WA800L 3 - Sn52001and Up

SEBM035601
MACHINE MODEL SERIAL NUMBER

WA800L-3 52001 and up
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice.
• WA800L-3 mount the SAA12V140ZE-2 engine.

For details of the engine, see the Engine Shop Manual.
© 2004
All Rights Reserved
Printed in Japan 05-04 (01)
00-1
(1)
GENERAL
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
10 STRUCTURE AND FUNCTION ................................................................ 10-1
20 TESTING AND ADJUSTING ......................................................................... 20-1
30 DISASSEMBLY AND ASSEMBLY ........................... To be issued next time
40 MAINTENANCE STANDARD ..................................................................... 40-1
90 OTHERS ................................................................................................................................ 90-1
00-2 WA800L-3
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LIST OF REVISED PAGES
The affected pages are indicated by the use of the

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

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

Mark Page Mark Page Mark Page Mark Page Mark Page
revision revision revision revision revision
q 00-1 (1) 01-1 10-13 10-41 10-70

q 00-2 (1) 01-2 10-14 10-42 10-71
Q 00-2-1 (1) 01-3 10-15 10-43 10-72
Q 00-2-2 (1) 01-4 10-16 10-44 10-73
Q 00-2-3 (1) 01-5 10-17 10-45 10-74
Q 00-2-4 (1) 01-6 10-18 10-46 10-75
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00-6 01-10 10-22 10-50 10-79
00-7 01-11 10-23 10-51 10-80
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10-12 10-40 10-69 10-97
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10-98 10-138 10-179 Q 20-104 (1) Q 20-202 (1)

10-99 10-139 10-180 Q 20-105 (1) Q 20-203 (1)
10-100 10-140 10-181 Q 20-106 (1) Q 20-204 (1)
10-101 10-141 10-182 Q 20-107 (1) Q 20-205 (1)
10-102 10-142 10-183 Q 20-108 (1) Q 20-206 (1)
10-103 10-143 10-184 Q 20-109 (1) Q 20-207 (1)
10-104 10-144 10-185 Q 20-110 (1) Q 20-208 (1)
10-105 10-145 10-186 Q 20-111 (1) Q 20-209 (1)
10-106 10-146 10-187 Q 20-112 (1) Q 20-210 (1)
10-107 10-147 10-188 Q 20-113 (1) Q 20-211 (1)
10-108 10-148 10-189 Q 20-114 (1) Q 20-212 (1)
10-109 10-149 q 10-190 (1) Q 20-115 (1) Q 20-213 (1)
10-110 10-150 10-191 Q 20-116 (1) Q 20-214 (1)
10-111 10-151 10-192 Q 20-117 (1) Q 20-215 (1)
10-112 10-152 10-193 Q 20-118 (1) Q 20-216 (1)
10-113 10-154 10-194 Q 20-119 (1) Q 20-217 (1)
10-114 10-155 10-195 Q 20-120 (1) Q 20-218 (1)
10-115 10-156 10-196 Q 20-121 (1) Q 20-220 (1)
10-116 10-157 Q 20-122 (1) Q 20-221 (1)
10-117 10-158 Q 20-123 (1) Q 20-222 (1)
10-118 10-159 Q 20-1 (1) Q 20-124 (1) Q 20-223 (1)
10-119 q 10-160 (1) Q 20-2 (1) Q 20-125 (1) Q 20-224 (1)
10-120 10-161 Q 20-3 (1) Q 20-126 (1) Q 20-225 (1)
10-121 10-162 Q 20-4 (1) Q 20-127 (1) Q 20-226 (1)
10-122 10-163 Q 20-5 (1) Q 20-128 (1) Q 20-227 (1)
10-123 10-164 Q 20-6 (1) Q 20-129 (1) Q 20-228 (1)
10-124 10-165 Q 20-7 (1) Q 20-130 (1) Q 20-229 (1)
10-125 q 10-166 (1) Q 20-8 (1) Q 20-131 (1) Q 20-230 (1)
10-126 10-167 Q 20-9 (1) Q 20-132 (1) Q 20-231 (1)
10-127 10-168 Q 20-10 (1) Q 20-133 (1) Q 20-232 (1)
10-128 q 10-169 (1) Q 20-11 (1) Q 20-134 (1) Q 20-233 (1)
10-129 10-170 Q 20-12 (1) Q 20-135 (1) Q 20-234 (1)
10-130 10-171 Q 20-13 (1) Q 20-136 (1) Q 20-235 (1)
10-131 10-172 Q 20-14 (1) Q 20-137 (1) Q 20-236 (1)
10-132 10-173 Q 20-15 (1) Q 20-138 (1) Q 20-237 (1)
10-133 10-174 Q 20-16 (1) Q 20-139 (1) Q 20-238 (1)
10-134 10-175 Q 20-140 (1) Q 20-239 (1)
10-135 10-176 Q 20-101 (1) Q 20-141 (1) Q 20-240 (1)
10-136 10-177 Q 20-102 (1) Q 20-241 (1)
10-137 10-178 Q 20-103 (1) Q 20-201 (1) Q 20-242 (1)
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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)
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Q 20-908 (1) 40-28

Q 20-909 (1) 40-29
Q 20-910 (1) q 40-30 (1)
Q 20-911 (1) 40-31
Q 20-912 (1) 40-32
Q 20-913 (1) 40-33
Q 20-914 (1) 40-34
Q 20-915 (1) 40-36
Q 20-916 (1) 40-37
Q 20-917 (1) 40-38
Q 20-918 (1) 40-39
Q 20-919 (1) 40-40
40-41
q 40-1 (1) 40-42
40-2 40-43
40-3 40-44
40-4 40-45
40-5 40-46
40-6 40-47
40-7 40-48
40-8 40-49
40-9 40-50
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40-11 40-53
40-12 40-54
40-13 40-56
40-14 40-57
40-15 40-58
40-16 40-59
40-17
40-18
40-19 q 90-1 (1)
40-20 90-3
40-21 90-5
40-22 90-7
40-23 90-9
40-24 90-11
40-25 90-13
40-26 Q 90-15 (1)
40-27 Q 90-17 (1)
00-2-4 WA800L-3
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
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.
STRUCTURE AND FUNCTION

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

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

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume:
}
Attachments volume: · volume to cover all
models
PAGES next to the CONTENTS page.
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.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
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
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

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

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

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

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

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

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding 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
• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
1 kg
(Set of adhesive
LT-3 Hardening Can
and hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g container
Holtz • Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
• Quick hardening type adhesive
Three bond Polyethylene • Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
• Quick cure type (max. strength after
Aron-alpha Polyethylene
790-129-9130 2g 30 minutes)
201 container • Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite Polyethylene
79A-129-9110 50 cc • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
pipe joints, flanges.
LG-5 790-129-9080 1 kg Can • Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil an, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
790-129-9090 100 g Tube pairing engine.
1211
• Features: Silicone type, heat resist-
ant, vibration resistant, and impact
Three bond 419-15-18131 100 g Tube resistant sealing material
1207B • Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used as lubricant for sliding portion

LM-G 09940-00051 60 g Can (to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light

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

SYG2-400M 400 g × 10 Bellows type
disulphide
Grease SYG2-400M-A 400 g × 20 Bellows type
grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
• Seizure resistance and heat resist-
Hyper White
Grease G2-T SYG2-400T-A ance higher than molybdenum di-
SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district
body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type less effects on microorganisms,
*: For high SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
• "S" is used for high-tempera-

SUNSTAR ture season (April - October)
PENGUINE Polyethylene and "W" for low-temperature
SEAL 580 320 ml container season (November - April) as
SUPER "S" or
Adhesive adhesive for glass.
"W" (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml (Using limit: 6 months)
Sikaflex 256HV container
SUNSTAR • Used to seal joints of glass

Polyethylene parts.
PENGUINE 417-926-3920 320 ml container (Using limit: 4 months)
SEAL No. 2505
Caulking
material • Used to seal front window.
SEKISUI Polyethylene (Using limit: 6 months)
SILICONE 20Y-54-55130 333 ml container
SEALANT
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

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

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

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

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
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.
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
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
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
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from 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
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
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
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a 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
–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

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

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

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

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

SPECIFICATIONS ........................................................................................................................................01- 3
WEIGHT TABLE............................................................................................................................................01- 6
LIST OF LUBRICANT AND WATER.............................................................................................................01- 8
WA800L-3 01-1
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING
01-2 WA800L-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model WA800L-3
Serial No. 52001 and up
Operating weight kg 101,130

Weight
Distribution (front) kg 55,290

Distribution (rear) kg 45,840
Bucket capacity (piled) m 3
11.0
Rated load kg 19,800
FORWARD 1st km/h 7.0
FORWARD 2nd km/h 12.3
FORWARD 3rd km/h 28.0
Performance
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
Min. turning Center of outside wheel mm 9,200

radius Outside portion of chassis mm 10,930
Overall length mm 14,325 (with tooth)
Overall width (chassis) mm 4,585
4,815 (Cutting edge)
Bucket width mm
5,045 (Tire guard)
Overall height (top of ROPS cab) mm 5,275
Overall height (Bucket raised) mm 9,300
Wheelbase mm 5,450
Dimensions
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
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
Maximum torque Nm/rpm {kgm/rpm} 3,800/1,400 {388/1,400}

Performance Fuel consumption ratio g/kWh {g/HPh} 208.6 {155.6}
High idling speed rpm 2,250
Low idling speed rpm 650/900
Starting motor 24 V 11 kW
Alternator 24 V 100 A
Battery 12 V 200 Ah x 4
3-element, 1-stage, single-phase
Torque converter
(TCA51-1A)
Power train
Planetary gear, multiple-disc,

Transmission
hydraulically actuated, modulation type
Reduction gear Spiral bevel gear
Differential Straight bevel gear
Final drive Planetary gear, single reduction, oil bath
Drive type Front/rear-wheel drive
Front axle Fixed-frame, full-floating
Axle, wheel
Rear axle Center pin support type, full-floating

Tire 45/65-45-46PR(L-5)
Wheel rim 36.00 x 45WTB
Inflation pressure kPa {kg/cm2} 515 {5.25}
Front/rear wheel braking,
Main brake separate front/rear wheel, wet disc,
Brakes
hydraulically actuated
Mounted on front axle input shaft, dry disc,
Parking brake
hydraulically release spring apply
01-4 WA800L-3
Type Articulated type

Steering
system
Structure Fully hydraulically power steering
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
(Fixed capacity piston pump: HPF95+95)

68
PPC pump l/min
(Gear type: SAR(1)032)
29
Brake pump l/min
(Gear type: SAR(1)014)
405
l/min
Hydraulic system
Work equipment pump

(Variable capacity piston pump: HPV95+95)
2.5 {25}
Transmission valve MPa {kg/cm2}
(Spool type, electric control)
Control valve
Set pressure
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
Boom cylinder No. - bore x stroke mm
2 – 260 x 1,368
Bucket cylinder No. - bore x stroke mm
1 – 300 x 906
equipment
Link type Single Z bar link

Work
Bucket edge type Spade nose bucket with teet
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
Rear frame 8,924

Bucket link (including bushing) 593
Bellcrank (including bushing) 1,850
Boom (including bushing) 8,495
Bucket (with teeth) 11,430
Counterweight 2,900
Additional counterweight 1,600
Fuel tank 780
Battery (each) 59
Cab 430
Air conditioner unit 55
Operator’s seat 50
Floor plate 348
ROPS support assembly 1,420
WA800L-3 01-7
GENERAL LIST OF LUBRICANT AND WATER
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
ENGINE OIL SPECIFICATIONS
NORMAL OPERATION
Oil performance recommendations are as follows:
The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals are 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.
Oil viscosity recommendations are as follows:
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
TRANSMISSION, TORQUE CONVERTER, TRANSFER CASE AND OIL COOLER, SERVICE

BRAKES AND HYDRAULIC SYSTEM OIL SPECIFICATIONS
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.
FINAL DRIVE OIL SPECIFICATIONS

Komatsu Gear Lubricant or an equivalent multi-purpose gear lubricant meeting API GL-5 or MIL-L-2105C is rec-
ommended.
DRIVE AXLE OIL SPECIFICATIONS

For drive axle oil, use only the recommended oil as follows:
SHELL: DONAX TD
MOBIL: MOBIL FLUID 424
ESSO: TORQUE FLUID 56
Engine oil: SAE 30 API classification CD (May increase brake noise, but will not affect durability.)
DIESEL FUEL SPECIFICATIONS
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
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
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
SUPPLEMENTAL COOLANT ADDITIVES

1. All supplemental cooling system additives, including those in antifreeze solutions, become depleted through
normal operation. If the coolant additives in antifreeze are allowed to become depleted, the antifreeze
becomes corrosive and attacks and coats the metallic surfaces of the cooling system which reduces heat
transfer. Cooling system conditioners which contain these additives must be added to maintain corrosion
protection.
2. SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer 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
Maintenance of Supplemental Coolant Additives

Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and
corrosion.
New machines are delivered with antifreeze protection. Service at 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.
Coolant Testing for Conditioner Concentration

When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory.
The SCA concentration must not fall below 1.0 unit per 3.8 liters (1 gal) or exceed 2 units per 3.8 liters (1 gal) of
coolant. The only accurate method for testing chemical concentrations in coolant with mixed chemical com-
pounds is a laboratory analysis. For this reason, the coolant inhibitor should be maintained as shown in the
Oparation and Maintenance Manual.
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.
Replenishing Coolant Conditioner

Install a "precharge" coolant filter when the coolant is changed or a significant (more than 50%) coolant loss
occurs. When antifreeze is added, add coolant conditioner equal to 1.0 unit per 3.8 liters (1 US gal) of anti-
freeze.
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
Supplemental Coolant Additive Maintenance Guide

Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion.
Antifreeze alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental
corrosion protection must be supplied through periodic additions of supplemental coolant additives to the cool-
ant.
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].
DCA4 UNIT GUIDE

Fleetguard Part No. DCA4 Units
DCA4 Coolant Filter
WF-2070 2
WF-2071 4
WF-2072 6
WF-2073 8
WF-2074 12
WF-2075 15
WF-2076 23
WF-2077 0
DCA4 Liquid
DCA60L 4 (1 pt)
DCA80L 1760 (55 gal)
DCA4 Powder
DCA95 20
DCA4 Precharge and Service Filters

System Capacity
Precharge Filter (See NOTE 1) Service Filter (See NOTE 3)
Liters Gallons
19-26 5-7 WF-2072 WF-2070
30-38 8-10 WF-2073 WF-2071
42-57 11-15 WF-2074 WF-2071
61-76 16-20 WF-2075 WF-2071
80-114 21-30 WF-2076 WF-2072
118-190 31-50 (See NOTE 2) WF-2073
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
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.
SCA Unit Concentration Guide

Number of Solution A Drops
Coolant Condition Action Required
to Cause Color Change
Extremely under-concentrated - less than Initially charge the system to a minimum
0 – 10 Drops
0.4 SCA units per 3.8 liters (1 US gal) of 1.0 SCA unit per 3.8 liters (1 US gal)
Add SCA liquid units to maintain 1.0 SCA
Marginally under-concentrated - 0.45 to
11 – 16 Drops unit per 3.8 liters (1 US gal) minimum or
0.8 SCA units per 3.8 liters (1 US gal)
change the DCA 4 coolant filter.
Acceptable - 0.85 to 1.3 SCA units per 3.8
17 – 25 Drops None.
liters (1 US gal)
Highly acceptable - 1.35 to 2.0 SCA units
26 – 35 Drops None.
per 3.8 liters (1 US gal)
Marginally over-concentrated - 2.1 to 3.3
36 – 55 Drops Review maintenance practice.
SCA units per 3.8 liters (1 US gal)
Drain 50% of the coolant and replace with
Over 55 Drops Extremely over-concentrated water antifreeze mixture. Retest the sys-
tem for correct SCA unit concentration.
COOLING SYSTEM TEST KIT

The following cooling system test kit may be pur-
chased from your Komatsu distributor.
This Fleetguard® coolant test kit, part number CC-

2626 is used to check the concentration of coolant
additives in the cooling system.
1. Test strip bottles

2. Solution #1 bottle
3. Small plastic container
4. Large plastic cup
5. Syringe
WA800L-3 01-15
10 STRUCTURE AND FUNCTION
POWER TRAIN ....................................... 10- 2 BRAKE .....................................................10- 97

POWER TRAIN SYSTEM ....................... 10- 3 PARKING BRAKE ....................................10- 98
ENGINE CONTROL ................................ 10- 4 SPRING CYLINDER ................................10-100
RADIATOR AND COOLER...................... 10- 6 PARKING BRAKE SOLENOID VALVE.....10-101
DAMPER ................................................. 10- 8 HYDRAULIC PIPING ...............................10-102
TORQUE CONVERTER AND WORK EQUIPMENT LEVER LINKAGE ..10-105
TRNSMISSION PIPING ..................... 10- 9 HYDRAULIC TANK ..................................10-106
TRANSMISSION HYDRAULIC MAIN PISTON PUMP...............................10-109
SYSTEM DIAGRAM........................... 10- 10 ES VALVE (Engine sensing valve) ...........10- 117
TRANSMISSION HYDRAULIC SERVO VALVE.........................................10- 119
CIRCUIT DIAGRAM........................... 10- 11 PPC VALVE
TORQUE CONVERTER .......................... 10- 12 (Proportional pressure valve)..............10-122
TRANSMISSION ..................................... 10- 17 PPC RELIEF VALVE ................................10-126
TRANSFER ............................................. 10- 25 ACCUMULATOR (For PPC valve) ...........10-127
TRANSMISSION CONTROL VALVE....... 10- 26 MAIN CONTROL VALVE..........................10-128
TORQUE CONVERTER OIL COOLER... 10- 42 LUBRICATION OF WORK
DRIVE SHAFT ......................................... 10- 43 EQUIPMENT.......................................10-141
CENTER SUPPORT................................ 10- 44 WORK EQUIPMENT LINKAGE ...............10-144
AXLE ....................................................... 10- 45 BUCKET POSITIONER AND
DIFFERENTIAL ....................................... 10- 47 BOOM KICK-OUT...............................10-146
FINAL DRIVE .......................................... 10- 50 OPERATION OF PROXIMITY SWITCH ..10-148
CENTER HINGE PIN .............................. 10- 51 CAB AND ROPS CANOPY ......................10-152
AXLE MOUNT ......................................... 10- 52 AIR CONDITIONER .................................10-154
TIRE AND WHEEL .................................. 10- 54 MACHINE MONITOR SYSTEM ...............10-158
STEERING PIPING ................................. 10- 55 MAIN MONITOR ......................................10-159
JOYSTICK STEERING LINKAGE ........... 10- 56 MAINTENANCE MONITOR .....................10-163
STEERING PUMP ................................... 10- 58 ENGINE STARTING CIRCUIT .................10-166
SWITCH PUMP ....................................... 10- 60 ENGINE STOP CIRCUIT .........................10-169
STEERING DEMAND VALVE.................. 10- 62 PREHEATING CIRCUIT...........................10-170
EPC VALVE ............................................. 10- 73 ELECTRICAL TRANSMISSION
ROTARY VALVE ...................................... 10- 74 CONTROL ..........................................10-171
TWO-WAY RESTRICTOR VALVE ........... 10- 76 KICK-DOWN, HOLD SWITCH .................10-172
DIVERTER VALVE .................................. 10- 77 AUTOMATIC TRANSMISSION (ATM)
BRAKE PIPING ....................................... 10- 81 SYSTEM .............................................10-173
BRAKE CIRCUIT DIAGRAM ................... 10- 82 AJSS (Advanced joystick
BRAKE VALVE ........................................ 10- 84 steering system)..................................10-183
CHARGE VALVE ..................................... 10- 89 ELECTRIC PARKING BRAKE
ACCUMULATOR (For brake) .................. 10- 93 CONTROL ..........................................10-188
SLACK ADJUSTER ................................. 10- 94
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
POWER TRAIN SYSTEM
1. Front differential 11. Torque converter 19. Rear final drive

2. Front brake 12. Steering pump 20. Rear wheel
3. Front final drive 13. Main pump 21. Rear axle
4. Front wheel 14. Upper drive shaft 22. Rear differential
5. Front axle 15. Damper 23. Rear brake
6. Front drive shaft 16. Engine 24. Rear drive shaft
7. Center drive shaft 17. Switch pump 25. Center support
8. Emergency steering pump 18. Torque converter charging pump (x 2) 26. Parking brake
9. Transfer + PPC pump + brake pump
10. Transmission
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
RADIATOR AND COOLER
10-6 WA800L-3
STRUCTURE AND FUNCTION RADIATOR AND COOLER
1. Torque converter oil cooler SPECIFICATIONS

2. Coolant level sensor Radiator
3. Radiator Core model: PF2-7
4. Hydraulic oil cooler Allheat resistance area:213.66 m2
5. Sub tank
6. After cooler Hydraulic oil cooler
Core model: PF4-6
A. Radiator coolant inlet port Allheat resistance area:156.3 m2
B. Radiator coolant outlet port
C. After cooler inlet port
D. After cooler outlet port
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
TORQUE CONVERTER AND TRNSMISSION PIPING
1. Transmission control valve

2. Torque converter
3. Torque converter oil cooler
4. Torque converter charging pump (x 2)
5. Torque converter oil filter
6. Transmission oil level gauge
7. Transfer
WA800L-3 10-9
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM

(Engine running, F.R. lever in NEUTRAL, speed lever in 1st)
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
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
1. Transfer case 18. Modulating valve

2. Strainer 19. Quick return valve
3. Torque converter charging pump (SAR4-112) 20. Reducing valve
4. Torque converter charging pump (SAR3-100) 21. Solenoid valve
5. PPC pump (SAR1-032) 22. Emergency manual spool
6. Brake pump (SAR1-014) 23. Reverse spool
7. Torque converter oil filter 24. Forward spool
8. Torque converter oil filter 25. 2nd spool
9. Transmission lubrication 26. 1st spool
10. Main relief valve 27. 3rd spool
11. Torque converter relief valve 28. Reverse clutch
12. Torque converter regulator valve 29. Forward clutch
13. Oil cooler 30. 2nd clutch
14. Lubrication relief valve 31. 1st clutch
15. Pilot oil filter 32. 3rd clutch
16. Pilot reducing valve 33. Torque converter
17. Priority valve
WA800L-3 10-11
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
1. Torque converter regulator valve

2. Torque converter outlet oil pressure pick-up
(PT1/8)
3. Torque converter inlet oil pressure pick-up
(PT1/8)
4. Switch pump mounting
5. Main pump mounting
6. Coupling
7. Steering pump mounting
8. Torque converter charging pump + PPC pump + brake pump mounting
A. Torque converter outlet port

B. Torque converter oil temperature
sensor mounting port
C. Torque converter inlet port
D. Drain port (to transmission)
10-12 WA800L-3
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
Flow of motive force

• The torque converter is installed between the
damper and transmission. The motive force
from the damper passes through the drive shaft
and enters coupling (6).
Coupling (6), pump (14) and PTO gear (drive)
(11) are fixed with bolts. They are rotated
directly by the rotation of the engine. The motive
force of pump (14) uses oil to rotate turbine (9).
This transmits motive force to transmission input
shaft (15).
• The motive force of coupling (6) passes through
PTO gear (drive) (11) and is also used as the
motive force to drive the pump.
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
TORQUE CONVERTER RELIEF VALVE
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.
• If the oil at port A exceeds the specified pres-

sure, the oil from orifice a of torque converter re-
lief valve (2) enters port B and moves torque
converter relief valve (2) to the left in the direc-
tion of the arrow.
As a result, the oil from port A flows from port C,
lubricates the transmission, and is drained.
WA800L-3 10-15
TORQUE CONVERTER REGULATOR VALVE
1. Valve body
2. Spring
3. Spool
A. Oil inlet port

(From torque converter)
B. Oil outlet port
(to oil cooler)
• The torque converter regulator valve is installed

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

higher than the tension of spring (2), it pushes
spool (3) in the direction of the arrow, and the oil
at port A flows to port C.
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
A. To torque converter charging pump
WA800L-3 10-17
10-18 WA800L-3
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
11. Forward ring gear (Teeth 90)
12. Sun gear (Teeth 38)
16. 2nd clutch
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)
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
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
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
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
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
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
1. Transmission output shaft OUTLINE

2. Transfer input gear (Teeth 32) • The transfer is installed at the power output end
3. Transfer idler gear (Teeth 33) of the transmission and is secured to the trans-
4. Idler gear (Teeth 34) mission case by bolts.
5. Output shaft
6. Front coupling TRANSMISSION PATH
7. Strainer • Output shaft (1) of the transmission is coupled to
8. Rear coupling transfer input gear (2) by a spline. The motive
9. Output gear (Teeth 44) force is transmitted to output shaft (5) through
idler gears (3), (4) and output gear (9).
Part of the power transmitted to the output shaft
is transmitted to the front axle through the center
drive shaft and front drive shaft. The rest of the
power is transmitted to the rear axle through the
rear drive shaft.
WA800L-3 10-25
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
1. Pilot oil filter A. Pilot reducing pressure pick-up

2. Main relief valve B. Modulating valve piston load pressure pick-up
3. Torque converter relief valve C. Torque converter relief pressure pick-up
4. Transmission solenoid valve D. Transmission lubricating pressure pick-up
5. Emergency manual spool E. Modulating pressure pick-up
6. Connector F. Modulating pressure pick-up
7. Lower valve (After quick return valve)
8. Upper valve
9. Breather
10-26 WA800L-3
TRANSMISSION SOLENOID VALVE
10. REVERSE solenoid valve

11. FORWARD solenoid valve
12. 2nd solenoid valve
13. 1st solenoid valve
14. 3rd solenoid 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
LOWER VALVE
1. Transmission solenoid valve 10. Emergency manual spool

2. FORWARD spool 11. Priority valve
3. REVERSE spool 12. Pilot valve
4. Pilot oil filter 13. Load piston
5. Torque converter relief valve 14. Quick return valve
6. Main relief valve 15. Lubrication valve
7. 2nd spool 16. Pilot reducing valve
8. 1st spool 17. Modulating valve
9. 3rd spool
10-28 WA800L-3
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
PILOT OIL FILTER
1. Oil filter head SPECIFICATION

2. Element Filtration area: 370 cm2
3. Case Mesh: 105 m
10-30 WA800L-3
MAIN RELIEF 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.
• When the pressure goes above the specified

level, oil passes through the orifice in relief valve
(1), pushes poppet (2), and moves relief valve
(1) to the left. The oil is relieved to the torque
converter, so the specified pressure is main-
tained.
a Specified pressure: 2.75 MPa {28 kg/cm2}
WA800L-3 10-31
PILOT REDUCING 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.
• When the pressure inside port C rises, pressu-

rized oil flows from orifice a of pilot reducing
valve (1) and goes to port D.
As a result, pilot reducing valve (1) moves to the
left, and port A and B are shut off, so the pres-
surized oil at port C is maintained at the same
pressure.
10-32 WA800L-3
TRANSMISSION SOLENOID 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
PRIORITY VALVE
FUNCTION
• Priority valve (1) controls the minimum pressure
of pilot reducing valve (2). In addition, priority
valve (1) gives the oil flow to pilot reducing valve
(2) priority over the other circuit.
OPERATION
• The oil from the pump flows to port A of priority
valve (1) and port B of pilot reducing valve (2).
• The oil entering port A flows from orifice a of pri-

ority valve (1) to port D. The hydraulic pressure
and force of poppet spring (3) push back spring
(4) and move priority valve (1) to the left. When
this happens, port A and port C are connected,
and the oil flows from port C to the modulating
valve (5).
10-34 WA800L-3
MODULATING VALVE AND QUICK RETURN 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.
2. Hydraulic pressure starts to rise

When the oil sent under pressure from pump fills
the circuit from port A to the clutch cylinder, the
hydraulic pressure starts to rise.
The oil passing through orifice a of quick return
valve (2) moves quick return valve (2) to the left
in the direction of the arrow. As a result, the pas-
sage between port E and port G is closed.
WA800L-3 10-35
In addition, the oil passes through orifice b of

modulating valve (1) and flows to port C to push
piston (6). In reaction to this, modulating valve
(1) compresses springs (4) and (5), and moves
to the left in the direction of the arrow. As a
result, modulating valve (1) restricts the passage
to port B.
The oil passing through orifice a of quick return
valve (2) passes through the center passage
and then flows from orifice c to port E, and to
back pressure port F of piston (3). For this rea-
son, piston (3) moves to the right in the the
direction of the arrow and compresses springs
(4) and (5).
As the hydraulic pressure in the circuit rises, the

back pressure of piston (3) rises and piston (3)
moves to the right in the direction of the arrow.
The tension of springs (4) and (5) opens the
passage between port A and port B of modulat-
ing valve (1).
In addition, as the hydraulic pressure pushing
piston (6) rises, the reaction moves modulating
valve (1) to the left in the direction of the arrow
and compresses springs (4) and (5) to close port
A and port B.
3. Rise in hydraulic pressure completed

The operation described above is repeated con-
tinuously to increase the load on springs (4) and
(5). The hydraulic pressure rises gradually and
finally piston (3) comes into contact with the
valve stopper and does not move any further.
When this happens, modulating valve (1) stops
in a position where the passage to port B is kept
closed, and this completes the rise in hydraulic
pressure.
10-36 WA800L-3
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.
OPERATION (3rd speed spool actuated)

• The oil from quick return valve (1) enters port A,
flows from port B to the 3rd speed spool, and
the 3rd clutch is engaged.
• When oil fills the 3rd clutch, and the hydraulic

pressure rises, the oil passes from port B
through orifice a and enters port C.
The pressure of the oil pushes poppet (3), and
the reaction compresses spring (4) and moves
reducing spool (2) to the right in the direction of
the arrow.
• As a result, port A and port B are closed, and
the oil stops flowing.
The hydraulic pressure at this point is 1.96 MPa
{20 kg/cm2}.
WA800L-3 10-37
EMERGENCY MANUAL SPOOL
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).
2. When solenoid valve is abnormal:

a. Clutch in disengaged position
(Emergency manual spool is pushed to
the right)
Emergency manual spool (3) is pushed to
the right, and the oil at port A is shut off
regardless of the action of solenoid valve
(2). The oil cannot flow to port B, so the
clutch is not actuated.
b. Clutch in engaged position (Emergency

manual spool is pulled to the left)
When emergency manual spool (3) is pulled
to the left, the oil at port A is drained to port
B regardless of the operation of solenoid
valve (2). As a result, the clutch is actuated.
10-38 WA800L-3
TRANSMISSION LUBRICATION 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.
In this condition, if abnormally high pressure is

generated by the restriction in the lubricating cir-
cuit, the oil entering port B compresses spring
(2) and moves spool (1) to the left in the direc-
tion of the arrow. This opens port A and port C,
as the oil in the lubricating circuit is relieved to
port C. The hydraulic pressure at this point is 0.3
MPa {3 kg/cm2}
WA800L-3 10-39
HYDRAULIC CIRCUIT SCHEMATICS
FORWARD 1ST
A. To PPC valve
B. To brake line
C. From hydraulic tank
D. From brake oil tank
10-40 WA800L-3
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
TORQUE CONVERTER OIL COOLER
1. Torque converter oil cooler OUTLINE

The oil which comes from the torque converter outlet
A. Coolant outlet port (to engine port) port is at a high temperature because of the energy
B. Coolant inlet port (from water pump) used in transmitting the motive force. This torque
C. Oil outlet port (to transmission) converter oil passes through the oil cooler port and
D. Oil inlet port (from torque converter enters the oil cooler. Here it is cooled by the engine
regulator valve) cooling water. The oil then flows out from the oil out-
let port, lubricates the transmission and returns to
the transfer case.
10-42 WA800L-3
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
1. Front drive shaft 4. Rear drive shaft

2. Center support 5. Upper drive shaft
3. Center 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
1. Front coupling FUNCTION

2. Case • The center support is installed to the front frame
3. Grease nipple between the center drive shaft and the front
4. Rear coupling drive shaft.
• With the articulating frame, this part is constantly
twisting from side to side, so there is liable to be
large stress on the drive shaft. Therefore, the
center support is used to transmit the power
smoothly, to reduce the stress on the drive
shafts, and in this way improve the durability of
the drive shafts.
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
1. Bevel gear (Teeth 39)

2. Differential case
3. Differential side gear (Teeth 28)
4. Differential pinion gear (Teeth 22)
5. Shaft
6. Bevel pinion (Teeth 10)
WA800L-3 10-47
REAR DIFFERENTIAL
1. Bevel pinion (Teeth 10)

2. Bevel gear (Teeth 39)
3. Shaft
4. Differential pinion gear (Teeth 22)
5. Differential side gear (Teeth 28)
6. Differential case
7. Coupling
10-48 WA800L-3
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
When driving straight forward

• When the machine is driven straight forward, the
rotating speed of the left and right wheels is the 6
same, so pinion gear (4) inside carrier (6) is sent
through pinion gear (4) and side gear (3) and is
transmitted equally to the left and right axle
shafts (2).
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
1. Axle shaft OUTLINE

2. Brake • To gain a large drive force, the final drive uses a
3. Planetary gear (Teeth 39) planetary gear system to reduce the speed and
4. Ring gear (Teeth 99) send drive force to the tires.
5. Drain plug
6. Housing OPERATION
7. Sun gear (Teeth 18) • The motive force transmitted from the differen-
8. Wheel tial through axle shaft (1) to sun gear (7) is
transmitted to planetary gear (3). The planetary
gear rotates around the inside of fixed ring gear
(4) and in this way transmits rotation at a re-
duced speed to planetary carrier. This motive
force is then sent to wheels (8) which are in-
stalled to planetary carriers.
10-50 WA800L-3
STRUCTURE AND FUNCTION CENTER HINGE PIN
CENTER HINGE PIN
1. Front frame OUTLINE

2. Rear frame • The front frame and rear frame are joined by the
3. Rear axle center hinge pin through a bearing.
4. Front axle The steering cylinders adjust the angle of curva-
5. Upper hinge pin ture to the left and right of the front and rear
6. Lower hinge pin frame (in other words, they adjust the turning
radius).
WA800L-3 10-51
STRUCTURE AND FUNCTION AXLE MOUNT
AXLE MOUNT
10-52 WA800L-3
STRUCTURE AND FUNCTION AXLE MOUNT
1. Front frame Front axle

2. Rear frame • Front axle (4) receives the force directly during
3. Rear axle operations, so it is fixed directly to front frame
4. Front axle (1) by axle mounting bolts.
5. ROPS support
Rear axle
• Rear axle (3) has a structure which allows the
center of the rear axle to float, so that all tires
can be in contact with the ground when traveling
over soft ground.
WA800L-3 10-53
STRUCTURE AND FUNCTION TIRE AND WHEEL
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
1. Steering demand valve a Since the steering hydraulic circuit is shown

2. Hydraulic tank together with the work equipment circuit dia-
3. EPC valve gram, see “WORK EQUIPMENT HYDRAULIC
4. Steering pump CIRCUIT DIAGRAM”.
5. Rotary valve
6. Steering cylinder
WA800L-3 10-55
STRUCTURE AND FUNCTION JOYSTICK steering LINKAGE
JOYSTICK STEERING LINKAGE
1. Joystick (Steering lever) 7. Rotary valve

2. Potentiometer (Lever operating angle) 8. Potentiometer (Steering angle)
3. Upper joint 9. Rod
4. Universal joint 10. Bracket
5. Lower joint 11. Front frame
6. Universal joint
10-56 WA800L-3
STRUCTURE AND FUNCTION STEERING PUMP
STEERING PUMP
1. Shaft (front) 10. Cradle (rear) OUTLINE

