
is sent to the cylinder chamber by centrifugal
force to make suction easier.
10-112 WA800L-3
STRUCTURE AND FUNCTION MAIN PISTON PUMP
OPERATION
1. Operation of pump
• Cylinder block (7) rotates together with shaft (1),
and shoe (5) slides on flat surface A.
When this happens, rocker cam (4) moves along
cylindrical surface B, so angle between cen-
ter line X of rocker cam (4) and the axial direc-
tion of cylinder block (7) changes. (Angle is
called the swash plate angle.)
WA800L-3 10-113
STRUCTURE AND FUNCTION MAIN PISTON PUMP
10-114 WA800L-3
STRUCTURE AND FUNCTION MAIN PISTON PUMP
1. Collar SPECIFICATION
2. Body Model: BAR 25
3. Housing Theoretical delivery: 25 cc/rev.
4. Drive gear Max. delivery pressure: 2.9 MPa {30 kg/cm2}
5. Driven gear
WA800L-3 10-115
STRUCTURE AND FUNCTION MAIN PISTON PUMP
RELIEF VALVE
1. Adjustment screw
2. Lock nut
3. Pilot valve spring
4. Pilot valve
5. Main valve spring
6. Main valve
FUNCTION
The relief valve is built in the body of control pump. It
relieves the oil delivered from the pump.
10-116 WA800L-3
STRUCTURE AND FUNCTION ES VALVE (Engine sensing valve)
1. Plug
2. Valve body
3. Shaft
4. Plug
5. Plug
6. Spool
7. Spool
8. Plug
9. Plug
WA800L-3 10-117
STRUCTURE AND FUNCTION ES VALVE (Engine sensing valve)
FUNCTION
• This valve acts to control the delivery amount of
the hydraulic pump to match the changes in the
engine speed.
• A variable displacement piston pump is used for
the hydraulic pump to save energy by reducing
the consumption of hydraulic pressure when the
engine is running at low speed. At the same
time, it is also used to increase the engine ac-
celeration from low speed.
For this reason, a pressure difference valve is
used to detect the engine speed by using a
pressure difference system. The delivery (deliv-
ery per rotation) is then adjusted to match the
engine speed.
10-118 WA800L-3
STRUCTURE AND FUNCTION SERVO VALVE
SERVO VALVE
1. Sleeve
2. Body
3. Spool
4. Arm
5. Plug
6. Sleeve
7. Spool
8. Plug
WA800L-3 10-119
STRUCTURE AND FUNCTION SERVO VALVE
OPERATION
• Input signal pressure Pi acts on chamber E in • With the movement of guide spool (12), port B
the control piston from port D. Pressure Pc in and port A connect to each other, allowing oil
the charging pump is guided into port B. pressure Pc, in the control pump to act on
• If input signal pressure Pi is raised a little, the oil chamber F in servo piston (11). Servo piston
pressure acting on chamber E will increase ac- (11) is then pushed rightward, increasing the
cordingly. Control piston (9) therefore moves to swash plate angle of the main piston pump.
a position (rightward) where the force of spring Thus, the pump discharge is increased.
(10) is in balance with the oil pressure in cham- • Since arm (4) turns counterclockwise on pin
ber E, thus allowing arm (4) to swing rightward (13), guide spool (12) moves leftward, causing
with servo piston (11) serving as the supporting port B, port C and drain port A to close. The
point. As a result, guide spool (12) moves to the pump discharge, therefore, increases with the
right. change in input signal pressure Pi.
10-120 WA800L-3
STRUCTURE AND FUNCTION SERVO VALVE
• Next, let’s examine the case where servo piston • With the movement of guide spool (12), port B
(11) is moved leftward. Assume that the servo and port A are shut off and port A becomes
piston is in a balanced position at a certain loca- open to the drain.
tion. If Pi is decreased, control piston (9) moves On the other hand, port B and port C are con-
to a position where the oil pressure in chamber nected to each other, allowing the oil to flow into
E balances with the force of spring (10). Then, chamber H in the servo cylinder. Servo piston
arm (4) swings leftward, using servo piston (11) (11) is then pushed leftward by the force of
as a support point, and cause, guide spool (12) spring (14), decreasing the swash plate angle of
to move leftward. the main piston pump. Thus, the pump dis-
charge is decreased.
• Since arm (4) rotates clockwise on pin (13),
guide spool (12) moves rightward, shutting off
port B, port C and port A. The pump discharge,
therefore, decreases with the change in input
signal pressure Pi.
WA800L-3 10-121
STRUCTURE AND FUNCTION PPC VALVE (Proportional pressure valve)
10-122 WA800L-3
STRUCTURE AND FUNCTION PPC VALVE (Proportional pressure valve)
1. Bolt
2. Piston
3. Plate
P : From pump
4. Collar
T : To tank (drain)
5. Retainer
P1 : To boom cylinder (Raise)
6. Center spring
P2 : To bucket cylinder (Dump)
7. Metering spring
P3 : To boom cylinder (Lower)
8. Valve
P4 : To bucket cylinder (Tilt)
9. Body
WA800L-3 10-123
STRUCTURE AND FUNCTION PPC VALVE (Proportional pressure valve)
OPERATION
1. Control lever at “neutral” (Fig. 1):
Ports PA1, P2, PB1 and P4 are connected to
drain chamber D through fine control hole f in
spool (10).
(Fig. 1)
2. Control lever operated slightly (fine control)
(Fig. 2):
When piston (4) starts to be pushed by plate (2),
retainer (7) is pushed. Valve (10) is also pushed
by spring (9) and moves down.
When this happens, fine control hole f is shut off
from drain chamber D. At almost the same time
it is connected to pump pressure chamber PP,
and the pilot pressure of the control valve is sent
through fine control hole f to port P2 and PA1.
When the pressure at port P2 rises, valve (10) is
pushed back. Fine control hole f is shut off from
pump pressure chamber PP. At almost the same
time it is connected to drain chamber D, so the
pressure at port P2 escapes to drain chamber
D.
10-124 WA800L-3
STRUCTURE AND FUNCTION PPC VALVE (Proportional pressure valve)
(Fig. 3)
(Fig. 4)
WA800L-3 10-125
STRUCTURE AND FUNCTION PPC RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
FUNCTION
• The PPC relief valve is between the PPC pump
and the PPC valve. When the PPC valve is not
being actuated, or when abnormal pressure is
generated, the oil sent from the pump is relieved
through this valve to protect the pump and cir-
cuit from damage. (Sets maximum pressure in
the circuit).
OPERATION
• Port A is connected to the pump circuit, and port
C is connected to the drain circuit.
The oil passes through the orifice of main valve
(1) and fills port B. Pilot poppet (3) is in close
contact with valve seat (2).
10-126 WA800L-3
STRUCTURE AND FUNCTION ACCUMULATOR (For PPC valve)
1. Cap
2. Nut
3. Body
4. Bladder
5. Oil port
6. Nut
SPECIFICATIONS
Type of gas: Nitrogen gas
Gas amount: 3,000 cc
Max. actuation pressure: 2.9 MPa {30 kg/cm2}
Min. actuation pressure: 1.2 MPa {12 kg/cm2}
FUNCTION
• The accumulator is installed between the hy-
draulic pump and PPC valve. An inflatable blad-
der is filled with nitrogen gas, and the
compressibility is used to store the pressure of
the oil. As a result, the boom and bucket can be
lowered under their own weight even after the
engine has been stopped.
OPERATION
• After the engine stops, when the PPC valve is a
NEUTRAL, chamber A (volume of nitrogen gas:
3,000 cc) inside the bladder is compressed by
chamber B.
WA800L-3 10-127
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
10-128 WA800L-3
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
FUNCTION
• The two main control valves control the actua- • There are two safety valves (with suction valves)
tion of the boom and the bucket in the hydraulic (10) to protect the circuit if abnormal pressure is
system. It has a tandem circuit which gives pri- generated in the bucket circuit. If one of the two
ority to the bucket circuit. safety valves is acting as a relief valve, the other
• The oil from the pump enters port P. The maxi- valve acts as a suction valve to make up any
mum pressure is set by main relief valve (1). lack of oil.
The oil passes through the bypass circuit of
bucket spool (5) and boom spool (4). It then
flows from port T to the drain circuit, passes
through the filter and returns to the tank. If the
buket and boom spools are actuated, the oil
flows to the bucket and boom cylinders.
However, the circuit gives priority to the bucket,
so when the bucket spool is being operated,
even if the boom spool is operated, the boom
will not move.
WA800L-3 10-129
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
RELIEF VALVE
1. Main valve
2. Piston
3. Piston spring
4. Poppet
5. Poppet spring
6. Plug with valve seat
7. Sleeve
8. Adjustment screw
9. Lock nut
10. Orifice
FUNCTION
• The relief valve is installed at the inlet of the
work equipment valve. When the oil pressure
rises above the specified level, this valve drains
the oil into the hydraulic tank to limit the maxi-
mum pressure of the work equipment circuit and
protect the circuit.
OPERATION
• Ports A and B are connected to the pump circuit
and drain circuit respectively. The oil pressure in
port A is applied through the hole of piston (3) to
port C.
• When the oil pressure is below the set relief
pressure, poppet (4) is in contact with the seat
of plug (6) and the oil does not flow from cham-
ber C into the drain circuit. Accordingly, the oil
pressure in port A is equal to that in chamber C.
• Since d2 < d3, main valve (2) is in contact with
the left side. The sectional areas are set in the
following order; d5 > d4 > d1 > d3 > d2.
10-130 WA800L-3
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
1 2 3 4 5 6
1. Suction valve
2. Main valve
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
FUNCTION
• The safety valve (with suction valve) is in the
bucket cylinder circuit in the main valve. If shock
causes any abnormally high pressure in the cyl-
inder when the main valve is at neutral, the safe-
ty valve (with suction v alve) releases the
abnormal pressure and protects the cylinder
from damage.
• This valve prevents generation of negative pres-
sure in the circuit.
OPERATION
As a safety valve
• Port A is the cylinder circuit and port B is the
drain circuit. A B C 2 4 D
The pressure oil in port A flows to port D through
a hole in pilot piston (4). It also flows to port C
through an orifice consisting of the main valve
and pilot piston (4).
Pilot piston (4) is secured to the suction valve by
lock nut. The diameter of the cross section
(cross sectional area) gives a relationship of d2
> d1 > d3 > d4.
d1 d3 d4 d2 SEW00167
WA800L-3 10-131
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
As a sunction valve
• If negative pressure is generated in port A, port
D also has negative pressure, because port D
and A are connected with each other. The tank
pressure in port B is applied to port E.
Hydraulic pressure a equivalent to the area dif-
ference between d2 and d1 is applied to the
safety valve because of the tank pressure in port
E. Therefore, hydraulic pressure e acts to open
the valve and hydraulic pressure a acts to close
suction valve (1).
• If the pressure in port A drops, (approaching
negative pressure) hydraulic pressure a be-
comes smaller than oil pressure e.
• When oil pressure e becomes larger than oil
pressure a + valve spring (5) force, suction valve
(1) opens, causing the oil to flow from port B into
port A. This prevents negative pressure from
building up in port A.
SUCTION VALVE
1 2 3
1. Main poppet
2. Sleeve
3. Spring
SEW00170
OPERATION
• If negative pressure is generated in port A
(boom cylinder rod end) (if the pressure is lower
than in port B in the tank circuit), main poppet
(1) opens because oil then flows from port B at
the tank end to port A at the cylinder port end.
10-132 WA800L-3
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
FUNCTION
• The float selector valve (2) and the unloader
valve (3) are inside the main control valve.
When the boom control lever is moved to the
float position, the float selector valve (2) detects
this. When it is actuated, it actuates the unload-
er valve (3) and sets the boom in the FLOAT po-
sition.
OPERATION
1. LOWER position
This shows the condition with the boom control
lever in the LOWER position.
2. FLOAT position
When the boom control lever is pushed forward
from the LOWER position, it enters the FLOAT
position.
Boom spool (1) of the main control valve is in
the same condition as at the LOWER position.
The hydraulic pressure at port A is higher than
at the LOWER position, so float selector valve
(2) moves in the direction of the rightward. The
back pressure of unloader valve (3) is drained,
so unloader valve (3) opens to give the FLOAT
condition.
WA800L-3 10-133
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
10-134 WA800L-3
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
OPERATION
• The oil enters port A from the steering valve, • The oil from the PPC pump passes through
and the maximum pressure is set by relief valve check valve (13), and enters port L of the PPC
(11). valve. However, the boom and bucket levers are
• Bucket spool (1) is at the HOLD position, so the at the HOLD position, so the oil returns to the
bypass circuit is open and the oil at port A pass- hydraulic tank from PPC relief valve (12).
es around the spool and flows to port B. Boom
spool (2) is also at HOLD, so the bypass circuit
is open and the oil at port B passes around the
spool, enters port C of the drain circuit, passes
through the filter in the hydraulic tank, and re-
turns to the tank.
WA800L-3 10-135
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
OPERATION
• When boom lever (3) is pulled, the oil flows from • At the same time, the oil at the cylinder rod end
port L of the PPC valve to port N and port T. In enters drain port C from port K and returns to
addition, the oil at port S passes through port M the tank. Therefore, the boom rises.
and flows to the drain circuit. The oil pressure at
port T pushes boom spool (2) and moves it to
the RAISE position.
• The oil from the steering valve passes through
the bypass circuit of the bucket spool (1) and
flows to the bypass circuit of boom spool (2).
The bypass circuit is closed by the spool, so the
oil pushes open check valve (10). The oil flows
from port H to port I, and flows to the cylinder
bottom.
10-136 WA800L-3
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
OPERATION
• When boom lever (3) is pushed, the oil flows • At the same time, the oil at the cylinder bottom
from port L of the PPC valve to port M and port enters drain port C from port I and returns to the
S. In addition, the oil at port T flows to the drain tank. Therefore, the boom goes down.
circuit.
The oil pressure at port S pushes boom spool
(2) and moves it to the LOWER position.
• The oil from the steering valve passes through
the bypass circuit of the bucket spool (1) and
flows to the bypass circuit of boom spool (2).
The bypass circuit is closed by the spool, so the
oil pushes open check valve (10). The oil flows
from port J to port K, and flows to the cylinder
rod end.
WA800L-3 10-137
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
OPERATION
• When boom lever (3) is pushed to the FLOAT • If a difference in pressure greater than the spec-
position, the PPC valve spool moves beyond the ified pressure is generated at port W and port X,
LOWER position to the FLOAT position. The valve (7) moves to the right, opens port C1 and
pressure oil at port L flows to port M, and at the port C, and connects to the drain circuit. When
same time, it also flows to port S and port W. In port C1 is connected to the drain circuit, unload
addition, the pressurized oil at port T flows to valve (8) moves up and the oil from the pump
port N. flows to the drain circuit.
• The pressurized oil at port S pushes boom spool • Therefore, the oil at the cylinder rod end passes
(2) to the LOWER position. from port K through unload valve (8) and flows
to the drain circuit. The oil at the cylinder bottom
flows from port I to port C, and then flows to the
drain circuit. Therefore, the boom is set to the
FLOAT condition.
10-138 WA800L-3
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
OPERATION
• When bucket lever (4) is pushed, the pressure • At the same time, the oil at the cylinder bottom
oil at port L of the PPC valve flows from port Q flows from port D to drain port C, and returns to
to port V. In addition, the oil at port R flows to the the tank, so the bucket is dumped.
drain circuit. The pressure oil at port V moves
bucket spool (1) to the DUMP position.
• The bypass circuit is closed by bucket spool (1),
so the oil from port A pushes open check valve
(10). The oil from check valve (10) flows from
port F to port G, and then flows to the cylinder
rod end.
WA800L-3 10-139
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
OPERATION
• When bucket lever (4) is pulled, the pressure oil • At the same time, the oil at the cylinder rod end
at port L of the PPC valve flows from port P to flows from port G to drain port C, and returns to
port R. In addition, the oil at port V flows to the the tank, so the bucket is tilted.
drain circuit. The pressure oil at port R moves
bucket spool (1) to the TILT position.
• The bypass circuit is closed by bucket spool (1),
so the oil from port A pushes open check valve
(10). The oil from check valve (10) flows from
port E to port D, and then flows to the cylinder
bottom.
10-140 WA800L-3
STRUCTURE AND FUNCTION LUBRICATION OF WORK EQUIPMENT
WA800L-3 10-141
STRUCTURE AND FUNCTION LUBRICATION OF WORK EQUIPMENT
9. Grease injector (Center hinge, upper) 19. Grease injector (Rear axle support, front)
10. Grease injector (Bucket cylinder bottom side) 20. Grease injector (Torque converter trunnion mount)
11. Grease injector (Boom hinge, L.H.) 21. Grease injector (Rear axle support, rear/upper)
12. Grease injector (Boom hinge, R.H.) 22. Grease injector (Rear axle support, rear/cover)
13. Grease injector (Steering cylinder bottom side, L.H.) 23. Grease injector (Steering cylinder rod side, L.H.)
14. Grease injector (Steering cylinder bottom side, R.H.) 24. Grease injector (Steering cylinder rod side, R.H.)
15. Grease injector (Center support) 25. Pressure switch
16. Grease injector (Boom cylinder bottom side, L.H.) 26. Grease pump
17. Grease injector (Boom cylinder bottom side, R.H.) 27. Timer
18. Grease injector (Center hinge, lower) 28. Pressure gauge
10-142 WA800L-3
STRUCTURE AND FUNCTION LUBRICATION OF WORK EQUIPMENT
WA800L-3 10-143
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
1. Bucket 7. Boom
2. Bucket hinge pin 8. Boom cylinder
3. Bucket link pin 9. Cord ring
4. Bucket link 10. Tooth with tip
5. Bellcrank 11. Sweeper wing
6. Bucket cylinder
10-144 WA800L-3
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
WA800L-3 10-145
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
10-146 WA800L-3
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER
• The bucket positioner is an electrically actuated
system which is used to set the bucket to the de-
sired angle when the bucket is moved from the
DUMP position to the TILT position. When the
bucket reaches the desired position, the bucket
lever is returned from the TILT position to the
HOLD position, and the bucket is automatically
set to the suitable digging angle.
• Bar (2) is secured to bucket cylinder rod (5) by
bolts. In addition, proximity switch (1) is fixed to
the cylinder by bolts.
• When the bucket is moved from the DUMP posi-
tion to the TILT position, the bucket cylinder rod
moves to the left, and at the same time, bar (2)
also moves to the left. Bar (2) separates from
proximity switch (1) at the desired position, and
the bucket lever is returned to neutral.
BOOM KICK-OUT
• The boom kick-out is electrically operated and
acts to stop the boom. When the boom reaches
the desired position before the maximum height,
the boom lever is returned to neutral.
• Plate (4) is secured to the boom. The proximity
switch (3) is fixed to the frame. When the boom
is moved from the LOWER position to the
RAISE position, the boom rises. When it reach-
es the desired position, the proximity switch and
plate come into contact and the boom lever is
returned to neutral.
WA800L-3 10-147
STRUCTURE AND FUNCTION OPERATION OF PROXIMITY SWITCH
10-148 WA800L-3
STRUCTURE AND FUNCTION OPERATION OF PROXIMITY SWITCH
WA800L-3 10-149
STRUCTURE AND FUNCTION OPERATION OF PROXIMITY SWITCH
BUCKET TILT
• When the bucket is dumped beyond the set po-
sition for the auto-leveler, the sensor (steel
plate) is above the detection surface of the
bucket proximity switch, so electric current flows
in the proximity switch load circuit. The position-
er relay is turned ON and the current for the so-
lenoid is shut off.
10-150 WA800L-3
STRUCTURE AND FUNCTION OPERATION OF PROXIMITY SWITCH
WA800L-3 10-151
STRUCTURE AND FUNCTION CAB AND ROPS CANOPY
1. ROPS canopy
2. Cab
10-152 WA800L-3
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
10-154 WA800L-3
STRUCTURE AND FUNCTION AIR CONDITIONER
WA800L-3 10-155
STRUCTURE AND FUNCTION AIR CONDITIONER
10-156 WA800L-3
STRUCTURE AND FUNCTION AIR CONDITIONER
1. Electric wiring
2. Fan
3. Refrigerant gas inlet port
4. Refrigerant gas outlet port
DRY RESERVOIR
1. Body
2. Drier
3. Filter
WA800L-3 10-157
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
OUTLINE
• The machine monitor system uses the sensors • There are also various switches built into the
and other devices installed to various parts of monitor panel which function to operate the ma-
the machine to observe the condition of the ma- chine.
chine. It processes this information swiftly and
displays it on the monitor panel to inform the op- a The main monitor uses the network wiring to
erator of the condition of the machine. send signals to the controller, and functions to
• The machine monitor system consists of the display the following information.
main monitor, maintenance monitor, sensors, 1) Shift indicator: 1st – 3rd, N, F, R
switches, relays, alarm buzzer, and power 2) HOLD
source. 3) Failure action code, failure code, time
• The displays can be broadly divided into the fol- elapsed since failure (failure data display
lowing: Cautions displayed on the monitors (ab- mode)
normalities in the machine where an alarm is
given) and normal conditions which are always
displayed on the instrument panel (pilot lamps
and readings for the gauges, speedometer, and
service meter).
10-158 WA800L-3
STRUCTURE AND FUNCTION MAIN MONITOR
MAIN MONITOR
WA800L-3 10-159
STRUCTURE AND FUNCTION MAIN MONITOR
Display
Symbol Display item Display range Display method
category
When there is abnormality
Display flashes (for details, see MAINTE-
Check Check display on maintenance
NANCE MONITOR DISPLAY FUNCTION)
monitor
Emergency
steering When actuated Display flashes
actuated
Turn signal
When operated Display lights up
(left, right)
Emergency
When normal (oil is flowing
Pilot steering Display lights up
in hydraulic circuit)
normal
Lights up Lighting up time changes accord-
ing to engine water temperature when
Preheating When preheating
starting switch is turned ON (for details,
see PREHEATING CIRCUIT)
Shift
Shift indicator 1–3N Digital display
indicator
Shift
F, R, display F, R Digital display
indicator
10-160 WA800L-3
(1)
STRUCTURE AND FUNCTION MAIN MONITOR
WA800L-3 10-161
STRUCTURE AND FUNCTION MAIN MONITOR
With engine stopped and starting switch turned All switch displays (LEDs) go out, and failure
ON, press 2nd switch from top on left side of main code is displayed on speedometer display and
monitor (switch below emergency steering dis- time elapsed since failure is displayed on failure
play) and working lamp (front) switch simulta- action code display.
neously for at least 5 seconds. 1) Failure code is a two-digit display given in
numbers or letters. The display for the failure
Method of now occurring flashes and the display for
switching to ON past failures lights up. If there is no failure,
trouble data CC is displayed (000 is displayed for time
display mode elapsed since failure)
2) The time elapsed since failure is to show
how long ago the failure occurred (the oldest
failure time is displayed. Any time greater
than 999H is displayed as 999H).
SDW00241
3) A maximum of 9 items are stored in memory
for the failure code.
SDW01254
SDW00242
ON
Failure code and time elapsed since failure being
Clearing failure displayed are cleared. Failure code for problem
code now occurring (flashing display) cannot be
cleared.
SDW00243
10-162 WA800L-3
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR
WA800L-3 10-163
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
Display
Symbol Display item Display range Display method
category
Engine water level Below low level Displays when engine is stopped and start-
ing switch is ON
Display when normal: OFF
Display when abnormal: Flashes
Check Engine oil level Below low level CHECK lamp flashes
Engine coolant
Above 102°C Buzzer sounds if above 105°C
temperature
Caution
Torque converter oil
Above 120°C Buzzer sounds if above 130°C
temperature
When charge is
Battery charge Displays when engine is running
defective
Display when normal: OFF
Display when abnormal: Flashes
Above specified neg- CHECK lamp flashes
Air cleaner
ative pressure
10-164 WA800L-3
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
Display
Symbol Display item Display range Display method
category
WA800L-3 10-165
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
FUNCTION
• The neutral safety circuit is employed to prevent • The automatic lubrication system (included with
starting the engine when the directional switch is the engine) reduces wear and increases engine
in any position but N (Neutral). life by suppying lubricant to engine internal parts
Also a steering neutral interlock circuit prevents to pre-lube the components before cranking the
to start the engine when the joystick lever is not engine itself. The system consists of an engine-
in neutral position. mounted pump driven by an electric motor (part
• The safety relay that senses alternator output of the cranking motor assembly), which is con-
voltage controls switch closure across terminals trolled by a pre-lube timer/solenoid assembly.
B and C. This prevents unintentional engage- The pre-lube timer/solenoid assembly is con-
ment of the cranking motor when the engine is nected to the starting motor and an engine oil
already running. pressure switch.
10-166 WA800L-3
(1)
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
OPERATION
• When the directional switch is set to the N (Neu-
tral) position, its neutral contact is "closed" and
contacts 3 – 5 of the neutral relay are "closed".
On the other hand, when the joystick steering
lever is set to the N (Neutral) position, contacts 3
– 6 of the steering lever neutral safety relay are
"closed".
If the starting switch is set to the START position
at this time, a current flows through the following
parts.
• Battery (+) o starting switch terminal BR o bat-
tery relay coil o ground and the switch of the
battery relay is closed.
• At the same time, current flows from starting
switch terminal C o neutral relay terminals 5 – 3
o steering lever neutral safety relay terminals 6
– 3 o pre-lube solenoid/timer terminal 3.
The solenoid/timer sends current to the starting
motor which rotates the oil pump. After lube oil
pressure opens the pressure switch, the prelube
solenoid/timer sends current to the starting
motor solenoid, which causes the pinion and
gear to be engaged and the motor to crank the
engine.
• Meanwhile, current flows from starting switch
terminal ACC o short connector o ECM (En-
gine Control Module). The ECM controls the
opening of the fuel shutoff valves at the engine
fuel pumps. Fuel is allowed to flow, and the en-
gine starts after reaching sufficient cranking
speed.
• If the directional switch is not at the N (Neutral)
position, the neutral relay is not actuated, so the
circuit is not formed and the engine does not
start.
If the joystick steering lever is not at the N (Neu-
tral) position, a current flows from the transmis-
sion joystick steering controller to the coil of the
steering lever neutral safety relay to "open" con-
tacts 3 – 6. Accordingly, the starting circuit is not
formed and the engine does not start.
WA800L-3 10-167
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
SAFETY RELAY
10-168 WA800L-3
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
OPERATION
• When the starting switch is turned to the OFF
position, current no longer flows to ECM.
The ECM stops current flow to the fuel shutoff
valves and the engine stops.
WA800L-3 10-169
(1)
STRUCTURE AND FUNCTION PREHEATING CIRCUIT
PREHEATING CIRCUIT
OUTLINE
• The engine's automatic preheating system is de- • When the preset preheating time has elapsed,
signed to ease starting in cold weather. This the preheating relays are turned off and the pre-
system is controlled by the engine ECM and will heating pilot lamp is turned off.
automatically set the preheating time based on
the engine coolant temperature when the start-
ing switch is operated.
• When the starting switch is turned to the ON po-
sition, an engine ECM circuit temperature sen-
sor detects the coolant temperature. The ECM
then sets a preheating time and sends current to
the heater relays. The preheating pilot lamp on
the main monitor lights up.
• Turning the starting switch to the START can-
cels the preheating, so the starting switch must
be left at the ON position. The preheating pilot
lamp glows as long as the preheating is actuat-
ed.
10-170 WA800L-3
STRUCTURE AND FUNCTION ELECTRICAL TRANSMISSION CONTROL
FUNCTION
Selection of F, R, and N positions Using directional switch
Selection of speed range Using shift-down switch and shift-up switch
It is possible to shift down to 1st using this switch.
Kick-down switch
If directional switch is operated to R or N, kick-down is reset.
In auto shift mode, if this switch is pressed, gear speed is fixed. If it is pressed again,
Hold switch
gear speed is unfixed.
Transmission cut-off function Transmission is shifted to neutral when left brake pedal is operated.
It is possible to select whether to actuate or not actuate the transmission cut-off func-
Transmission cut-off selector tion. In this way, it is possible to obtain the same or greater ease of operation as on
function conventional loaders with the left brake when carrying out scooping work or when load-
ing or unloading the machine from a trailer.
To prevent seizure of the parking brake when traveling with the parking brake applied,
Neutralizer
the transmission is shifted to neutral when the parking brake is applied.
