Wa700 3
Wa700 3
Wa700 3
• 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.
© 2007
All Rights Reserved 00-1
Printed in Japan 10-07 (01) (12)
Contents
No. of page
01 General .......................................................................................................................... 01-1
00-2 WA700-3
(11)
List of revised pages
WA700-3 00-2-1
(12)
List of revised pages
10-102 (10) 10-146 (10) 10-186 (10) 10-226 (10) 20-8 (10)
10-103 (10) 10-147 (10) 10-187 (10) 10-227 (10) 20-9 (10)
10-104 (10) 10-148 (10) 10-188 (10) 10-228 (10) 20-10 (10)
10-106 (10) 10-149 (10) 10-189 (10) 10-229 (10) 20-11 (10)
10-107 (10) 10-150 (10) 10-190 (10) 10-230 (10) 20-12 (10)
10-108 (10) 10-151 (10) 10-191 (10) 10-231 (10) 20-13 (10)
10-109 (10) 10-152 (10) 10-192 (10) 10-232 (10) 20-14 (10)
10-110 (10) 10-153 (10) 10-193 (10) 10-233 (10) 20-15 (10)
10-111 (10) 10-154 (10) 10-194 (10) 10-234 (10) 20-16 (10)
10-112 (10) 10-155 (10) 10-195 (10) 10-235 (10) 20-17 (10)
10-113 (10) 10-156 (10) 10-196 (10) 10-236 (10) 20-18 (10)
10-114 (10) 10-157 (10) 10-197 (10) 10-237 (10) 20-19 (10)
10-115 (10) 10-158 (10) 10-198 (10) 10-238 (10) 20-20 (10)
10-116 (10) 10-159 (10) 10-199 (10) 10-239 (10) 20-21 (10)
10-117 (10) 10-160 (10) 10-200 (10) 10-240 (10) 20-22 (10)
10-118 (10) 10-161 (10) 10-201 (10) 10-241 (10) 20-23 (10)
10-119 (10) 10-162 (10) 10-202 (10) 10-242 (10) 20-24 (10)
10-120 (10) 10-163 (10) 10-203 (10) 10-243 (10) 20-25 (10)
10-121 (10) 10-164 (10) 10-204 (10) 10-244 (10)
10-122 (10) 10-165 (10) 10-205 (10) Q 10-244-1 (12) 20-101 (11)
10-124 (10) 10-166 (10) 10-206 (10) Q 10-244-2 (12) 20-102 (10)
10-125 (10) 10-167 (10) 10-207 (10) Q 10-244-3 (12) 20-103 (10)
10-126 (10) 10-168 (10) 10-208 (10) Q 10-244-4 (12) 20-104 (10)
10-127 (10) 10-169 (10) 10-209 (10) Q 10-244-5 (12) 20-105 (10)
10-129 (10) 10-170 (10) 10-210 (10) Q 10-244-6 (12) 20-106 (10)
10-130 (10) 10-171 (10) 10-211 (10) 10-245 (11) 20-107 (10)
10-131 (10) 10-172 (10) 10-212 (10) 10-246 (11) 20-108 (10)
10-133 (10) 10-173 (10) 10-213 (10) 10-247 (11) 20-109 (10)
10-134 (10) 10-174 (10) 10-214 (10) 10-248 (11) 20-110 (10)
10-135 (10) 10-175 (10) 10-215 (10) 10-249 (11) 20-111 (10)
10-136 (10) 10-176 (10) 10-216 (10) 10-250 (11) 20-112 (10)
10-137 (10) 10-177 (10) 10-217 (10) 10-251 (11) 20-113 (10)
10-138 (10) 10-178 (10) 10-218 (10) 20-114 (10)
10-139 (10) 10-179 (10) 10-219 (10) 20-1 (10) 20-115 (10)
10-140 (10) 10-180 (10) 10-220 (10) 20-2 (10) 20-116 (10)
10-141 (10) 10-181 (10) 10-221 (10) 20-3 (10) 20-117 (10)
10-142 (10) 10-182 (10) 10-222 (10) 20-4 (10) 20-118 (10)
10-143 (10) 10-183 (10) 10-223 (10) 20-5 (10) 20-119 (10)
10-144 (10) 10-184 (10) 10-224 (10) 20-6 (10) 20-120 (10)
10-145 (10) 10-185 (10) 10-225 (10) 20-7 (10) 20-121 (10)
00-2-2 WA700-3
(12)
List of revised pages
20-122 (10) 20-162 (11) 20-230 (10) 20-306 (10) 20-371 (10)
20-123 (10) 20-163 (11) 20-231 (10) 20-307 (10) 20-372 (10)
20-124 (10) 20-164 (11) 20-232 (10) 20-308 (10) 20-373 (10)
20-125 (10) 20-165 (11) 20-233 (10) 20-309 (10) 20-374 (10)
20-126 (10) 20-166 (11) 20-234 (10) 20-310 (10) 20-375 (10)
20-127 (10) 20-167 (11) 20-235 (10) 20-312 (10) 20-376 (10)
20-128 (10) 20-168 (11) 20-236 (10) 20-313 (10) 20-377 (10)
20-129 (10) 20-169 (11) 20-237 (10) 20-314 (10) 20-378 (10)
20-130 (10) 20-170 (11) 20-238 (10) 20-315 (10) 20-379 (10)
20-131 (10) 20-171 (11) 20-239 (10) 20-316 (10) 20-380 (10)
20-132 (10) 20-172 (11) 20-240 (10) 20-317 (10) 20-381 (10)
20-133 (10) 20-173 (11) 20-241 (10) 20-318 (10) 20-382 (10)
20-134 (10) 20-242 (10) 20-319 (10) 20-383 (10)
20-135 (10) 20-201 (11) 20-243 (10) 20-320 (10) 20-384 (10)
20-136 (10) 20-202 (10) 20-244 (10) 20-321 (10) 20-385 (10)
20-137 (10) 20-203 (10) 20-245 (10) 20-322 (10) 20-386 (10)
20-138 (10) 20-204 (10) 20-246 (10) 20-323 (10) 20-387 (10)
20-139 (10) 20-205 (10) 20-247 (10) 20-324 (10) 20-388 (10)
20-140 (10) 20-206 (10) 20-248 (10) 20-325 (10)
20-141 (10) 20-207 (10) 20-249 (10) 20-326 (10) 20-401 (10)
20-142 (10) 20-208 (10) 20-250 (10) 20-402 (10)
20-143 (10) 20-209 (10) 20-251 (10) 20-351 (10) 20-403 (10)
20-144 (10) 20-210 (10) 20-252 (10) 20-352 (10) 20-404 (10)
20-145 (10) 20-211 (10) 20-253 (10) 20-354 (10) 20-405 (10)
20-146 (10) 20-212 (10) 20-254 (10) 20-355 (10) 20-406 (10)
20-147 (10) 20-214 (10) 20-255 (10) 20-356 (10) 20-407 (10)
20-148 (10) 20-215 (10) 20-256 (10) 20-357 (10) 20-408 (10)
20-149 (10) 20-216 (10) 20-257 (10) 20-358 (10) 20-409 (10)
20-150 (10) 20-217 (10) 20-258 (10) 20-359 (10) 20-410 (10)
20-151 (10) 20-218 (10) 20-259 (10) 20-360 (10) 20-411 (10)
20-152 (10) 20-219 (10) 20-260 (10) 20-361 (10) 20-412 (10)
20-153 (10) 20-220 (10) 20-261 (10) 20-362 (10) 20-413 (10)
20-154 (10) 20-221 (10) 20-262 (10) 20-363 (10) 20-414 (10)
20-155 (10) 20-222 (10) 20-263 (10) 20-364 (10) 20-415 (10)
20-156 (10) 20-223 (10) 20-365 (10) 20-416 (10)
20-157 (11) 20-224 (10) 20-301 (10) 20-366 (10) 20-417 (10)
20-158 (11) 20-226 (10) 20-302 (10) 20-367 (10) 20-418 (10)
20-159 (11) 20-227 (10) 20-303 (10) 20-368 (10) 20-419 (10)
20-160 (11) 20-228 (10) 20-304 (10) 20-369 (10) 20-420 (10)
20-161 (11) 20-229 (10) 20-305 (10) 20-370 (10) 20-421 (10)
WA700-3 00-2-3
(12)
List of revised pages
20-422 (10) 20-489 (10) 20-553 (10) 20-602 (10) 20-657 (10)
20-423 (10) 20-490 (10) 20-554 (10) 20-604 (10) 20-658 (10)
20-424 (10) 20-491 (10) 20-555 (10) 20-605 (10) 20-659 (10)
20-425 (10) 20-492 (10) 20-556 (10) 20-606 (10) 20-660 (10)
20-426 (10) 20-494 (10) 20-557 (10) 20-607 (10) 20-661 (10)
20-427 (10) 20-495 (10) 20-558 (10) 20-608 (10) 20-662 (10)
20-496 (10) 20-559 (10) 20-609 (10) 20-663 (10)
20-451 (10) 20-497 (10) 20-560 (10) 20-610 (10) 20-664 (10)
20-452 (10) 20-498 (10) 20-561 (10) 20-611 (10) 20-665 (10)
20-454 (10) 20-499 (10) 20-562 (10) 20-612 (10) 20-666 (10)
20-455 (10) 20-500 (10) 20-563 (10) 20-613 (10) 20-667 (10)
20-456 (10) 20-501 (10) 20-564 (10) 20-614 (10) 20-668 (10)
20-457 (10) 20-502 (10) 20-565 (10) 20-615 (10) 20-669 (10)
20-458 (10) 20-504 (10) 20-566 (10) 20-616 (10) 20-670 (10)
20-459 (10) 20-505 (10) 20-567 (10) 20-617 (10) 20-671 (10)
20-460 (10) 20-506 (10) 20-568 (10) 20-618 (10) 20-672 (10)
20-461 (10) 20-507 (10) 20-569 (10) 20-619 (10) 20-673 (10)
20-462 (10) 20-508 (10) 20-570 (10) 20-620 (10) 20-674 (10)
20-464 (10) 20-509 (10) 20-571 (10) 20-621 (10) 20-675 (10)
20-465 (10) 20-510 (10) 20-572 (10) 20-622 (10) 20-676 (10)
20-466 (10) 20-511 (10) 20-573 (10) 20-624 (10) 20-677 (10)
20-468 (10) 20-512 (10) 20-574 (10) 20-625 (10) 20-678 (10)
20-469 (10) 20-513 (10) 20-575 (10) 20-626 (10) 20-679 (10)
20-470 (10) 20-514 (10) 20-576 (10) 20-627 (10) 20-680 (10)
20-471 (10) 20-515 (10) 20-577 (10) 20-628 (10) 20-681 (10)
20-472 (10) 20-516 (10) 20-578 (10) 20-629 (10) 20-682 (10)
20-474 (10) 20-517 (10) 20-579 (10) 20-630 (10) 20-683 (10)
20-475 (10) 20-518 (10) 20-580 (10) 20-631 (10) 20-684 (10)
20-476 (10) 20-519 (10) 20-581 (10) 20-632 (10) 20-685 (10)
20-477 (10) 20-520 (10) 20-582 (10) 20-633 (10) 20-686 (10)
20-478 (10) 20-521 (10) 20-583 (10) 20-634 (10) 20-688 (10)
20-479 (10) 20-522 (10) 20-584 (10) 20-635 (10) 20-689 (10)
20-480 (10) 20-523 (10) 20-585 (10) 20-636 (10) 20-690 (10)
20-481 (10) 20-524 (10) 20-586 (10) 20-637 (10) 20-691 (10)
20-482 (10) 20-525 (10) 20-587 (10) 20-692 (10)
20-483 (10) 20-526 (10) 20-588 (10) 20-651 (10) 20-693 (10)
20-484 (10) 20-527 (10) 20-589 (10) 20-652 (10) 20-694 (10)
20-485 (10) 20-590 (10) 20-654 (10) 20-695 (10)
20-486 (10) 20-551 (10) 20-655 (10) 20-696 (10)
20-487 (10) 20-552 (10) 20-601 (10) 20-656 (10) 20-697 (10)
00-2-4 WA700-3
(12)
List of revised pages
20-698 (10) 20-811 (10) 20-882 (10) 20-1013 (11) 20-1056 (11)
20-699 (10) 20-812 (10) 20-883 (10) 20-1014 (11) 20-1057 (11)
20-700 (10) 20-813 (10) 20-884 (10) 20-1015 (11) 20-1058 (11)
20-701 (10) 20-814 (10) 20-885 (10) 20-1016 (11)
20-702 (10) 20-815 (10) 20-886 (10) 20-1017 (11) 30-1 (7)
20-703 (10) 20-816 (10) 20-887 (10) 20-1018 (11) 30-2 (7)
20-704 (10) 20-817 (10) 20-888 (10) 20-1020 (11) 30-2-1 (7)
20-705 (10) 20-818 (10) 20-889 (10) 20-1021 (11) 30-3 (3)
20-706 (10) 20-819 (10) 20-890 (10) 20-1022 (11) 30-4 (3)
20-707 (10) 20-891 (10) 20-1023 (11) 30-5 (3)
20-851 (10) 20-892 (10) 20-1024 (11) 30-6 (3)
20-751 (10) 20-852 (10) 20-893 (10) 20-1025 (11) 30-7 (3)
20-752 (10) 20-853 (10) 20-894 (10) 20-1026 (11) 30-8 (7)
20-754 (10) 20-854 (10) 20-895 (10) 20-1027 (11) 30-9 (7)
20-755 (10) 20-856 (10) 20-896 (10) 20-1028 (11) 30-10 (7)
20-756 (10) 20-857 (10) 20-897 (10) 20-1029 (11) 30-11 (10)
20-757 (10) 20-858 (10) 20-898 (10) 20-1030 (11) 30-11-1 (4)
20-758 (10) 20-859 (10) 20-899 (10) 20-1032 (11) 30-12 (3)
20-759 (10) 20-860 (10) 20-900 (10) 20-1033 (11) 30-13 (10)
20-760 (10) 20-861 (10) 20-901 (10) 20-1034 (11) 30-14 (3)
20-761 (10) 20-862 (10) 20-902 (10) 20-1035 (11) 30-15 (3)
20-762 (10) 20-863 (10) 20-903 (10) 20-1036 (11) 30-16 (7)
20-763 (10) 20-864 (10) 20-904 (10) 20-1037 (11) 30-17 (7)
20-764 (10) 20-865 (10) 20-905 (10) 20-1038 (11) 30-17-1 (7)
20-765 (10) 20-866 (10) 20-906 (10) 20-1040 (11) 30-18 (7)
20-766 (10) 20-867 (10) 20-907 (10) 20-1041 (11) 30-18-1 (7)
20-767 (10) 20-868 (10) 20-908 (10) 20-1042 (11) 30-19 (7)
20-768 (10) 20-869 (10) 20-909 (10) 20-1043 (11) 30-20 (7)
20-769 (10) 20-870 (10) 20-1044 (11) 30-21 (7)
20-770 (10) 20-871 (10) 20-1001 (11) 20-1045 (11) 30-22 (7)
20-872 (10) 20-1002 (11) 20-1046 (11) 30-23 (7)
20-801 (10) 20-873 (10) 20-1004 (11) 20-1047 (11) 30-24 (7)
20-802 (10) 20-874 (10) 20-1005 (11) 20-1048 (11) 30-25 (7)
20-804 (10) 20-875 (10) 20-1006 (11) 20-1049 (11) 30-26 (7)
20-805 (10) 20-876 (10) 20-1007 (11) 20-1050 (11) 30-27 (9)
20-806 (10) 20-877 (10) 20-1008 (11) 20-1051 (11) 30-28 (9)
20-807 (10) 20-878 (10) 20-1009 (11) 20-1052 (11) 30-29 (7)
20-808 (10) 20-879 (10) 20-1010 (11) 20-1053 (11) 30-30 (3)
20-809 (10) 20-880 (10) 20-1011 (11) 20-1054 (11) 30-31 (3)
20-810 (10) 20-881 (10) 20-1012 (11) 20-1055 (11) 30-32 (7)
WA700-3 00-2-5
(12)
List of revised pages
30-33 (3) 30-67 (3) 30-107 (3) 30-145 (3) 30-185 (3)
30-34 (7) 30-68 (3) 30-108 (3) 30-146 (3) 30-186 (3)
30-35 (7) 30-69 (3) 30-109 (3) 30-147 (3) 30-187 (3)
30-36 (7) 30-70 (3) 30-110 (3) 30-148 (3) 30-188 (3)
30-36-1 (7) 30-71 (3) 30-111 (3) 30-149 (3) 30-189 (3)
30-36-2 (7) 30-72 (3) 30-112 (3) 30-150 (3) 30-190 (3)
30-36-3 (7) 30-73 (3) 30-113 (3) 30-151 (3) 30-191 (3)
30-37 (7) 30-74 (3) 30-114 (3) 30-152 (3) 30-191-1 (9)
30-38 (3) 30-75 (3) 30-115 (3) 30-153 (3) 30-191-2 (9)
30-39 (7) 30-76 (3) 30-116 (3) 30-154 (3) 30-191-3 (4)
30-39-1 (7) 30-77 (3) 30-117 (3) 30-155 (3) 30-191-4 (9)
30-39-2 (7) 30-78 (3) 30-118 (3) 30-156 (3) 30-191-5 (4)
30-39-3 (7) 30-79 (3) 30-119 (3) 30-157 (3) 30-191-6 (4)
30-40 (3) 30-80 (3) 30-120 (3) 30-158 (3) 30-191-7 (9)
30-41 (3) 30-81 (3) 30-121 (3) 30-159 (3) 30-191-8 (4)
30-42 (3) 30-82 (3) 30-122 (3) 30-160 (3) 30-191-9 (4)
30-43 (3) 30-83 (3) 30-123 (3) 30-161 (3) 30-191-10 (4)
30-44 (3) 30-84 (3) 30-124 (3) 30-162 (3) 30-191-11 (9)
30-45 (3) 30-85 (3) 30-125 (3) 30-163 (3) 30-191-12 (4)
30-46 (3) 30-86 (3) 30-126 (3) 30-164 (3) 30-191-13 (9)
30-47 (3) 30-87 (3) 30-127 (3) 30-165 (3) 30-191-14 (4)
30-48 (3) 30-88 (3) 30-128 (3) 30-166 (3) 30-191-15 (4)
30-49 (3) 30-89 (3) 30-129 (3) 30-167 (3) 30-191-16 (4)
30-50 (3) 30-90 (3) 30-130 (7) 30-168 (3) 30-191-17 (9)
30-51 (3) 30-91 (3) 30-131 (7) 30-169 (3) 30-191-18 (4)
30-52 (3) 30-92 (3) 30-131-1 (7) 30-170 (3) 30-191-19 (4)
30-53 (3) 30-93 (3) 30-131-2 (7) 30-171 (3) 30-191-20 (9)
30-54 (3) 30-94 (3) 30-132 (3) 30-172 (3) 30-191-21 (4)
30-55 (3) 30-95 (3) 30-133 (3) 30-173 (3) 30-192 (3)
30-56 (3) 30-96 (3) 30-134 (3) 30-174 (3) 30-193 (3)
30-57 (3) 30-97 (3) 30-135 (3) 30-175 (3) 30-194 (3)
30-58 (3) 30-98 (3) 30-136 (3) 30-176 (3) 30-195 (3)
30-59 (3) 30-99 (3) 30-137 (3) 30-177 (3) 30-196 (3)
30-60 (3) 30-100 (3) 30-138 (3) 30-178 (3) 30-197 (3)
30-61 (3) 30-101 (3) 30-139 (3) 30-179 (3) 30-198 (3)
30-62 (3) 30-102 (3) 30-140 (3) 30-180 (3) 30-199 (3)
30-63 (3) 30-103 (3) 30-141 (3) 30-181 (3) 30-200 (3)
30-64 (3) 30-104 (3) 30-142 (3) 30-182 (3) 30-201 (3)
30-65 (3) 30-105 (3) 30-143 (3) 30-183 (3) 30-202 (3)
30-66 (3) 30-106 (3) 30-144 (3) 30-184 (3) 30-203 (3)
00-2-6 WA700-3
(12)
List of revised pages
WA700-3 00-2-7
(12)
Safety Safety notice
Safety
Safety notice
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 dangerous situa-
tion 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
Mistakes in operation are extremely dangerous. tools and removed parts. Always keep the tools
Read the Operation and Maintenance Manual care- and parts in their correct places. Always keep
fully BEFORE operating the machine. the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the
1. Before carrying out any greasing or repairs, read areas provided for smoking. Never smoke while
all the precautions given on the decals which working.
are fixed to the machine.