2. Cradle (front) 11. Shaft (rear) • This pump consists of 2 fixed-displacement
3. Case (front) 12. Case (rear) swash plate-type piston pumps and 1 impeller
4. Swash plate 13. End cap (rear) pump between them.
5. Shoe 14. End cap (front) • The front pump and rear pump are originally of
6. Piston 15. Servo piston the variable displacement type, but their dis-
7. Cylinder block 16. Collar placement is fixed since inserted collars (16)
8. Valve plate 17. Collar and (17) disable servo piston (15) and fix swash
9. Impeller plate (4).
• For explanation of the operation, see the section
of the work equipment pump. The work equip-
SPECIFICATION ment pump is of the variable displacement type,
Model: HPF 76 + 71 however, since its swash plate (4) can move.
Rated delivery pressure: 31.4 MPa {320 kg/cm2}
Rated rpm: 2,120 rpm
Theoretical delivery (front):76.2 cc/rev
Theoretical delivery (rear): 71.5 cc/rev
Max. delivery: 161.6 + 151.6 l/min
10-58 WA800L-3
STRUCTURE AND FUNCTION STEERING PUMP
WA800L-3 10-59
STRUCTURE AND FUNCTION SWITCH PUMP
SWITCH PUMP
1. Shaft (front) 9. Impeller OUTLINE

2. Cradle (front) 10. Cradle (rear) • This pump consists of 2 fixed-displacement
3. Case (front) 11. Shaft (rear) swash plate-type piston pumps and 1 impeller
4. Swash plate 12. Case (rear) pump between them.
5. Shoe 13. End cap (rear) • The front pump and rear pump are originally of
6. Piston 14. End cap (front) the variable displacement type, but their dis-
7. Cylinder block 15. Servo piston placement is fixed since inserted collar (16) dis-
8. Valve plate 16. Collar able servo piston (15) and fix swash plate (4).
• For explanation of the operation, see the section
of the work equipment pump. The work equip-
SPECIFICATION ment pump is of the variable displacement type,
Model: HPF 95 + 95 however, since its swash plate can move.
Rated delivery pressure: 31.4 MPa {320 kg/cm2}
Rated rpm: 2,120 rpm
Theoretical delivery (front):97.4 cc/rev
Theoretical delivery (rear): 97.4 cc/rev
Max. delivery: 206.5 + 206.5 l/min
10-60 WA800L-3
STRUCTURE AND FUNCTION SWITCH PUMP
WA800L-3 10-61
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
STEERING DEMAND VALVE
1. Overload relief valve

2. Surge cut relief valve
3. Steering spool
4. Demand spool
5. Main relief valve
A. To steering cylinder
B. To steering cylinder
P1. From steering pump
P2. From switch pump
PB. To main control valve
T. To hydraulic tank
(through hydraulic oil cooler)
10-62 WA800L-3
OVERLOAD RELIEF VALVE
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
FUNCTION
• The overload relief valve is installed in the 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.
• When the pressure at port A reaches the set

pressure of the relief valve, pilot poppet (4)
opens and the oil goes around pilot poppet (4)
and flows to port B.
WA800L-3 10-63
• When pilot poppet (4) opens, the pressure at the

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

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

• Negative pressure is generated at port A, the
difference in the area of diameters d3 and d4
opens check valve poppet (3), and the oil flows
from port B to port A to prevent a vacuum from
forming in the circuit.
10-64 WA800L-3
MAIN RELIEF VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
FUNCTION
• The main relief valve of the steering demand
valve is inside the valve and sets the maximum
pressure in the steering circuit when it is 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
OPERATION OF STEERING RELIEF 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
OPERATION OF DEMAND VALVE
WHEN STEERING SPOOL IS AT NEUTRAL
• 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
WHEN STEERING SPOOL IS OPERATED
• Engine running at low speed
• When the steering is operated, oil flows from the • The merged oil passes through notches c and d,
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
• Engine running at high speed
• There is no need for supply of extra oil from the • The oil from the steering pump passes through
switch pump, so the steering pump pressure 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
OPERATION OF STEERING 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
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
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
1. Min. pressure assurance pressure reducing valve OUTLINE

2. Electromagnetic proportional valve • The EPC valve controls the oil flow to the rotary
valve with the electromagnetic proportional
P1. From PPC pump valve controlled with the command current from
P2. From diverter valve the work equipment and joystick controller.
C. To rotary valve • Even if the electromagnetic proportional valve
D. To hydraulic tank does not work because of a controller trouble,
the minimum pressure assurance pressure re-
ducing valve supplies the minimum oil pressure
to the rotary valve.
WA800L-3 10-73
STRUCTURE AND FUNCTION ROTARY VALVE
ROTARY VALVE
1. Neutral position spring

2. Valve body
3. Check valve
4. Spool
5. Sleeve
6. Feedback spool
7. Feedback sleeve
8. Loose spring
9. Drive shaft
10. Center pin
11. Body
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
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.
• When the oil is flowing to arrow i, the oil flows

only from orifice a inside poppet (1), so the flow
is controlled.
10-76 WA800L-3
STRUCTURE AND FUNCTION DIVERTER VALVE
DIVERTER VALVE
1. Check valve A. To emergency pump FUNCTION

2. Check valve B. Sensor mounting port • The diverter valve is a selector valve which
3. Check valve C. To hydraulic oil tank senses the pilot pressure from the steering
4. Check valve D. To steering valve pump and if there is no abnormality in the steer-
5. Spool E. From hydraulic tank ing circuit, it drains the oil from the emergency
6. Valve body F. From steering circuit pump to the tank. If no pilot pressure from the
steering pump reaches the diverter valve, the oil
from the emergency pump is switched to the
steering circuit and flows to enable the machine
to be steered.
WA800L-3 10-77
EMERGENCY STEERING RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
FUNCTION
Compared to the steering valve relief pressure of
31.4 MPa {320 kg/cm 2}, the rated pressure of the
emergency steering pump and diverter valve are
both 20.6 MPa {210 kg/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).
• When the pressure inside port A and B reaches

the pressure set by the poppet spring (set pres-
sure), pilot poppet (3) opens and the hydraulic
pressure at port B escapes from port D to port
C. This lowers the pressure at port B.
• When the pressure at port B drops, the orifice of
main valve (1) generates a difference in pres-
sure between port A and port B. Main valve (1)
is opened by the pressure at port A and the oil
at port A is relieved.
10-78 WA800L-3
HYDRAULIC CIRCUIT SCHEMATICS FOR EMERGENCY STEERING
Pump, engine working normally
(a) Sensor (f) Hydraulic tank (P1.)Emergency steering pump

(b) Relief valve (g) Oil cooler (P2.)Main pump
(c) From steering cylinder (h) Oil filter (P3.)Steering pump
(d) To steering cylinder (j) From rotary valve (P4.)Switch pump
(e) To main control valve
When the steering pump and engine are working

normally, the main pump, steering pump, and switch
pump are rotated by the engine. Therefore, oil is
sent to the steering valve, and the machine can be
steered. In addition, the emergency steering pump is
rotated by the transmission, so oil from port A of the
diverter valve pushes open check valve (2) and
enters port B. Pressure oil from the steering pump is
flowing to port D, so it pushes spool (3) in the direc-
tion of the arrow. As a result, the oil from port B
flows to port C and is drained to the hydraulic tank.
WA800L-3 10-79
Failure in pump or engine when machine is traveling
(a) Sensor (f) Hydraulic tank (P1.)Emergency steering pump

(b) Relief valve (g) Oil cooler (P2.)Main pump
(c) From steering cylinder (h) Oil filter (P3.)Steering pump
(d) To steering cylinder (j) From rotary valve (P4.)Switch pump
(e) To main control valve
If there is a failure in the pump or engine when the

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

that it can rotate both directions.
10-80 WA800L-3
STRUCTURE AND FUNCTION BRAKE PIPING
BRAKE PIPING
1. Front brake (right) 9. Charge valve

2. Brake valve (right) 10. Brake oil tank
3. Parking brake switch 11. Accumulators
4. Rear brake (right) 12. Brake valve (left)
5. Strainer 13. Front brake (left)
6. Slack adjuster (rear) 14. Parking brake spring cylinders
7. Torque converter charging (x 2), PPC, brake pump 15. Slack adjuster (front)
8. Rear brake (left) 16. Parking brake solenoid valve
WA800L-3 10-81
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
BRAKE CIRCUIT DIAGRAM
10-82 WA800L-3
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
1. Torque converter charging (x 2), PPC, brake pump

1A. Torque converter charging pump
1B. Torque converter charging pump
1C. PPC pump
1D. Brake pump
2. Strainer
3. Charge valve
3A. Safety relief valve
3B. Relief valve
3C. Filter
4. Check valve
5. Low pressure switch
6. Rear brake accumulator
7. Front brake accumulator
8. Emergency brake switch
9. Brake valve (left)
10. Transmission cut-off switch
11. Brake valve (right)
12. Stop lamp switch
13. Rear slack adjuster
14. Front slack adjuster
15. Parking brake solenoid valve
16. Parking brake switch
17. Parking brake spring cylinder
18. Parking brake pilot lamp switch
19. Brake oil tank
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
BRAKE VALVE (LEFT)
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
OPERATION
Brake applied (right brake valve)

Upper 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,
drain port a is closed, and the oil from the pump
and accumulator flows from port A to port C and
actuates the front brake cylinders.
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.
Brake applied (left brake pedal)

• When pedal (7) is depressed, spool (10) is
pushed up by rod (8) and spring (9), and drain
port c is closed. The oil from the pump and the
accumulator flows from port E to port F.
• Port F of the left brake valve and port PP of the
right brake valve are connected by a hose, so
the oil flowing to port F flows to pilot port PP of
the right brake valve.
• The oil entering pilot port PP enters port G from
orifice d, and pushes pilot piston (11). The
spring pushes spool (3) down, so the operation
is the same as when the right brake valve is de-
pressed.
10-86 WA800L-3
Applying brake when upper valve fails

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

(right brake valve)
• Even if there is leakage of oil in the lower piping,
the upper portion is actuated normally.
When actuation is balanced

Upper portion
• When oil fills the front brake cylinder and the
pressure between port A and port C becomes
high, the oil entering port H from orifice e of
spool (3) pushes against spring (4). It pushes up
spool (3) and shuts off the circuit between port A
and port C. When this happens, drain port a
stays closed, so the oil entering the brake cylin-
der is held and the brake remains applied.
Lower portion
• When spool (3) in the upper portion moves up
and the circuit between port A and port C is shut
off, oil also fills the 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
Brake released (right brake valve)

Upper portion
• When pedal (1) is released and the operating
force is removed from the top of the spool, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (3)
up. Drain port a is opened and the oil from the
brake cylinder flows to the hydraulic tank return
circuit to release the front brake.
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
A: To brake oil tank FUNCTION

ACC: Plug • The charge valve is actuated to maintain the oil
PP: To brake valve pressure from the pump at the specified pres-
P: From pump sure and to store it in the accumulator.
T: Drain • When the oil pressure reaches the specified
pressure, the oil from the pump is connected to
the drain circuit to reduce the load on the pump.
WA800L-3 10-89
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
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.
2. When oil is supplied to accumulator

1) Cut-in condition
• When the pressure at port B is lower than the
set pressure of the relief valve (R1), piston
(8) is pushed back down by spring (5). Valve
seat (7) and poppet (6) are brought into tight
contact, and port C and port T are shut off.
(15) is also shut off from port T, so the pres-
sure rises, and the pressure at port P also
rises in the same way.
• When the pressure at port P goes above the
pressure at port B (accumulator pressure),
the supply of oil to the accumulator starts im-
mediately. In this case, it is decided by the
size (area) of orifice (17) and the pressure
difference (equivalent to the load on spring
(14)) generated on both sides of the orifice.
A fixed amount is supplied regardless of the
engine speed, and the remaining oil flows to
port A.
WA800L-3 10-91
2) When cut-out pressure is reached

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

• If the pressure at port P (pump pressure)
goes above the set pressure of the relief
valve (R3), the oil from the pump pushes
spring (3). Ball (11) is pushed up and the oil
flows to the brake oil tank circuit, so this sets
the maximum pressure in the brake circuit
and protects the circuit.
10-92 WA800L-3
STRUCTURE AND FUNCTION ACCUMULATOR (For brake)
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}
A. Inlet port (from brake valve) FUNCTION

B. Outlet port (to brake) • The slack adjuster is installed in the brake oil
line from the brake valve to the brake piston. It
acts to keep the clearance between the brake
piston and discs constant even when the brake
discs are worn. In this way it acts to keep a con-
stant time lag when the brake is operated.
10-94 WA800L-3
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
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.
2. Brake pedal released

When the brake is released, pressure is applied to the back of the brake piston because of the hydraulic
pressure of the brake. Piston (4) is moved back stroke S and the disc clearance returns to normal.
10-96 WA800L-3
STRUCTURE AND FUNCTION BRAKE
BRAKE
1. Guide pin FUNCTION

2. Return spring • The brakes are wet-type multiple disc brakes,
3. Brake piston and are fitted to all four wheels.
4. Plate
5. Disc OPERATION
6. Floating seal • When the brake pedal is depressed, moves
brake piston (3) to the right, and presses disc (5)
and plate (4) together to hold them in position.
Disc (5) is rotating together with the wheel, so
when it is held in position, the rotation stops, the
brake is actuated, and the machine is stopped.
When the brake pedal is released, the pressure
at the rear face of piston (3) is released, and the
piston is moved to the left by the force of return
spring (2) to release the brake.
WA800L-3 10-97
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
1. Spring cylinder OUTLINE

2. Caliper • The parking brake is a disc type and is installed
3. Disc on the front axle.
4. Caliper • The force of the spring inside spring cylinders
5. Spring cylinder (1) and (5) is used to apply the brake mechani-
6. Differential case cally; it is released by oil pressure.
7. Spring • The parking brake caliper is fixed to the front dif-
ferential case.
The disc is installed to the differential yoke and
rotates together with the coupling.
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
1. Outer spring OUTLINE

2. Inner spring • The oil pressure from the parking brake solenoid
3. Piston valve pushes the spring and releases the park-
4. Cylinder ing brake.
5. Boot When the engine is stopped, the parking brake
6. Rod is applied by springs (1) and (2), so the machine
is prevented from moving.
10-100 WA800L-3
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
1. Solenoid valve assembly FUNCTION

2. Block • When the parking brake switch is turned ON/
OFF, the solenoid valve is energized or deener-
B. Outlet port gized, so the brake oil pressure is taken to the
B1. Port for parking brake pilot lamp switch brake spring cylinder or removed from the brake
P. Inlet port cylinder to set the parking brake at the PARKED
T. Drain port position or TRAVEL position.
• Parking brake solenoid valve
Energized: TRAVEL
Deenergized: PARKED
WA800L-3 10-101
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
10-102 WA800L-3
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
• The work equipment system consists of the hy-

draulic circuit and steering circuit. The hydraulic
circuit controls the operation of the bucket and
attachment.
• The oil from hydraulic tank is sent from main
pump (4), and switch pump (7) through the
steering valve to two main control valves (10). If
the bucket and boom spools of the main control
valve are both in neutral, the oil passes through
the drain circuit of the main control valve, is fil-
tered by the filter inside the hydraulic tank, and
returns to the tank.
• The bucket or boom spool in PPC valve is acti-
vated by operating the work equipment control
lever, causing each spool in the work equipment
valve to be hydraulically activated. Thereby, the
oil is allowed to flow from the work equipment
valve to boom cylinder (9) or bucket cylinder (1),
thus operating the boom or the bucket.
• The maximum pressure of the hydraulic circuit is
regulated by the relief valve inside the main con-
trol valve. There are two safety valves (with suc-
tion valve) and an unloader valve in the bucket
cylinder circuit to protect the circuit.
• Even when engine is at rest, the boom can be
lowered to the ground because accumulator (3)
is provided in the circuit.
• Hydraulic tank is a pressurized, sealed type and
has a breather with a relief valve. This acts to
pressurize the tank and at the same time pre-
vents negative pressure. This protects the pump
from cavitation.
• In the hydraulic tank there is pressurizing valve
installed to pressurize the hydraulic tank with air
pressure. It is used to carry out air bleeding of
the pump when changing the oil inside the tank
or when assembling after removing the piping of
the piston pump and pump.
10-104 WA800L-3
STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
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
1. Filter bypass valve OUTLINE

2. Hydraulic filter • The oil from the hydraulic tank is sent from the
3. Strainer pump through the control valve to the cylinders.
4. Drain valve In the return circuit, the oil from various parts
5. Strainer merges. A part of oil is cooled in the oil cooler,
6. Breather passes through hydraulic filter (2) and returns to
7. Oil filler the tank.
• Hydraulic filter (2) filters all the oil in the circuit. If
A. Oil cooler return port hydraulic filter (2) becomes clogged, bypass
B. Main return port valve (1) acts to allow the oil to return directly to
C. Gear pump suction the tank. This prevents damage to filter (2). By-
D. Main piston pump suction port pass valve (1) is also actuated when negative
E. Emergency pump suction pressure is generated in the circuit.
F. Emergency pump return port
10-106 WA800L-3
OPERATION OF OIL FILTER BYPASS VALVE
When the filter is clogged.

Bypass valve (1) opens and the oil returns directly to
the tank without passing through the filter.
Bypass valve set pressure: 125 kPa {1.27 kg/cm2}
When negative pressure is formed in the return

circuit.
Valve (2) moves up and acts a check valve.
Check valve set pressure: 25.5 kPa {0.26 kg/cm2}
WA800L-3 10-107
BREATHER
1. Body
2. Filter element
3. Poppet
SEW00141
4. Sleeve
FUNCTION
Preventing negative pressure inside the tank

The tank is pressurized, sealed type, so negative
pressure is formed inside the hydraulic tank when
the oil level drops during operations.
When this happens, the difference in pressure
between the tank and the outside atmospheric pres-
sure opens poppet (3), and air from the outside is let
into the tank to prevent negative pressure.
Preventing rise in pressure inside the tank

When the hydraulic cylinder are being used, the oil
level in the hydraulic circuit changes and the tem-
perature rises. If the hydraulic pressure rises above
the set pressure, sleeve (4) is actuated to release
the hydraulic pressure inside the tank.
10-108 WA800L-3
STRUCTURE AND FUNCTION MAIN PISTON PUMP
MAIN PISTON PUMP

MODEL: HPV95 + 95
1. ES valve (Engine sensing) OUTLINE

2. Front servo valve • These pump assemblies consist of two variable
3. Rear servo valve displacement swash-plate type pumps, two ser-
4. Front main pump vo valve units, and impeller pump (built in be-
5. Rear main pump tween the front main pump and the rear main
6. Control pump (BAR025) pump), a control pump and a relief valve.
7. Relief valve
8. Pump sub-assembly
9. Front servo valve assembly
10. Rear servo valve assembly
11. Impeller pump
WA800L-3 10-109
PISTON PUMP
1. Shaft (front) SPECIFICATION

2. Cradle (front) Model: HPV 95 + 95
3. Case (front) Rated delivery pressure: 34.3 MPa {350 kg/cm2}
4. Swash plate Rated rpm: 2,100 rpm
5. Shoe Theoretical delivery: front 97.4 cc/rev
6. Piston rear 97.4 cc/rev
7. Cylinder block Max. delivery: 204.5 + 204.5 l/min
8. Valve plate
9. Impeller
10. Cradle (rear)
11. Shaft (rear)
12. Case (rear)
13. End cap (rear)
14. End cap (front)
15. Servo piston
10-110 WA800L-3
WA800L-3 10-111
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
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.)
1) Center line X of rocker cam (4) maintains swash

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

the axial direction of cylinder block (7) (swash
plate angle = 0), the difference between vol-
um es E’ and F’ inside cy l inder bl ock (7)
becomes 0, so the pump does not carry out any
suction or discharge of oil.
WA800L-3 10-113
2. Control of discharge amount

If swash plate angle becomes larger, the dif-
ference in volumes E and F becomes larger and
the discharge volume increases.
Swash plate angle is changed by servo piston
(15). Servo piston (15) moves in a reciprocal
movement ( ) in accordance with the com-
mand from the servo valve. This straight line
movement is transmitted through the rod of
rocker cam (4) to rocker cam (4), and rocker
cam (4), which is supported by the cylindrical
surface to cradle (10), slides in an oscillating
movement in direction ( ) along the cylindrical
surface.
10-114 WA800L-3
CONTROL PUMP (BAR025)
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
RELIEF VALVE
1. Adjustment screw
2. Lock nut
3. Pilot valve spring
4. Pilot valve
5. Main valve spring
6. Main valve
Set pressure: 2.9 MPa {30 kg/cm2}

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

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

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

differential pressure occurs between the cham-
bers A and B, moving valve (6) to the left. This
allows the oil in chamber A to flow into chamber
C.
10-116 WA800L-3
STRUCTURE AND FUNCTION ES VALVE (Engine sensing valve)
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.
OPERATION When the pilot pressure difference reaches

• Oil from the PPC pump passes through pres- point a
sure difference valve (1) and is sent to the PPC
valve. Pilot pressure from the inlet and outlet
ports (ports A and B) of the pressure differential
valve is supplied to the ES valve (2).
The difference in pilot pressure becomes larger
as the flow from the PPC pump increases (in
other words, as the engine speed increases).
When the pilot pressure difference reaches
point a (0.12 MPa {1.24 kg/cm 2}), the ES valve
starts to operate, and actuates the servo valve
and servo cylinder to change the swash plate
angle of the pump.
When the swash plate angle is changed, the pis-
ton stroke also changes to change the delivery
of the pump (delivery per rotation).
Until the difference in pilot pressure reaches
0.31 MPa {3.2 kg/cm2}, the pump delivery (deliv-
When the pilot pressure difference reaches
ery per rotation) increases in proportion with the
point b
increase in the difference in pilot pressure (in
other words, the increase in the engine speed).
When the difference in pressure reaches 0.31
MPa {3.2 kg/cm 2}, the pump delivery (delivery
per rotation) reaches the maximum.
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
OPERATION
1. Increasing of delivery amount (swash plate angle changes to the right)
• 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
2. Decreasing of delivery amount (swash plate angle changes to the left)
• 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)
PPC VALVE (Proportional pressure valve)
10-122 WA800L-3
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
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.
Valve (10) moves up and down until the force of

spring (9) is balanced with the pressure of port
P2.
The position of valve (10) and body (11) (when
fine control hole f is midway between drain
chamber D and pump pressure chamber PP)
does not change until the head of valve (10)
contacts the bottom of piston (4).
Therefore, spring (9) is compressed in propor-
tion to the travel of the control lever, so the pres-
sure at port P2 also rises in proportion to the
travel of the control lever. The spool of the con- (Fig. 2)
trol valve moves to a position where the pres-
sure of port PA1 (same as pressure at port P2)
and the force of the return spring of the control
valve are balanced.
10-124 WA800L-3
3. Control lever moved back from slightly oper-

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

(Fig. 4):
Plate (2) pushes piston (4) down, and piston (4)
forcibly pushes in valve (10).
Fine control hole f is shut off from drain chamber
D, and is connected to pump pressure chamber
PP.
Therefore, pressure oil from the charging pump
passes through fine control hole f, and flows
from port P2 to chamber PA1 to push the spool
of the control valve.
The oil returning from chamber A2 flows from
port PB1 through fine control hole f’ to drain
chamber D.
(Fig. 4)
WA800L-3 10-125
STRUCTURE AND FUNCTION PPC RELIEF VALVE
PPC RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
FUNCTION
• The PPC relief valve is between the PPC pump
and the PPC valve. When the PPC valve is not
being actuated, or when abnormal pressure is
generated, the oil sent from the pump is relieved
through this valve to protect the pump and 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).
• If the pressure at ports A and B reach the pres-

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

ence is generated between ports A and B due to
the orifice in main valve (1). Main valve (1) is
pushed open by the pressure at port A, and the
oil at port A is relieved.
10-126 WA800L-3
STRUCTURE AND FUNCTION ACCUMULATOR (For PPC valve)
ACCUMULATOR (For PPC valve)
1. Cap
2. Nut
3. Body
4. Bladder
5. Oil port
6. Nut
SPECIFICATIONS
Type of gas: Nitrogen gas
Gas amount: 3,000 cc
Max. actuation pressure: 2.9 MPa {30 kg/cm2}
Min. actuation pressure: 1.2 MPa {12 kg/cm2}
FUNCTION
• The accumulator is installed between the 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.
• When the PPC valve is operated, the pressure

in chamber B drops below 2.9 MPa {30 kg/cm2}
and the pressure of the nitrogen gas in chamber
A makes the bladder expand. The actuating
pressure is 1.2 to 2.9 MPa {12 to 30 kg/cm2}.
WA800L-3 10-127
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE
1. Main relief valve PA1: From PA1 of PPC valve

2. Bucket spool return spring PA2: From PB2 of PPC valve
3. Boom spool return spring PB1: From PB1 of PPC valve
4. Boom spool PB2: From PA2 of PPC valve
5. Bucket spool A1: To bucket cylinder bottom side
6. Body A2: To boom cylinder bottom side
7. Suction valve B1: To bucket cylinder rod side
8. Unloader valve B2: To boom cylinder rod side
9. Float selector valve P: Pump port
10. Safety valve (with suction) P1: From PA2 of PPC valve
P2: From PB2 of PPC valve
T: Drain port (to hydraulic tank)
10-128 WA800L-3
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
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.
• If the pump pressure is raised by spring (5) to

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

(2)]. its pressure lowers. As a result, the pres-
sure in chamber C is lower than that in port A,
thus main valve (1) moves to the right.
• Then, the oil flows from port A to port B and lim-
its the maximum pressure to protect the circuit.
10-130 WA800L-3
SAFETY VALVE (with suction 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

SEW00166
FUNCTION
• The safety valve (with suction valve) is in the
bucket cylinder circuit in the main valve. If shock
causes any abnormally high pressure in the 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
• If abnormally high oil pressure occurs in port A,

suction valve (1) is not actuated because of the A B 1 2 3 D
relationship d2 > d1.
However, because of the relationship d3 > d4 in
port A and C, the hydraulic pressure on main
valve (2) is equivalent to the area difference
between d3 and d4. If this pressure goes up to
the main valve spring force (set pressure), main
valve (2) is actuated, and the oil in port A flows
into port B.
SEW00168
WA800L-3 10-131
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
FLOAT SELECTOR VALVE AND UNLOADER 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
3. FLOAT position (pushed up)

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

When the machine is moving in reverse and the
boom comes down under its own weight, the
pressure at the cylinder bottom end is high, and
it is drained from port C.
The vacuum is formed at the cylinder rod end,
so oil flows in from port B.
10-134 WA800L-3
OPERATION OF HYDRAULIC CIRCUIT
BOOM AND BUCKET SPOOLS IN “HOLD”
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
BOOM SPOOL IN “RAISE”
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
BOOM SPOOL IN “LOWER”
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
BOOM SPOOL IN “FLOAT”
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
BUCKET SPOOL IN “DUMP”
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
BUCKET SPOOL IN “TILT BACK”
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
LUBRICATION OF WORK EQUIPMENT
1. Grease injector (Bucket hinge, R.H.)

2. Grease injector (Boom cylinder rod side, R.H.)
3. Grease injector (Boom cylinder rod side, L.H.)
4. Grease injector (Bucket hinge, L.H.)
5. Grease injector (Bucket link, front)
6. Grease injector (Bucket link, rear)
7. Grease injector (Bellcrank, center)
8. Grease injector (Bucket cylinder rod side)
WA800L-3 10-141
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
WA800L-3 10-143
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
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
BUCKET POSITIONER AND BOOM KICK-OUT
1. Proximity switch (dump)

2. Lever
3. Proximity switch (boom)
4. Plate
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
OPERATION OF PROXIMITY SWITCH

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

position, the boom spool is held at the RAISE
position by the cam follower and cam on the le-
ver, and the boom rises.
10-148 WA800L-3
• When the boom rises and reaches the set posi-

tion for the kick-out, in other words, the detector
(steel plate) is in position on the detection sur-
face of the proximity switch, an electric current is
sent to the solenoid by the action of the proximi-
ty switch and relay circuit. As a result, the sole-
noid is actuated, and the cam is pulled away
from the cam detent, so the boom spool is re-
turned to the HOLD position by the return
spring.
Action of proximity switch

When detector is in position at detection When detector is separated from detection
Position
surface of proximity switch surface of proximity switch
Proximity switch actuation
Lights up Goes out
display
Proximity switch load circuit
Current flows Current is shut off
(relay switch circuit)
Relay switch load circuit
Current flows Current is shut off
(solenoid circuit)
WA800L-3 10-149
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.
• When the bucket lever is moved to the TILT po-

sition, the bucket spool is held at the TILT posi-
tion by the cam follower and cam on the lever,
and the bucket tilts.
10-150 WA800L-3
• When the bucket tilts and reaches the set posi-

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

When sensor is in position at detection sur- When sensor is separated from detection
Position
face of proximity switch surface of proximity switch
Proximity switch actuation dis-
Lights up Goes out
play
Positioner relay Current flows Current is shut off
Solenoid (for bucket) Current is shut off Current flows
WA800L-3 10-151
STRUCTURE AND FUNCTION CAB AND ROPS CANOPY
CAB AND ROPS CANOPY
1. ROPS canopy
2. Cab
10-152 WA800L-3
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Duct A. Warm water outlet port

2. Air conditioner unit B. Warm water inlet port
3. Dry reservoir
4. Condenser
5. Condenser
6. Compressor
10-154 WA800L-3
WA800L-3 10-155
AIR CONDITIONER COMPRESSOR
1. Refrigerant outlet port SPECIFICATIONS

2. Refrigerant inlet port Type: Piston pump type
3. Charge port on suction side Refrigerant used: R134a
4. Clutch
5. Relief valve
10-156 WA800L-3
AIR CONDITIONER CONDENSER
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
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 machine.
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
1. Check lamp OUTLINE

2. Caution lamp • The main motor has display function for the
3. Caution items speedometer and other gauges and a switching
3A. Emergency steering actuated function to control the electric components and
4. Pilot items controllers.
4A. Turn signal (left) • There is one CPU (Central Processing Unit) in-
4B. Turn signal (right) stalled internally, and this processes the signals
4C. Shift indicator from the sensors and outputs the display.
4D. Speedometer • A liquid crystal display and LEDs are used for
4E. Shift hold the display. The switches are embossed sheet
4F. Parking brake switches.
4G. Emergency steering normal
4H. Monitor pilop lamp (preheating, afterheating)
4I. Failure action code
5. Switches
5A. Auto grease switch
5B. Engine low idling switch
5C. Working lamp (front) switch
5D. Working lamp (rear) switch
5E. Transmission cut-off switch
5F. Auto shift, manual selector switch
WA800L-3 10-159
MAIN MONITOR DISPLAY FUNCTION
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
Caution Parking brake actuated,

Display flashes and buzzer sounds
transmission not at neutral
Caution When there is abnormality Display flashes (buzzer may also sound)
display on maintenance (for details, see MAINTENANCE MONI-
monitor TOR DISPLAY FUNCTION)
Turn signal
When operated Display lights up
(left, right)
Display lights up Buzzer sounds when

Parking brake When operated parking brake is applied and shift lever is
not at N
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 hold When shift is held Display lights up
Speed Digital display (display switches between

Travel speed 0 – 99 km/h
meter tachometer and speedometer)
Shift
Shift indicator 1–3N Digital display
indicator
When controller detects

failure and action by opera-
Digital display Buzzer sounds (For details
Failure Failure action tor is needed, CALL is dis-
of the travel data display mode, see TROU-
action code code played, or CALL and E TT
BLE DATA DISPLAY MODE)
(action code) are dis-
played in turn
Shift
F, R, display F, R Digital display
indicator
10-160 WA800L-3
(1)
MAIN MONITOR SWITCH FUNCTION
Item Function Display Actuation
Lights up (goes out Auto-greasing control actuated (auto-

momentarily when matic greasing carried out at fixed inter-
switch is turned ON) val)
Forced greasing is carried out while
Auto-greasing switch is being pressed when display Flashes (slowly) Grease empty
is lighted up Abnormality in auto-greasing controller
Flashes (rapidly)
system
Goes out Auto-greasing controller not installed
Low idling speed set to approx. 900
Engine low idling speed is changed Lights up
Engine low rpm
between two stages each time switch
idling Low idling speed set to approx. 650
is pressed Goes out
rpm
Front working lamp lights up or goes Lights up Front working lamp lights up
Working lamp
out each time switch is pressed when
(front) Goes out Front working lamp goes out
side lamps are lighted up
Rear working lamp lights up or goes Lights up Rear working lamp lights up
Working lamp
out each time switch is pressed when
(rear) Goes out Rear working lamp goes out
side lamps are lighted up
Transmission cut-off function is actu- Lights up Cut-off function actuated
Transmission
ated or stopped each time switch is
cut-off Goes out Cut-off function stopped
pressed
Auto shift mode switches to manual Lights up Manual mode

Manual
mode when switch is pressed Goes out Auto shift mode
WA800L-3 10-161
TROUBLE DATA DISPLAY MODE
Item Switch operation Actuation
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.
Press working lamp (front) switch

Failure code and time elapsed since failure
change to next item.
ON
Method of Failure code

SPEED
sending failure x 100
RPM
code km/h
MPH Time elapsed
since failure
SDW01254
SDW00242
Press working lamp (rear) switch for at least 2

seconds
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
Press 2nd switch from top on left side of main

Resetting from
monitor (switch below emergency steering dis-
travel data Changes to normal display
play) and working lamp (front) switch simulta-
display mode
neously for at least 5 seconds, or start the engine.
10-162 WA800L-3
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR
1. Check items (Checks before starting) OUTLINE

1A. Engine coolant level • The maintenance monitor has a display function
1B. Engine oil level for the caution items and gauges.
2. Caution items (warning items) • The maintenance monitor consists of the moni-
2A. Engine oil pressure tor module, switch module, service meter, case,
2B. Brake oil pressure and other mechanisms.
2C. Battery charge • The monitor module has a built-in CPU (Central
2D. Air cleaner (L.H.) Processing Unit). It processes the signal from
2E. Air cleaner (R.H.) the sensors, and carries out the display and out-
2F. Transmission oil filter put.
3. Gauge items • A liquid crystal display and LEDs are used for
3A. Fuel level the display portions. The switches are em-
3B. Engine coolant temperature bossed sheet switches.
3C. Torque converter oil temperature
4. Service meter
4A. Service meter numeric display
4B. Service meter RUN pilot lamp
5. Monitor module
6. Switch module
WA800L-3 10-163
MAINTENANCE MONITOR DISPLAY FUNCTION
Display
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
Displays when engine is running

Above specified dif-
Transmission oil filter Display when normal: OFF
ferential pressure
Engine coolant level Below low level

Below specified pres-
Engine oil pressure Display when abnormal: Flashes
sure
CAUTION lamp flashes
Buzzer sounds
Below specified pres-
Brake oil pressure
sure
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

Fuel level Below low level
CAUTION lamp flashes
When charge is
Battery charge Displays when engine is running
defective
Above specified neg- CHECK lamp flashes
Air cleaner
ative pressure
Actuated when charge is normal

Service meter 0 – 9999.9h
Advances 1 for every hour
Service
meter
Service meter
Lights up when service meter is running
indicator
10-164 WA800L-3
Display
category
All lamps light up below applicable level

Fuel level
Flashes when level is 1
One place lights up to show applicable

Engine coolant
Gauges level
temperature
Flashes when level is 6 or 7
One place lights up to show applicable