If the directional switch is not at the N position, the engine will not start when the start-
Neutral safety function ing switch is turned. This prevents the machine from starting suddenly. (For details, see
STARTING CIRCUIT.)
When traveling in reverse, the backup lamp lights up and the back-up horn sounds to
Warning function
warn people in the area.
WA800L-3 10-171
STRUCTURE AND FUNCTION KICK-DOWN, HOLD SWITCH
1. Kick-down switch
2. Spring
3. Spring
4. Hold switch
5. Wiring harness
10-172 WA800L-3
STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION (ATM) SYTEM
• The automatic transmission system consists of • The self-diagnosis system monitors the input
a transmission controller, directional switch, and output conditions constantly and displays
shift-down switch, shift-up switch, engine rota- them on the two "7-segment LED's" of the trans-
tion sensor, speed sensor, transmission oil tem- mission controller. If it detects any failure, it dis-
perature sensor, and solenoid for the all gear plays the failure code, and displays the "remedy
speeds. code" on the main monitor and flashes the cau-
• The transmission controller shifts the transmis- tion lamp for higher safety, depending on the de-
sion to the gear speed selected with the shift- gree of the failure.
down switch and shift-up switch or to a proper • The transmission controller has a communicat-
gear speed judged from the travel speed signal. ing function and transmits the travel direction
• The transmission controller has the "joystick and gear speed information (F, N, R, 1, 2, 3) to
steering control function". the main monitor, and the main monitor displays
• The safety function prevents the machine from it.
starting when the engine is started and protects
the transmission when the travel direction is
changed. With this function, the transmission
and clutch are protected and their durability is
heightened.
WA800L-3 10-173
STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION (ATM) SYTEM
System configuration
P Travel speed
Engine speed D
*1. The output of the manual indicator lamp is judged by the main monitor.
10-174 WA800L-3
STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION (ATM) SYTEM
OUTLINE
1. Auto gear shift function 5) Skip shift
When the engine speed is 1,450 rpm or higher, If the accelerator pedal is pressed while the
shifting up and shifting down operations of the machine is coasting in the 3rd gear speed at
transmission are controlled with the signals of speed below 8 km/h (in the engine speed
the directional switch, shift-down switch, shift-up OFF mode), the 2nd gear speed is selected
switch, and travel speed sensor, according to immediately so that the machine can be
the "automatic gear shift change points table" accelerated easily. If the travel speed is 8
(Table 1) saved in the transmission controller. km/h or higher, however, the present gear
1) Gear shift range (1 – 3) speed is maintained. Then, if the engine
The highest gear speed (gear shift range) speed exceeds 1,450 rpm, the gear speed
for the auto gear shift is limited. matched to the travel speed is selected.
Example: 6) Period in which gear speed cannot be
Gear shift range 3: changed
Between 2nd and 3rd gear speeds A certain period to keep each gear speed
Gear shift lever 2: Only 2nd gear speed after gear shifting operation is set to prevent
Gear shift lever 1: Only 1st gear speed gear shift hunting. This period depends on
2) When directional switch is in "N" position the gear shifting pattern. See "Table 1 Auto-
If the directional switch is in the neutral posi- matic gear shift change points table".
tion, only the gear speed clutch of the trans-
mission is operated. 2. Hold function
3) When directional switch is in "F" position The gear speed when the hold switch is pressed
If the directional switch is set from the N is held as the optimum gear speed. In this case,
position to the F position, the solenoids of even if the travel speed lowers, the transmission
the F and 2nd of the transmission are turned is not shifted down. If the travel direction is
on (F2). (Auto 2nd start) changed, however, the transmission is usually
a) When the gear is shifted up (when gear shifted down to the 2nd, then shifted up to the
shift range is "3rd") set hold gear speed according to the gear shift
When the accelerator pedal is pressed travel speed condition. (This function prevents
to accelerate the machine and the travel unnecessary gear shift-down operation while the
speed reaches about 5.4 km/h, the 2nd machine is traveling on finished or downhill
solenoid is turned "ON" and the 1st is ground.)
turned "OFF". (The transmission is set
in the F2.) 3. Kick-down function
If the travel speed reaches about 10.9 If the operation (the operation of turning "ON"
km/h, the 3rd solenoid is turned "ON" the kick-down switch) by the operator satisfies
and the 2nd is turned "OFF". (The the conditions (gear speed and travel speed) in
transmission is set in the F3.) "Table 1 Automatic gear shift change points
b) When the gear is shifted down (when table, Item 5. Kick-down", the transmission is
gear shift range is "3rd") shifted down to the 1st gear forcibly, regardless
If the accelerator pedal is released and of the auto shift function.
the travel speed lowers to about 10.3 This function is reset when the travel speed
km/h while traveling in the 3rd gear rises or the travel direction is changed. In this
speed, the 2nd solenoid is turned "ON" case, the transmission is set in the 2nd gear
and the 3rd is turned "OFF". (The trans- speed. This function is effective while the gear
mission is set in the F2 position.) speed is held (Hold or engine speed OFF
4) When directional switch is in "R" position mode).
Similarly to the operation in the F position,
the 2nd or 3rd gear speed (when the gear
shift range is 3) is selected automatically
according to the travel speed when the
modulated clutch outlet speed is 1,450 rpm
or higher.
WA800L-3 10-175
STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION (ATM) SYTEM
10-176 WA800L-3
STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION (ATM) SYTEM
WA800L-3 10-177
STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION (ATM) SYTEM
Joystick steering
Auto mode
Effective functions: Auto shift, kick-down switch, hold, and transmission protect
Solenoid output The highest using gear speed is set with the shift-
Directional down switch and shift-up switch
Gear speed before
switch F R
setting to N (The function of protecting the transmission from a
F Q change of the travel direction is installed)
N Q (*1) Transmission shift Solenoid output
R Q lever position 1 2 3
*1. Initial output value of gear speed solenoid. 1 Q
2 Q Q
When the starting switch is turned ON, the geer speed
used finaly in the previous operation is selected. When 3 Q Q Q
the mode is changed between auto-shift and manual- Effective area of kick-down (Shifting down to 1st)
shift, the 2nd gear speed is selected.
Manual mode
(Note) When the gearshift lever is in the "2" or higher position and the gear speed is the 1st, if the travel direction
is changed, the transmission is shifted to the 2nd.
10-178 WA800L-3
STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION (ATM) SYTEM
7. Self-diagnosis function
The transmission controller constantly monitors
the input and output signals of the automatic
transmission system, and executes self-diagno-
sis and displays the result with the LED of the
transmission controller.
The transmission controller also transmits the
following data to the main monitor.
1) Normal display: The output gear speed is
displayed with the LED of the transmission
controller.
2) Display of failure code: If any trouble is
detected, its contents are displayed by the
code. For the failure codes, see Table 2
Failure codes table
WA800L-3 10-179
STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION (ATM) SYTEM
a On the LED display unit, "0o 0o" is displayed after the program part No.
10-180 WA800L-3
STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION (ATM) SYTEM
WA800L-3 10-181
STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION (ATM) SYTEM
Display Contents 0o 2o Fo 2o
10-182 WA800L-3
STRUCTURE AND FUNCTION AJSS (Advanced joystick steering system)
WA800L-3 10-183
STRUCTURE AND FUNCTION AJSS (Advanced joystick steering system)
Control function
• Potentiometer calibration function
• Neutral interlock function
• Troubleshooting function
Outline
• The flow rate gain of the steering hydraulic system is controlled according to the difference between the joy-
stick steering lever angle and the frame angle to improve the narrow steering angle characteristics and re-
sponse in quick counter steering. As a result, the controllability of the vehicle is improved.
Troubleshooting function
The controller constantly checks that the electronic devices composing each potentiometer which collects input
signals, each solenoid valve which receives output signals, etc. are operating normally.
If any of those devices becomes abnormal, the controller detects it and indicate it by the “Failure code” on the
main monitor to notify the operator of it.
10-184 WA800L-3
STRUCTURE AND FUNCTION AJSS (Advanced joystick steering system)
POTENTIOMETER
1. Connector 5. Bearing
2. Case 6. Contact
3. Shaft 7. Mold
4. Element
Function
The potentiometer senses the operating angle. In
the potentiometer, the source voltage of 5 V is con-
verted with a variable resistor into a signal voltage
according to the angle, then sent to the controller.
The hatched area in the above figure is the abnor-
mality detection area. If the controller receives the
above signal in this area, it judges that the potenti-
ometer system has a trouble such as wire breakage,
short circuit, etc. Since the correct position cannot
be sensed in this case, the control output is turned
off and the failure code is displayed on the main
monitor.
WA800L-3 10-185
STRUCTURE AND FUNCTION AJSS (Advanced joystick steering system)
10-186 WA800L-3
STRUCTURE AND FUNCTION AJSS (Advanced joystick steering system)
Connector signal
C1 C3A C4
Pin Input/ Pin Input/ Pin Input/
Name of signal Name of signal Name of signal
No. output No. output No. output
1 NC — 1 NC — 1 NC —
2 T/M F SOL. Output 2 NC — Engine revolution sensor
2 Input
3 T/M 1 SOL. Output 3 S/T lever potentiometer Input (+)
4 Engine revolution output Output 4 NC — 3 RS232C TXD Input
5 T/M 3 SOL. Output 5 NC — 4 RS232C RXD Input
6 GND Input Pressure sensor power 5 NC —
6 Output
7 Power supply (+24V) Input supply (+24V) 6 NC —
8 Back lamp relay Output Potentio power supply 7 NC —
7 Output
(+5V) 8 Flash write switch. Input
9 T/M R SOL. Output
8 NC — 9 Puls GND Output
10 T/M 2 SOL. Output
9 NC — 10 RS232C GND Input
11 NC —
10 Engine select Input 11 NC —
12 GND Input
11 NC — 12 NC —
13 Power supply (+24V) Input
12 NC —
C2 C5
Frame angle potentiome-
13 Input
Pin Input/ ter Pin Input/
Name of signal Name of signal
No. output 14 NC — No. output
SOL. power supply 15 NC — 1 GND (for Plus) Output
1 Input
(+24V) GND (for pressure sen- 2 Speed sensor (+) Input
16 Output
2 Auto 1 range LED (+) Output sor) 3 GND Output
3 Auto 3 range LED (+) Output 17 GND (for potentio) Output 4 GND Output
4 Auto 2 range LED Output 18 NC — 5 Kick down switch Input
5 NC — Potentiometer CAL 6 T/M cut off switch Input
19 Input
6 NC — switch 7 NC Ñ
7 S/T EPC SOL (+) Output 20 NC — 8 NC Ñ
J/S lever neutral safety C3B 9 NC Ñ
8 Output
relay (+) 10 GND (for Plus) Output
Pin Input/
J/S caution buzzer relay Name of signal 11 NC Ñ
9 Output No. output
(+)
1 NC — 12 NC Ñ
10 Caution (monitor) (+) Output
2 Machine select 1 Input 13 Hold switch Input
11 PGND Input
Machine select (EVEN 14 Auto/manual switch Input
SOL. power supply 3 Input
12 Input parity) 15 NC Ñ
(+24V)
4 S-NET (+) Input 16 NC Ñ
13 NC —
5 Direction F Input 17 NC Ñ
14 NC —
6 Direction R Input
15 NC — Machine Select Table
7 Shift up switch (N. O.) Input
16 NC — Machine
8 Shift down switch (N. O.) Input WA800-3
17 S/T EPC SOL (–) Output Pin
S/T lever lock pressure
18 NC — 9 Input C3B-2 OPEN
switch
J/S caution buzzer relay C3B-10 GND
19 Output 10 Machine select 2 Input
(–) C3B-3 OPEN
11 NC —
20 NC —
12 S-NET (+) Input Engine Selection Table
21 PGND Input
13 Direction N Input
Engine
14 Neutralizer relay Input KOMATSU CUMMINS
Pin
15 Shift up switch (N. C.) Input C3A-10 OPEN GND
16 Shift down switch (N. C.) Input GND: Connect GND.
OPEN: Disconnect GND.
WA800L-3 10-187
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
10-188 WA800L-3
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
FUNCTION
1. Applying and releasing parking brake
The parking brake is applied or released by
using the parking brake switch (combination
switch).
2. Emergency brake
If there is damage to the hydraulic circuit, and
the pressure inside the accumulator drops and it
is impossible to guarantee the braking force of
the brake, the parking brake is automatically
applied to act as an emergency brake.
4. Neutralizer
The parking brake may seize if the machine is
driven with the parking brake still applied. To
prevent this problem, the caution lamp lights up
and the alarm buzzer sounds to warn the opera-
tor of the mistaken operation. In addition to this,
when the parking brake is applied, the transmis-
sion is forcibly shifted to neutral to make it
impossible to driven the machine. However, the
braking distance will become longer if the trans-
mission is shifted to neutral when the emer-
gency brake is applied. It may also be
necessary to move the machine if it stops in
places where it is prohibited to stop (such as on
railway crossings). To overcome this, the circuits
is designed so that the transmission is not
shifted to neutral when the emergency brake is
applied.
WA800L-3 10-189
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
10-190 WA800L-3
(1)
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
OPERATION
1. STARTING SWITCH OFF
WA800L-3 10-191
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
2. STARTING SWITCH ON
2-1 When parking brake switch is ON (actuated) before starting switch is turned ON
10-192 WA800L-3
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
2-2 When parking brake switch is OFF (released) before starting switch is turned ON
WA800L-3 10-193
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
10-194 WA800L-3
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
WA800L-3 10-195
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
10-196 WA800L-3
20 TESTING AND ADJUSTING
a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert
the safety pins, and use blocks to prevent the machine from moving.
k When carrying out work together with other workers, always use signals and do not let unauthorized
people near the machine.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed
when the water is still hot, the water will spurt out and cause burns.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
WA800L-3 20-1
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
Engine SAA12V140ZE-2
(Water temperature:
Blow-by pressure kPa 1.47 2.94
Operating range)
(SAE30 oil) {mmH2O} {150} {300}
Rated output
(Water temperature:
0.25 – 0.39 0.18
Operating range)
{2.5 – 4.0} {1.8}
At high idling (SAE30)
20-2 WA800L-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
45 – 55°C
LOWERoFLOAT N {kg} Max. 34.3 {3.5} 51.9 {5.3}
• Hook push-pull scale to center
FLOAToHOLD of lever knob and measure. Max. 14.7 {1.5} 23.5 {2.3}
• Measure maximum value.
HOLDoDUMP Max. 23.5 {2.4} 35.3 {3.6}
45 – 55°C
HOLDoFLOAT mm 67 ± 15 67 ± 30
• Hook push-pull scale to center
HOLDoDUMP of lever knob and measure. 60 ± 15 60 ± 30
Bucket • Measure maximum value.
HOLDoTILT 60 ± 15 60 ± 30
Operating
lever
Operating angle ( 1) 50 —
deg.
Operating angle ( 2) 33 —
• Engine stopped
Operating angle
Neutral ( 1) 45 —
deg.
Maximum ( 2) 15 —
Play mm 5 ± 0.5 —
WA800L-3 20-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
B mm Max. 4.0 —
• Steering is relieved.
• Engine started
Emergency steering relief • Hydraulic oil temperature: MPa 20.58 ± 0.49 20.58 ± 0.98
pressure 45 – 55°C {kg/cm2} {210 ± 5} {210 ± 10}
• Machine speed: 24 km/h
• Brake oil
pressure 5.88 +0.49
–0 5.88 +0.98
–0.49
Charge cut-in pressure warning
• Engine speed: +5 +10
lamp: When {60 +0 } {60 –5 }
Accumulator
20-4 WA800L-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
(11°20’) grade
• Machine at operating condition
31.36 +0.98
–0.29 31.36 +0.98
–1.27
Boom relief pressure
Oil pressure
+0.98 +0.98
31.36 –0.29 31.36 –1.27
Bucket relief pressure • Relieve only measuring circuit
+10 +10
{320 –3 } {320 –13 }
Clearance between bucket
positioner and proximity 3–5 —
switch mm
Clearance between boom
3–5 —
kick-out and proximity switch
WA800L-3 20-5
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
RAISE
• Engine coolant temperature: 10.4 ± 0.5 13.3
Within operating range
• No load
• Steering: Straight
Boom speed
LOWER
• Full throttle
Work equipment speed
45 – 55°C
DUMP
At full stroke
horizontal
mm
Retraction of bucket
Max. 20 20
cylinder rod
20-6 WA800L-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Measure
Between C1 (7), (13) – chassis
voltage
C1 3) Turn starting
Power supply Between C2 (1), (12) – chassis
C2 20 – 30 V switch ON.
Between C1 (7), (13) – (6), (12)
Between C2 (1), (12) – (11), (21)
2) Insert T-adapter.
voltage
switch ON.
Turn parking brake (1) – (3)
Max. 1 V
switch OFF
TR1 2) Disconnect
Solenoid (3rd) Between (3) – (6) 5 – 15 z
(male) connectors.
Between (3), (6) – chassis Max. 1 Mz 3) Connect T-
adapter.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
resistance
Measure
TR1 2) Disconnect
Solenoid (R) Between (5) – (6) 5 – 15 z
(male) connectors.
Between (5), (6) – chassis Max. 1 Mz 3) Connect T-
adapter.
WA800L-3 20-7
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
resistance
Measure
Engine speed Between (A) – (B) 500 – 1,000 z 2) Disconnect
E03
sensor connectors.
Between (A), (B) – chassis Max. 1 Mz 3) Connect T-
adapter.
Measure in AC range. 1) Turn starting
Controller
Measure
voltage
Engine speed switch OFF.
C4 Between (2) – (9) Min. 0.5 V
sensor 2) Insert T-adapter.
3) Start engine.
1) Screw in the engine speed sensor until it con-
Adjust
Engine speed
— tacts the ring gear, then turn it back 1 turn. —
sensor
2) It works normally by adjustment above.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
resistance
Measure
adapter.
1) Screw in until the tip of sensor contact gear,
Adjust
Measure
voltage
2) Disconnect
Measure
2) Disconnect
Measure
Shift-up switch at
Shift-up switch Max. 1 z connectors.
ON Between
3) Connect T-
Shift-up switch at (3) – (4)
Min. 1 Mz adapter.
OFF
20-8 WA800L-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Measure
voltage
Manual Manual switch at ON Between Max. 1 V 2) Insert T-adapter.
C5 3) Turn starting
switch (14) –
Manual switch at switch ON.
chassis 20 – 30 V
OFF
Measure
Joystick FNR
voltage
When joystick FNR
button switch Between 17 – 30 V 3) Turn starting
switch is in “F”
“F” (5) – switch ON.
When joystick FNR chassis Max. 1 V
switch is not in “F”
Joystick FNR
voltage
Joystick gear
voltage
Joystick
voltage
Joystick
voltage
Joystick
voltage
WA800L-3 20-9
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Measure
Joystick
voltage
When joystick shift-
shift-down Between 17 – 30 V 3) Turn starting
down switch is “ON”
switch (N.C) (16) – switch ON.
When joystick shift- chassis Max. 1 V
down switch is “OFF”
C3B
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Measure 2) Insert T-adapter.
Steering lock voltage When steering lock
Between 17 – 30 V 3) Turn starting
signal lever is in “LOCK”
(9) – switch ON.
When steering lock chassis Max. 1 V
lever is in “FREE”
Joystick lever
voltage
20-10 WA800L-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
resistance
2) Disconnect
Measure
System cut-off (male) System cut-off
Transmission & Joystick steering controller
WA800L-3 20-11
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
All specifications
aBe sure no one is nearby, and then carry out testing.
Measure
voltage
Power supply L05 Between (1), (2) – chassis 2) Insert T-adapter.
20 – 30 V 3) Turn starting
Between (1), (2) – (3) switch ON.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
Engine running 2) Insert T-adapter.
Measure
voltage 28 ± 2 V
Charge (At above 1/2 throttle) Between
L05 (5) – (3)
(Alternator)
Starting switch ON Max. 1 V
* If the battery is old, or after starting in cold
areas, the voltage may not rise for some time.
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
resistance
Measure
o1V
voltage
20-12 WA800L-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Measure
voltage
Starting switch 2) Insert T-adapter.
L07 Starting switch ON Between 20 – 30 V
BR terminal
Starting switch OFF (10) – (12) Max. 1 V
resistance
2) Disconnect
Measure
Parking brake F13 Parking brake
Max. 1 z connectors.
indicator switch (male) switch ON Between
3) Connect
Parking brake (1) – (2)
Min. 1 Mz T-adapter.
switch OFF
2) Disconnect
Measure
2) Disconnect
Measure
WA800L-3 20-13
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
resistance
Measure
R05 to stopper 4) Remove fuel
Fuel level sensor
(male) level sensor.
Float 5) Connect
lowered Approx. 85 z T-adapter.
to stopper
Brake T-adapter.
(male) {55 ± 5 kg/cm }2
accumulator low Between
BC06
pressure switch Depress brake and (1) – (2)
(male)
lower accumulator
BC07
pressure to below Min. 1 Mz
(male)
4.41 ± 0.49 MPa
{45 ± 5 kg/cm2}
2) Disconnect
Measure
20-14 WA800L-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
R.H.
B09 2) Disconnect
continuity
Between B09
Air cleaner normal Continuity
Check
Air cleaner (male) (1) – B08(1) connectors.
clogging sensor B06 3) Start engine.
Air cleaner clogged Between B07 No
(female) 4) Check sensor
L.H. or engine stopped (1) – B06 (1) continuity
B07 side connector
(male) by using tester.
If the condition is as shown in the table below, monitor panel is normal. 1) Connect
T-adapter.
Table 1 (CHECK lamp & CAUTION lamp)
s
Engine water
temperature
Gauge gauge
L18 (male)
Measure
resistance
between
(4) – (3)
Torque
converter oil
temperature
gauge
L18 (male)
Measure
resistance
between
(5) – (3)
WA800L-3 20-15
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
resistance
Measure
monitor
20-16 WA800L-3
(1)
TESTING AND ADJUSTING
Table of tools for testing, adjusting and troubleshooting ............................................................................. 20-102
Measuring engine speed............................................................................................................................. 20-104
Measuring exhaust gas color ...................................................................................................................... 20-105
Adjusting valve clearance ........................................................................................................................... 20-106
Measuring compression pressure ............................................................................................................... 20-106
Measuring blow-by pressure....................................................................................................................... 20-106
Testing and adjusting fuel injection timing................................................................................................... 20-106
Measuring engine oil pressure.................................................................................................................... 20-106
Measuring exhaust temperature ................................................................................................................. 20-106
Measuring air supply pressure (boost pressure)......................................................................................... 20-106
Testing and adjusting alternator belt tension............................................................................................... 20-107
Testing and adjusting belt tension for air conditioner compressor .............................................................. 20-108
Measuring accelerator pedal....................................................................................................................... 20-109
Testing and adjusting torque converter and transmission oil pressure ....................................................... 20- 110
Procedure for operating emergency steering spool when transmission valve fails..................................... 20- 112
Testing and adjusting steering oil pressure ................................................................................................. 20- 114
Testing and adjusting emergency steering oil pressure .............................................................................. 20- 115
Bleeding air from steering circuit................................................................................................................. 20- 117
Testing and adjusting steering stopper bolt................................................................................................. 20- 118
Testing and adjusting steering lever angle sensor and frame angle sensor ............................................... 20- 119
Testing wheel brake performance ............................................................................................................... 20-120
Testing wheel brake oil pressure drop ........................................................................................................ 20-121
Measuring wear of wheel brake disc........................................................................................................... 20-123
Testing and adjusting accumulator charge cut-in and cut-out pressure...................................................... 20-124
Bleeding air from wheel brake circuit .......................................................................................................... 20-126
Testing parking brake performance............................................................................................................. 20-127
Measuring parking brake solenoid output pressure .................................................................................... 20-128
Checking and adjusting parking brake pad ................................................................................................. 20-129
Testing and adjusting PPC pressure........................................................................................................... 20-131
Adjusting PPC valve linkage ....................................................................................................................... 20-132
Testing and adjusting work equipment hydraulic pressure ......................................................................... 20-133
Bleeding air from piston pump .................................................................................................................... 20-135
Bleeding air from work equipment circuit .................................................................................................... 20-136
Adjusting work equipment lever linkage...................................................................................................... 20-137
Releasing remaining pressure in hydraulic circuit....................................................................................... 20-138
Testing and adjusting bucket proximity switch ............................................................................................ 20-139
Testing and adjusting boom proximity switch.............................................................................................. 20-139
Testing proximity actuation pilot lamp ......................................................................................................... 20-140
Adjusting speedometer module of main monitor......................................................................................... 20-141
WA800L-3 20-101
(1)
TESTING AND ADJUSTING TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Check or measurement
Part No. Part name Remarks
item
20-102 WA800L-3
(1)
TESTING AND ADJUSTING TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
Symbol
Check or measurement
Part No. Part name Remarks
item
Measuring voltage,
R 79A-264-0211 Tester —
resistance value
1 799-601-7400 T-adapter assembly —
799-601-7310 SWP12P
Troubleshooting of wiring 799-601-7320 SWP16P
S
harness, sensors 2 799-601-7340 Adapter M8P
799-601-7380 JFC2P
799-601-3460 MS10P
WA800L-3 20-103
(1)
TESTING AND ADJUSTING MEASURING ENGINE SPEED
20-104 WA800L-3
(1)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
WA800L-3 20-105
(1)
TESTING AND ADJUSTING ADJUSTING ENGINE
ADJUSTING VALVE
CLEARANCE
MEASURING COMPRESSION
PRESSURE
MEASURING BLOW-BY
PRESSURE
MEASURING EXHAUST
TEMPERATURE
20-106 WA800L-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION
WA800L-3 20-107
(1)
TESTING AND ADJUSTING BELT TENSION FOR AIR
TESTING AND ADJUSTING CONDITIONER COMPRESSOR
20-108 WA800L-3
(1)
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
WA800L-3 20-109
(1)
TESTING AND ADJUSTING TORQUE CONVERTER AND
TESTING AND ADJUSTING TRANSMISSION OIL PRESSURE
MEASURING PROCEDURE
a The following preparatory work is necessary be-
fore measuring any oil pressure.
• Remove cover on upper side of the transmis-
sion.
• Turn transmission cut-off selector switch (2)
to OFF and use the left brake. (Check that
the pilot lamp is OFF).
• Remove the plug (P5) (PT 1/8) from the
measuring port of the transmission valve.
• Install nipple C2 and hydraulic tester C1 (2.5
MPa {25 kg/cm2})to the measuring port, pull
the gauge to the operator’s compartment,
then start the engine and measure the pres-
sure.
a Check that there is no leakage of oil from any
joints.
20-110 WA800L-3
(1)
TESTING AND ADJUSTING TORQUE CONVERTER AND
TESTING AND ADJUSTING TRANSMISSION OIL PRESSURE
WA800L-3 20-111
(1)
PROCEDURE FOR OPERATING EMERGENCY STEERING
TESTING AND ADJUSTING SPOOL WHEN TRANSMISSION VALVE FAILS
PROCEDURE FOR
OPERATING EMERGENCY
STEERING SPOOL WHEN
TRANSMISSION VALVE FAILS
OUTLINE
• The transmission valve is controlled electrically.
Therefore, the emergency manual spool is in-
stalled to enable the machine to be moved if
there is any failure in the electrical system, or in
the solenoid valve and spool.
k The emergency manual spool is for use when
failure in the transmission control prevents the 3. Decide the direction to move the machine (for-
machine from being moved. It allows the ma- ward or in reverse), then move the emergency
chine to be moved from a dangerous place to a manual spool to the operating position.
place where repairs can be carried out safety.
The emergency manual spool must never be FORWARD: Rotate FORWARD clutch spool and
used except when the transmission control has 1st spool counterclockwise, and
broken down.
k
pull out approx. 10 mm to the oper-
When operating the emergency manual spool, ating position.
follow the correct order of operation exactly, and REVERSE: Rotate REVERSE clutch spool and
pay full attention to safety when moving the ma- 1st spool counterclockwise, and
chine.
k
pull out approx. 10 mm to the oper-
To prevent the machine from moving, lower the ating position.
bucket to the ground, apply the parking brake,
and block the wheels.
OPERATION
1. Open cover on upper side of transmission.
k Always stop the engine before operating
spool.