Preparations for work
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose 7. Before adding oil or making any repairs, park
work clothes, or clothes with buttons missing. the machine on hard, level ground, and block
• Always wear safety glasses when hitting the wheels or tracks to prevent the machine
parts with a hammer. from moving.
• Always wear safety glasses when grinding
parts with a grinder, etc. 8. Before starting work, lower blade, ripper, bucket
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
fellow workers before starting any step of the 10. Remove all mud and oil from the steps or other
operation. Before starting work, hang UNDER places used to get on and off the machine.
REPAIR signs on the controls in the operator's Always use the handrails, ladders or steps when
compartment. getting on or off the machine. Never jump on or
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 with
Before disconnecting or removing components
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 carrying
that connecting parts are correctly installed.
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-
ticularly careful to check that they are installed
14. When raising heavy components, use a hoist or
correctly.
crane.
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.
Install the lifting equipment at the correct places.
23. When measuring hydraulic pressure, check that
Use a hoist or crane and operate slowly to pre-
the measuring tool is correctly assembled
vent the component from hitting any other part.
before taking any measurements.
Do not work with any part still raised by the hoist
or crane.
24. Take care when removing or installing the tracks
of track-type machines.
15. When removing covers which are under internal
When removing the track, the track separates
pressure or under pressure from a spring,
suddenly, so never let anyone stand at either
always leave two bolts in position on opposite
end of the track.
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
00-4
Foreword General
Foreword
General
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
Maintenance standard
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in “Structure and function”.
Others
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
Notice
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
Foreword General
00-6
Foreword Hoisting instructions
Hoisting instructions
Hoisting
Slinging near the edge of the hook may
k
cause the rope to slip off the hook during
Heavy parts (25 kg or more) must be lifted
hoisting, and a serious accident can result.
with a hoist, etc. In the Disassembly and
Hooks have maximum strength at the mid-
assembly section, every part weighing 25
dle portion.
kg or more is indicated clearly with the
symbol 4
interference with the part to be removed. 3) Do not sling a heavy load with one rope
alone, but sling with two or more ropes
Wire ropes symmetrically wound onto the load.
k
1) Use adequate ropes depending on the
Slinging with one rope may cause
weight of parts to be hoisted, referring to the
turning of the load during hoisting,
table below:
untwisting of the rope, or slipping of the
Wire ropes rope from its original winding position on
(Standard “Z” or “S” twist ropes the load, which can result in a dangerous
without galvanizing) accident.
Rope diameter Allowable load
mm kN tons 4) Do not sling a heavy load with ropes forming
10 9.8 1.0 a wide hanging angle from the hook.
11.5 13.7 1.4 When hoisting a load with two or more
12.5 15.7 1.6 ropes, the force subjected to each rope will
14 21.6 2.2 increase with the hanging angles. The table
16 27.5 2.8 below shows the variation of allowable load
18 35.3 3.6 kN {kg} when hoisting is made with two
20 43.1 4.4 ropes, each of which is allowed to sling up
22.4 54.9 5.6
to 9.8 kN {1000 kg} vertically, at various
30 98.1 10.0
hanging angles.
40 176.5 18.0
50 274.6 28.0 When two ropes sling a load vertically, up to
60 392.2 40.0 19.6 kN {2000 kg} of total weight can be
suspended. This weight becomes 9.8 kN
a The allowable load value is estimated to be {1000 kg} when two ropes make a 120?
one-sixth or one-seventh of the breaking hanging angle. On the other hand, two
strength of the rope used. ropes are subjected to an excessive force
as large as 39.2 kN {4000 kg} if they sling a
2) Sling wire ropes from the middle portion of 19.6 kN {2000 kg} load at a lifting angle of
the hook. 150°.
00-7
Foreword Method of disassembling, connecting push-pull type coupler
Disconnection
1) Release the residual pressure from the
hydraulic tank. For details, see “Testing and
adjusting”, Releasing residual pressure from
hydraulic tank.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
a Do not hold rubber cap portion (4).
00-8
Foreword Method of disassembling, connecting push-pull type coupler
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding and push body (2) in straight until sliding
prevention ring (1) contacts contact surface a of prevention 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 lever 2) Hold in the condition in Step 1), and push until
(4) to the right (clockwise). 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 pull 3) Hold in the condition in Steps 1) and 2), and pull
out whole body (2) to disconnect it. out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion and • Hold the mouthpiece of the tightening portion and
push body (2) in straight until sliding prevention push body (2) in straight until sliding prevention
ring (1) contacts contact surface a of the ring (1) contacts contact surface a of the
hexagonal portion at the male end to connect it. hexagonal portion at the male end to connect it.
Connection
00-9
Foreword Coating materials
Coating materials
a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
00-10
Foreword Coating materials
Category Komatsu code Part No. Q’ty Container Main applications, features
• Used as lubricant for sliding portion (to
LM-G 09940-00051 60 g Can
prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuffling of the
lubricant thread when press fitting or shrink fitting.
LM-P 09940-00040 200 g Tube
• Used as lubricant for linkage, bearings,
etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light load
SYG2-350CA bearing at places in contact with water or
G2-CA SYG2-400CA-A Various Various 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)
Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
G0-T (*) • Since this grease is white, it does not
SYG0-400T-A (*) 16 kg Can
*: For use in stand out against machine body.
SYG0-16CNT (*)
cold district
Biogrease G2B • Since this grease is decomposed by
SYG2-400B
G2-BT (*) bacteria in short period, it has less effects
SYGA-16CNB 400 g Bellows type
*: For high on microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
temperature
SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side
Glass
PAINT PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
417-926-3910
SUNSTAR • Used as primer for glass side
Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
580 SUPER
SUNSTAR • Used as primer for painted surface on
Glass
PAINT PRIMER 22M-54-27230 20 ml cab side
Primer container
435-95 (Using limit: 4 months)
• Used as primer for black ceramic-
SUNSTAR
coated surface on glass side and for
GLASS PRIMER 22M-54-27240 150 ml Can
hard polycarbonate-coated surface
435-41
(Using limit: 4 months)
SUNSTAR • Used as primer for sash (Alumite).
Adhesive for cab glass
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
Foreword Standard tightening torque
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
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
00-12
Foreword Standard tightening torque
00-13
Foreword Standard tightening torque
2) Eye joints
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51
3) Tapered screws
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.20
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92
Tightening torque table for hoses (taper seal type and face seal type)
a Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
a Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
Nominal type
Width
size of
hose across flats Thread size Nominal thread size Root diameter
Range Target – Threads per inch, (mm)
(mm) (Reference)
Thread series
9
34 – 54 {3.5 – 5.5} 44 {4.5} — – 18UN 14.3
16
02 19
34 – 63 {3.5 – 6.5} 44 {4.5} 14 — —
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} — – 16UN 17.5
16
03
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 20.6
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 – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 — —
00-14
Foreword Electric wire code
Classification by thickness
Copper wire
Norminal Cable O.D. Current rating
Number of Dia. of Cross section Applicable circuit
number (mm) (A)
strands strands (mm2) (mm2)
Code W B B R Y G L
1 Primary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
White & White & Red & Rellow & Green & Blue &
Color —
Red Black White Red White White
Code WB — BY RB YB GR LR
3
White & Black & Red & Yellow & Green & Blue &
Color —
Black Yellow Black Black Red Yellow
Code WL — BR RY YG GY LY
4 Auxiliary
White & Black & Red & Yellow & Green & Blue &
Color —
Blue Red Yellow Green Yellow Yellow
Code WG — — RG YL GB LB
5
White & Red & Yellow & Green & Blue &
Color — —
Green Green Blue Black Black
Code — — — RL YW GL —
6
Yellow & Green &
Color — — — Red & Blue —
White Blue
00-15
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
millimeters 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.
00-16
Foreword Conversion table
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
Foreword Conversion table
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
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
Foreword Conversion table
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
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
Foreword Conversion table
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
Foreword Conversion table
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centi-
grade 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
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 04-05
01 General
WA700-3 01-1
(10)
General General assembly drawing
01-2 WA700-3
(10)
General General assembly drawing
WA700-3 01-3
(10)
General General assembly drawing
WA700-3, WA700-3D
Serial No.: 51001 and up Unit: mm
01-4 WA700-3
(10)
General Specifications
Specifications
[ ]: WA700-3D
Wheelbase mm 4,800
Tread mm 3,000
Min. ground clearance mm 540
Height of bucket hinge pin mm 5,990
Dumping clearance (tip of edge) mm 4,380
Dumping reach (tip of edge) mm 1,910
Bucket dump angle deg 61.5
Bucket tilt angle (travel posture) deg 50
Digging depth (10° dump) (with tooth) mm 570
WA700-3 01-5
(10)
General Specifications
[ ]: WA700-3D
Maximum torque
{kgm/rpm} {286.5/1,400} {294/1,400}
Fuel consumption ratio (at rated output) g/kW·h {g/HP·h} 207 {154} 214 {160}
High idling speed rpm 2,240 [ 2,190] 2,240
Low idling speed rpm 650 725
Starting motor 24 V 7.5 kW × 2
Alternator 24 V 50 A
Battery 12 V 200 Ah × 2
Torque converter 3-element, 1-stage, single-phase
Planetary gear, constant-mesh multiple-disc,
Power train
01-6 WA700-3
(10)
General Specifications
WA700-3 01-7
(10)
General Weight table
Weight table
k This weight table is a guide for use when transporting or handling components.
Unit: kg
[ ]: WA700-3D
01-8 WA700-3
(10)
General Weight table
Unit: kg
[ ]: WA700-3D
WA700-3 01-9
(10)
General List of lubricant and water
SAE 30 63 54
Serial No.: Serial No.:
SAE 10W 50001 – 51000 50001 – 51000
Engine oil pan
SAE 10W-30 61 52
Serial No.: Serial No.:
SAE 15W-40 51001 and up 51001 and up
Engine SAE 30
Transmission case 120 105
oil SAE 10W
245 245
Serial No.: Serial No.:
Axle
50001 – 50045 50001 – 50045
(Front and rear) See Note 1 315 315
(each) Serial No.: Serial No.:
50046 and up 50046 and up
200 190
Serial No.: Serial No.:
50001 – 51000 50001 – 51000
Cooling system Water Add antifreeze
219 209
Serial No.: Serial No.:
51001 and up 51001 and up
Note 1:
For axle oil, use only recommended oil as follows.
SHELL: DONAX TD
MOBIL: 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.
01-10 WA700-3
(10)
General List of lubricant and water
REMARK
• When fuel sulphur content is less than 0.5%,
ch ang e oi l i n t he o il pa n every p eri odi c
maintenance hours described in this manual.
Change oil according to the following table if fuel
sulphur content is above 0.5%.
Change interval of oil in
Fuel sulphur content
engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval
WA700-3 01-11
(10)
10 Structure and function
WA700-3 10-1
(12)
Structure and function Outline
Outline
Outline
• Power from engine (7) is transmitted to damper 1. Center drive shaft
(6) through the engine flywheel. The damper 2. Transfer
output shaft is connected to torque converter (4) 3. Transmission
through upper drive shaft (5) and the torque 4. Torque converter
converter turbine is connected to transmission 5. Upper drive shaft
(3) input shaft. 6. Damper
• The transmission is equipped with 6 hydrau- 7. Engine
lically-actuated clutches, by which the speed can 8. Rear axle
be set in four stages for both FORWARD and 9. Rear drive shaft
REVERSE, and can be selected by the electric 10. Center support
control lever. 11. Front drive shaft
• Output shaft of transmission is connected to the 12. Front axle
transfer (2) gear and transmitted to the output
shaft.
Power is transmitted from the transfer output
shaft to front axle (12) through center drive shaft
(1), center support (10) and front drive shaft (11),
also power is transmitted from the transfer output
shaft to rear axle (8) through rear drive shaft (9).
10-2 WA700-3
(10)
Structure and function Power train system
10-4 WA700-3
(10)
Structure and function Power train system
1. Engine
2. Damper
3. Upper drive shaft
4. Four tandem pump
(T/C charging + cooling + PPC + brake pump)
5. Piston pump (Steering + Switch pump)
6. Piston pump (work equipment pump x 2)
7. Torque converter
8. Transmission
9. Transfer
10. Emergency steering pump
11. Center drive shaft
12. Center support
13. Front drive shaft
14. Parking brake
15. Front axle
16. Front differential
17. Front brake
18. Front final drive
19. Front wheel
20. Rear drive shaft
21. Rear differential
22. Rear axle
23. Rear brake
24. Rear final drive
25. Rear wheel
WA700-3 10-5
(10)
Structure and function Damper
Damper
1. Shaft Operation
2. Rubber cushion • The motive force from the engine is transmitted
3. Inner body from the flywheel to outer body (4), and the
4. Outer body torsional vibration of the engine is absorbed by
rubber cushion (2). The power then passes
through inner body (3) to shaft (1), and is
transmitted to the upper drive shaft.
10-6 WA700-3
(10)
Structure and function Radiator and oil cooler
WA700-3 10-7
(10)
Structure and function Radiator and oil cooler
10-8 WA700-3
(10)
Structure and function Transmission hydraulic system diagram
10-10 WA700-3
(10)
Structure and function Transmission hydraulic system diagram
1. Transmission case
2. Strainer
3. Torque converter charging pump
4. Oil filter (x 4)
5. Transmission main relief valve
6. Torque converter relief valve
7. Torque converter
8. Oil cooler
9. PTO case
10. Lubrication valve
11. Transmission lubrication
12. Lubrication bypass valve
13. Priority valve
14. Modulating valve
15. Quick return valve
16. Pilot reducing valve
17. Pilot filter
18. Reducing valve
19. Reverse spool
20. Forward spool
21. 4th spool
22. 3rd spool
23. 2nd spool
24. 1st spool
25. Emergency manual spool
26. Solenoid valve
27. Reverse clutch
28. Forward clutch
29. 4th clutch
30. 3rd clutch
31. 2nd clutch
32. 1st clutch
33. Quick fill valve
34. PTO lubrication
WA700-3 10-11
(10)
Structure and function Transmission hydraulic system diagram
10-12 WA700-3
(10)
Structure and function Transmission hydraulic system diagram
1. Transmission case
2. Strainer
3. Torque converter charging pump
4. Oil filter (x 4)
5. Transmission main relief valve
6. Torque converter relief valve
7. Torque converter
8. Oil cooler
9. PTO case
10. Lubrication valve
11. Transmission lubrication
12. Lubrication bypass valve
13. Priority valve
14. Modulating valve
15. Quick return valve
16. Pilot reducing valve
17. Pilot filter
18. Reducing valve
19. Reverse spool
20. Forward spool
21. 4th spool
22. 3rd spool
23. 2nd spool
24. 1st spool
25. Emergency manual spool
26. Solenoid valve
27. Reverse clutch
28. Forward clutch
29. 4th clutch
30. 3rd clutch
31. 2nd clutch
32. 1st clutch
33. Quick fill valve
34. PTO lubrication
35. Torque converter regulator valve
WA700-3 10-13
(10)
Structure and function Transmission hydraulic circuit diagram
10-14 WA700-3
(10)
Structure and function Transmission hydraulic circuit diagram
WA700-3 10-15
(10)
Structure and function Torque converter and transmission piping
1. Transfer
2. Transmission control valve
3. Torque converter
4. Torque converter oil cooler
5. Torque converter charging pump
6. Transmission
7. Torque converter oil filter
8. Transmission oil sight gauge
10-16 WA700-3
(10)
Structure and function Torque converter and transmission piping
1. Transfer
2. Transmission control valve
3. Torque converter
4. Torque converter oil cooler
5. Torque converter charging pump
6. Transmission
7. Torque converter oil filter
8. Transmission oil sight gauge
9. Torque converter regulator valve
WA700-3 10-17
(10)
Structure and function Torque converter and PTO
Specifications
Type: 3-element, single stage, single phase
Stall torque ratio: 2.84
10-18 WA700-3
(10)
Structure and function Torque converter and PTO
7. Turbine
8. Drive case
9. Pump
10. Transmission input shaft
11. Rear housing
12. Front housing
13. PTO gear (Teeth 86)
14. Stator
15. Gear (Teeth 81)
16. Gear (Teeth 81)
WA700-3 10-19
(10)
Structure and function Torque converter and PTO
Flow of oil
• The oil enters torque converter inlet port A,
passes through the oil hole in housing (6), and
flows to pump (2). The oil is given centrifugal
force by pump (2), enters turbine (4), and
transmits the energy of the oil to the turbine.
Turbine (4) is fixed to transmission input shaft
(5), so the power is transmitted to the
transmission. The oil from turbine (4) is sent to
stator (7), and enters the pump again. However,
part of the oil is sent from the stator through
torque converter outlet port B of housing (6) to
the oil cooler.
10-20 WA700-3
(10)
Structure and function Torque converter and PTO
Specifications
Type: 3-element, single stage, single phase
Stall torque ratio: 2.84
10-22 WA700-3
(10)
Structure and function Torque converter and PTO
7. Turbine
8. Drive case
9. Torque converter regulator valve
10. Pump
11. Transmission input shaft
12. Rear housing
13. Front housing
14. PTO gear (Teeth 86)
15. Stator
16. Gear (Teeth 81)
17. Gear (Teeth 81)
WA700-3 10-23
(10)
Structure and function Torque converter and PTO
Flow of oil
• The oil enters torque converter inlet port A,
passes through the oil hole in housing (6), and
flows to pump (2). The oil is given centrifugal
force by pump (2), enters turbine (4), and
transmits the energy of the oil to the turbine.
Turbine (4) is fixed to transmission input shaft
(5), so the power is transmitted to the
transmission. The oil from turbine (4) is sent to
stator (7), and enters the pump again. However,
part of the oil is sent from the stator through
torque converter outlet port B of housing (6) to
the torque converter regulator valve (9).
The oil sent to torque converter regulator valve
(9) is passed and cooled through the oil cooler
and then used to lubricate the transmission.
10-24 WA700-3
(10)
Structure and function Torque converter regulator valve
1. Valve body
2. Spring
3. Spool
Function
• 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.