Torque converter oil
level
temperature
Flashes when level is 6 or 7
WA800L-3 10-165
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
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)
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
SAFETY RELAY
10-168 WA800L-3
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
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
ELECTRICAL TRANSMISSION CONTROL
1. Transmission cut-off selector switch 7. Relays 13. Transmission control valve

2. Auto shift/Manual shift selector switch 8. Fuse boxes 14. Speed sensor
3. Parking brake switch 9. Transmission controller 15. Transmission cut-off switch
4. Kick-down switch 10. Directional switch 16. Brake valve (left)
5. Hold switch 11. Shift-down switch 17. Brake valve (right)
6. Maintenance monitor 12. Shift-up switch
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
KICK-DOWN, HOLD SWITCH
1. Kick-down switch
2. Spring
3. Spring
4. Hold switch
5. Wiring harness
KICK-DOWN SWITCH HOLD SWITCH

OPERATION • The hold switch is installed to the boom lever,
• If the kick-down switch is pressed while the gear and when the hold switch is pressed, the speed
speed and travel speed conditions are satisfied, range displayed on the main monitor transmis-
the transmission is shifted to 1st forcibly. sion indicator is held (when equipped with auto
shift).
CANCELLATION (or not actuated) • Press the hold switch again to cancel (when
• When directional switch is at N equipped with auto shift).
• When directional switch is at R
• When starting switch is OFF
10-172 WA800L-3
STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION (ATM) SYTEM
AUTOMATIC TRANSMISSION (ATM) SYTEM

Outline of system
• 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
System configuration
Model selection signal
D Directional switch Forward solenoid D
D Range switch Reverse solenoid D
D Transmission cut-off SW 1st solenoid D
D Kick-down switch 2nd solenoid D
P Engine speed 3rd solenoid D
P Travel speed
D Neutral relay signal Kick-down signal D

Transmission controller
D Hold switch Failure code S-Net
D Manual switch Shift indicator S-Net
D Engine selection Error display buzzer output S-Net
D Auto shift transmission signal Main monitor F-N-R S-Net
Hold pilot lamp S-Net
Engine speed D
Manual indicator lamp (*1)
Backup lamp relay D
D Joystick lever F-N-R switch
A Steering lever angle potentiometer
A Frame angle potentiometer
D Shift-up switch Joystick caution relay D
D Shift-down switch Engine speed P
Neutral safety output D
1st gear speed LED D

A: Analog signal 2nd gear speed LED D
D: Digital signal
P: Pulse signal 3rd gear speed LED D
: Signal for joystick steering
*1. The output of the manual indicator lamp is judged by the main monitor.
10-174 WA800L-3
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
4. Travel mode 3) Protection of transmission in joystick man-

Manual gear shift mode ual mode
The auto or manual gear shift mode can be As the travel direction changing operation
selected. and the shift-down operation are facilitated,
In the manual gear shift mode, the gear speed is the gear is shifted up from the 1st or 2nd to
changed wit h the shift- up and shift- down the 3rd to protect the transmission in the joy-
switches one step by one. While the machine is stick manual mode. When this function is
traveling in the forward 2nd gear speed, the applied, the caution buzzer sounds.
kick-down function is usable. 4) Manual gear shift mode
If the travel speed data cannot be obtained
5. Safety functions because of a travel speed sensor trouble,
1) Neutral safety the transmission is set in the manual (gear
When the engine is started, if the directional shift mode).
switch is not in the N position, the transmis-
sion controller keeps itself in the neutral
state and the machine cannot start. This
function is reset if the N signal is input once
after the engine is started.
2) Protection of transmission
If the travel direction is changed or the gear
is shifted down while the machine is travel-
ing, the gear speed is controlled and warn-
ing buzzer is turned on to protect the
transmission.
a) Gear speed control
When the engine speed and travel
speed are under a certain condition, the
transmission is shifted down to the 2nd
gear speed.
transmission is kept at the current gear
speed but shifted down to the 2nd gear
speed as the travel speed lowers.
(See Fig. 1,2 Control at shift-down oper-
ation, Fig. 3,4 Control at F-R
changeover, Table 1 Automatic gear
shift change points table, Item 5. Shift-
down when kick-down is ON, and Item
6. F-R changeover.)
b) Warning with caution buzzer
caution buzzer sounds for warning.
(See Fig. 1,2 Control at shift-down oper-
ation, Fig. 3,4 Control at F-R
changeover, Table 1 Automatic gear
shift change points table, Item 5. Shift-
down when kick-down is ON, and Item
6. F-R changeover.)
10-176 WA800L-3
Table 1 Automatic gear shift change points table
Travel speed Period to prevent gear

Item Gear speed
(km/h) shifting (sec)
1o2 5.4 (5.6) or higher 2
1. Basic gear shift change 2o3 10.9 (11.4) or higher 2
3o2 Below 10.4 (9.9) 2
2. Engine speed
3o2 Below 1.0 0
(Below 1,450 rpm)
3. Engine speed
3o2 Below 8.0 2
(Below 1,450 rpm o 1,450 rpm or higher)
4. When hold is ON 1o2 5.4 0
Shift-up 2o3 10.9 0
5. When kick-down is ON
— — 5
Shift-down (See Fig. 1 and Fig. 2)
6. F-R changeover (See Fig. 3 and Fig. 4)
(F) o N o R — —
2
(R) o N o F
7. F-R changeover
FoNoF o3 10.9 or higher
0
RoNoR o2 Below 10.9
Fig. 1 Control at shift-down operation Fig. 2 Control at shift-down operation

(Manual shift transmission) (Auto shift transmission)
Fig. 3 Control at F-R changeover Fig. 4 Control at F-R changeover

(Manual shift transmission) (Auto shift transmission)
WA800L-3 10-177
6. List of transmission controller travel modes and functions
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.
Condition for resetting kick-down function (Kick-down function is effective in F and R)

(1) Joystick knob switch: F o N, R o N, or F io R
(2) Increase of travel speed: As per automatic gear shift change points table
(3) Power supply: OFF
Condition for resetting hold function

(1) Hold switch: ON (GND) Switch is pressed again
(2) Manual switch: ON (GND) Manual mode is selected
(3) Power supply: OFF
Manual mode
Effective functions: Shift-up/down function and transmission protect
Solenoid output In the joystick manual mode, gear speed is shifted

Directional with the shift-up and shift-down switches one step by
Gear speed before
switch F R one.
setting to N
F Q
N Q (*1) Solenoid output
Gear speed
R Q 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
the mode is changed between auto-shift and manual- Effective area of kick-down (only for forward)
shift, the 2nd gear speed is selected.
(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
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
Table 2 Failure codes table

• Transmission controller
Auto/Manual transmission control system
System Main monitor Remarks
Code Item
Short circuit Disconnection Remedy code
10 Backup lamp relay Q Q Not set
11 Not set – – – –
12 F solenoid Q Q CALL
13 R solenoid Q Q CALL
14 1st solenoid Q Q CALL
15 2nd solenoid Q Q CALL
16 3rd solenoid Q Q CALL
17 Not set – – – –
18 Not set – – – –
19 Joystick directional switch Q Q E00
20 Directional switch signal Q Q CALL
21 Gear shifting signal Q Q Not set
22 Travel speed sensor x Q E00
23 Engine speed sensor x Q E00
8. Communicating function 9. Power source of transmission controller

The transmission controller has a communicat- When the starting switch is turned on and the
ing function through "S-NET", and it keeps com- source voltage is 20 V or higher and a voltage of
municating with the main monitor. +20 V or higher is applied to the transmission
If any trouble occurs, the transmission controller controller solenoid, drive of each solenoid valve
displays the remedy code on the main monitor can be controlled.
to notify the operator for higher safety, depend- If the source voltage lowers below 19 V, all the
ing on the degree of the trouble. outputs are turned off and each solenoid cannot
The failure code saved in the main monitor can be controlled. (The machine cannot travel.)
be checked in the failure history mode of the
main monitor. For the method of operating the
main monitor, see Main Monitor.
WA800L-3 10-179
10. Input signals

1) Direction switch (F, N, R) signal 5) Neutralizer relay signal
This signal is a +24V/OPEN digital signal. This signal is a +24V/OPEN digital signal. If
When the machine is normal, one of the F the parking brake switch is turned off, +24 V
(Forward), N (Neutral), and R (Reverse) sig- is input and the machine can travel. When
nals is input (+24 V). this signal is OPEN, the transmission con-
2) Shift-up/Shift-down switch signal troller keeps itself in neutral state.
This signal is a +24V/OPEN digital signal. If 24 V: Parking brake is released
the switch is pressed, its N.C side is opened OPEN: Parking brake is applied
and its N.O side becomes +24 V. If the 6) Transmission cut-off switch signal
switch is released, its N.C side becomes This signal is a GND/OPEN digital signal,
+24 V and its N.O side is opened. The which becomes OPEN while the transmis-
operation of the switch is judged by these sion cut-off switch is turned ON (while the
signals. left brake is used).
3) Kick-down switch signal When the transmission cut-off switch is
This signal is a +24V/OPEN digital signal. If turned ON, the transmission controller out-
the kick-down switch installed to the work puts the neutral signal. If the transmission
equipment control lever is pressed, +24 V is controller is reset, the gear speed matched
input. The operation of the switch is judged to the current travel speed is set.
by the rise of +24 V from 0 at this time. 7) Manual mode signal
4) Hold switch signal This signal is a GND/OPEN digital signal.
This signal is a +24V/OPEN digital signal. If When the manual mode switch is turned
the hold switch installed to the work equip- ON, the GND signal is input.
ment control lever is pressed, +24 V is input.
The operation of the switch is judged by the
rise of +24 V from 0 at this time.
11. Function selection signal

This signal is a GND/OPEN digital signal. When the engine is started, the function is judged by this signal.
1) Model selection 2) Engine selection
Table 3. Model selection signals table Table 4. Engine selection table

Model CN3B-2 CN3B-10 CN3B-3 Selected engine
Komatsu Cummins
WA800-3 OPEN GND OPEN
Signal and data
WA900-3 GND GND GND
Engine select (CN3A-10) OPEN GND
3) Optional function selection
Table 5. Optional function selection table

Input signal name Stage of signal
Auto shift transmission
OPEN GND OPEN GND
(CN3A-20)
Joystick steering
OPEN OPEN GND GND
(CN3B-1)
Objective models Function
Transmission protec- Transmission protec-
Transmission protec- Transmission protec-
WA800-3, WA900-3 tion and transmis- tion/Joystick and
tion tion and joystick
sion auto transmission auto
a On the LED display unit, "0o 0o" is displayed after the program part No.
10-180 WA800L-3
12. Engine rotation sensor signal

This signal is a pulse signal. The number of
pulses sent from the electromagnetic pickup
sensor is converted into rpm and used for con-
trol.
The mode where the engine speed is 1,450 rpm
or higher is called the "Engine rotation ON"
mode, and the mode where the engine speed is
below 1,450 rpm is called the "Engine rotation
OFF" mode.
13. Travel speed sensor signal

This signal is a pulse signal. The number of
pulses sent from the electromagnetic pickup
sensor is converted into rpm and used for con-
trol.
14. Communication signal (S-NET)

A code used for troubleshooting is sent to the
main monitor.
15. Output signals

1) Transmission solenoid signal
Table 6. Combinations of gear speed and solenoids

Q: ON
Solenoid
F R 1st 2nd 3rd
Gear speed
F1 Q Q
F2 Q Q
F3 Q Q
N
R1 Q Q
R2 Q Q
R3 Q Q
2) Backup lamp relay 4) Communication signal (Data displayed on

This signal is a digital (ON/OFF) output of main monitor)
+24 V, which is turned ON when the direc- For the display position and operation of the
tional switch is in the R position to turn on main monitor, see Main Monitor.
the backup lamp and backup alarm. a) Display of gear speed
3) Engine rotation signal (Open collector) 1st gear speed output: "1"
A signal having the same frequency as the 2nd gear speed output: "2"
engine rotation sensor signal input to the 3rd gear speed output: "3"
transmission controller is output. Neutral: "N"
b) Display of forward and reverse
"F" is displayed for the forward travel
and "R" for the reverse travel.
c) Display of hold
When the hold function is turned ON,
the pilot lamp is displayed on the main
monitor.
WA800L-3 10-181
16. LED display

When the engine is started, the LED is set in
1. "Program part No. display mode", then 2.
"Output gear speed display mode". If any trou-
ble is detected, however, the LED is set in the
"Troubleshooting display mode" immediately.
1) Program part No. display mode
When the power is turned on, the following
are displayed in order at the interval of 1
second.
–o –o 7o 8o 2o 3o 1o 6o A o 1o 0o 0o oTo display mode 2
2) Output gear speed display mode

LED display Xo Y.. (Dots of both are turned
off.)
X: Drive condition of directional solenoid
Forward F: F, Reverse R: A, Neutral: '0'
Y: Drive condition of gear speed solenoid
1–4
Example oIf trouble is detected, LED is set in display mode 3.
Display Contents 0o 2o Fo 2o
'0o 2o' Neutral, 2nd Gear shifting

N
'Fo 1o' Forward, 1st (Gear speed F2 is displayed continuously)
'Ao 2o' Reverse, 2nd
'Fo Fo' Neutral safety state
3) Troubleshooting display mode (Trouble cur-

rently detected)
"E- (2 sec)" and "Code (2 sec)" are repeated
as one routine.
a) When there is only one trouble item
Example
Eo – o 2o 3o oRepeat
b) When there are two trouble items

Example
Eo – o 2o 3o Eo – o 1o 8o oRepeat
10-182 WA800L-3
STRUCTURE AND FUNCTION AJSS (Advanced joystick steering system)
AJSS (Advanced joystick steering system)
System configuration diagram
Control circuit configration diagram
WA800L-3 10-183
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.
Potentiometer calibration function

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

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

System Main monitor
Code Item
Short circuit Disconnection action code
55 Travel speed sensor Q Q E00
56 Joystick caution buzzer relay Q Q None
57 Steering lever angle sensor Q Q E01 + CALL
Shifting of steering lever angle sensor, frame angle
58 — — E01 + CALL
sensor, or potentiometer signal
59 Frame angle sensor Q Q E01 + CALL
60 Steering lever lock switch Q Q E01 + CALL
62 Joystick neutral interlock relay Q Q E00
63 Joystick basic pressure control EPC solenoid Q Q E01 + CALL
10-184 WA800L-3
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
TRANSMISSION AND JOYSTICK STEERING CONTROLLER
10-186 WA800L-3
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
ELECTRIC PARKING BRAKE CONTROL
1. Parking brake display switch OUTLINE

2. Parking brake switch • When electric current flows to the parking brake
3. Accumulators valve (solenoid valve), the hydraulic pressure
4. Emergency brake switch from the accumulator is applied to the spring cyl-
5. Low pressure switch inder to release the parking brake.
6. Spring cylinders On the other hand, if the electric current is
7. Parking brake solenoid valve turned off, the oil pressure from the accumulator
8. Neutralizer relay is cut off, so the oil pressure inside the spring
9. Parking safety relay cylinder passes through the parking brake valve
and is drained, the parking brake is actuated by
the force of the spring.
10-188 WA800L-3
FUNCTION
1. Applying and releasing parking brake
The parking brake is applied or released by
using the parking brake switch (combination
switch).
2. Emergency brake
If there is damage to the hydraulic circuit, and
the pressure inside the accumulator drops and it
is impossible to guarantee the braking force of
the brake, the parking brake is automatically
applied to act as an emergency brake.
3. Parking brake safety

It is dangerous if the parking brake can be
released simply by turning the starting switch
ON after the automatic parking brake has been
applied. Therefore, to ensure safety, the system
is designed so the brake cannot be released
unless the starting switch is turned ON and then
the parking brake switch is also turned ON.
4. Neutralizer
The parking brake may seize if the machine is
driven with the parking brake still applied. To
prevent this problem, the caution lamp lights up
and the alarm buzzer sounds to warn the 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
PARKING BRAKE SOLENOID VALVE
PARKING SAFETY RELAY

NEUTRALIZER RELAY
Relay actuation table

Terminal No.
Electricity 3 6 5
between 1 and 2
OFF
ON
EMERGENCY BRAKE SWITCH
10-190 WA800L-3
(1)
OPERATION
1. STARTING SWITCH OFF
• When the starting switch is turned OFF, the bat-

tery relay is opened, so electricity does not flow
to the parking brake circuit. For this reason, if
the starting switch is at the OFF position, no
electric current flows to the parking brake sole-
noid valve, regardless of whether the parking
brake switch is ON (applied) or OFF (released),
so the parking brake is actuated.
WA800L-3 10-191
2. STARTING SWITCH ON
2-1 When parking brake switch is ON (actuated) before starting switch is turned ON
• The electric current flows in circuit (1) from the

battery o starting switch o battery relay coil o
ground, so the battery relay is closed. When this
happens, electric current flows in circuit (2) from
the battery o battery relay o parking brake
switch terminal 1 – 3 o parking brake safety re-
lay terminal 1 – 2 o ground. In this way, the
parking safety relay is actuated and safety relay
terminals 3 – 5 are closed.
• When this happens, circuit (3) is formed from
the battery o battery relay o parking safety re-
lay terminal 5 – 3 o parking safety relay termi-
nal 1 – 2 o ground. From this point, the parking
safety relay is in the condition of circuit (3) until
the starting switch is turned OFF.
• In this condition, electric current does not flow to
the parking brake solenoid valve, so the parking
brake is actuated.
• In addition, in this condition, the trans-mission is
shifted to neutral by transmission controller.
10-192 WA800L-3
2-2 When parking brake switch is OFF (released) before starting switch is turned ON
• Electric current flows in circuit (1) from the bat-

tery o starting switch o battery relay coil o
ground, so the battery relay is closed. However,
in this case, the parking brake switch is OFF (re-
leased), so the parking safety relay is not actuat-
ed. For this reason, the electric current does not
flow to the parking brake solenoid valve, so after
the automatic parking brake is applied, the park-
ing brake is not released automatically even
when the starting switch is turned ON.
• In addition, the electric current does not flow to
the transmission controller, so the machine does
not move.
WA800L-3 10-193
3. PARKING BRAKE SWITCH OFF (RELEASED)

When the parking brake switch is turned from ON to OFF after the starting switch is turned ON
• If the parking brake switch is turned from ON

(actuated) to OFF (released), the circuit for ter-
minals 2 and 3 of the parking brake switch is
connected, and the parking brake safety relay is
also actuated. For this reason, electric current
flows in circuit (1) from the battery (+) o battery
relay o parking brake safety relay o parking
brake switch, and then flows to circuit (2).
(2) This circuit is formed from the emergency
brake switch o parking brake solenoid valve o
ground, and the parking brake is released.
• In addition, a signal is sent at the same time
from terminal 3 of the neutralizer relay to the
transmission controller to make it possible to
travel.
10-194 WA800L-3
4. PARKING BRAKE SWITCH ON (ACTUATED)
• If the parking brake switch is turned ON (ap-

plied) after carrying out operations with the park-
ing brake switch OFF (released), the circuit in
the diagram above is formed.
• Electric current does not flow to the parking
brake solenoid valve, so the oil pressure from
the accumulator to the spring cylinder is shut off.
At the same time, the oil pressure inside the
spring cylinder passes through the parking
brake valve and is drained, so the parking brake
is applied by the force of the spring.
• In addition, at the same time, the neutralizer re-
lay is reset, so the circuit between terminals 3
and 5 is opened, and no electricity flows to the
transmission directional circuit, so the transmis-
sion is shifted to neutral.
As a result, the signal from terminal 3 to the
transmission controller is cut and the transmis-
sion is shifted to neutral.
In this way, the transmission is shifted to neutral
when the parking brake is applied. This makes it
impossible for the machine to travel with the
parking brake applied, and prevents the parking
brake from seizing.
WA800L-3 10-195
5. WHEN MAIN BRAKE OIL PRESSURE DROPS (EMERGENCY BRAKE ACTUATED)
• If the accumulator pressure drops, the emergen-

cy brake switch installed to the accumulator is
opened.
For this reason, the electric current stops flowing
to the parking brake solenoid valve, so the oil
pressure inside the spring cylinder is drained
and the parking brake is applied.
However, in this case, the condition is different
from the case where the parking brake switch is
ON (applied), because there is electric current
flowing to the neutralizer relay coil.
• For this reason, a signal is sent to the transmis-
sion controller, and it is possible to engage the
transmission clutch. In this way, it is possible to
use the engine brake when the emergency
brake is applied, so the braking distance be-
comes shorter. At the same time, if the emer-
gency brake has been applied and it is
necessary to move the machine (for example, if
the emergency brake is applied when the ma-
chine is on a railway crossing), it is possible to
move the machine by operating the transmis-
sion lever.
10-196 WA800L-3
20 TESTING AND ADJUSTING
Standard value table for engine ..................................................................................................................20- 2

Standard value table for chassis .................................................................................................................20- 3
Standard value table for electrical parts......................................................................................................20- 7
TESTING AND ADJUSTING ......................................................................................................................20- 101
TROUBLESHOOTING ................................................................................................................................20- 201
a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert
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
STANDARD VALUE TABLE FOR ENGINE
Mchine model WA800L-3
Engine SAA12V140ZE-2
Cate- Standard value

Item Measurement conditions Unit Service limit value
gory for new machine
High idling 2,250 ± 50 2,250 ± 50
Engine speed Low idling rpm 650 +50 650 +50

+0 +0
Rated speed 2,000 2,000
Air supply pressure kPa

At rated output 133 {1,000} 106 {800}
(boost pressure) {mmHg}
Whole speed range

Exhaust temperature °C Max. 650 700
(ambient temperature: 20°C)
At sudden acceleration Max. 4.0 6.0

Bosch
Exhaust gas color
index
At high idling Max. 2.0 3.0
Intake valve 0.43 —

Valve clearance
mm
(normal temperature)
Exhaust valve 0.80 —
Oil temperature: 40 – 60°C

Compression pressure MPa Min. 3.14 2.2
(Engine speed:
(SAE30 oil) {kg/cm²} {Min. 32} {22}
160 – 200 rpm)
Engine
(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)
MPa Min. 0.12 0.07

Oil pressure At low idling (SAE30)
{kg/cm²} {Min. 1.2} {0.7}
Min. 0.10 0.07

At low idling (SAE10W)
{Min. 1.0} {0.7}
Oil temperature Whole speed range (oil pan) °C 80 – 110 120
Fuel injection timing Before top dead center deg. 29 ± 1 29 ± 1
Deflection of one belt when

Alternator belt tension pressed with finger force of mm 20 20 – 22
approx. 59 N {approx. 6 kg}
Deflection when pressed

Air conditioner
with finger force of approx. mm 9 – 12.5 16.5
compressor belt tension
98 N {approx. 10 kg}
20-2 WA800L-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Cate- Standard value Service limit

Item Measurement conditions Unit
gory for new machine value
HOLDoRAISE Max. 23.5 {2.4} 35.3 {3.6}
RAISEoHOLD Max. 15.7 {1.6} 23.5 {2.4}
HOLDoLOWER Max. 24.5 {2.5} 37.2 {3.8}

Operrating efffort
Lift arm • Low idling

LOWERoHOLD • Hydraulic oil temperature: — —
Work equipment control lever
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}
Bucket HOLDoTILT Max. 23.5 {2.4} 35.3 {3.6}
TILToHOLD Max. 14.7 {1.5} 23.5 {2.3}

HOLDoRAISE 67 ± 15 67 ± 30
• Low idling
Lift arm HOLDoLOWER • Hydraulic oil temperature: 53 ± 15 53 ± 30
Travel
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
• Hydraulic oil temperature:

Low idling Max. 6.8 6.8
45 – 55°C
Joystick
Operating
lever
• Flat, horizontal, straight, dry sec.

time
paved road surfac
High idling Max. 5.0 5.0
• Left lock – right lock
Operating force N {kg} 54 {5.5} 60 {6.1}

Accelerator
pedal
Operating angle ( 1) 50 —
deg.
Operating angle ( 2) 33 —
• Put push-pull scale in contact at

point 150 mm from pedal ful-
crum a, and measure maximum
249 ± 29
Operating effort value to end of stroke. N {kg} 421 {43}
{30 ± 3}
• Engine started
45 – 55°C
Brake pedal
• Engine stopped
Operating angle
Neutral ( 1) 45 —
deg.
Maximum ( 2) 15 —
Play mm 5 ± 0.5 —
WA800L-3 20-3
(1)

• Tire inflation pressure:

A Specified value Max. 2.5 —
Insertion of wheel lock
ring
Tire
B mm Max. 4.0 —
Clearance of wheel lock

C 20 – 35 —
ring
• Engine coolant temperature:

Torque converter stall 2,050 ± 50 2, 050 ± 50
Within operating range
Engine speed
• Torque converter oil tempera-

Hydraulic stall ture: 60 – 80°C rpm 2,075 ± 100 2,075 ± 200
Torque converter stall + 45 – 55°C
1,670 ± 100 1,670 ± 200
hydraulic stall (full stall) • Joystick lever switch: F3
Transmission main relief valve • Torque converter oil tempera- +0.29 +3 +0.29 +3
2.75 +0 {28 +0 } 2.75 +0 {28 +0 }
pressure ture: 60 – 80°C
1.03 ± 0.10 1.03 ± 0.10
Transmission, torque converter
Pilot reducing pressure

{10.5 ± 1.0} {10.5 ± 1.0}
Modulate pressure +0.29 +3 +0.29 +3
2.65 +0 {27 +0 } 2.65 +0 {27 +0 }
(excluding F3, R3)
Torque converter inlet port MPa 0.79 – 0.94 0.59 – 0.94
pressure • Engine: High idling {kg/cm2} {8.0 – 9.5} {6.0 – 9.5}
• Torque converter oil tempera-
Torque converter outlet port ture: 60 – 80°C 0.59 ± 0.10 0.59 ± 0.10
pressure {6 ± 1} {6 ± 1}
0.14 ± 0.06 0.14 ± 0.06
Lubrication valve pressure
{1.4 ± 0.6} {1.4 ± 0.6}
Reducing valve pressure 1.96 ± 0.10 1.96 ± 0.10
(for F3, R3) {20 ± 1} {20 ± 1}
• Hydraulic oil temperature: +0.49 +0.98
45 – 55°C MPa 31.36 –0.39 31.36 –0.78
Steering relief pressure
• Engine full {kg/cm2} +5 +10
{320 –4 } {320 –8 }
Steering
• 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
Low idling goes out MPa

• Brake oil tem-
• When oil {kg/cm 2
}
perature:
45 – 55°C pressure 9.8 +0.98
+0 9.8 +1.47
–0.49
Charge cut-out pressure turns from
+10 +15
increasing to {100 +0 } {100 –5 }
decreasing
20-4 WA800L-3
(1)

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

MPa 3.72 +0 3.72 –0.2
PPC
FLOAT, bucket • Hydraulic oil temperature:

PPC valve 45 – 55°C {kg/cm2
} {38 +2 {38 +2
DUMP, TILT +0 } –2 }
output • Engine speed: High idling
pressure • Work equipment control lever: 2.54 ± 0.05 2.54 ± 0.05
Boom LOWER Full operating {26 ± 0.5} {26 ± 0.5}
• Tire inflation pressure: Speci-

fied pressure
• Flat, horizontal, straight, dry
paved road surface
• Speed when applying brake: 20
km/h, braking delay: 0.1 second
Performance m Max. 7.5 —
• Brake pedal operating
effort:Specified operating effort
Wheel brake
(373 N {38 kg})

• Transmission cut-off switch:
ON
• Measure stopping distance.
• Engine stopped
• Compress by pump to 4.2 – 5.2
MPa Max. 0.49
Drop in brake pressure MPa {43 – 53 kg/cm2} —
{kg/cm2} {Max. 5.0}
• Measure drop in brake pressure
after 5 minutes
Disc wear • Measure piston stroke mm 40.7 ± 1.4 Max. 46.3
• Tire inflation pressure:
Specified pressure
Performance • Flat dry paved road with 1/5 — Stopped —
Parking brake
(11°20’) grade
• Machine at operating condition
Pad thickness • Including back metal 31.7 12.7

mm
Pad clearance • Total of each end 1.06 ± 0.18 Max. 2.1
31.36 +0.98
–0.29 31.36 +0.98
–1.27
Boom relief pressure
Oil pressure
• High idling +10 +10

• Hydraulic oil temperature: MPa {320 –3 } {320 –13 }
45 – 55°C {kg/cm2}
Work equipment
+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)

• High idling
45 – 55°C
RAISE
• Engine coolant temperature: 10.4 ± 0.5 13.3
• No load
• Steering: Straight
Boom speed
LOWER
4.8 ± 0.5 6.4
• Full throttle
Work equipment speed

At full stroke
45 – 55°C
DUMP
• Engine coolant temperature:

sec. 2.5 ± 0.3 3.7
• No load
Work equipment
At full stroke
Bucket speed 3.8 ± 0.3 4.9

TILT
When bucket horizontal
2.0 ± 0.3 2.9

45 – 55°C
• Stop engine, leave for 5 min-
Retraction of boom utes, then measure for next 15 Max. 40 40
cylinder rod minutes.
• Bucket empty, boom, bucket
Hydraulic drift
horizontal
mm
Retraction of bucket
Max. 20 20
cylinder rod
20-6 WA800L-3
(1)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS

aBe sure no one is nearby, and then carry out testing.
Sys- Name of Connector Inspection Measurement

Judgement table
tem component No. method condition
If the condition is as shown in the table below, it is 1) Turn starting
normal. switch OFF.
2) Insert T-adapter.
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)

normal. switch OFF.
Measure
voltage
Power supply (for Between (6) – (16)

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

L01 20 – 30 V 3) Turn starting
switch switch ON Between
Transmission & Joystick steering controller
switch ON.
Turn parking brake (1) – (3)
Max. 1 V
switch OFF

normal. switch OFF.
resistance
Measure
TR1 Between (6) – (16) 5 – 15 z 2) Disconnect

Solenoid (1st)
(male) connectors.
Between (6) – chassis Max. 1 Mz 3) Connect T-
adapter.
normal. switch OFF.
resistance
Measure

Solenoid (2nd)
(male) connectors.
Between (2), (6) – chassis Max. 1 Mz 3) Connect T-
adapter.
normal. switch OFF.
resistance
Measure
TR1 2) Disconnect
Solenoid (3rd) Between (3) – (6) 5 – 15 z
(male) connectors.
adapter.
normal. switch OFF.
resistance
Measure

Solenoid (F)
(male) connectors.
adapter.
normal. switch OFF.
resistance
Measure
TR1 2) Disconnect
Solenoid (R) Between (5) – (6) 5 – 15 z
(male) connectors.
adapter.
WA800L-3 20-7
(1)

Judgement table
normal. switch OFF.
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.
normal. switch OFF.
resistance
Measure
BC01 Between (1) – (2) 500 – 1,000 z 2) Disconnect

Speed sensor
(male) connectors.
adapter.
1) Screw in until the tip of sensor contact gear,
Adjust
then turn back 3/4 – 1 turn.

Speed sensor — —
2) Sensor should work normally when adjusted as
above.
System If the condition is as shown in the table below, it is 1) Turn starting
network normal. switch OFF.
Controller
Measure
voltage
(S-NET) 2) Insert T-adapter.

C3B Between (4), (12) – chassis 4–8V
(Between T/M 3) Turn starting
controller and switch ON.
main monitor)
normal. switch OFF.
resistance
2) Disconnect
Measure
Kick-down Kick-down switch at

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

normal. switch OFF.
resistance
Measure
Transmission L12 Normal condition Max. 1 z 2) Disconnect

cut-off switch (male) Between connectors.
L.H. brake pedal is (1) – (2) 3) Connect T-
Min. 1 Mz
depressed adapter.
20-8 WA800L-3
(1)

Judgement table
normal. switch OFF.
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

normal. switch 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”

normal. switch OFF.
Measure
Joystick FNR
voltage
When joystick FNR

button switch Between 17 – 30 V 3) Turn starting
switch is in “N”
“N” (13) – switch ON.
switch is not in “N”

normal. switch OFF.

Measure
Joystick gear
voltage
When joystick FNR

shift switch Between 17 – 30 V 3) Turn starting
switch is in “R”
“R” (6) – switch ON.
switch is not in “R”
Controller

normal. switch OFF.
Measure
voltage
Neutralizer When joystick FNR

C3B Between 17 – 30 V 3) Turn starting
relay signal switch is in “N”
(14) – switch ON.
switch is not in “N”

normal. switch OFF.
Measure
Joystick
voltage
When joystick shift-

shift-up Between Max. 1 V 3) Turn starting
up switch is “ON”
switch (N.O) (7) – switch ON.
When joystick shift- chassis 17 – 30 V
up switch is “OFF”

normal. switch OFF.
Measure
Joystick
voltage

shift-down Between Max. 1 V 3) Turn starting
down switch is “ON”
switch (N.O) (8) – switch ON.
When joystick shift- chassis 17 – 30 V
down switch is “OFF”

normal. switch OFF.
Measure
Joystick
voltage

shift-up Between 17 – 30 V 3) Turn starting
up switch is “ON”
switch (N.C) (15) – switch ON.
When joystick shift- chassis Max. 1 V
up switch is “OFF”
WA800L-3 20-9
(1)

Judgement table
normal. switch OFF.
Measure
Joystick
voltage
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
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”

normal. switch OFF.
Measure
voltage
Steering lever When steering

3.5 – 4.5 V 3) Start engine.
Controller
angle sensor angle is RIGHT Between

4) Move joystick to
When steering (3) – (16)

0.5 – 1.5 V left or right stoke
angle is LEFT end.
C3A
normal. switch OFF.
Measure
voltage
Frame angle When frame angle

sensor is RIGHT Between
4) Move joystick to
When frame angle (13) – (16)
is LEFT end.
normal. switch OFF.
When joystick 2) Insert T-adapter.
steering lever is in Max. 1 V 3) Turn starting
Measure
Joystick lever
voltage
neutral Between switch ON.

neutral C2 (8) –
interlock relay When joystick chassis
steering lever is not 17 – 30 V
in neutral
a Set machine in straight travel position.
normal. switch OFF.
When steering lock 2) Disconnect
Measure
voltage
3.5 – 4.5 V connectors.

angle is in RIGHT Between
3) Start engine.
When steering lock (1) – (3)
0.5 – 1.5 V 4) Move joystick to
Steering lever angle is in LEFT left or right stoke
JS2
angle sensor end.
resistance
normal. switch OFF.

Measure
Between (1) – (2) 0 – 5 kz 2) Insert T-adapter.

3) Turn starting
Between (3) – (2) 4 – 5 kz switch ON.
20-10 WA800L-3
(1)

Judgement table
normal. switch OFF.
JS3
resistance
2) Disconnect
Measure
System cut-off (male) System cut-off
Between Max. 1 z connector.

switch JS4 switch ON
JS3 (1) – 3) Connect
(female) System cut-off JS4 (1) T-adapter.
Min. 1 Mz
switch OFF

normal. switch OFF.
Measure
voltage
When frame angle
is RIGHT. Between
4) Move joystick to
When frame angle (1) – (3)
Frame angle is LEFT. end.
L27
sensor
normal. switch OFF.
resistance
Measure
Between (1) – (2) 0 – 5 kz 2) Disconnect

connector.
Between (3) – (2) 4 – 5 kz 3) Connect
T-adapter.
WA800L-3 20-11
(1)
All specifications
aBe sure no one is nearby, and then carry out testing.