20-112 WA800L-3
(1)
PROCEDURE FOR OPERATING EMERGENCY STEERING
TESTING AND ADJUSTING SPOOL WHEN TRANSMISSION VALVE FAILS
WA800L-3 20-113
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING OIL PRESSURE
TESTING AND ADJUSTING 3. Start the engine and run it at the full speed. Turn
the joystick lever to the left and measure the
STEERING OIL PRESSURE hydraulic pressure when the relief valve actu-
ates.
MEASURING a When removing the oil pressure measure-
• Hydraulic oil temperature: 45 – 55°C ment plug from left-hand steering cylinder,
turn the joystick lever to the right and meas-
k Install the safety bar to lock front frame and rear ure the oil pressure.
frame.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then operate ADJUSTING
k
the joystick lever 2 – 3 times to release the re- If the relief pressure is not normal, adjust the
maining pressure in the hydraulic piping. steering relief valve according to the following
procedure.
k
1. Remove hydraulic oil pressure measurement Adjust the steering relief valve while the engine
plug (2) (PT 1/8) from right-hand steering cylin- is stopped.
der (1). Loosen lock nut (3), then turn adjustment screw
(4) to adjust.
a Amount of adjustment for 1 turn of adjust-
ment screw.
1 turn: Approx. 17.8 MPa {181 kg/cm2}
a Adjust the set pressure as follows.
To INCREASE pressure, TIGHTEN screw.
To DECREASE pressure, LOOSEN screw.
a If it is impossible to measure relief pressure
accurately, do not try to adjust the pressure.
20-114 WA800L-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE
TESTING AND ADJUSTING 4. Remove plug (5) (PT 1/8) between diverter
valve and steering valve, and install nipple C2
EMERGENCY STEERING OIL and hydraulic tester C1 (39.2 Mpa {400 kg/
PRESSURE cm2}).
MEASURING
• Hydraulic oil temperature: 45 – 55°C
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank. Then operate
the steering wheel 2 – 3 times to release the re-
maining pressure in the hydraulic piping.
k Fit the safety bar to lock the front frame and rear
frame.
WA800L-3 20-115
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE
20-116 WA800L-3
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM STEERING CIRCUIT
WA800L-3 20-117
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING STOPPER BOLT
TESTING ADJUSTING
1. Start the engine and set steering lock lever (1) in a If clearance a is abnormal, adjust it according to
the free position. the following procedure.
2. Run the engine at low idling and move joystick 1. Set the steering lock lever in the free position
steering lever (2) to the right or left stroke end and return the steering lever to the neutral posi-
and keep it at that position. tion.
k Operate the steering lever slowly and take
care not to catch your body or arm between 2. Set the steering lock lever in the lock position.
the front frame and rear frame.
3. Adjust projection b of adjustment bolt (5) on the
3. Set steering lock lever (1) in the lock position. side where clearance a is abnormal.
a If projection b is increased, clearance a is in-
4. Check that clearance a between the end stop- creased, too. If the former is decreased, the
pers of the front frame (3) and rear frame (4) is latter is decreased, too.
20-118 WA800L-3
(1)
TESTING AND ADJUSTING STEERING LEVER ANGLE
TESTING AND ADJUSTING SENSOR AND FRAME ANGLE SENSOR
TESTING ADJUSTING
1. Start the engine and set steering lock lever (1) in a If the caution buzzer does not sound, adjust the
the free position. sensors according to the following procedure.
2. Run the engine at low idling and operate joystick 1. Loosen the mounting bolt of steering lever angle
steering lever (2) to set the steering system in sensor (4) or frame angle sensor (5) and adjust
the neutral position (position for straight travel). the position of the sensor.
a When the front frame can be locked with the a Standard position (Reference):
safety bar, the steering system is in the neu- Position at which bolt is at center of oblong
tral position (straight travel position). hole
3. Set steering lock lever (1) in the lock position a After adjusting, check the operation of the cau-
and run the engine at low idling. tion buzzer according to the procedure explained
a Do not move the joystick steering lever dur- above.
ing steps 3 through 5.
WA800L-3 20-119
(1)
TESTING AND ADJUSTING TESTING WHEEL BRAKE PERFORMANCE
20-120 WA800L-3
(1)
TESTING AND ADJUSTING TESTING WHEEL BRAKE OIL PRESSURE DROP
TESTING WHEEL BRAKE OIL 3. Set brake tester kit J1 in position and connect
coupler J2 and pump J3.
PRESSURE DROP
k
4. Loosen bleeder (4), operate pump J3 to bleed
Apply the parking brake and put blocks securely the air, then tighten bleeder (4).
under the tires.
WA800L-3 20-121
(1)
TESTING AND ADJUSTING TESTING WHEEL BRAKE OIL PRESSURE DROP
20-122 WA800L-3
(1)
TESTING AND ADJUSTING MEASURING WEAR OF WHEEL BRAKE DISC
MEASURING WEAR OF
WHEEL BRAKE DISC
k Stop the machine on level ground and block the
tires.
WA800L-3 20-123
(1)
TESTING AND ADJUSTING ACCUMULATOR CHARGE
TESTING AND ADJUSTING CUT-IN AND CUT-OUT PRESSURE
TESTING AND ADJUSTING 3. Install adapter and nipple C2, then connect oil
pressure gauge C1 (39.2 MPa {400 kg/cm2}) .
ACCUMULATOR CHARGE
CUT-IN AND CUT-OUT
PRESSURE
MEASURING
a Brake oil temperature: 45 – 55°C
k Depress the brake pedal at least 100 times with
the engine stopped to release the pressure in-
side the accumulator circuit.
20-124 WA800L-3
(1)
TESTING AND ADJUSTING ACCUMULATOR CHARGE
TESTING AND ADJUSTING CUT-IN AND CUT-OUT PRESSURE
ADJUSTING
Accumulator charge cut-out pressure
a When the accumulator charge cut-out pressure
is adjusted, the cut-in pressure also changes in
proportion to the ratio of the valve area. For this
reason, there is no adjustment screw for the cut-
in pressure.
a Adjustment screw
• To INCREASE cut-out pressure, turn
CLOCKWISE
• To DECREASE cut-out pressure, turn
COUNTERCLOCKWISE
a Pressure adjustment for one turn of adjustment
WA800L-3 20-125
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM WHEEL BRAKE CIRCUIT
BLEEDING AIR FROM WHEEL 5. Similarly, bleed air from the slack adjuster on the
opposite side and bleeder (3) of each wheel.
BRAKE CIRCUIT a If the accumulator pressure goes down, start
the engine and charge the accumulator.
a If brake circuit hoses were disconnected be- a After completion of the air bleed operation,
cause of removing brake valve or axle, bleed air run the engine at low idling, check the hy-
as follows.
k Apply the parking brake and put blocks securely
draulic oil level, and add oil if necessary.
a After bleeding air, perform "TESTING WHEEL
under the tires.
k When engine is running, never bleed air from
BRAKE PERFORMANCE".
20-126 WA800L-3
(1)
TESTING AND ADJUSTING TESTING PARKING BRAKE PERFORMANCE
WA800L-3 20-127
(1)
TESTING AND ADJUSTING MEASURING PARKING BRAKE SOLENOID OUTPUT PRESSURE
MEASURING PARKING
BRAKE SOLENOID OUTPUT
PRESSURE
a Brake oil temperature: 45 – 55°C
k Put blocks securely under the tires.
k Depress the brake pedal at least 100 times with
the engine stopped to release the pressure in-
side the accumulator circuit.
2. Remove front frame right sidecover. 5. Start engine and after accumulator charged,
turn parking brake switch ON.
3. Disconnect parking brake spring cylinder output
hose (1) from parking brake solenoid valve. 6. Measure oil pressure with the engine slow.
20-128 WA800L-3
(1)
TESTING AND ADJUSTING CHECKING AND ADJUSTING PARKING BRAKE PAD
WA800L-3 20-129
(1)
TESTING AND ADJUSTING CHECKING AND ADJUSTING PARKING BRAKE PAD
20-130 WA800L-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING PPC PRESSURE
MEASURING
1. Measuring PPC relief pressure
1) Remove plug (PT 1/8) (1) for P port oil pres-
sure measuring from bottom of PPC valve
assembly.
WA800L-3 20-131
(1)
TESTING AND ADJUSTING PPC PRESSURE
TESTING AND ADJUSTING ADJUSTING PPC VALVE LINKAGE
20-132 WA800L-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
MEASUREMENT
Measuring work equipment relief pressure
1. Raise bucket portion a approx. 30 – 50 mm and
set portion b in contact with the ground.
2. Stop the engine, then operate the work equip- 4. Start the engine and raise the boom, then dump
ment control lever and check that the bottom the bucket with the engine at the full speed and
surface of the bucket (both portion a and portion measure the hydraulic pressure when the relief
valve operates.
k After measuring, repeat the procedure used
b) is in contact with the ground.
k After lowering the bucket to the ground, op-
erate the work equipment control lever 2 – 3 when installing the oil pressure gauge to re-
times to release the remaining pressure in lease the pressure inside the circuit, then
the piping. remove the oil pressure gauge.
WA800L-3 20-133
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
ADJUSTING
Adjusting work equipment relief valve
k Adjust the hydraulic pressure while the engine is
stopped.
Loosen locknut (3) of work equipment relief valve
(2), then turn adjustment screw (4) to adjust.
a Turn the adjustment screw to adjust as follows.
• To INCREASE the pressure, turn CLOCK-
WISE.
• To DECREASE the pressure, turn COUN-
TERCLOCKWISE.
a Amount of adjustment for one turn of adjustment
screw: 12.6 MPa {128 kg/cm2)
a After completion of the adjustment, repeat the
above procedure to measure the work equip-
ment relief pressure again.
20-134 WA800L-3
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM PISTON PUMP
BLEEDING AIR FROM PISTON 4. Loosen the mouthpiece of the case drain hose
(4), starting an engine at the condition of low
PUMP idling. Tighten the mouthpiece, confirming that
hydraulic oil flows from the mouthpiece.
a When replacing oil inside hydraulic tank or re-
moving piston pump or hydraulic pipings of pis-
ton pump, bleed air from piston pump to prevent
pump inner parts seizing as follows.
WA800L-3 20-135
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT
20-136 WA800L-3
(1)
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT LEVER LINKAGE
ADJUSTING WORK
EQUIPMENT LEVER LINKAGE
If the operating effort or travel of the work equipment
control lever is not within the standard value, or the
work equipment control lever, PPC valve assembly,
or boom or bucket solenoids have been removed,
adjust as follows.
WA800L-3 20-137
(1)
ADJUSTING WORK EQUIPMENT LEVER LINKAGE
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
20-138 WA800L-3
(1)
TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM PROXIMITY SWITCH
ADJUSTING
1. Raise the boom to the desired position, stop the
engine, then lock the control lever.
WA800L-3 20-139
(1)
TESTING AND ADJUSTING TESTING PROXIMITY ACTUATION PILOT LAMP
TESTING PROXIMITY
ACTUATION PILOT LAMP
Proximity switch actuation pilot lamp (red)
The proximity switch is equipped with a pilot lamp
which shows when it is being actuated, so use this
when adjusting.
Proximity switch
actuation Lights up Goes out
pilot lamp
When detector is positioned at detection surface When detector has moved away from detection
Detector position
of proximity switch surface of proximity switch
Bucket positioner
Boom kick-out
20-140 WA800L-3
(1)
TESTING AND ADJUSTING ADJUSTING SPEEDOMETER MODULE OF MAIN MONITOR
DIP switch 4
Specification
1 2 3 4
Without auto shift system ON ON OFF ON
With auto shift system ON ON OFF OFF
Switch 2 Switch 3
Switch 1
(speedo- (tacho-
Tire size (model
meter meter input
selection)
correction) selection)
0 (for km/h)
45/65-45-46PR 7 0
9 (for mph)
WA800L-3 20-141
(1)
TROUBLESHOOTING
Points to remember when troubleshooting.................................................................................................. 20-202
Sequence of events in troubleshooting ....................................................................................................... 20-203
Points to remember when carrying out maintenance.................................................................................. 20-204
Checks before troubleshooting ................................................................................................................... 20-212
Types and locations of connectors.............................................................................................................. 20-213
Connector location stereogram ................................................................................................................... 20-220
Connection table for connector pin numbers .............................................................................................. 20-226
T-branch box and T-branch table ................................................................................................................ 20-251
Explanation of functions of electric control mechanism .............................................................................. 20-254
Method of displaying action code and failure code ..................................................................................... 20-258
Chart of action codes and failure codes, and re-enaction........................................................................... 20-260
Transmission controller led display ............................................................................................................. 20-262
Method of using judgement table ................................................................................................................ 20-263
Method of using troubleshooting charts ...................................................................................................... 20-264
Method of using matrix troubleshooting tables............................................................................................ 20-266
Method of using troubleshooting charts ...................................................................................................... 20-302
Troubleshooting of transmission control system (T MODE)........................................................................ 20-401
Troubleshooting of main monitor system (M MODE) .................................................................................. 20-501
Troubleshooting of maintenance monitor system (K MODE) ...................................................................... 20-601
Troubleshooting of electrical system (E MODE) ......................................................................................... 20-701
Troubleshooting of hydraulic and mechanical system (H MODE)............................................................... 20-801
Troubleshooting of ajss (advanced joystick steering system) control system (A MODE) ........................... 20-901
WA800L-3 20-201
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or a When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the a The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
20-202 WA800L-3
(1)
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
WA800L-3 20-203
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-204 WA800L-3
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
WA800L-3 20-205
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull with one hand.
20-206 WA800L-3
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
a If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
a If there is any damage or breakage, re-
place the connector.
WA800L-3 20-207
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
20-208 WA800L-3
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
WA800L-3 20-209
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
20-210 WA800L-3
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c o n tr o l v a lv e , e t c .) o r wh e n r u n ni n g t he
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
WA800L-3 20-211
(1)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
10. Check for looseness, corrosion of alternator terminal, wiring — Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, wiring — Tighten or replace
12. Check operation of instruments — Repair or replace
13. Check for abnormal noise, smell — Repair
mechanical
equipment
Hydraulic,
20-212 WA800L-3
(1)
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
Connector No. of
Type Name of device Address
No. pins
A4 X 2 Air conditioner REC & FRE air servomotor U-9
A5 M 2 Air conditioner thermistor X-6
A6 SWP 6 Air conditioner air mix servomotor X-7
A7 M 6 Air conditioner blower motor & resistor X-6
A8A S 10 Intermediate connector (Air conditioner) X-6
A8B S 8 Intermediate connector (Air conditioner) X-5
A9 YAZAKI 4 Air conditioner blower relay (MAIN) X-4
A10 YAZAKI 4 Air conditioner blower relay (Hi) X-4
A11 YAZAKI 4 Air conditioner blower relay (M2) X-4
A12 YAZAKI 4 Air conditioner condenser relay X-3
A13 YAZAKI 4 Air conditioner blower relay (M1) X-5
A14 YAZAKI 4 Air conditioner condenser Hi (1) relay W-3
A15 YAZAKI 4 Air conditioner condenser Hi (2) relay W-2
A16 YAZAKI 4 Air conditioner magnetic clutch relay X-3
A16 AMP 12 Air conditioner control amplifier R-1
A17 AMP 16 Air conditioner control amplifier Q-1
A18 SWP 8 Air conditioner left air flow servomotor S-1
A19 SWP 8 Air conditioner right air flow servomotor N-5
A21 X 2 Air conditioner condenser Hi-Lo switch X-7
A22 YAZAKI 2 Air conditioner condenser Me switch X-8
AL01 One-pin connector 1 Battery relay L-5
AL02 Terminal 1 Battery relay L-5
AR01 One-pin connector 1 Battery relay L-7
AR02 Terminal 1 Battery relay K-9
AR03 Terminal 1 Battery relay K-9
ASS X 2 Air suspension seat W-8
B02 KES1 2 Front windshield washer I-9
B03 KES1 2 Diode L-5
B04 KES1 2 Rear windshield washer I-9
B05 KES1 2 Diode I-9
B06 One-pin connector 1 Left dust indicator L-4
B07 One-pin connector 1 Left dust indicator L-4
B08 One-pin connector 1 Right dust indicator G-9
B09 One-pin connector 1 Right dust indicator G-9
B10 X 2 Air conditioner left condenser L-6
B11 X 1 Air conditioner left condenser L-6
B12 X 2 Air conditioner right condenser H-9
B13 X 1 Air conditioner right condenser H-9
BC01 X 2 Speed sensor F-1
BC02 X 2 Torque converter oil filter sensor I-2
BC03 X 2 Torque converter oil filter sensor H-1
BC04 X 2 Brake accumulator low pressure switch G-1
BC05 X 2 Brake accumulator low pressure switch H-1
BC06 X 2 Brake accumulator low pressure switch J-3
BC07 X 2 Brake accumulator low pressure switch J-2
BC08 X 2 Emergency brake switch G-1
BC09 X 2 Emergency brake switch H-1
BC10 X 2 Emergency brake switch I-2
WA800L-3 20-213
(1)
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
Connector No. of
Type Name of device Address
No. pins
BC11 X 2 Emergency brake switch J-2
BR1 SWP 12 Intermediate connector K-3
C1 MIC 13 Transmission & joystick steering controller P-7
C2 MIC 21 Transmission & joystick steering controller N-6
C3A AMP040 20 Transmission & joystick steering controller O-7
C3B AMP040 16 Transmission & joystick steering controller P-7
C4 AMP040 12 Transmission & joystick steering controller O-6
C5 MIC 17 Transmission & joystick steering controller N-6
C01 M 6 Front wiper motor C-7
C02 YAZAKI 9 Cassette stereo & radio C-7
C03 M 2 Right front working lamp D-8
C04 M 2 Left front working lamp D-8
C05 KYORITSU 4 Warning lamp (Beacon) switch D-8
C06 KES1 2 Room lamp E-9
C07 M 4 Rear wiper motor K-3
C08 One-pin connector 1 Cigarette lighter C-7
C09 Terminal 1 Cigarette lighter D-8
C10 M 1 Power supply C-7
C11 One-pin connector 1 Right room lamp door switch —
C12 One-pin connector 1 Left room lamp door switch —
C13 KES0 2 Left speaker G-9
C14 KES0 2 Right speaker F-9
C15 One-pin connector 1 Warning lamp (Beacon) E-8
C16 M 2 Left side working lamp G-9
C17 M 2 Right side working lamp E-8
CBL1 SWP 8 Intermediate connector U-1
CL1 S 12 Intermediate connector N-4
CL2 S 10 Intermediate connector (Air conditioner) N-3
CL3 M 6 Intermediate connector (Air conditioner) N-3
CL4 M 6 Intermediate connector N-3
CL18 YAZAKI 1 Left power window regulator —
CL19 YAZAKI 1 Left power window regulator —
CL20 YAZAKI 1 Right power window regulator —
CL21 YAZAKI 1 Right power window regulator —
E01 PACKARD 4 Engine oil level sensor a-2
E02 Terminal 1 Starting motor Z-3
E03 PACKARD 2 Engine speed sensor Z-3
E04 X 2 Engine water temperature sensor (For monitor) b-7
E06 ECONOSEAL 3 Intermediate connector Y-3
E08 X 1 Air compressor magnetic clutch c-7
E09 Terminal 1 Engine oil pressure switch Z-3
E10 Terminal 1 Right heater relay Z-7
E11 Terminal 1 Right heater relay Z-7
E12 Terminal 1 Left heater relay c-3
E13 Terminal 1 Left heater relay d-4
E14 KES 2 Diode Y-5
E15 KES 2 Diode Y-4
E18 KES 2 Diode d-5
E20 Terminal 1 Alternator (B) d-6
E21 Terminal 1 Alternator (I) d-7
E22 Terminal 1 Alternator (E) d-6
E23 PACKARD 1 Intermediate connector Y-5
20-214 WA800L-3
(1)
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
Connector No. of
Type Name of device Address
No. pins
E24 PACKARD 1 Intermediate connector Y-5
ECM1 HD24 31 Engine control (ECM) Y-6
ECM2 HD24 21 Engine control (ECM) Y-5
ER1 SWP 14 Intermediate connector Y-6
ER2 L 2 Intermediate connector Y-4
ER3 L 2 Intermediate connector a-2
ER4 SWP 16 Intermediate connector a-7
F AXLE RH M 2 Front axle work lamp RH A-1
F AXLE LH M 2 Front axle work lamp LH A-1
F01 M 4 Intermediate connector A-5
F02 M 3 Intermediate connector A-5
F03 M 3 Intermediate connector A-3
F04 M 4 Intermediate connector A-2
F05 X 3 Proximity switch for bucket positioner A-3
F06 X 3 Proximity switch for boom kick-out A-4
F07 Terminal 1 Horn (350 Hz) C-1
F08 Terminal 1 Horn (350 Hz) D-1
F09 Terminal 1 Horn (315 Hz) A-5
F10 Terminal 1 Horn (315 Hz) A-4
F11 X 2 Parking brake solenoid B-1
F13 X 2 Parking brake indicator switch B-1
FL1 S 12 Intermediate connector X-5
FL2 SWP 6 Intermediate connector W-2
FL3 One-pin connector 1 Intermediate connector —
FS1 L 2 Intermediate connector (Fuse box) W-8
FS2 S 12 Intermediate connector (Fuse box) W-8
FS2A S 12 Intermediate connector (Fuse box) —
FS3 M 6 Intermediate connector (Fuse box) V-9
FS4 L 2 Intermediate connector (Fuse box) V-9
FS5 M 6 Intermediate connector (Fuse box) V-9
FS6 M 4 Intermediate connector (Fuse box) U-9
G01 M 6 Right rear combination lamp I-9
G02 M 2 Right working lamp (If equipped) K-9
G03 M 2 Right working lamp J-9
G04 Terminal 1 Backup buzzer L-6
G05 Terminal 1 Backup buzzer L-6
G06 X 2 Radiator water level sensor J-9
G07 M 2 Left working lamp K-8
G08 M 2 Left working lamp (If equipped) L-6
G09 M 6 Left combination lamp L-8
GND M 1 Right front combination lamp B-6
GND M 1 Left front combination lamp D-1
GND One-pin connector 1 Intermediate connector (GND) —
GND One-pin connector 1 Intermediate connector (GND) (If equipped) —
GR1 SWP 12 Intermediate connector K-8
GRE SWP 6 Auto grease connector T-1
HEAD M 2 Right head lamp A-6
HEAD M 2 Left head lamp A-1
IL1 One-pin connector 1 Joystick 3 indicator LED F-2
IL2 One-pin connector 1 Joystick 3 indicator LED F-2
IL3 One-pin connector 1 Joystick 1 indicator LED E-3
IL4 One-pin connector 1 Joystick 1 indicator LED E-3
WA800L-3 20-215
(1)
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
Connector No. of
Type Name of device Address
No. pins
IL5 One-pin connector 1 Joystick 2 indicator LED E-3
IL6 One-pin connector 1 Joystick 2 indicator LED E-2
IL7 KES 2 Diode —
IL8 KES 2 Diode —
IL9 KES 2 Diode —
IL10 YAZAKI 2 Diode —
IL11 Relay 5 LED dimmer relay —
JL1 SWP 6 Intermediate connector j-3
JL2 S 10 Intermediate connector I-2
JS1 SWP 12 Joystick lever J-8
JS2 X 3 Steering angle potentiometer J-8
JS3 One-pin connector 1 Joystick console switch J-7
JS4 One-pin connector 1 Joystick console switch J-6
L01 M 3 Parking brake switch E-6
L02 SWP 4 Lighting switch E-6
L03 SWP 2 Hazard switch E-6
L05 AMP040 20 Main monitor N-5
L06 AMP040 16 Main monitor N-2
L07 AMP040 12 Main monitor N-4
L08 AMP040 8 Main monitor O-2
L09 M 4 Starting switch O-2
L10 S 10 Front & rear wiper switch P-1
L12 X 2 Transmission cut-off switch R-1
L15 M 4 Kickdown switch & shift-up switch P-7
L16 KES1 2 Boom kick-out solenoid O-6
L17 KES1 2 Bucket positioner solenoid N-5
L18 AMP040 16 Maintenance monitor Q-8
L19 AMP040 8 Maintenance monitor Q-8
L21 KES1 2 Maintenance monitor R-8
L22 KES1 2 Maintenance monitor R-9
L25 — 3 Throttle pedal O-2
L26 — 2 Joystick EPC solenoid H-2
L27 DT2 3 Frame angle potentiometer H-1
L31 One-pin connector 1 Turn signal switch F-8
L31 — 3 Idle validation switch O-2
L32 One-pin connector 1 Turn signal switch F-8
L33 One-pin connector 1 Turn signal switch E-7
L39 DT2 2 Steering lock oil pressure switch I-2
L40 YAZAKI 7 Right power window switch Q-8
L41 YAZAKI 7 Left power window switch P-8
L42 One-pin connector 1 Caution buzzer S-9
L43 One-pin connector 1 Caution buzzer S-9
L44 KES 6 Wiper relay T-9
L46 KES 4 Flasher unit T-9
L48 Relay 5 Bucket relay M-7
L49 Relay 5 Boom relay N-7
L51 Relay 6 Side working lamp relay N-9
L52 Relay 5 Hazard relay M-7
L53 Relay 5 Stop lamp relay M-7
L54 Relay 5 Backup lamp relay N-9
L55 Relay 6 Horn relay g-9
L57 Relay 5 Neutral relay M-7
20-216 WA800L-3
(1)
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
Connector No. of
Type Name of device Address
No. pins
L58 Relay 5 Neutralizer relay M-8
L59 Relay 5 Parking brake safety relay M-9
L60 Relay 6 Front working lamp relay N-9
L61 Relay 6 Rear working lamp relay O-9
L64 Relay 5 Engine oil pressure relay M-8
L65 Relay 5 Joystick steering caution relay N-7
L66 Relay 6 Head lamp relay G-9
L67 Relay 5 Small lamp relay —
L68 Relay 6 Turn signal and hazard relay H-9
L71 Relay 11 Power window relay P-9
L79 Relay 5 Left dust indicator relay M-9
L80 Relay 5 Right dust indicator relay M-8
L81 X 2 Stop lamp switch Q-1
L82 One-pin connector 1 ECM lamp red X-9
L83 One-pin connector 1 ECM lamp red X-9
L84 One-pin connector 1 ECM lamp yellow W-9
L85 One-pin connector 1 ECM lamp yellow X-8
L86 One-pin connector 1 ECM lamp orange X-8
L87 One-pin connector 1 ECM lamp orange X-8
L88 M 4 Diagnostic and INC/DEC switch S-2
L89 M 6 Intermediate connector S-2
L90 Relay 6 Axle work lamp relay M-9
L95 Relay 5 Steering lever neutral lock relay —
LM1 S 10 Control monitor (If equipped) X-8
LR1 SWP 14 Intermediate connector V-1
LR2 SWP 12 Intermediate connector V-2
LR3 SWP 16 Intermediate connector T-1
LR4 M 4 Intermediate connector U-1
LR5 L 2 Intermediate connector U-1
LR6 SWP 16 Intermediate connector —
MASTER DEUTCH 6 Master ECM V-9
OP1 One-pin connector 1 Intermediate connector (Fuse box) —
OP2 One-pin connector 1 Intermediate connector (Fuse box) —
OP3 One-pin connector 1 Intermediate connector (Fuse box) —
OP4 One-pin connector 1 Intermediate connector (Fuse box) —
OP4 One-pin connector 1 Intermediate connector —
OP5 One-pin connector 1 Intermediate connector (Fuse box) —
OP5 One-pin connector 1 Power converter —
OP6 One-pin connector 1 Power connector —
R01 X 2 Emergency steering indicator switch G-1
R03 KES 2 Diode L-5
R04 KES 2 Diode L-4
R05 X 2 Fuel level sensor L-5
R06 Terminal 1 Slow-blow fuse a-2
R07 Terminal 1 Slow-blow fuse b-2
R08 Terminal 1 Slow-blow fuse c-3
R09 Terminal 1 Slow-blow fuse c-3
R10 Terminal 1 Battery —
R11 Terminal 1 Battery L-6
R12 X 2 Intermediate connector —
RA1 X 3 Battery relay L-6
RA2 X 2 Battery relay L-5
WA800L-3 20-217
(1)
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
Connector No. of
Type Name of device Address
No. pins
RPM One-pin connector 1 Intermediate connector (If equipped) —
SEL1 M 4 Model selector connector Q-1
SEL2 M 2 Short connector —
SLAVE DEUTCH 6 Slave ECM V-9
SHUT X 2 Shut-off switch T-1
SL1 M 2 Intermediate connector (Rear step light) —
SL2 M 2 Rear step light switch j-6
SL3 Relay 5 Rear step light relay —
SL4 M 6 Rear step light timer —
SL5 M 2 Rear step light —
SLR1 Terminal 1 Step light switch L-5
SLR2 Terminal 1 Step light switch L-5
SMALL M 1 Right front combination B-7
SMALL M 1 Left front combination lamp E-1
T01 MS 10 Transmission solenoid J-3
T02 X 2 Torque converter oil temperature sensor F-9
TL1 SWP 8 Intermediate connector —
TR1 SWP 8 Intermediate connector H-9
TURN M 1 Right front combination lamp B-6
TURN M 1 Left front combination lamp F-1
WORK M 2 Right working lamp A-6
WORK M 2 Left working lamp A-1
20-218 WA800L-3
(1)
TROUBLESHOOTING CONNECTOR LOCATION STEREOGRAM
20-220 WA800L-3
(1)
TROUBLESHOOTING CONNECTOR LOCATION STEREOGRAM
WA800L-3 20-221
(1)
TROUBLESHOOTING CONNECTOR LOCATION STEREOGRAM
20-222 WA800L-3
(1)
TROUBLESHOOTING CONNECTOR LOCATION STEREOGRAM
WA800L-3 20-223
(1)
TROUBLESHOOTING CONNECTOR LOCATION STEREOGRAM
20-224 WA800L-3
(1)
TROUBLESHOOTING CONNECTOR LOCATION STEREOGRAM
WA800L-3 20-225
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
3 799-601-7030
4 799-601-7040
20-226 WA800L-3
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
WA800L-3 20-227
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
16 799-601-7320
20-228 WA800L-3
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
M type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
WA800L-3 20-229
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
20-230 WA800L-3
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
WA800L-3 20-231
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
Body part No.: 79A-222-2660 (Q’ty: 5) Body part No.: 79A-222-2650 (Q’ty: 5)
13 799-601-2720
Body part No.: 79A-222-2710 (Q’ty: 2) Body part No.: 79A-222-2690 (Q’ty: 2)
20-232 WA800L-3
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
17 799-601-2730
Body part No.: 79A-222-2730 (Q’ty: 2) Body part No.: 79A-222-2720 (Q’ty: 2)
21 799-601-2740
Body part No.: 79A-222-2750 (Q’ty: 2) Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770 Terminal part No.: 79A-222-2760
—
(Q’ty: 50) (Q’ty: 50)
WA800L-3 20-233
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
20-234 WA800L-3
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
WA800L-3 20-235
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
L type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
10 799-601-3460
— —
20-236 WA800L-3
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
WA800L-3 20-237
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 —
Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
5 799-601-7360
— —
6 799-601-7370
— —
20-238 WA800L-3
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
F type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
8 —
— —
WA800L-3 20-239
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Metri-Pack connector
No.of
pins T-adapter
Female terminal (socket)
Part No.