WA700-3 10-25
(10)
Structure and function Transmission
Transmission
Serial No.: 50001 – 51000
10-26 WA700-3
(10)
Structure and function Transmission
WA700-3 10-27
(10)
Structure and function Transmission
10-28 WA700-3
(10)
Structure and function Transmission
1. Input shaft
2. Sun gear (Teeth 32)
3. Planetary gear (Teeth 29)
4. Reverse clutch
5. Ring gear (Teeth 112)
6. Ring gear (Teeth 90)
7. Sun gear (Teeth 45)
8. Forward clutch
9. Ring gear (Teeth 95)
10. Planetary gear (Teeth 25)
11. Planetary gear (Teeth 25)
12. Sun gear (Teeth 45)
13. 4th clutch
14. Ring gear (Teeth 124)
15. 2nd clutch
16. Hub (Teeth 90)
17. 3rd clutch
18. Ring gear (Teeth 95)
19. Planetary gear (Teeth 21)
20. Sun gear (Teeth 53)
21. 1st clutch
22. Ring gear (Teeth 95)
23. Planetary gear (Teeth 21)
24. Sun gear (Teeth 53)
25. Output shaft
26. Carrier (1st)
27. Carrier (3rd)
28. Carrier (Forward and 4th)
29. Carrier (Reverse)
WA700-3 10-29
(10)
Structure and function Transmission
Outline
• The transmission consists of a 4-FORWARD, 4-
Speed range Clutch combination
REVERSE speed planetary gear transmission,
transfer, and transmission control valve. F1 Forward, 1st
• In the transmission, the motive force of the input F2 Forward, 2nd
shaft is changed by the combination of Forward
or Reverse clutch with 1st, 2nd, 3rd or 4th clutch F3 Forward, 3rd
to give FORWARD 1 – 4 or REVERSE 1 – 4 F4 Forward, 4th
speed, and is transmitted to the output shaft.
R1 Reverse, 1st
R2 Reverse, 2nd
R3 Reverse, 3rd
R4 Reverse, 4th
Operation of clutch
• Engaged
The oil sent from the transmission control valve
passes through the oil passage inside the trans-
mission. 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 sepa-
rated. Ring gear (6) then rotates freely, and no
motive force is transmitted.
10-30 WA700-3
(10)
Structure and function Transmission
Forward 1st
• In the case of FORWARD 1st, FORWARD clutch • The rotation of carrier (28) is transmitted along
(8) and 1st clutch (21) are engaged. The power two paths. One path goes through planet gear
transmitted from the torque converter to input (11) and ring gear (14) and rotates carrier (27).
shaft (1) is transmitted to output shaft (25). The other goes through planet gear (11) and sun
• FORWARD clutch (8) is actuated by the oil gear (12) and is transmitted to output shaft (25).
pressure applied by the clutch piston, and holds • The rotation of carrier (27) is also transmitted
ring gear (9) in position. 1st clutch (21) is along two paths. One path goes through planet
actuated by the oil pressure applied by the clutch gear (19) and ring gear (18) and is transmitted to
piston, and holds ring gear (22) in position. sun gear (24). The other goes through planet
• The power from the torque converter is gear (19) and sun gear (20) and is transmitted to
transmitted to input shaft (1). The rotation of output shaft (25).
input shaft (1) is transmitted through sun gear (7) • Ring gear (22) is held in position by 1st clutch
to planet gear (10). Ring gear (9) is held in (21), so the rotation of sun gear (24) passes
position by FORWARD clutch (8), so the rotation through planet gear (23) and is transmitted from
of planet gear (10) rotates carrier (28) inside ring carrier (26) to output shaft (25).
gear (9). • The rotation of output shaft (25) is output in
combination with the power transmitted from sun
gear (12), sun gear (20), and carrier (26).
WA700-3 10-31
(10)
Structure and function Transmission
Forward 2nd
• In the case of FORWARD 2nd, FORWARD • The rotation of carrier (28) is transmitted along
clutch (8) and 2nd clutch (15) are engaged. The two paths. One path goes through planet gear
power transmitted from the torque converter to (11) and rotates ring gear (14). The other goes
input shaft (1) is transmitted to output shaft (25). through planet gear (11) and sun gear (12) and
• FORWARD clutch (8) is actuated by the oil is transmitted to output shaft (25).
pressure applied by the clutch piston, and holds • Ring gear (14) and hub (16) are formed into one
ring gear (9) in position. 2nd clutch (15) is unit by 2nd clutch (15), and the rotation of hub
actuated by the oil pressure applied by the clutch (16) is transmitted to output shaft (25).
piston, and engages ring gear (14) and hub (16). • The rotation of output shaft (25) is output in
• The power from the torque converter is combination with the power transmitted from sun
transmitted to input shaft (1). The rotation of gear (12) and hub (16).
input shaft (1) is transmitted through sun gear (7)
to planet gear (10). Ring gear (9) is held in
position by FORWARD clutch (8), so the rotation
of planet gear (10) rotates carrier (28) inside ring
gear (9).
10-32 WA700-3
(10)
Structure and function Transmission
Forward 3rd
• In the case of FORWARD 3rd, FORWARD clutch • The rotation of carrier (28) is transmitted along
(8) and 3rd clutch (17) are engaged. The power two paths. One path goes through planet gear
transmitted from the torque converter to input (11) and ring gear (14) and rotates carrier (27).
shaft (1) is transmitted to output shaft (25). The other goes through planet gear (11) and sun
• FORWARD clutch (8) is actuated by the oil gear (12) and is transmitted to output shaft (25).
pressure applied by the clutch piston, and holds • Ring gear (18) is held in position by 3rd clutch
ring gear (9) in position. 3rd clutch (17) is (17), so the rotation of carrier (27) passes
actuated by the oil pressure applied by the clutch through planet gear (19) and is transmitted from
piston, and holds ring gear (18) in position. sun gear (20) to output shaft (25).
• The power from the torque converter is • The rotation of output shaft (25) is output in
transmitted to input shaft (1). The rotation of combination with the power transmitted from sun
input shaft (1) is transmitted through sun gear (7) gear (12) and sun gear (20).
to planet gear (10). Ring gear (9) is held in
position by FORWARD clutch (8), so the rotation
of planet gear (10) rotates carrier (28) inside ring
gear (9).
WA700-3 10-33
(10)
Structure and function Transmission
Forward 4th
• In the case of FORWARD 4th, FORWARD clutch • Ring gear (14) is held in position by 4th clutch
(8) and 4th clutch (13) are engaged. The power (13), so the rotation of carrier (28) is transmitted
transmitted from the torque converter to input through planet gear (11) to sun gear (12) and
shaft (1) is transmitted to output shaft (25). rotates output shaft (25).
• FORWARD clutch (8) is actuated by the oil
pressure applied by the clutch piston, and holds
ring gear (9) in position. 4th clutch (13) is
actuated by the oil pressure applied by the clutch
piston, and holds ring gear (14) in position.
• The power from the torque converter is
transmitted to input shaft (1). The rotation of
input shaft (1) is transmitted through sun gear (7)
to planet gear (10). Ring gear (9) is held in
position by FORWARD clutch (8), so the rotation
of planet gear (10) rotates carrier (28) inside ring
gear (9).
10-34 WA700-3
(10)
Structure and function Transmission
Reverse 1st
• In the case of REVERSE 1st, REVERSE clutch • The rotation of ring gear (6) is transmitted along
(4) and 1st clutch (21) are engaged. The power two paths. One path is transmitted to carrier (28)
transmitted from the torque converter to input and then goes through planet gear (11) and ring
shaft (1) is transmitted to output shaft (25). gear (14) and rotates carrier (27). The other goes
• REVERSE clutch (4) is actuated by the oil through planet gear (11) and sun gear (12) and
pressure applied by the clutch piston, and holds is transmitted to output shaft (25).
ring gear (5) in position. 1st clutch (21) is • The rotation of carrier (27) is also transmitted
actuated by the oil pressure applied by the clutch along two paths. One path goes through planet
piston, and holds ring gear (22) in position. gear (19) and ring gear (18) and is transmitted to
• The power from the torque converter is sun gear (24). The other goes through planet
transmitted to input shaft (1). The rotation of gear (19) and sun gear (20) and is transmitted to
input shaft (1) is transmitted through sun gear (2) output shaft (25).
to planet gear (3). Ring gear (5) is held in position • Ring gear (22) is held in position by 1st clutch
by REVERSE clutch (4), so carrier (29) rotates, (21), so the rotation of sun gear (24) passes
and the rotation of planet gear (3) rotates ring through planet gear (23) and is transmitted from
gear (6). Ring gear (6) rotates in the opposite carrier (26) to output shaft (25).
direction from input shaft (1). • The rotation of output shaft (25) is output in
combination with the power transmitted from sun
gear (12), sun gear (20), and carrier (26).
WA700-3 10-35
(10)
Structure and function Transmission control valve
10-36 WA700-3
(10)
Structure and function Transmission control valve
Upper valve
WA700-3 10-37
(10)
Structure and function Transmission control valve
Lower valve
Outline
• The oil from the torque converter charging pump • The other oil line flows to modulating valve (3)
enters port A of main relief valve, and passes and quick return valve (2). The action of
through priority valve (4) via by main relief valve modulating valve (3) and quick return valve (2)
(9). It is then divided into three lines; there are; to raises the clutch pressure smoothly. This
the clutch pistons, to pilot reducing valve (4) and reduces the shock when actuating the
main relief valve. Priority valve (4) acts to control FORWARD, REVERSE and 1st, 2nd, 3rd and
the three lines so that pilot reducing valve (15) is 4th speed clutches to change gear.
the priority circuit. • The quick fill valve controls the oil pressure when
• The oil flowing to pilot reducing valve (15) oil fills the second clutch and reduces the filling
controls the pilot pressure used to actuate the time when shifting from 1st to 2nd or from 3rd to
directional and speed spools. The oil regulated 2nd.
by pilot reducing valve (15) presses through the • Lubrication valve (16) controls the lubrication oil
orifice in each spool and fills the spool. inside the transmission.
10-38 WA700-3
(10)
Structure and function Transmission control valve
WA700-3 10-39
(10)
Structure and function Transmission control valve
10-40 WA700-3
(10)
Structure and function Transmission control valve
Function
• The main relief valve acts to supply the
necessary 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
filter and enters port A of main relief valve (1).
• Until the specified pressure is reached, the oil
flows to the priority valve.
WA700-3 10-41
(10)
Structure and function Transmission control valve
Function
• The main relief valve acts to supply the
necessary 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
filter and enters port A of main relief valve (1).
• Until the specified pressure is reached, the oil
flows to the priority valve.
10-42 WA700-3
(10)
Structure and function Transmission control valve
Function
• The pilot reducing valve acts to control the
pressure 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.
WA700-3 10-43
(10)
Structure and function Transmission control valve
Function
• There is one solenoid valve installed for each
directional and speed spool in the transmission
valve.
When the directional lever and speed control
levers in the operator's compartment are
operated, 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, solenoid valve (1) 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 A becomes the low pres-
sure circuit, and directional and speed spool (2)
is actuated.
10-44 WA700-3
(10)
Structure and function Transmission control valve
Priority valve
Function
• Priority valve (1) controls the minimum pressure
of pilot reducing valve (2). In addition, priority
valve (1) gives the oil flow to pilot reducing valve
(2) priority over the other circuit.
Operation
• The oil from the pump flows to port A of priority
valve (1) and port B of pilot reducing valve (2).
WA700-3 10-45
(10)
Structure and function Transmission control valve
Function
• The modulating valve and quick return valve act
together to r aise the trans mis sion clutc h
pressure slowly. In this way, they reduce the
shock when shifting gear, and prevent the
generation of peak torque in the power train. As
a result, operator fatigue is reduced, and at the
same time, operator comfort and the durability of
the power train is increased.
• The oil sent from the pump flows from priority C. The quick return valve moves to the right and
valve (1) through port A, passes through the oil flows to clutch (5). In addition, when quick
modulating valve (2), and enters port B of quick return valve (3) moves to the right, drain port D is
return valve (3). The oil passes through orifice opened, and the pressurized oil at the rear of
"a" of quick return valve (3) and flows to the piston (4) flows to the drain circuit.
clutch piston, which has been actuated. However
when it passes through orifice "a" it creates a
difference in pressure between port B and port
10-46 WA700-3
(10)
Structure and function Transmission control valve
WA700-3 10-47
(10)
Structure and function Transmission control valve
10-48 WA700-3
(10)
Structure and function Transmission control valve
Reducing valve
Function
• The reducing valve is in the circuit between the
quick return valve and the 2nd spool. It reduces
the pressure applied to the 2nd clutch.
The maximum pressure in the main circuit is kept
to the specified level by the main relief pressure.
Operation
• The oil from quick return valve enters port A, and
then flows from port B to 2nd spool (2).
WA700-3 10-49
(10)
Structure and function Transmission control valve
Operation
• When 2nd spool (1) is switched, the oil from
modulating valve (2) passes through quick return
valve (3) and reducing valve (4), and enters the
clutch piston.
• At the same time, it enters port A of quick fill
valve (5), and quick fill valve (5) is pushed to the
right in the direction of the arrow.
• As a result, springs (6) and (7) are compressed,
the load becomes greater, and the actuation
starting pressure of modulating valve (2)
becomes higher than for the other clutches.
• The hydraulic pressure rises suddenly to the
pressure where the actuation of modulating
v a l v e ( 2 ) s t a r t s . F ol l o w i n g t hi s , n o r m a l
modulation is carried out to raise the pressure
until modulating valve (2) reaches the set
pressure.
• In this way, the pressure for the start of actuation
of modulating valve (2) is higher than for the
other clutches, and the time lag is reduced by a
corresponding amount.
10-50 WA700-3
(10)
Structure and function Transmission control valve
Function
• This valve acts to keep the oil entering the torque
converter to a constant pressure. It drains the oil
if the press ure goes abov e the spec ified
pressure.
Operation
• The oil from the pump passes through main relief
valve (1), enters port A, and flows to the torque
converter.
WA700-3 10-51
(10)
Structure and function Transmission control valve
Function
• This valve acts to keep the oil entering the torque
converter to a constant pressure. It drains the oil
if the pressure goes abov e the specified
pressure.
Operation
• The oil from the pump passes through main relief
valve (1), enters port A, and flows to the torque
converter.
10-52 WA700-3
(10)
Structure and function Transmission control valve
Function
• The lubricating relief valve protects the
transmission lubrication circuit from abnormal
high pressure.
Operation
• The oil from the oil cooler and torque converter
relief valve flows from port A and lubricates the
transmission.
WA700-3 10-53
(10)
Structure and function Transmission control valve
Function
• A directional spool and the speed spools are
installed to make it possible to actuate the
transmission valve mechanically if there should
be a failure in the electrical system of the
transmission controller system and the solenoid
valve cannot be actuated.
(This spool is used to move the machine under
its own power to a place where it can be
serviced.)
a When using this spool, pay particularly
careful attention to safety.
Operation
• Normal position
When the solenoid valve is working normally,
spool (3) is held in the position shown in the dia-
gram.
The oil from the directional spool and speed
spool (1) enters port A, but it is shut off by sole-
noid valve (2).
• Clutch at ON position
When emergency manual spool (3) is pulled out
to the right (loosened 10 mm), the oil at port A is
drained to port B regardless of the operation of
solenoid valve (2). Therefore, the clutch is actu-
ated.
10-54 WA700-3
(10)
Structure and function Transmission control valve
Function
• When traveling in 4th gear, the transmission
gears are rotating at high speed. Because of this,
the churning resistance of the transmission
lubrication oil increases. To reduce this power
loss, only enough oil to lubricate the gears at 4th
speed is kept. All the rest of the oil is bypassed
to the transmission case.
Operation
• 4th clutch not being operated
When the 4th clutch is not being operated, there
is no hydraulic pressure at port a of spool (1). As
a result, spool (1) is pushed to the left by the
spring. The oil from the torque converter is
stopped by spool (1), so all the oil is used for
lubricating the transmission.
WA700-3 10-55
(10)
Structure and function Transmission control valve
Forward 1st
Serial No.: 50001 – 51000
10-56 WA700-3
(10)
Structure and function Transmission control valve
Operation
• When the directional and speed levers are
operated to F1, solenoid valves (1) and (2) are
actuated.
• The oil from pump (3) is divided into three lines,
but during gearshifting, it flows mainly to each
clutch.
• One of the three lines passes from main relief
valve (4) through torque converter (5) and enters
oil cooler (6).
• The second line goes from pilot reducing valve
(7) through the orifice of each speed spool to the
solenoid valve, but solenoid valves (1) and (2) of
FORWARD spool (8) and 1st spool (9) are being
actuated, so the oil passing through the orifice
flows to the drain circuit, and a difference in
pressure is created between port A and port B.
This overcomes springs (10) and (11) and the
port to the clutch is connected.
• The oil flows in the third line goes from priority
valve (12) into quick return valve (14), passes
through orifice a, then flows to spools (8) and (9)
to forward clutch (15) and 1st clutch (16).
When the oil starts to flow into the clutches, it
passes through orifice a, so a difference in
pressure is created between port C and port D,
quick return valve (14) is moved to the right, and
the oil at the rear of piston (17) flows to drain
circuit E.
When each clutch becomes filled with oil, the
difference in pressure between port C and port D
disappears, so the valve is returned to the left by
the difference in the cross-sectional area of the
quick return valve (4), and drain circuit E is
closed.
At this point, each clutch is filled with oil, but the
set pressure is not being generated. The oil at
port D passes through orifice b, goes to the rear
face of piston (17), moves piston (17) to the right,
and gradually raises the clutch pressure. When
piston (17) reaches the end of its stroke, the set
clutch pressure is reached, and the clutch is
completely engaged.
WA700-3 10-57
(10)
Structure and function Transmission control valve
10-58 WA700-3
(10)
Structure and function Transmission control valve
Operation
• When the directional and speed levers are
operated to F1, solenoid valves (1) and (2) are
actuated.
• The oil from pump (3) is divided into three lines,
but during gearshifting, it flows mainly to each
clutch.
• One of the three lines passes from main relief
valve (4) through torque converter (5) and torque
converter regulator valve (18) and then enters oil
cooler (6).
• The second line goes from pilot reducing valve
(7) through the orifice of each speed spool to the
solenoid valve, but solenoid valves (1) and (2) of
FORWARD spool (8) and 1st spool (9) are being
actuated, so the oil passing through the orifice
flows to the drain circuit, and a difference in
pressure is created between port A and port B.
This overcomes springs (10) and (11) and the
port to the clutch is connected.
• The oil flows in the third line goes from priority
valve (12) into quick return valve (14), passes
through orifice a, then flows to spools (8) and (9)
to forward clutch (15) and 1st clutch (16).
When the oil starts to flow into the clutches, it
passes through orifice a, so a difference in
pressure is created between port C and port D,
quick return valve (14) is moved to the right, and
the oil at the rear of piston (17) flows to drain
circuit E.
When each clutch becomes filled with oil, the
difference in pressure between port C and port D
disappears, so the valve is returned to the left by
the difference in the cross-sectional area of the
quick return valve (4), and drain circuit E is
closed.
At this point, each clutch is filled with oil, but the
set pressure is not being generated. The oil at
port D passes through orifice b, goes to the rear
face of piston (17), moves piston (17) to the right,
and gradually raises the clutch pressure. When
piston (17) reaches the end of its stroke, the set
clutch pressure is reached, and the clutch is
completely engaged.
WA700-3 10-59
(10)
Structure and function Torque converter oil cooler
10-60 WA700-3
(10)
Structure and function Transmission oil filter
WA700-3 10-61
(10)
Structure and function Transmission oil filter
Operation
• Oil flows from torque converter charging pump to
filter inlet port A. It passes from the outside to the
inside of element (2) and flows to outlet port B.
10-62 WA700-3
(10)
Structure and function Transfer
Transfer
WA700-3 10-63
(10)
Structure and function Axle
Axle
Front axle
1. Front axle
2. Front differential
3. Brake
4. Final drive
5. Drain plug
6. Spring cylinder
7. Parking brake
10-64 WA700-3
(10)
Structure and function Axle
Rear axle
1. Rear differential
2. Rear axle
3. Brake
4. Final drive
5. Drain plug
WA700-3 10-65
(10)
Structure and function Differential
Differential
Front differential
10-66 WA700-3
(10)
Structure and function Differential
Rear differential
WA700-3 10-67
(10)
Structure and function Final drive
Final drive
Serial No.: 50001 – 50045
1. Axle shaft
2. Brake
3. Planetary gear (Teeth 37)
4. Ring gear (Teeth 93)
5. Planetary carrier
6. Drain plug
7. Wheel hub
8. Sun gear (Teeth 18)
9. Wheel
10-68 WA700-3
(10)
Structure and function Final drive
1. Axle shaft
2. Brake
3. Planetary gear (Teeth 37)
4. Ring gear (Teeth 93)
5. Planetary carrier
6. Drain plug
7. Wheel hub
8. Sun gear (Teeth 18)
9. Wheel
WA700-3 10-69
(10)
Structure and function Final drive
Outline
• To gain a large drive force, the final drive uses a
planetary gear system to reduce the speed and
send drive force to the tires.