Judgement table
normal. switch OFF.
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.
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.
normal. switch OFF.
resistance
Measure
Engine water 2) Disconnect

E05 Normal temperature Between
temperature Approx. 2 kz connectors.
(male) (25°C) (1) –
sensor 3) Connect
5°C chassis Approx. 4 kz
T-adapter.
normal. switch OFF.
Measure
voltage
Directional switch Joystick FNR switch

L05 20 – 30 V 3) Turn starting
(N) at N Between
switch ON.
Joystick FNR switch (8) – (3)
Max. 1 V
not at N
Main monitor

normal. switch OFF.
Measure
voltage
Starting switch C L09 Starting switch

Between 20 – 30 V
terminal (male) START
(3) –
Starting switch OFF chassis Max. 1 V
or ON

normal. switch OFF.
Measure
voltage
Starting switch C Start engine 20 – 30 V 2) Insert T-adapter.

terminal Between
Starting switch OFF (4) – (3) Max. 1 V
or ON

L05 normal. switch OFF.
* 20 – 30 V 2) Insert T-adapter.
Starting switch ON Between
Measure
o1V
voltage
Preheating switch (19) – (3)

ON Starting switch OFF Max. 1 V
* Voltage changes only when water temperature

is below 0°C, and time taken to change differs
according to water temperature.
normal. switch OFF.
Measure
voltage
Starting switch L09 2) Insert T-adapter.

Starting switch ON Between 20 – 30 V
BR terminal (male) (2) –
Starting switch OFF chassis Max. 1 V
20-12 WA800L-3
(1)

Judgement table
normal. switch OFF.
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

normal. switch OFF.
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

normal. switch OFF.
resistance
Measure
Main monitor
Low idling select B01 Between (1) – (2) 19 – 23 z 2) Disconnect

solenoid (male) connectors.
Between (1), (2) – chassis Min. 1 Mz 3) Connect
T-adapter.
normal. switch OFF.
Measure
voltage

(F) at F
(7) – switch ON.
Joystick FNR switch chassis Max. 1 V
not at F
L08
normal. switch OFF.
Measure
voltage

(R) at R
(8) – switch ON.
Joystick FNR switch chassis Max. 1 V
not at R

normal. switch OFF.
Measure
voltage
Power supply L18 Between (1), (2) – chassis 2) Insert T-adapter.

20 – 30 V 3) Turn starting
Between (1), (2) – (3) switch ON.
Maintenance monitor
normal. switch OFF.

resistance
2) Disconnect
Measure
Engine water Normal temperature Approx.

E04 connectors.
temperature (25°C) Between 40 kz
(male) 3) Connect
sensor (1) – (2) Approx. T-adapter.
130°C
1.7 kz

normal. switch OFF.
resistance
2) Disconnect
Measure
Torque converter Normal temperature Approx.

T02 connectors.
oil temperature (25°C) Between 40 kz
(male) 3) Connect
sensor (1) – (2) Approx. T-adapter.
130°C
1.7 kz
WA800L-3 20-13
(1)

Judgement table
normal. switch OFF.
2) Disconnect
Float connectors.
raised Approx. 4 z 3) Drain fuel.
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

normal. switch OFF.
resistance
Measure
Radiator water G06 Water level normal Max. 1 z 2) Disconnect

Between
level sensor (male) connectors.
Water level low (1) – (2) Min. 1 Mz 3) Connect
T-adapter.
normal. switch OFF.
Engine oil pressure 2) Disconnect
when engine running: terminal.
resistance
Min. 1 Mz 3) Start engine.

Measure
Engine oil above 0.07 MPa

E09 {0.7 kg/cm2} Between
pressure sensor
Engine oil pressure (1) – (3)
Maintenance monitor
when starting switch

Max. 1 z
ON:above 0.03 MPa
{0.3 kg/cm2}

normal. switch OFF.
BC04 Accumulator 2) Disconnect
(male) pressure: connectors.
BC05 Max. 1 z 3) Connect
resistance
Min. 5.39 ± 0.49 MPa

Measure
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}

normal. switch OFF.
Engine running 2) Insert T-adapter.
Measure
voltage
Charge Between 28 ± 2 V 3) Start engine.

L18 (above half throttle)
(Alternator) (12) – (3)
Starting switch ON Max. 1 V
* If the battery is old, or after starting in cold
areas, the voltage may not rise for some time.
normal. switch OFF.
resistance
2) Disconnect
Measure
Engine oil level R02 Engine oil level

Between Max. 1 z connectors.
sensor (male) normal
(1) –
Engine oil level chassis Min. 1 Mz
abnormal
20-14 WA800L-3
(1)

Judgement table
B08 If the condition is as shown in the table below, it is 1) Turn starting
(female) normal. switch OFF.
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
Connector Monitor item Measurement Sensor

Display
No. (input connector) conditions signal input
Engine water level Engine stopped Flashing 15 – 20 V
((8) – (3)) Starting switch ON Lighted OFF Max. 1 V
Engine oil level Engine stopped Flashing 15 – 20 V
((13) – (3)) Starting switch ON Lighted OFF Max. 1 V
CHECK lamp & Engine oil pressure Flashing 15 – 20 V
Engine start
CAUTION lamp ((10) – (3)) Lighted OFF Max. 1 V
L18 Brake oil pressure Flashing 15 – 20 V
Engine start
(male) ((11) – (3)) Lighted OFF Max. 1 V
Transmission oil filter Flashing 15 – 20 V
Engine start
((16) – (3)) Lighted OFF Max. 1 V
Battery charge Flashing 15 – 20 V
Engine start
((12) – (3)) Lighted OFF Max. 1 V
Maintenance monitor
Air cleaner Flashing 15 – 20 V

Engine start
((14), (15) – (3)) Lighted OFF Max. 1 V
Table 2 (Gauge) 1) Turn starting

switch OFF,
s
Display level resisitance

Gauge display position then insert
(monitor panel input resistance)
Starting switch ON Starting switch OFF dummy
resistance or
Fuel level measure
gauge resistance of
L18 (male) sensor.
Measure 2) Turn starting
resistance switch ON and
between check display.
(6) – (3)
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)

Judgement table
Maintenance
BC02 normal. switch OFF.
resistance
Measure
monitor
Transmission oil (male) Fileter normal Max. 1 z 2) Disconnect

Between
filter sensor BC03 connectors.
Filter clogged (1) – (2) Min. 1 Mz
(male) 3) Connect
T-adapter.
normal. switch OFF.
BC08 Accumulator 2) Disconnect
Between
(male) pressure: connectors.
BC08 Max. 1 z
BC09 resistance
Min. 3.92 ± 0.49 MPa (1) – (2), 3) Connect
Measure
Emergency brake (male) {40 ± 5 kg/cm }2 T-adapter.

BC09
switch BC10 (1) – (2),
Depress brake and
(male) BC10
lower accumulator
BC11 (1) – (2),
pressure to below Min. 1 Mz
(male) BC11
3.63 ± 0.49 MPa
{37 ± 5 kg/cm2} (1) – (2)

normal. switch OFF.
Accumulator 2) Insert T-adapter.
pressure: 3) Turn starting
20 – 30 V switch ON.
Min. 3.92 ± 0.49 MPa
Measure
voltage
Emergency brake {40 ± 5 kg/cm2}

CBL1 Between
switch
Depress brake and (3) – (4)
lower accumulator
pressure to below Max. 1 V
3.63 ± 0.49 MPa
{37 ± 5 kg/cm2}

Others
normal. switch OFF.

Between (1) – (3) 20 – 30 V 2) Insert T-adapter.
Measure
voltage
Bucket positioner 3) Turn starting

F05 Between switch ON.
proximity switch Bucket fully dumped Max. 1 V
(2) – (3)
Between
Bucket fully tilted 20 – 30 V
(2) – (3)

normal. switch OFF.
Between (1) – (3) 20 – 30 V 2) Insert T-adapter.
Measure
voltage
Bucket kick-out 3) Turn starting

F06 Between
proximity switch Bucket fully dumped Max. 1 V switch ON.
(2) – (3)
Between
Bucket fully tilted 20 – 30 V
(2) – (3)

normal. switch OFF.
resistance
Measure
Bucket kick-out Between (1) – (2) 19 – 23 z 2) Disconnect

L16
solenoid connectors.
T-adapter.
normal. switch OFF.
resistance
Measure
Bucket positioner Between (1) – (2) 19 – 23 z 2) Disconnect

L17
solenoid connectors.
T-adapter.
20-16 WA800L-3
(1)
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
TABLE OF TOOLS FOR TESTING, ADJUSTING AND

TROUBLESHOOTING
Symbol
Check or measurement
Part No. Part name Remarks
item
IBM PC or 100% compatible

486DX 66 MHz or higher
16 MB RAM memory
3.5" 1.44 MB Floppy drive
Commercially Laptop or Desk top 120 MB Hard drive or larger
Engine speed available computer SVGA 800 x 600 Color display
One serial/One parallel ports
A 14.4k bps Data/fax modem
Engine electronic
control system MS-DOS 6.2 or later
MS Windows 3.1 or later
Available from Komatsu America Interna-
Insite for Quantum soft- tional Co.
3824801
ware ONLY if certified through service training
program.
Water, oil, exhaust Digital temperature
B 799-101-1502 –99.9 to +1,299°C
temperatures gauge
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester
1 {25, 60, 400, 600 kg/cm2}
Oil pressure C 790-261-1203 Digital hydraulic tester Pressure gauge: 68.6 MPa {700 kg/cm2}
2 • 799-101-5160 • Nipple PT 1/8
3 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm2}
1 795-502-1590 Compression gauge 0 – 6.9 MPa {0 – 70 kg/cm2}
Compression pressure D
2 795-502-1500 Adapter Kit part No.: 795-502-1205
1 799-201-1504 Blow-by checker —
Blow-by pressure E
2 799-201-1590 Gauge 0 – 9.8 kPa {0 – 1,000 mmH2O}
Commercially
Valve clearance F Feeler gauge —
available
1 799-201-9000 Handy smoke checker Discoloration 0 – 70% (with standard
Exhaust color G Commercially color)
2 Smoke meter (Discoloration x 1/10 C Bosch index)
available
Air supply pressure
H 799-201-2201 Pressure gauge –101.3 – 199.9 kPa {–760 – 1,500 mmHg}
(boost pressure)
1 793-605-1001 Brake tester kit
Brake oil pressure J 2 790-101-1430 Coupler —
3 790-101-1102 Pump
79A-264-0020 0 – 294.2 N {0 – 30 kg}
Operating effort K Push-pull scale
79A-264-0090 0 – 490.3 N {0 – 50 kg}
Commercially
Operating angle of pedal L Angle gauge —
available
Commercially
Stroke, hydraulic drift M Scale —
available
Commercially
Work equipment speed N Stop watch —
available
Commercially
Measuring brake disc wear P Caliper gauge —
available
Moving machine when
there is failure in Q 793T-685-1110 Plate —
transmission valve
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
MEASURING ENGINE SPEED 4. Measuring torque converter stall and

hydraulic stall (full stall) speed
k When removing or installing the measuring 1) Start the engine.
equipment, be careful not to touch any high tem- 2) Turn the transmission cut-off switch OFF
perature parts. and depress the left brake pedal fully. Check
k Before starting measurement, check that there
that the transmission cut-off pilot lamp goes
is no one in the surrounding area. out.
k Put blocks under the wheel to stop the machine
3) Turn joystick FNR switch to 3rd.
from moving. 4) Release the parking brake.
a Measure the engine speed under the following 5) Run the engine at full throttle and stall the
conditions. torque converter, and at the same time,
• Water temperature: Within operating range extend the boom cylinder or bucket cylinder
• Hydraulic temperature: 45 – 55°C fully and measure the engine speed when
• Power train oil temperature: 60 – 80°C the circuit is relieved.
1. Measuring low idling speed and high idling

speed
a Before measuring the engine speeds con-
nect the test harness of the portable diag-
nostic computer to "Master ECM" (Electronic
Control Module) connection point at lower
left front panel.
a Check that the engine speed is in the stand-
ard range.
2. Measuring torque converter stall speed

1) Start the engine.
2) Turn the transmission cut-off switch OFF
and depress the left brake pedal fully. Check
that the transmission cut-off pilot lamp goes
out.
3) Turn speed control joystick lever switch to
3rd.
4) Release the parking brake.
5) Run the engine at full throttle and measure
the engine speed when the torque converter
stalls.
3. Measuring hydraulic stall speed

1) Start the engine.
2) Run the engine at full throttle and extend the
boom cylinder or bucket cylinder fully, and
measure the engine speed when the circuit
is relieved.
20-104 WA800L-3
(1)
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS 2) Connect the probe hose, accelerator switch

plug, and air hose to tool G2.
COLOR a The pressure of the air supply should be
less than 1.5 MPa {15 kg/cm2}.
• When measuring in the field when there is no air 3) Connect the power cord to the AC power
or power supply, use handy smoke checker G1; supply.
when recording official data, use smoke meter a When connecting the port, check first
G2. that the power switch of tool G2 is OFF.
a Raise the coolant temperature to the operating 4) Loosen the cap nut of the suction pump,
range before measuring.
k When removing or installing the measuring
then fit the filter paper.
a Fit the filter paper securely so that the
equipment, be careful not to touch any high tem- exhaust gas does not leak.
perature part. 5) Turn the power switch of tool G2 ON.
6) Accelerate the engine suddenly, and at the
1. Measuring with handy smoke checker G1 same time, depress the accelerator pedal of
1) Fit filter paper in tool G1. tool G2 and catch the exhaust gas color on
2) Insert the exhaust gas intake port of tool G1 the filter paper.
into the exhaust pipe, accelerate the engine 7) Lay the filter paper used to catch the
suddenly, and at the same time operate the exhaust gas color on top of unused filter
handle of tool G1 to catch the exhaust gas papers (10 sheets or more) inside the filter
on the filter paper. paper holder, and read the indicated value.
3) Remove the filter paper and compare it with
the scale provided to judge the condition.
2. Measuring with smoke meter G2

1) Insert probe [1] into exhaust pipe, then
tighten the clip to secure it to the exhaust
pipe.
WA800L-3 20-105
(1)
TESTING AND ADJUSTING ADJUSTING ENGINE
a For the following items, see the Cummins

Engine shop manual.
ADJUSTING VALVE
CLEARANCE
MEASURING COMPRESSION
PRESSURE
MEASURING BLOW-BY
PRESSURE

FUEL INJECTION TIMING
MEASURING ENGINE OIL

PRESSURE
MEASURING EXHAUST
TEMPERATURE
MEASURING AIR SUPPLY

PRESSURE
(BOOST PRESSURE)
20-106 WA800L-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING ADJUSTING

1. Loosen the alternator assembly mounting bolts
ALTERNATOR BELT TENSION and nuts (1), (2), (3) and lock nut (4).
TESTING 2. Turn adjustment nut (5) to adjust the tension of
• Measure deflection a of the belt when each belt belt (6).
is pushed with a force of approx. 59 N {approx. 6
kg} at a point midway between the alternator pul- 3. After positioning the alternator, secure it by tight-
ley and the drive pulley. ening lock nut (4), mounting bolts and nuts (1),
a Deflection a of belt (standard value): (2) and (3).
approx. 20 mm
4. After adjusting the belt tension, check that

deflection is the standard value according to the
above procedure.
WA800L-3 20-107
(1)
TESTING AND ADJUSTING BELT TENSION FOR AIR
TESTING AND ADJUSTING CONDITIONER COMPRESSOR
TESTING AND ADJUSTING ADJUSTING

1. Loosen mount bolts and nuts (1), (2), (3), lock-
BELT TENSION FOR AIR nut (4).
CONDITIONER COMPRESSOR
2. Turn adjustment nut (5) to adjust the tension of
TESTING air conditioner compressor belt (6).
• Measure deflection b of the belt when it is
pushed with a force of approx. 98 N {approx. 10 3. When the position of the air conditioner com-
kg} at a point midway between the drive pulley pressor is correct, tighten locknut (4), mounting
and the air conditioner compressor pulley. bolts and nuts (1), (2), (3) to secure it in position.
a Deflection b of belt (standard value):
9 – 12.5 mm
4. After adjusting the belt tension, repeat the test-

ing procedure above to check that the deflection
is adjusted within the standard range.
20-108 WA800L-3
(1)
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
MEASURING ACCELERATOR OPERATING ANGLE

1. Measuring procedure
PEDAL 1) Stop the engine.
2) Measure the operating angle a = a1 – a2,
OPERATING FORCE put the angle gauge L in contact with the
1. Measuring procedure accelerator pedal when it operated at low
1) Put push-pull gauge K in contact with the idle and again when it is at high idle.
accelerator pedal at a point 150 mm from Note: No adjustment is provided. Inspect
pedal fulcrum a. pedal assembly for worn or bent parts
a The center of push-pull gauge K must be in and replace as necessary.
contact with a point 150 mm from pedal ful-
crum.
2. Start the engine, push the pedal in the direction

of operation and measure the maximum value
when pushing from idle to the end of the pedal
travel (high idle).
Note: No adjustment is provided. Inspect
pedal assembly for worn or bent parts
and replace as necessary.
WA800L-3 20-109
(1)
TESTING AND ADJUSTING TORQUE CONVERTER AND
TESTING AND ADJUSTING TRANSMISSION OIL PRESSURE
TESTING AND ADJUSTING 4. Measuring torque converter inlet pressure

1) Remove plug (P10) (PT 1/8), and install nip-
TORQUE CONVERTER AND ple C2 and hydraulic tester C1 (2.5 MPa {25
TRANSMISSION OIL kg/cm2}).
PRESSURE 2) Start the engine and measure the pressure
at engine full.
MEASUREMENT CONDITIONS
• Coolant temperature: Inside operating range
• Torque converter oil temperature: 60 to 80°C
k Apply the parking brake and block the tires.
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.
1. Transmission main relief valve pressure

ple C2 and hydraulic tester C1 (5.9 MPa {60
kg/cm2}). 5. Measuring torque converter outlet pressure
2) Start the engine and measure the pressure 1) Remove plug (P11) (PT 1/8), and install nip-
at 2,000 rpm. ple C2 and hydraulic tester C1 (2.5 MPa {25
kg/cm2}).
2. Measuring pilot reducing pressure 2) Start the engine and measure the pressure
1) Remove plug (P5) (PT 1/8), and install nip- at engine full.
kg/cm2}).
2) Run the engine at engine full and put the
joystick lever switch in neutral, and measure
the pressure when the joystick lever is oper-
ated.
3. Measuring modulating pressure

kg/cm2}).
2) Run the engine at engine full and put the
joystick lever switch in neutral, and measure
the pressure when the joystick lever is oper-
ated.
a Measure pressure except F3 and R3.
20-110 WA800L-3
(1)
TESTING AND ADJUSTING TORQUE CONVERTER AND
TESTING AND ADJUSTING TRANSMISSION OIL PRESSURE
6. Measuring lubrication valve pressure ADJUSTING PROCEDURE

1) Remove plug (P9) (PT 1/8), and install nip- k Always stop engine before adjusting hydraulic
ple C2 and hydraulic tester C1 (2.5 MPa {25 pressure.
kg/cm2}). a If it is impossible to measure relief pressure ac-
2) Start the engine and measure the pressure culately, do not try to adjust pressure.
at engine full. a If the main relief pressure is out of the standard
range, adjust it according to the following proce-
7. Measuring reducing valve pressure dure.
ple C2 and hydraulic tester C1 (2.5 MPa {25 Adjusting of transmission main relief pressure
kg/cm2}). 1) Loosen cap (1) to reduce spring tension.
2) Start the engine and measure the pressure 2) Remove cover (2), and pull out plunger (3), then
at engine full. increase or decrease shims (4) to adjust oil
pressure.
a Standard shim thickness: 6.0 mm
a Amount of adjustment for one shim (t = 0.5
mm): approx. 11.8 kPa {0.12 kg/cm2}
a To increase pressure, increase shims.
To decrease pressure, decrease shims.
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.
2. Remove lock plate (2) of emergency manual

spool (1) of the transmission valve.
a Simply loosen the mounting bolts to remove
the lock plate (2).
20-112 WA800L-3
(1)
PROCEDURE FOR OPERATING EMERGENCY STEERING
TESTING AND ADJUSTING SPOOL WHEN TRANSMISSION VALVE FAILS
4. Check that the area around the machine is safe,

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

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

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

engaged and the machine will start. Therefore,
before starting the engine, always check that the
direction of travel is safe, and always keep the
brake pedal depressed.
If the machine does not start, turn the 2nd spool
and 3rd spool clockwise, and screw in approx.
10 mm to the OFF position.
7. After moving the machine, stop the engine,

apply the parking brake, and block the wheels.
8. Return the emergency manual spool to the neu-

tral position, and install the lock plate.
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.
2. Install nipple C2, then install oil pressure mea-

surement gauge C1 (39.2 MPa {400 kg/cm2}).
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
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.
1. Disconnect drive shaft (1) between transmission

and center support at transmission side.
2. Disconnect drive shaft (2) between transmission

and rear axle at transmission side.
5. Start engine, shift transmission gear shift lever

to F3 or R3 raise speedometer until 24 km/h.
3. Disconnect hose (3) to pilot port of diverter Turn the joystick lever to the right or left and
valve, replace elbow (4) by oil passage shut off measure the pressure when the relief valve is
elbow (for details, see next page), then connect actuated.
hose (3).
(As a result of this, oil pressure to pilot port of
diverter valve is shut off, emergency steering is
operating.)
WA800L-3 20-115
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE
ADJUSTING a Preparatory of oil passage shut off elbow

k Always stop the engine before adjusting the hy- Prepare elbow (07236-10210), insert pin (dia.: 5
draulic pressure. mm) in drilled hole, then weld pin and elbow to
shut off passage.
1. Remove capnut (6) of the relief valve.
2. Loosen locknut (7), then turn adjustment screw

(8) to adjust.
a Amount of adjustment for 1 turn of adjust-
ment screw.
1 turn: Approx. 3.5 MPa {35.7 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.
20-116 WA800L-3
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM STEERING CIRCUIT
BLEEDING AIR FROM

STEERING CIRCUIT
a Bleed the air from the circuit as follows if the
steering valve or steering cylinder have been re-
moved and installed again.
1. Start the engine and run at idling for approx. 5

minutes.
2. Run the engine at low idling and turn 4 – 5 times

to the left and right in turn.
a Operate the piston rod to approx. 100 mm
before the end of its stroke. Be careful not to
relieve the circuit.
3. Repeat Step 2 with the engine at full throttle.
4. Run the engine at engine slow and operate the

piston to the end of its stroke to relieve the cir-
cuit.
WA800L-3 20-117
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING STOPPER BOLT
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.
3 Locknut: 8.8 – 10.8 Nm {0.9 – 1.1 kgm}

normal. a Standard projection b (Reference): 15 mm
a Clearance a: 20 – 23 mm
a Perform the above test at the right and left
steering ends separately. a After adjusting, check clearance a again accord-
ing to the procedure explained above.
20-118 WA800L-3
(1)
TESTING AND ADJUSTING STEERING LEVER ANGLE
TESTING AND ADJUSTING SENSOR AND FRAME ANGLE SENSOR
TESTING AND ADJUSTING STEERING LEVER ANGLE 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.
4. Slide left armrest (3) to the storage position (rear

end).
a At this position, the console switch for testing
is turned on.
5. Set steering lock lever (1) in the free position

and check that the caution buzzer sounds.
a If the system is normal, the caution buzzer
makes pips 1 second after the steering lock
lever is operated.
WA800L-3 20-119
(1)
TESTING AND ADJUSTING TESTING WHEEL BRAKE PERFORMANCE
TESTING WHEEL BRAKE PERFORMANCE
a Test the performance of the wheel brake under

the following conditions.
• Road surface: Flat, horizontal, dry paved
surface.
• Travel speed: 20 km/h when brakes are ap-
plied
• Tire inflation pressure: Specified pressure
(235.4 kPa {2.4 kg/cm2})
• Operating effort of pedal: 373 N {38 kg}
• Operation delay time: 0.1 sec.
1. Start the engine, operate the directional lever to

F and the speed lever to 3rd, and drive the
machine.
2. Maintain the travel speed at 20 km/h, and

depress the brake pedal with the specified oper-
ating force.
a Before carrying out this operation, determine
the run-up path and the point for applying the
brakes, then travel at 20 km/h and apply the
brakes when the machine reaches the brak-
ing point.
a Switch the transmission cut-off switch ON
when carrying out this operation.
3. Measure the distance from the point where the

brakes were applied to the point where the
machine stopped.
a Repeat this measurement three times and
take the average.
20-120 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.
1. Remove the brake hose cover (1).
2. Remove hose (2) and nipple (3) from the brake

system to be measured.
k If the brake pedal is depressed when the
hose is disconnected, high-pressure oil will
spurt out. Never depress the brake pedal in
this condition.
5. Operate the pump to raise the oil pressure to the

specified pressure, then close the stop valve.
a Specified oil pressure:
4.2 – 5.2 MPa {43 – 53 kg/cm2}
6. Leave in this condition for 5 minutes, then check

the drop in pressure over the next 5 minutes.
a If the hose is moved during the inspection,
the pressure will change, so be careful not to
move the hose.
a After completion of the inspection, operate
the pump to release the oil pressure, then re-
move the brake tester kit.
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.
1. Remove plug (1).
2. Depress the brake pedal fully to the end of its

stroke.
3. Measure depth a from the end face of the hous-

ing to the spring guide by using caliper gauge P.
a Keep the brake pedal depressed while
measuring.
Wear limit: a = 46.3 mm

(Reference: When machine is new, a = 40.7
± 1.4 mm)
a When the disc is near the wear limit, carry

out inspection frequently, regardless of the
maintenance interval.
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.
1. Remove the brake oil tank side cover (on the

front side of the machine body).
2. Disconnect hose (PP port) (2) from accumulator

charge valve (1) on the accumulator distribution
tube (3) side.
4. Measure the accumulator charge cut-in pres-

sure.
Start the engine, run the engine at engine slow,
and measure the oil pressure when the brake oil
pressure warning pilot lamp on the maintenance
monitor goes out and buzzer stops.
5. Measure the accumulator charge cut-out pres-

sure.
After the accumulator charge cut-in is actuated,
measure the oil pressure when the indicator of
the oil pressure gauge rises and becomes going
down.
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.
Loosen locknut (5) of cut-out valve (4) and adjust

cut-out pressure with the adjustment screw (6) as
follows.
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
3 Locknut: 9.8 – 11.8 Nm {1.0 – 1.2 kgm}

screw: 5.59 MPa {57 kg/cm2}
a After adjustment, check again the cut-in and cut-

out pressure according to the procedure men-
tioned in the previous page.
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".
slack adjuster because drive shift is rotating.
1. Start the engine and accumulate the pressure in

the accumulator (about 30 seconds at the high
idling speed).
2. Stop the engine and insert either end of vinyl

hoses [1] in bleeders (2) of slack adjuster (1),
then insert the other end in the container.
3. Depress the brake pedal, loosen the bleeder

screw, and bleed the air. Tighten the screw,
then release the brake pedal slowly.
a Carry out this operation with two workers:
one worker depresses the brake pedal, and
the other worker bleeds the air from the
bleeder screw.
a Use L.H. brake pedal.
a If brake oil level goes down, refill oil to keep
full.
4. Repeat this operation until no more bubbles

come out with the fluid from the vinyl hose, then
depress the pedal fully and tighten the bleeder
screw while the oil is flowing out.
20-126 WA800L-3
(1)
TESTING AND ADJUSTING TESTING PARKING BRAKE PERFORMANCE
TESTING PARKING BRAKE

PERFORMANCE
a Measurement condition
• Tire inflation pressure: Specified pressure
• Road surface: Flat, dry, paved surface with 1/5
(11°20’) gradient.
• Machine: In operating condition
1. Start the engine and drive the machine straight

up a 1/5 gradient with the bucket unloaded.
2. Depress the brake, place the joystick lever in

neutral, then stop the engine.
3. Turn the parking brake switch ON, then slowly

release the brake pedal and keep the machine
must be kept stopped.
a The measurement must be made with the
machine facing either up or down the slope.
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.
1. Turn starting switch ON, then parking brake

switch OFF to release brake.
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.
k After measuring parking brake oil pressure, de-

press the brake pedal at least 100 times with the
engine stopped to release the pressure inside
the accumulator circuit, and remove measuring
tools after turning parking brake switch OFF.
4. Connect nipple C2 and oil pressure gauge C1

(39.2 MPa {400 kg/cm2}).
20-128 WA800L-3
(1)
TESTING AND ADJUSTING CHECKING AND ADJUSTING PARKING BRAKE PAD
CHECKING AND ADJUSTING ADJUSTING

a If the measured value is not within the standard
PARKING BRAKE PAD value, adjust as follows.
k Block the tires securely.
1. Turn the starting switch ON, then turn the park-
ing brake switch OFF to release the brake.
MEASURING a If the main switch is turned OFF, so be care-
1. Turn the starting switch ON, and turn the parking ful the parking brake will be actuated.
brake switch (1) OFF to release the brake. 2. Turn adjustment screws (3) and (4) of parking
brake slack adjuster until parking brake pad (2)
2. Measure the thickness of the parking brake pad. is lightly in contact with disc (1).
Measure the thickness of the parking brake pad a If the adjustment bolt is tightened too much
with thickness gauge F.
k When the starting switch is turned OFF, the
and parking brake pad (2) and disc (1) are
brought strongly into contact, it may cause
parking brake is applied, so be careful not to the brake to squeak or the discs to overheat.
turn it OFF. a Turn adjustment screw (3) counterclockwise
a Measure 4 pads. and adjustment screw (4) clockwise.
a If the thickness is not within the standard val-
ue, replace the 2 parking brake pads as one
set.
a For details of removing the parking brake
pad, see "DISASSEMBLY AND ASSEM-
BLY".
3. Measure the parking brake pad clearance.

Insert thickness gauge F between disc (1) and
pad (2), then measure the clearances.
a The clearance value mentioned above indi-
cates the total value of both sides. (a + b)
k Note that the parking brake is actuated if the
starting switch is turned OFF.
WA800L-3 20-129
(1)
TESTING AND ADJUSTING CHECKING AND ADJUSTING PARKING BRAKE PAD
3. Return adjustment screws (3) and (4) 180° ± 30°

(three notch) counterclockwise.
a Return adjustment screw (3) clockwise and
adjustment screw (4) counterclockwise.
a This will adjust the total clearance (a + b) on
the left and right between pad (2) and disc
(1) to 1.06 ± 0.18 mm.
a After adjusting, measure the brake performance

again and check that it is within the standard val-
ue.
20-130 WA800L-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING PPC PRESSURE
TESTING AND ADJUSTING 2. Measuring PPC valve output pressure

1) Remove work equipment valve cover.
PPC PRESSURE 2) Remove plug (PT 1/8) (2) for bucket DUMP
circuit oil pressure measuring, and install
a Hydraulic oil temperature: 45 – 55°C
nipple C2 and oil pressure gauge C1 (5.9
MPa {60 kg/cm2}).
pressure inside the hydraulic tank.
k Operate the control levers 2 – 3 times to release
the pressure in the PPC accumulator circuit.
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.
2) Install nipple C2 and oil pressure gauge C1

(5.9 MPa {60 kg/cm2}).
3) Start the engine and raise the boom. Dump

the bucket with the engine at the full speed
and measure the hydraulic pressure when
the relief valve operates.
3) Start engine and measure oil pressure with

the engine full throttle.
WA800L-3 20-131
(1)
TESTING AND ADJUSTING PPC PRESSURE
TESTING AND ADJUSTING ADJUSTING PPC VALVE LINKAGE
ADJUSTING ADJUSTING PPC VALVE

1. Adjusting PPC relief valve
k Adjust the hydraulic pressure while the engine is
LINKAGE
stopped.
k Gradually loosen the oil filler cap of the hydraulic
1. Remove cover at the bottom of the work equip-
ment control lever.
tank to release the pressure from the tank.
k Operate the work equipment control lever two –
2. Adjust dimension a from nut (1) of the PPC
three times to release the pressure from the ac-
valve linkage to the top surface of the floor.
cumulator circuit for PPC.
• Dimension a (target value): 54 mm
1) Remove the upper cover of the transmis-
sion.
3. Loosen nuts (2) and (3), then adjust the installed
2) Remove cap nut (3) of the PPC relief valve
height of trunnion (5) so that there is no play in
beside the accumulator charge valve for
lever (4).
PPC.
4. After adjusting, tighten nuts (2) and (3).
3) Loosen locknut (4) and adjust with the

adjustment screw (5).
a Adjustment screw
• To INCREASE, turn CLOCKWISE
• To DECREASE, turn COUNTERCLOCK-
WISE
a Pressure adjustment for one turn of adjust-
ment screw: 0.96 MPa {9.8 kg/cm2}
20-132 WA800L-3
(1)
TESTING AND ADJUSTING TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE

WORK EQUIPMENT
HYDRAULIC PRESSURE
a Hydraulic oil temperature: 45 – 55°C
pressure inside the hydraulic tank.
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.
3. Remove plug (PT 1/8) (1) for bucket DUMP cir-

cuit hydraulic pressure measuring, and install
nipple C2 and oil pressure gauge C1 (39.2 MPa
{40 kg/cm2}).
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.
1. Check that the hydraulic tank is filled with

hydraulic oil.
a The cap of the hydraulic tank remains re-
moving, until the air bleeding of the piston
pump finishes.
2. Loosen plugs (1), (2) and (3) of piston pump

suction tube.
3. When oil overflows from plugs (1), (2) and (3) in

turn, and tighten plugs under air is bled com-
pletely. After that, in order to fill the inside of the
pump with the hydraulic oil, leave it for 10 min-
utes.
a Since the oil level in the hydraulic tank is higher

than positions (1), (2) and (3) above, air is bled
easily.
WA800L-3 20-135
(1)
TESTING AND ADJUSTING BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT
BLEEDING AIR FROM WORK

EQUIPMENT CIRCUIT
a Bleed the air from the circuit as follows if the work
equipment control valve or work equipment cylin-
ders have been removed and installed again.
1. Start the engine and run at idling for approx. 5

minutes.
2. Run the engine at engine slow and raise and

lower the boom 4 – 5 times in turn.
a Operate the piston rod to approx. 100 mm
before the end of its stroke. Be careful not to
relieve the circuit.
3. Repeat Step 2 with the engine at full throttle.
4. Run the engine at engine slow and operate the

piston to the end of its stroke to relieve the cir-
cuit.
5. Repeat Steps 2 to 3 for the bucket cylinder also.
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.
k Carry out the adjustment with the engine

stopped.
a Check if the operating effort of the work equip-
ment lever is within the standard value.
1. Remove the side cover from the work equipment

control lever.
2. Operate boom lever (1) and adjust rod (4) so

that boom lever cam follower (2) enters the
detent portion at both ends of cam (3) uniformly
and clearance a is 0 – 1 mm.
a Distance b between pins on both ends of rod
(4): 337 mm (for reference)
3. Operate bucket lever (5) and adjust rod (8) so

that bucket lever cam follower (6) enters the
detent portion of cam (7) uniformly and clear-
ance c is 0 – 1 mm. 4. Do as follows to set boom kickout solenoid (9)
a Distance b between pins on both ends of rod and bucket positioner solenoid (10) at the pulled
(8): 337 mm (for reference) (electricity flowing) condition.
1) Disconnect wiring connectors (F05) (11) and
(F06) (12).
a F05 (11): Proximity switch for bucket po-
sitioner
F06 (12): Proximity switch for boom
kickout
2) Connect T-adapter and short circuit
between terminals (1) and (2).
a Check that the solenoid is pulled in full
stroke 12 mm.
WA800L-3 20-137
(1)
ADJUSTING WORK EQUIPMENT LEVER LINKAGE
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
5. Set with boom kickout solenoid (9) pulled, then

move to adjust the solenoid so that clearance d
RELEASING REMAINING
between boom lever cam (3) and cam follower PRESSURE IN HYDRAULIC
(2) is 0 – 0.5 mm. CIRCUIT
a When adjusting, hold boom lever at HOLD.
1. Releasing remaining pressure between each
6. Set with bucket positioner solenoid (10) pulled, hydraulic cylinder and control valve
then move to adjust the solenoid so that clear- a If the piping between the hydraulic cylinder
ance e between bucket lever cam (7) and cam and the control valve is to be disconnected,
follower (6) is 0 – 0.5 mm. release the remaining pressure from the cir-
a When adjusting, hold bucket lever at HOLD. cuit as follows.
1) Stop the engine.
2) Loosen the oil filler cap slowly to release the
pressure inside the tank.
3) Operate the control levers.
a When the levers are operated 2 – 3
times, the pressure stored in the PPC
accumulator is removed. Start the en-
gine, run at low idling for approx. 5 min-
utes, then stop the engine and operate
the control levers.
a Repeat the above operation 2 – 3 times
to release all the remaining pressure.
2. Releasing remaining pressure in brake accu-