2 —
— —
3 —
— —
Metri-Pack connector
No.of
pins T-adapter
Male terminal (pin)
Part No.
4 —
— —
20-240 WA800L-3
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9210
799-601-9210
799-601-9220
799-601-9220
WA800L-3 20-241
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9230
799-601-9230
799-601-9240
799-601-9240
20-242 WA800L-3
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9250
799-601-9250
799-601-9260
799-601-9260
WA800L-3 20-243
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9270
799-601-9270
799-601-9280
799-601-9280
20-244 WA800L-3
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9290
799-601-9290
WA800L-3 20-245
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
20-246 WA800L-3
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820 (normal type) Part No.: 08192-1810 (normal type)
08192-2820 (fine wire type) 08192-2810 (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920 (normal type) Part No.: 08192-1910 (normal type)
08192-2920 (fine wire type) 08192-2910 (fine wire type)
WA800L-3 20-247
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9010
2
[The pin No. is also marked on the connector (electric wire insertion end)]
1 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-248 WA800L-3
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Deutch connector
No.of
pins T-adapter
Receptacle Plug
Part No.
2 —
— —
WA800L-3 20-249
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
ECONOSEAL CONNECTOR
No.of
pins T-adapter
Female terminal (Socket) Male terminal (Pin)
Part No.
2 —
— —
3 —
— —
4 —
— —
8 —
— —
12 —
— —
20-250 WA800L-3
(1)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
WA800L-3 20-251
(1)
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-7140 S 8P
799-601-7150 S 10P-White
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD24 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DEUTSCH 40P
799-601-9360 DEUTSCH 24P
799-601-9410 For NE, G sensor 2P
For fuel, boost
799-601-9420 3P
press.
799-601-9430 PVC socket 2P
20-252 WA800L-3
(1)
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
20-254 WA800L-3
(1)
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
WA800L-3 20-255
(1)
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
20-256 WA800L-3
(1)
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
WA800L-3 20-257
(1)
TROUBLESHOOTING METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
METHOD OF DISPLAYING
ACTION CODE AND FAILURE
CODE
1. Outline
The speedometer display on the main monitor is
used to display the troubleshooting for each control
system. The nature of the troubleshooting is dis-
played as the failure action code, failure code, and
the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the net-
work circuit. (Only the engine controller uses a spe-
cial parallel signal.)
20-258 WA800L-3
(1)
TROUBLESHOOTING METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
WA800L-3 20-259
(1)
TROUBLESHOOTING CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION
• After an error occurs, turn the starting switch OFF, and if the display goes out, it is possible to re-enact the
problem as follows.
• Re-enaction marks.
a : Turn stating switch ON (with engine stopped)
T : Start engine
t : Carry out operation to actuate actuator.
• After an error occurs, turn the starting switch OFF, and if the display goes out, it is possible to re-enact the
problem as follows.
• Re-enaction marks.
a : Turn stating switch ON (with engine stopped)
T : Start engine
t : Carry out operation to actuate actuator.
• If any abnormality is detected, the joystick caution system operates.
• For E56, monitor cannot detect disconnection because E56 is normally closed.
20-260 WA800L-3
(1)
TROUBLESHOOTING CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION
Automatic
gearshifting not
Disconnection in carried out Normal operation
speed sensor (changes to — — possible at man-
system manual ual
gearshifting)
(If equipped)
E00 No
Gearshifting not
Disconnection in Normal operation
carried out in
engine speed — — possible at man-
Auto mode
sensor system ual
(If equipped)
Stop travelling
F, R solenoid
immediately, Turn
signal system Become neutral
starting switch
CALL disconnection, and cannot travel — — Yes
OFF, Call service
short circuit with (Output off)
after action
GND, short circuit
above.
WA800L-3 20-261
(1)
TROUBLESHOOTING TRANSMISSION CONTROLLER LED DISPLAY
20-262 WA800L-3
(1)
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
WA800L-3 20-263
(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-264 WA800L-3
(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example>
(1) M-5 Turn signal display does not light up
(2) a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is
not blown.
a) L.H turn signal display does not light up
(3) a)Divided into sections a) and b)
b) R.H. turn signal display does not light up
(4) Flow charta) L.H. turn signal display does not light up
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L06 (14)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between L06 Repair or
• Repeats 0 V and NO (female) (14) and L33 replace
20 – 30 V. (female) (1)
• Turn starting switch ON.
• Turn L.H. turn signal ON.
b) R.H. turn signal display does not light up
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L06 (15)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between L06 Repair or
• Repeats 0 V and NO (female) (15) and L31 replace
20 – 30 V. (female) (1)
• Turn starting switch ON.
• Turn R.H. turn signal ON.
WA800L-3 20-265
(1)
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES
Step 1. Questioning the operator 1. Steering does not work i Symptom [Example]
The questions to ask the operator are given below
the failure symptom. If the answers to the questions Ask the operator about the following points.
match the information given, follow the arrow to • Did the steering suddenly stop working o
reach the probable cause of the failure. Breakage in steering equipment
• Had the steering gradually been becoming
Consider the contents of the questions and consult
heavy? o Internal wear of steering equipment,
the table while proceeding to Steps 2 and 3 to grasp
defective seal
the true cause.
20-266 WA800L-3
(1)
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES
7) Remedy
If the causes are narrowed down to one com-
mon cause, take the aciton given in the remedy
column.
The symbols given in the remedy column indi-
cate the following:
X: Replace, E: Repair, A; Adjust, C: Clean
WA800L-3 20-267
(1)
TROUBLESHOOTING OF ENGINE
(S MODE)
Method of using troubleshooting charts ...................................................................................................... 20-302
S-1 Starting performance is poor (Starting always takes time) ................................................................... 20-306
S-2 Engine does not start............................................................................................................................ 20-307
(1) Engine does not turn....................................................................................................................... 20-307
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected)
(including cases with V-type engine where there is no fuel injection for the bank on one side) ..... 20-308
(3) Exhaust gas comes out but engine does not start (Fuel is being injected) ..................................... 20-309
S-3 Engine does not pick up smoothly (Follow-up is poor) ......................................................................... 20-310
S-4 Engine stops during operations (For V type engine, including cases where one bank stops) ..............20-311
S-5 Engine does not rotate smoothly (hunting)........................................................................................... 20-312
S-6 Engine lacks output (no power) (With V-type engine, for cases where there is injection
for only one bank, go to troubleshooting S-2-(2) or S-4.) ..................................................................... 20-313
S-7 Exhaust gas is black (incomplete combustion) .................................................................................... 20-314
S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................................................... 20-315
S-9 Oil becomes contaminated quickly ....................................................................................................... 20-316
S-10 Fuel consumption is excessive........................................................................................................... 20-317
S-11 Oil is in cooling water, or water spurts back, or water level goes down.............................................. 20-318
S-12 Oil pressure lamp lights up (drop in oil pressure) ............................................................................... 20-319
S-13 Oil level rises ...................................................................................................................................... 20-320
S-14 Water temperature becomes too high (overheating) .......................................................................... 20-321
S-15 Abnormal noise is made..................................................................................................................... 20-322
S-16 Vibration is excessive ......................................................................................................................... 20-323
WA800L-3 20-301
(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in (B) are items that can be
obtained from the user, depending on the user’s
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under (C) in the
chart on the right correspond to this.
The serviceman narrows down the causes from
information (A) that he has obtained from the user
and the results of (C) that he has obtained from his
own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been
marked as having the highest probability from infor-
mation gained from [Questions] and [Check
items].
20-302 WA800L-3
(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
WA800L-3 20-303
(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-304 WA800L-3
(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
WA800L-3 20-305
(1)
TROUBLESHOOTING S-1
20-306 WA800L-3
(1)
TROUBLESHOOTING S-2
WA800L-3 20-307
(1)
TROUBLESHOOTING S-2
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected)
(including cases with V-type engine where there is no fuel injection for the bank on one side)
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
Ambient temprature
Type of fuel –22 –4 –14 32 50 68 86 104°F
–30 –20 –10 0 10 20 30 140°C
20-308 WA800L-3
(1)
TROUBLESHOOTING S-2
(3) Exhaust gas comes out but engine does not start
(Fuel is being injected)
WA800L-3 20-309
(1)
TROUBLESHOOTING S-3
20-310 WA800L-3
(1)
TROUBLESHOOTING S-4
WA800L-3 20-311
(1)
TROUBLESHOOTING S-5
20-312 WA800L-3
(1)
TROUBLESHOOTING S-6
WA800L-3 20-313
(1)
TROUBLESHOOTING S-7
20-314 WA800L-3
(1)
TROUBLESHOOTING S-8
WA800L-3 20-315
(1)
TROUBLESHOOTING S-9
20-316 WA800L-3
(1)
TROUBLESHOOTING S-10
WA800L-3 20-317
(1)
TROUBLESHOOTING S-11
S-11 Oil is in cooling water, or water spurts back, or water level goes down
20-318 WA800L-3
(1)
TROUBLESHOOTING S-12
SAE 30
WA800L-3 20-319
(1)
TROUBLESHOOTING S-13
20-320 WA800L-3
(1)
TROUBLESHOOTING S-14
WA800L-3 20-321
(1)
TROUBLESHOOTING S-15
20-322 WA800L-3
(1)
TROUBLESHOOTING S-16
WA800L-3 20-323
(1)
TROUBLESHOOTING OF TRANSMISSION
CONTROL SYSTEM (T MODE)
Judgement table for transmission control system related parts .................................................................. 20-402
Action taken by controller when abnormality occurs and problems on machine......................................... 20-404
Electrical circuit diagram for transmission control system........................................................................... 20-408
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in backup lamp
relay) is displayed .............................................................................................................................. 20-410
T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid) is
displayed............................................................................................................................................ 20- 411
T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid) is
displayed............................................................................................................................................ 20-412
T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid) is
displayed............................................................................................................................................ 20-413
T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid) is
displayed............................................................................................................................................ 20-414
T-6 Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd solenoid) is
displayed............................................................................................................................................ 20-415
T-7 Failure code [20] (Short circuit or disconnection in joystick lever switch system) is displayed .......... 20-416
T-8 Failure code [21] (Short circuit or disconnection in joystick shift-up/shift-down switch system) is
displayed............................................................................................................................................ 20-417
T-9 Failure code [22] (Disconnection in travel speed sensor) is displayed .............................................. 20-418
T-10 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is displayed ........... 20-419
T-11 Kickdown switch signal system and hold switch signal system ......................................................... 20-420
T-12 Transmission cut-off signal system .................................................................................................... 20-421
T-13 Neutralizer signal system................................................................................................................... 20-422
T-14 Buzzer signal system ......................................................................................................................... 20-423
T-15 Network system ................................................................................................................................. 20-424
T-16 Transmission controller power source system ................................................................................... 20-425
T-17 Short circuit in travel speed sensor system ....................................................................................... 20-426
T-18 Abnormality in machine selection wiring harness .............................................................................. 20-427
WA800L-3 20-401
(1)
JUDGEMENT TABLE FOR TRANSMISSION CONTROL
TROUBLESHOOTING SYSTEM RELATED PARTS
20-402 WA800L-3
(1)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
1) Defective F solenoid
2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between
Short circuit, disconnection
12 transmission & joystick controller C1 (female) (2) – TR1 (4) – T01 (4)
in F solenoid system
3) Short circuit with chassis ground, defective contact, disconnection in
wiring harness between chassis – TR1 (6) – T01 (1)
4) Defective transmission & joystick controller
1) Defective R solenoid
2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between
Short circuit, disconnection
13 transmission & joystick controller C1 (female) (9) – TR1 (5) – T01 (3)
in R solenoid system
3) Short circuit with chassis ground, defective contact, disconnection in
wiring harness between chassis – TR1 (6) – T01 (1)
4) Defective transmission & joystick controller
1) Defective 1st solenoid
2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between
Short circuit, disconnection
14 transmission & joystick controller C1 (female) (3) – TR1 (1) – T01 (8)
in 1st solenoid system
3) Short circuit with chassis ground, defective contact, disconnection in
wiring harness between chassis – TR1 (6) – T01 (2)
4) Defective transmission & joystick controller
1) Defective 2nd solenoid
2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between
Short circuit, disconnection transmission & joystick controller C1 (female) (10) – TR1 (2) – T01
15
in 2nd solenoid system (7)
3) Short circuit with chassis ground, defective contact, disconnection in
wiring harness between chassis – TR1 (6) – T01 (2)
4) Defective transmission & joystick controller
1) Defective 3rd solenoid
2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between
Short circuit, disconnection
16 transmission & joystick controller C1 (female) (5) – TR1 (3) – T01 (6)
in 3rd solenoid system
3) Short circuit with chassis ground, defective contact, disconnection in
wiring harness between chassis – TR1 (6) – T01 (2)
4) Defective transmission controller
20-404 WA800L-3
(1)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
WA800L-3 20-405
(1)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
20-406 WA800L-3
(1)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
1) Resistance between engine speed sensor E03 1) Switches to manual 1) Does not carry out
(1) and (2): 100 – 500 z mode auto-shift
2) Voltage between transmission & joystick 2) Shifts gear 2) Switches to manual
controller C4 (female) (2) and (9) according to shift
operation of range T-14
lever
WA800L-3 20-407
(1)
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION
TROUBLESHOOTING CONTROL SYSTEM
20-408 WA800L-3
(1)
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION
TROUBLESHOOTING CONTROL SYSTEM
a This circuit diagram is made by extracting the part of the transmission & joystick steering controller system
from the general circuit diagram.
WA800L-3 20-409
(1)
TROUBLESHOOTING T-1
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in
backup lamp relay) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 YES
Go to A
Is resistance
YES between L54
(female) (2) and Defective contact or
3 chassis ground disconnection in wiring
Is resistance normal? Repair or
harness between L54
YES between C1
• Max. 1 z NO (female) (2) and chassis replace
(female) (8) and • Turn starting
2 chassis ground switch OFF. ground
normal? • Disconnect C1 Short circuit with chassis
• Min. 1 Mz
Is resistance
and L54. ground in harness Repair or
YES between C1
(female) (8) and L54 • Turn starting NO between C1 (female) (8) replace
1 (female) (1) normal? switch OFF. and L54 (female) (1)
• Disconnect C1
• Max. 1 z
Is failure code 10 Defective contact or
displayed when and L54. disconnection in wiring Repair or
backup relay is • Turn starting
NO harness between C1 replace
replaced with other switch OFF.
(female) (8) and L54
relay of same type? • Disconnect C1
(female) (1)
• Turn starting and L54.
switch OFF. Defective backup lamp
Repair
• Replace backup NO relay
relay with other relay of same type.
• Turn starting switch ON.
• Set directional lever to R. 5 YES Defective transmission &
joystick steering Repair
Is voltage between controller
C1 (female) (8) and
From A
chassis ground Short circuit with power
normal? source in wiring harness Repair or
• Turn starting NO between C1 (female) (8) replace
switch ON. and L54 (female) (1)
• Disconnect C1
and L54.
• Max. 1 V
20-410 WA800L-3
(1)
TROUBLESHOOTING T-2
T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source in
F solenoid) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 YES
Go to A
Is resistance
YES between T01 Defective contact or
(female) (1) and disconnection in wiring
3 chassis ground
Is resistance harness between T01 Repair or
normal?
• Max. 1 z
(female) (1) and chassis replace
YES between C1 NO
(female) (2) and ground
• Turn starting
2 chassis ground
switch OFF. Short circuit with chassis
normal?
• Min. 1 Mz
Is resistance • Disconnect T01. ground or another part in
YES Repair or
between C1 harness between C1
(female) (2) and T01
• Turn starting NO replace
(female) (2) and T01
1 (female) (4) normal? switch OFF.
(female) (4)
• Disconnect C1
Is resistance between
• Max. 1 z and T01. Defective contact or
T01 (male) (1) and (4)
disconnection in wiring Repair or
and between (1), (4)
• Turn starting
NO replace
and chassis ground switch OFF. harness between C1
normal? • Disconnect C1 (female) (2) and T01
• Between (1) and and T01. (female) (4)
(4): 5 – 15 z Defective F solenoid Replace
• Between (1), (4) NO
and chassis ground: Min. 1 Mz
• Turn starting switch OFF.
• Disconnect T01. Defective transmission &
5 YES
joystick steering Replace
Is voltage between controller
C1 (female) (2) and
From A chassis ground
Short circuit with power
normal?
source in wiring harness Repair or
• Turn starting NO between C1 (female) (2) replace
switch ON. and T01 (female) (4)
• Disconnect C1
and T01.
• Max. 1 V
WA800L-3 20-411
(1)
TROUBLESHOOTING T-3
T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source in
R solenoid) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 YES
Go to A
Is resistance
YES between T01
Defective contact or
(female) (1) and
3 chassis ground
disconnection in wiring
Is resistance normal? harness between T01 Repair or
YES between C1 • Max. 1 z NO
(female) (1) and chassis replace
(female) (9) and ground
chassis ground
• Turn starting
2 switch OFF.
normal? Short circuit with chassis
Is resistance • Min. 1 Mz • Disconnect T01. ground or another part in Repair or
YES between C1 harness between C1
• Turn starting NO replace
(female) (9) and T01 (female) (9) and T01
1 (female) (3) normal? switch OFF.
(female) (3)
• Disconnect C1
• Max. 1 z
Is resistance between
and T01. Defective contact or
T01 (male) (1) and (3) Repair or
and between (1), (3) • Turn starting disconnection in wiring
NO replace
and chassis ground switch OFF. harness between C1
normal? • Disconnect C1 (female) (9) and T01
• Between (1) and and T01. (female) (3)
(3): 5 – 15 z Defective R solenoid Replace
• Between (1), (3) NO
and chassis ground: Min. 1
Mz
• Turn starting switch OFF. 5 YES Defective transmission &
• Disconnect T01. joystick steering Replace
Is voltage between controller
C1 (female) (9) and
From A chassis ground Short circuit with power
normal? source in wiring harness Repair or
• Max. 1 V NO between C1 (female) (9) replace
• Turn starting and T01 (female) (3)
switch ON.
• Disconnect C1
and T01.
20-412 WA800L-3
(1)
TROUBLESHOOTING T-4
T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source in
1st solenoid) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 YES
Go to A
Is resistance
YES between T01 Defective contact or
(female) (2) and disconnection in wiring
3 chassis ground
Is resistance harness between T01
normal? Repair or
• Max. 1 z
YES between C1 (female) (2) and chassis replace
(female) (3) and
NO ground
chassis ground
• Turn starting
2 switch OFF. Short circuit with chassis
normal?
• Min. 1 Mz
Is resistance • Disconnect T01. ground or another part in
YES Repair or
between C1 harness between C1
(female) (3) and T01
• Turn starting NO replace
(female) (3) and T01
1 (female) (8) normal? switch OFF.
(female) (8)
• Disconnect C1,
• Max. 1 z
Is resistance between
T01 (male) (2) and (8) T01 and L05. Defective contact or Repair or
and between (2), (8) • Turn starting disconnection in wiring
NO replace
and chassis ground switch OFF. harness between C1
normal? • Disconnect C1 (female) (3) and T01
• Between (2) and and T01. (female) (8)
(8): 5 – 15 z Defective 1st solenoid Replace
• Between (2), (8) NO
and chassis ground: Min. 1 Mz
• Turn starting switch OFF.
• Disconnect T01. 5 YES Defective transmission &
joystick steering Replace
Is voltage between controller
C1 (female) (3)
From A and chassis
ground normal?
Short circuit with power
source in wiring harness Repair or
• Max. 1 V NO between C1 (female) (3) replace
• Turn starting and T01 (female) (8)
switch ON.
• Disconnect C1,
T01 and L05.
WA800L-3 20-413
(1)
TROUBLESHOOTING T-5
T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source in
2nd solenoid) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 YES
Go to A
Is resistance
YES between T01 Defective contact or
(female) (2) and disconnection in wiring
3 chassis ground
Is resistance harness between T01
normal? Repair or
• Max. 1 z
(female) (2) and chassis
YES between C1 NO replace
(female) (10) and ground
chassis ground
• Turn starting
2 switch OFF. Short circuit with chassis
Is resistance normal?
• Min. 1 Mz • Disconnect T01. ground or another part in
YES between C1 harness between C1 Repair or
(female) (10) and • Turn starting NO replace
(female) (10) and T01
T01 (female) (7) switch OFF.
1 normal?
(female) (7)
• Disconnect C1,
• Max. 1 z
Is resistance between
T01 (male) (2) and (7) T01 and L05. Defective contact or
Repair or
and between (2), (7) • Turn starting disconnection in wiring
NO replace
and chassis ground switch OFF. harness between C1
normal? • Disconnect C1 (female) (10) and T01
• Between (2) and and T01. (female) (7)
(7): 5 – 15 z Defective 2nd solenoid Replace
• Between (2), (7) NO
and chassis ground: Min. 1 Mz
• Turn starting switch OFF.
• Disconnect T01. 5 YES Defective transmission &
joystick steering Replace
Is voltage between controller
C1 (female) (10) and
From A chassis ground Short circuit with power
normal? source in wiring harness Repair or
• Max. 1 V NO between C1 (female) (10) replace
• Turn starting and T01 (female) (7)
switch ON.
• Disconnect C1,
T01 and L05.
20-414 WA800L-3
(1)
TROUBLESHOOTING T-6
T-6 Failure code [16] (Short circuit, disconnection, short circuit with power source in
3rd solenoid) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 YES
Go to A
Is resistance
YES between T01
Defective contact or
(female) (2) and
3 chassis ground
disconnection in wiring
Is resistance normal? harness between T01 Repair or
YES between C1 • Max. 1 z NO
(female) (2) and chassis replace
(female) (5) and ground
chassis ground
• Turn starting
2 switch OFF.
normal? Short circuit with chassis
Is resistance
• Min. 1 Mz • Disconnect T01. ground in harness Repair or
YES between C1 between C1 (female) (5)
• Turn starting NO replace
(female) (5) and T01
switch OFF. and T01 (female) (6)
1 (female) (6) normal?
• Disconnect C1,
• Max. 1 z Defective contact or
Is resistance between
T01 (male) (2) and (6) T01 and L05. Repair or
• Turn starting disconnection in wiring
and between (2), (6) harness between C1 replace
and chassis ground switch OFF. NO
• Disconnect C1 (female) (5) and T01
normal?
and T01. (female) (6)
• Between (2) and
(6): 5 – 15 z Defective 3rd solenoid Replace
• Between (2), (6) NO
and chassis ground: Min. 1 Mz
• Turn starting switch OFF.
• Disconnect T01. 5 YES Defective transmission &
joystick steering Replace
Is voltage between controller
C1 (female) (5) and
From A chassis ground
Short circuit with power
normal?
source in wiring harness Repair or
• Max. 1 V NO between C1 (female) (5) replace
• Turn starting and T01 (female) (6)
switch ON.
• Disconnect C1,
T01 and L05.
WA800L-3 20-415
(1)
TROUBLESHOOTING T-7
T-7 Failure code [20] (Short circuit or disconnection in joystick lever switch system)
is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Check that fuse II (6) is normal.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective transmission
3 YES
and joystick steering Replace
Is voltage between
controller
YES C3B (5), (13), (6) and
chassis ground as Disconnection, defective
2 shown in Table 1? contact, short circuit with
Is voltage chassis ground, or short Repair or
YES between JS1 (1) circuit in wiring harness replace
• Turn starting NO between JS1 (female) (2), (3),
and chassis switch ON. (4) – C3B (female) (5), (13), (6)
1 ground normal?
Is voltage between • 20 – 30 V Disconnection or defective
JS1 (2), (3), (4) and contact in wiring harness Repair or
• Turn starting NO replace
chassis ground as between fuse II (6) – JS1
shown in Table 1? switch ON.
(female) (1)
• Turn starting
switch ON. Defective joystick lever
Replace
NO switch
JS1 (male) (1) – (2) C3B (5) – Chassis ground 20 – 30 V Max. 1 V Max. 1 V
JS1 (male) (1) – (3) C3B (13) – Chassis ground Max. 1 V 20 – 30 V Max. 1 V
JS1 (male) (1) – (4) C3B (6) – Chassis ground Max. 1 V Max. 1 V 20 – 30 V
20-416 WA800L-3
(1)
TROUBLESHOOTING T-8
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Check that fuse II (6) is normal.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective transmission
3 YES
and joystick steering Replace
Is voltage between
controller
YES C3B (16), (8), (15), Disconnection, defective
(7) and chassis
2 ground as shown in
contact, short circuit with
chassis ground, or short
Is voltage Table 1? circuit in wiring harness Repair or
YES between JS1 (1) • Turn starting NO between JS1 (female) (5), (6), replace
and chassis (7), (8) – C3B (female) (16),
1 switch ON. (8), (15), (7)
ground normal?
Is voltage between
Disconnection or defective
JS1 (5), (6), (7), (8) • 20 – 30 V Repair or
and chassis ground contact in wiring harness
• Turn starting NO replace
as shown in Table between fuse II (6) – JS1
switch ON.
1? (female) (1)
• Turn starting
Defective joystick shift-
switch ON. Replace
NO up/shift-down switch
When shift-up/shift-down
Shift-up Shift-down
switch is pressed
switch ON switch ON
Terminals
WA800L-3 20-417
(1)
TROUBLESHOOTING T-9
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
20-418 WA800L-3
(1)
TROUBLESHOOTING T-10
T-10 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is
displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 YES
Go to A
Is resistance
YES between C4 Defective contact or
3 (female) (9) and E03 disconnection in wiring
(female) (2) normal?