Operation
• The motive force transmitted from the differential
through axle shaft (1) t o sun gear (8) 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 reduced
speed to planetary carrier. This motive force is
then sent to wheels (9) which are installed to
planetary carriers.
10-70 WA700-3
(10)
Structure and function Steering piping diagram
WA700-3 10-71
(10)
Structure and function Steering and switch pump
Outline
• This pump consists of 2 fixed-displacement • For explanation of the operation, see the section
swash plate-type piston pumps and 1 impeller o f t h e w o r k e q ui p m en t p um p . T he w o r k
pump between them. equipment pump is of the variable displacement
• The front pump and rear pump are originally of type, however, since its swash plate (4) can
the variable displacement type, but their move.
displacement is fixed since inserted collar (16)
disables servo piston (15) and fix swash plate
(4).
10-72 WA700-3
(10)
Structure and function Steering and switch pump
WA700-3 10-73
(10)
Structure and function Steering and switch pump
Outline
• This pump consists of 2 fixed-displacement • For explanation of the operation, see the section
swash plate-type piston pumps and 1 impeller o f t h e w o r k e q ui p m en t p um p . T he w o r k
pump between them. equipment pump is of the variable displacement
• The front pump and rear pump are originally of type, however, since its swash plate (4) can
the variable displacement type, but their move.
displacement is fixed since inserted collar (16)
disables servo piston (15) and fix swash plate
(4).
10-74 WA700-3
(10)
Structure and function Steering and switch pump
WA700-3 10-75
(10)
Structure and function Steering unit (Orbit-roll valve)
10-76 WA700-3
(10)
Structure and function Steering unit (Orbit-roll valve)
Outline
Structure
WA700-3 10-77
(10)
Structure and function Steering unit (Orbit-roll valve)
Operation
When turning
• When the steering wheel is turned, spool (4) • When the steering wheel is turned, the oil inside
overcomes neutral position spring (1) and turns gear (7) flows, passes inside sleeve (5) and
slightly in relation to sleeve (5). Because of this spool (4), operates the spool of the steering
rotation, the ports of sleeve (5) and spool (4) demand valve, and actuates the steering
overlap, so a passage is formed for the oil to cylinders.
flow, and the oil flows to gear (7).
At neutral
• When the turning of the steering wheel is • When the non-reaction type steering valve is at
stopped (the rotation of the spool is stopped), the the neutral position, the steering cylinder and
return force of neutral position spring (1) returns spool (4) and sleeve (5) are blocked, so the
spool (4) and sleeve (5) to the neutral position, reaction from the machine is not transmitted to
so the oil passage is shut off and the oil stops the steering wheel.
flowing.
10-78 WA700-3
(10)
Structure and function Steering demand valve
A. To steering cylinder
B. To steering cylinder
P1. From steering pump
P2. From switch pump
PB. To main control valve
T. To hydraulic tank
(through hydraulic oil cooler)
WA700-3 10-79
(10)
Structure and function Steering demand valve
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
Function
Operation
10-80 WA700-3
(10)
Structure and function Steering demand valve
WA700-3 10-81
(10)
Structure and function Steering demand valve
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
10-82 WA700-3
(10)
Structure and function Steering demand valve
• When the pressure in the circuit rises and • When demand spool (4) moves, the oil from the
reaches the pressure set by spring (2) and steering pump is drained and the oil from the
adjustment screw (1), pilot poppet (3) opens and switch pump is relieved to the main control valve,
drains the oil. so the steering circuit pressure is prevented from
• When this happens, the balance of the pressure going above the set value.
in pressure receiving chamber (I) and pressure
receiving chamber (II) is lost, and demand spool
(4) moves to the left.
WA700-3 10-83
(10)
Structure and function Steering demand valve
• The oil from the steering pump enters port A and • When the pressure in pressure receiving
the oil from the switch pump enters port B. chamber (I) reaches a certain value (set by
• When steering spool (2) is at the neutral position, spring (3)), notch f opens and the oil from the
pressure receiving pressure chamber (II) is steering pump goes to the drain circuit. Notch g
connected to the drain circuit through orifice b, is closed, so the oil from the switch pump all
and notch c is closed. flows 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 (I) and moves demand spool (1) to the
left.
10-84 WA700-3
(10)
Structure and function Steering demand valve
• When the steering is operated, oil flows from the • The merged oil passes through notches c and d,
Orbit-Roll to steering spool (2) and pushes pushes load check valve (5), and flows to the
steering spool (2) to the right. The circuit cylinder. The return oil from the cylinder passes
between pressure receiving chamber (II) 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 passing
notch c opens. through notch c is sent to pressure receiving
• As a result, the pressure in pressure receiving chamber (I) and the pressure after passing
chamber (II) rises, and demand spool (1) moves through notch c is sent to pressure receiving
to the right until notch h closes. chamber (II). Demand spool (1) is actuated so
• The passage from port B to the main control that the difference in pressure on both sides of
valve is shut off, so the oil from the switch pump notch c is kept constant. Therefore, an oil flow
pushes up pump merge-divider check valve (4) corresponding to the opening of notch c is
and merges with the oil from the steering pump supplied to the cylinder port. These pressure
at port A. differences (control pressure) are set by spring
(3).
WA700-3 10-85
(10)
Structure and function Steering demand valve
• There is no need for supply of extra oil from the • The oil from the steering pump passes through
switch pump, so the steering pump pressure notches c and d, pushes load check valve (5),
rises 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 pump
from the steering pump is drained from notch f to all flows from port B and is sent to the main
the drain circuit. (At this point, notch g is control valve.
completely closed.)
10-86 WA700-3
(10)
Structure and function Steering demand valve
Neutral
• The steering wheel is not being operated, so • When the pressure at ports A and B rises,
steering spool (2) does not move. demand spool (1) moves to the left, so the oil
• The oil from the steering pump enters port A. The from the steering pump passes through port C of
oil from the switch pump enters port B. the spool and is drained.
The oil from the switch pump passes through
port D and all flows to the main control valve.
WA700-3 10-87
(10)
Structure and function Steering demand valve
Turning right
• When the steering wheel is turned to the right, load check valve (5) of the steering spool and is
the Orbit-roll valve is operated and steering spool drained. The oil from the switch pump enters port
(2) moves to the left. B, goes through demand spool (1), pushes open
The oil from the steering pump enters port A, check valve (4), and is merged with the oil from
then flows to steering spool (2) through demand the steering pump.
spool (1). The oil pushes open load check valve
(6) of the spool, and flows to the bottom end of
the left cylinder and the rod end of the right
cylinder to turn the machine to the right . The oil
from the left and right cylinders passes through
10-88 WA700-3
(10)
Structure and function Steering demand valve
Turning left
• When the steering wheel is turned to the left, the load check valve (6) of the steering spool and is
Orbit-roll valve is operated and steering spool (2) drained. The oil from the switch pump enters port
moves to the right. B, goes through demand spool (1), pushes open
The oil from the steering pump enters port A, check valve (4), and is merged with the oil from
then flows to steering spool (2) through demand the steering pump.
spool (1). The oil pushes open load check valve
(5) of the spool, and flows to the rod end of the
left cylinder and the bottom end of the right
cylinder to Sturn the machine to the left. The oil
from the left and right cylinders passes through
WA700-3 10-89
(10)
Structure and function Two-way restrictor valve
1. Poppet
2. Spring
3. Body
Function
• To reduce the shock caused by the inertia of the
machine when the steering is operated, an orifice
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
between poppet (1) and the poppet seat.
10-90 WA700-3
(10)
Structure and function Stop valve
Stop valve
WA700-3 10-91
(10)
Structure and function Diverter valve
Diverter valve
10-92 WA700-3
(10)
Structure and function Diverter valve
Operation
WA700-3 10-93
(10)
Structure and function Diverter valve
10-94 WA700-3
(10)
Structure and function Diverter valve
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/cm2}. 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 passes
through the orifice in main valve (1) and fills port
B. Pilot poppet (3) is in contact with valve seat
(2).
WA700-3 10-95
(10)
Structure and function Brake piping
Brake piping
10-96 WA700-3
(10)
Structure and function Brake circuit diagram
WA700-3 10-97
(10)
Structure and function Brake valve
Brake valve
Brake valve (right)
A
D
5 B
6
C
7
SDW00107
10-98 WA700-3
(10)
Structure and function Brake valve
9
E
10
SDW00108
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
transmission solenoid valve electrically and set
the transmission to neutral.
WA700-3 10-99
(10)
Structure and function Brake valve
Operation
Brake applied (right brake valve)
Upper portion
• When brake pedal (1) is depressed, the 1
operating force is transmitted to spool (3)
through rod (2) and spring (4). When spool (3) 2
goes down, drain port a is closed, and the oil
from the pump and accumulator flows from port
A to port C and actuates the rear brake cylinders.
3
Drain
Lower portion 4
• When brake pedal (1) is depressed, the a
Accumulator C
operating force is transmitted to spool (3)
A
through rod (2) and spring (4). When spool (3)
goes down, spool (5) is also pushed down by From pump To rear brake
Accumulator cylinder
plunger (6). When this happens, drain port b is b 6
closed, and the oil from the pump and 5
accumulator flows from port B to port D and From pump To front brake
cylinder
actuates the front brake cylinders. B D SED00109
Right brake
valve
d
G PP
11 To rear brake
cylinder
From pump
3
From pump
To front brake
cylinder
SEW00110
10-100 WA700-3
(10)
Structure and function Brake valve
Lower portion
• When spool (3) in the upper portion moves up
and the circuit between port A and port C is shut
off, oil also fills the front brake cylinder at the
same time, so the pressure in the circuit between
port B and port D rises. The oil entering port J
from orifice f of spool (5) pushes up spool (5) by
the same amount that spool (3) moves, and
shuts off port B and port D. Drain port b is closed,
so the oil entering the brake cylinder is held, and 4
the brake is applied. 3
a
• The pressure in the space in the upper portion is e H
To rear brake
balanced with the operating force of the pedal, A
From pump C cylinder
and the pressure in the space in the lower portion
5
is balanced with the pressure in the space in the b To front brake
f
upper portion. When spools (3) and (5) move to From pump Dcylinder
the end of their stroke, the circuits between ports
B
A and C and between ports B and D are fully J SEW00112
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.
WA700-3 10-101
(10)
Structure and function Brake valve
Lower portion
• When the pedal is released, spool (3) in the 3
upper portion moves up. At the same time, the a
back pressure from the brake cylinder and the
force of the spool return spring move spool (5) From pump From rear brake
up. Drain port b is opened and the oil from the cylinder
brake cylinder flows to the hydraulic tank return
circuit to release the front brake. From pump b From front brake
5 cylinder
SEW00113
10-102 WA700-3
(10)
Structure and function Charge valve
Charge valve
10-104 WA700-3
(10)
Structure and function Charge valve
Operation
1. When no oil is being supplied to accumulator
(cut-out condition)
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.
• The spring chamber at the right end of spool (15)
is also shut off from port T, so the pressure 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
immediately. 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.
10-106 WA700-3
(10)
Structure and function Charge valve
WA700-3 10-107
(10)
Structure and function Accumulator (for brake)
SEW00120
Function Specifications
• The accumulator is installed between the charge Gas used: Nitrogen gas
valve and the brake valve. It is charged with Charge amount: 4000 cc
nitrogen gas between cylinder (3) and free piston Charging pressure: 3.4 ± 0.15 MPa
(4), and uses the compressibility of the gas to (35 ± 1.5 kg/cm2) (at 50°C)
absorb the pulse of the hydraulic pump or to
maintain the braking force and to make it
possible to operate the machine if the engine
should stop.
10-108 WA700-3
(10)
Structure and function Slack adjuster
Slack adjuster
1. Cylinder Specification
2. Check valve Serial No.: 50001 – 50055
3. Bleeder Check valve cracking pressure:
4. Piston 0.93 MPa {9.5 kg/cm2}
5. Spring Check valve closing pressure:
0.59 MPa {6.0 kg/cm2}
A. Inlet port
B. Outlet port Serial No.: 50056 and up
Check valve cracking pressure:
0.59 MPa {6.0 kg/cm2}
Check valve closing pressure:
0.36 MPa {3.7 kg/cm2}
Function
• The slack adjuster is installed in the brake oil line
from the brake chamber to the brake piston. It
acts to keep the clearance between the brake
piston and discs constant even when the brake
discs are worn. In this way it acts to keep a
constant time lag when the brake is operated.
WA700-3 10-109
(10)
Structure and function Slack adjuster
Operation
1. When brake pedal is depressed
• Before the brake is depressed, piston (4) is
returned by the distance of stoke S (full stroke).
When the brake pedal is depressed, the oil
discharged from the brake valve flows from port
P of the slack adjuster and is divided to left and
right cylinders (2), where it moves piston (4) by
stroke S to the left and right.
10-110 WA700-3
(10)
Structure and function Slack adjuster
WA700-3 10-111
(10)
Structure and function Brake
Brake
Serial No.: 50001 – 50045
1. Guide pin
2. Return spring
3. Brake piston
4. Disc
5. Plate
6. Floating seal
10-112 WA700-3
(10)
Structure and function Brake
1. Guide pin
2. Return spring
3. Brake piston
4. Disc
5. Plate
6. Floating seal
WA700-3 10-113
(10)
Structure and function Brake
Function
• Main brakes are wet-type multiple-disc brakes
and are installed to all four wheels.
Operation
• When the brake pedal is depressed, the
pressure oil from the brake valve moves brake
piston (4) to the right in the direction of the arrow.
This brings disc (8) and plate (7) into contact,
and friction is generated between the disc and
plate. The wheel is rotating together with the
disc, so the machine speed is reduced and the
machine is stopped by this friction.
10-114 WA700-3
(10)
Structure and function Parking brake
Parking brake
Serial No.: 50001 – 50044
WA700-3 10-115
(10)
Structure and function Parking brake
1. Caliper Outline
2. Pad • Caliper (1) is fitted with a piston guide. Piston (3)
3. Piston and piston shaft (4) are fitted inside, and the
4. Piston shaft rotation of the piston shaft moves the piston in
5. Lever the axial direction to compress pad (2).
6. Adjustment bolt • Lever (5) is connected by a spline to the spline
side of the piston shaft.
Pad (2) is fitted and held in position together with
caliper (1) in the caliper mounting plate.
• The caliper body follows the wear of pad (2) and
slides in the axial direction on the plate.
Adjustment bolt (6) of lever (5) is used to adjust
the clearance between the pad and the disc.
Hold the lever and turn the adjustment bolt to
adjust the clearance as follows.
To INCREASE, turn COUNTERCLOCKWISE.
To DECREASE, turn CLOCKWISE.
10-116 WA700-3
(10)
Structure and function Parking brake
WA700-3 10-117
(10)
Structure and function Parking brake
1. Caliper Outline
2. Pad • Caliper (1) is fitted with a piston guide. Piston (3)
3. Piston and piston shaft (4) are fitted inside, and the
4. Piston shaft rotation of the piston shaft moves the piston in
5. Lever the axial direction to compress pad (2).
6. Adjustment bolt • Lever (5) is connected by a spline to the spline
side of the piston shaft.
Pad (2) is fitted and held in position together with
caliper (1) in the caliper mounting plate.
• The caliper body follows the wear of pad (2) and
slides in the axial direction on the plate.
Adjustment bolt (6) of lever (5) is used to adjust
the clearance between the pad and the disc.
Hold the lever and turn the adjustment bolt to
adjust the clearance as follows.
To INCREASE, turn COUNTERCLOCKWISE.
To DECREASE, turn CLOCKWISE.
10-118 WA700-3
(10)
Structure and function Spring cylinder
Spring cylinder
WA700-3 10-119
(10)
Structure and function Parking brake solenoid valve
10-120 WA700-3
(10)
Structure and function Hydraulic piping
Hydraulic piping
10-122 WA700-3
(10)
Structure and function Hydraulic circuit diagram
10-124 WA700-3
(10)
Structure and function Hydraulic circuit diagram
WA700-3 10-125
(10)
Structure and function Main piston pump
WA700-3 10-127
(10)
Structure and function Main piston pump
WA700-3 10-129
(10)
Structure and function Main piston pump
WA700-3 10-131
(10)
Structure and function
WA700-3 10-133
(10)
Structure and function
Function
• The engine rotation and torque transmitted to the
pump shaft is converted into hydraulic energy,
and pressurized oil is discharged according to
the load.
• It is possible to change the delivery amount by
changing the swash plate angle.
Structure
• Cylinder block (7) is supported to shaft (1) by a surface is designed so that the oil pressure
spline, and shaft (1) is supported by the front and balance is maintained at a suitable level. The oil
rear bearings. inside each cylinder chamber of cylinder block
• The tip of piston (6) is spherical, and shoe (5) is (7) is sucked in and discharged through valve
caulked to it to form one unit. Piston (6) and shoe plate (8).
(5) form a spherical bearing. • Impeller (9) is connected to shaft (1) through the
• Swash plate (4) has plane surface A, and shoe spline boss (10) and rotates together with the
(5) is always pressed against this surface while shaft. The oil sucked in through the suction port
sliding in a circular movement. is sent to the cylinder chamber by centrifugal
Swash plate (4) brings high pressure oil at force to make suction easier.
cylindrical 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
10-134 WA700-3
(10)
Structure and function
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 a between center
line X of rocker cam (4) and the axial direction of
cylinder block (7) changes. (Angle a is called the
swash plate angle.)
WA700-3 10-135
(10)
Structure and function
10-136 WA700-3
(10)
Structure and function
2. Control pump
Model: BAR025
1. Collar Outline
2. Body • The control pump is a gear pump for the ES
3. Housing (engine sensing) valve, and its specifications are
4. Drive gear as follows.
5. Driven gear
Specification
Model: BAR025
Theoretical delivery: 25 cc/rev.
Max. delivery pressure: 2.9 MPa {30 kg/cm2}
WA700-3 10-137
(10)
Structure and function
Function
The relief valve is built in the body of control pump. It
relieves the oil delivered from the pump.
10-138 WA700-3
(10)
Structure and function ES valve
1. Plug Function
2. Valve body • This valve acts to control the delivery amount of
3. Shaft the hydraulic pump to match the changes in the
4. Plug engine speed.
5. Plug
6. Spool
7. Spool
8. Plug
WA700-3 10-139
(10)
Structure and function Servo valve
Servo valve
1. Plug
2. Arm
3. Spool
4. Body
5. Sleeve
6. Sleeve
7. Spool
8. Plug
10-140 WA700-3
(10)
Structure and function Pressure differential valve
WA700-3 10-141
(10)
Structure and function PPC valve
P : From pump
T : To tank (drain)
P1 : To bucket cylinder (Tilt)
P2 : To boom cylinder (Raise)
P3 : To boom cylinder (Lower)
P4 : To bucket cylinder (Dump)
10-142 WA700-3
(10)
Structure and function PPC valve
1. Bolt
2. Piston
3. Plate
4. Collar
5. Retainer
6. Center spring
7. Metering spring
8. Valve
9. Body
WA700-3 10-143
(10)
Structure and function PPC valve
Operation
(Fig. 2)
10-144 WA700-3
(10)
Structure and function PPC valve
(Fig. 3)
(Fig. 4)
WA700-3 10-145
(10)
Structure and function PPC relief valve
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 circuit
from damage. (Sets maximum pressure in the
circuit).