7. If the operating effort for releasing the boom mulator circuit
lever is not 19.6 N (2 kg} and the operating effort a If the piping between the accumulator and
for releasing the bucket lever is not 9.8 N {1 kg}, accumulator check valve, and between the
change the position of the mounting holes (4 accumulator and brake valve is to be discon-
places) of spring (13) to adjust the release effort. nected, release the remaining pressure from
a When the machine is shipped from the facto- the circuit as follows.
ry, the spring is hooked to the 2nd mounting 1) Stop the engine.
hole from the top. 2) Depress the brake pedal at least 100 times
to release the pressure inside the brake
accumulator circuit.
3. Releasing remaining pressure PPC accumu-

lator circuit
a If the piping between the PPC accumulator
and PPC valve is to be disconnected, re-
lease the remaining pressure from the circuit
as follows.
• Operate the control lever 2 – 3 times to re-
lease all the remaining pressure.
8. After the adjustment, operate the bucket control

lever and boom control lever to check that those
levers are held at the TILT, DUMP, RAISE and
FLOAT positions.
20-138 WA800L-3
(1)
TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM PROXIMITY SWITCH
TESTING AND ADJUSTING TESTING AND ADJUSTING

BUCKET PROXIMITY SWITCH BOOM PROXIMITY SWITCH
TESTING TESTING
1. With the engine stopped, check that the clear- 1. With the engine stopped, check that the clear-
ance between switch (1) and angle (2) is within ance a between switch (1) and plate (2) is within
the standard value. the standard value.
2. Start the engine, run at high idling and check the

actuating position. (Measure three times and
take the average.)
ADJUSTING
1. Raise the boom to the desired position, stop the
engine, then lock the control lever.
2. Loosen mounting bolt (3), then adjust and fix the

plate so that the clearance b between center of
proximity switch (1) and end of plate (2) is within
the standard value.
2. Start the engine, run at high idling and check the
actuating position. (Measure three times and 3. Adjust and fix nut (4) of proximity switch (1) so
take the average.) that the clearance a between the proximity switch
(1) sensing surface and plate (2) is 3 – 5 mm.
3 Mounting nut of proximity switch:

• Standard clearance a : 3 – 5 mm
ADJUSTING
1. Lower the bucket to the ground and operate the 14.7 – 19.6 Nm {1.5 – 2.0 kgm}
bucket to the desired digging angle. Return the a After adjusting, operate the boom lever and
lever to the hold position and stop the engine. check that the boom is actuated at the de-
sired position.
2. Fix support (3) to the bucket cylinder bracket so
that the tip of angle (2) align the center of the
proximity switch (1).
3. Adjust and fix nut (4) of switch so that the clear-

ance a between the proximity switch sensing
surface and the angle is within the standard
value.
3 Mounting nut of proximity switch:

• Standard clearance a : 3 – 5 mm
14.7 ± 19.6 Nm {1.5 ± 2.0 kgm}

a After adjusting, operate the bucket lever and
check that the buckrt is actuated at the de-
sired position.
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
ADJUSTING SPEEDOMETER 3) After completing adjustment, fit the rubber

caps securely and install the main monitor.
MODULE OF MAIN MONITOR
Correction amount of switch 2 (for reference)
• The speedometer on the main monitor is a com-
mon part for all machines, and the input signal for Switch position 0 1 2 3 4 5 6 7
the travel speed differs according to the ma- Correction
chine, so it is necessary to adjust the monitor for +14 +12 +10 +8 +6 +4 +2 0
amount (%)
use with the particular model.
Switch position 8 9 A B C D E F
ADJUSTMENT PROCEDURE
• Turn off the power, then remove the machine Correction
0 –2 –4 –6 –8 –10 –12 –14
amount (%)
monitor and adjust the switches at the back of
the speedometer.
a DIP switch 4 is set as shown in the figure at right
1. Setting machine model when delivered. If it is changed, the machine will
1) Remove the rubber caps from dipswitches not function normally. Accordingly, do not
1, 2 and 3 at the back of the speedometer. change it. When the main monitor is replaced,
check the setting of DIP switch 4.
DIP switch 4
Specification
1 2 3 4
Without auto shift system ON ON OFF ON
With auto shift system ON ON OFF OFF
2) When the rubber cap is removed, a rotary

switch can be seen inside. Using a flat-
headed screwdriver, turn this switch to
adjust it to the settings in the table below.
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
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
POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 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
SEQUENCE OF EVENTS IN TROUBLESHOOTING
WA800L-3 20-203
(1)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on “Handling electric equipment“ and “Handling hydraulic
equipment” (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-204 WA800L-3
(1)
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.
4) High-pressure water entering connector

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

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
a When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before
cleaning with compressed air.
WA800L-3 20-205
(1)
2) Removing, installing, and drying connectors

and wiring harnesses
• 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.
2) When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
a If the connector is twisted up and down
or to the left or right, the housing may
break.
3) Action to take after removing connectors

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
a If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 WA800L-3
(1)
• 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.
2) Fix the connector securely.

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

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

be sure to return it to its original position.
Check also that there are no loose clamps.
• Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
WA800L-3 20-207
(1)
• Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

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

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

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
a After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 WA800L-3
(1)
3) Handling control box

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

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

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

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
a If there is any change, there is probably defective contact in that circuit.
WA800L-3 20-209
(1)
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of

hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
necessary to be particularly careful.
1) Be careful of the operating environment.

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

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-210 WA800L-3
(1)
5) Change hydraulic oil when the temperature

is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
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
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Remedy
standard
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil,
cooling water
3. Check hydraulic oil level — Add oil

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

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

19. Check for discolored, burnt, exposed wiring — Replace
20. Check for missing wiring clamps, hanging wiring — Repair
21. Check for water leaking on wiring (be particularly careful attention to — Disconnect
water leaking on connectors or terminals) — connector and dry
22. Check for blown, corroded fuses — Replace
23. Check alternator voltage (engine running at 1/2 throttle or above) —
(If the battery charge is low, the voltage may be approx. 25 V immedi- 28.5– 29.5 V Replace
ately after starting.)
24. Sound of actuation of battery relay — —
(when starting switch is turned ON, OFF)
20-212 WA800L-3
(1)
TROUBLESHOOTING TYPES AND LOCATIONS OF CONNECTORS
TYPES AND LOCATIONS OF CONNECTORS

a The addresses in the following table refer to approximate locations in the connector arrangement drawing.
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)
Connector No. of
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)
Connector No. of
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
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
WA800L-3 20-215
(1)
Connector No. of
No. pins
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
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)
Connector No. of
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) —
OP4 One-pin connector 1 Intermediate connector —
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)
Connector No. of
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
CONNECTOR LOCATION STEREOGRAM
20-220 WA800L-3
(1)
WA800L-3 20-221
(1)
20-222 WA800L-3
(1)
WA800L-3 20-223
(1)
20-224 WA800L-3
(1)
WA800L-3 20-225
(1)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
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
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

Terminal part No.: 79A-222-3370 Terminal part No.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty : 20
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-226 WA800L-3
(1)
SWP type connector

No.of
pins T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
WA800L-3 20-227
(1)
SWP type connector

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

Terminal part No.: Terminal part No.:
— —
• Grommet: Black • Grommet: Black
• Q’ty: 20 • Q’ty: 20
Terminal part No.: Terminal part No.:
— —
• Grommet: Red • Grommet: Red
• Q’ty: 20 • Q’ty: 20
20-228 WA800L-3
(1)
M type connector
No.of
pins T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
WA800L-3 20-229
(1)
S type connector
No.of
pins T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(White)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(White)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(White)
Part No.: 08056-11671 Part No.: 08056-11681
20-230 WA800L-3
(1)
S type connector
No.of
pins T-adapter
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(Blue)
Part No.: 08056-11672 Part No.: 08056-11682
WA800L-3 20-231
(1)
MIC type connector

No.of
pins T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
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
13 799-601-2720
20-232 WA800L-3
(1)
MIC type connector

No.of
pins T-adapter Part
No.
17 799-601-2730
21 799-601-2740
—
(Q’ty: 50) (Q’ty: 50)
WA800L-3 20-233
(1)
AMP040 type connector

No.of
pins T-adapter Part
No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
16 799-601-7210
20 799-601-7220
a Terminal part No.: 79A-222-3470 (No relation with number of pins)
20-234 WA800L-3
(1)
AMP070 type connector

No.of
pins T-adapter Part
No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
WA800L-3 20-235
(1)
L type connector
No.of
pins T-adapter Part
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
No.
10 799-601-3460
— —
20-236 WA800L-3
(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —
08027-10420 (Black) 08027-10470 (Black)
6 —
08027-10620 (Black) 08027-10670 (Black)
WA800L-3 20-237
(1)
KES 1 (Automobile) connector

No.of
pins T-adapter Part
No.
8 —
08027-10820 (Black) 08027-10870 (Black)
Connector for relay (Socket type)

No.of
pins T-adapter Part
No.
5 799-601-7360
— —
6 799-601-7370
— —
20-238 WA800L-3
(1)
F type connector
No.of
pins T-adapter Part
No.
8 —
— —
WA800L-3 20-239
(1)
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)
[The pin No. is also marked on the connector (electric wire insertion end)]
Type HD30 Series connector

(shell
size T-adapter
Body (plug) Body (receptacle)
code) Part No.
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

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

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

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

08191-22205, 08191-22206 08191-23105, 08191-23106
WA800L-3 20-241
(1)

(shell
size T-adapter
code) Part No.
799-601-9230
18-20 Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102

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

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

799-601-9240
Part No.:08191-42201, 08191-42202 Part No.:08191-43101, 08191-43102
20-242 WA800L-3
(1)

(shell
size T-adapter
code) Part No.
799-601-9250
24-9 Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102

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

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

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
WA800L-3 20-243
(1)

(shell
size T-adapter
code) Part No.
799-601-9270
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
799-601-9280
Part No.: 08191-81201, 08191-81202 Part No.: 08191-84101, 08191-84102

08191-81203, 08191-81204 08191-84103, 08191-84104
24-22 08191-81205, 08191-80206 08191-84105, 08191-84106
799-601-9280
Part No.: 08191-82201, 08191-82202 Part No.: 08191-83101, 08191-83102

08191-82203, 08191-82204 08191-83103, 08191-83104
08191-82205, 08191-82206 08191-83105, 08191-83106
20-244 WA800L-3
(1)

(shell
size T-adapter
code) Part No.
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
WA800L-3 20-245
(1)
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
4 799-601-9040
6 799-601-9050
20-246 WA800L-3
(1)
No.of DT Series connector

pins Body (plug) Body (receptacle) T-adapter Part No.
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
WA800L-3 20-247
(1)
DTM Series connector

No.of
pins T-adapter Part
No.
799-601-9010
2
Part No.: 08192-02200 Part No.: 08192-02100
DTHD Series connector

No.of
pins T-adapter Part
No.
1 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
20-248 WA800L-3
(1)
Deutch connector
No.of
pins T-adapter
Receptacle Plug
Part No.
2 —
— —
WA800L-3 20-249
(1)
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
T-BRANCH BOX AND T-BRANCH TABLE

a The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Ass'y.
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
799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P
799-601-3200 Measurement box MS-37P
799-601-3300 Measurement box Econo-24P
799-601-3360 Plate For MS box
799-601-3410 BENDIX (MS) 24P
799-601-3420 BENDIX (MS) 24P
799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P
799-601-3450 BENDIX (MS) 5P
799-601-3460 BENDIX (MS) 10P
799-601-3510 BENDIX (MS) 5P
799-601-3520 BENDIX (MS) 14P
799-601-3530 BENDIX (MS) 19P
799-601-2910 BENDIX (MS) 14P
799-601-3470 Case
799-601-2710 MIC 5P
799-601-2720 MIC 13P
799-601-2730 MIC 17P
799-601-2740 MIC 21P
799-601-2950 MIC 9P
799-601-2750 ECONO 2P
799-601-2760 ECONO 3P
799-601-2770 ECONO 4P
799-601-2780 ECONO 8P
799-601-2790 ECONO 12P
799-601-2810 DLI 8P
799-601-2820 DLI 12P
799-601-2830 DLI 16P
799-601-2840 Additional cable
799-601-2850 Case
799-601-7010 X 1P
799-601-7020 X 2P
799-601-7030 X 3P
799-601-7040 X 4P
799-601-7050 SWP 6P
799-601-7060 SWP 8P
799-601-7310 SWP 12P
799-601-7070 SWP 14P
799-601-7320 SWP 16P
799-601-7080 M 1P
799-601-7090 M 2P
799-601-7110 M 3P
799-601-7120 M 4P
799-601-7130 M 6P
799-601-7340 M 8P
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
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM

TRANSMISSION CONTROL SYSTEM
20-254 WA800L-3
(1)
MAIN MONITOR SYSTEM
WA800L-3 20-255
(1)
MAINTENANCE MONITOR SYSTEM
20-256 WA800L-3
(1)
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.)
2. Display of failure action code

This code informs the operator directly of the
abnormality, and takes action, such as stopping
the machine immediately.
There are three types of action code: E00, E01
+ CALL (E01 and CALL are displayed alter-
nately), and CALL. If a failure occurs suddenly,
one of these codes is shown on the speedome-
ter display.
3. Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible
to tell from this code which system in which con-
troller has failed, so carry out troubleshooting for
the applicable controller.
4. Saving failure code

The transmission and joystick steering controller
writes the failure codes to memory.
1) A total of 9 failure codes can be saved in
memory.
2) The data that is saved to memory is as fol-
lows: (1)Failure code
(2)Time elapsed since failure
(up to 1000 hours)
3) The failures are saved in the order that they
occur. If a failure code already exists in the
memory, the repeat failure code is not
saved.
4) If there are already 9 items in memory, and
a 10th failure occurs, the oldest item is
deleted and the new item is saved.
a It is possible to display the failure code and
time elapsed since failure for items saved in
memory by operating the main monitor set
switch.
20-258 WA800L-3
(1)
TROUBLESHOOTING METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE
5. Switch operation procedure and actuation
Switch operation Actuation
Trouble data memory

mode display
1) Stop engine. • The failure code is dis-
2) Turn starting switch ON. played on the speedom-
3) Push operation mode eter display and the
switch (1) and head time elapsed since fail-
lamp switch (2) simulta- ure is displayed on the
neously and keep action code display.
pressed for at least 5 • If there is no failure, the
seconds. speedometer display
shows [CC] and the
action code display
shows [0000].
Going to nest failure
code
4) Press head lamp switch • The failure code and
(2). time elapsed since fail-
ure are displayed in turn
(when this is done, the
failure code for the lat-
est failure is displayed
first).
• If the failure still exists,
the display flashes; if
the failure has been
restored, the display
lights up.
Clearing failure code
5) Keep rear lamp switch • The failure code and
(3) pressed for at least elapsed time on the dis-
2 seconds. play are cleared.
• If the failure still exists,
the failure code is not
cleared.
Quitting trouble data
memory display mode
6) Push operation mode • The display returns to
switch (1) and head the normal display.
lamp switch (2) simulta-
neously and keep
pressed for at least 5
seconds. Or start the
engine.
WA800L-3 20-259
(1)
TROUBLESHOOTING CHART OF ACTION CODES AND FAILURE CODES, AND RE-ENACTION
CHART OF ACTION CODES AND FAILURE CODES, AND

RE-ENACTION
1. Transmission control system codes table
Failed system Re-enaction
Action Failure Caution
Item Short Discon- Short Discon- Saving
code code buzzer
circuit nection circuit nection
— 10 Backup lamp relay Q Q t a Q ×
12 F solenoid Q Q t a Q Q
13 R solenoid Q Q t a Q Q
14 1st solenoid Q Q t a Q Q
CALL
15 2nd solenoid Q Q t a Q Q
16 3rd solenoid Q Q t a Q Q
20 Joystick forward-reverse switch Q Q a a Q Q
— 21 Joystick shift-up/down switch Q Q a a Q Q
22 Speed sensor × Q × a Q Q
E00
23 Engine speed sensor × Q × a Q ×
• 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.
2. AJSS (Advanced Joystick Steering System) control system codes table

Failed system Re-enaction
Action Failure Caution
Item Short Discon- Short Discon- Saving
code code buzzer
circuit nection circuit nection
— 56 Caution buzzer relay output Q × a t Q ×
57 Steering lever angle sensor Q Q a a Q Q
Shifting of steering lever angle
58 Q Q a a Q Q
sensor or frame angle sensor
59 Frame angle sensor Q Q a a Q Q
E00
60 Steering lock pressure switch Q Q a t Q Q
62 Steering neutral interlock relay Q Q a a Q Q
Steering basic pressure control EPC
63 Q Q a a Q Q
solenoid
• 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
3. Action code table
Transmission AJSS (Advanced Joystick steering system)

Action control system control system Action Action by
code buzzer operator
Problem system Action of machine Problem system Action of machine
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)
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
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.
1st, 2nd, 3rd

solenoid system Become neutral
disconnection, and cannot travel — —
short circuit with (Output off)
GND, short circuit
WA800L-3 20-261
(1)
TROUBLESHOOTING TRANSMISSION CONTROLLER LED DISPLAY
TRANSMISSION CONTROLLER LED DISPLAY

The transmission controller uses two 7-segment LEDs to display the internal condition of the controller and
input/output errors. The display shows two characters at the same time, and changes these in turn to give the
display.
a When the engine is started, “Program part No. display mode” appears, follwed by “Output speed range dis-
play mode”. If there is any abnormality in the controller, it changes to “Troubleshooting mode”.
a The failure mode is saved to memory by the main monitor.
Table 1 (Output speed range display mode)

Display Content Display Content
0. 1° Neutral, 1st F. 3° FORWARD, 3rd
0. 2° Neutral, 2nd A. 1° REVERSE, 1st
0. 3° Neutral, 3rd A. 2° REVERSE, 2nd
F. 1° FORWARD, 1st Neutral safety condition or
E. 0°
F. 2° FORWARD, 2nd abnormality in selection signal
20-262 WA800L-3
(1)
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in the
electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used to
decide which troubleshooting table
(E–QQ, H–QQ, etc.) matches the symptoms.
The judgement table is designed so that it is easy to determine from the self-diagnostic display which trouble-
shooting table to go to.
a The abnormality display given by the monitor panel leads directly to troubleshooting of the monitor system
(M–QQ, K–QQ).
(See troubleshooting of the machine monitor system)
[Method of using judgement table]

• A Q mark is put at the places where the failure mode and self-diagnostic display match, so check if an error
code is displayed on the graphic display portion of the monitor panel.
• If an error code is displayed:
Go to the troubleshooting code at the bottom of the judgement table (E–QQ, etc.).
• If there is a problem but no error code is displayed:
Go to the troubleshooting code on the right of the judgement table (H–QQ).
• For failure modes where no Q mark is given, go directly to the troubleshooting code on the right of the
judgement table.
WA800L-3 20-263
(1)
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component
S–QQ Troubleshooting of engine system
T–QQ Troubleshooting of transmission control system
M–QQ Troubleshooting of main monitor system
K–QQ Troubleshooting of maintenance monitor system
E–QQ Troubleshooting of electrical systems
H–QQ Troubleshooting of hydraulic, mechanical system
A–QQ Troubleshooting of AJSS (Advanced Joystick Steering System) control system
2. Method of using troubleshooting table

(1) Troubleshooting code number and problem
The top left of the troubleshooting chart gives the troubleshooting code number and the problem with
the machine.
(2) General precautions
When using the troubleshooting chart, precautions that apply to all items are given at the top of the
page and marked with a.
The precautions marked a are not given in the , but must always be followed when carrying out the
check inside the .
(3) Distinguishing conditions
Even with the same problem, the method of troubleshooting may differ according to the model, compo-
nent, or problem. In such cases, the troubleshooting chart is further divided into sections marked with
small letters (for example, a), b)), so go to the appropriate section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check item.
(4) Method of following troubleshooting chart
YES
• Check or measure the item inside NO
, and according to the answer follow either the YES line or the
NO line to go to the next . (Note: The number written at the top right corner of the is an index
number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead finally to
the Cause column. Check the cause and take the action given in the Remedy column on the right.
• Below the there are the methods for inspection or measurement, and the judgement values. If the
judgement values below the are correct or the answer to the question inside the is YES, follow
the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and the judgement
values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is
danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before
starting inspection or measurement, always read the instructions carefully, and start the work in order
from Item 1).
(5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
(6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin number con-
nection. When carrying out troubleshooting, see this chart for details of the connector pin number and
location for inspection and measurement of the wiring connector number appearing in the troubleshoot-
ing flow chart.
20-264 WA800L-3
(1)
<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.
Cause Remedy
1 YES
Is voltage
between L06 (15)
20 – 30 V. (female) (1)
• Turn R.H. turn signal ON.
M-5 Related electrical circuit diagram
WA800L-3 20-265
(1)
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES
METHOD OF USING MATRIX TROUBLESHOOTING TABLES

The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the
causes of failures in the machine. The troubleshooting tables are divided broadly into categories for the main
components, such as the steering system and work equipment hydraulic system. Follow the procedure given
below and carry out troubleshooting to locate the problems accurately and swiftly.
Step 1. Questioning the operator 1. Steering does not work i Symptom [Example]
The questions to ask the operator are given 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.
Step 2. Checks before troubleshooting 2. Checks before starting [Example]

Before starting the main troubleshooting and mea-
suring the hydraulic pressure, first check the Checks • Is the oil level in the hydraulic tank correct?
before Starting items, and check for oil leakage and Is the type of oil correct?
loose bolts. These checks may avoid time wasted • Is there any leakage of oil from the steering
valve or Orbit-roll?
on unnecessary troubleshooting.
• Has the safety bar been removed from the
The items given under Checks before Starting are
frame?
items which must be considered particularly for that
symptom before starting troubleshooting.
Step 3. Using cross-reference table [Example 1]

1) Operate the machine to carry out the checks in
No. Remedy
the troubleshooting item column. Problems
Mark the items where the results match the 1 Steering does not work to the left or right.
symptom.
Same as Item 1, but abnormality in actuation of
a It is not necessary to follow the troubleshoot- 2
work equipment.
ing checks in order; follow an order which is
easiest to carry out troubleshooting. 3 Steering can lnly be operated to one side.
4 Steering wheel is heavy and cannot be turned.
2) Find the appropriate cause from the cause col- [Example 2]

umn. If the symptom appears, the Q marks on
that line indicate the possible causes. (For item
No. 2 in the table on the right, the possible
causes are c or e.)
If there is only one Q:
Carry out the other troubleshooting items (where
the same cause is marked with Q), check if the
symptom appears, then repair.
If there are two Q:
Go on to Step 3) to narrow down the possible
causes.
20-266 WA800L-3
(1)
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES
3) Operate the machine and check the trouble-

shooting items other than those in 1).
Operate the machine and check the items in the
same way as in 1), and if the symptom appears,
mark that item. (In the chart on the right, the
symptom appears again for item 5).
4) Find the appropriate cause from the cause col-

umn. In the same way as in Step 2), if the symp-
tom appears, the Q marks on that line indicate
the possible causes. (For item No. 5 in the table
on the right, the possible causes are b or e.)
5) Narrow down the possible causes.

There is one common cause among the causes
located in Steps 2) and 4). (One cause marked
Q appears on the line for both items.) This
cause is common to both the symptoms in trou-
bleshooting Steps 1) and 3).
a The causes which are not common to both
troubleshooting items (items which are not
marked Q for both symptoms) are unlikely
causes, so ignore them.
(In the example given on the right, the
causes for Troubleshooting Item 2 are c or
e, and the cause for Troubleshooting Item 5
are b or e, so cause e is common to both.)
6) Repeat the operations in Steps 3), 4) and 5)

until one cause (one common cause) remains.
a If the causes cannot be narrowed down to
one cause, narrow the causes down as far
as possible.
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)
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)
METHOD OF USING TROUBLESHOOTING CHARTS

Using troubleshooting chart for engine-
related failure
This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshooting.
The questions and check items are used to pinpoint
high probability causes that can be located from the
failure symptoms or simple inspeciton without using
troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[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)
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high proba-
bility are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
1. For [Confirm recent repair history] in the
[Questions] Section, ask the user, and mark
the Cause column with E to use as refer-
ence for locating the cause of the failure.
However, do not use this when making cal-
culations to narrow down the causes.
2. Use the E in the Cause column as refer-
ence for [Degree of use (Operated for long
period)] in the [Questions] section as refer-
ence.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if necessary to determine the order
for troubleshooting.
WA800L-3 20-303
(1)
• Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became
weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is black
• Insufficient intake of air
• Improper condition of fuel injection
• Excessive injection of fuel
20-304 WA800L-3
(1)
WA800L-3 20-305
(1)
TROUBLESHOOTING S-1
S-1 Starting performance is poor (Starting always takes time)
General causes why starting performance is poor

• Defective electrical system
• Insufficient supply of fuel
• Improper selection of fuel
(At ambient temperature of –10°C [–14°F] or below, use ASTM D975
No. 1, and –10°C [–14°F] or above, use ASTM D975 No. 2 diesel fuel.)
a Battery charging rate
Charging rate
Ambient 100% 90% 80% 75% 70%
temperature
20°C [–68°F] 1.28 1.26 1.24 1.23 1.22
0°C [–32°F] 1.29 1.27 1.25 1.24 1.23
–10°C [–14°F] 1.30 1.28 1.26 1.25 1.24
• The specific gravity should exceed the value

for the charging rate of 70% in the above table.
• In cold weather the specific gravity must exceed
the value for the charging rate of 75% in the above table.
20-306 WA800L-3
(1)
TROUBLESHOOTING S-2
S-2 Engine does not start
(1) Engine does not turn
General causes why engine does not turn

• Internal parts of engine seized
a If internal parts of the engine are
seized, carry out troubleshooting
for “Engine stops during opera-
tions”.
• Failure in power train
• Defective electrical system
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
ASTM D975 No.2

Diesel oil
ASTM D975A
No.1
20-308 WA800L-3
(1)
TROUBLESHOOTING S-2
(3) Exhaust gas comes out but engine does not start
(Fuel is being injected)
General causes why exhaust gas comes out but

engine does not start
• Lack of rotating force due to defective electrical
system
• Improper selection of fuel
WA800L-3 20-309
(1)
TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (Follow-up is poor)
General causes why engine does not pick up smoothly

• Improper fuel used
20-310 WA800L-3
(1)
TROUBLESHOOTING S-4
S-4 Engine stops during operations

(For V type engine, including cases where one bank stops)
General causes why engine stops during operations

• Seized parts inside engine
• Overheating
a If there is overheating and insuffi-
cient output, carry out trouble-
shooting for overheating.
• Failure in power train
a If the engine stops because of a
failure in the power train, carry out
troubleshooting for the chassis.
WA800L-3 20-311
(1)
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly

• Air in fuel system
• Defective governor mechanism
20-312 WA800L-3
(1)
TROUBLESHOOTING S-6
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.)
General causes why engine lacks output
• Improper fuel used
(if non-specified fuel is used, output drops)
• Lack of output due to overheating
a If there is overheating and insufficient
output, carry out troubleshooting for
overheating.
WA800L-3 20-313
(1)
TROUBLESHOOTING S-7
S-7 Exhaust gas is black (incomplete combustion)
General causes why exhaust gas is black

20-314 WA800L-3
(1)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust gas is blue)
a Do not run the engine at idling for more than 20

minutes continuously. (Both low and high idling)
General causes why oil consumption is excessive

• Abnormal combustion of oil
• External leakage of oil
• Wear of lubrication system
a Judge the oil consumption by comparing it
with the fuel consumption during the same
period.
More than 0.5%: Check the engine
More than 1.0%: There is some abnormality
WA800L-3 20-315
(1)
TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly

• Intake of exhaust gas due to internal wear
• Clogging of lubrication passage
• Improper combustion
• Improper oil used
• Operation under excessive load
20-316 WA800L-3
(1)
TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

• Leakage of fuel
WA800L-3 20-317
(1)
S-11 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water

• Internal leakage in lubrication system
• Internal leakage in cooling system
20-318 WA800L-3
(1)
S-12 Oil pressure lamp lights up (drop in oil pressure)
General causes why oil pressure lamp lights up

• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
a Standards for use of oil

Type of oilSelection of oil SAE number
Type of according to ambient temperature
fuel –22 –4 –14 32 50 68 86 1104°F
–30 –20 –10 0 10 20 30 140°C
SAE 30
Engine SAE 10W

oil SAE 10W-30
SAE 15W-40
WA800L-3 20-319
(1)
S-13 Oil level rises
a If there is oil in the cooling water, carry out trou-

bleshooting for “Oil is in cooling water”.
General causes why oil level rises

• Water in oil (cloudy white)
• Fuel in oil (diluted, and smells of diesel fuel)
• Entry of oil from other component
20-320 WA800L-3
(1)
S-14 Water temperature becomes too high (overheating)
General causes why water temperature becomes too high

• Lack of cooling water (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise in oil temperature of power train
a Carry out troubleshooting for chassis.
a Check that the maintenance monitor panel coolant
level caution lamp is not lighted up.
a When the maintenance monitor panel water tempera-
ture gauge is normal, go to troubleshooting of
machine monitor system (M mode).
WA800L-3 20-321
(1)
S-15 Abnormal noise is made
a Judge if the noise is an internal noise or an external noise.
General causes why abnormal noise is made

• Abnormality due to defective parts
• Abnormal combustion noise
• Air sucked in from intake system
20-322 WA800L-3
(1)
S-16 Vibration is excessive
a If there is abnormal noise together with the

vibration, carry out troubleshooting for
“Abnormal noise is made”.
General causes why vibration is excessive

• Defective parts (abnormal wear, breakage)
• Improper alignment
• Abnormal combustion
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
JUDGEMENT TABLE FOR TRANSMISSION CONTROL SYSTEM

RELATED PARTS
20-402 WA800L-3
(1)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE

OCCURS AND PROBLEMS ON MACHINE
Failure code Abnormal system Nature of abnormality
1) Defective back lamp relay

2) Short circuit with power source, short circuit with chassis ground,
defective contact, disconnection in wiring harness between
transmission & joystick controller C1 (female) (8) and L54 (1)
Short circuit, disconnection 3) Defective contact or disconnection in wiring harness between back
10
in back lamp relay system lamp relay L54 (female) (2) and chassis ground
4) Defective transmission & joystick controller
1) Defective F solenoid
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)
1) Defective R solenoid
in R solenoid system
1) Defective 1st solenoid
in 1st solenoid system
1) Defective 2nd solenoid
Short circuit, disconnection transmission & joystick controller C1 (female) (10) – TR1 (2) – T01
15
in 2nd solenoid system (7)
1) Defective 3rd solenoid
in 3rd solenoid system
4) Defective transmission controller
20-404 WA800L-3
(1)
Action by controller Problem that appears Trouble-

Condition when normal
when abnormality is on machine when shooting
(voltage, current, resistance)
detected there is abnormality code
1) Resistance of relay coil: 200 – 400 z Neutral Back lamp is not

2) Voltage between transmission & joystick (F, R, 1st, 2nd, 3rd actuated when driving
controller C1 (8) and chassis ground at neutral: solenoid output: off) in reverse
Less than 1 V
3) Resistance in wiring harness between
T-2
transmission & joystick controller C1 (female) (8)
and L54 (female) (1): Max. 1 z
4) Resistance in wiring harness between back lamp
relay L54 (female) (2) and chassis ground:
Max. 1 z
1) Resistance between transmission & joystick Neutral It is impossible to travel
controller C1 (female) (2) and chassis ground: (F, R, 1st, 2nd, 3rd
5 – 15 z solenoid output: off)
2) Voltage between transmission & joystick T-3
controller C1 (2) and chassis ground at neutral:
Less than 1 V

Less than 1 V

Less than 1 V

2) Voltage between transmission & joystick
T-6
Less than 1 V

Less than 1 V
WA800L-3 20-405
(1)
Failure code Abnormal system Nature of abnormality
1) Defective joystick forward-reverse switch

2) Disconnection or defective contact in wiring harness between fuse –
JS1 (female) (1)
3) Disconnection, defective contact, short circuit with chassis ground, or
short circuit in wiring harness between transmission & joystick
controller C3B (female) (5) – JS1 (female) (2)
Short circuit or disconnection
20 in joystick forward-reverse
switch signal system
1) Defective joystick shift-up/down switch

2) Disconnection or defective contact in wiring harness between fuse –
JS1 (female) (1)
Short circuit or disconnection
21 in joystick shift-up/down
switch signal system
1) Defective speed sensor

2) Defective adjustment of speed sensor mount
3) Defective contact or disconnection in wiring harness between
transmission & joystick controller C5 (female) (2) – CBL1 (6) – C01
Disconnection in speed
22 (1)
sensor system
transmission & joystick controller C5 (female) (1) – CBL1 (7) – C01
(2)
1) Defective engine speed sensor
2) Defective adjustment of engine speed sensor mount
Short circuit, disconnection transmission & joystick controller C4 (female) (2) – LR3 (14) – ER1
23 in engine speed sensor (10) – E03 (1)
system 4) Defective contact or disconnection in wiring harness between
transmission & joystick controller C4 (female) (9) – LR3 (15) – ER1
(17) – E03 (2)
20-406 WA800L-3
(1)
Action by controller Problem that appears Trouble-

Condition when normal
when abnormality is on machine when shooting
(voltage, current, resistance)
detected there is abnormality code
1) Voltage between transmission & joystick 1) When N signal is 1) When in F: Stops.