Is resistance harness between C4 Repair or
YES between C4 (female) • Max. 1 z NO (female) (9) and E03 replace
2
(2) and chassis • Disconnect C4 and E03. (female) (2)
ground normal? • Turn starting switch Short circuit with chassis
• Min. 1 Mz
Is resistance OFF.
YES between C4 ground in harness Repair or
(female) (2) and E03 • Disconnect C4, NO between C4 (female) (2) replace
1 (female) (1) normal E03 and L07. and E03 (female) (1)
• Turn starting
• Max. 1 z
Defective contact or
Is resistance switch OFF. disconnection in wiring Repair or
between E03 • Disconnect C3,
NO harness between C4 replace
(male) (1) and (2) E03 and L07. (female) (2) and E03
normal? • Turn starting (female) (1)
• 100 – 500 z switch OFF.
• Disconnect E03. Defective engine speed Replace
• Turn starting NO sensor
switch OFF.
Defective transmission &
6 YES joystick steering Replace
Is resistance controller
YES between C4 Short circuit of harness
From A 5 (female) (2) and between C4 (female) (2)
(9) normal? and E03 (female) (1) and Repair or
Is resistance
• Min. 1 Mz
harness between C4 replace
between C4 (female) NO (female) (9) and E03
(9) and chassis • Disconnect C4, (female) (2) with each
ground normal? E03 and L07. other
• Min. 1 Mz
• Turn starting switch OFF. Short circuit with chassis Repair or
• Disconnect C4 NO ground in harness replace
and E03. between C4 (female) (9)
• Turn starting and E03 (female) (2)
switch OFF.
WA800L-3 20-419
(1)
TROUBLESHOOTING T-11
T-11 Kickdown switch signal system and hold switch signal system
STEERING WHEEL SPECIFICATION,
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).
Kickdown switch
Cause Remedy
Hold switch
Cause Remedy
a Hold switch is applied to only the auto-shift specification.
20-420 WA800L-3
(1)
TROUBLESHOOTING T-12
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).
Cause Remedy
WA800L-3 20-421
(1)
TROUBLESHOOTING T-13
Cause Remedy
20-422 WA800L-3
(1)
TROUBLESHOOTING T-14
a Check that the main monitor and alarm buzzer works normally.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).
Cause Remedy
WA800L-3 20-423
(1)
TROUBLESHOOTING T-15
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).
Cause Remedy
20-424 WA800L-3
(1)
TROUBLESHOOTING T-16
Cause Remedy
WA800L-3 20-425
(1)
TROUBLESHOOTING T-17
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
20-426 WA800L-3
(1)
TROUBLESHOOTING T-18
Cause Remedy
Table 1
Machine model
WA800-3
Connector
WA800L-3 20-427
(1)
TROUBLESHOOTING OF MAIN MONITOR SYSTEM
(M MODE)
Trouble data display.................................................................................................................................... 20-503
Electrical circuit diagram for main monitor system...................................................................................... 20-506
M-1 Main monitor does not work.............................................................................................................. 20-508
M-2 When starting switch is turned ON (within 3 seconds) and engine is started immediately,
all lamps stay lighted up.................................................................................................................... 20-509
M-3 Speedometer display does not work properly ................................................................................... 20-510
M-4 Abnormality in shift indicator ............................................................................................................. 20- 511
a) Displays N even when directional switch is at F ........................................................................... 20- 511
b) Displays N even when directional switch is at R .......................................................................... 20- 511
c) Does not display N even when directional switch is at N (Display 1st – 3rd)................................ 20- 511
M-5 Turn signal display does not light up................................................................................................. 20-513
a) L.H. turn signal display does not light up ...................................................................................... 20-513
b) R.H. turn signal display does not light up ..................................................................................... 20-513
M-6 Abnormality in parking display .......................................................................................................... 20-515
a) Parking lamp display does not light up ......................................................................................... 20-515
b) Parking lamp display stays lighted up........................................................................................... 20-515
M-7 Night lighting does not light up.......................................................................................................... 20-516
M-8 Abnormality in front working lamp..................................................................................................... 20-518
a) Neither monitor display nor front working lamp light up................................................................ 20-518
b) Working lamp lights up but monitor display does not light up....................................................... 20-518
c) Monitor display lights up but front working lamp does not light up................................................ 20-518
M-9 Abnormality in rear working lamp ..................................................................................................... 20-520
a) Neither monitor display nor rear working lamp light up ................................................................ 20-520
b) Rear working lamp lights up but monitor display does not light up............................................... 20-520
c) Monitor display lights up but rear working lamp does not light up ................................................ 20-520
M-10 Abnormality in transmission cut-off ................................................................................................... 20-522
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is not
switched and display does not change ......................................................................................... 20-522
b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out but
cut-off function is actuated when pedal is depressed ................................................................... 20-522
c) When monitor display is turned off (transmission cut-off switch turned OFF), cut-off
function is always actuated ........................................................................................................... 20-522
d) Cut-off function is always actuated regardless of monitor display (transmission cut-off
switch ON or OFF) ........................................................................................................................ 20-522
e) Monitor display lights up (transmission cut-off switch turned ON), but cut-off function
is not actuated .............................................................................................................................. 20-523
WA800L-3 20-501
(1)
M-11 Abnormality in low idle selection ....................................................................................................... 20-524
a) When monitor switch (low idle selector switch) is turned ON, the low idle speed does not
rise and display does not change ................................................................................................. 20-524
b) When monitor switch (low idle selector switch) is turned ON, the monitor lights up but the
low idle speed does not rise.......................................................................................................... 20-524
c) When monitor switch (low idle selector switch) is turned OFF, the monitor goes off but the
low idle speed does not lower....................................................................................................... 20-525
M-12 Abnormality in emergency steering normal display .......................................................................... 20-526
M-13 Abnormality in emergency steering actuation display....................................................................... 20-527
a) Emergency steering actuation display does not light up............................................................... 20-527
b) Emergency steering actuation display stays lighted up ................................................................ 20-527
M-14 Abnormality in parking brake dragging warning................................................................................ 20-528
a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes
even when directional switch is at N ............................................................................................. 20-528
b) When parking brake is applied, buzzer does not sound and CAUTION lamp does not
light up even when directional switch is at position other than N.................................................. 20-528
M-15 When parking brake dragging warning is given, buzzer and CAUTION lamp are actuated
continuously, or they are not actuated .............................................................................................. 20-529
a) Actuated continuously................................................................................................................... 20-529
b) Not actuated ................................................................................................................................. 20-529
M-16 Abnormality in buzzer ....................................................................................................................... 20-530
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check) .......... 20-530
b) Buzzer always sounds .................................................................................................................. 20-530
M-17 Condition of monitor switches is not stored in memory..................................................................... 20-531
M-18 Abnormality in failure display mode .................................................................................................. 20-532
a) Does not enter failure display mode ............................................................................................. 20-532
b) Count for time elapsed since failure in failure display mode does not advance ........................... 20-532
M-19 Buzzer is not made to sound by transmission & joystick steering controller..................................... 20-533
M-20 Abnormality in auto-greasing system................................................................................................ 20-534
a) Forced greasing cannot be carried out ......................................................................................... 20-534
b) Monitor display flashes rapidly (2 times/sec) ................................................................................ 20-534
c) When no more grease remains, monitor display flashes rapidly (2 times/sec)............................. 20-534
d) Monitor display flashes slowly (1 time/sec)
Confirm that grease is not empty. ................................................................................................. 20-535
e) Monitor display goes out............................................................................................................... 20-535
M-21 Failure code is not sent to main monitor (abnormality in network).................................................... 20-536
20-502 WA800L-3
(1)
TROUBLESHOOTING TROUBLE DATA DISPLAY
WA800L-3 20-503
(1)
TROUBLESHOOTING TROUBLE DATA DISPLAY
Automatic
Disconnection in
gearshifting not
travel speed sensor Normal operation
carried out
system — — possible at
(changes to manual
manual
gearshifting)
(If equipped)
Disconnection in Gearshifting not
engine speed carried out in Auto Normal operation
E00 No
sensor system mode. (If equipped) — — possible at
manual
Breakage, short
Set to neutral
circuit with chassis Normal operation
position. (Can be
— — ground or short possible at wheel
changed to steering
circuit of joystick steering mode
wheel mode.)
FNR signal line
Shift lever system Become neutral
disconnection, and cannot travel
short circuit with (Judges controller — —
GND, short circuit input as N)
Stop travelling
F, R solenoid signal Become neutral
immediately, Turn
system and cannot travel
starting switch
CALL disconnection, (Output off) — — Yes
OFF, Call service
short circuit with
after action
GND, short circuit
above.
1st, 2nd, 3rd Become neutral
solenoid system and cannot travel
disconnection, (Output off) — —
short circuit with
GND, short circuit
20-504 WA800L-3
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM
20-506 WA800L-3
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM
a This circuit diagram is made by extracting the part of the main monitor system from the general circuit
diagram.
WA800L-3 20-507
(1)
TROUBLESHOOTING M-1
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
YES
Defective main monitor Replace
1
20-508 WA800L-3
(1)
TROUBLESHOOTING M-2
M-2 When starting switch is turned ON (within 3 seconds) and engine is started
immediately, all lamps stay lighted up
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 YES
Defective main monitor Replace
When engine is
started, is voltage
between L05 (4) and Defective contact or
chassis ground disconnection in wiring
normal? Repair or
harness between L05
• 20 – 30 V NO replace
(female) (4) and L95
• Start engine. (female) (3)
WA800L-3 20-509
(1)
TROUBLESHOOTING M-3
Cause Remedy
1 YES
Defective main monitor Replace
Is resistance
between L07
(female) (1) – (2) Defective contact or
normal? disconnection in wiring
Repair or
harness between L07
• 500 – 1 kz NO (female) (1), (2) – BC01
replace
• Turn starting (female) (1), (2)
switch OFF.
• Disconnect L07.
20-510 WA800L-3
(1)
TROUBLESHOOTING M-4
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L08 (7)
and chassis Defective contact or
ground normal? disconnection in wiring
Repair or
harness between L08
• 20 – 30 V NO replace
(female) (7) and JS1
• Turn starting (female) (2)
switch ON.
• Directional switch: F
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L08 (8)
and chassis Defective contact or
ground normal? disconnection in wiring
Repair or
harness between L08
• 20 – 30 V NO replace
(female) (8) and JS1
• Turn starting (female) (4)
switch ON.
• Directional switch: R
c) Does not display N even when directional switch is at N (Display 1st – 3rd).
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L08 (7) Short circuit with power
or (8) and chassis source in wiring harness
ground normal? between L08 (female) (7)
Repair or
and JS1 (female) (2) or
• Max. 1 V NO replace
harness between L08
• Turn starting (female) (8) and JS1
switch ON. (female) (4)
• Set directional
switch to N.
WA800L-3 20-511
(1)
TROUBLESHOOTING M-4
20-512 WA800L-3
(1)
TROUBLESHOOTING M-5
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not
blown.
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L06 (14)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between L06 Repair or
• Repeats 0 V and NO (female) (14) and L33 replace
20 – 30 V. (female) (1)
• Turn starting switch ON.
• Turn L.H. turn signal ON.
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L06 (15)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between L06 Repair or
• Repeats 0 V and NO (female) (15) and L31 replace
20 – 30 V. (female) (1)
• Turn starting switch ON.
• Turn R.H. turn signal ON.
WA800L-3 20-513
(1)
TROUBLESHOOTING M-5
20-514 WA800L-3
(1)
TROUBLESHOOTING M-6
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Cause Remedy
2 YES
Defective main monitor Replace
Is voltage
YES between F13 (1)
1 and chassis Short circuit with power
ground normal? source in harness Repair or
Is resistance
between F13 •0–2V NO between L06 (female) replace
(male) (1) and (2) • Turn starting (11) – F13 (female) (1)
normal? switch ON.
• Max. 1 z
• Turn parking switch OFF. Defective parking brake
Replace
• Disconnect F13. NO indicator switch
• Turn starting
switch ON.
• Turn parking
switch OFF.
WA800L-3 20-515
(1)
TROUBLESHOOTING M-7
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the lamp bulbs are not blown.
a Check that fuse I-6 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring
harness between FS2 (female) (5) and L05 (female) (16).
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L05 (16)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between L05 Repair or
• 20 – 30 V NO (female) (16) and FS2 replace
• Turn starting (female) (5)
switch ON.
• Turn small lamp
switch ON.
20-516 WA800L-3
(1)
TROUBLESHOOTING M-7
WA800L-3 20-517
(1)
TROUBLESHOOTING M-8
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the monitor lighting is lighted up.
Defective contact or
disconnection in wiring
YES harness between L60 Repair or
(female) (1) – L05 replace
(female) (17), CL1
(female) (7)
1 YES Defective front working
Replace
Is voltage 3 lamp relay
between L60 (1) Is voltage
and chassis YES between L60 (6)
ground normal? and chassis 4 YES
• Max. 1 V ground normal? Defective main monitor Replace
2 Is voltage
• Turn starting • Max. 1 V between L06 (1)
Is voltage between Defective contact or
switch ON. • Turn starting NO and chassis
L60 (2), (4), (5) and disconnection in wiring
switch ON. ground normal? harness between L06
NO chassis ground Repair or
normal? • 20 – 30 V NO (female) (1) and L60 replace
• Turn starting (female) (6)
• 20 – 30 V
switch ON. Defective contact or
• Turn starting
switch ON. disconnection in wiring Repair or
NO harness between L60 replace
(female) (2), (4), (5) and
FS5 (female) (1)
1 YES
Defective main monitor Replace
Is voltage
between L05 (17)
and chassis Defective contact or
ground normal? disconnection in wiring
Repair or
harness between L05
• 20 – 30 V NO replace
(female) (17) and L60
• Turn starting (female) (1)
switch ON.
20-518 WA800L-3
(1)
TROUBLESHOOTING M-8
WA800L-3 20-519
(1)
TROUBLESHOOTING M-9
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the monitor lighting is lighted up.
Cause Remedy
Defective contact or
disconnection in wiring
YES harness between L61 Repair or
(female) (1) – L05 replace
(female) (18), LR1
(female) (7)
1 YES Defective rear working
Replace
Is voltage 3 lamp relay
between L61 (1) Is voltage
and chassis YES between L61 (6)
ground normal? and chassis 4 YES
• 20 – 30 V ground normal? Defective main monitor Replace
2 Is voltage
• Turn starting • Max. 1 V between L06 (2)
Is voltage between Defective contact or
switch ON. • Turn starting NO and chassis
L61 (2), (4), (5) and disconnection in wiring
switch ON. ground normal? harness between L06
NO chassis ground Repair or
normal? • Max. 1 V NO (female) (2) and L61 replace
• Turn starting (female) (6)
• 20 – 30 V
switch ON. Defective contact or
• Turn starting
switch ON. disconnection in wiring Repair or
NO harness between L61 replace
(female) (2), (4), (5) and
FS5 (female) (2)
b) Rear working lamp lights up but monitor display does not light up
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L05 (18)
and chassis Defective contact or
ground normal? disconnection in wiring
Repair or
harness between L05
• 20 – 30 V NO replace
(female) (18) and L61
• Turn starting (female) (1)
switch ON.
20-520 WA800L-3
(1)
TROUBLESHOOTING M-9
WA800L-3 20-521
(1)
TROUBLESHOOTING M-10
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
20-522 WA800L-3
(1)
TROUBLESHOOTING M-10
WA800L-3 20-523
(1)
TROUBLESHOOTING M-11
a Before carrying out troubleshooting, be sure that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a) When monitor switch (low idle selector switch) is turned ON, the low idle speed does not rise and
display does not change
Cause Remedy
b) When monitor switch (low idle selector switch) is turned ON, the monitor lights up but the low idle
speed does not rise
Cause Remedy
20-524 WA800L-3
(1)
TROUBLESHOOTING M-11
c) When monitor switch (low idle selector switch) is turned OFF, the monitor goes off but the low idle
speed does not lower
Cause Remedy
WA800L-3 20-525
(1)
TROUBLESHOOTING M-12
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L05 (10)
and chassis Defective contact or
ground normal? disconnection in wiring Repair or
• 20 – 30 V NO harness between L05 replace
• Turn starting (female) (10) – chassis
switch ON.
20-526 WA800L-3
(1)
TROUBLESHOOTING M-13
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 YES
Defective main monitor Replace
Is resistance
YES between L05
(female) (11) and
1 chassis ground Short circuit with chassis
Is resistance normal? ground in harness Repair or
between R01 • Min. 1 Mz NO between L05 (female) replace
(male) (1) and (2) • Turn starting switch OFF. (11) and R01 (female) (1)
normal? • Disconnect L05 and R01.
• Min. 1 Mz Defective emergency
Replace
• Turn starting NO steering indicator switch
switch ON.
• Disconnect R01.
Cause Remedy
2 YES
Defective main monitor Replace
Is voltage
YES between L05 (11)
1 and chassis Defective contact or
ground normal? disconnection in wiring
Is resistance Repair or
harness between L05
between R01 • 20 – 30 V NO replace
(female) (11) and chassis
(male) (1) and (2) • Turn starting ground
normal? switch ON.
• Max. 1 z Defective emergency
Replace
• Start engine. NO steering indicator switch
• Disconnect R01.
WA800L-3 20-527
(1)
TROUBLESHOOTING M-14
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even
when directional switch is at N
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L05 (8)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between L05 Repair or
• 20 – 30 V NO (female) (8) – JS1 replace
• Turn starting (female) (3)
switch ON.
• Directional
switch: N
b) When parking brake is applied, buzzer does not sound and CAUTION lamp does not light up even
when directional switch is at position other than N
a Check that the synchronous flash is normal.
Cause Remedy
YES
Defective main monitor Replace
1
Is voltage Short circuit with power
between L05 (8) supply in wiring harness
and chassis 2 YES between L05 (female) (8) Repair or
ground normal? Is resistance – JS1 (female) (3), or replace
between L05 defective directional
•0–5V
(male) (8) and (3) lever
• Turn starting NO
switch ON. normal?
• Directional switch: • 3 kΩ – 4 kz Defective main monitor Replace
NO
Other than N • Turn starting
switch OFF.
• Disconnect L05.
20-528 WA800L-3
(1)
TROUBLESHOOTING M-15
M-15 When parking brake dragging warning is given, buzzer and CAUTION lamp are
actuated continuously, or they are not actuated
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a) Actuated continuously
Cause Remedy
YES
Defective main monitor Replace
1
b) Not actuated
Cause Remedy
YES
Defective main monitor Replace
1
Do buzzer and
lamp work? 2 YES Defective maintenance
Replace
monitor (sub monitor)
• Turn starting Do buzzer and
switch ON. NO lamp work? Short circuit with power
• Disconnect L07. source in harness Repair or
• Turn starting NO between L07 (female) (6) replace
switch ON. and L19 (female) (5)
• Disconnect L19.
WA800L-3 20-529
(1)
TROUBLESHOOTING M-16
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)
Cause Remedy
Defective contact or
YES disconnection in wiring
Repair or
harness between L06
1 replace
(female) (8) and L43
(male) (1)
Does buzzer
sound? 2 YES
Defective buzzer Replace
Is voltage between
• Turn starting L42 (female) (1)
switch ON. and chassis Defective contact or
NO disconnection in wiring
• Contact L43 ground normal? Repair or
(female) to harness between L42
• 20 – 30 V NO replace
chassis ground. (female) (1) and FS2
• Turn starting (female) (9)
switch ON.
Cause Remedy
20-530 WA800L-3
(1)
TROUBLESHOOTING M-17
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L07 (10)
and chassis Defective contact or
ground normal? disconnection in wiring
harness between L07 Repair or
• 20 – 30 V NO (female) (10) and L09 replace
• Turn starting (female) (2)
switch ON.
WA800L-3 20-531
(1)
TROUBLESHOOTING M-18
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L05 (5) Short circuit with power
and chassis source in wiring harness
ground normal? between L05 (female) (5) Repair or
•0–5V NO – alternator terminal I, or replace
• Turn starting defective alternator
switch ON.
b) Count for time elapsed since failure in failure display mode does not advance
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L05 (5) Defective contact or
and chassis disconnection in wiring
ground normal? harness between L05 Repair or
• 20 – 30 V NO (female) (5) – alternator replace
• Start engine. terminal I, or defective
alternator
20-532 WA800L-3
(1)
TROUBLESHOOTING M-19
M-19 Buzzer is not made to sound by transmission & joystick steering controller
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA800L-3 20-533
(1)
TROUBLESHOOTING M-20
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
YES
Defective main monitor Replace
1
Is voltage
between L08 (5) Defective contact or
and chassis 2 YES disconnection in wiring Repair or
ground normal? Is voltage harness between L08 replace
• 20 – 30 V between GRE (3) (female) (5) and GRE (3)
• Turn starting and chassis See “Handling auto-
NO
switch ON. ground normal? greasing system” in
—
• 20 – 30 V NO Operation and
• Turn starting Maintenance Manual
switch ON.
YES
Defective main monitor Replace
1
Is voltage
between L07 (11) Defective contact or
and chassis 2 YES disconnection in wiring Repair or
ground normal? Is voltage harness between L07 replace
• 20 – 30 V between GRE (2) (female) (11) and GRE (2)
• Turn starting and chassis See “Handling auto-
NO
switch ON. ground normal? greasing system” in
—
• 20 – 30 V NO Operation and
• Turn starting Maintenance Manual
switch ON.
20-534 WA800L-3
(1)
TROUBLESHOOTING M-20
YES
Defective main monitor Replace
1
Is voltage
Defective contact or
between L07 (11)
disconnection in wiring
and chassis 2 YES Repair or
harness between L07
ground normal? replace
Is voltage between (female) (11) and GRE
• Max. 3 V GRE (female) (2) (female) (2)
• Turn starting and chassis
NO See “Handling auto-
switch ON. ground normal?
greasing system” in —
•2–3V NO Operation and
• Turn starting Maintenance Manual
switch ON.
• Disconnect GRE.
WA800L-3 20-535
(1)
TROUBLESHOOTING M-21
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Set dipswitch 3 at the rear of the main monitor to "F".
Cause Remedy
See troubleshooting of
transmission & joystick
controller system (T mode)
3 YES or defective control
Is resistance
—
monitor (If equipped)
YES between C3B
(female) (4), (12) – Defective contact or
2 L08 (female) (3) disconnection in wiring
Is voltage normal ? harness between L08 Repair or
YES between LM1 NO (female) (1), (3) – C3B replace
(female) (4), (12)
(male) (5) and (6)
1 normal? Defective contact or
Is voltage disconnection in wiring Repair or
• Repeats 0 V and harness between L08
between L08 replace
12 V. NO (female) (1), (3), L08
(male) (1) and (2)
• Turn starting (female) (2), (4) – LM1
normal?
switch ON. (male) (5), (6)
• Repeats 0 V and • Disconnect LM1.
12 V. Defective main monitor Replace
NO
• Turn starting
switch ON.
• Disconnect L08.
20-536 WA800L-3
(1)
TROUBLESHOOTING OF MAINTENANCE MONITOR
SYSTEM (K MODE)
Electrical circuit diagram for maintenance monitor system ......................................................................... 20-602
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for
3 seconds, maintenance monitor dose not work .............................................................................. 20-604
a) No lamps on maintenance monitor light up .................................................................................. 20-604
b) Some lamps do not light up .......................................................................................................... 20-604
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out
(even after 3 seconds) ...................................................................................................................... 20-605
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds),
no lamps on maintenance monitor go out......................................................................................... 20-606
K-4 When starting switch is truned on (engine stopped), CHECK items flash ........................................ 20-608
a) Engine oil level display flashes ..................................................................................................... 20-608
b) Engine water level display flashes................................................................................................ 20-609
K-5 When starting switch is turned ON (engine started), CAUTION items flash ..................................... 20-610
a) Engine oil pressure display flashes .............................................................................................. 20-610
b) Battery charge level display flashes ............................................................................................. 20- 611
c) Brake oil pressure display flashes (Check that the brake oil pressure is correct.)........................ 20-612
d) Air cleaner (R.H.) clogging display flashes (Check that the air cleaner (R.H.) is not clogged.).... 20-614
e) Air cleaner (L.H.) clogging display flashes (Check that the air cleaner (L.H.) is not clogged.) ..... 20-615
f) Transmission oil filter display flashes (The transmission oil filter must not be clogged.) ............... 20-616
K-6 CAUTION items are flashing but buzzer does not sound ................................................................. 20-617
K-7 There is no abnormality in monitor display but caution buzzer sounds ............................................ 20-618
K-8 CAUTION items are flashing but neither CHECK lamp nor CAUTION lamp flashes........................ 20-619
a) CHECK lamp ................................................................................................................................ 20-619
b) CAUTION lamp............................................................................................................................. 20-619
K-9 There is no abnormality in maintenance monitor display but CHECK lamp or CAUTION lamp
lights up ............................................................................................................................................ 20-620
a) CHECK lamp ................................................................................................................................ 20-620
b) CAUTION lamp............................................................................................................................. 20-620
K-10 Only night lighting of maintenance monitor does not light up when lighting switch is turned ON ..... 20-621
K-11 Night lighting lights up even when lighting switch is turned OFF ...................................................... 20-622
K-12 Service meter does not work ............................................................................................................ 20-623
K-13 Service meter is running even when engine is stopped ................................................................... 20-623
K-14 Abnormality in gauge display ............................................................................................................ 20-625
a) Abnormality in fuel gauge ............................................................................................................. 20-625
b) Abnormality in engine water temperature gauge .......................................................................... 20-626
c) Abnormality in torque converter oil temperature gauge ................................................................ 20-627
WA800L-3 20-601
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM
20-602 WA800L-3
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MAINTENANCE MONITOR SYSTEM
a This circuit diagram is made by extracting the part of the maintenance monitor system from the general cir-
cuit diagram.
WA800L-3 20-603
(1)
TROUBLESHOOTING K-1
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not
light up for 3 seconds, maintenance monitor dose not work
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Defective monitor
YES
module of maintenance Replace
monitor
Defective contact or
1 disconnection in wiring
Repair or
YES harness between L18
Is voltage replace, or
3 (female) (1), (2) – fuse I-
between L18 (1), replace fuse
10 – FS1 (male) (2), or
(2) – (3) normal? Is voltage between
YES FS1 (female) (2) blown fuse I-10
• 20 – 30 V and chassis
• Turn starting ground normal? Defective contact or
2
switch ON. disconnection in wiring Repair or
Is resistance • 20 – 30 V
between L18
harness between FS1 replace, or
• Disconnect FS1. (female) (2) – battery
(female) (3),(9),L19 NO replace fuse
NO • Turn starting relay, or blown slow
(8) and chassis
ground normal?
switch ON. blow fuse (120A)
• Max. 1 z
• Turn starting Defective contact or Repair or
switch OFF. NO disconnection in wiring replace
• Disconnect L18, harness between L18 (3),
L19. (9), L19 (female) (8) –
chassis ground
Defective monitor
module of maintenance Replace
monitor
20-604 WA800L-3
(1)
TROUBLESHOOTING K-2
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up
but do not go out (even after 3 seconds)
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective monitor
module of maintenance Replace
monitor
WA800L-3 20-605
(1)
TROUBLESHOOTING K-3
K-3 When engine is started immediately after starting switch is turned ON (within 3
seconds), no lamps on maintenance monitor go out
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective monitor
1 YES
module of maintenance Replace
When starting
engine, is voltage monitor
between L19 (female)
(1) and chassis Defective contact or
ground normal? disconnection in wiring Repair or
• 20 – 30 V NO harness between L19 replace
• Disconnect L19. (female) (1) – L95
• Start engine. (female) (3)
• Measure when starting motor is turning.
(starting switch at START).