Operation
• Port A is connected to the pump circuit, and port
C is connected to the drain circuit.
The oil passes through the orifice of main valve
(1) and fills port B. Pilot poppet (3) is in close
contact with valve seat (2).
10-146 WA700-3
(10)
Structure and function Accumulator (for PPC valve)
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
hydraulic pump and PPC valve. An inflatable
bladder is filled with nitrogen gas, and the
compressibility is used to store the pressure of
the oil. As a result, the boom and bucket can be
lowered under their own weight even after the
engine has been stopped.
WA700-3 10-147
(10)
Structure and function Main control valve
10-148 WA700-3
(10)
Structure and function Main control valve
Outline
• A work equipment valve is installed. The control and boom spool are operated, the oil flows into
valve controls the operations of the bucket and the bucket cylinder and boom cylinder.
boom of the hydraulic system and has a tandem Since the bucket is given priority, however, the
circuit, in which the bucket circuit is given the boom dose not move even if the boom spool is
priority. The work equipment valve operates operated while the bucket spool is operated.
each spool with the hydraulic pressure from the
PPC valve. • The bucket circuit has 2 safety-suction valves
• The oil from the pump flows in port P and its (10), which protect the circuit when abnormal
maximum pressure is limited by the relief valve. pressure is generated.
Then, it flows through bucket spool (6), bypass When either of the 2 safety-suction valves
circuit of boom spool (4), port T, drain circuit, and operates as a relief valve, the other one supplies
filter and returns to the tank. If the bucket spool a deficiency of oil as a suction valve.
WA700-3 10-149
(10)
Structure and function Main control valve
10-150 WA700-3
(10)
Structure and function Main control valve
Outline
• A work equipment valve is installed. The control and boom spool are operated, the oil flows into
valve controls the operations of the bucket and the bucket cylinder and boom cylinder.
boom of the hydraulic system and has a tandem Since the bucket is given priority, however, the
circuit, in which the bucket circuit is given the boom dose not move even if the boom spool is
priority. The work equipment valve operates operated while the bucket spool is operated.
each spool with the hydraulic pressure from the
PPC valve. • The bucket circuit has 2 safety-suction valves
• The oil from the pump flows in port P and its (10), which protect the circuit when abnormal
maximum pressure is limited by the relief valve. pressure is generated.
Then, it flows through bucket spool (6), bypass When either of the 2 safety-suction valves
circuit of boom spool (4), port T, drain circuit, and operates as a relief valve, the other one supplies
filter and returns to the tank. If the bucket spool a deficiency of oil as a suction valve.
WA700-3 10-151
(10)
Structure and function Main control valve
Relief valve
Serial No.: 50001 – 51000
1. Main valve
2. Valve seat
3. Pilot poppet
4. Pilot poppet spring
5. Adjustment screw
6. Lock nut
Function
• The relief valve is installed at the inlet of the main
control valve. When the oil goes above the set
pressure, the relief valve drains the oil to the
tank. In this way, it sets the maximum pressure in
the hydraulic circuit and protects the circuit.
Operation
• Port A is connected to the pump circuit, and port
C is connected to the drain circuit. The oil passes
through the orifice of main valve (1) and flows to
port B. Pilot poppet (3) is in close contact with
valve seat (2).
• When the hydraulic pressure in the circuit inside
port A and port B reaches the set pressure of
pilot poppet spring (4), pilot poppet (3) opens,
and the pressurized oil from port B flows from
port D to port C, so the pressure at port B drops.
10-152 WA700-3
(10)
Structure and function Main control valve
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 maximum
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 chamber
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.
WA700-3 10-153
(10)
Structure and function Main control valve
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
cylinder when the main valve is at neutral, the
safety valve (with suction valve) releases the
abnormal pressure and protects the cylinder
from damage.
• This valve prevents generation of negative
pressure in the circuit.
Operation A B C 2 4 D
As a safety valve
• Port A is the cylinder circuit and port B is the
drain circuit.
• 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
d1 d3 d4 d2
sectional area) gives a relationship of d2 > d1 > d3 SEW00167
> d4 .
10-154 WA700-3
(10)
Structure and function Main control valve
As a suction 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
difference 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"
becomes 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. Main poppet
2. Sleeve
1 2 3 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.
WA700-3 10-155
(10)
Structure and function Main control valve
Function
• The float selector valve (2) and the unloader
valve (3) are inside the main control valve. When
the boom control lever is moved to the float
position, the float selector valve (2) detects this.
When it is actuated, it actuates the unloader
valve (3) and sets the boom in the FLOAT
position.
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.
10-156 WA700-3
(10)
Structure and function Main control valve
WA700-3 10-157
(10)
Structure and function Main control valve
Function
• The float selector valve (2) and the unloader
valve (3) are inside the main control valve. When
the boom control lever is moved to the float
position, the float selector valve (2) detects this.
When it is actuated, it actuates the unloader
valve (3) and sets the boom in the FLOAT
position.
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.
10-158 WA700-3
(10)
Structure and function Main control valve
WA700-3 10-159
(10)
Structure and function Main control valve
Operation
• The oil enters port A from the steering valve, and • The oil from the PPC pump passes through
the maximum pressure is set by relief valve (11). check valve (13), and enters port L of the PPC
• Bucket spool (1) is at the HOLD position, so the valve. However, the boom and bucket levers are
bypass circuit is open and the oil at port A at the HOLD position, so the oil returns to the
passes around the spool and flows to port B. hydraulic tank from PPC relief valve (12).
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 returns to the tank.
10-160 WA700-3
(10)
Structure and function Main control valve
Operation
• When boom lever (3) is pulled, the oil flows from • The oil from the steering valve passes through
port L of the PPC valve to port N and port S. In the bypass circuit of the bucket spool and flows
addition, the oil at port T passes through port M to the bypass circuit of boom spool (2). The
and flows to the drain circuit. The oil pressure at bypass circuit is closed by the spool, so the oil
port S pushes boom spool (2) and moves it to the pushes open check valve (10). The oil flows from
RAISE position. port H to port I, and flows to the cylinder bottom.
• At the same time, the oil at the cylinder rod end
enters drain port C from port K and returns to the
tank. Therefore, the boom rises.
WA700-3 10-161
(10)
Structure and function Main control valve
Operation
• When boom lever (3) is pushed, the oil flows • The oil from the steering valve passes through
from port L of the PPC valve to port M and port the bypass circuit of the bucket spool and flows
T. In addition, the oil at port S flows to the drain to the bypass circuit of boom spool (2). The
circuit. bypass circuit is closed by the spool, so the oil
The oil pressure at port T pushes boom spool (2) pushes open check valve (10). The oil flows from
and moves it to the LOWER position. port J to port K, and flows to the cylinder rod end.
• At the same time, the oil at the cylinder bottom
enters drain port C from port I and returns to the
tank. Therefore, the boom goes down.
10-162 WA700-3
(10)
Structure and function Main control valve
Operation
• When boom lever (3) is pushed to the FLOAT port X, valve (7) moves to the right, opens port C1
position, the PPC valve spool moves beyond the and port C, and connects to the drain circuit.
LOWER position to the FLOAT position. The When port C1 is connected to the drain circuit,
pressure oil at port L flows to port M, and at the unload valve (8) moves up and the oil from the
same time, it also flows to port T and port W. In pump flows to the drain circuit.
addition, the pressurized oil at port S flows to port • Therefore, the oil at the cylinder rod end passes
N. from port K through unload valve (8) and flows to
• The pressurized oil at port T pushes boom spool the drain circuit. The oil at the cylinder bottom
(2) to the LOWER position. flows from port I to port C, and then flows to the
• If a difference in pressure greater than the drain circuit. Therefore, the boom is set to the
specified pressure is generated at port W and FLOAT condition.
WA700-3 10-163
(10)
Structure and function Main control valve
Operation
• When bucket lever (4) is pushed, the pressure oil port F to port G, and then flows to the cylinder rod
at port L of the PPC valve flows from port Q to end.
port V. In addition, the oil at port R flows to the • At the same time, the oil at the cylinder bottom
drain circuit. The pressure oil at port V moves flows from port D to drain port C, and returns to
bucket spool (1) to the DUMP position. the tank, so the bucket is dumped.
• 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
10-164 WA700-3
(10)
Structure and function Main control valve
Operation
• When bucket lever (4) is pulled, the pressure oil port E to port D, and then flows to the cylinder
at port L of the PPC valve flows from port P to bottom.
port R. In addition, the oil at port V flows to the • At the same time, the oil at the cylinder rod end
drain circuit. The pressure oil at port R moves flows from port G to drain port C, and returns to
bucket spool (1) to the TILT position. the tank, so the bucket is tilted.
• 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
WA700-3 10-165
(10)
Structure and function Main control valve
Operation
• The oil enters port A from the steering valve, and • The oil from the PPC pump passes through
the maximum pressure is set by relief valve (11). check valve (13), and enters port L of the PPC
• Bucket spool (1) is at the HOLD position, so the valve. However, the boom and bucket levers are
bypass circuit is open and the oil at port A at the HOLD position, so the oil returns to the
passes around the spool and flows to port B. hydraulic tank from PPC relief valve (12).
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 returns to the tank.
10-166 WA700-3
(10)
Structure and function Main control valve
Operation
• When boom lever (3) is pulled, the oil flows from flows to the bypass circuit of boom spool (2). The
port L of the PPC valve to port N and port T. In bypass circuit is closed by the spool, so the oil
addition, the oil at port S passes through port M pushes open check valve (10). The oil flows from
and flows to the drain circuit. The oil pressure at port H to port I, and flows to the cylinder bottom.
port T pushes boom spool (2) and moves it to the • At the same time, the oil at the cylinder rod end
RAISE position. enters drain port C from port K and returns to the
• The oil from the steering valve passes through tank. Therefore, the boom rises.
the bypass circuit of the bucket spool (1) and
WA700-3 10-167
(10)
Structure and function Main control valve
Operation
• When boom lever (3) is pushed, the oil flows flows to the bypass circuit of boom spool (2). The
from port L of the PPC valve to port M and port bypass circuit is closed by the spool, so the oil
S. In addition, the oil at port T flows to the drain pushes open check valve (10). The oil flows from
circuit. port J to port K, and flows to the cylinder rod end.
The oil pressure at port S pushes boom spool (2) • At the same time, the oil at the cylinder bottom
and moves it to the LOWER position. enters drain port C from port I and returns to the
• The oil from the steering valve passes through tank. Therefore, the boom goes down.
the bypass circuit of the bucket spool (1) and
10-168 WA700-3
(10)
Structure and function Main control valve
Operation
• When boom lever (3) is pushed to the FLOAT port X, valve (7) moves to the right, opens port C1
position, the PPC valve spool moves beyond the and port C, and connects to the drain circuit.
LOWER position to the FLOAT position. The When port C1 is connected to the drain circuit,
pressure oil at port L flows to port M, and at the unload valve (8) moves up and the oil from the
same time, it also flows to port S and port W. In pump flows to the drain circuit.
addition, the pressurized oil at port T flows to port • Therefore, the oil at the cylinder rod end passes
N. from port K through unload valve (8) and flows to
• The pressurized oil at port S pushes boom spool the drain circuit. The oil at the cylinder bottom
(2) to the LOWER position. flows from port I to port C, and then flows to the
• If a difference in pressure greater than the drain circuit. Therefore, the boom is set to the
specified pressure is generated at port W and FLOAT condition.
WA700-3 10-169
(10)
Structure and function Main control valve
Operation
• When bucket lever (4) is pushed, the pressure oil port F to port G, and then flows to the cylinder rod
at port L of the PPC valve flows from port Q to end.
port V. In addition, the oil at port R flows to the • At the same time, the oil at the cylinder bottom
drain circuit. The pressure oil at port V moves flows from port D to drain port C, and returns to
bucket spool (1) to the DUMP position. the tank, so the bucket is dumped.
• 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
10-170 WA700-3
(10)
Structure and function Main control valve
Operation
• When bucket lever (4) is pulled, the pressure oil port E to port D, and then flows to the cylinder
at port L of the PPC valve flows from port P to bottom.
port R. In addition, the oil at port V flows to the • At the same time, the oil at the cylinder rod end
drain circuit. The pressure oil at port R moves flows from port G to drain port C, and returns to
bucket spool (1) to the TILT position. the tank, so the bucket is tilted.
• 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
WA700-3 10-171
(10)
Structure and function Lubrication of work equipment
10-172 WA700-3
(10)
Structure and function Lubrication of work equipment
WA700-3 10-173
(10)
Structure and function Work equipment linkage
10-174 WA700-3
(10)
Structure and function Work equipment linkage
WA700-3 10-175
(10)
Structure and function Bucket positioner and boom kick-out
10-176 WA700-3
(10)
Structure and function Bucket positioner and boom kick-out
Bucket positioner
• The bucket positioner is electrically actuated and
is used to automatically obtain the optimum
digging angle for the bucket.
When the bucket is moved from the DUMP
position to the TILT position, and it reaches the
desired angle, the bucket lever is automatically
moved from the TILT position to the neutral.
• Lever (2) is secured by bolts to bucket cylinder
rod (1). A proximity switch (3) is fixed by bolts to
the cylinder.
• When the bucket is moved from the DUMP
position to the TILT position, the bucket cylinder
rod moves to the lift. At the same time, lever (2)
also moves to the left. When it reaches the
desired position, lever (2) separates from
proximity switch, and the bucket lever returns 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. A proximity
switch (5) is fixed to the frame. When the boom
is moved from the LOWER position to the RAISE
position, the boom rises. When it reaches the
desired position, the proximity switch and plate
come into contact and the boom lever is returned
to neutral.
WA700-3 10-177
(10)
Structure and function Operation of proximity switch
10-178 WA700-3
(10)
Structure and function Operation of proximity switch
Proximity switch
Lights up Goes out
actuation 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)
WA700-3 10-179
(10)
Structure and function Operation of proximity switch
Bucket TILT
• When the bucket is dumped beyond the set
position for the auto-leveler, the sensor (steel
plate) is above the detection surface of the
bucket proximity switch, so electric current flows
in the proximity switch load circuit. The positioner
relay is turned ON and the current for the
solenoid is shut off.
10-180 WA700-3
(10)
Structure and function Operation of proximity switch
Proximity switch
Lights up Goes out
actuation display
Positioner relay Current flows Current is shut off
Solenoid (for bucket) Current is shut off Current flows
WA700-3 10-181
(10)
Structure and function Air conditioner
Air conditioner
Air conditioner piping
Serial No.: 50001 – 51000
1. Vent 6. Compressor
2. Window defroster 7. Hot water inlet port
3. Vent 8. Hot water outlet port
4. Dry receiver 9. Air conditioner unit
5. Air conditioner condenser
10-182 WA700-3
(10)
Structure and function Air conditioner
1. Vent 6. Compressor
2. Window defroster 7. Hot water inlet port
3. Vent 8. Hot water outlet port
4. Dry receiver 9. Air conditioner unit
5. Air conditioner condenser
WA700-3 10-183
(10)
Structure and function Air conditioner
Specifications
Type: Piston pump type
Refrigerant used: R134a
10-184 WA700-3
(10)
Structure and function Air conditioner
Dry reservoir
1. Cap
2. Body
3. Drier
WA700-3 10-185
(10)
Electric circuit diagram
Structure and function Machine monitor system
Outline
• The machine monitor system uses the sensors • There are also various switches built into the
and other devices installed to various parts of the monitor panel which function to operate the
machine to observe the condition of the machine. machine.
It processes this information swiftly and displays
it on the monitor panel to inform the operator of a The main monitor uses the network wiring to
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 – 4th, N, F, R (F, R are
switches, relays, alarm buzzer, and power optional) (When auto shift, joystick steering
source. are installed)
• The displays can be broadly divided into the 2) HOLD
following: Cautions displayed on the monitors 3) Failure action code, failure code, time
(abnormalities in the machine where an alarm is elapsed since failure (failure data display
given) and normal conditions which are always mode)
displayed on the instrument panel (pilot lamps
and readings for the gauges, speedometer, and
service meter).
10-186 WA700-3
(10)
Structure and function Main monitor
Main monitor
Outline
• The main motor has display function for the • A liquid crystal display and LEDs are used for the
speedometer and other gauges and a switching display. The switches are embossed sheet
function to control the electric components and switches.
controllers.
• There is one CPU (Central Processing Unit)
installed internally, and this processes the
signals from the sensors and outputs the display.
WA700-3 10-187
(10)
Structure and function Main monitor
Display
Symbol Display item Display range Display method
category
Emergency steering
actuated (when
When actuated Display flashes
equipped with
emergency steering)
Parking brake actuated,
Caution Display flashes and buzzer sounds
transmission not at neutral
Turn signal
When operated Display lights up
(left, right)
Display lights up
Parking
brake P Parking brake When operated Buzzer sounds when parking brake
is applied and shift lever is not at N
Emergency steering
normal (when When normal (oil is flowing
Display lights up
equipped with emer- in hydraulic circuit)
Pilot gency steering)
Lights up
Lighting up time changes according
to engine water temperature when
Preheating When preheating
starting switch is turned ON (for
details, see PREHEATING CIR-
CUIT)
Shift hold
(Machine equipped When shift is held Display lights up
with auto shift)
Shift
Shift indicator 1 – 4, N Digital display
indicator
F, R, display (when
Shift
equipped with joy- F, R Digital display
indicator
stick steering)
10-188 WA700-3
(10)
Structure and function Main monitor
Engine low idling speed is changed Low idling speed set to approx.
Lights up
between two stages each time 850 rpm
Engine low idling
switch is pressed Low idling speed set to approx.
(Serial No.: 50001 – 51000) Goes out
650 rpm
Front working lamp lights up or goes Lights up Front working lamp lights up
Working lamp
out each time switch is pressed
(front)
when side lamps are lighted up Goes out Front working lamp goes out
Rear working lamp lights up or goes Lights up Rear working lamp lights up
Working lamp
out each time switch is pressed
(rear) Goes out Rear working lamp goes out
when side lamps are lighted up
Transmission cut-off function is Lights up Cut-off function actuated
Transmission
actuated or stopped each time
cut-off
switch is pressed Goes out Cut-off function stopped
WA700-3 10-189
(10)
Structure and function Main monitor
Method of switching to With engine stopped and starting All switch displays (LEDs) go out, and fail-
trouble data display switch turned ON, press 2nd switch ure code is displayed on speedometer dis-
mode from top on left side of main monitor play and time elapsed since failure is
(switch below emergency steering displayed on failure action code display.
display) and working lamp (front) 1) Failure code is a two-digit display
switch simultaneously for at least 5 given in numbers or letters.
seconds. T he displa y fo r the failure now
occurring flashes and the display for
past failures lights up.
If there is no failure, CC is displayed
ON
(000 is displayed for time elapsed
since failure)
2) The time elapsed since failure is
displayed as a three-digit number to
show how long ago the failure
occurred (the oldest failure time is
SDW00241
displayed. Any time greater than
999H is displayed as 999H).
3) A maximum of 9 items are stored in
memory for the failure code.
Method of sending fail- Press working lamp (front) switch Failure code and time elapsed since fail-
ure code ure change to next item.
ON
SDW01254
SDW00242
Clearing failure code Press working lamp (rear) switch for Failure code and time elapsed since fail-
at least 2 seconds ure being displayed are cleared.
Failure code for problem now occurring
ON (flashing display) cannot be cleared.
SDW00243
Resetting from travel Press 2nd switch from top on left Changes to normal display
data display mode side of main monitor (switch below
emergency steering display) and
working lamp (front) switch simulta-
neously for at least 5 seconds, or
start the engine.