controller C3B (5) and chassis ground input: Shifts to N 2) When in N or R:
When joystick forward-reverse switch is in "F": immediately. Starts moving
17 – 30 V 2) When F/R signal is forward suddenly.
When joystick forward-reverse switch is not in "F": input: Shifts to N 3) When in N: N signal
Max. 1 V immediately. is not output.
2) Voltage between transmission & joystick 3) When there is no 4) When in F or R: Sets
controller C3B (13) and chassis ground signal: Holds to neutral suddenly.
When joystick forward-reverse switch is in "N": previous signal 5) When in R: Stops.
T-10
17 – 30 V condition for 2 6) When in N or F:
When joystick forward-reverse switch is not in seconds, then shifts Starts moving in
"N": Max. 1 V to N. reverse suddenly.
controller C3B (6) and chassis ground
When joystick forward-reverse switch is in "R":
17 – 30 V
When joystick forward-reverse switch is not in
"R": Max. 1 V
1) Voltage between transmission & joystick 1) Holds current gear 1) Cannot shift gear up.
controller C3B (7) and chassis ground (Shift-up speed. 2) Cannot shift gear
NO) down.
When joystick shift-up switch is ON: Max. 1 V
When joystick shift-up switch is OFF: 17 – 30 V
controller C3B (8) and chassis ground (Shift-
down NO)
When joystick shift-down switch is ON: Max. 1 V
When joystick shift-down switch is OFF: 17 – 30 V
T-12
controller C3B (15) and chassis ground (Shift-up
NC)
When joystick shift-up switch is ON: 17 – 30 V
When joystick shift-up switch is OFF: Max. 1 V
controller C3B (16) and chassis ground (Shift-
down NC)
When joystick shift-down switch is ON: 17 – 30 V
When joystick shift-down switch is OFF: Max. 1 V
1) Resistance between speed sensor C01 (1) and 1) Switches to manual 1) Does not carry out
(2): 500 – 1,000 z mode auto-shift
2) Voltage between transmission & joystick 2) Shifts gear 2) Switches to manual
controller C5 (female) (1) and (2): Min. 0.5 V according to shift
operation of range T-13
lever
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

CONTROL SYSTEM
20-408 WA800L-3
(1)
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.
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.
• 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
T-1 Related electrical circuit diagram
20-410 WA800L-3
(1)
TROUBLESHOOTING T-2
F solenoid) is displayed
has been removed.
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
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
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
R solenoid) is displayed
has been removed.
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
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
(female) (9) and T01 (female) (9) and T01
(female) (3)
• Disconnect C1
• Max. 1 z
and T01. Defective contact or
T01 (male) (1) and (3) Repair or
and between (1), (3) • Turn starting disconnection in wiring
NO replace
(3): 5 – 15 z Defective R solenoid Replace
and chassis ground: Min. 1
Mz
• Turn starting switch OFF. 5 YES Defective transmission &
• Disconnect T01. joystick steering Replace
C1 (female) (9) and
From A chassis ground Short circuit with power
• 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
1st solenoid) is displayed
has been removed.
Cause Remedy
4 YES
Go to A
Is resistance
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) (8)
• Disconnect C1,
• Max. 1 z
T01 (male) (2) and (8) T01 and L05. Defective contact or Repair or
NO replace
(8): 5 – 15 z Defective 1st solenoid Replace
• Disconnect T01. 5 YES Defective transmission &
C1 (female) (3)
From A and chassis
ground normal?
switch ON.
• Disconnect C1,
T01 and L05.
WA800L-3 20-413
(1)
TROUBLESHOOTING T-5
2nd solenoid) is displayed
has been removed.
Cause Remedy
4 YES
Go to A
Is resistance
3 chassis ground
Is resistance harness between T01
normal? Repair or
• Max. 1 z
(female) (2) and chassis
YES between C1 NO replace
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
T01 (female) (7) switch OFF.
1 normal?
(female) (7)
• Disconnect C1,
• Max. 1 z
T01 (male) (2) and (7) T01 and L05. Defective contact or
Repair or
NO replace
(7): 5 – 15 z Defective 2nd solenoid Replace
C1 (female) (10) and
From A chassis ground Short circuit with power
switch ON.
• Disconnect C1,
T01 and L05.
20-414 WA800L-3
(1)
TROUBLESHOOTING T-6
3rd solenoid) is displayed
has been removed.
Cause Remedy
4 YES
Go to A
Is resistance
YES between T01
(female) (2) and
3 chassis ground
Is resistance normal? harness between T01 Repair or
YES between C1 • Max. 1 z NO
chassis ground
• Turn starting
2 switch OFF.
Is resistance
• Min. 1 Mz • Disconnect T01. ground in harness Repair or
YES between C1 between C1 (female) (5)
switch OFF. and T01 (female) (6)
1 (female) (6) normal?
• Disconnect C1,
• Max. 1 z Defective contact or
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
C1 (female) (5) and
From A chassis ground
normal?
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
has been removed.
a Check that fuse II (6) is normal.
Cause Remedy
Defective transmission
3 YES
and joystick steering Replace
Is voltage between
controller
YES C3B (5), (13), (6) and
chassis ground as Disconnection, defective
2 shown in Table 1? contact, short circuit with
Is voltage chassis ground, or short Repair or
YES between JS1 (1) circuit in wiring harness replace
• Turn starting NO between JS1 (female) (2), (3),
and chassis switch ON. (4) – C3B (female) (5), (13), (6)
1 ground normal?
Is voltage between • 20 – 30 V Disconnection or defective
JS1 (2), (3), (4) and contact in wiring harness Repair or
chassis ground as between fuse II (6) – JS1
shown in Table 1? switch ON.
(female) (1)
• Turn starting
switch ON. Defective joystick lever
Replace
NO switch
Table 1 Voltage measured with joystick lever switch at each position
Position of FNR switch

F N R
Terminals
JS1 (male) (1) – (2) C3B (5) – Chassis ground 20 – 30 V Max. 1 V Max. 1 V
JS1 (male) (1) – (3) C3B (13) – Chassis ground Max. 1 V 20 – 30 V Max. 1 V
JS1 (male) (1) – (4) C3B (6) – Chassis ground Max. 1 V Max. 1 V 20 – 30 V
20-416 WA800L-3
(1)
TROUBLESHOOTING T-8
T-8 Failure code [21] (Short circuit or disconnection in joystick shift-up/shift-down

switch system) is displayed
has been removed.
Cause Remedy
Defective transmission
3 YES
and joystick steering Replace
Is voltage between
controller
YES C3B (16), (8), (15), Disconnection, defective
(7) and chassis
2 ground as shown in
contact, short circuit with
chassis ground, or short
Is voltage Table 1? circuit in wiring harness Repair or
YES between JS1 (1) • Turn starting NO between JS1 (female) (5), (6), replace
and chassis (7), (8) – C3B (female) (16),
1 switch ON. (8), (15), (7)
ground normal?
Is voltage between
Disconnection or defective
JS1 (5), (6), (7), (8) • 20 – 30 V Repair or
and chassis ground contact in wiring harness
as shown in Table between fuse II (6) – JS1
switch ON.
1? (female) (1)
• Turn starting
Defective joystick shift-
switch ON. Replace
NO up/shift-down switch
Table 1 Voltage measured with joystick shift-up/shift-down switch at each position
When shift-up/shift-down
Shift-up Shift-down
switch is pressed
switch ON switch ON
Terminals
JS1 (5) – Chassis ground C5 (16) – Chassis ground 20 – 30 V Max. 1 V

JS1 (6) – Chassis ground C5 (8) – Chassis ground Max. 1 V 20 – 30 V
JS1 (7) – Chassis ground C5 (15) – Chassis ground Max. 1 V 20 – 30 V
JS1 (8) – Chassis ground C5 (7) – Chassis ground 20 – 30 V Max. 1 V
WA800L-3 20-417
(1)
TROUBLESHOOTING T-9
T-9 Failure code [22] (Disconnection in travel speed sensor) is displayed
has been removed.
3 YES Defective transmission &

Is resistance controller
YES between C5 (female)
(1) and BC01 Defective contact or
2
(female) (2) normal? disconnection in wiring
Is resistance
harness between C5 Repair or
• Max. 1 z
between C5
YES (female) (2) and NO (female) (1) and BC01 replace
BC01 (female) (1) • Disconnect C5, BC01 and (female) (2)
1 normal? L07.
• Max. 1 z
Is resistance between • Turn starting switch OFF.
BC01 (male) (1) and disconnection in wiring Repair or
(2) and between (1), • Disconnect BC01, NO harness between C5 replace
(2) and chassis C5 and L07. (female) (2) and BC01
ground normal? • Turn starting (female) (1)
• Between (1) and switch OFF.
(2): 500 – 1000 z NO
Defective speed sensor Replace
• Disconnect BC01.
• Turn starting
switch OFF.
20-418 WA800L-3
(1)
TROUBLESHOOTING T-10
T-10 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is
displayed
has been removed.
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
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
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)
T-11 Kickdown switch signal system and hold switch signal system
STEERING WHEEL SPECIFICATION,
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).
Kickdown switch
Cause Remedy

YES joystick steering Replace
1 controller
Is resistance Short circuit with chassis
between C5 ground, defective
(female) (5) and 2 YES contact, or disconnection Repair or
chassis normal?
Is resistance in wiring harness replace
• Disconnect C5. between L15 between C5 (female) (5)
• Kick-down (male) (1) and (2) and L15 (female) (1)
NO normal?
switch Defective kick-down
ON: Max. 1 z • Disconnect L15. NO switch
Replace
OFF: Min. 1 Mz • Kick-down switch
ON: Max. 1 z
OFF: Min. 1 Mz
Hold switch
Cause Remedy
a Hold switch is applied to only the auto-shift specification.

YES
1 controller
Is resistance
between C5 Short circuit with chassis
(female) (13) and ground, defective
2 YES Repair or
chassis normal? contact, or disconnection
Is resistance in wiring harness replace
• Disconnect C5. between L15 between C5 (female) (13)
• Hold switch (male) (3) and (4) and L15 (female) (3)
NO normal?
ON: Max. 1 z
OFF: Min. 1 Mz NO
Defective hold switch Replace
• Disconnect L15.
• Hold switch
ON: Max. 1 z
OFF: Min. 1 Mz
20-420 WA800L-3
(1)
T-12 Transmission cut-off signal system
socket).
Cause Remedy

1 controller
• Short circuit with chassis
Is resistance ground, defective contact, or
between C5 disconnection in wiring
(female) (6) and 2 YES harness between C5 (female) Repair or
chassis normal? (6) and L12 (female) (1)
Is resistance • Short circuit with chassis
replace
• Disconnect C5. between L12 ground in wiring harness
• Transmission (male) (1) and (2) between C5 (female) (6) and
NO normal? L06 (female) (3)
cut-off switch
ON: Max. 1 z Defective transmission Replace
NO
OFF: Min. 1 Mz
• Disconnect L12. cut-off switch
• Transmission
cut-off switch
ON: Max. 1 z
OFF: Min. 1 Mz
WA800L-3 20-421
(1)
T-13 Neutralizer signal system
a Check that the parking brake works normally.

socket).
Cause Remedy

YES Replace
joystick steering
controller
1 4 YES Defective neutralizer

Is resistance relay Replace
Is voltage
between C3B (14) YES between C3A Defective contact or
(female) (6) and
and chassis 3 disconnection in wiring
C3B (female) (14)
normal? Is voltage harness between C3A
normal?
(female) (6) – L58 (female) Repair or
YES between L58 • Disconnect C3A and NO (5), L58 (female) (3) – C3B replace
• Turn starting
(female) (1) and L58.
switch ON. (female) (14)
2 chassis normal? • Short circuit L58
• Parking brake (female) (3) and (5) Short circuit with chassis
switch: Is resistance • Disconnect L58. • Max. 1 z ground, defective contact, Repair or
ON → OFF between L58 • Turn starting or disconnection in wiring replace
NO harness between L58
• 20 – 30 V NO (female) (2) and switch ON.
chassis normal? • Parking brake switch: ON → OFF (female) (3)
• Disconnect L58. • 20 – 30 V
Defective contact or Repair or
• Max. 1 z NO disconnection in wiring replace
harness between L58
20-422 WA800L-3
(1)
T-14 Buzzer signal system
a Check that the main monitor and alarm buzzer works normally.
socket).
Cause Remedy
2 YES Defective transmission &

Is resistance
between C2 controller
YES
1 L08 (female) (6)
Is resistance normal? Repair or
harness between C2
between C2 • Disconnect C1 NO replace
(female) (10) and and L08. (female) (6)
chassis normal? • Max. 1 z
• Disconnect C1 Short circuit with chassis
Repair or
and L08. ground in wiring harness
NO replace
• Min. 1 Mz betwen C2 (female) (10)
and L08 (female) (6)
WA800L-3 20-423
(1)
T-15 Network system
socket).
Cause Remedy

controller
YES C3B (female) (4), (12)
and L08 (female) (1), Defective contact or
1 (3) or LM1 (female) disconnection in wiring
Is resistance (5) normal? harness between C3B Repair or
• Max. 1 z
between C3B (female) (4), (12) and L08
NO replace
(female) (4), (12) (female) (1), (3), or LM1
and chassis • Turn starting switch OFF.
(male) (5)
normal? • Disconnect C3B, L08 and
• Min. 1 Mz LM1. Short circuit with chassis
Repair or
ground in wiring harness
betwen C3B (female) (4),
switch OFF.
(12) and L08 (female) (1),
• Disconnect C3B, (3), or LM1 (male) (5)
L08 and LM1.
20-424 WA800L-3
(1)
T-16 Transmission controller power source system

socket).
Cause Remedy

1 controller
Is voltage between Short circuit with chassis
C1 (7), (13), C2 (1), ground, defective contact or
(12) and C1 (6), (12), disconnection in wiring
C2 (11), (21)
2 YES harness between C1 (female) Repair or
normal? Is resistance between (7), (13) and FS5 (female) (6), replace
C1 (female) (6), (12) and between C2 (female) (1),
• 20 – 30 V
and chassis, and C2 (12) and FS5 (female) (6)
• Turn starting NO (female) (11), (21)
switch ON. Defective contact or
and chassis normal? disconnection in wiring Repair or
• Max. 1 z NO harness between C1 (female) replace
• Turn starting (6), (12) and chassis, and
between C2 (female) (1), (12)
switch OFF.
and chassis
• Disconnect C1
and C2.
WA800L-3 20-425
(1)
T-17 Short circuit in travel speed sensor system
Cause Remedy

2 YES Replace
joystick steering
YES between C5 Short circuit in wiring
1 (female) (2) and harness betwen C5 (female)
(1) normal? (2) – L07 (female) (1) – BC01
Is resistance (male) (1) or short circuit in Repair or
between C5 • Min. 1 Mz NO wiring harness between C5 replace
(female) (2) and • Turn starting switch OFF. (female) (1) – L07 (female)
(2) – BC01 (female) (2)
chassis normal? • Disconnect C5, BC01 and
• Min. 1 Mz L07. Short circuit in wiring
harness betwen C5 (female) Repair or
• Turn starting NO (2) – TM2 (9) – CN3 (female) replace
switch OFF. (2), or short circuit in
between C5 (female) (2) and
• Disconnect C5, L07 (female) (1)
BC01 and L07.
20-426 WA800L-3
(1)
T-18 Abnormality in machine selection wiring harness
a Check that machine selection connector is properly selected.

Cause Remedy

Is resistance
controller
between C3B
(female) (2), (3), (10) Defective machine
and C1 (female) (6), selection connector, or
(12) normal? defective contact or Repair or
• Turn starting NO disconnection in wiring replace
switch OFF. harness
• Disconnect C3B
and C1.
Table 1
Machine model
WA800-3
Connector
Between C3B (female) (2) and C1 (female) (6), (12) Min. 1 Mz

Between C3B (female) (3) and C1 (female) (6), (12) Min. 1 Mz
Between C3B (female) (10) and C1 (female) (6), (12) Max. 1 z
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
TROUBLE DATA DISPLAY

1. Outline
The speedometer display on the main monitor is
used to display the troubleshooting for each
control system. The nature of the troubleshoot-
ing is displayed as the failure action code, failure
code, and the time elapsed since failure.
The signals between the main monitor and each
controller are transmitted in serial through the
network circuit. (Only the engine controller uses
a special parallel signal.)
2. Display of failure action code

This code informs the operator directly of the
abnormality, and takes action, such as stopping
the machine immediately.
There are three types of action code: E00, E01
+ CALL (E01 and CALL are displayed alter-
nately), and CALL. If a failure occurs suddenly,
one of these codes is shown on the speedome-
ter display.
3. Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible
to tell from this code which system in which con-
troller has failed, so carry out troubleshooting for
the applicable controller.
For failure that have occurred and been reset,
the failure code and the time elapsed since fail-
ure are displayed to make it easy to check fail-
ures that are not occurring at present.
The failure codes for failures that are now occur-
ring flash, and the codes for failures that are not
occurring light up.
For details of the method of operating and trans-
ferring data to the trouble data display mode,
see STRUCTURE AND FUNCTION for the main
monitor.
NOTE: If the engine is not stopped, it is impos-
sible to switch to the trouble data dis-
play mode, so the codes for failures
which can only be detected when the
engine is operating light up.
For the correspondence between the failure
codes for each controller and the failed system,
see Item 4.
WA800L-3 20-503
(1)
TROUBLESHOOTING TROUBLE DATA DISPLAY
4. Action code table
Transmission control system Joystick control system

Action Action Action by
code buzzer operator
Problem system Action of machine Problem system Action of machine
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
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
M-1 Main monitor does not work
Cause Remedy
YES
1
Is voltage Defective contact or

between L05 (1), disconnection in wiring
2 YES Repair or
(2) – (3) normal? harness between L05
Is resistance replace
between L05 (female) (1), (2) and FS2
• 20 – 30 V (female) (9)
(female) (3) and
• Turn starting NO chassis ground
normal? Repair or
• Turn starting NO harness between L05 replace
switch OFF. (female) (3) and LR4
• Disconnect L05. (male) (3)
• Max. 1 z
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
Cause Remedy
1 YES
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
• Start engine. (female) (3)
WA800L-3 20-509
(1)
TROUBLESHOOTING M-3
M-3 Speedometer display does not work properly
a When error code is not displayed.

a Check that the gap between the speed sensor and gear is normal.
Cause Remedy
1 YES
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
M-4 Abnormality in shift indicator
a Check that error code is not displayed.

a Check that the transmission shifts.
a) Displays N even when directional switch is at F
Cause Remedy
1 YES
Is voltage
between L08 (7)
Repair or
harness between L08
(female) (7) and JS1
• Turn starting (female) (2)
switch ON.
• Directional switch: F
b) Displays N even when directional switch is at R
Cause Remedy
1 YES
Is voltage
between L08 (8)
Repair or
harness between L08
switch ON.
• Directional switch: R
c) Does not display N even when directional switch is at N (Display 1st – 3rd).
Cause Remedy
1 YES
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
• Set directional
switch to N.
WA800L-3 20-511
(1)
TROUBLESHOOTING M-4
20-512 WA800L-3
(1)
TROUBLESHOOTING M-5
M-5 Turn signal display does not light up
a Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not
blown.
a) L.H. turn signal display does not light up
Cause Remedy
1 YES
Is voltage
between L06 (14)
20 – 30 V. (female) (1)
• Turn L.H. turn signal ON.
Cause Remedy
1 YES
Is voltage
between L06 (15)
20 – 30 V. (female) (1)
• Turn R.H. turn signal ON.
WA800L-3 20-513
(1)
TROUBLESHOOTING M-5
20-514 WA800L-3
(1)
TROUBLESHOOTING M-6
M-6 Abnormality in parking display
a) Parking lamp display does not light up
Cause Remedy
3 YES Defective main monitor Replace

Is resistance
YES between F13
Is voltage normal? harness between F13 Repair or
YES between L06 (11) • Max. 1 z NO (female) (2) and chassis replace
and chassis • Turn starting ground
1 ground normal? switch OFF.
Is resistance • Disconnect F13. Repair or
• 20 – 30 V disconnection in wiring
between F13 • Turn starting NO harness between L06 replace
(male) (1) and (2) switch ON. (female) (11) – F13
normal? • Turn parking (female) (1)
• Max. 1 z switch ON. Defective parking brake Replace
• Disconnect F13. NO indicator switch
• Turn starting
switch ON.
• Turn parking
switch ON.
b) Parking lamp display stays lighted up
Cause Remedy
2 YES
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
M-7 Night lighting does not light up
a Before starting troubleshooting, check that the lamp bulbs are not blown.
a Check that fuse I-6 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring
harness between FS2 (female) (5) and L05 (female) (16).
Cause Remedy
1 YES
Is voltage
between L05 (16)
• 20 – 30 V NO (female) (16) and FS2 replace
switch ON.
• Turn small lamp
switch ON.
20-516 WA800L-3
(1)
TROUBLESHOOTING M-7
WA800L-3 20-517
(1)
TROUBLESHOOTING M-8
M-8 Abnormality in front working lamp
a Before starting troubleshooting, check that the monitor lighting is lighted up.
a) Neither monitor display nor front working lamp light up

Cause Remedy
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
• 20 – 30 V
• Turn starting
switch ON. disconnection in wiring Repair or
NO harness between L60 replace
(female) (2), (4), (5) and
FS5 (female) (1)
b) Working lamp lights up but monitor display does not light up

Cause Remedy
1 YES
Is voltage
between L05 (17)
Repair or
harness between L05
switch ON.
c) Monitor display lights up but front working lamp

Cause Remedy
does not light up
harness between L60
(female) (1) – C03 Repair or
(female) (1), C04 (female) replace
(1), or L60 (female) (3) –
WORK (female) (1), or
blown working lamp bulb
20-518 WA800L-3
(1)
TROUBLESHOOTING M-8
WA800L-3 20-519
(1)
TROUBLESHOOTING M-9
M-9 Abnormality in rear working lamp
a Before starting troubleshooting, check that the monitor lighting is lighted up.
a) Neither monitor display nor rear working lamp light up
Cause Remedy
YES 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
• 20 – 30 V
• Turn starting
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
Is voltage
between L05 (18)
Repair or
harness between L05
switch ON.
c) Monitor display lights up but rear working lamp

Cause Remedy
does not light up
harness between L61
(female) (1) – G03 (female) Repair or
(1), G07 (female) (1),or L61 replace
(female) (3) – G02 (female)
(1), G08 (female) (1), or
blown working lamp bulb
20-520 WA800L-3
(1)
TROUBLESHOOTING M-9
WA800L-3 20-521
(1)
TROUBLESHOOTING M-10
M-10 Abnormality in transmission cut-off
a) When monitor switch (transmission cut-off switch) is pressed,

Cause Remedy
cut-off function is not switched and display does not change
b) When monitor switch (transmission cut-off switch) is OFF,

Cause Remedy
monitor display goes out but cut-off function is actuated when
pedal is depressed
1 YES harness between L06
Repair or
Is voltage replace
(female) (3) and C5
between L06 (3) (female) (6)
and chassis
ground normal?
• Max 1 V NO
• Turn starting
switch ON.
• Disconnect L12.
c) When monitor display is turned off (transmission cut-off switch

Cause Remedy
turned OFF), cut-off function is always actuated
2 YES harness between L12 Repair or
Is resistance (female) (1) and C5 replace
YES between L12 (female) (6)
(female) (2) and
1 chassis ground Defective contact or
Is resistance normal? disconnection in wiring Repair or
between L12 • Max. 1 z NO harness between L12 replace
(male) (1) and (2) • Turn starting (female) (2) and chassis
normal? switch OFF. ground
• Max. 1 z • Disconnect L12. Defective transmission Replace

• Turn starting NO cut-off switch
switch OFF.
• Disconnect L12.
d) Cut-off function is always actuated regardless of monitor

Cause Remedy
display (transmission cut-off switch ON or OFF)
1 YES Defective transmission Replace

Is voltage controller
between C5 (6)
Repair or
harness between C5
• Max 1 V NO replace
(female) (3), L12 (female)
(1)
20-522 WA800L-3
(1)
e) Monitor display lights up (transmission cut-off switch turned

Cause Remedy
ON), but cut-off function is not actuated
YES Defective transmission

Replace
cut-off switch
1
Does cut-off
function work
YES
when L12 is Defective main monitor Replace
2
disconnected?
Does cut-off
• Disconnect L12.
function work
• Turn starting Defective transmission &
NO when L06 is 3 YES
switch ON. joystick steering Replace
disconnected? Is voltage controller
• Disconnect L06. between C5 (6)
• Turn starting NO and chassis Short circuit with chassis
switch ON. ground normal? ground in harness Repair or
between L06 (female) (3) replace
• Disconnect L12. NO – C5 (female) (6), L12
switch ON.
• 20 – 30 V
WA800L-3 20-523
(1)
M-11 Abnormality in low idle selection
a Before carrying out troubleshooting, be sure that all the related connectors are properly inserted.
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
YES See engine manual for

ECM and harness –
1
procedures
Is voltage
between ECM1 Short circuit with ground
(female) (18) and 2 YES or disconnection in wire Repair or
chassis normal ? harness between LR3 replace
Is voltage
• 20 – 30 V between L06 and ECM1
• Turn starting NO (female) (7) and
switch ON chassis normal ?
• Turn low idle Defective main monitor Replace
• Disconnect LR3 NO
select switch ON (male) (10) wire
from connector
• 20 – 30V
• Turn starting
switch ON
• Turn idle select
switch OFF
20-524 WA800L-3
(1)
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
2 YES See engine

Fault in engine ECM
Is voltage manual
YES between ECM1
Short circuit power
(female) (18) and source in wire harness
chassis normal ? between LR3 pin (10) and
Repair or
1 • MAX. 1 V NO ECM1 pin (18) and
replace
Is voltage • Turn starting disconnect or break in
between L06 switch ON wire between L06 pin (7)
(female) (7) and • Turn low idle and LR3 pin (10)
chassis normal ? select switch OFF
Short circuit power
• MAX. 1 V 2 YES source in wire harness Repair or
• Turn starting between LR3 pin (10) and replace
Is voltage
switch ON ECM1 pin (18)
between L06
• Turn low idle
select switch NO (female) (7) and
chassis normal ?
OFF Defective main monitor Repair
• Remove LR3 NO
(male) (10) wire
form connector
• MAX. 1 V
• Turn starting
switch ON
• Turn low idle
select switch OFF
WA800L-3 20-525
(1)
M-12 Abnormality in emergency steering normal display
Emergency steering normal display does not light up
Cause Remedy
1 YES
Is voltage
between L05 (10)
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)
M-13 Abnormality in emergency steering actuation display
a) Emergency steering actuation display does not light up
Cause Remedy
2 YES
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.
b) Emergency steering actuation display stays lighted up
Cause Remedy
2 YES
Is voltage
YES between L05 (11)
1 and chassis Defective contact or
Is resistance Repair or
harness between L05
between R01 • 20 – 30 V NO replace
(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)
M-14 Abnormality in parking brake dragging warning
a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even
when directional switch is at N
Cause Remedy
1 YES
Is voltage
between L05 (8)
• 20 – 30 V NO (female) (8) – JS1 replace
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
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)
M-15 When parking brake dragging warning is given, buzzer and CAUTION lamp are
actuated continuously, or they are not actuated
a) Actuated continuously
Cause Remedy
YES
1
Does buzzer stop

and lamp go out? 2 YES Defective maintenance
Replace
monitor (sub monitor)
• Turn starting Does buzzer stop
switch ON. and lamp go out? Defective contact or
NO disconnection in wiring
• Connect L07 Repair or
(male) (6) to harness between L07
chassis ground. (female) (6) and L19
• Connect L19
(female) (5) to
chassis ground.
b) Not actuated
Cause Remedy
YES
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)
M-16 Abnormality in buzzer
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)
Cause Remedy
YES disconnection in wiring
Repair or
harness between L06
1 replace
(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
chassis ground. (female) (1) and FS2
switch ON.
b) Buzzer always sounds
Cause Remedy
YES Defective main monitor Replace

1
Does buzzer stop
when L06 is See troubleshooting (K
YES
disconnected? mode) for maintenance —
2
monitor
• Turn starting Does buzzer stop
Short circuit with chassis
switch ON. when L19 is
NO 3 YES ground in harness Repair or
• Disconnect L06. disconnected?
between L06 (female) (8) replace
Does buzzer stop and L43 (male) (1)
• Turn starting when L43 is
switch ON. NO disconnected?
• Disconnect L19.
Defective buzzer Replace
switch ON.
• Disconnect L43.
20-530 WA800L-3
(1)
M-17 Condition of monitor switches is not stored in memory
Cause Remedy
1 YES
Is voltage
between L07 (10)
• 20 – 30 V NO (female) (10) and L09 replace
switch ON.
WA800L-3 20-531
(1)
M-18 Abnormality in failure display mode
a) Does not enter failure display mode
Cause Remedy
1 YES
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
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)
M-19 Buzzer is not made to sound by transmission & joystick steering controller
Cause Remedy
2 YES See troubleshooting of

transmission controller Replace
Is resistance between system (T mode)
YES L08 (female) (6) and
1 C2 (female) (10) Defective contact or
normal? disconnection in wiring Repair or
Does buzzer sound
• Max. 1 z.
harness between L08 replace
when C2 (female) NO (female) (6) and C2
(10) is grounded to • Turn starting
chassis? (female) (10)
switch OFF.
• Disconnect L01 and C1.
• Turn starting Defective main monitor Replace
switch ON. NO
• Disconnect C1.
• Connect C1
(female) (2) to
chassis ground.
WA800L-3 20-533
(1)
M-20 Abnormality in auto-greasing system
a) Forced greasing cannot be carried out

Cause Remedy
See “Handling auto-

2 YES greasing system” in
Operation and —
Is voltage
YES between GRE (1) Maintenance Manual
Is voltage ground normal? disconnection in wiring Repair or
between L06 (5) NO harness between L06 replace
• Max. 3 V
and chassis • Turn starting switch ON. (female) (5) and GRE (1)
ground normal? • Turn auto-greasing
• Max. 3 V switch ON.
switch ON.
• Turn auto-greasing
switch ON.
b) Monitor display flashes rapidly (2 times/sec)

Cause Remedy
YES
1
Is voltage
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.
c) When no more grease remains, monitor display flashes rapidly

Cause Remedy
(2 times/sec)
YES
1
Is voltage
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
switch ON.
20-534 WA800L-3
(1)
d) Monitor display flashes slowly (1 time/sec)

Cause Remedy
Confirm that grease is not empty.
See “Handling auto-

greasing system” in
—
Operation and
Maintenance Manual
e) Monitor display goes out

Cause Remedy
YES
1
Is voltage
between L07 (11)
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
switch ON.
• Disconnect GRE.
Table 1 (Relationship between input signal and display)

L07 (11) L8 (5) Display
L L Rapid flashing (2 times/sec)
H L Slow flashing (1 times/sec)
H H OFF
L H ON
WA800L-3 20-535
(1)
M-21 Failure code is not sent to main monitor (abnormality in network)
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
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) No lamps on maintenance monitor light up

Cause Remedy
Defective monitor
YES
module of maintenance Replace
monitor
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
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
b) Some lamps do not light up

Cause Remedy
Defective monitor
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)
Cause Remedy
Defective monitor
monitor
K-1, K-2 Related electrical circuit diagram
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
Cause Remedy
Defective monitor
1 YES
When starting
engine, is voltage monitor
between L19 (female)
(1) and chassis Defective contact or
ground normal? disconnection in wiring Repair or
• 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
K-3 Related electrical circuit diagram
WA800L-3 20-607
(1)
TROUBLESHOOTING K-4
K-4 When starting switch is truned on (engine stopped), CHECK items flash
a) Engine oil level display flashes

a Before starting troubleshooting, check the engine oil level again.
(Check that the engine oil level is correct.)
Cause Remedy
Defective monitor
3 YES module of maintenance Replace
Is resistance
between L18
monitor
YES
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
(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
K-4 a) Related electrical circuit diagram
20-608 WA800L-3
(1)
TROUBLESHOOTING K-4
b) Engine water level display flashes

a Before starting troubleshooting, check the engine water level again.
(Check that the engine water level is correct.)
Cause Remedy
Defective monitor
3 YES module of maintenance Replace
Is resistance monitor
YES between L18
(female) (8) and
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.
K-4 b) Related electrical circuit diagram
WA800L-3 20-609
(1)
TROUBLESHOOTING K-5
K-5 When starting switch is turned ON (engine started), CAUTION items flash
a) Engine oil pressure display flashes

• Check that the engine oil pressure is correct.
• Check to see if engine ECM fault/diagnostic lamps are illuminated.
Cause Remedy
Read codes
YES and follow
—
engine manual
procedures
1
Are ECM warning

lamps active ?
YES Defective engine oil
Replace
2 pressure relay
• Start engine
• Observe lamps Does condition
become normal
when engine oil Defective monitor
NO pressure relay L64 3 YES
is interchanged ? Is resistance monitor
between L18
• Interchange (female) (10) and
engine oil NO Defective contact or
chassis ground
pressure relay normal ? disconnection in wire
• Max. 1 z
L64 with a NO harness between L18 Repair or
normal relay (female) (10) — L64 replace
• Disconnect L18
(female) (3), (6) — chassis
• Turn starting
ground
switch OFF
20-610 WA800L-3
(1)
TROUBLESHOOTING K-5
b) Battery charge level display flashes
Cause Remedy
2 YES Defective monitor

Is voltage between monitor
YES L18 (female) (12)
Is voltage between Repair or
harness between L18
alternator terminal • 20 – 30 V NO replace
(female) (12) – alternator
R and chassis • Start engine. terminal R
ground normal?
• 20 – 30 V
Defective alternator Replace
• Start engine. NO
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
Is resistance
between L18
monitor
YES
5 BC04 (female) (1)
Is resistance
normal?
between BC04
• Max. 1 z NO (female) (11) and BC04 replace
From A (female) (2) and
chassis ground
normal? switch OFF.
• Max. 1 z
• Disconnect L18 and BC04.
• Turn starting NO harness between BC04 replace
switch OFF. (female) (2) and chassis
• Disconnect BC04. ground
20-612 WA800L-3
(1)
TROUBLESHOOTING K-5
K-5 c) Related electrical circuit diagram
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
YES Defective dust indicator Replace

(R.H.) sensor
1
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
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
Is resistance
between B09
monitor
YES
5 chassis ground
Is resistance
normal?
harness between B09 Repair or
between L18
NO (female) (1) and BR1 replace
chassis ground (female) (9)
normal?
• 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)
K-5 d) Related electrical circuit diagram
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
YES Defective dust indicator Replace

(L.H.) sensor
1
Does display go
out when B07 is YES Defective dust indicator
(L.H.) relay Replace
disconnected?
2
• Start engine.
Does display go
• Disconnect B07. 4 YES
out when dust Go to A
Is resistance
NO indicator relay between L79 Defective contact or
L79 is replaced? YES
3 chassis ground harness between L79
Is voltage between normal? (female) (6) and chassis Repair or
B07 (female) (1) • Max. 1 z NO ground replace
NO and chassis • Turn starting
Short circuit with chassis
ground normal? switch OFF.
ground in harness
• Turn starting • Disconnect L79. Repair or
between B07 (female) (1)
switch ON NO and L79 (female) (2) replace
• Disconnect B07. (contact with chassis
• 20 – 30 V ground)
6 YES Defective monitor
Is resistance
Replace
module of maintenance
YES between B06
monitor
(female) (1) and
5 chassis ground Defective contact or
Is resistance normal? disconnection in wiring Repair or
between L18 harness between B06
NO replace
From A (female) (15) and (female) (1) and BR1
chassis ground
(female) (9)
normal?
• Max. 1 z Defective contact or Repair or
• Turn starting disconnection in wiring replace
NO
switch OFF. harness between L18
• Disconnect L18. (female) (15) and L79
(female) (3)
K-5 e) Related electrical circuit diagram
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
Is resistance
monitor
YES between L18
3 BC02 (male) (2)
Is resistance
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)
• Max. 1 z Defective transmission