20-606 WA800L-3
(1)
TROUBLESHOOTING K-3
WA800L-3 20-607
(1)
TROUBLESHOOTING K-4
K-4 When starting switch is truned on (engine stopped), CHECK items flash
a Before carrying out troubleshooting, be sure that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective monitor
3 YES module of maintenance Replace
Is resistance
between L18
monitor
YES
(female) (13) and Defective contact or
2 chassis ground
disconnection in wire
normal ? Repair or
Is resistance harness between L18
YES between E01 • Max. 1 z NO (female) (13) and E01
replace
(male) (B) and (C) • Turn starting (female) (C)
1 normal ? switch OFF
• Max. 1 z
Is voltage • Disconnect L18 Defective engine oil level
between E01 sensor Replace
• Turn starting NO
(female) (D) and
chassis normal ? switch OFF
• Disconnect E01 Blown fuse, defective
• +24 V contact or disconnection Repair or
• Turn starting NO in wire harness between replace
switch ON R08 and E01 (female) (D)
• Disconnect E01
20-608 WA800L-3
(1)
TROUBLESHOOTING K-4
Cause Remedy
Defective monitor
3 YES module of maintenance Replace
Is resistance monitor
YES between L18
(female) (8) and
Defective contact or
2 chassis ground disconnection in wiring
Is resistance normal? harness between L18 Repair or
YES between G06 • Max. 1 z NO (female) (8) and G01 replace
(female) (2) and (female) (1)
• Turn starting
1 chassis ground
normal?
switch OFF. Defective contact or
• Max. 1 z
Is resistance • Disconnect L18. disconnection in wiring Repair or
between G06 • Turn starting NO harness between G06 replace
(male) (1) and (2) switch OFF. (female) (2) and chassis
normal? • Disconnect G06. ground
• Max. 1 z
• Turn starting Defective radiator water Replace
NO
switch OFF. level sensor
• Disconnect G06.
WA800L-3 20-609
(1)
TROUBLESHOOTING K-5
K-5 When starting switch is turned ON (engine started), CAUTION items flash
a Before carrying out troubleshooting, be sure that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Read codes
YES and follow
—
engine manual
procedures
1
20-610 WA800L-3
(1)
TROUBLESHOOTING K-5
Cause Remedy
WA800L-3 20-611
(1)
TROUBLESHOOTING K-5
c) Brake oil pressure display flashes (Check that the brake oil pressure is correct.)
Cause Remedy
4 YES
Go to A
Is resistance
YES between BC07
3 (male) (1) and (2) Defective brake
Is resistance normal? accumulator oil pressure
YES between BC06 • Max. 1 z NO (low pressure) switch
Replace
(male) (1) and (2) • Start engine. (SW4)
2
normal? • Disconnect BC07. Defective brake
• Max. 1 z
Is resistance
accumulator oil pressure
YES between BC05 Replace
• Start engine. NO (low pressure) switch
(male) (1) and (2)
1 • Disconnect BC06. (SW3)
normal?
• Max. 1 z
Is resistance Defective brake
between BC04 accumulator oil pressure Replace
• Start engine.
(low pressure) switch
(male) (1) and (2) • Disconnect BC05. NO
normal? (SW2)
• Max. 1 z Defective brake
• Start engine. accumulator oil pressure Replace
• Disconnect BC04. NO (low pressure) switch
(SW1)
Defective monitor
6 YES
module of maintenance Replace
Is resistance
between L18
monitor
YES
(female) (11) and Defective contact or
5 BC04 (female) (1)
Is resistance
disconnection in wiring
normal?
harness between L18 Repair or
between BC04
• Max. 1 z NO (female) (11) and BC04 replace
From A (female) (2) and
chassis ground
• Turn starting (female) (1)
normal? switch OFF.
Defective contact or
• Max. 1 z
• Disconnect L18 and BC04.
disconnection in wiring Repair or
• Turn starting NO harness between BC04 replace
switch OFF. (female) (2) and chassis
• Disconnect BC04. ground
20-612 WA800L-3
(1)
TROUBLESHOOTING K-5
WA800L-3 20-613
(1)
TROUBLESHOOTING K-5
d) Air cleaner (R.H.) clogging display flashes (Check that the air cleaner (R.H.) is not clogged.)
Cause Remedy
Does display go
YES Defective dust indicator
out when B08 is Replace
(R.H.) relay
disconnected?
2
• Start engine.
• Disconnect B09. Does display go
4 YES
out when dust Go to A
Is resistance
NO indicator relay between L80
L80 is replaced? YES
(female) (6) and Defective contact or
3 chassis ground disconnection in wiring
Is voltage between normal? Repair or
harness between L80
B08 (female) (1) • Max. 1 z NO (female) (6) and chassis replace
NO and chassis • Turn starting ground
ground normal? switch OFF.
• Disconnect L80. Short circuit with chassis
• Turn starting ground in harness Repair or
switch ON. NO between B08 (female) (1) replace
• Disconnect B08. and L80 (female) (2)
• 20 – 30 V
Defective monitor
6 YES
module of maintenance Replace
Is resistance
between B09
monitor
YES
(female) (1) and Defective contact or
5 chassis ground
Is resistance
disconnection in wiring
normal?
harness between B09 Repair or
between L18
NO (female) (1) and BR1 replace
From A (female) (14) and
chassis ground (female) (9)
normal?
Defective contact or
• Max. 1 z disconnection in wiring Repair or
• Turn starting NO harness between L18 replace
switch OFF. (female) (14) and L80
• Disconnect L18. (female) (3)
20-614 WA800L-3
(1)
TROUBLESHOOTING K-5
e) Air cleaner (L.H.) clogging display flashes (Check that the air cleaner (L.H.) is not clogged.)
Cause Remedy
WA800L-3 20-615
(1)
TROUBLESHOOTING K-5
f) Transmission oil filter display flashes (The transmission oil filter must not be clogged.)
Cause Remedy
Defective monitor
4 YES
module of maintenance Replace
Is resistance
monitor
YES between L18
(female) (16) and Defective contact or
3 BC02 (male) (2)
Is resistance
disconnection in wiring
normal? harness between L18 Repair or
YES between BC02 • Max. 1 z NO replace
(male) (1) and • Turn starting switch
(female) (16) and BC02
2 chassis ground OFF. (male) (2)
normal? • Disconnect L18 and Defective contact or
Is resistance
• Max. 1 z BC02. disconnection in wiring Repair or
YES between BC03
• Turn starting NO harness between BC02 replace
(female) (1) and
switch OFF. (male) (1) and chassis
1 (2) normal?
• Disconnect BC02. ground
Is resistance • Max. 1 z Defective transmission
between BC02 • Start engine. oil filter sensor (BC03 Replace
(female) (1) and • Disconnect BC03. NO
(2) normal? side)
20-616 WA800L-3
(1)
TROUBLESHOOTING K-6
K-6 CAUTION items are flashing but buzzer does not sound
a Buzzer does not sound when battery charge or engine oil level is abnormal.
a ßBefore carrying out troubleshooting, check that all the related connectors are properly connected.
a ßAlways connect any disconnected connectors before going on to the next step.
a Check that fuse I-10 is normal. If it is blown, check for a short circuit with the chassis ground in wiring
harness between fuses I-10 to FS2 (9) and L42 (1).
Cause Remedy
Defective contact or
disconnection in wiring
3 YES
harness between L19 Replace
Does buzzer sound (female) (4) and L43
YES When L43 (female) (male) (1)
2 (1) is connected to
chassis ground ?
Does buzzer sound Defective buzzer Replace
YES When L19 (female) • Turn starting NO
(4) is connected to switch ON.
1 chassis ground ? • Disconnect L43.
Is voltage between
Defective monitor
• Disconnect L19. module of maintenance Replace
L42 (female) (1)
and chassis • Turn starting NO monitor
ground normal? switch ON.
Defective contact or
• 20 – 30 V disconnection in wiring
Repair or
• Disconnect L42. harness between FS2
NO replace
• Turn starting (female) (9) and L42
switch ON. (female) (1)
WA800L-3 20-617
(1)
TROUBLESHOOTING K-7
a Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before carrying out troubleshooting, check that buzzer stays sounded when L06 is disconnected.
Cause Remedy
Defective monitor
2 YES
module of maintenance Replace
Is resistance
monitor
YES between L19
(female) (4) and Short circuit with chassis
1 chassis ground
Is resistance ground in wiring harness
normal? Repair or
between L19 (female) (4)
• Min. 1 Mz
between L43
NO replace
(female) (1) and – L43 (male) (1) – L06
chassis ground • Turn starting switch OFF. (female) (8)
normal? • Disconnect L06, L19 and
L43.
• Min. 1 Mz Defective buzzer
NO Replace
• Turn starting
switch OFF.
• Disconnect L42
and L43.
20-618 WA800L-3
(1)
TROUBLESHOOTING K-8
K-8 CAUTION items are flashing but neither CHECK lamp nor CAUTION lamp flashes
a Before carrying out troubleshooting, check that there are no blown lamp bulbs.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a) CHECK lamp
Cause Remedy
Defective monitor
YES
module of maintenance Replace
1
monitor
Does CHECK lamp
light up when L19 Defective contact or
(female) (2) is disconnection in wiring
connected to 2 YES Repair or
Does CHECK lamp harness between L19
chassis ground ? replace
light up when L06 (female) (2) and L06
• Disconnect L19. (female) (10)
(male) (10) is
• Turn starting NO connected to
switch ON. chassis ground ?
Defective main monitor Replace
• Disconnect L06. NO
• Turn starting
switch ON.
b) CAUTION lamp
Cause Remedy
WA800L-3 20-619
(1)
TROUBLESHOOTING K-9
a Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a) CHECK lamp
Cause Remedy
Defective monitor
1 YES
module of maintenance Replace
Is resistance
between L19 monitor
(female) (2) and
chassis ground Short circuit with chassis
normal? ground in wiring harness Repair or
• Min. 1 Mz NO between L19 (female) (2) replace
• Turn starting and L06 (female) (10)
switch OFF.
• Disconnect L06
and L19.
b) CAUTION lamp
Cause Remedy
Defective monitor
1 YES
module of maintenance Replace
Is resistance
between L19 monitor
(female) (3) and
chassis ground Short circuit with chassis
normal? ground in wiring harness Repair or
• Min. 1 Mz NO between L19 (female) (3) replace
and L06 (female) (9)
• Turn starting
switch OFF.
• Disconnect L06
and L19.
20-620 WA800L-3
(1)
TROUBLESHOOTING K-10
K-10 Only night lighting of maintenance monitor does not light up when lighting
switch is turned ON
a Before carrying out troubleshooting, check that there are no blown lamp bulbs.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA800L-3 20-621
(1)
TROUBLESHOOTING K-11
K-11 Night lighting lights up even when lighting switch is turned OFF
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Switch Continuity
ON YES
OFF NO
20-622 WA800L-3
(1)
TROUBLESHOOTING K-12, K-13
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
YES
Defective service meter Replace
1 Defective contact or
Is voltage disconnection in wiring
3 YES harness between L22 Repair or
between L22
Is resistance (female) (2) and replace
(female) (2) and
between L22 alternator terminal I
(1) normal? YES
(female) (1) and
• 20 – 30 V 2 chassis ground Defective contact or
• Start engine. Is voltage between normal? disconnection in wiring Repair or
• Disconnect L22. alternator terminal • Turn starting NO harness between L22 replace
NO I and chassis switch OFF. (female) (1) and chassis
ground normal? • Disconnect L22. ground
• 20 – 30 V Defective alternator Replace
• Start engine. NO
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
YES
Defective service meter Replace
1
Is voltage
between L22 Short circuit with power
(female) (2) and 2 YES supply in wiring harness Repair or
(1) normal? between L22 (female) (2) replace
Is voltage between
• Max. 3 V alternator terminal and alternator terminal I
• Turn starting I and chassis
NO
switch ON. ground normal?
• Disconnect L22. Defective alternator Replace
• Max. 3 V NO
• Turn starting
switch ON.
WA800L-3 20-623
(1)
TROUBLESHOOTING K-12, K-13
20-624 WA800L-3
(1)
TROUBLESHOOTING K-14
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
1
Defective monitor
Does fuel gauge 3 YES
module of maintenance Replace
show FULL when Is resistance between
L18 (female) (6) and monitor
short connector
is connected to YES chassis ground
normal when short
R05 (female)? connector is Defective contact or
2 connected to R05? disconnection in wiring
• Disconnect R05.
• Max. 1 z
Is resistance Repair or
• Connect short harness between R05
between R05 replace
connector to R05 • Turn starting NO (female) (1) and L18
(female) (2) and
(female). NO chassis ground switch OFF. (female) (6)
• Turn starting normal? • Connect short connector
• Max. 1 z
Defective contact or
switch ON. to R05 (female).
disconnection in wiring
• Turn starting • Disconnect L18. Repair or
harness between R05
switch OFF. NO replace
(female) (2) and chassis
• Disconnect R05. ground
(2) Display always shows FULL and does not move Cause Remedy
WA800L-3 20-625
(1)
TROUBLESHOOTING K-14
1
When short Defective monitor
connector is
3 YES
module of maintenance Replace
connected to E04 Is resistance
(female), does between L18
monitor
engine water (female) (4) and
temperature gauge
display area rise one YES chassis ground
stage at a time, and normal when short
finally do all lamps connector is Defective contact or
2 connected to E04 disconnection in wiring
• Disconnect E04. Repair or
Is resistance (female)?
harness between E04
• Max. 1 z
• Connect short between E04 replace
connector to E04 NO (female) (1) – L18
(female) (2) and
(female). NO • Turn starting switch OFF. (female) (4)
chassis ground
• Turn starting normal?
• Connect short connector to
switch ON. E04 (female). Defective contact or
• Turn starting
• Disconnect L18. disconnection in wiring
switch OFF. Repair or
• Disconnect E04. harness between E04
replace
• Max. 1 z NO (female) (2) – chassis
ground
20-626 WA800L-3
(1)
TROUBLESHOOTING K-14
Defective torque
YES
converter oil temperature Replace
sensor
1
When short Defective monitor
connector is 3 YES
module of maintenance Replace
connected to T02, Is resistance
does torque between L18
monitor
converter oil (female) (5) and
temperature gauge
display area rise one YES chassis ground
stage at a time, and normal when short
finally do all lamps connector is Defective contact or
2 connected to T02 disconnection in wiring
• Disconnect T02. Repair or
Is resistance (female)?
• Connect short harness between T02
• Max. 1 z
between T02 replace
connector to T02 NO (female) (1) – L18
(female) (2) and
(female). NO • Turn starting switch OFF. (female) (5)
chassis ground
• Turn starting normal? • Connect short connector to
switch ON. • Max. 1 z T02 (female). Defective contact or
• Turn starting • Disconnect L18. disconnection in wiring
harness between T02 Repair or
switch OFF. replace
• Disconnect T02. NO (female) (2) – chassis
ground
WA800L-3 20-627
(1)
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
Electrical circuit diagram for power supply, engine starting, engine stopping and preheating .................... 20-702
Electrical circuit diagram for parking brake ................................................................................................. 20-704
Electrical circuit diagram for boom kick-out and bucket positioner ............................................................. 20-705
E-1 Engine does not start............................................................................................................................ 20-706
a) Starting motor does not turn ............................................................................................................ 20-706
b) Starting motor turns ......................................................................................................................... 20-710
E-2 Engine does not stop............................................................................................................................ 20- 711
E-3 Abnormality in preheating system ........................................................................................................ 20-714
a) Does not carry out preheating ......................................................................................................... 20-714
b) Only monitor display lights up .......................................................................................................... 20-714
c) Monitor display does not light up when preheating is completed .................................................... 20-715
d) Monitor display keeps lighting up when preheating is not completed .............................................. 20-715
E-4 Parking brake does not have effect ...................................................................................................... 20-717
a) Parking brake has no effect when parking brake switch is turned ON............................................. 20-717
b) Parking brake has no effect when brake pressure (accumulator pressure) drops
(Does not work as emergency brake) .............................................................................................. 20-717
E-5 Parking brake is applied when machine is traveling............................................................................. 20-718
E-6 Parking brake is released when starting switch is turned ON .............................................................. 20-720
E-7 Transmission does not change to neutral when parking brake is applied
(but parking brake works normally) ...................................................................................................... 20-720
E-8 Kick-down switch does not work .......................................................................................................... 20-722
a) Kick-down switch does not work even though gear shift works normally ........................................ 20-722
b) Kick-down cannot be canceled ........................................................................................................ 20-723
E-9 Boom kick-out does not work ............................................................................................................... 20-724
E-10 Abnormality in bucket positioner function........................................................................................... 20-728
E-11 Abnormality in lighting up of front working lamp ................................................................................. 20-731
E-12 Abnormality in lighting up of rear working lamp.................................................................................. 20-731
E-13 Abnormality in transmission cut-off..................................................................................................... 20-731
E-14 Abnormality in low idling selection...................................................................................................... 20-731
E-15 Abnormality in parking brake dragging warning ................................................................................. 20-731
E-16 Abnormality in buzzer ......................................................................................................................... 20-731
WA800L-3 20-701
(1)
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,
TROUBLESHOOTING ENGINE STARTING, ENGINE STOPPING AND PREHEATING
20-702 WA800L-3
(1)
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,
TROUBLESHOOTING ENGINE STARTING, ENGINE STOPPING AND PREHEATING
a This circuit diagram is made by extracting the parts of the power supply, engine starting, engine stopping,
and preheating systems from the general circuit diagram.
WA800L-3 20-703
(1)
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE
20-704 WA800L-3
(1)
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT
TROUBLESHOOTING AND BUCKET POSITIONER
WA800L-3 20-705
(1)
TROUBLESHOOTING E-1
a When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks,
always turn the starting switch OFF before starting.
a When connecting T-adapter (or socket adapter), connect to the connector specified as CNOE( ).
a After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to
original condition before going on to the next check.
4 YES
NO
3
Is voltage between 6 YES
YES starting motor
terminal B and Is voltage between
chassis normal ? YES battery relay
terminals and
• Turn starting switch chassis normal ?
ON
5 • Turn starting switch ON NO
• 20 -30V
• Check voltage between
Does battery relay chassis and both
From A make sound of terminals connected by
NO actuation ? thick cable YES
• 20 - 30V
2 • Starting switch 7
Is resistance ON io OFF Is voltage between
YES between starting both connection
motor terminal G terminals of AR01 –
and chassis normal ? NO AR02, AL01 – AL02
battery relay normal ?
• Turn starting
• Turn starting
switch OFF.
• Max. 1 z switch OFF
• 20 - 30V
1 NO
Is voltage between
E24 (male) (1) and
chassis normal ?
• Disconnect E24
• Directional switch:
Neutral
NO
• Joystick steering
lever: Neutral
• Turn starting switch 10 YES
to START
• Wait for prelube Is voltage between
cycle to complete ER1 (male) (8) and
• 20 - 30V
NO chassis normal?
• Turn starting NO
switch to START
• 20 - 30 V
20-706 WA800L-3
(1)
TROUBLESHOOTING E-1
Cause Remedy
Go to C on page 20-710 -
Go to A on previous
-
page
Defective contact or
disconnection in cable
between battery relay and Repair or
starting motor terminal B replace
• If answer is NO for both
terminals: Defective contact or
disconnection in wire harness
between battery and battery Repair or
relay replace
• If answer is NO for one terminal:
Defective battery relay
Defective battery relay Replace
Defective contact or
disconnection in wire
9 YES harness between starting Repair or
switch terminal replace
YES Is resistance BR–AR01, AL01
between AR02, AL02
8 and chassis normal ? Defective contact or
Is voltages between disconnection in wire Repair or
starter switch • Max. 1 z NO harness between AR02,
AL02 and chassis ground
replace
terminal BR and • Turn starting
chassis normal ? switch OFF.
• Turn starting Defective starting switch Replace
switch ON NO
• 20 - 30V
Defective contact or
Repair or
disconnection in starting
replace
motor ground cable
Defective contact or
disconnection in wire Repair or
harness between ER1 replace
(female) (8) and E24
(male)
Go to B on next page -
WA800L-3 20-707
(1)
TROUBLESHOOTING E-1
YES
YES
13
YES
Is voltage between
11 YES L95 (female) (6) and
Does starting motor chassis ground
turn when L95 is normal ?
From
replaced with other
B • Disconnect L95
relay of same type ?
• Set directional 14
• Replace steering switch to N YES
Does starting motor
lever neutral • Set joystick turn when L57 is 16
safety relay (L95) steering lever to
with other relay of NO replaced with other Is voltage between
N relay of same type ? YES L57 (female) (1) and
same type • Turn starting
• Set directional • Replace neutral chassis ground
switch to START
switch to N relay (L57) with normal ?
position
• Set joystick • 20 - 30V other relay of • Disconnect L57
steering lever to N 12 same type 15 • Set direcitonal
• Turn starting • Set directional
NO
switch to N
switch to START switch to N Is voltage between
• Set joystick steering
position Is voltage between L57 (female) (5) and
L95 (female) (1) and • Set joystick lever to N
NO steering lever to N NO chassis ground
(2) normal ? • 20 - 30V
normal ?
• Turn starting • Turn starting switch
switch to START • Disconnect L57 ON YES
• Disconnect L95
position • Set directional 18
• Set directional
switch to N
switch to N Set joystick steering Is voltage between
• Set joystick lever to N terminal B of
steering lever to N • 20 - 30V NO starting switch and
• Turn starting • Turn starting chassis normal ?
switch to ON switch to START • Turn starting switch
position position OFF NO
• Max. 1 V • 20 - 30V
20 YES
Is resistance
between L95
(female) (2) and
NO chassis ground
normal ?
• Disconnect L95 NO
• Turn starting
switch OFF
• Max. 1 z
20-708 WA800L-3
(1)
TROUBLESHOOTING E-1
Cause Remedy
Defective contact or
disconnection in wire Repair or
harness between L95 replace
(female) (3), LR3 (7) and
ER 1(male) (8)
WA800L-3 20-709
(1)
TROUBLESHOOTING E-1
Cause Remedy
Cause Remedy
20-710 WA800L-3
(1)
TROUBLESHOOTING E-2
a When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks,
always turn the starting switch OFF before starting.
a When connecting T-adapter (or socket adapter), connect to the connector specified as CNOE( ).
a After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to
original condition before going on to the next check.
Cause Remedy
WA800L-3 20-711
(1)
TROUBLESHOOTING E-1, E-2
20-712 WA800L-3
(1)
TROUBLESHOOTING E-1, E-2
WA800L-3 20-713
(1)
TROUBLESHOOTING E-3
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective contact or
disconnection in wiring
3 YES harness between E11,
Repair or
replace
Is voltage E13 and terminal B of
YES between E11, E13 starting motor
2 and chassis
Is voltage between ground normal?
electrical intake air Defective heater relay Replace
YES heater terminal of • 20 – 30 V NO
heater relay and • Turn starting
1 chassis ground
normal? switch ON.
Is voltage Defective electrical intake
• 20 – 30 V Replace
between E10, E12 air heater
• Turn starting NO
and engine ECM
switch ON.
normal?
Defective contact or
• 20 – 30 V disconnection in wiring Repair or
• Turn starting harness between engine replace
switch ON. NO
ECM and E10, E12
Cause Remedy
YES
Defective main monitor Replace
1
3 YES Defective preheating
Replace
Does preheating relay
Is voltage between
stop? YES E10, E12 - engine
ECM and chassis Short circuit with chassis
2 ground normal? ground in wiring harness
• Turn starting Repair or
switch OFF. • 20 – 30 V NO between E10, E12 and replace
• Disconnect Does preheating • Turn starting engine ECM
engine ECM NO stop? switch ON.
4 YES Defective electrical intake
Replace
• Turn starting air heater
switch OFF. Does preheating
• Remove NO stop?
preheating relay. Electrical intake air Repair or
• Turn starting NO heater contacts + 24 V replace
switch OFF
• Remove electrical
intake air heater
20-714 WA800L-3
(1)
TROUBLESHOOTING E-3
Cause Remedy
1 Yes
Is resistance
Defective main monitor Replace
between L05
(female) (19) and Defective contact or
chassis groud disconnection in wire
normal ? harness between L05 Repair or
• Max. 4 kz No (female) (19), LR3 (6), replace
• Turn starting ER1 (3) and heater replay
switch OFF (R.H.)
• Disconnect L05
Cause Remedy
2 Yes Repair or
Defective main monitor
replace
Yes Is voltage between
L05 (19) and chassis Defective contact or
ground normal ?
disconnection in wire
1 Replace
harness between E09
• Max. 1 V No
Is voltage between
and L05 (female) (19)
• Turn starting
E09 and chassis
switch ON
ground normal ?
Defective heater relay
• Max. 1 V No Replace
(R.H.)
• Turn starting
switch ON
WA800L-3 20-715
(1)
TROUBLESHOOTING E-3
20-716 WA800L-3
(1)
TROUBLESHOOTING E-4
Cause Remedy
1
Does condition 3 YES Defective parking brake
become normal Replace
Is voltage between solenoid
when L01 is
YES F11 (female) (1)
disconnected? Short circuit with power
2 and chassis
• Start engine ground normal? source in wiring harness
Is resistance Repair or
(Charge between L01 (female) (3) and
between L01 • Max. 1 V NO L58 (female) (1), F11 (female)
replace
accumulator).
NO (female) (2) and • Start engine (Charge (1)
(3) normal? accumulator).
Short circuit of wiring
• Min. 1 M z • Turn parking switch ON. harness between L01 Repair or
• Turn starting NO (female) (3) and L58 (female) replace
switch OFF. (1), F11 (female) (1) and
• Disconnect L01, wiring harness between L01
(female) (2) and L59 (female)
L58, L59 and F11.
(1), (3) with each other
b) Parking brake has no effect when brake pressure (accumulator pressure) drops (Does not work as
emergency brake)
Cause Remedy
WA800L-3 20-717
(1)
TROUBLESHOOTING E-5
a When carrying out troubleshooting of the brake system, stop the machine on level ground.
a When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks,
always turn the starting switch OFF before starting.
a When connecting the T-adapter (or socket adapter), connect to the connector specified as CNQE( ).
a Always connect any disconnected connectors and disconnect the T-adapter before going on to the next
step.
2 YES
Is resistance
YES between F11
(female) (2) and
chassis ground
normal?
• Disconnect L59. NO
• Turn starting
switch OFF.
• Max. 1 z YES
1
Is voltage between 4 YES
F11 (female) (1) Does condition
and chassis become normal
YES
ground normal? when L59 is
replaced with other
• 20 – 30 V relay of same type?
• Start engine • Replace parking
(Charge brake safety relay
accumulator). (L59) with other 5
relay of same Does condition
become normal when
type.
BC08, BC09, BC10 and
• Start engine NO C11 are connected to
(Charge short connector?
accumulator). • Connect short
3 YES
connector to
Is resistance of
BC08 (female), 7
L01 (male) (1), (2)
BC09 (female),
NO and (3) as shown BC10 (female) Is resistance
in Table 1? YES between L59
and C11 (female).
• Disconnect L01. (female) (1) and (3)
• Start engine
• Turn starting 6 normal?
(Charge with
switch OFF. brake oil Is voltage between • Max. 1 z
• Turn parking pressure). L59 (female) (5) • Turn starting
brake switch ON/ NO and chassis switch OFF. NO
OFF. ground normal? • Disconnect L59.
• 20 – 30 V
• Turn starting
switch ON. NO
• Disconnect L59.
NO
Table 1
Between Between
Operation
L01 (2) – (3) L01 (1) – (2)
ON (Parking) Min. 1 Mz Max. 1z
OFF (Traveling) Max. 1 z Min. 1 Mz
20-718 WA800L-3
(1)
TROUBLESHOOTING E-5
Cause Remedy
Defective contact or
disconnection in wiring Repair or
harness between F11 replace
(female) (2) and chassis
Defective contact or
10 YES disconnection in wiring Repair or
Is voltage between
harness between BC08 replace
(female) (1) – F11 (female) (1)
YES BC08 (female) (1)
9 and chassis
Defective contact or
normal? Repair or
Is resistance disconnection in wiring
YES between L59 • 20 – 30 V NO harness between BC08 replace
(female) (2) and • Turn starting switch ON. (female) (1) – L01 (female) (3)
8
chassis normal? • Turn parking brake switch ON o OFF.
Defective contact or
Is voltage between
L59 (female) (1)
• Max. 1 z • Disconnect BC08. disconnection in wiring Repair or
and chassis • Turn starting NO harness between L59 replace
switch OFF. (female) (2) and chassis
normal?
• Disconnect L59. Defective contact or
• 20 – 30 V disconnection in wiring harness Repair or
• Turn starting between L59 (female) (1) and
NO replace
switch ON. L01 (female) (2), or between FS2
• Turn parking (female) (7) and L01 (female) (1)
brake switch ON. Defective contact or
• Disconnect L59. disconnection in wiring Repair or
harness between L59 (female) replace
(1) and L59 (female) (3)
Defective contact or
disconnection in wiring Repair or
harness between L59 replace
(female) (5) – fuse I (8)
WA800L-3 20-719
(1)
TROUBLESHOOTING E-6, E-7
a When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks,
always turn the starting switch OFF before starting.
a When connecting the T-adapter (or socket adapter), connect to the connector specified as CNQE( ).
a Always, connect any disconnected connectors and disconnect the T-adapter before going on to the next
step.