10-190 WA700-3
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Structure and function Maintenance monitor
Maintenance monitor
1. Check items 2D. Air cleaner (L.H.) 3C. Torque converter oil tem-
(Checks before starting) (Serial No.: 50001 – 51000) perature
1A. Engine water level 2E. Air cleaner (R.H.) 4. Service meter
1B. Engine oil level (Serial No.: 50001 – 51000) 4A. Service meter numeric dis-
2. Caution items (warning items) 2F. Transmission oil filter play
2A. Engine oil pressure 3. Gauge items 4B. Service meter RUN pilot
2B. Brake oil pressure 3A. Fuel level lamp
2C. Battery charge 3B. Engine water temperature 5. Monitor module
6. Switch module
Outline
• The maintenance monitor has a display function • A liquid crystal display and LEDs are used for the
for the caution items and gauges. display portions. The switches are embossed
• The maintenance monitor consists of the monitor sheet switches.
module, switch module, service meter, case, and
other mechanisms.
• The monitor module has a built-in CPU (Central
Processing Unit). It processes the signal from the
sensors, and carries out the display and output.
WA700-3 10-191
(10)
Structure and function Maintenance monitor
Engine water level Below low level Displays when engine is stopped and
starting switch is ON
Display when normal: OFF
Engine oil level Below low level Display when abnormal: Flashes
Check CHECK lamp flashes
Transmission oil filter Above specified dif- Displays when engine is running
ferential pressure Display when normal: OFF
Dispplay when abnormal: Flashes
Engine water level Below low level Displays when engine is running
Display when normal: OFF
Display when abnormal: Flashes
Engine oil pressure Below specified pres- CAUTION lamp flashes
sure Buzzer sounds
Caution Torque converter oil Above 120°C Buzzer sounds if above 130°C
temperature
Engine water temper- 67 80 90 97 102 105˚C One place lights up to show applicable
ature level
Gauges 1 2 3 4 5 6 7 Flashes when level is 6 or 7
C H
White Green Red
Torque converter oil 50 70 90 110 120 130˚C One place lights up to show applicable
temperature level
1 2 3 4 5 6 7 Flashes when level is 6 or 7
C H
Green Red
10-192 WA700-3
(10)
Structure and function Automatic transmission system (ATM)
Auto shift
Hold function
Kickdown function
Safety function
Manual shift
Kickdown function
Self-diagnostic function
Condition display (output, failure code)
Troubleshooting (detection of system abnormality, system disconnection, short circuit)
Communications function
( ) For the machines, serial No. 51001 and up, see AJSS (Advanced Joystick Steering System).
• Automatic transmission system consists of the • The self-diagnostic function always observes the
transmission controller, directional and speed input and output condition, and displays the
levers, engine speed sensor, speed sensor and output condition on the two 7-segment LED
all-speed-range solenoid. displays on the transmission controller. There is
• The transmission controller controls the shifting also a failure detection function, and if any
to the appropriate speed range according to the abnormality occurs, it displays a failure code.
lever position and travel speed signal. Depending on the condition, it also displays a
• A travel damper function and joystick steering failure action code on the main monitor and
control function are available as options, and flashes the caution lamp to improve safety.
these controls are possible if the function is • The transmission controller has a
installed to the machine. communications function, and it sends the speed
• To improve durability, there is a safety function range (N, 1st – 4th) data to the main monitor,
which prevents the machine from moving which displays the speed range. (If the joystick
suddenly when the engine is started, and a mode is used, it also displays F and R.)
transmission protection function which protects
the clutch when the direction of travel is
changed.
WA700-3 10-193
(10)
Structure and function Automatic transmission system (ATM)
10-194 WA700-3
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Structure and function Automatic transmission system (ATM)
WA700-3 10-195
(10)
Structure and function Automatic transmission system (ATM)
10-196 WA700-3
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Structure and function Automatic transmission system (ATM)
Note 1: When the engine speed is less than 1800 rpm and the travel speed is less than 16 km/h, or when the
travel speed is less than 13 km/h.
Note 2: When the travel speed is 1800 rpm or above and the travel speed is 13 km/h or above, or when the
travel speed is 16 km/h or above, the speed range is maintained and the transmission shifts down to
2nd according to the deceleration.
WA700-3 10-197
(10)
Structure and function Automatic transmission system (ATM)
10-198 WA700-3
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Structure and function Automatic transmission system (ATM)
WA700-3 10-199
(10)
Structure and function Automatic transmission system (ATM)
Auto lever
(switches at N)
(*2 (1))
Steering wheel
2nd (*1)
Manual 2nd (*2 (3))
(switches at N)
Holds previous
2nd (*1)
Auto position
(switches at N)
(*2 (2))
Joystick
Position of speed
Manual lever 2nd (*2 (3))
(switches at N)
(*1): Normally, when switching the mode [steering wheel io joystick], the switching is carried out with the
machine stopped and in neutral, so the speed range becomes 2nd.
If the machine is moving, the auto-shift [restart data] is used, and the transmission is set to a speed range
that matches the travel speed. However, if the shift lever position is 1, the speed range becomes 1st.
(*2): It is possible to switch between auto and manual when traveling if the same mode is retained.
(1) Steering wheel mode: For auto o manual, the speed range is the position of the shift lever.
(2) Joystick mode: For auto o manual, the speed range before shifting the mode is maintained (the speed
range does not change).
(3) For manual o auto, the auto-shift data [Table 1 Automatic shift change point table, Item 8 Switching
between F and R] is used, and the transmission is set to a speed range that matches the travel speed.
However, if the shift lever position is 1, the speed range becomes 1st.
10-200 WA700-3
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Structure and function Automatic transmission system (ATM)
8. Self-diagnostic function
The transmission controller always observes the input and output signals of the automatic gear-shifting sys-
tem. It carries out self-diagnosis and displays the results on the LEDs of the transmission controller. In addi-
tion, it sends the following data to the main monitor.
1) Normal display: Transmission controller LEDs display output speed range.
2) Failure code display: If an abnormality is detected, the nature of the failure is displayed as a code. For
details of the failure codes, see [Table 3 Failure code table].
a E59 and E60 cannot be distinguished and are output at the same time.
a E56 always outputs ON, so it is impossible to judge if there is a disconnection.
WA700-3 10-201
(10)
Structure and function Automatic transmission system (ATM)
9. Communications function
The transmission controller is equipped with a When signal is OPEN, the transmission con-
communications function using S-NET, and it troller maintains the neutral condition.
always maintains communications with the main 24V: Parking brake released
monitor. When any abnormality occurs, it dis- OPEN: Parking brake applied
plays an action code on the main monitor 6) Transmission cut-off signal
according to the condition of the problem to This signal is a GND/OPEN digital signal,
warn the operator in order to increase safety. and when the transmission cut-off switch is
The failure code can recognize the codes operated (using the left brake), it changes to
recorded in the main monitor memory using the OPEN. When it is actuated, the transmis-
main monitor trouble data mode. For details of sion controller changes to the neutral output
operating the main monitor, see the section on condition, and when it is canceled, it sets to
the main monitor. a suitable speed range for the travel speed
at that point.
10. Transmission controller power source 7) Manual mode signal
When the starting switch is turned ON and the This signal is a GND/OPEN digital signal.
supply voltage is more than 20V, and +20V or When the manual mode switch is ON, GND
more is supplied to the transmission controller is input.
solenoid power source input, it is possible to
control the drive of each solenoid valve.
If the supply voltage is less than 19V, all outputs
are turned OFF and the solenoids cannot carry
out control (travel is impossible).
10-202 WA700-3
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Structure and function Automatic transmission system (ATM)
1) Model selection
Table 4 Machine model selection signal table
Machine model CN3B-2 CN3B-10 CN3B-3
WA600-3 OPEN OPEN GND
WA700-3 GND OPEN OPEN
2) Engine selection
Table 5 Engine selection table
Engine
Komatsu Cummins
Signal and data
Engine selection (CN3A-10) OPEN GND
*1: When Not set condition is detected, all controller outputs are turned OFF and it is impossible to travel.
a After displaying the program part number, the LED display shows [0o0o].
WA700-3 10-203
(10)
Structure and function Automatic transmission system (ATM)
1) Transmission signal
Table 7 Combination of speed ranges and
solenoid
Q: ON
SOL
F R 1st 2nd 3rd 4th
Speed range
F1 Q Q
F2 Q Q
F3 Q Q
F4 Q Q
N
R1 Q Q
R2 Q Q
R3 Q Q
R4 Q Q
10-204 WA700-3
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Structure and function Automatic transmission system (ATM)
Example
Display Content
'0o 2o' Neutral, 2nd
'Fo 1o' FORWARD, 1st
'Ao 2o' REVERSE, 2nd
'Fo Fo' Neutral safety condition
<Example>
Eo –o 2o 3o o Repeated
<Example>
Eo –o 2o 3o Eo – o 1o 8o o Repeated
WA700-3 10-205
(10)
Structure and function Joystick steering system
1. Joystick
2. Transmission and joystick steering controller
3. Proportional solenoid valve
4. Control pump
5. Stop valve
6. Steering demand valve
7. Steering cylinder
10-206 WA700-3
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Structure and function Joystick steering system
WA700-3 10-207
(10)
Structure and function AJSS (Advanced Joystick Steering System)
10-208 WA700-3
(10)
Structure and function AJSS (Advanced Joystick Steering System)
WA700-3 10-209
(10)
Structure and function AJSS (Advanced Joystick Steering System)
Troubleshooting function
The controller constantly checks that the electronic devices composing each potentiometer which collects input
signals, each solenoid valve which receives output signals, etc. are operating normally.
If any of those devices becomes abnormal, the controller detects it and indicate it by the "Failure code" on the
main monitor to notify the operator of it.
10-210 WA700-3
(10)
Structure and function AJSS (Advanced Joystick Steering System)
Potentiometer
1. Connector 5. Bearing
2. Case 6. Contact
3. Shaft 7. Mold
4. Element
Function
The potentiometer senses the operating angle. In short circuit, etc. Since the correct position cannot
the potentiometer, the source voltage of 5 V is con- be sensed in this case, the control output is turned
verted with a variable resistor into a signal voltage off and the failure code is displayed on the main
according to the angle, then sent to the controller. monitor.
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,
WA700-3 10-211
(10)
Structure and function Transmission and joystick controller
10-212 WA700-3
(10)
Structure and function Transmission and joystick controller
WA700-3 10-213
(10)
Structure and function Transmission and joystick controller
10-214 WA700-3
(10)
Structure and function Engine starting circuit
Function
• It is possible to start or stop the engine by turning terminal C o neutral relay terminals 3 – 5 o
the starting switch ON or OFF. An electrical starting motor terminal C o starting motor
device is used which controls the fuel injection terminal E o ground.
amount and improves the ease of operation. • At the same time, the electric current from
starting switch terminal ACC flows to the engine
Operation throttle controller as the governor cut relay and
• When the directional lever is placed at the N starting motor signal. Here, various signals, such
position, the neutral contacts of the directional as the water temperature, are calculated, and a
lever switch are closed. In this condition, if the signal is sent to the fuel injection pump to set the
starting switch is turned to the ON position, fuel injection amount to the optimum value.
electric current flows from the starting switch • A circuit is formed from the battery o battery
terminal BR o battery relay coil o ground, and relay o starting motor terminal B, so the engine
the switch of the battery relay coil is closed. The starts.
power supply from the battery passes through • If the directional lever is not at the N position, the
the directional lever switch, the neutral relay is neutral relay is not actuated, so the circuit is not
actuated, and terminals 3 – 5 close. formed and the engine does not start.
• When the starting switch is turned to START,
electric current flows from starting switch
WA700-3 10-215
(10)
Structure and function Engine starting circuit
APS completely
APS started stopped
Passage of time
Glow plug Starting Engine starts,
preheats motor turns intake air
heated
10-216 WA700-3
(10)
Structure and function Engine starting circuit
Function
• For the safety at the time of starting engine, the • The ECM controller controls fuel injection
neutral safety circuit prevents the engine from amount and injection timing according to input
starting when the directional lever is at other than signals.
N (neutral) position. • Battery, battery relay and starting motor B
• When the starting switch is turned OFF, the fuel terminal are electrically connected, and then
supply is shut off and the engine stops. engine starts.
When the directional lever is at other than N
Operation (neutral) position, the engine does not start
• When the directional lever is at the N (neutral) because the neutral relay is not actuated, and
position, the neutral contacts of the directional the circuit (1) is not composed.
lever close. When the starting switch is turned
ON, the neutral relay is ac tuated and its
terminals 3 to 5 are closed. The current flows
from starting switch BR terminal, to battery relay
coil, and to the ground, then battery relay
becomes closed.
When starting switch is turned to START, the
current flows from battery positive terminal, to
starting switch B to C, and to neutral relay
terminals (5) to (3), and to starting motor C to E
,and to the ground (circuit (1)).
WA700-3 10-217
(10)
Structure and function Engine stop circuit
Function
• An electrical device is used which controls the
fuel injection amount and improves the ease of
operation by making it possible to start or stop
the engine by turning the starting switch ON or
OFF.
Operation
• When the starting switch is turned OFF, starting
switch terminal B and terminals BR and Care
opened.
• The current to the engine throttle controller is
also shut off, so there is no injection from the
injection pump, and the engine stops.
10-218 WA700-3
(10)
Structure and function Engine stop circuit
Operation
• When the starting switch is turned OFF, the
starting switch B, BR and ACC terminals are
disconnected with each other.
• The ECM controller outputs signal to shut off the
fuel supply, then engine stops.
WA700-3 10-219
(10)
Structure and function Auto priming system (APS)
1. Main monitor
2. Monitor pilot lamp
(preheating, afterheating)
3. Heater switch
4. Starting switch
5. Fuel cut-off switch
6. APS controller
7. APS water temperature sensor
8. Battery
9. Fuel tank
10. Fuel injection pump
11. Engine cut-off valve
12. Fuel filter
13. Fuel valve
14. APS fuel injection nozzle
15. Glow plug
16. APS assister
Function Outline
• The APS system is used in cold areas to make it • The fuel flows from the tank through the feed
easier to start the engine. It works by burning fuel pump of fuel injection pump (10) and is sent to
inside the intake manifold to heat the intake air. fuel filter (12). At the outlet port of the fuel filter, it
• The APS assister turns OFF the spray signal to is connected to the APS fuel circuit.
t he AP S co nt r ol l e r w he n s t a r t in g i n l ow • The APS fuel circuit consists of fuel valve (13),
temperatures, when the engine speed pick-up is bracket which divides the fuel, and APS fuel
slow, or when the starting switch is released injection nozzle (14) which uses APS controller
before the engine speed picks up (when the (6) to automatically adjust the amount of the fuel
engine speed has not reached the speed spray.
required for the alternator to start generating).
Therefore, it acts to hold the starting switch
signal and maintain a continuous spray by the
APS.
10-220 WA700-3
(10)
Structure and function Auto priming system (APS)
APS controller
APS assister
WA700-3 10-221
(10)
Structure and function Auto priming system (APS)
Operation of APS
1. Operation of preheating
• When the starting switch is ON and the ground, and the glow plugs become red hot.
preheating switch is turned ON, electricity flows While glow plugs 1 and 2 are being heated, the
to the APS controller and APS assister power output signal is also sent to the preheating lamp
source circuit and makes it possible for it to be ci rc ui t i nsi de t he APS cont roll er, so t he
actuated. preheating/afterheating pilot lamp lights up.
• When this happens, if the engine cooling water • After the preheating pilot lamp lights up for the
temperature is below 13°C, the APS water set time (approx. 12 sec), it goes out.
temperature sensor is closed (ON). For this This shows that glow plugs 1 and 2 have been
reason, even if the preheating switch is returned heated enough by the action of the APS.
from ON o AUTO, electric power is flowing to the • The APS assister acts to hold the starting switch
APS controller, so the circuit is connected inside signal and maintain a continuous spray by the
the controller. APS when starting in low temperatures, when
When the water temperature is below 20°C, the the engine speed pick-up is slow, or when the
APS water temperature sensor closes (is turned starting switch is released before the engine
ON). speed picks up.
When the APS water temperature sensor is
turned ON, the output signal is sent to glow 1 and
glow 2 circuits inside the APS controller. Electric
current flows in a circuit from glow plugs 1, 2 o
10-222 WA700-3
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Structure and function Auto priming system (APS)
2. Operation of afterheating
• After the preheating pilot lamp goes out, if the After the engine starts, the signal from the
starting switch is turned to the START position, preheating switch – APS water temperature
electric current flows to neutral relay terminals 3 sensor actuates the fuel injection nozzle and
– 5 and the starting motor starts to turn. At the carries out afterheating.
same time, electric current flows from APS After the engine starts and the warming-up
assister terminal S through terminal C to the operation raises the engine cooling water
circuit of starting switch terminal C of the APS temperature to 20°C or above, the APS water
controller and actuates the controller. temperature sensor opens (OFF). As a result,
• The APS fuel injection nozzle inside the intake the water temperature sensor signal to the APS
manifold is switched ON/OFF to inject fuel controller is turned OFF. The output signal to
intermittently (10 times/sec) to glow plugs 1 and glow plugs 1 and 2 is cut off, and at the same
2. (When electric power is applied, the APS time the afterheating pilot lamp flashes.
controller sends the start signal, or when the stop When starting work when the engine is running
signal is input because the starting safety relay is with the APS actuated and the engine water
actuated, the intermittent injection signal is temperature above 20°C, if the preheating switch
output to the APS fuel injection nozzle.) is turned OFF, the APS controller power circuit is
The fuel injection to glow plugs 1 and 2 is burned cut off, and the operation of the APS is stopped.
inside the intake manifold and heats the intake At the same time, the afterheating pilot lamp
air. display goes out.
WA700-3 10-223
(10)
Structure and function Preheating circuit
Preheating circuit
(Automatic preheating system)
Serial No.: 51001 and up
Outline Operation
• An automatic preheating system is provided to • When the starting switch is turned ON, the ECM
improve engine starting performance in cold controller outputs a signal to actuate the
area. By turning the starting switch ON, the preheating relay contacts to be closed. Then, the
system sets the preheating time automatically current flows from the preheating relay terminal
according to the coolant temperature, it causes (5) to the heater relay, then the heater relay is
reducing preheating time. actuated.
• By turning the starting switch ON, electrical • The current flows from battery to battery relay, to
intake air heater preheats the intake air. The heater relay, and to electrical intake air heater,
preheating time is controlled by the ECM then the preheating is carried out.
controller according to the coolant temperature • When preheating time is finished, the ECM
which is detected by the coolant temperature controller outputs a signal to cut off the current to
sensor. the preheating relay, and the heater relay
• The preheating pilot lamp lights up while contacts open, thereby preheating is finished.
preheating. The lamp goes out when preheating • While preheating, the current flows to the main
is finished. monitor to light up the preheating pilot lamp.
10-224 WA700-3
(10)
Structure and function Fuel system
Fuel system
Serial No.: 51001 and up
WA700-3 10-225
(10)
Structure and function Electrical transmission control
Function
1 Selection of F, R, and N position Using directional lever
2 Selection of speed range Using speed lever
When traveling in F2, it is possible to shift down to 1st using this switch without
3 Kick-down switch using the speed lever. If directional lever is operated to R or N, speed range auto-
matically returned to 2nd.
4 Transmission cut-off function Transmission is shifted to neutral when left brake is operated.
It is possible to select whether to actuate or not actuate the transmission cut-off
Transmission cut-off selector function. In this way, it is possible to obtain the same or greater ease of operation
5
function as on conventional loaders with the left brake when carrying out scooping work or
when loading or unloading the machine from a trailer.