• Start engine. oil filter sensor (BC02 Replace
• Disconnect BC02. NO side)
K-5 f) Related electrical circuit diagram
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
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.
• 20 – 30 V disconnection in wiring
Repair or
• Disconnect L42. harness between FS2
NO replace
• Turn starting (female) (9) and L42
WA800L-3 20-617
(1)
TROUBLESHOOTING K-7
K-7 There is no abnormality in monitor display but caution buzzer sounds
a Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
a Before carrying out troubleshooting, check that buzzer stays sounded when L06 is disconnected.
Cause Remedy
Defective monitor
2 YES
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) CHECK lamp
Cause Remedy
Defective monitor
YES
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 ?
• Disconnect L06. NO
• Turn starting
switch ON.
b) CAUTION lamp
Cause Remedy
YES Defective monitor

1
Does CAUTION
monitor
lamp light up when Defective contact or
L19 (female) (3) is disconnection in wiring
connected to 2 YES Repair or
harness between L19
chassis ground ? Does CAUTION replace
lamp light up when (female) (3) and L06
• Disconnect L19. L06 (male) (9) is (female) (9)
• Turn starting NO connected to
switch ON. chassis ground ?
• Turn starting
switch ON.
WA800L-3 20-619
(1)
TROUBLESHOOTING K-9
K-9 There is no abnormality in maintenance monitor display but CHECK lamp or

CAUTION lamp lights up
a Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
a) CHECK lamp
Cause Remedy
Defective monitor
1 YES
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
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
• 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.
Cause Remedy
1 YES Disconnection in wiring

Replace
Is voltage harness of lamp holder
between
L21(female) (1) Defective contact or
and (2) normal? disconnection in wiring Repair or
• Disconnect L21. (female) (1) and FS2 (5)
• Turn starting
switch ON.
• Turn lamp switch
ON.
WA800L-3 20-621
(1)
K-11 Night lighting lights up even when lighting switch is turned OFF
Cause Remedy

supply in wiring harness
2 YES between FS2 (male) (4) – Repair or
Is voltage between fuse box – L21 (female) replace
YES FS2 (female) (4) (1)
1 and chassis
ground normal?
supply in wiring harness Repair or
Is lighting switch • Max. 1 V NO between L02 (female) (4) replace
normal? • Disconnect FS2. and FS2 (female) (4)
• Turn lighting switch OFF.
• Turn starting Defective lighting switch Replace
switch OFF. NO
• Disconnect L02.
• Check that continuity between
L02 (male) (3) and (4) is as
shown in table below when
lamp switch is turned ON–OFF.
Switch Continuity
ON YES
OFF NO
20-622 WA800L-3
(1)
TROUBLESHOOTING K-12, K-13
K-12 Service meter does not work
Cause Remedy
YES
Defective service meter Replace
1 Defective contact or
Is voltage disconnection in wiring
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
K-13 Service meter is running even when engine is stopped
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
K-12, K-13 Related electrical circuit diagram
20-624 WA800L-3
(1)
K-14 Abnormality in gauge display
a) Abnormality in fuel gauge

a Before carrying out troubleshooting, check the fuel level again. (Check that the fuel level is correct.)
(1) Little or nothing is displayed in display area Cause Remedy
YES Defective fuel level

Replace
sensor
1
Defective monitor
Does fuel gauge 3 YES
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
• 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
switch ON. to R05 (female).
• Turn starting • Disconnect L18. Repair or
harness between R05
switch OFF. NO replace
• Disconnect R05. ground
(2) Display always shows FULL and does not move Cause Remedy
YES Defective fuel level

Replace
1 sensor
Do all display areas
on fuel gauge go
out when R05 is YES Defective monitor
disconnected? module of maintenance Replace
Is resistance 2
between R05
monitor
• Disconnect R05.
(female) (1) and
• Turn starting NO Short circuit with chassis
chassis ground
switch ON. normal? ground in wiring harness Repair or
• Min. 1 Mz NO between R05 (female) (1) replace
• Turn starting switch OFF. – L18 (female) (6)
• Disconnect L18 and R05.
WA800L-3 20-625
(1)
b) Abnormality in engine water temperature gauge
(1) Nothing is displayed in display area

Cause Remedy
YES Defective engine water

Replace
1 temperature sensor
Does engine water
temperature gauge
show minimum Defective monitor
level when E04 is
2 YES
disconnected? Is resistance
monitor
• Disconnect E04. between E04
(female) (1) and
• Turn starting NO Short circuit with chassis
chassis ground
switch ON. normal? ground in wiring harness Repair or
• Min. 1 Mz NO between E04 (female) (1) replace
• Turn starting – L18 (female) (4)
switch OFF.
• Disconnect L18
and E04.
(2) Display shows lowest level and does not move

Cause Remedy
YES Defective engine water

Replace
temperature sensor
1
When short Defective monitor
connector is
3 YES
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)
c) Abnormality in torque converter oil temperature gauge
(1) Nothing is displayed in display area

Cause Remedy
YES Defective torque

converter oil temperature Replace
1
sensor
Does torque converter
oil temperature gauge
show minimum level Defective monitor
when T02 is
2 YES
disconnected? Is resistance
monitor
• Disconnect T02. between T02
(female) (1) and Short circuit with chassis
• Turn starting NO chassis ground ground in wiring harness
switch ON. normal? Repair or
between T02 (female) (1)
– L18 (female) (5) (contact
switch OFF. with chassis ground)
• Disconnect L18
and T02.
• Min. 1 Mz
(2) Display shows lowest level and does not move

Cause Remedy
Defective torque
YES
converter oil temperature Replace
sensor
1
When short Defective monitor
connector is 3 YES
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
K-14 c) Related electrical circuit diagram
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
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, 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
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE

a This circuit diagram is made by extracting the part of the parking brake system from the general circuit dia-
gram.
20-704 WA800L-3
(1)
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT
TROUBLESHOOTING AND BUCKET POSITIONER
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND

BUCKET POSITIONER
a This circuit diagram is made by extracting the parts of the boom kick-out and bucket positioner systems
from the general circuit diagram.
WA800L-3 20-705
(1)
TROUBLESHOOTING E-1
E-1 Engine does not start
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.
a) Starting motor does not turn

1) Confirm that ground level shutoff switch is in “RUN” position.
2) Confirm the normal operation of the prelubrication system (See engine lubrication system section). Ver-
ify pressure switch ground action.
3) For all steps requiring starting switch “ON”, wait for prelube post pump delay cycle to complete before
measuring voltage. (3–5 seconds)
4 YES
YES Does normal prelube

occur ?
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?
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
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
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
Repair or
disconnection in starting
replace
motor ground cable
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 steering lever

Replace
neutral safty relay (L95)
disconnection in wire Repair or
(female) (3), LR3 (7) and
ER 1(male) (8)
Defective neutral relay (L57) Replace

disconnection or short
circuit with chassis ground Repair or
17 YES in wiring harness between
Is resistance
replace
L57 (female) (3) and L95
(female) (2) and
chassis ground
normal ?
• Disconnect L57 NO (female) (2) and chassis replace
• Turn starting ground
switch OFF
• Max. 1 z
harness between L57 (female) replace
(2), LR4 (2) and chassis ground
19 YES disconnection in wiring
Repair or
harness between terminal
Is voltage between replace
C of starting switch, L09 (3)
terminal C of starting and L57 (female) (5)
switch and chassis
normal ?
• Set directional switch to N
Defective starting switch Replace
• Set joystick steering lever NO
to N Defective contact or
• Turn starting switch to disconnection in wiring
START position
• 20 - 30V harness between
Repair or
terminal B of starting
replace
switch, fuse (I) (12) and
LR4 (female) (1)
Disconnection or short circuit
with chassis ground in Repair or
steering lever neutral safety replace
relay system [Refer to
troubleshooting of AJSS
control system (A mode) A-6]
Defective contact or Repair or
disconnection in wiring replace
harness between L95
ground
WA800L-3 20-709
(1)
TROUBLESHOOTING E-1
Cause Remedy
22 YES Defective starting motor

Repair or
assemly
Is voltages between replace
YES starting switch
terminal S and Defective wire, poor
chassis normal ?
connection from relay C Repair or
• Turn starting NO to starting switch replace
switch ON terminal S
21 • 20 - 30 V
Is voltages between YES Defective starting motor Repair or
From safety relay 24 assemly replace
C terminal C and
chassis normal ? Is voltages between
YES starting switch
• Set directional terminal S and 26YES
switch to N chassis normal ? Is resistance
Defective safety relay Replace
• Set joystick • Turn starting between E06
23 (female) (3) and
steering lever to N switch ON
• Turn starting NO chassis grond Defective contact or open
Is voltages between • 20 - 30 V normal ? in wire harness between Repair or
switch to START E06 (1) and (3)
position NO normal ? • Disconnect E06 NO E06 (female) (3), E01 (9) replace
• 20 - 30 V • Turn starting switch ON and chassis ground
• Max. 1 z
• Turn starting
switch ON 25 YES Defective pre-lube
Replace
• 20 - 30 V timer/solenoid assembly
Is voltages between
E06 (1) and chassis Defective contact or open
NO normal ?
in wire harness between Repair or
E06 (female) (1), E23 and replace
• Turn starting NO pre-lube timer/solenoid
switch ON pin 5
• 20 - 30 V
b) Starting motor turns
Cause Remedy
YES See engine ECM section

Read out codes —
of manual
1
Is the engine ECM

reporting faults ?
3 YES
See engine manual —
• Turn starting switch
ON Are ECM lamps
• Move "diagnostic" NO working properly ?
switch ON Use service computer to
—
NO check ECM
20-710 WA800L-3
(1)
TROUBLESHOOTING E-2
E-2 Engine does not stop
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
2 YES Defect in ECM or in See engine

engine fuel shut-off valve manual
YES Is voltage between
ER1 (male) (14) and Incorrect wiring at starting
1
chassis normal ? switch or short in wire
Repair or
Is voltage between harness between ECM2
• With engine not NO replace
ER1 (male) (14) and (female) (A) and starter
chassis normal ? running, starting switch terminal ACC
switch in OFF position
• Max. 1 V Incorrect wiring at starting Repair or
• With engine not
switch or short in wire replace
running, starting NO harness between ECM2
switch in OFF
(female) (A) and starting
position
switch terminal ACC
• Max. 1 V
WA800L-3 20-711
(1)
TROUBLESHOOTING E-1, E-2
E-1, E-2 Related electrical circuit diagram
20-712 WA800L-3
(1)
WA800L-3 20-713
(1)
TROUBLESHOOTING E-3
E-3 Abnormality in preheating system
a) Does not carry out preheating

a Check that the water temperature is below 5°C.
Cause Remedy
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
and engine ECM
switch ON.
normal?
• 20 – 30 V disconnection in wiring Repair or
• Turn starting harness between engine replace
switch ON. NO
ECM and E10, E12
b) Only monitor display lights up
Cause Remedy
YES
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
c) Monitor display does not light up when preheating is completed
Cause Remedy
1 Yes
Is resistance
between L05
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
d) Monitor display keeps lighting up when preheating is not completed
Cause Remedy
2 Yes Repair or
Defective main monitor
replace
Yes Is voltage between
L05 (19) and chassis Defective contact or
ground normal ?
1 Replace
harness between E09
• Max. 1 V No
Is voltage between
• 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
E-3 related electrical circuit diagram
20-716 WA800L-3
(1)
TROUBLESHOOTING E-4
E-4 Parking brake does not have effect
a Check that the brake hydraulic system is normal.

a When carrying out troubleshooting of the brake system, stop the machine on level ground.
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) Parking brake has no effect when parking brake switch is turned ON
Cause Remedy
YES Defective parking brake

Replace
switch
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
(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
1 YES Defective parking brake

Replace
Is resistance solenoid
between CBL1
(female) (3) and Defect of all four
(4) normal? emergency brake
Replace
• Start engine NO switches (SW1, SW2,
(Charge SW3, SW4)
accumulator).
WA800L-3 20-717
(1)
TROUBLESHOOTING E-5
E-5 Parking brake is applied when machine is traveling
a When carrying out troubleshooting of the brake system, stop the machine on level ground.
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?
• 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 parking brake

Replace
solenoid
harness between F11 replace
Defective parking brake

Replace
safety relay
Defective emergency Replace

brake switch
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
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.
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)
(female) (5) – fuse I (8)
Defective parking brake Replace

switch
WA800L-3 20-719
(1)
E-6 Parking brake is released when starting switch is turned ON
a Always, connect any disconnected connectors and disconnect the T-adapter before going on to the next
step.
Cause Remedy
YES Defective parking safety

Replace
relay
1
Does condition
become normal
when L59 is YES Defective parking brake
Replace
replaced with other 2 switch
relay of same type?
Does condition Short circuit of wiring
• Replace parking harness between L01
become normal
safety relay (L59) (female) (3) and L58 (female)
NO when L01 is 3 YES Repair or
with another (1), CBL1 (male) (3) and
disconnected? wiring harness between L59 replace
relay of same Is resistance
• Disconnect L01. between L59 (female) (5) and L01 (female)
type.
(1) with each other
• Start engine. • Start engine. NO (female) (3) and (5)
• Charge • Charge normal? Short circuit of wiring Repair or
accumulator, accumulator,
then turn starting
• Min. 1 Mz NO
harness between L59
(female) (3) and L01 (female)
replace
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
1 YES Defective neutralizer

Replace
relay
Is voltage between
neutralizer relay
L58 (female) (5) – Short circuit with power
chassis normal? source in wiring harness Repair or
• Max. 1 V NO between L58 (female) (5) replace
• Disconnect and C3A (female) (6)
neutralizer relay
L58.
• Turn starting
switch ON.
• Shift directional
switch between
F, N, and R, and
check each
voltage.
20-720 WA800L-3
(1)
TROUBLESHOOTING E-5, E-6, E-7
E-5, E-6, E-7 Related electrical circuit diagram
WA800L-3 20-721
(1)
TROUBLESHOOTING E-8
E-8 Kick-down switch does not work
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), (4) • Disconnect L08.
2 Defective contact or
normal? • Turn starting
• Max. 1 z
Is resistance switch OFF. disconnection in wiring
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.
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
b) Kick-down cannot be canceled
Cause Remedy
YES Defective kick-down

Replace
switch
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.
E-8 Related electrical circuit diagram
WA800L-3 20-723
(1)
TROUBLESHOOTING E-9
E-9 Boom kick-out does not work
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.
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 boom relay

Replace
(L49)
Is resistance (female) (5) and L16 replace
(female) (2) and
chassis ground
normal? Repair or
• Max. 1 z
harness between L16
NO replace
(female) (2) – chassis
switch OFF.
• Disconnect L16. Repair or
Repair or
harness between fuse I (11) –
replace
L49 (female) (1), (3), between
FS2 (10) – F06 (female) (1)
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
E-10 Abnormality in bucket positioner function
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.
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)
Cause Remedy
Defective bucket relay Replace

(L48)
Is resistance (female) (5) and L17 replace
(female) (2) and
chassis ground
normal? Repair or
• Max. 1 z
harness between L17
NO (female) (2) – chassis
replace
switch OFF.
• Disconnect L17.
Repair or
harness between fuse I (11) –
L48 (female) (1), (3), between
replace
FS2 (10) – F05 (female) (1)
ground
Defective bucket
Replace
positioner solenoid
Defective bucket
Replace
proximity switch
WA800L-3 20-729
(1)
20-730 WA800L-3
(1)
TROUBLESHOOTING E-11, E-12, E-13, E-14, E-15, E-16
E-11 Abnormality in lighting up of front working lamp

a Go to Troubleshooting M-8.
E-12 Abnormality in lighting up of rear working lamp

E-13 Abnormality in transmission cut-off

E-14 Abnormality in low idling selection

E-15 Abnormality in parking brake dragging warning

E-16 Abnormality in buzzer

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
H-1 Machine does not move
Ask the operator the following points

• Did the machine suddenly stop moving?
Yes = Component seized or damaged
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.
defe valve s ht insid

ctiv
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
r reg valve d iting o

ive
o
• Is drive shaft broken?
uit d
lutc operati
vert
f
Sha g clutc lutch s smissi iorated ctive
e
defe ive
alve
d
ratio of sole part of tch for aling d
e
(b
ssi fective ue con
l rin cing va lating lief valv f valve
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
Dam seal rin for 3rd ed

p de
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
H-2 Machine lacks power or speed (every speed range)
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)
Relief pressure at torque converter too low

8
(Items 5 and 7 normal)
Torque converter regulator valve pressure (outlet port

9
pressure) too low
10 Iron or alumimum particles stuck to strainer of transmission

case.
11 Modulating pressure drops when oil temperature rises.
WA800L-3 20-803
(1)
TROUBLESHOOTING H-3
H-3 Excessive time lag when starting machine or shifting gear

• Is there any leakage of oil from joints of
piping or valves?
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.
4 Transmission modulating pressure too low in every speed

range
5 As in Items 4; indicator fluctuates violently

6 Torque converter oil temperature is above operating range.
20-804 WA800L-3
(1)
TROUBLESHOOTING H-4
H-4 Torque converter oil temperature is high

• Does torque converter oil temperature go
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
e de
fect
ng d
vert
valv
e de
con
al ri
• Is transmission filter clogged?
ator
valv
r (se
rque
lgul
f
erte
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
H-5 Steering does not turn

• Did the problem suddenly start?
Yes = Related equipment broken
• Was there any abnormal noise when this
happened? Where did the noise come
from?

• Is the oil level in the hydraulic tank cor-
rect?
Is the type of oil correct?
• Is the steering shaft broken?
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
Oil pressure is low or there is no pressure in

8 both directions (left and right)
When steering
relief pressure
is measured Oil pressure is low or there is no pressure in
9 one direction (left or right)
10 When rotary valve output pressure is measured, oil pressure

is found to be low or there is no oil pressure
11 When PPC valve (rotary valve) Oil pressure is low

12 basic pressure is measured There is no oil pressure
a There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is felt in the steering, check the operation of the work equipment also.
20-806 WA800L-3
(1)
TROUBLESHOOTING H-6
H-6 Turning, response of steering is poor

from?
• Was there previously any symptom, such
as difficulty in steering?
Yes = Wear of related equipments, defec-
tive seal

ses
ool
ol
ump
spo
rect?
d sp
Cau
of p
ing
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
Hydraulic pump Rotary Steering valve Cylin-

valve der
a b c d e f g h i j k
Remedy
No. Problems
1 Turning, response of steering is poor in both directions (left and right)
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
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)
When rotary valve output pressure is measured, oil pressure is

12
found to be low
When PPC valve (rotary valve) basic pressure is measured, oil

13
pressure is found to be low
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
H-7 Joystick lever is heavy

• Is the steering difficult to turn?
Yes = Go to H-6
• Measure the operating effort and turn-
ing speed, and check the STANDARD
VALUE TABLE to see if they are abnor-
mal.

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
valv
joys
atio
tary
e of
u
rect?
t
e ac
e ro
enc
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)
Joystick lever is heavy even when joint between steering

3
shaft and rotary valve is disconnected
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)
When rotary valve output pressure is measured, oil pressure

6
is found to be low
20-808 WA800L-3
(1)
TROUBLESHOOTING H-8
H-8 Steering wheel shakes or jerks

• Is the steering difficult to turn?
Yes = Go to H-6
• Is there any abnormal noise from around
the steering equipment?

• Is the joystick lever play correct?
• Is there any abnormality in the connec-
tion between the steering shaft and the
steering pilot valve?
• Is the tire inflation pressure correct?
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)
During operations or when traveling (when steering is neutral),

3
steering wheel shakes or jerks in both directions (left and right)
During operations or when traveling (when steering is neutral),

4
steering wheel shakes or jerks in one direction (left or right)
5 Steering wheel jerks or there is excessive shock when

steering is operated to end of its stroke
6 Work equipment also jerks
7 Oil pressure is unstable in both directions

When steering (left and right)
relief pressure
is measured Oil pressure is unstable in one direction
8
(left or right)
9 Oil pressure is unstable in both directions

When rotary
valve output (left and right)
pressure
10 is measured Oil pressure is unstable in one direction
(left or right)
11 When PPC valve (rotary valve) basic pressure is measured, oil

pressure is found to be unstable
WA800L-3 20-809
(1)
TROUBLESHOOTING H-9
H-9 Minimum turning radii to right and left are different
Cause and remedy

• Defective adjustment of steering stopper bolt (E)
20-810 WA800L-3
(1)
TROUBLESHOOTING H-10
H-10 Wheel brakes do not work or braking effect is poor

• Measure the actual brake performance,
and check if there is actually an abnor-
mality or whether it is just the feeling of
the operator. For details, see TESTING
AND ADJUSTING, Measuring brake
performance.
Ask the operator the following points.

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
ctiv eft brak al or de e valve

pum
ton
ive
uit
i
d of
fect
p
rg
rect?
oil ake circ

rake
al
e
a
n en
v
h
Defe ive sla brake v e
n se
l
c
lv
a
of b
ter
r
e va
Defe ve brak t suctio
ke
mp
Defe tive pis mulato
Brea tive ac e pisto
br
djus
• Is the brake pedal play correct?
a
ion
e
c
r
e pu
ctiv air from

s
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
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)
H-11 Wheel brakes are not released or brakes drag
Ask the operator the following points.

from?

• Does the brake pedal come back fully?
• Is the parking brake still applied (ON)?
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
When remaining pressure is released from brake accumulator

3
circuit with left brake pedal only, brake is released
When remaining pressure is released from brake accumulator

4
circuit with right brake pedal only, brake is released
When air bleed plug in wheel portion is loosened, oil flows

5
out and brake is released
6 When air bleed plug is loosened, a large amount of oil flows out
When brake disc wear is measured and brake pedal is released,

7
piston returns
When brake disc wear is measured and brake pedal is released,

8
piston does not return
20-812 WA800L-3
(1)
H-12 Boom does not rise

• Did the problem suddenly fail to rise?
o Seizure or damage to various units.
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
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.
The machine body can be lifted up by the boom however, the

2 boom is unable to rise. Or, the bucket operates but the 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.
6 When the engine is at full, steering action is light and excessively

fast.
7 When the engine is at full, steering action is heavy and slow.
WA800L-3 20-813
(1)
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
Tank- Steering PPC Work equipment Cylin-

pump valve valve control valve der
a b c d e f g h
Remedy C
No. Problems
Bucket tilt back force and speed are abnormal and boom
1
lifting speed is low.
Bucket tilt back force and speed are normal but boom lifting
2
speed is slow.
Some as Item 1 except that boom lifting speed becomes

3
particularly low when oil temperature rises.
4 Hydraulic pump emits abnormal noise.
When the engine is at full, steering action is light and

5
excessively fast.
6 When the engine is at full, steering action is heavy and slow.

7 Cylinder has a large amount of hydraulic drift.
The relief pressure of relief valve of work equipment control

8
valve.
20-814 WA800L-3
(1)
TROUBLESHOOTING H-14, H-15, H-16
H-14 When raising boom, becomes slow at certain height

• External deformation of boom cylinder.
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”.
H-15 Boom cylinder cannot hold down bucket
Refer to item “H-13 Boom moves slowly or does not have sufficient lifting power”.

• Is travel of boom spool of work equipment control valve correct?
Cause
• Defective boom cylinder rod side suction valve seat of work equipment control valve
• Oil leakage from boom cylinder piston seal
H-16 Boom has large amount of hydraulic drift

• Did the hydraulic drift suddenly become large?
o Dirt lodged in valve or damaged parts.
• Did the hydraulic drift gradually become large?
o Worn parts.

• Is the boom spool in the hold position?
o Seized ring bushing, defective spool detent.
Troubleshooting and cause

• When measuring hydraulic drift, internal leakage of boom cylinder makes oil leakage noise.
o Damaged cylinder packing.
• When measuring hydraulic drift, boom cylinder does not make oil leakage noise.
o Defective oil sealing of boom spool.
o Defective check valve between pipings.
WA800L-3 20-815
(1)
TROUBLESHOOTING H-17, H-18
H-17 Boom fluctuates while working

During excavation or ground leveling when the boom control lever is in the “HOLD” position, the bucket
and boom move up and down in accordance with the terrain.
Troubleshooting and cause

Check the amount of hydraulic drift and whether or not the machine body can be lifted up by the boom
cylinder.
1. If the amount of hydraulic drift is greater than the standard value, refer to item “H-16 Boom has
large amount of hydraulic drift”.
2. If the machine body can not be lifted up by the boom cylinder, refer to item “H-15 Boom cylinder
cannot hold down bucket”.
3. If the amount of hydraulic drift is normal and the machine body can be lifted up by the boom cylinder
after the boom is moved several times to cause the boom cylinder to move through its entire stroke
o the trouble is due to the generation of a vacuum in the cylinder.
a If a vacuum is generated frequently o defective suction valve on boom cylinder rod side.
H-18 Boom drops momentarily when lever is operated from HOLD to RAISE
The boom drops momentarily under its own weight when the boom control lever is gradually shifted from
the “HOLD” position to the “RAISE” position while the engine is at low idling. When the control lever is
put completely into the “RAISE” position, the boom moves normally.
Cause
• Defective seating of work equipment control valve or boom spool check valve.
20-816 WA800L-3
(1)
H-19 Bucket does not tilt back

• Did the bucket suddenly cease to move?
o Seized or damaged equipment.
• Was any abnormal noise emitted (where
did it emanate from?)
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
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.
6 Steering action is light and excessively fast when the engine is at

full.
7 Steering action is heavy and slow when the engine is at full.
WA800L-3 20-817
(1)
H-20 Bucket moves slowly or has insufficient tilt back power
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.
Phenomena of item 1 become particularly bad when the oil

3
temperature increases.
4 The hydraulic pump emits an abnormal noise.
Steering action is light and excessively fast when the engine

5
is at full.
6 Steering action is heavy and slow when the engine is at full.

7 The bucket cylinder has a large amount of hydraulic drift.
8 The relief pressure of relief valve of work equipment control

valve is also low.
9 The discharge volume of the hydraulic pump is low.
20-818 WA800L-3
(1)
TROUBLESHOOTING H-21, H-22, H-23
H-21 Bucket movement becomes slow during tilt back

• External deformation of bucket cylinder.
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”.
H-22 Bucket cylinder cannot hold down bucket
Refer to item “H-20 Bucket moves slowly or has insufficient tilt back power”.

• Is the travel of bucket spool of work equipment control valve correct?
Cause
• 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.
H-23 Bucket has large amount of hydraulic drift

• Did the hydraulic drift suddenly become large?
oDirt lodged in valve or damaged parts.
• Did the hydraulic drift gradually become large?
oWorn parts.

• Is the bucket spool in the hold position?
oSeized ring bushing, faulty spool detent.
Fault check
• Use the standard value table to check whether or not the hydraulic drift of the bucket is actually
large.
Cause
• 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
H-24 Bucket fluctuates while traveling under load

(work equipment valve “HOLD”)

• Excessive play in pin and bushing of work equipment linkage. (Was an abnormal noise produced?)
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)
H-26 Boom and bucket levers do not move smoothly
Fault check
Using the standard value table, check
whether or not the operating effort of the
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.
2 Movement of boom and bucket levers becomes sluggish along

with change in oil temperature.
3 Movement of boom and bucket levers becomes partially sluggish

irrespective of oil pressure and temperature.
4 Movement of boom and bucket levers becomes generally sluggish

irrespective of oil pressure and temperature.
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
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
frame angle sensor system) is displayed ............................................................................................. 20-913
steering lever lock pressure switch system) is displayed ..................................................................... 20-914
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
Engine cannot be started
Steering speed is lowered

Steering speed is heightened
Failure
code
Response of steering system is lowered

Response of steering system is heightened
Location of failure
Steering speeds in both directions are different
Diagnosis code when failure code is displayed

Engine can be started while machine is steered
Caution buzzer does not sound or keeps sounding
Machine is steered suddenly after engine is started
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

CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Failure code Abnormal system Contents of abnormality
Disconnection or short cir- 1) Defective caution buzzer relay

cuit with chassis ground in 2) Disconnection, defective contact, or short circuit with chassis ground
caution buzzer relay sys- in wiring harness between T/M and J/S controller C2 (female) (9) –
tem L65 (female) (1)
3) Disconnection or defective contact in wiring harness between T/M and
56
J/S controller C2 (female) (19) – L65 (female) (2)
4) Defective T/M and J/S controller
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)
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)
Disconnection or short cir- 1) Improper installation (Misalignment) of frame angle sensor

cuit with chassis ground in 2) Defective frame angle sensor
frame angle sensor (poten- 3) Disconnection, defective contact, or short circuit with chassis ground
tiometer) system in wiring harness between T/M and J/S controller C3A (female) (13) –
59 L27 (female) (1)
20-904 WA800L-3
(1)
Normal condition Operation of controller Condition of machine Diagnosis

(Voltage, current, resistance) against abnormality caused by abnormality code
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
(female) (9) – L65 (female) (1): Max. 1 z
(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)
Failure code Abnormal system Contents of abnormality
Disconnection or short cir- 1) Defective steering lock pressure switch

steering lever lock pressure in wiring harness between T/M and J/S controller C3B (female) (9) –
switch system L39 (female) (1)
3) Disconnection or defective contact in wiring harness between T/M
and J/S controller L39 (female) (2) – chassis ground
60 4) Defective T/M and J/S controller
Disconnection or short cir- 1) Defective steering neutral interlock relay

steering neutral interlock in wiring harness between T/M and J/S controller C2 (female) (8) –
relay system L95 (female) (1)
62 3) Disconnection or defective contact in wiring harness between L95
(female) (2) – chassis ground
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)
20-906 WA800L-3
(1)
Normal condition Operation of controller Condition of machine Diagnosis

(Voltage, current, resistance) against abnormality caused by abnormality code
Voltage between T/M and J/S controller 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.
(In case of short circuit A-5

with chassis ground)
1) Machine can travel
although steering sys-
tem is locked.
2) Gear is shifted in F or R.
3) Gear is shifted in F or R.
Voltage between T/M and J/S controller C2 (8) – Does not operate at all. 1) Engine can be started
chassis ground: while machine is
• When steering lock lever is in NEUTRAL: 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
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
has been removed.
a When the joystick steering lever is not being used, leave it at the neutral position.
Cause Remedy
4 YES Defective T/M and J/S

Replace
YES between C2
(female) (9) and Short circuit or short circuit
3 chassis ground with chassis ground in
Is resistance normal? wiring harness between C2 Repair or
• Min. 1 Mz
YES between C2 NO (female) (9) – L65 (female) replace
(female) (9) and L65 • Turn starting (1)
Is resistance Disconnection or defective
• Max. 1 z
• Disconnect C2 and L65.
between L65 contact in wiring harness Repair or
YES between C2 (female) (9) –
(female) (2) and • Turn starting NO replace
chassis ground switch OFF. L65 (female) (1)
1 normal?
• Disconnect C2
• Max. 1 z
and L65. contact in wiring harness Repair or
between L65 • Turn starting
(male) (1) and (2) NO between C2 (female) (19) – replace
switch OFF. L65 (female) (2)
normal? • Disconnect L65.
• 200 – 400 z
• Turn starting Defective caution buzzer
relay Replace
switch OFF. NO
• Disconnect L65.
A-1 Related electrical circuit diagram
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
has been removed.
Cause Remedy
Improper installation of Replace or

YES steering lever angle adjust neutral
2 sensor (Deviation of position
neutral position)
Does voltage Disconnection, defective
YES
between C3A (3) contact, short circuit with
and (16) change?
3 YES chassis ground, or short circuit Repair or
Does resistance with power source in wiring replace
1
• Lean steering between JS2 harness between C3A (female)
lever to right or NO (male) (1) and (3) (3) – JS2 (female) (1)
Is voltage
between C3A (7) left change? Defective steerintg lever
• 0.5 – 4.5 V Replace
and (16) normal? • Lean steering NO angle sensor
• Starting switch lever to right or
• 4.9 – 5.1 V ON. left
• 0.2 – 5 kz
• Starting switch
ON. Defective T/M and J/S
Replace
NO • Starting switch OFF. controller
• Disconnect JS2.
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
has been removed.
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)
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)
• Change frame Defective frame angle

Replace
angle NO sensor
• 0.2 – 5 kz
• Start engine.
• Disconnect L27.
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
has been removed.
Remedy
Improper installation of Replace or

YES frame angle sensor adjust neutral
2 (Deviation of neutral position
position)
YES Does voltage Disconnection, defective
between C3A (13) contact, short circuit with
3 YES Repair or
and (16) change? chassis ground, or short circuit
Does resistance with power source in wiring replace
1
• Change frame between L27 harness between C3A (female)
(13) – L27 (female) (1)
Is voltage angle NO (male) (1) and (3)
between C3A (7) • 0.5 – 4.5 V change? Defective frame angle
and (16) normal? • Start engine. Replace
• Change frame NO sensor
angle
• 0.2 – 5 kz
• 4.9 – 5.1 V
• Turn starting switch
• Start engine. Defective T/M and J/S
ON. Replace
NO • Disconnect L27. controller
WA800L-3 20-913
(1)
TROUBLESHOOTING A-5
lever lock pressure switch system) is displayed
has been removed.
a When the steering lock lever is in the LOCK position, the steering lock pressure switch is opened (since the
oil pressure is not heightened).
Cause Remedy

Replace
YES between L39
(female) (2) and
3 chassis ground Disconnection or defective
Is resistance normal? contact in wiring harness Repair or
• Max. 1 z
between C3B replace
YES
(female) (9) and
NO between L39 (female) (2) –
chassis ground
2 chassis ground • Turn starting
normal? switch OFF. Disconnection or defective
Is voltage
YES between C3B (9) • Min. 1 M z • Disconnect L39. contact in wiring harness Repair or
• Turn starting between C3B (female) (9) – replace
and chassis NO
1 ground normal?
• Disconnect C3B Short circuit with chassis
Is resistance •0–2V and L39. ground in wiring harness Repair or
between L39 • Start engine.
between C3B (female) (9) replace
(male) (1) and (2) • When steering NO
normal? – L39 (female) (1)
lock lever is in
• Max. 1 z FREE.
• Disconnect L39. Defective steering lock
Replace
• Start engine. NO pressure switch
When steering
lock lever is in FREE:
Max. 1 z
When steering
lock lever is in LOCK:
Min. 1 Mz
20-914 WA800L-3
(1)
TROUBLESHOOTING A-6
neutral interlock relay system) is displayed
has been removed.
Cause Remedy
YES Defective steering neutral

relay Replace
1 4 YES Defective T/M and J/S

Is resistance controller Replace
If L95 relay is YES between L95
replaced, is (female) (2) and
3 chassis ground
Disconnection or defective
system normal? Is resistance contact in wiring harness Repair or
normal?
• Replace L95 with
YES between C2
(female) (8) and
• Min. 1 z between L95 (female) (2) –
NO chassis ground replace
normal relay. chassis ground

• Turn starting
2 switch OFF.
Is resistance
Min. 1 M z • Disconnect L95. ground in wiring harness Repair or
between C2 between C2 (female) (8) –
NO (female) (8) and L95
(female) (1) normal?
• Disconnect C2
• Max. 1 z
Disconnection or
and L95. defective contact in
• Turn starting Repair or
NO wiring harness between replace
switch OFF. C2 (female) (8) – L95
• Disconnect C2 (female) (1)
and L95.
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
has been removed.
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
chassis ground Short circuit with power
• 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
A-8 Steering speeds in both directions are different
a If an error code is displayed, check the parts corresponding to it.
Cause Remedy
Deviation of steering
lever angle sensor or Repair or
frame angle sensor replace
potentiometer
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)
Cause Remedy

controller Replace
Is voltage between
YES C3A (female) (19)
3 and chassis ground
normal? Repair or
Is resistance source in wiring harness
YES between C3A • Max. 1 V NO between C3A (female) (19) replace
(female) (6) and JS3 • Turn starting switch – JS4 (male) (1)
2 (female) (1) normal? ON.
Is resistance • Disconnect C3A and JS4. Disconnection or defective
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
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
• Disconnect JS3 and JS4.
20-918 WA800L-3
(1)
TROUBLESHOOTING A-10
A-10 Abnormality in power source and voltage
Cause Remedy
YES Defective T/M and J/S Replace