Cause Remedy
o
then turn starting
o
• Disconnect L59. (2) and wiring harness
switch OFF switch OFF • Turn starting between L59 (female) (5) and
ON. ON. switch OFF. L01 (female) (1) with each
other
• Turn parking
brake switch OFF.
• Disconnect L59
and L01.
E-7 Transmission does not change to neutral when parking brake is applied (but
parking brake works normally)
Cause Remedy
20-720 WA800L-3
(1)
TROUBLESHOOTING E-5, E-6, E-7
WA800L-3 20-721
(1)
TROUBLESHOOTING E-8
a When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks,
always turn the starting switch OFF before starting.
a When connecting the T-adapter (or socket adapter), connect to the connector specified as CNQE( ).
a Always, connect any disconnected connectors and disconnect the T-adapter before going on to the next
step.
a) Kick-down switch does not work even though gear shift works normally
Cause Remedy
4 YES Repair or
Defective main monitor replace
Is resistance
YES between L08 (male)
3 (2), (4) and chassis
Is resistance ground normal? Defective transmission &
Repair or
joystick steering
YES between L15 • Max. 1 z NO controller replace
(female) (2) and L08
(female) (2), (4) • Disconnect L08.
2 Defective contact or
normal? • Turn starting
• Max. 1 z
Is resistance switch OFF. disconnection in wiring
harness between L15 Repair or
YES between L15
(female) (1) – C5 • Turn starting NO (female) (2) and L08 (female) replace
1 (female) (5) normal? switch OFF. (2), (4)
• Disconnect L15
Is resistance • Max. 1 z and L08.
Defective contact or
between L15 disconnection in wiring Repair or
• Turn starting
(male) (1) and (2) NO harness between L15 replace
switch OFF.
normal? (female) (1) and C5 (female)
• Disconnect L15 (5)
• Max. 1 z and C5.
• Turn starting Defective kick-down
Replace
switch OFF. NO switch
• Disconnect L15.
• Press kick-down
switch.
20-722 WA800L-3
(1)
TROUBLESHOOTING E-8
Cause Remedy
1
Does condition Defective transmission &
3 YES Repair or
become normal joystick steering
Is resistance between replace
when L15 is L08 (female) (2), (4) –
controller
YES
disconnected? chassis ground normal
2 Short circuit between L15 (female)
when C5 (female) (5) is
Is voltage between (1) and L15 (female) (2), or short Repair or
grounded to chassis?
circuit with chassis ground in
L15 (female) (2),
• Min. 1 Mz NO wiring harness between L08
replace
L08 (female) (2), (4) • Turn starting switch OFF.
NO – chassis ground (female) (2), (4) – L15 (female) (2)
• Disconnect C05 and L08.
normal? • Turn kick-down switch OFF. Short circuit with power
• Max. 1 V • Ground C5 (female) (5) to chassis. source in wiring harness Repair or
• Turn starting NO between L15 (female) (2) and replace
switch ON. L08 (female) (2), (4)
• Disconnect C05
and L08.
WA800L-3 20-723
(1)
TROUBLESHOOTING E-9
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Check that fuse I (10) is normal. If it is blown, check for a short circuit with the ground in the wiring harness
between fuse I (11) – FS2 (10) – L49 (3), (1), or FS2 (10) – FL2 (1) – F06 (female) (1).
YES
YES
6
Is voltage
YES between L49 (2)
and chassis
1
5 ground normal?
Does condition
become normal Is voltage • 20 – 30 V
when L49 is • Turn starting NO
YES between F06 (1) switch ON.
replaced with other and chassis
relay of same type? 4 • Bring a screwdriver
ground normal? close to boom kickout
• Replace with Is resistance
proximity switch.
other relay of YES between L06 • 20 – 30 V
same type. (female) (3) and • Turn starting NO
chassis ground switch ON.
3 normal?
Is resistance • Max. 1 z
YES between L16 • Turn starting
NO
(female) (1) and switch OFF.
(2) normal? • Disconnect F06.
2
Is voltage • 19 – 23 z
between each pin • Disconnect L16. NO
NO of F06 as shown
in Table?
• See Table 1.
• Turn starting NO
switch ON.
Table 1
Item When screwdriver comes close When screwdriver does not come close
Between (1) and (2) 20 – 30 V Max. 3 V
Between (1) and (3) 20 – 30 V 0 – 30 V
Between (2) and (3) Max. 3 V 20 – 30 V
20-724 WA800L-3
(1)
TROUBLESHOOTING E-9
Cause Remedy
Defective contact or
disconnection in wiring
7 YES harness between L49 Repair or
Is resistance (female) (5) and L16 replace
between L16 (female) (1)
(female) (2) and
Defective contact or
chassis ground
disconnection in wiring
normal? Repair or
• Max. 1 z
harness between L16
NO replace
(female) (2) – chassis
• Turn starting ground
switch OFF.
Defective contact or
• Disconnect L16. Repair or
disconnection in wiring
harness between L49 replace
(female) (2) – F06 (female) (2)
Defective contact or
disconnection in wiring
Repair or
harness between fuse I (11) –
replace
L49 (female) (1), (3), between
FS2 (10) – F06 (female) (1)
Defective contact or
disconnection in wiring Repair or
harness between F06 replace
(female) (3) and chassis
ground
Defective boom kick-out
Replace
solenoid
Defective boom
Replace
proximity switch
WA800L-3 20-725
(1)
TROUBLESHOOTING E-9
20-726 WA800L-3
(1)
TROUBLESHOOTING E-10
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Check that fuse I (10) is normal. If it is blown, check for a short circuit with the ground in the wiring harness
between fuse I (11) – FS2 (10) – L48 (1), (3), or FS2 (10) – FL2 (1) – F05 (female) (1).
YES
YES
6
Is voltage
YES between L48 (2)
and chassis
1
5 ground normal?
Does condition
become normal Is voltage • 20 – 30 V
when L48 is • Turn starting NO
YES between F05 (1) switch ON.
replaced with other and chassis
relay of same type? 4 • Bring a screwdriver close
ground normal? to bucket positioner
• Replace with Is resistance
proiximity switch.
other relay of YES between F05 • 20 – 30 V
same type. (female) (3) and • Turn starting NO
chassis ground switch ON.
3 normal?
Is resistance • Max. 1 z
YES between L17 • Turn starting
NO
(female) (1) and switch OFF.
(2) normal? • Disconnect F05.
2
Is voltage • 19 – 23 z
between each pin • Disconnect L17. NO
NO of F05 as shown
in Table?
• See Table 1.
• Turn starting NO
switch ON.
Table 1
Item When screwdriver comes close When screwdriver does not come close
Between (1) and (2) 20 – 30 V Max. 3 V
Between (1) and (3) 20 – 30 V 0 – 30 V
Between (2) and (3) Max. 3 V 20 – 30 V
20-728 WA800L-3
(1)
TROUBLESHOOTING E-10
Cause Remedy
Defective bucket
Replace
positioner solenoid
Defective bucket
Replace
proximity switch
WA800L-3 20-729
(1)
TROUBLESHOOTING E-10
20-730 WA800L-3
(1)
TROUBLESHOOTING E-11, E-12, E-13, E-14, E-15, E-16
WA800L-3 20-731
(1)
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H MODE)
H-1 Machine does not move ....................................................................................................................... 20-802
H-2 Machine lacks power or speed (every speed range) ........................................................................... 20-803
H-3 Excessive time lag when starting machine or shifting gear.................................................................. 20-804
H-4 Torque converter oil temperature is high .............................................................................................. 20-805
H-5 Steering does not turn .......................................................................................................................... 20-806
H-6 Turning, response of steering is poor................................................................................................... 20-807
H-7 Joystick lever is heavy ......................................................................................................................... 20-808
H-8 Steering wheel shakes or jerks ............................................................................................................ 20-809
H-9 Minimum turning radii to right and left are different .............................................................................. 20-810
H-10 Wheel brakes do not work or braking effect is poor ............................................................................20-811
H-11 Wheel brakes are not released or brakes drag .................................................................................. 20-812
H-12 Boom does not rise ............................................................................................................................ 20-813
H-13 Boom moves slowly or does not have sufficient lifting power ............................................................ 20-814
H-14 When raising boom, becomes slow at certain height ......................................................................... 20-815
H-15 Boom cylinder cannot hold down bucket............................................................................................ 20-815
H-16 Boom has large amount of hydraulic drift........................................................................................... 20-815
H-17 Boom fluctuates while working ........................................................................................................... 20-816
H-18 Boom drops momentarily when lever is operated from HOLD to RAISE ........................................... 20-816
H-19 Bucket does not tilt back .................................................................................................................... 20-817
H-20 Bucket moves slowly or has insufficient tilt back power ..................................................................... 20-818
H-21 Bucket movement becomes slow during tilt back .............................................................................. 20-819
H-22 Bucket cylinder cannot hold down bucket .......................................................................................... 20-819
H-23 Bucket has large amount of hydraulic drift ......................................................................................... 20-819
H-24 Bucket fluctuates while traveling under load (work equipment valve “HOLD”)................................... 20-820
H-25 Bucket dumps momentarily when lever is operated from HOLD to TILT ........................................... 20-820
H-26 Boom and bucket levers do not move smoothly ................................................................................ 20-821
WA800L-3 20-801
(1)
TROUBLESHOOTING H-1
dte
iora
• Was there any abnormal noise when the
ng d rated
eter
machine stopped moving?
terio
e, v ring de )
e
Yes = Component broken.
spri
defe
alve
Checks before troubleshooting
g
p
or v fective irt cau
ool
• Is oil level in transmission case correct?
fect n of sp
ump
tive
ctiv
rd
)
• Is monitor display normal?
curc ective
efec
e sp defec efectiv
,
er p
uit d
lutc operati
vert
f
Sha g clutc lutch s smissi iorated ctive
e
defe ive
alve
d
e
(b
ssi fective ue con
h de
t
ive
ses
ue c verter defect
3rd
ssio
il se
ulat
n of rque co ve spo ctive
Cau
lie
ool
q
f
f tor
on c
relie
smi
n re
fe
(
n c of tran deter
ol
Ope ge to in in rotai fective
Ope tion of er pum side o
tran
e de
Pilo tion of odulat on mai
valv
erte
lu
re
ng
valv
ng c
onv
de
on
ing
eiz
spri
n
val
Ope e conve at sucti
noid
smi
trol
lve
al
u
mod
tern
torq
e
tran
con
oov
rt
to
g
p
h
Torq cking u
n of
n of
n of
Tran g, gr
ssio
n
u
ratio
ratio
ratio
ratio
t red
smi
in
ra
ra
u
su
e
ft
Rota
Ope
Ope
Ope
Ope
Sea
Air
Torque Torque
converter Transmission
pump converter
a b c d e f g h i j k l m n o
Remedy A
No. Problems
1 Abnormal noise between pump and filter.
2 Machine does not move in any speed range. (Item 1 normal)
3 Machine moves normally in certain speed ranges.
4 Machine will not move when T/C oil temperature rises.
5 Transmission main relief pressure too low
6 Transmission Low at every speed range.
7 modulating Low at certain speed ranges.
8 pressure too low Indicator fluctuates violently.
9 Pilot pressure defective
10 Torpue converter relief valve pressure too low
11 Torpue converter regulator valve pressure too low
Note 1: If the solenoid valve and hydraulic pressure The following symbols are used to indicate the action to
are normal, the "m" in the Causes column be taken when a cause of failure is located.
indicates that the valve spool does not work.
Note 2: If the transmission clutch pressure is low, X: Replace E: Repair
but the cause cannot be found in the above A: Adjust C: Clean
table, a possible cause is cracks in the valve
or transmission.
20-802 WA800L-3
(1)
TROUBLESHOOTING H-2
ted
• Is oil level transmission case correct?
ted
iora
iora
• Is there any leakage of oil from joints of
eter
e)
eter
piping or valves?
)
ose
ctiv
ng d
• Is parking brake or wheel brake dragged?
ng d
g lo
defe
spri
spri
, plu
e
alve
ivet
ctiv
Checking for abnormalities
ump
, or
tive
ne r
ve, v
e
defe
• Engine high idling speed
ctiv
er p
e
efec
ctiv
urbi
i
• Torque converter stall speed
t
defe
ion
c
vert
defe
defe
ng d
er (t
• Machine travel speed
erat
con
lve
alve
i
vert
• Transmission clutch pressure (both
ctiv
alve
r
, op
f va
eal
rque
v
defe
high pressure and low pressure)
con
ief v
ated
r
er (s
relie
o
ulat
ses
of to
• Pressure at outlet port of torque con-
que
ive
r rel
alve
rior
vert
ain
r reg
Cau
verter pump
fect
f tor
ide
dete
erte
ng v
nm
con
ce
erte
• Pilot reducing pressure
p de
s
art o
onv
ssio
n
i
ring
rque
c
orm
onv
ctio
u
pum
t red
ue c
al p
smi
e sp
ue c
e to
t su
perf
tern
rter
torq
tran
pilo
valv
up a
torq
nsid
ine
e
to in
onv
n of
n of
n of
ng i
eng
n of
ing
ing
ue c
ratio
ratio
ratio
ulat
ege
ratio
eaki
suck
p in
Torq
Dam
Mod
Ope
Ope
Ope
Oil l
Ope
Dro
Air
Torque
converter Engine Torque converter
pump
a b c d e f g h i j
Remedy A
No. Problems
1 Abnormal noise from between pump and filter.
2 Torque converter stall speed too high.
3 Torque converter stall speed too low
4 Transmission main relief valve pressure too low
5 Transmission Low at every speed range (Item 2 abnormal)
modulating
6 pressure too low Indicator fluctuates violently.
7 Pilot reducing pressure too low (Items 5 and 6 normal)
WA800L-3 20-803
(1)
TROUBLESHOOTING H-3
iv e
fect
l de
poo
ump
of s
er p
tive
tive
tion
vert
e)
efec
ctiv
efec
pera
con
ed
ch d
defe
e
uit d
g
o
v
rque
clog
i
,
t
clut
ated
ing
circ
defe
ses
of to
lve
ive
ion
seal
rior
utch
lve
n va
Cau
s
c
side
dete
s
defe
(oil
a
i
g cl
m
v
r
retu
s
turn
ion
tive
ing
tran
tatin
mp
t
uick
r
k re
efec
c
r pu
e of
t su
n ro
e s
quic
of q
d
erte
valv
up a
roov
ng i
ch
hole
clut
onv
n of
al ri
ing
g, g
ing
ue c
ratio
ting
ulat
ft se
suck
ttle
l rin
Torq
Thro
Mod
Rota
Ope
Sha
Sea
Air
Torque
converter Transmission
pump
a b c d e f g h
Remedy
No. Problems
1 Abnormal noise between pump and filter
2 Excessive time lag in every speed range.
3 Machine moves normally in certain speed ranges.
20-804 WA800L-3
(1)
TROUBLESHOOTING H-4
ump
up during torque converter stall, and
e, p
down when the torque converter is not
oos
installed?
ug l
Yes = Normal (incorrect selection of gear
), pl
speed)
ive
ump
tive
fect
efec
er p
ive
Checks before troubleshooting
e de
fect
ng d
vert
• Is oil level in transmission case correct?
valv
e de
con
al ri
• Is transmission filter clogged?
ator
valv
r (se
rque
lgul
f
erte
Checking for abnormalities
e
ses
of to
i
ive
r rel
er re
a If the oil temperature is normal but the oil
onv
Cau
fect
ide
erte
temperature gauge is outside the operat-
ue c
vert
p de
s
onv
n
ing range, the oil temperature gauge is
torq
n
ctio
o
pum
ue c
ue c
defective.
t su
crac inside
torq
torq
rter
up a
ked)
e
il
n of
n of
onv
of o
ing
ue c
ratio
ratio
age
suck
ine
Torq
Leak
(turb
Ope
Ope
Air
Torque
converter Torque converter
pump
a b c d e
Remedy A
No. Problems
1 Pump makes abnormal noise when oil temperature is low.
2 High idling and low idling speeds are too low.
3 Hydraulic pressure at inlet port of torque converter too low
4 Transmission modulating pressure too low
WA800L-3 20-805
(1)
TROUBLESHOOTING H-5
l
l
poo
poo
p
• Has the safety bar been removed from the
es
pum
nd s
aus
ng s
frame?
e
itch
valv
ema
• Is steering valve open?
eeri
w
t
nd s
tion
of d
of s
e
seal
v
mp
-suc
ng a
l
ion
ion
v a
C pu
ston
tuat
tuat
tary
fety
eeri
e PP
e ac
e ac
e sa
e ro
e pi
e st
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Hydraulic Rotary Cylin-
pump valve Steering valve der
a b c d e f g
Remedy
No. Problems
1 Steering wheel does not turn in both directions (left and right)
2 Steering wheel turns only in one direction (left or right)
3 Joystick lever is heavy in both directions (left and right)
4 Work equipment moves
5 Work equipment does not move
6 Abnormal noise comes from around PTO
7 Abnormal noise comes from around PPC pump or hydraulic tank
a There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is felt in the steering, check the operation of the work equipment also.
20-806 WA800L-3
(1)
TROUBLESHOOTING H-6
ses
ool
ol
ump
spo
rect?
d sp
Cau
of p
ing
Is the type of oil correct?
e
man
valv
end
teer
e
valv
f de
ump
tion
of s
tion
ump
e
o
valv
seal
mp
ng p
relie
-suc
ion
ion
c
t su
ch p
C pu
tuat
tuat
ston
tary
fety
eeri
ain
a
O
swit
d in
e PP
e PT
e ac
c
e ro
e sa
e St
e pi
e a
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
suck
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
Remedy
No. Problems
1 Turning, response of steering is poor in both directions (left and right)
2 Turning, response of steering is poor in one direction (left or right)
3 Joystick lever is heavy in both directions
4 Joystick lever is heavy in one direction (left or right)
5 Work equipment moves
6 Work equipment also speed is slow
7 Abnormal noise comes from around PTO
8 Abnormal noise comes from around steering pump or hydraulic tank
9 Abnormal noise comes from around switch pump or hydraulic tank
Oil pressure is low or there is no pressure in
10 When steering both directions (left and right)
relief pressure
is measured Oil pressure is low or there is no pressure in
11 one direction (left or right)
a There is a close connection between the steering circuit and the work equipment circuit, so if any abnormal-
ity is felt in the steering, check the operation of the work equipment also.
WA800L-3 20-807
(1)
TROUBLESHOOTING H-7
ft
sha
• Yes = Related equipment broken
ring
• Was there previously any symptom,
ol
stee
such as heavy steering?
ses
spo
Yes = Wear of related equipment, de-
r or
Cau
ring
fective seal
leve
stee
tick
e
n of
Checks before troubleshooting
valv
joys
atio
• Is the oil level in the hydraulic tank cor-
tary
e of
u
rect?
t
e ac
e ro
enc
Is the type of oil correct?
ctiv
ctiv
rfer
• Is the tire inflation pressure correct?
Defe
Defe
Inte
Rotary Steering
valve valve Others
a b c
Remedy
No. Problems
1 Joystick lever is heavy when turned in both directions (left and right)
2 Joystick lever is heavy when turned in one direction (left or right)
4 When steering Oil pressure is low in both directions (left and right)
relief pressure
5 is measured Oil pressure is low in one direction (left or right)
20-808 WA800L-3
(1)
TROUBLESHOOTING H-8
ool
poo
ses
g sp
nd s
Cau
e
erin
valv
ema
lve
t e
of d
tion
f va
of s
e
valv
seal
elie
-suc
ion
ion
r
tuat
tuat
ston
tary
fety
ain
e ac
e ac
e ro
e sa
em
e pi
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Rotary Steering valve Cylin-
valve der
a b c d e f
Remedy
No. Problems
1 Steering wheel shakes or jerks in both directions (left and right)
2 Steering wheel shakes or jerks in one directions (left or right)
WA800L-3 20-809
(1)
TROUBLESHOOTING H-9
20-810 WA800L-3
(1)
TROUBLESHOOTING H-10
ator
• Was there any abnormal noise when
mul
this happened? Where did the noise
accu
come from?
ro m
• Did the problem gradually appear?
as f
Yes = Wear of related equipments, de-
of g
fective seal
ding
ses
blee
Cau
p
Checks before troubleshooting
ton
ive
• Is the oil level in the hydraulic tank cor-
uit
i
d of
fect
p
rg
rect?
v
h
n se
Is the type of oil correct?
l
c
lv
a
of b
ter
r
e va
Defe ve brak t suctio
ke
mp
Defe tive pis mulato
br
djus
• Is the brake pedal play correct?
a
ion
e
c
r
e pu
b
i s
ck a
• Is there any leakage of oil from the
ton
tuat
d
side
na
ht
cu
xle
ak
rake
Air ive PTO
e rig
e ac
brake tube?
e br
Defe ucked i
e in
e a
el
b
e
d th
ctiv
ctiv
ctiv
Is there any deformation of the tube?
kag
r of
cti
ct
ct
c
c
s
Defe
Defe
Defe
W ea
Defe
Defe
Defe
Blee
• Is the tire inflation pressure and tread
pattern correct? Brake Charge Accu- Brake Slack-
pump valve mulator valve adjuster Wheel brake Others
a b c d e f g h i j k l m n
Remedy
No. Problems
1 Brake has no effect only when left brake pedal is depressed
2 Left brake pedal is light when it is depressed
3 Right brake pedal is light when it is depressed
4 Left brake pedal is heavy when it is depressed
5 Right brake pedal is heavy when it is depressed
6 Abnormally large operating force is needed to obtain specified braking force
7 Abnormal noise is heard from brake when brake is applied
8 Work equipment, steering also do not work
9 Movement of work equipment, steering is slow
10 Abnormal noise comes from around PTO
11 Abnormal noise comes from around brake pump or hydraulic tank
12 Many metal particles are found in oil drained from axle case
13 When accumulator charge pressure is measured, oil pressure is found to be low
14 Brake stops having effect immediately when engine is stopped
15 There is a time lag before brake takes effect
16 When brake oil pressure is measured, it is found to be low
17 When drop in brake piston pressure is measured, it is found to be excessive
18 When wear of brake disc is measured, it is found to be excessive
19 When air is bled from brake line, air comes out
WA800L-3 20-811
(1)
TROUBLESHOOTING H-11
ster
on
ses
pist
adju
Cau
rake
lack
e
valv
e
valv
of b
te
of s
, pla
rake
ion
ake
ion
disc
ht b
tuat
tuat
ft br
rake
e rig
e ac
e ac
e le
ed b
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Seiz
Brake Slack Wheel
valve adjuster brake
a b c d e
Remedy
No. Problems
1 Machine cannot travel at all
2 Machine can travel a small amount
6 When air bleed plug is loosened, a large amount of oil flows out
20-812 WA800L-3
(1)
TROUBLESHOOTING H-12
oil
in
• Was unusual noise produced? (Where did
ined
it emanate from?)
onta
• Were there previous signs of the boom
air c
slowing down?
o Wear of parts of flattening of spring.
t of
oun
Checks before troubleshooting
e am
• Is oil level in hydraulic tank correct?
ssiv
• Is travel of lift arm control lever and spool
exce
l)
correct?
lve
poo
ses
e al
p or
ol
f va
ump
lift s
spo
Cau
on s
alve
pum
relie
iven
dy (
p
and
pist
v
tch
t of
ol
ain
lief
g dr
e bo
dem
der
spo
i
d sw
r
of m
f re
n po
bein
ylin
valv
n of
n of
o
lty P aulic an
ctio
ion
ion
mc
mp
atio
atio
not
age
tuat
tuat
Pum e in su
boo
u
actu
actu
m
O is
PC p
e ac
e ac
dr
d a
ged
y
p PT
e
e
lty h
rnal
kag
ctiv
ctiv
ctiv
ctiv
ama
Defe
Defe
Defe
Defe
Bloc
Inte
Fau
Fau
D
Steering PPC Work
Tank-pump equipment Cylin-
valve valve control valve der
a b c d e f g h i j
Remedy C
No. Problems
1 Bucket cannot be operated and boom is unable to rise.
3 The boom can rise under no load but cannot rise under load.
4 The hydraulic pump produces an abnormal noise.
5 Boom cylinder has large amount of hydraulic drift.
WA800L-3 20-813
(1)
TROUBLESHOOTING H-13
H-13 Boom moves slowly or does not have sufficient lifting power
il
in o
• Is the travel of the boom control lever and
sted
ned
also the spool of the work equipment control
valve correct?
ntai
adju
• Seizure of work equipment linkage bushing.
ir co
erly
(Does emits abnormal noise)
of a
prop
unt
ty im
Fault check
amo
There is a strong relationship between faults
fau l
sive
involving lifting force and lifting speed. Such
an d
faults appear initially in the from of insufficient
xces
lve
lifting speed. Measure the lifting speed of the lift
or e
f va
dy
o
eal
arm when loaded and refer to the standard
o
ses
e bo
ump
d sp
alve
ump
on s
relie
value table to determine whether or not there is
Cau
valv
man
v
ch p
pist
of p
ain
l
a fault.
lief
poo
of m
swit
orn
f de
der
of re
port
of s
or w
cylin
o
and
ion
ion
ion
ion
ion
age
suct
tuat
tuat
tuat
tuat
om
ulic
dam
d bo
ydra
e ac
e ac
e ac
e ac
e of
age
ctiv
ctiv
ctiv
ctiv
lty h
rnal
kag
Defe
Defe
Defe
Defe
Dam
Bloc
Inte
Fau
Bucket tilt back force and speed are normal but boom lifting
2
speed is slow.
20-814 WA800L-3
(1)
TROUBLESHOOTING H-14, H-15, H-16
Cause
• Swollen or internally damaged boom cylinder tube.
a Regarding other faults occurring during boom rise, refer to item “H-13 Boom moves slowly or
does not have sufficient lifting power”.
Refer to item “H-13 Boom moves slowly or does not have sufficient lifting power”.
Cause
• Defective boom cylinder rod side suction valve seat of work equipment control valve
• Oil leakage from boom cylinder piston seal
WA800L-3 20-815
(1)
TROUBLESHOOTING H-17, H-18
H-18 Boom drops momentarily when lever is operated from HOLD to RAISE
The boom drops momentarily under its own weight when the boom control lever is gradually shifted from
the “HOLD” position to the “RAISE” position while the engine is at low idling. When the control lever is
put completely into the “RAISE” position, the boom moves normally.
Cause
• Defective seating of work equipment control valve or boom spool check valve.
20-816 WA800L-3
(1)
TROUBLESHOOTING H-19
il
• Was there previous signs of the bucket
in o
slowing down?
ned
ntai
o Worn parts or flattening of spring.
ir co
of a
Checks before troubleshooting
unt
• Is the travel of the bucket control lever
amo
and spool correct?
sive
ses
ol)
xces
spo
lve
Cau
ump
or e
eal
ump
poo
f va
p
on s
e
ump
relie
nd s
valv
ing
y (d
iven
pist
teer
of p
bod
ema
ain
lief
g dr
der
nd s
of m
of re
port
of d
lve
cylin
bein
lic a
d va
mp
ion
ion
ion
ion
C pu
drau
cket
not
age
tuat
tuat
suct
tuat
ool
dam
O is
d bu
e PP
e sp
e hy
e ac
e ac
e ac
e in
p PT
age
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
rnal
kag
Defe
Defe
Defe
Defe
Dam
Defe
Defe
Pum
Bloc
Inte
Tank-pump Steering PPC Work equipment
valve valve control valve Cylinder
a b c d e f g h i j
Remedy C A
No. Problems
1 Boom cannot be operated and bucket is unable to tilt back.
2 The machine can be lifted up by the bucket but the bucket cannot
tilt back. Or, the boom operates but the bucket cannot tilt back.