To prevent seizure of the parking brake when traveling with the parking brake
6 Neutralizer
applied, the transmission is shifted to neutral when the parking brake is applied.
If the directional lever is not at the N position, the engine will not start when the
7 Neutral safety function starting 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 backup horn sounds
8 Warning function
to warn people in the area.
10-226 WA700-3
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Structure and function Electrical transmission control
Combination switch
1 8 7
2 3 9 10 4 6 5
SDW00301
Outline
• The directional lever has three positions and the two pins, and is secured to the body by three
speed lever switch has four positions. As an screws. When each lever is operated to the
individual part, the switch does not have a detent desired position, the switch, which is
mechanism; the detent mechanism is in the interconnected by a shaft, acts to allow electric
combination switch. Each switch is positioned by current to flow to that circuit only.
WA700-3 10-227
(10)
Structure and function Electrical transmission control
Operation
• Directional lever (1) and shaft (2) of the speed F
lever of the combination switch form one unit with
magnet (3), and magnet (3) also moves together
with lever (1). N
• Control switch (5) with built-in hole IC (4) is
installed at the bottom of magnet (3), and hole IC
(4) is positioned on the board to match each R
2
position.
1
• When directional lever (1) is operated to the F
position, magnet (3) is immediately above hole
IC (4) for the F position of the control switch. The
magnetism from magnet (3) passes through the
gap and case (6), and magnetism is applied to
hole IC (4).
• When this happens, hole IC (4) is inside a
3
magnetism detection circuit, so it detects the
magnetism of magnet (3) and sends the F
position signal to the electric current 4
6
amplification circuit. In the electric current
amplification circuit, a signal is output to actuate 5
the transmission.
SEW00302
10-228 WA700-3
(10)
Structure and function Kick-down, hold switch
1. Kick-down switch
2. Spring
3. Spring
4. Hold switch
5. Wiring harness
WA700-3 10-229
(10)
Structure and function Kick-down electrical circuit
10-230 WA700-3
(10)
Structure and function Kick-down electrical circuit
WA700-3 10-231
(10)
Structure and function Kick-down electrical circuit
• When the directional lever switch is at a position • In addition, the circuit between 2nd-1st selector
other than F, the F terminal contact is OFF, so relay terminals 3 – 6 is closed, so the electric
the electric current from the battery is cut off. No current from the battery flows to the 2nd
electric current flows to FORWARD solenoid solenoid, and the transmission speed range is
relay terminals 5 – 6 and the FORWARD set to 2nd, the same as the position of the speed
solenoid is reset. lever.
• When this happens, FORWARD solenoid relay • In this way, the actuation of the kick-down switch
terminals 3 – 4 are opened, so the electric is canceled and travel operations are carried out
current stops flowing to kick-down relay coil according to the normal lever commands. If the
terminals 5 – 6, the kick-down relay is reset, and directional lever is set to R, the machine will
the self-hold circuit is canceled. travel in R2.
• When the kick-down relay is reset, kick-down
relay terminals 3 – 4 are opened, so the electric
current from the battery is cut off and stops
flowing. The 2nd-1st selector relay is reset, the
circuit between relay terminals 3 – 5 is opened,
and the circuit between terminals 3 – 6 is closed.
• The electric current flowing to the 1st solenoid is
cut off and the kick-down setting to 1st is
canceled.
10-232 WA700-3
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Structure and function Kick-down electrical circuit
• When the speed lever is operated to a position speed range set by the position of the speed
other than 2nd, speed lever switch 2nd terminal lever.
is cut off. The electric current stops flowing from • The speed lever switch 2nd terminal is opened,
battery o FORWARD solenoid relay terminals 3 so even if 2nd-1st selector relay terminals 3 – 6
– 4 o kick-down relay terminals 1 – 2, 5 – 6 o are closed, electric current does not flow to the
ground, and the kick-down relay is reset. 2nd solenoid and it is not actuated.
• When this happens, the circuit between kick- • In this way, the actuation of the kick-down switch
down relay terminals 1 – 2 is opened and the is canceled and travel operations are carried out
self-hold is canceled, so even if the speed lever according to the normal lever commands.
is again set to 2nd, the kick-down switch is not
actuated.
• At the same time, kick-down relay terminals 3 –
4 are also opened, so electric current from the
battery stops flowing. To 2nd-1st selector relay
terminals 2 – 1, and 2nd-1st selector relay is
reset.
When the relay is reset, relay terminals 3 – 5 are
opened, and electric current stops flowing to the
1st solenoid, so the kick-down setting to 1st
canceled and the transmission returns to the
WA700-3 10-233
(10)
Structure and function Kick-down electrical circuit
• When the parking brake switch is turned ON • As a result, electricity flows from the battery o
(applied), electric current stops flowing to the kick-down relay terminals 3 – 4 o 2nd-1st
parking brake valve and the parking brake is selector relay terminals 2 – 1. The relay is
actuated. At the same time, the neutralizer relay actuated, so electric current flows from terminals
is also reset, so neutralizer relay terminals 3 – 5 3 – 5 o 1st solenoid o ground, and the 1st clutch
are opened. is actuated.
The electric current from the battery is cut off and • In this way, when the parking brake is applied,
does not flow to the FORWARD solenoid, so the the actuation of the kick-down switch is not
transmission is set to neutral. canceled, but the directional lever switch is set to
At the same time, in directional lever switch neutral and the speed range to 1st, and the
terminal F, electric current flows from the battery machine is stopped from moving.
o FORWARD solenoid relay terminals 5 – 6 o
ground, so the circuits between terminals 1 – 2
and between terminals 3 – 4 are closed.
• The speed lever switch is at 2nd, so electric
current flows from FORWARD solenoid relay
terminals 3 – 4 o kick-down switch o kick-down
relay terminals 6 – 5 o ground, the relay is
actuated, and the circuit between terminals 1 – 2
and between terminals 3 – 4 are closed.
10-234 WA700-3
(10)
Structure and function Kick-down electrical circuit
WA700-3 10-235
(10)
Structure and function Electric parking brake control
Outline
• When electric current flows to the parking brake 1. Parking brake switch
valve (solenoid valve), the hydraulic pressure 2. Accumulator
from the accumulator is applied to the spring 3. Emergency brake switch
cylinder to release the parking brake. 4. Parking brake display switch
On the other hand, if the electric current is turned 5. Parking brake valve
off, the oil pressure from the accumulator is cut 6. Spring cylinder
off, so the oil pressure inside the spring cylinder 7. Neutralizer relay
passes through the parking brake valve and is 8. Parking safety relay
drained, the parking brake is actuated by the
force of the spring.
10-236 WA700-3
(10)
Structure and function Electric parking brake control
Function
1. Applying and releasing parking brake : The parking brake is applied or released by using the
parking brake switch (combination switch).
2. Emergency brake : If there is damage to the hydraulic circuit, and the
pressure inside the accumulator drops and it is
impossible to guarantee the braking force of the
brake, the parking brake is automatically applied to
act as an emergency brake.
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. There-
fore, 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 operator of the mistaken
operation. In addition to this, when the parking brake
is applied, the transmission is forcibly shifted to neu-
tral to make it impossible to drive the machine.
However, the braking distance will become longer if
the transmission is shifted to neutral when the
e me r ge nc y br a k e is a ppl i ed . I t m a y a ls o be
necessary to move the machine if it stops in places
where it is prohibited to stop (such as on railway
crossings). To overcome this, the circuit is designed
so that the transmission is not shifted to neutral
when the emergency brake is applied.
WA700-3 10-237
(10)
Structure and function Electric parking brake control
10-238 WA700-3
(10)
Structure and function Electric parking brake control
Operation
1. Starting switch OFF
WA700-3 10-239
(10)
Structure and function Electric parking brake control
2. Starting switch ON
2-1 When parking brake switch is ON (actuated) before starting switch is turned ON
• The electric current flows in circuit (1) from the relay is in the condition of circuit (3) until the
battery o starting switch o battery relay coil o starting switch is turned OFF.
ground, so the battery relay is closed. When this • In this condition, electric current does not flow to
happens, electric current flows in circuit (2) from the parking brake solenoid valve, so the parking
the battery o battery relay o parking brake brake is actuated.
switch terminal 1 – 3 o parking brake safety • In addition, in this condition, neutralizer relay
relay terminal 1 – 2 o ground. In this way, the terminals 3 and 5 are open, so electric current
parking safety relay is actuated and safety relay does not flows to the transmission directional
terminals 3 – 5 are closed. circuit, and the transmission is shifted to neutral.
• When this happens, circuit (3) is formed from the
battery o battery relay o parking safety relay
terminal 5 – 3 o parking safety relay terminal 1 –
2 o ground. From this point, the parking safety
10-240 WA700-3
(10)
Structure and function Electric parking brake control
2-2 When parking brake switch is OFF (actuated) before starting switch is turned ON
WA700-3 10-241
(10)
Structure and function Electric parking brake control
• If the parking brake switch is turned from ON battery relay o neutralizer relay terminal 3 – 5 o
(actuated) to OFF (released), the circuit for transmission directional circuit, so when the
terminals 2 and 3 of the parking brake switch is directional lever is operated, the machine will
connected, and the parking brake safety relay is move.
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) and (3)
given below.
(2) This circuit is formed from the emergency
brake switch o parking brake solenoid valve o
ground, and the parking brake is released.
(3) This circuit is formed from the battery (+) o
10-242 WA700-3
(10)
Structure and function Electric parking brake control
• If the parking brake switch is turned ON (applied) transmission directional circuit, so the
after carrying out operations with the parking transmission is shifted to neutral. This kind of
brake switch OFF (released), the circuit in the neutralizer relay shuts off the electric current
diagram above is formed. going to the transmission solenoid valve when
• Electric current does not flow to the parking the parking brake is applied and shifts the
brake solenoid valve, so the oil pressure from the transmission to neutral to prevent seizure of the
accumulator to the spring cylinder is shut off. At parking brake if the operator should drive the
the same time, the oil pressure inside the spring machine with the parking brake still applied.
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
relay is reset, so the circuit between terminals 3
and 5 is opened, and no electricity flows to the
WA700-3 10-243
(10)
Structure and function Electric parking brake control
Operation
• If the accumulator pressure drops, the to engage the transmission clutch. In this way, it
emergency brake swit ch inst al led t o t he is possible to use the engine brake when the
accumulator is opened. emergency brake is applied, so the braking
For this reason, the electric current stops flowing distance becomes shorter. At the same time, if
to the parking brake solenoid valve, so the oil the emergency brake has been applied and it is
pressure inside the spring cylinder is drained and necessary to move the machine (for example, if
the parking brake is applied. the emergency brake is applied when the
However, in this case, the condition is different machine is on a railway crossing), it is possible to
from the case where the parking brake switch is move the machine by operating the transmission
ON (applied), because there is electric current lever.
flowing to the neutralizer relay coil.
• For this reason, electric current flows to the
transmission directional circuit, and it is possible
10-244 WA700-3
(10)
Structure and function Electric circuit diagram of active power maximizing system
Outline
• When the work equipment circuit does not need Powerful Loading: Delivery of switching pump is
much oil flow during digging operation, the active reduced during digging operation.
power maximizing hydraulic system minimizes Drive force is increased and work
the delivery from the switching pump (variable- equipment speed is decreased
capacity piston pump) to reduce the load on the during digging operation.
engine and increase the drive force. Normal Loading: Delivery of switching pump is not
• When the active working switch is set in reduced even during digging
"Powerful Loading" and the lift arm is at the operation.
digging position (height) and the oil pressure on Work equipment speed is high.
the lift arm cylinder bottom side increases, the
solenoid valve is operated to change the oil flow
for the switching pump servo valve to minimize
the delivery.
WA700-3 10-244-1
(12)
Structure and function Electric circuit diagram of active power maximizing system
Operation
• If the starting switch is turned ON, power is • Accordingly, even if the active working switch is
supplied to the active working switch and neutral set in "Powerful Loading", the current from it is
1 relay terminal (3). blocked by neutral 2 relay and the active power
• When the directional lever is in "N" (Neutral), the maximizing system does not work.
neutral signal (+24 V) flows to neutral 1 relay
terminal (1) to "close" contacts (3) and (5).
Then, the current flows through neutral relay
terminals (3) and (5) and neutral 2 relay
terminals (1) and (2) to the ground to "open"
neutral 2 relay contacts (3) and (6).
10-244-2 WA700-3
(12)
Structure and function Electric circuit diagram of active power maximizing system
Operation
• If the directional lever is set in the forward Accordingly, no current flows in the lift arm
position, the neutral signal does not flow and cylinder bottom pressure relay coil and contacts
neutral 1 relay contacts (3) and (5) are "open". (3) and (6) are "closed", thus the current flows
Accordingly, no current flows in the neutral 2 from neutral 2 relay terminal (6) through lift arm
relay coil and contacts (3) and (6) are closed. bottom pressure relay terminals (3) and (6) to
Then, power is supplied from the active working timer 1 terminal (14).
switch through neutral 2 relay terminals (3) and • If the current keeps flowing through timer 1
(5) to the position sensing proximity switch and terminals (14) and (13) to the ground for the set
lift arm cylinder bottom pressure switch. time, contacts (8) and (12) are "closed".
• If the lift arm is lowered and the lift arm position Then, the current flows from timer 1 terminal (12)
sensing proximity switch is turned ON, the through no-load relay terminals (1) and (2) to the
ground side (terminal (6)) of the pump cut-off ground, and consequently contacts (3) and (5)
relay coil is connected to the ground through the are "closed".
proximity switch. Since the current keeps flowing through no-load
• Since the lift arm cylinder bottom pressure is not relay terminals (5) and (1) to the ground, no-load
increased at the start of digging operation, the oil relay terminals (3) and (5) are kept "closed".
pressure switch is turned OFF.
WA700-3 10-244-3
(12)
Structure and function Electric circuit diagram of active power maximizing system
Operation
• If the lift arm cylinder bottom pressure increases through the load relay coil to the ground, and
and the oil pressure switch is turned ON because consequently load relay contacts (3) and (5) are
of digging operation, the current stops flowing to "closed".
the lift arm cylinder bottom pressure relay coil • Then, the current flows from neutral 2 relay
and the current to timer 1 terminal (14) is cut off. terminal (6) through no-load relay terminals (3)
Timer 1 contacts (8) and (12) are "opened" and and (5), load relay terminals (5) and (3), timer 2
the current flowing from timer 1 terminal (12) to terminals (4) and (12), pump cutoff relay coil and
the no-load relay coil is cut off. Since the current proximity switch to the ground, and consequently
flows from no-load relay terminal (5) to the coil, pump cutoff relay contacts (3) and (4) are
however, no-load relay contacts (3) and (5) are "closed". Then, a circuit is made up from the
kept "closed". active working switch through the neutral 2 relay,
• At this time, the current also flows through lift arm pump cutoff relay and solenoid valve to the
cylinder bottom pressure relay terminals (1) and ground. As a result, the solenoid valve operates
(2) and oil pressure switch to the ground, and and the delivery of the switching pump is
consequently contacts (3) and (5) are "closed". minimized.
As a result, the current flows from terminal (5)
10-244-4 WA700-3
(12)
Structure and function Electric circuit diagram of active power maximizing system
Operation
• After digging operation is finished, if the lift arm Accordingly, the delivery of the work equipment
cylinder bottom pressure decreases and the oil pump is returned to the normal level.
pressure switch is turned OFF, the current to the • After digging operation is finished, if the lift arm
lift arm cylinder bottom pressure relay coil is cut rises to the position (height) where the proximity
off and contacts (3) and (5) are "opened", and switch is turned OFF, the circuit from pump cutoff
consequently the current to the load coil is cut relay terminal (6) through the proximity switch to
off. the ground is turned OFF, thus pump cutoff relay
Load relay contacts (3) and (6) are "closed" and contacts (3) and (4) are "opened" and the current
the current flows from terminal (6) to timer 2 to the solenoid valve is cut off.
terminal (14). • After digging operation is finished, if the
• If the current keeps flowing from terminal (14) directional lever is set in "N" (Neutral), the neutral
through terminal (13) to the ground for the set 1 relay coil is energized and the current flows
time, timer 2 "opens" contacts (4) and (12). from neutral 1 relay to neutral 2 relay coil and
• Then, the current from timer 2 to pump cut-off contacts (3) and (6) are "opened"
relay coil is cut off and contacts (3) and (4) are Then, the current flowing from neutral 2 relay
"opened" and the current to the solenoid valve is terminal (6) is cut off and each relay and timer is
cut off. reset to the initial state.
WA700-3 10-244-5
(12)
Structure and function Electric circuit diagram of active power maximizing system
Operation
• In the normal loading mode, no current flows
from the active working switch to the neutral 2
relay. Accordingly, no current flows to the
solenoid valve and the delivery of the switching
pump is kept in the normal level.
10-244-6 WA700-3
(12)
VHMS controller
Structure and function Blow-by pressure sensor
VHMS controller
VHMS : Vehicle Health Monitoring System
Specifications
1. Voltage of power supply : DC20V - DC30V
2. Size : W272 x D169 x H72
(mm)
Function
The VHMS controller collects and stores signals
from each sensor and signals from the machine con-
troller. It also gives commands for transmitting the
accumulated data through the communications sat-
ellite.
Function
The blow-by sensor converts the pressure inside the
engine crankcase into a voltage and inputs this into
the VHMS controller as the blow-by pressure.
WA700-3 10-245
(11)
Structure and function Engine oil temperature sensor
Function
The engine oil temperature sensor is installed to the
engine oil filter. It inputs the change in temperature
to the VHMS controller as a change in the resistance
of the thermistor.
10-246 WA700-3
(11)
Exhaust temperature sensor/amp
Structure and function Ambient temperature sensor
Detection
temperature 50 100 400 700 800
(°C)
Output
1.191 1.397 2.626 3.899 4.316
voltage (V)
Function
The exhaust temperature sensor is a thermoelectric
type temperature sensor. It is installed to the turbo-
charger inlet port and outputs the exhaust tempera-
ture data to the VHMS controller.
Detection
temperature -20 -10 0 10 20 50
(°C)
Resistance
30.32 18.58 11.74 7.623 5.077 1.712
(kz)
Function
The ambient temperature sensor inputs the ambient
temperature to the VHMS controller as a change in
the resistance of the thermistor.
WA700-3 10-247
(11)
Structure and function Transmission pump oil pressure sensor
Function
The transmission pump oil pressure sensor is
installed to the transmission pump. It converts the
transmission pump pressure into a voltage and
inputs the converted voltage as the transmission
pump pressure to the VHMS controller.
10-248 WA700-3
(11)
Brake oil temperature sensor
Structure and function Hydraulic oil temperature sensor
Performance
The brake oil temperature sensor and hydraulic oil
temperature sensor are installed to the right side of
the front axle. They input changes of temperature
as changes of resistance of thermistors to the
VHMS controller.
WA700-3 10-249
(11)
Brake oil pressure sensor
Steering oil pressure sensor
Structure and function Work equipment pump oil pressure sensor
10-250 WA700-3
(11)
Structure and function Communications (ORB: Orbcomm) controller/antenna
Specifications
1. Power supply voltage: DC12V – DC30V
2. Size : W306 x D152 x H52 (mm)
Installation location
Installed at inside console box.
Connector portion
CN1A (ORB-A) : AMP070-14
CN1B (ORB-B) : AMP070-10
CN2 : Communications antenna cable connector
Antenna
Specifications
1. Type : Helical whip antenna (1)
2. Impedance : 50 z
3. Input terminal: M-P type
4. Length : 165 ± 20 mm
a: Communications antenna mount
Installation location
Installed at left rear of cab
Function
The antenna transmits the data collected and accu-
mulated by the VHMS controller through the com-
munications satellite to the computer center.