1 controller
Is voltage between Short circuit with chassis
C1 (7), (13), C2 (1), ground, disconnection, or
(12) and C1 (6),
(12), C2 (11), (21)
2 YES defective contact in wiring
Repair or
Is resistance harness between C1
normal?
between C1
replace
(female) (7), (13), C2
• 20 – 30 V (female) (6), (12), C2 (female) (1), (12) – fuse II (6)
• Turn starting (female) (11), (21)
NO and chassis ground Disconnection or defective
switch ON. normal?
• Max. 1 z
contact in wiring harness Repair or
NO between C1 (female) (6), replace
• Turn starting (12), C2 (female) (1), (12) –
switch OFF. chassis ground
• Disconnect C1
and C2.
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
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

Clearance between trunnion size Shaft Hole clearance limit
1
and torque converter case
–0.100 +0.072 0.100 –
230
–0.172 0 0.242
Clearance between O.D. of Replace
0 +0.035
2 shaft and I.D. of rubber cush- 63 0 – 0.065
–0.030 0
ion
Clearance between O.D. of
+0.115 +0.054 –0.115 –
3 rubber cushion and I.D. of 97
+0.080 0 –0.026
bracket hole
Standard shim thickness: 1.5 mm (parallelism of coupling mating
4 Thickness of mount shim —
joint of transmission output shaft and sensor of sensor pin: Max.
WA800L-3 40-3
MAINTENANCE STANDARD DAMPER
DAMPER
40-4 WA800L-3
MAINTENANCE STANDARD DAMPER
Unit: mm

Clearance between bearing size Shaft Hole clearance limit
1
and shaft
+0.015 0 –0.035 –
95 0.025
+0.003 –0.020 –0.003
Clearance between bearing 0 –0.008 –0.033 –
2 170 0.030
and housing –0.025 –0.033 0.017
Clearance between inner +0.035 +0.099 0.029 –
3 94.3 0.1 Replace
body and shaft +0.013 +0.064 0.086
Standard size Tolerance Repair limit
Wear of surface in shaft and
4 0
oil seal 115 –0.140
–0.087
Wear of surface in sleeve and 0
5 140 –0.160
oil seal –0.100
6 Backlash of spline 0.068 – 0.263
WA800L-3 40-5
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP
TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP
40-6 WA800L-3
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING, PPC AND BRAKE PUMP
Unit: mm
Model Standard clearance Clearance limit

SAR4 – 112 0.11 – 0.16 0.19
Clearance between rotor and
1 SAR3 – 100 0.13 – 0.18 0.22
shaft
SAR1 – 32 0.10 – 0.15 0.19
SAR1 – 14 0.10 – 0.15 0.19
SAR4 – 112 0.06 – 0.140 0.20
Clearance between inside SAR3 – 100 0.06 – 0.149 0.20
2 diameter of plain bearing and
outside diameter of gear shaft SAR1 – 32 0.06 – 0.119 0.20 Replace
SAR1 – 14 0.06 – 0.149 0.20
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
4 Rotating torque of spline shaft 20.6 – 36.3 Nm {2.1 – 3.7 kgm} —

Standard Repair limit
Revolution Discharge
Model discharge discharge
(rpm) pressure
(l/min) (l/min)
2.9 MPa
SAR4 – 112 2,200 242 222
{30 kg/cm2}
Discharge
— Oil: EO10-CD 2.9 MPa —
SAR3 – 100 2,200 210 183
Temperature: 45 to 55°C {30 kg/cm2}
2.9 MPa
SAR1 – 32 2,200 68 57
{30 kg/cm2}
9.8 MPa
SAR1 – 14 2,200 29 24
{100 kg/cm2}
WA800L-3 40-7
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
Unit: mm

Inside diameter of seal ring
1 +0.040 Repair
surface of retainer 170 170.5
0 chrome plat-
ing or replace
Inside diameter of seal ring +0.035
2 85 85.1
surface of sleeve 0
0
Width and thick- Width 4.45 4.05
3 –0.1
ness of seal ring
Thickness 6.0 ±0.1 5.5 Replace
Backlash of PTO gear
4 0.20 – 0.52
(Drive gear)
40-8 WA800L-3
MAINTENANCE STANDARD TORQUE CONVERTER REGULATOR VALVE
TORQUE CONVERTER REGULATOR VALVE
Unit: mm

Clearance between size Shaft Hole clearance limit
1
poppet and spool
–0.020 +0.021 0.020 –
22 0.08
–0.030 0 0.051
Clearance between –0.035 +0.016 0.035 –
2 40 0.08
spool and body –0.045 0 0.061
Standard size Repair limit Replace
Installation Installation Installation

Free length Free length
3 Poppet spring length load load
22.4 N 20.6 N
43.9 21 42
{2.28 kg} {2.1 kg}
Spool spring 107.9 N 98.1 N
4 172 92 167
{11 kg} {10.0 kg}
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
Unit: mm
Standard size Repair limit

1 R clutch springs (12 pieces) length load load
114.7 N 97.1 N
91 78 85.5
{11.7 kg} {9.9 kg}
139.3 N 108.9 N
2 F clutch springs (12 pieces) 108.5 92 102
{14.2 kg} {11.1 kg}
123.6 N 104.9 N
3 2nd clutch springs (12 pieces) 91 77 85.5
{12.6 kg} {10.7 kg}
194.2 N 164.8 N
4 1st clutch springs (12 pieces) 91 69 85.5
{19.8 kg} {16.8 kg}
Thickness of assembled 6 Standard size Tolerance Repair limit

5
discs and 5 plates for R clutch 61.4 — 59.5
Thickness of assembled 6
6 61.4 — 59.0
discs and 5 plates for F clutch
7 discs and 3 plates for 2nd 39.0 — 37.4
clutch
8 50.8 — 48.8
discs and 4 plate for 1st clutch Replace
9 discs and 5 plates for 3rd 61.4 — 59.0
clutch
10 Thickness of 1 disc 5.4 ±0.1 5.0
11 Thickness of 1 plate 5.8 ±0.1 5.3
–0.01
Wear of seal ring Width 3.0 –0.03 2.6
12
for input shaft Thickness 3.5 ±0.100 3.35
–0.01
13
for output shaft Thickness 4.3 ±0.120 4.15
–0.01
14
for 2nd carrier Thickness 5.0 ±0.15 4.85
–0.01
15
for F carrier Thickness 5.0 ±0.15 4.85
–0.01
16
for R carrier Thickness 4.0 ±0.12 3.85
–0.01
17
for idler shaft Thickness 4.0 ±0.12 3.85
WA800L-3 40-11
TRANSMISSION (2/2)
1 2 3 4 5 6 7 8 9 10
SEW01601
Unit: mm
Backlash between reverse

1 0.15 – 0.40
sun gear and planetary gear
Backlash between reverse
2 0.15 – 0.39
planetary gear and ring gear
Backlash between forward
3 0.15 – 0.40
sun gear and planetary gear
Backlash between forward
4 0.15 – 0.40
planetary gear and ring gear
Backlash between sun gear
5 0.15 – 0.40
and planetary gear
Replace
Backlash between planetary
6 0.15 – 0.40
gear and ring gear
Backlash between 2nd sun
7 0.15 – 0.40
gear and planetary gear
Backlash between 2nd plane-
8 0.15 – 0.39
tary gear and ring gear
Backlash between 1st sun
9 0.15 – 0.40
gear and planetary gear
Backlash between 1st plane-
10 0.15 – 0.39
tary gear and ring gear
40-12 WA800L-3
MAINTENANCE STANDARD TRANSFER
TRANSFER
Unit: mm

Oil seal sliding surface of out-
1 0
put shaft coupling (R) 170 169.8
–0.10
Oil seal sliding surface of out- 0
2 170 169.8
put shaft coupling (F) –0.10
Standard clearance Clearance limit
Clearance between output
3 –0.05 – 0.05
cover and case 1 Replace
(After installed shim)
Backlash between input gear
4 0.23 – 0.59
and idler gear
Backlash between output gear
5 0.23 – 0.59
and idler gear
Backlash between 2nd shaft
6 0.23 – 0.59
gear and 3rd shaft gear
WA800L-3 40-13
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE

UPPER VALVE
40-14 WA800L-3
Unit: mm

Clearance between pilot size Shaft Hole clearance limit
1
reducing valve spool and body
–0.035 +0.013 0.035 –
28 0.08
–0.045 0 0.058
Clearance between priority –0.035 +0.013 0.035 –
2 28 0.08
valve and body –0.045 0 0.058
Clearance between quick –0.035 +0.013 0.035 –
3 19 0.08
return valve spool and body –0.045 0 0.058
Clearance between modulat- –0.035 +0.016 0.035 –
4 35 0.08
ing valve spool and body –0.045 0 0.061
Clearance between reducing –0.035 +0.013 0.035 –
5 28 0.08
valve spool and body –0.045 0 0.058
Clearance between lubrication –0.035 +0.013 0.035 –
6 28 0.08
valve spool and body –0.045 0 0.058
Installation Installation Installation Replace
7 Priority valve spring (Large) length load load
164.7 N 156.9 N
41.5 31.0 40.3
{16.8 kg} {16.0 kg}
130.4 N 123.6 N
8 Priority valve spring (Small) 35.0 31.0 34.0
{13.3 kg} {12.6 kg}
163.8 N 155.9 N
9 Pilot reducing valve spring 68.7 54.0 66.6
{16.7 kg} {15.9 kg}
319.7 N 304.0 N
10 Reducing valve spring 86.0 54.0 83.4
{32.6 kg} {31.0 kg}
Modulating valve spring 266.7 N 253.0 N
11 80.0 71.5 77.6
(Small) {27.2 kg} {25.8 kg}
Modulating valve spring 688.3 N 654.1 N

12 100 76.0 97.0
(Large) {70.2 kg} {66.7 kg}
116.7 N 110.8 N
13 Lubrication valve spring 74.5 48.0 72.3
{11.9 kg} {11.3 kg}
Shim adjustment for pilot

14 One shim will charge the pressure by 31.4 kPa {0.32 kg/cm 2}
reducing valve
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}
Thickness of shim for priority Adjust

16 3 (One shim will charge the pressure by 136.3 kPa {1.39 kg/cm2}
valve
Adjustment of shim for reduc-

17 One shim will charge the pressure by 28.4 kPa {0.29 kg/cm 2}
ing valve
Adjustment of shim for lubrica-

18 One shim will charge the pressure by 3.9 kPa {0.04 kg/cm2}
tion valve
WA800L-3 40-15
LOWER VALVE
40-16 WA800L-3
Unit: mm

Clearance between forward size Shaft Hole clearance limit
1
spool and body
–0.035 +0.013 0.035 –
22 0.08
–0.045 0 0.058
Clearance between first –0.035 +0.013 0.035 –
2 22 0.08
speed spool and body –0.045 0 0.058
Clearance between second –0.035 +0.013 0.035 –
3 22 0.08
Clearance between third –0.035 +0.013 0.035 –
4 22 0.08
Clearance between reverse –0.035 +0.013 0.035 –
5 22 0.08
spool and body –0.045 0 0.058
Clearance between main –0.035 +0.016 0.035 –
6 45 0.08
relief valve spool and body –0.045 0 0.061
Replace
Clearance between torque
–0.035 +0.016 0.035 –
7 converter relief valve spool 45 0.08
–0.045 0 0.061
and body
Springs for FORWARD, Installation Installation Installation
8 REVERSE, first, second, and length load load
third speeds
113.8 N 107.9 N
78 45 75
{11.6 kg} {11 kg}
Torque converter relief valve 517.8 N 492.3 N
9 206.5 143 200
spring {52.8 kg} {50.2 kg}
681.6 N 647.2 N
10 Main relief valve spring (inner) 185 138 179
{69.5 kg} {66.0 kg}
926.7 N 880.6 N
11 Main relief valve spring (outer) 160 97 155
{94.5 kg} {89.8 kg}
Thickness of main relief valve Standard shim thickness: 6.0
12
shim (One shim will charge the pressure 11.8 kPa {0.12 kg/cm2})
Adjust
Thickness of torque converter Standard shim thickness: 1.0
13
relief shim (One shim will charge the pressure 6.9 kPa {0.07 kg/cm2})
WA800L-3 40-17
SOLENOID VALVE
40-18 WA800L-3
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
WA800L-3 40-19
MAINTENANCE STANDARD CENTER SUPPORT
CENTER SUPPORT
Unit: mm

Clearance between case and size Shaft Hole clearance limit
1
bearing
0 –0.022 –0.051 –
230 0.011
–0.030 –0.051 0.008
Clearance between case and 0 –0.022 –0.051 – Replace
2 215 0.011
bearing –0.030 –0.051 0.008
Clearance between coupling +0.052 0 –0.007 –
3 130 –0.024
shaft and bearing +0.027 –0.025 –0.027
Clearance between coupling +0.045 0 –0.065 –
4 120 –0.020
shaft and bearing +0.023 –0.020 –0.023
5 Wear of oil seal surface 0 Repair
160 –0.20
–0.100 chrome plat-
ing or replace
0
6 Wear of oil seal surface 160 –0.20
–0.100
7 End play of coupling shaft 0.05 – 0.15 Replace
40-20 WA800L-3
MAINTENANCE STANDARD DIFFERENTIAL (1/2)
DIFFERENTIAL (1/2)
Unit: mm

1 Thickness of side gear washer
9.0 — 8.5
Thickness of pinion gear Replace
2 10.75 — 10.25
washer sleeve
0
3 Wear of oil seal surface 150 —
–0.100
WA800L-3 40-21
DIFFERENTIAL (2/2)
40-22 WA800L-3
Unit: mm

Clearance of bearing outer size clearance limit
Shaft Hole
1 race in differential gear
assembly 0 +0.036 –0.016 –
280 —
–0.035 –0.016 0.071
Clearance of bearing inner
+0.074 0 –0.049 –
2 race in differential gear 180 —
+0.049 –0.025 –0.099
assembly
Clearance of outer race of pin- 0 0 –0.046 –
3 215 —
ion shaft bearing –0.030 –0.046 0.030
Clearance of inner race of pin- 0 0 –0.020 –
4 120 —
Clearance of outer race of pin- 0 0 –0.052 –
5 290 —
Clearance of inner race of pin- +0.040 0 –0.015 –
6 160 —
ion shaft bearing +0.015 –0.025 –0.065
Clearance of differential pinion 0 –0.028 –0.003 –
7 160 —
gear outer race bearing –0.025 –0.068 –0.068
Clearance of differential pinion +0.013 0 –0.028 –
8 90 —
gear inner race bearing –0.009 –0.015 0.009
Clearance of differential pinion 0 –0.028 –0.010 –
9 140 —
gear outer race bearing –0.018 –0.068 –0.068 Replace
Clearance of differential pinion +0.013 0 –0.028 –
10 90 —
gear inner race bearing –0.009 –0.015 0.009
Clearance between differen- 0 +0.057
11 330 0 – 0.114 —
tial carrier and cage –0.057 0
Clearance between spider 0 +0.030
12 70 0 – 0.060 —
and differential pinion bushing –0.030 0
13 Backlash of bevel gear 0.43 – 0.61
14 Backlash of differential gear 0.31 – 0.40
Free rotating torque of pinion
22.6 Nm {2.3 kgm}
15 gear
Preload of pinion bearing 21 kN {2,140 kg}
Free rotating torque of bevel
25.5 Nm {2.6 kgm}
16 gear
Preload of side bearing 28 kN {2,860 kg}
17 Rear face runout of bevel gear 0.13
Standard thickness of shims
18 Clearance "a" + (0.1± 0.05)
for stop shaft
Standard thickness of shims
19 2.0
for differential cage
WA800L-3 40-23
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
40-24 WA800L-3
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm

Clearance between planetary size Shaft Hole clearance limit
1
shaft and bearing
+0.018 0 –0.038 –
100 —
+0.003 –0.020 –0.003
Clearance between planetary 0 –0.028 –0.003 –
2 180 —
gear and bearing –0.025 –0.068 –0.068
Clearance between axle –0.017 0 –0.018 –
3 300 —
housing and bearing –0.069 –0.035 0.069
Clearance between wheel hub 0 –0.045 –0.108 –
4 460 —
and bearing –0.045 –0.018 0
Clearance between axle –0.018 0 –0.022 –
5 320 — Replace
housing and bearing –0.075 –0.040 0.075
Clearance between wheel hub 0 –0.045 –0.108 –
6 480 —
and bearing –0.045 –0.108 0
Thickness of retainer at ring Standard size Tolerance Repair limit

7
gear hub mount 30 ±0.1 29.6
Backlash between planet gear Standard clearance Clearance limit

8
and sun gear 0.26 – 0.58 1.0
Backlash between planet gear
9 0.30 – 0.78 1.2
and ring gear
Thickness of standard shim
10 2.0
for wheel hub
WA800L-3 40-25
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
40-26 WA800L-3
MAINTENANCE STANDARD AXLE MOUNT
Unit: mm

Clearance of shaft and hole size clearance limit
Shaft Hole
1 (Front support side)
(Before press-fit bushing) +4.8 +0.155 –4.80 –
470.2
+0.8 0 –0.645
Clearance of shaft and hole
–0.068 +1.021 0.323 –
2 (Front support side) 460 1.6
–0.165 +0.255 1.186
(After press-fit bushing)
+4.800 +0.155 –4.80 –
3 (Rear support side) 470.2
+0.800 0 –0.645
(Before press-fit bushing)
Replace
–0.068 +1.021 0.323 –
4 (Rear support side) 460 1.6
–0.165 +0.255 1.186
(After press-fit bushing)
Standard size Clearance limit
5 Thickness of thrust washer
8 ±0.2
–0.21
6 Thickness of thrust plate 37
–0.35
7 Thickness of rear bushing 5 ±0.1
8 Thickness of front bushing 5 ±0.1
WA800L-3 40-27
MAINTENANCE STANDARD CENTER HINGE PIN
CENTER HINGE PIN
40-28 WA800L-3
MAINTENANCE STANDARD CENTER HINGE PIN
Unit: mm

Clearance between lower size Shaft Hole clearance limit
1
hinge pin and bushing
–0.043 +0.070 0.043 –
146.05 —
–0.068 0 0.138
Clearance between lower –0.043 +0.063 0.043 –
2 146.05 1.0
hinge pin and spacer (small) –0.068 0 0.131
3 146.05 —
hinge pin and bearing –0.068 0 0.093
4 146.05 1.0
hinge pin and spacer (large) –0.068 0 0.131
Clearance between lower
–0.050 +0.077 0.050 –
5 hinge spacer (large) and 206.0 —
–0.122 0 0.199
bushing
Clearance between front
+0.025 –0.067 –0.138 –
6 frame and upper hinge bear- 234.95 —
0 –0.113 –0.067
ing
Clearance between upper –0.043 +0.063 0.043 –
7 127 —
hinge pin and rear frame –0.068 0 0.131
Clearance between upper –0.043 +0.025 0.043 –
8 127 —
hinge pin and bearing –0.068 0 0.093
Replace
Clearance between front +0.025 –0.078 –0.155 –
9 304.8 —
frame and lower hinge bearing 0 –0.130 –0.078
Clearance between rear +0.310 +0.063 0.043 –
10 170 —
frame and bushing +0.210 0 0.131
Clearance at press-fitted part –0.043 +0.063 –0.310 –
11 146.05 —
of seal of upper hinge pin –0.068 0 –0.147
Clearance at press-fitted part +0.260 +0.072 –0.260 –
12 210 —
of seal of lower hinge pin +0.160 0 –0.088
+0.186 +0.063 –0.186 –
13 hinge bushing and frame 161.0 —
+0.146 0 –0.083
(upper)
+0.242 +0.072 –0.242 –
14 hinge bushing and frame 226.0 —
+0.196 0 –0.124
(lower)
Height of lower hinge spacer Standard size Tolerance Repair limit

15
(small) 73 ±0.1 —
Height of lower hinge spacer
16 155.5 ±0.1 —
(large)
Thickness for lower hinge and
17 32 ±0.8 —
retainer
Shim thickness for lower
18 1.93
hinge and retainer
Shim thickness for lower
19 2.20 Adjust
hinge and retainer
Shim thickness for upper
20 2.31
hinge and retainer
WA800L-3 40-29
MAINTENANCE STANDARD STEERING DEMAND VALVE
STEERING DEMAND VALVE
40-30 WA800L-3
(1)
MAINTENANCE STANDARD STEERING DEMAND VALVE
Unit: mm

Free Installation Installation Free Load
1 Steering spool return spring length length load length limit
74.5 N 58.8 N
41.8 38.0 —
{7.6 kg} {6 kg}
8.8 N 7.0 N
2 Load check valve spring 20.9 13.2 —
{0.9 kg} {0.71 kg}
410 N 328 N
3 Demand spool return spring 90.8 83.0 —
{41.8 kg} {33.4 kg} Replace
182.4 N 145.1 N
4 Surge cut relief valve spring 24.0 22.19 —
{18.6 kg} {14.8 kg}
182.4 N 145.1 N
5 Main relief valve spring 24.0 22.19 —
{18.6 kg} {14.8 kg}
590 N 471 N
6 Overload relief valve spring 39.5 35.7 —
{60.2 kg} {40.8 kg}
8.8 N 7.0 N
7 Check valve return spring 20.9 13.2 —
{0.9 kg} {0.71 kg}
WA800L-3 40-31
MAINTENANCE STANDARD DIVERTER VALVE
DIVERTER VALVE
Unit: mm

Clearance between body and size Shaft Hole clearance limit
1
spool
–0.023 +0.015 0.020 –
40 —
–0.005 +0.007 0.03
Free length Free length Replace
2 Spool spring length load load
216.7 N 205.9 N
122.6 84 120.7
{22.1 kg} {21.0 kg}
5.6 N 5.3 N
3 Check valve spring 79.2 54.5 77.9
{0.57 kg} {0.54 kg}
4.9 N 4.6 N
4 Check valve spring 79.2 57.5 77.9
{0.50 kg} {0.47 kg}
40-32 WA800L-3
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
Unit: mm

Clearance between mounting
pin and bushing connection of size Shaft Hole clearance limit
1
steering cylinder rod and
–0.036 +0.307 0.256 –
frame 110 1.0
–0.090 +0.220 0.397
Clearance between mounting
pin and bushing at connec- –0.036 +0.020 0.036 –
2 110 1.0
tion of steering cylinder bot- –0.090 0 0.110
tom and frame
Replace
Standard clearance
Connection of steering cylin- Width of boss Width of hinge
3 (Clearance a + b)
der and front frame
0
93 –0.2 116 ± 1.5 0.5 – 3.7
Connection of steering cylin- After adjusting with
4 110 +0.8
+0 116 ± 1.5
der rod and rear frame shim: Less than 1.0
5 Width of spacer
10.5 ±0.5 —
WA800L-3 40-33
MAINTENANCE STANDARD EMERGENCY STEERING PUMP
EMERGENCY STEERING PUMP

MODEL: SAM(3)100 + 100
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}
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
Unit: mm

Clearance between pedal size Shaft Hole clearance limit
1
mount hole and bracket hole
–0.025 +0.1 0.175 –
10 0.25
–0.075 0 0.025
Clearance between roller and –0.025 +0.1 0.175 –
2 10 0.25
pin –0.075 0 0.025
3 Outside diameter of roller 0
30 29.2
–0.5
Installation Installation Installation Replace
4 Control spring length load load
30.6 N
34 30 33 —
{3.12 kg}
0N
5 Control spring 46 46 45 —
{0 kg}
60.8 N
6 Return spring 86.2 58 78 —
{6.2 kg}
17.7 N
7 Spring 17 16.5 16.2 —
{1.8 kg}
16.7 N
8 Return spring 31.5 19.5 28 —
{1.7 kg}
WA800L-3 40-37
LEFT
Unit: mm

Clearance between pedal size Shaft Hole clearance limit
1
mount hole and bracket hole
–0.025 +0.1 0.175 –
10 0.25
–0.075 0 0.025
Clearance between roller and –0.025 +0.1 0.175 –
2 10 0.25
pin –0.075 0 0.025
3 Outside diameter of roller 0
30 29.2
–0.5
Standard size Repair limit Replace
4 Control spring length load load
3.82 N
34 33.5 33 —
{0.39 kg}
12.8 N
5 Control spring 47.7 46 46.7 —
{1.3 kg}
60.8 N
6 Return spring 86.2 58 78 —
{6.2 kg}
16.7 N
7 Return spring 31.5 19.5 28 —
{1.7 kg}
40-38 WA800L-3
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
Unit: mm

Clearance between body and size Shaft Hole clearance limit
1
piston
–0.030 +0.074 0.030 –
80 0.250
–0.076 0 0.150
Replace
2 Slack adjuster spring length load load
117.7 N
246 88 — —
{12 kg}
123.6 N
3 Check valve spring 44.8 38 — —
{12.6 kg}
WA800L-3 40-39
MAINTENANCE STANDARD BRAKE
BRAKE
40-40 WA800L-3
MAINTENANCE STANDARD BRAKE
Unit: mm

Free Installation Installation Free Installation
1 Return spring length length load length load
999.3 N 887.5 N
114.0 98.8 112.3
{101.9 kg} {90.5 kg}
2 Thickness of plate
2.4 2.15
3 Thickness of disc 5.1 4.6
Total thickness of plate and
4 107.4 100.4
disc
Wear of contact surface of oil Replace
5 0
seal 580 —
–0.175
Wear of surface in contact +0.110
6 585 —
with piston seal 0
Wear of surface in contact +0.110
7 630 —
with piston seal 0
Deformation of friction surface Standard Repair limit

8
of plate and disc Max. 0.45 0.70
Backlash between outer gear
9 0.21 – 0.64
and plate
Backlash between inner gear
10 0.21 – 0.64
and disc
WA800L-3 40-41
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
40-42 WA800L-3
MAINTENANCE STANDARD PARKING BRAKE
Unit: mm

Remaining
thickness of fric- 22.2 — 3.7
1 Wear of pad Replace
tion material
Including back-
31.7 — 12.7
ing plate
2 Face runout of disc 0.6 — 1.2
–0.10
3 Wear of rod connecting pin 12.7 —
–0.17
Rebuild
Thickness of plate
Wear of disc must be under
4 25 ±0.7 23 mm
(Thickness of disc)
Less than 23 mm Replace
Clearance between pad and
5 disc 1.06 ±0.18 2.1
(Total of both sides) Adjust
Clearance between brake body
6 0.36 – 1.0
and plate
WA800L-3 40-43
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
40-44 WA800L-3
MAINTENANCE STANDARD PPC VALVE
Unit: mm

Centering spring Free length Free length
1 length load load
(Bucket dump, boom lower)
5.4 N
39.9 34.5 — —
{0.55 kg} Replace if
Centering spring 21.1 N damaged or
2 56.7 34.5 — — deformed
(Bucket tilt, boom raise) {2.15 kg}
33.3 N
3 Metering spring 33.5 29.4 — —
{3.4 kg}
14.7 N
4 Return spring 28.2 17.5 — —
{1.5 kg}
WA800L-3 40-45
MAINTENANCE STANDARD PPC RELIEF VALVE
PPC RELIEF VALVE
Unit: mm

1 Main valve spring length load load
19.6 N 15.7 N Replace
47 27 —
{2.0 kg} {1.6 kg}
58.4 N 47.1 N
2 Poppet spring 33.6 30.5 —
{5.95 kg} {4.8 kg}
40-46 WA800L-3
MAINTENANCE STANDARD CONTROL PUMP
CONTROL PUMP
MODEL: BAR025
Unit: mm
Standard clearance Tolerance

1 Top clearance of gear
0.090 – 0.130 0.145
2 Side clearance of gear 0.055 – 0.075 0.105 Replace
Clearance between gear shaft

3 0.045 – 0.076 0.13
and bushing
Pump Revolution
Discharge Pressure discharge discharge
model (rpm)
— Oil: EO10-CD (l/min) (l/min) —
Temperature: 45 to 55°C 2.9 MPa
BAR25 3,200 72 68
{30 kg/cm2}
Tightening torque for housing
— 110.3 ± 12.3 Nm {11.25 ± 1.25 kgm} Tighten
case mounting bolt
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
MAIN PISTON PUMP

MODEL: HPV95+95
40-50 WA800L-3
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE
40-52 WA800L-3
MAINTENANCE STANDARD MAIN CONTROL VALVE
Unit: mm

1 Spool return spring length load load
431.5 N 345.2 N
69.9 63.0 —
{44.0 kg} {35.2 kg}
0N
2 Spool return spring 77.0 77.0 — —
{0 kg}
61.6 N 49.0 N
3 Spool return spring 79.7 78.5 —
{6.28 kg} {5.0 kg}
Main valve spring of relief 5.6 N 4.5 N
4 12.0 12.1 —
valve (Large) {0.57 kg} {0.46 kg}
18.8 N 14.7 N
5 Check valve spring 78.2 52.0 —
{1.92 kg} {1.5 kg} Replace
Suction valve spring of safety 6.9 N 5.9 N
6 27.9 18.0 —
valve {0.70 kg} {0.6 kg}
6.9 N 5.9 N
7 Suction valve spring 27.9 18.0 —
{0.70 kg} {0.6 kg}
137.3 N 109.8 N
8 Float selector valve spring 53.0 42.1 —
{14.0 kg} {11.2 kg}
49.0 N 39.2 N
9 Unloader valve spring 82.7 47.0 —
{5.0 kg} {4.0 kg}
Pilot poppet spring of relief 319.7 N 256.0 N
10 30.7 26.9 —
valve {32.6 kg} {26.1 kg}
Main valve spring of relief 2.3 N 1.9 N
11 10.45 6.3 —
valve (Small) {0.236 kg} {0.19 kg}
WA800L-3 40-53
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
Unit: mm
Name of Standard Tolerance Standard Clearance

cylinder size Shaft Hole clearance limit
–0.036 +0.265 0.085 –

Steering 100 —
Clearance between –0.090 +0.049 0.355
1
piston rod and bushing
–0.043 +0.216 0.091 –
Bucket 180 0.622
–0.106 +0.048 0.322
–0.043 +0.228 0.091 –
Boom 160 0.634
–0.106 +0.048 0.334
–0.036 +0.307 0.256 –
Steering 110 —
–0.090 +0.220 0.397 Replace
Clearance between bushing
–0.043 +0.395 0.338 –
2 piston rod mounting Bucket 180 1.0
–0.106 +0.295 0.501
pin and bushing
–0.043 +0.395 0.338 –
Boom 180 1.0
–0.106 +0.295 0.501
–0.036 +0.020 0.036 –
Steering 110 —
–0.090 0 0.110
Clearance between
–0.043 +0.395 0.338 –
3 cylinder bottom mount- Bucket 180 1.0
–0.106 +0.295 0.501
ing pin and bushing
–0.043 +0.395 0.338 –
Boom 180 1.0
–0.106 +0.295 0.501
Steering +0.3
160
0
4 Cylinder bore +0.2 Replace
Bucket 300
0
+0.2
Boom 260 —
0
40-54 WA800L-3
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
40-56 WA800L-3
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
Unit: mm

Clearance between pin and size clearance limit
Shaft Hole
1 bushing at boss ends of
bucket link –0.043 +0.434 0.390 –
180 1.0
–0.106 +0.347 0.540
Clearance between pin and
–0.043 +0.434 0.390 –
2 bushing at joint of boom and 180 1.0
–0.106 +0.347 0.540
bucket
–0.050 +0.435 0.370 –
3 bushing at joint of boom and 200 1.0
–0.122 +0.320 0.557
frame
Clearance between pin and Replace
–0.043 +0.395 0.338 – also if other
4 bushing at joint of bucket cyl- 180 1.0
–0.106 +0.295 0.501 parts are
inder rod and bellcrank
biting into
Clearance between pin and pin
–0.043 +0.395 0.338 –
5 bushing at joint of bucket cyl- 180 1.0
–0.106 +0.295 0.501
inder bottom and frame
–0.050 +0.435 0.370 –
6 bushing at joint of bellcrank 200 1.0
–0.122 +0.320 0.557
and boom
–0.043 +0.395 0.338 –
7 bushing at joint of boom cylin- 180 1.0
–0.106 +0.295 0.501
der bottom and frame
–0.043 +0.395 0.338 –
8 bushing at joint of boom cylin- 180 1.0
–0.106 +0.295 0.501
der rod and boom
Width between Standard clearance
Width of hinge
9 Joint of boom and frame bosses (Clearance a + b) Insert shims
214 ± 0.8 210 ± 2.9 0.3 – 7.7 on both
sides to
10 Joint of boom and bucket 259 +1.5
+0 250 ± 1 8.0 – 11.5 make clear-
11 Joint of bucket link and bucket 259 +1.5 250 ± 1 8.0 – 11.5 ance on
+0
both left and
Joint of boom cylinder and right sides
12 214 ± 0.8 210 +0.8
+0 2.4 – 4.8
frame less than
Joint of frame and bucket cyl- 1.5 mm.
13 213 ± 0.8 210 +0.8 1.4 – 3.8
inder +0
Joint of bucket cylinder and

14 213 +1
+0 210 +0.8
+0 2.2 – 4.0
bellcrank
Joint of bellcrank and bucket
15 253 +1
+0 250 ± 1 2.0 – 5.0 Repain or
link
replace
16 Joint of bellcrank and boom 358 ± 0.5 355 ± 0.5 2.0 – 4.0
Joint of boom cylinder and
17 213 ± 1.5 210 +0.8
+0 0.7 – 4.5
boom
Standard clearance Repair limit
18 Wear of bucket tooth Replace
45 0
WA800L-3 40-57
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
Unit: mm
Clearance of bucket position

1 3–5
switch
Clearance of boom kick-out
2 3–5 .
switch
Adjust
Clearance between bucket
3 positioner protector and 0.5 – 1
switch
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 (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
WA800L-3 90-7
WA800L-3 90-9
WA800L-3 90-11
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)

WA800L 3 - Sn52001and Up

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SEBM035601

MACHINE MODEL SERIAL NUMBER

• WA800L-3 mount the SAA12V140ZE-2 engine.

10 STRUCTURE AND FUNCTION ................................................................ 10-1

20 TESTING AND ADJUSTING ......................................................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ........................... To be issued next time

40 MAINTENANCE STANDARD ..................................................................... 40-1

90 OTHERS ................................................................................................................................ 90-1

The affected pages are indicated by the use of the

q Page to be replaced Replace

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

Time of Time of Time of Time of Time of

q 00-1 (1) 01-1 10-13 10-41 10-70

Time of Time of Time of Time of Time of

10-98 10-138 10-179 Q 20-104 (1) Q 20-202 (1)

Time of Time of Time of Time of Time of

Time of Time of Time of Time of Time of

Q 20-908 (1) 40-28

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rub-

Holtz • Used as heat-resisting sealant for re-

• Used as lubricant for sliding portion

SYG2-400CA • Used for normal temperature, light

Molybdenum • Used for heavy load portion

SUNSTAR • Used as primer for cab side

• "S" is used for high-tempera-

SUNSTAR • Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Thread diameter Width across flat Tightening torque (Nm {kgm})

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Thread diameter Width across flat Tightening torque (Nm {kgm})