3 The bucket can tilt back under no load but cannot excavate or scoop.
4 The hydraulic pump produces an abnormal noise.
5 Bucket cylinder has large hydraulic drift.
WA800L-3 20-817
(1)
TROUBLESHOOTING H-20
il
r
in o
• Is the travel of the bucket control lever
inde
and the work equipment control valve
t cyl
ned
spool correct?
ucke
ntai
ted
• Seizure of bushing in bucket linkage?
the b
ir co
djus
(Does emits abnormal noise?)
of a
e of
tly a
d sid
unt
ol)
Fault checks
rrec
on ro
amo
spo
• Check deficient tilt back force by per-
inco
lve)
ket
sive
forming actual work.
and
n va
buc
xces
• Measure the operating speed of the
uctio
dy (
lve
bucket and check it against the standard
or e
ool
eal
f va
e bo
pum
ith s
value table to determine whether or not
ses
on s
p
e
mp
relie
s
w
valv
it is normal.
l
and
Cau
itch
(
f pu
pist
v
e
valv
ool
ain
lief
dem
w
e
ort o
g
der
nd s
p
of m
of re
ama
fety
s
cylin
f
n of
on o
p
of sa
lic a
d
ion
ion
ion
r
o
o
drau
cket
i
i
ation
tuat
tuat
tuat
suct
tuat
orn
d bu
e hy
e ac
e ac
e ac
e ac
actu
ly w
e in
age
ctiv
ctiv
ctiv
ctiv
ctiv
ctive
rnal
kag
Defe
Defe
Defe
Defe
Dam
Defe
Bloc
Defe
Inte
Tank- Steering PPC Main control Cylin-
pump valve valve valve der
a b c d e f g h i
Remedy C A
No. Problems
Boom lifting force and lifting speed are abnormal and also
1
bucket tilt force and tilt speed are abnormal.
Boom lifting force and lifting speed are normal but bucket tilt
2
force and tilt speed are abnormal.
20-818 WA800L-3
(1)
TROUBLESHOOTING H-21, H-22, H-23
Cause
• Swollen or internally damaged bucket cylinder tube.
• As to other faults which occur when operating bucket, refer to item “H-20 Bucket moves slowly or
has insufficient tilt back power”.
Refer to item “H-20 Bucket moves slowly or has insufficient tilt back power”.
Cause
• Defective seat of safety valve (with suction valve) of the rod side of bucket cylinder of work equip-
ment valve.
• Oil leakage from seal of bucket cylinder piston.
Fault check
• Use the standard value table to check whether or not the hydraulic drift of the bucket is actually
large.
Cause
• Oil leakage in bucket cylinder
• Defective seating of safety valve (with suction valve) at bottom side.
• Defective oil sealing of bucket spool.
• Defective check valve between pipings.
WA800L-3 20-819
(1)
TROUBLESHOOTING H-24, H-25
Cause
• Defective piston seal of bucket cylinder.
• Defective safety valve (with suction valve) for the head side of bucket cylinder.
If the above symptoms occur together, refer to the troubleshooting items corresponding to each
fault.
H-25 Bucket dumps momentarily when lever is operated from HOLD to TILT
The bucket dumps momentarily under its own weight when the bucket control lever is gradually shifted
from the “HOLD” position to the “TILT” position while the engine is at low idling.
When the control lever is put completely into the “TILT” position, the bucket moves normally.
Cause
• Defective seating of bucket spool check valve of work equipment valve.
20-820 WA800L-3
(1)
TROUBLESHOOTING H-26
Fault check
Using the standard value table, check
whether or not the operating effort of the
l
bolt
poo
lever is large.
ting
nd s
oun
dy a
l
poo
lve m
e bo lve bo
ool
nd s
e sp
f va
ool
dy a
va
ool
valv
ng o
e sp
trol
d sp
teni
trol
con
l
valv
a
y an
rol v
k
tigh
con
f lin
ent
poo
trol
bod
t
form
ent
m
rts o
con
ool
nd s
p
con
alve
ipm
i
e sp
u
-uni
ses
ent
g pa
q
dy a
ent
lve
equ
v
valv
ipm
non
k
Cau
C
atin
r
a
uipm
e bo
o
n PP
e bo n PPC v
ork
en w
equ
e to
trol
f rot
valv
nw
q
e
y du
con
e
k
e
twe
o
wor
etw
k
ed i
ed i
C
r
ver
o
und ance be
d
P
ent
ool
w
ce b
P
t of
odg
odg
ol le
f
f
ipm
e sp
o
o
eten
aran
valv
ter l
ter l
s
s
ontr
nes
nes
equ
Poo ct clear
valv
of d
t cle
mat
mat
n of
of c
und
r k
C
t wo
ortio
rrec
king
ign
ign
t PP
r ro
r ro
ure
rre
Fore
Fore
Inco
Inco
Ben
Seiz
Poo
Stic
Ben
Dist
PPC valve Work equipment
Lever control valve
a b c d e f g h i j k
Remedy C C
No. Problems
Movement of boom and bucket levers becomes sluggish when
1
load is applied and oil pressure increase.
Movement of boom and bucket levers does not become light even
5 when the link of the control lever is disconnected at the valve
connection part and the lever operated.
WA800L-3 20-821
(1)
TROUBLESHOOTING OF
AJSS (Advanced Joystick Steering System)
CONTROL SYSTEM
(A MODE)
Judgement table for AJSS control system .................................................................................................. 20-902
Operations of controller against abnormality and conditions of machine caused by abnormality............... 20-904
Electric circuit diagram for AJSS control ..................................................................................................... 20-908
A-1 Failure code [56] (Disconnection or short circuit with chassis ground in
caution buzzer relay system) is displayed............................................................................................ 20-910
A-2 Failure code [57] (Disconnection or short circuit with chassis ground in
steering lever angle sensor system) is displayed...................................................................................20911
A-3 Failure code [58] (Deviation of steering lever angle sensor and frame angle sensor signals)
is displayed........................................................................................................................................... 20-912
A-4 Failure code [59] (Disconnection or short circuit with chassis ground in
frame angle sensor system) is displayed ............................................................................................. 20-913
A-5 Failure code [60] (Disconnection or short circuit with chassis ground in
steering lever lock pressure switch system) is displayed ..................................................................... 20-914
A-6 Failure code [62] (Disconnection or short circuit with chassis ground in
steering neutral interlock relay system) is displayed ............................................................................ 20-915
A-7 Failure code [63] (Disconnection, short circuit with chassis ground, or
short circuit with power source in steering main pressure control EPC solenoid system) is displayed 20-916
A-8 Steering speeds in both directions are different ................................................................................... 20-917
A-9 Abnormality in console switch (adjustment of steering lever angle sensor and
frame angle sensor is impossible)........................................................................................................ 20-918
A-10 Abnormality in power source and voltage........................................................................................... 20-919
WA800L-3 20-901
(1)
9
8
7
6
5
4
3
2
1
(1)
20-902
Failure mode
TROUBLESHOOTING
Q
Disconnection or short circuit with chassis ground in caution buzzer relay system
56
A-1
Q
Disconnection or short circuit with chassis ground in steering lever angle sensor system
57
A-2
Q
Deviation of steering lever angle sensor and frame angle sensor potentiometer signals
58
A-3
Q
Disconnection or short circuit with chassis ground in frame angle sensor system
59
A-4
Disconnection or short circuit with chassis ground in steering lever lock pressure switch system
60
A-5
Q
Q
Q
Disconnection or short circuit with chassis ground in steering neutral interlock relay system
62
A-6
Disconnection, short circuit with chassis ground, or short circuit with power source in steering main
Q
Q
Q
Q
63
JUDGEMENT TABLE FOR AJSS CONTROL SYSTEM
A-7
pressure control EPC solenoid system
—
Diagnosis code when failure code is not displayed
—
—
—
—
—
E-1
Self-diagnosis display (Display of abnormality)
M-19
H-5, H-6, H-7, H-8
H-5, H-6, H-7, H-8
WA800L-3
JUDGEMENT TABLE FOR AJSS CONTROL SYSTEM
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND
TROUBLESHOOTING CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Disconnection or short cir- 1) Improper installation (Misalignment) of steering lever angle sensor
cuit with chassis ground in 2) Defective steering lever angle sensor
steering lever angle sensor 3) Disconnection, defective contact, or short circuit with chassis ground
(potentiometer) system in wiring harness between T/M and J/S controller C3A (female) (3) –
57 JS2 (female) (1)
4) Defective T/M and J/S controller
Deviation of steering lever 1) Improper installation (Misalignment) of steering lever angle sensor
angle sensor and frame 2) Defective steering lever angle sensor
angle sensor signals 3) Improper installation (Misalignment) of frame angle sensor
4) Defective frame angle sensor
5) Disconnection, defective contact, or short circuit with chassis ground
58 in wiring harness between T/M and J/S controller C3A (female) (3) –
JS2 (female) (1)
6) Disconnection, defective contact, or short circuit with chassis ground
in wiring harness between T/M and J/S controller C3A (female) (13) –
L27 (female) (1)
7) Defective T/M and J/S controller
20-904 WA800L-3
(1)
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND
TROUBLESHOOTING CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
1) Voltage between relay L65 (1) – chassis Does not operate at all. Caution buzzer does not
ground when caution buzzer is turned on: 20 – sound or keeps sounding.
30 V
2) Resistance between T/M and J/S controller C2
(female) (9) – (19), caution buzzer relay: 200 –
A-1
400z
3) Resistance between T/M and J/S controller C2
(female) (9) – L65 (female) (1): Max. 1 z
4) Resistance between T/M and J/S controller C2
(female) (19) – L65 (female) (2): Max. 1 z
1) Voltage between T/M and J/S controller C3A (7) 1) Turns off steering Steering speeds in both
– (16): 0.5 – 4.5 V main pressure control directions are different.
2) Resistance between steering lever angle sen- EPC solenoid output.
sor JS2 (male) (1) – (2): 0 – 5 kz 2) Controls steering lever
angle sensor signal A-2
voltage as input volt-
age.
1) Voltage between T/M and J/S controller C3A (7) Turns off steering main Steering speeds in both
– (16): 0.5 – 4.5 V pressure control EPC directions are different.
2) Voltage between T/M and J/S controller C3A solenoid output.
(3) – (16): 0.5 – 4.5 V
3) Resistance between steering lever angle sen-
sor JS2 (male) (1) – (2): 0 – 5 kz A-3
4) Resistance between frame angle sensor L27
(male) (1) – (2): 0 – 5 kz
1) Voltage between T/M and J/S controller C3A 1) Turns off steering Steering speeds in both
(7) – (16): 0.5 – 4.5 V main pressure control directions are different.
2) Resistance between frame angle sensor L27 EPC solenoid output.
(male) (1) – (2): 0 – 5 kz 2) Controls frame angle
sensor signal voltage A-4
as input voltage.
WA800L-3 20-905
(1)
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND
TROUBLESHOOTING CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Disconnection, short circuit 1) Defective steering main pressure control EPC solenoid system
with chassis ground, or 2) Disconnection, defective contact, short circuit with chassis ground,
short circuit with power short circuit, or short circuit with power source in wiring harness
source in steering main between T/M and J/S controller C2 (female) (7) – L26 (female) (2)
pressure control EPC sole- 3) Short circuit with chassis ground in wiring harness between T/M and
63
noid system J/S controller C2 (female) (17) – L26 (female) (1)
4) Defective T/M and J/S controller
20-906 WA800L-3
(1)
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND
TROUBLESHOOTING CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Voltage between T/M and J/S controller L39 Turns on caution buzzer. (In case of disconnection)
(female) (1) – chassis ground: 1) Transmission is kept in
• When steering lock lever is in LOCK: 20 – 30 V N.
• When steering lock lever is in FREE: Max. 1 V 2) Steering system is
operable normally.
Voltage between T/M and J/S controller C2 (8) – Does not operate at all. 1) Engine can be started
chassis ground: while machine is
• When steering lock lever is in NEUTRAL: Max. 1 V steered.
2) Machine is steered
suddenly after engine A-6
is started
3) Engine cannot be
started.
Current flowing between T/M and J/S controller C2 Turns off steering main 1) Response of steer-
(7) – (17): 600 ± 80 mA pressure control EPC ing system is low-
solenoid output. ered.
2) Steering speed is
lowered.
A-7
3) Response of steer-
ing system is height-
ened
4) Steering speed is
heightened
WA800L-3 20-907
(1)
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM FOR AJSS CONTROL
20-908 WA800L-3
(1)
TROUBLESHOOTING ELECTRIC CIRCUIT DIAGRAM FOR AJSS CONTROL
a This circuit diagram is made by extracting the part of the transmission & joystick steering controller from the
general circuit diagram.
WA800L-3 20-909
(1)
TROUBLESHOOTING A-1
A-1 Failure code [56] (Disconnection or short circuit with chassis ground in caution
buzzer relay system) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
20-910 WA800L-3
(1)
TROUBLESHOOTING A-2
A-2 Failure code [57] (Disconnection or short circuit with chassis ground in steering
lever angle sensor system) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA800L-3 20-911
(1)
TROUBLESHOOTING A-3
A-3 Failure code [58] (Deviation of steering lever angle sensor and frame angle sensor
signals) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at
the neutral position. Cause Remedy
a Always connect any disconnected connectors before going
on to the next step.
Improper installation of
Replace or
YES steering lever angle
adjust neutral
sensor (Deviation of
position
neutral position)
2
Improper installation of
4 YES frame angle sensor Replace or
YES Does voltage adjust neutral
between C3A (3) (Deviation of neutral
and (16) change? Does voltage position
YES position)
between C3A (13)
3 and (16) change?
• Lean steering
1 Does resistance
lever to right or Go to A.
between JS2 • Change frame NO
Is voltage left
• 0.5 – 4.5 V NO (male) (1) and (3) angle
between C3A (7) change?
• Starting switch • 0.5 – 4.5 V
and (16) normal?
ON. • Lean steering • Start engine. Defective steerintg lever
Replace
• 4.9 – 5.1 V lever to right or NO angle sensor
• Starting switch left
ON. • 0.2 – 5 kz
• Starting switch OFF. Defective T/M and J/S Replace
NO • Disconnect JS2. controller
Disconnection, defective
contact, short circuit with
chassis ground, or short circuit Repair or
6 YES replace
with power source in wiring
Is harness between C3A
harness between C3A (female)
(female) (3) and JS2
YES (female) (1) normal (no (13) – L27 (female) (1)
5 disconnection and short
circuit with chassis
Disconnection, defective
Does resistance ground or power source)? contact, short circuit with
chassis ground, or short circuit Repair or
between L27 • Disconnect C3A, NO with power source in wiring replace
From A
(male) (1) and (3) JS2. harness between C3A (female)
change? (3) – JS2 (female) (1)
20-912 WA800L-3
(1)
TROUBLESHOOTING A-4
A-4 Failure code [59] (Disconnection or short circuit with chassis ground in frame
angle sensor system) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position.
a Always connect any disconnected connectors before going on to the next step.
Remedy
WA800L-3 20-913
(1)
TROUBLESHOOTING A-5
A-5 Failure code [60] (Disconnection or short circuit with chassis ground in steering
lever lock pressure switch system) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the steering lock lever is in the LOCK position, the steering lock pressure switch is opened (since the
oil pressure is not heightened).
Cause Remedy
20-914 WA800L-3
(1)
TROUBLESHOOTING A-6
A-6 Failure code [62] (Disconnection or short circuit with chassis ground in steering
neutral interlock relay system) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA800L-3 20-915
(1)
TROUBLESHOOTING A-7
A-7 Failure code [63] (Disconnection, short circuit with chassis ground, or short
circuit with power source in steering main pressure control EPC solenoid system)
is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the joystick steering lever is not being used, leave it at the neutral position.
Cause Remedy
4 YES
Go to A.
Is resistance
YES between C2 Short circuit of wiring
3 (female) (7) and harness between C2
Is resistance (17) normal? (female) (7) – L26 (female) Repair or
(2) with wiring harness replace
YES between C2
(female) (17) and • Min. 1 Mz NO between C2 (female) (17)
chassis ground • Turn starting and L26 (female) (1)
2
normal? switch OFF.
Is resistance Short circuit with chassis
YES between C2 • Min. 1 M z • Disconnect C2 andL26.
ground in wiring harness Repair or
(female) (7) and • Turn starting NO between C2 (female) (17) – replace
chassis ground switch OFF. L26 (female) (1)
1 normal? • Disconnect C2
• Min. 1 M z
If L26 is replaced Short circuit with chassis
with other same and L26. ground in wiring harness Repair or
EPC solenoid, • Turn starting between C2 (female) (7) – replace
does failure code switch OFF. NO
L26 (female) (2)
appear? • Disconnect C2
• Turn starting and L26. Defective steering main
switch OFF. pressure control EPC Replace
• Replace with NO solenoid
other same EPC
solenoid.
• Turn starting 5 YES Defective T/M and J/S
switch ON. Is resistance controller Replace
between C2
From A (female) (7) and
chassis ground Short circuit with power
normal? source in wiring harness Repair or
• Max. 1 V NO between C2 (female) (7) – replace
• Disconnect C2 L26 (female) (2)
and L26.
• Turn starting
switch ON.
20-916 WA800L-3
(1)
TROUBLESHOOTING A-8
Cause Remedy
Deviation of steering
lever angle sensor or Repair or
frame angle sensor replace
potentiometer
WA800L-3 20-917
(1)
TROUBLESHOOTING A-9
A-9 Abnormality in console switch (adjustment of steering lever angle sensor and
frame angle sensor is impossible)
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
YES between C3A • Max. 1 z • Turn starting switch ON contact in wiring harness Repair or
(female) (19) and • Turn starting NO between C3A (female) (6) – replace
JS4 (male) (1) switch OFF. JS3 (female) (1)
1
normal? • Disconnect C3A
• Max. 1 z
Is resistance Disconnection or defective
between console and JS3. contact in wiring harness
switch JS3 (male) • Turn starting Replace
between C3A (female) (19)
(1) and JS4 (female) switch OFF. NO
– JS4 (male) (1)
(1) normal? • Disconnect C3A
• When left armrest is and JS4.
at rearmost position Defective console switch Replace
(switch is ON): NO
Max. 1 z
• When left armrest is not at rearmost
position (switch is OFF): Min. 1 M½
• Turn starting switch OFF.
• Disconnect JS3 and JS4.
20-918 WA800L-3
(1)
TROUBLESHOOTING A-10
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Check that fuse II (6) is normal.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA800L-3 20-919
(1)
40 MAINTENANCE STANDARD
ENGINE MOUNT ..........................................................................................................................................40- 2
TRANSMISSION MOUNT ............................................................................................................................40- 3
DAMPER.......................................................................................................................................................40- 4
TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP ................................................................40- 6
TORQUE CONVERTER ...............................................................................................................................40- 8
TORQUE CONVERTER REGULATOR VALVE ............................................................................................40- 9
TRANSMISSION (1/2) ..................................................................................................................................40- 10
TRANSMISSION (2/2) ..................................................................................................................................40- 12
TRANSFER...................................................................................................................................................40- 13
TRANSMISSION CONTROL VALVE ............................................................................................................40- 14
DRIVE SHAFT ..............................................................................................................................................40- 19
CENTER SUPPORT .....................................................................................................................................40- 20
DIFFERENTIAL (1/2) ....................................................................................................................................40- 21
DIFFERENTIAL (2/2) ....................................................................................................................................40- 22
FINAL DRIVE ................................................................................................................................................40- 24
AXLE MOUNT...............................................................................................................................................40- 26
CENTER HINGE PIN....................................................................................................................................40- 28
STEERING DEMAND VALVE .......................................................................................................................40- 30
DIVERTER VALVE ........................................................................................................................................40- 32
STEERING CYLINDER MOUNT ..................................................................................................................40- 33
EMERGENCY STEERING PUMP ................................................................................................................40- 34
BRAKE VALVE..............................................................................................................................................40- 36
SLACK ADJUSTER ......................................................................................................................................40- 39
BRAKE ..........................................................................................................................................................40- 40
PARKING BRAKE .........................................................................................................................................40- 42
PPC VALVE...................................................................................................................................................40- 44
PPC RELIEF VALVE .....................................................................................................................................40- 46
CONTROL PUMP .........................................................................................................................................40- 47
STEERING PUMP ........................................................................................................................................40- 48
SWITCH PUMP ............................................................................................................................................40- 49
MAIN PISTON PUMP ...................................................................................................................................40- 50
MAIN CONTROL VALVE ..............................................................................................................................40- 52
HYDRAULIC CYLINDER ..............................................................................................................................40- 54
WORK EQUIPMENT LINKAGE ....................................................................................................................40- 56
BUCKET POSITIONER AND BOOM KICK-OUT..........................................................................................40- 58
ROPS CANOPY............................................................................................................................................40- 59
WA800L-3 40-1
(1)
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
40-2 WA800L-3
MAINTENANCE STANDARD TRANSMISSION MOUNT
TRANSMISSION MOUNT
Unit: mm
WA800L-3 40-3
MAINTENANCE STANDARD DAMPER
DAMPER
40-4 WA800L-3
MAINTENANCE STANDARD DAMPER
Unit: mm
WA800L-3 40-5
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP
40-6 WA800L-3
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP
Unit: mm
SAR4 – 112 0
21 –0.5
SAR3 – 100 0
14 –0.5
3 Insertion depth of pin
SAR1 – 32 0
10 –0.5
SAR1 – 14 0
10 –0.5
WA800L-3 40-7
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
Unit: mm
40-8 WA800L-3
MAINTENANCE STANDARD TORQUE CONVERTER REGULATOR VALVE
Unit: mm
WA800L-3 40-9
MAINTENANCE STANDARD TRANSMISSION (1/2)
TRANSMISSION (1/2)
5 16 6 15 17 7 8 9 13
12 1 2 10 11 14 3 4
kgm 66.7±6.9Nm kgm 6.7±6.9Nm kgm 66.7±6.9Nm kgm 66.7±6.9Nm
{6.8±0.7kgm} {6.8±0.7kgm} {6.8±0.7kgm} {6.8±0.7kgm}
kgm 110.3±12.3Nm SEW01600
{11.25±1.25kgm}
40-10 WA800L-3
MAINTENANCE STANDARD TRANSMISSION (1/2)
Unit: mm
WA800L-3 40-11
MAINTENANCE STANDARD TRANSMISSION (2/2)
TRANSMISSION (2/2)
1 2 3 4 5 6 7 8 9 10
SEW01601
Unit: mm
40-12 WA800L-3
MAINTENANCE STANDARD TRANSFER
TRANSFER
Unit: mm
WA800L-3 40-13
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
40-14 WA800L-3
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit: mm
116.7 N 110.8 N
13 Lubrication valve spring 74.5 48.0 72.3
{11.9 kg} {11.3 kg}
Thickness of shim Large 1 (One shim will charge the pressure by 37.3 kPa {0.38 kg/cm2}
15 for modulating
valve Small 1 (One shim will charge the pressure by 41.2 kPa {0.42 kg/cm2}
WA800L-3 40-15
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
LOWER VALVE
40-16 WA800L-3
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit: mm
WA800L-3 40-17
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
SOLENOID VALVE
40-18 WA800L-3
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
WA800L-3 40-19
MAINTENANCE STANDARD CENTER SUPPORT
CENTER SUPPORT
Unit: mm
40-20 WA800L-3
MAINTENANCE STANDARD DIFFERENTIAL (1/2)
DIFFERENTIAL (1/2)
Unit: mm
WA800L-3 40-21
MAINTENANCE STANDARD DIFFERENTIAL (2/2)
DIFFERENTIAL (2/2)
40-22 WA800L-3
MAINTENANCE STANDARD DIFFERENTIAL (2/2)
Unit: mm
WA800L-3 40-23
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
40-24 WA800L-3
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
WA800L-3 40-25
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
40-26 WA800L-3
MAINTENANCE STANDARD AXLE MOUNT
Unit: mm
WA800L-3 40-27
MAINTENANCE STANDARD CENTER HINGE PIN
40-28 WA800L-3
MAINTENANCE STANDARD CENTER HINGE PIN
Unit: mm
WA800L-3 40-29
MAINTENANCE STANDARD STEERING DEMAND VALVE
40-30 WA800L-3
(1)
MAINTENANCE STANDARD STEERING DEMAND VALVE
Unit: mm
WA800L-3 40-31
MAINTENANCE STANDARD DIVERTER VALVE
DIVERTER VALVE
Unit: mm
40-32 WA800L-3
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
Unit: mm
WA800L-3 40-33
MAINTENANCE STANDARD EMERGENCY STEERING PUMP
Unit: mm
Clearance between gear case Pump model Standard clearance Clearance limit
1
and side plate gear SAM(3)100 0.10 – 0.15 0.19
Clarance between inside
2 diameter of plain bearing and SAM(3)100 0.020 – 0.043 0.075
Replace
outside diameter of gear shaft
Standard clearance Tolerance
3 Insertion depth of pin 0
14
–0.5
4 Rotating torque of spline shaft 13.7 – 23.5 Nm {1.4 – 2.4 kgm}
Standard Repair limit
Revolution
Discharge Pump model Pressure discharge discharge
(rpm) —
— Oil: EO10-CD (l/min) (l/min)
Temperature: 45 to 55°C SAM(3)100 20.6 MPa
2,000 352 312
+ 100 {210 kg/cm2}
40-34 WA800L-3
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
RIGHT
40-36 WA800L-3
MAINTENANCE STANDARD BRAKE VALVE
Unit: mm
WA800L-3 40-37
MAINTENANCE STANDARD BRAKE VALVE
LEFT
Unit: mm
40-38 WA800L-3
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
Unit: mm
WA800L-3 40-39
MAINTENANCE STANDARD BRAKE
BRAKE
40-40 WA800L-3
MAINTENANCE STANDARD BRAKE
Unit: mm
WA800L-3 40-41
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
40-42 WA800L-3
MAINTENANCE STANDARD PARKING BRAKE
Unit: mm
WA800L-3 40-43
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
40-44 WA800L-3
MAINTENANCE STANDARD PPC VALVE
Unit: mm
WA800L-3 40-45
MAINTENANCE STANDARD PPC RELIEF VALVE
Unit: mm
40-46 WA800L-3
MAINTENANCE STANDARD CONTROL PUMP
CONTROL PUMP
MODEL: BAR025
Unit: mm
WA800L-3 40-47
MAINTENANCE STANDARD STEERING PUMP
STEERING PUMP
MODEL: HPF76+71
40-48 WA800L-3
MAINTENANCE STANDARD SWITCH PUMP
SWITCH PUMP
MODEL: HPF95+95
WA800L-3 40-49
MAINTENANCE STANDARD MAIN PISTON PUMP
40-50 WA800L-3
MAINTENANCE STANDARD MAIN CONTROL VALVE
40-52 WA800L-3
MAINTENANCE STANDARD MAIN CONTROL VALVE
Unit: mm
WA800L-3 40-53
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
Unit: mm
40-54 WA800L-3
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
40-56 WA800L-3
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
Unit: mm
WA800L-3 40-57
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-OUT
Unit: mm
40-58 WA800L-3
MAINTENANCE STANDARD ROPS CANOPY
ROPS CANOPY
WA800L-3 40-59
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................90- 3
ELECTRICAL CIRCUIT DIAGRAM (1/5) ......................................................................................................90- 5
ELECTRICAL CIRCUIT DIAGRAM (2/5) ......................................................................................................90- 7
ELECTRICAL CIRCUIT DIAGRAM (3/5) ......................................................................................................90- 9
ELECTRICAL CIRCUIT DIAGRAM (4/5) ......................................................................................................90- 11
ELECTRICAL CIRCUIT DIAGRAM (5/5) ......................................................................................................90- 13
ELECTRICAL CIRCUIT DIAGRAM (ENGINE SHUT-DOWN) ......................................................................90- 15
ELECTRICAL CIRCUIT DIAGRAM (AUTO-GREASING) .............................................................................90- 17
WA800L-3 90-1
(1)
HYDRAULIC CIRCUIT DIAGRAM
WA800L-3 90-3
ELECTRICAL CIRCUIT DIAGRAM (1/5)
WA800L-3 90-5
ELECTRICAL CIRCUIT DIAGRAM (2/5)
WA800L-3 90-7
ELECTRICAL CIRCUIT DIAGRAM (3/5)
WA800L-3 90-9
ELECTRICAL CIRCUIT DIAGRAM (4/5)
WA800L-3 90-11
ELECTRICAL CIRCUIT DIAGRAM (5/5)
WA800L-3 90-13
ELECTRICAL CIRCUIT DIAGRAM (ENGINE SHUT-DOWN)
WA800L-3 90-15
(1)
ELECTRICAL CIRCUIT DIAGRAM (AUTO-GREASING)
WA800L-3 90-17
(1)