WA700-3 10-251
(11)
20 Testing and adjusting
a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based on the
results of various tests. It is used for reference together with the state of repair and the history of operation
to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
k When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert
k When carrying out work together with other workers, always use signals and do not let unauthorized
the safety pins, and use blocks to prevent the machine from moving.
k When checking the water level, always wait for the water to cool down. If the radiator cap is removed
people near the machine.
k Be careful not to get caught in the fan, fan belt or other rotating parts.
when the water is still hot, the water will spurt out and cause burns.
WA700-3 20-1
(10)
Testing and adjusting Standard value table for engine
Engine SAA6D170E-2
Low idling
Engine speed rpm 650 +50 650 +50
(mounted on machine) 0 0
(Water temperature:
Operating range)
20-2 WA700-3
(10)
Testing and adjusting Standard value table for engine
Engine SAA6D170E-2
(Water temperature:
Blow-by pressure kPa
Green range) Max. 3.92 {Max. 400} 7.9 {800}
Engine
(Water temperature:
0.39 – 0.54 0.21
Green range)
{4.0 – 5.5} {2.1}
At high idling (SAE30)
(Water temperature:
0.34 – 0.49 0.18
Green range) MPa
Oil pressure {3.5 – 4.0} {1.8}
At high idling (SAE10W) {kg/cm²}
Min. 0.12 0.07
At low idling (SAE30)
{Min.1.2} {0.7}
WA700-3 20-3
(10)
Testing and adjusting Standard value table for chassis
N–FORWARD,
Travel mm 35 ± 10 35 ± 10
REVERSE
1st – 2nd 35 ± 10 35 ± 20
3rd – 4th 35 ± 10 35 ± 20
HOLDoRAISE • Engine speed: Low idling Max. 23.5 {2.4} Max. 35.3 {3.6}
• Hydraulic oil temperature:
RAISEoHOLD 45 – 55°C Max. 15.7 {1.6} Max. 23.5 {2.4}
LOWERoHOLD — —
Work equipment control lever
HOLDoFLOAT mm 67 ± 15 67 ± 30
HOLDoDUMP 60 ± 15 60 ± 30
Bucket
HOLoDTILT 60 ± 15 60 ± 30
• Engine stopped
Play mm Max. 20 Max. 20
• Machine facing straight to front
• Flat, horizontal, straight, dry 10.0 ± 3.0
Operating effort N {kg} Max. 19.6 {2.0}
Steering wheel
20-4 WA700-3
(10)
Testing and adjusting Standard value table for chassis
Operating angle
Neutral ( 1) 45 —
deg.
Max. ( 2) 30 —
Neutral ( 1) 45 —
Brake pedal
deg.
+1
Max. ( 2) 15 0 —
Play mm 5 ± 0.5 —
B mm Max. 4.0 —
B
C
TEW00003 TEW00004
Clearance of wheel lock
C 20 – 35 —
ring
ture: 60 – 80°C
• Hydraulic oil temperature:
Hydraulic stall 45 – 55°C rpm 2,150 ± 50 2,150 ± 200
• Gearshift lever: F4 or R4
WA700-3 20-5
(10)
Testing and adjusting Standard value table for chassis
warning lamp +5 +1
Low idling {60 0 } {60 0 }
goes out MPa
• Hydrualic oil 2
• Point when oil {kg/cm }
temperature: +0.98 +1.47
45 – 55°C pressure is going 9.8 0 9.8 –0.49
Charge cut-out pressure
up and then starts +10 +15
{100 0 } {100 –5 }
to go down
1st 6.4 ±0.5 6.4 ±0.5
20-6 WA700-3
(10)
Testing and adjusting Standard value table for chassis
Specified pressure
• Flat, horizontal, straight, dry paved
road surface
• Speed when applying brake:
Performance m Max. 6 6
20 km/h, braking delay: 0.1 second
• Brake pedal operating effort:
Specified operating effort
(294 ±29.4 N {30 ± 3 kg})
• Measure stopping distance.
Disc wear • Measure piston stroke mm 3.6 ± 1.9 Max. 9.7
WA700-3 20-7
(10)
Testing and adjusting Standard value table for chassis
Bucket tiltback
Bucket horizontal
1.9 ± 0.3 Min. 2.7
(above ground)
horizontal
mm
Retraction of bucket
Max. 20 Max. 20
cylinder rod
Clearance of bucket
3–5 —
Proximity
mm
Clearaance of boom kick
3–5 —
out proximity switch
20-8 WA700-3
(10)
Testing and adjusting Standard value table for electrical parts
resistance
Measure
normal. OFF.
T01
Solenoid (1st) 2) Disconnect
(male) Between (B) – (H) 50 – 70 z
connectors.
Between (B), (H) – chassis Max. 1 Mz 3) Connect T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting switch
resistance
Measure
normal. OFF.
T01
Solenoid (2nd) 2) Disconnect
(male) Between (B) – (G) 50 – 70 z
connectors.
Between (B), (G) – chassis Max. 1 Mz 3) Connect T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting switch
resistance
Measure
normal. OFF.
T01
Solenoid (3rd) 2) Disconnect
(male) Between (B) – (F) 50 – 70 z
connectors.
Between (B), (F) – chassis Max. 1 Mz 3) Connect T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting switch
resistance
Measure
normal. OFF.
T01
Solenoid (4th) 2) Disconnect
(male) Between (B) – (E) 50 – 70 z
connectors.
Between (B), (E) – chassis Min. 1 Mz 3) Connect T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting switch
resistance
Measure
normal. OFF.
T01
Solenoid (F) 2) Disconnect
(male) Between (A) – (D) 50 – 70 z
Transmission control
connectors.
Between (A), (D) – chassis Max. 1 Mz 3) Connect T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting switch
resistance
Measure
normal. OFF.
T01
Solenoid (R) 2) Disconnect
(male) Between (A) – (C) 50 – 70 z
connectors.
Between (A), (C) – chassis Max. 1 Mz 3) Connect T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting switch
resistance
Measure
normal. OFF.
T05
Speed sensor 2) Disconnect
(male) Between (1) – (2) 500 – 1000 z
connectors.
Between (1), (2) – chassis Max. 1 Mz 3) Connect T-adapter.
1) Screw in until speed sensor contacts rin
Adjust
2) Disconnect
L15 Kick down switch
Kick down switch Max. 1 z connectors.
(male) ON Between
3) Connect T-adapter.
Kick down switch (1) – (2)
Min. 1 Mz
OFF
If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
resistance
Measure
2) Disconnect
Transmission cut L12 Normal condition Max. 1 z
Between connectors.
off switch (male) Left brake pedal is (1) – (2) Min. 1 Mz 3) Connect T-adapter.
depressed
WA700-3 20-9
(10)
Testing and adjusting Standard value table for electrical parts
Measure
normal. OFF.
voltage
Power supply L05 2) Insert T-adapter.
Between (1), (2) – chassis
20 – 30 V 3) Turn starting switch
Between (1), (2) – (3) ON.
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
2) Insert T-adapter.
Engine running (at
Battery charge Between 28 ± 2V
L05 above 1/2 throttle)
(alternator) (5) – (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.
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
2) Insert T-adapter.
Directional switch Directional lever at
L05 20 – 30V 3) Turn starting switch
(N) N Between
ON.
Directional lever (8) – (3)
Max. 1 V
not at N
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
2) Insert T-adapter.
Starting switch L09 Starting switch at
20 – 30V
terminal C (male) START
(3) – chassis
Starting switch at
Max. 1 V
Main monitor
OFF or ON
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
2) Insert T-adapter.
Starting switch Starting switch at
20 – 30V
terminal C START Between
Starting switch at (4) – (3)
Max. 1 V
OFF or ON
L05 If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
Measure voltage
20-10 WA700-3
(10)
Testing and adjusting Standard value table for electrical parts
resistance
Measure
Parking brake F12 2) Disconnect
Parking brake ON Max. 1 z
indicator switch (male) Between connectors.
Parking brake (1) – (2) 3) Connect T-adapter.
Min. 1 Mz
OFF
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
Main monitor
2) Insert T-adapter.
Directional switch Directional lever at
20 – 30 V 3) Turn starting switch
(F) F Between
ON.
Directional lever (7) – chassis
Max. 1 V
not at F
L08
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
2) Insert T-adapter.
Directional switch Directional lever at
20 – 30 V 3) Turn starting switch
(R) R Between
ON.
Directional lever (8) – chassis
Max. 1 V
not at R
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure
normal. OFF.
voltage
resistance
Measure
WA700-3 20-11
(10)
Testing and adjusting Standard value table for electrical parts
resistance
Measure
normal. OFF.
Radiator water G03
2) Disconnect
level sensor (male) Water level normal Between Max. 1 z
connectors.
Water level low (1) – (2) Min. 1 Mz 3) Connect T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
Measure resistance
2) Disconnect
Engine oil pressure:
terminal.
Min. 0.07 MPa
2 Min. 1 Mz 3) Engine running
ER1 {0.7 kg/cm }
(a) (Engine running) Between
Engine oil pressure: (2) – (7)
Max. 0.03 MPa
Engine oil Max. 1 z
{0.3 kg/cm2}
pressure switch
(Engine stopped)
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
2) Insert T-adapter.
POW Min. 0.05 MPa
Between 20 – 30 V 3) Start engine
(aa) {0.5 kg/cm2}
sensor POW
Max. 0.05 MPa (A) – chassis Max. 1 V
Maintenance monitor
{0.5 kg/cm2}
If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
2) Disconnect
Measure resistance
Accumulator
connectors.
pressure:
Brake Max. 1 z 3) Connect T-adapter.
C03 Min. 5.39 ± 0.49MPa
accumulator low {55 ± 5 kg/cm2}
C04 Between
pressure switch Depress brake and (1) – (2)
lower accumulator
pressure to below Min. 1 Mz
4.41 ± 0.49 MPa
{45 ± 5 kg/cm2}
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
2) Insert T-adapter.
Engine running
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.
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure resistance
normal. OFF.
2) Disconnect
Engine oil level ER1 Engine oil level
Max. 1 z terminal.
sensor (male) normal Between
Engine oil level (3) – chassis
Min. 1 Mz
abnormal
20-12 WA700-3
(10)
Testing and adjusting Standard value table for electrical parts
continuity
Measure
Dust indicator 2) Disconnect
Air cleaner normal Continuity
(L.H.) BR1 Between connector
(a) Air cleaner BR1 (6) – (9) No Continuity 3) Starting engigne.
clogged 4) Measure continuity
continuity
Measure
Dust indicator 2) Disconnect
Air cleaner normal Continuity
(R.H.) BR1 Between connector
(a) Air cleaner BR1 (7) – (9) No Continuity 3) Starting engigne.
clogged 4) Measure continuity
2) Disconnect
Dust indicator Air cleaner normal Between Continuity
ER1 connector
(aa) Air cleaner ER1 (5) –
No Continuity 3) Starting engigne.
clogged chassis
4) Measure continuity
If the condition is as shown in the table below, monitor panel is normal. 1) Insert T-adapter.
Maintenance monitor
WA700-3 20-13
(10)
Testing and adjusting Standard value table for electrical parts
Green 1
Green 2
Green 3
Green 4
Green 5
Green 6
gauge Green 5 12.6 – 24.0 display.
Red
L18 (male) Green 4 20.5 – 30.6
Measure Green 3 26.7 – 39.6
E F
resistance Green 2 35.2 – 51.6
Red Green
between Max. Green 1 46.5 – 80.6
Flash-
(6) – (3) ing ON (kz) Red 73.8 –
Maintenance monito
Torque
50 120 130°C
converter oil Min. Red 2 0.24 – 1.90
temperature
Green 1
Green 2
Green 3
Green 4
Green 5
20-14 WA700-3
(10)
Testing and adjusting Standard value table for electrical parts
Measure resistance
Accumulator
connectors.
pressure:
Max. 1 z 3) Connect T-adapter.
Min.3.92±0.49MPa
Emergency brake C07, C08
{40 ± 5 kg/cm2} Between
switch (male)
Depress brake and C07, C08
lower accumulator (1) – (2)
pressure to below Min. 1 Mz
3.63 ± 0.49 MPa
{37 ± 5 kg/cm2}
When When
screwdriver screwdriver is 3) Turn starting switch
Bucket positioner is brough not brough ON.
F05
proximity switch close close
Between (1) – (2) 20 – 30 V Max. 3 V
Between (1) – (3) 20 – 30 V 20 – 30 V
Between (2) – (3) Max. 3 V 20 – 30 V
If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
2) Insert T-adapter.
Measure voltage
When When
screwdriver screwdriver is 3) Turn starting switch
Boom kick-out is brough not brough ON.
F06
proximity switch close close
Between (1) – (2) 20 – 30 V Max. 3 V
Between (1) – (3) 20 – 30 V 20 – 30 V
Between (2) – (3) Max. 3 V 20 – 30 V
If the condition is as shown in the table below, it is 1) Turn starting switch
resistance
Measure
normal. OFF.
Boom kick-out
L16 2) Disconnect
solenoid Between (1) – (2) 19 – 23 z
connectors.
Between (1), (2) – chassis Min. 1 Mz 3) Connect T-adapter.
If the condition is as shown in the table below, it is 1) Turn starting switch
resistance
Measure
normal. OFF.
Bucket positioner
L17 2) Disconnect
solenoid Between (1) – (2) 19 – 23 z
connectors.
Between (1), (2) – chassis Min. 1 Mz 3) Connect T-adapter.
WA700-3 20-15
(10)
Testing and adjusting Standard value table for electrical parts
Measure voltage
normal. OFF.
2) Insert T-adapter.
C1 Between C1(7), (13) – chassis
Power supply 3) Turn starting switch
C2 Between C2(1), (12) – chassis ON.
20 – 30 V
Between C1(7), (13) – (6), (12)
Between C2(1), (12) – (11), (21)
If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
Measure
2) Insert T-adapter.
voltage
Power supply Between (6) – (17)
C3A 20 – 30 V 3) Turn starting switch
(for signal) Between (6) – chassis ON.
4) Turn parking brake
switch ON.
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
2) Insert T-adapter.
Parking brake Turn parking brake
L01 20 – 30 V 3) Turn starting switch
switch switch ON Between
ON.
Turn parking brake (1) – (3)
Max 1 V
switch OFF
Transmission & Joystick steering controller
normal. OFF.
2) Insert T-adapter.
Speed control Speed control
20 – 30 V 3) Turn starting switch
lever (1st) lever at 1st Between
ON.
Speed control (7) – chassis
Max 1 V
lever not at 1st
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
2) Insert T-adapter.
Speed control Speed control
20 – 30 V 3) Turn starting switch
lever (2nd) lever at 2nd Between
ON.
Speed control (15) – chassis
Max 1 V
lever not at 2nd
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
2) Insert T-adapter.
Speed control C3B Speed control
20 – 30 V 3) Turn starting switch
lever (3rd) (female) lever at 3rd Between
ON.
Speed control (8) – chassis
Max 1 V
lever not at 3rd
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
2) Insert T-adapter.
Speed control Speed control
20 – 30 V 3) Turn starting switch
lever (4th) lever at 4th Between
ON.
Speed control (16) – chassis
Max 1 V
lever not at 4th
If the condition is as shown in the table below, it is 1) Turn starting switch
Measure voltage
normal. OFF.
2) Insert T-adapter.
Directional lever Directional lever at
20 – 30 V 3) Turn starting switch
(F) F Between
ON.
Directional lever (5) – chassis
Max 1 V
not at F
20-16 WA700-3
(10)
Testing and adjusting Standard value table for electrical parts
Measure
2) Insert T-adapter.
voltage
Directional lever Directional lever at
20 – 30 V 3) Turn starting switch
(R) R Between
ON.
Directional lever (6) – chassis
Max 1 V
not at R
C3B
(female) If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
Measure
2) Insert T-adapter.
voltage
Directional lever Directional lever at
20 – 30 V 3) Turn starting switch
(N) N Between
ON.
Directional lever (13) – chassis
Max 1 V
not at N
If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
resistance
Measure
T05 2) Disconnect
Speed Between (1) – (2) 500 – 1000 z
(male) connectors.
Between (1), (2) – chassis Max. 1 Mz 3) Connect T-adapter.
Adjust
Measure
voltage
OFF.
Engine speed C4 Between (2) – (9) Min. 0.5 V
2) Insert T-adapter.
3) Start engine.
1) Screw in until the tip of sensor contacts gear,
Adjust
Measure
WA700-3 20-17
(10)
Testing and adjusting Standard value table for electrical parts
resistance
Measure
Transmission cut- L12 2) Disconnect
Normal condition Max. 1 z
off switch (male) Between connectors.
L.H. brake pedal is (1) – (2) 3) Connect T-adapter.
Min. 1 Mz
depressed
If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
Controller
Measure
20-18 WA700-3
(10)
Testing and adjusting Standard value table for electrical parts
Measure continuity
2) Disconnect
Between (1) – (2) Continuity
ON connectors.
Between (3) – (4) Continuity 3) Connect T-adapter.
APS switch L74
Between (1) – (2) No continuity
AUTO
Between (3) – (4) Continuity
Between (1) – (2) No continuity
OFF
Between (3) – (4) No continuity
If the condition is as shown in the table below, it is 1) Turn starting switch
resistance
Measure
APS water normal. OFF.
E08
temperature 2) Disconnect
(male) Between Up to 20°C Max. 0.5 z
sensor connectors.
terminal – chassis 20°C and up Min. 1 Mz
resistance
Measure
2) Disconnect
E17 Between
Glow plug No. 1 glow plug connectors.
(male) (1) – chassis
0.8 – 1.3 z
Between
No. 2 glow plug
(4) – chassis
If the condition is as shown in the table below, it is 1) Turn starting switch
resistance
Measure
normal. OFF.
APS nozzle — 2) Disconnect
Between nozzle terminals 1.5 – 2.5 z
terminals.
normal. ON.
voltage
L71
Power source 2) Insert T-adapter.
L72 Between L72 (1) – L71 (1) 20 – 30 V
APS controller
normal. ON.
voltage
L72
Glow plug 1 2) Insert T-adapter.
L71 Between APS stopped Max. 1 V
L72 (2) – L71 (1) APS operating 4 – 12 V
WA700-3 20-19
(10)
Testing and adjusting Standard value table for electrical parts
Measure
voltage
L72 2) Insert T-adapter.
Glow plug 2 Between APS stopped Max. 1 V
L71
L72 (3) – L71 (1) APS operating 4 – 12 V
normal. ON.
voltage
starting signal
L71 2) Insert T-adapter.
of starting Between (3) – (1) 10 – 24 V
switch
2) Insert T-adapter.
Monitor lamp APS stopped Max. 1 V
Between (4) – (1)
signal of L71 APS operating 4 – 12 V
preheating
Voltage is kept 12 – 20 V for 12 seconds after
starting switch ON, then goes down to below
1 V.
If the condition is as shown in the table below, it is 1) Turn starting switch
Pre-heat system (aa)
normal. OFF.
Measure voltage
2) Connect T-adapter.
Between (2) – chassis 20 – 30 V
3) Turn starting switch
When water temperature is maintained at lower ON.
Pre-heat power HEAT than 0°C for more than 30 seconds.
20-20 WA700-3
(10)
Testing and adjusting Standard value table for electrical parts
Measure voltage
normal. OFF.
2) Insert T-adapter.
C1 Between C1(7), (13) – chassis
Power supply 3) Turn starting switch
C2 Between C2(1), (12) – chassis ON.
20 – 30 V
Between C1(7), (13) – (6), (12)
Between C2(1), (12) – (11), (21)
2) Insert T-adapter.
voltage
normal. OFF.
T01
Solenoid (1st) 2) Disconnect
(male) Between (H) – (B) 5 – 15 z
connectors.
Between (H), (B) – chassis Max. 1 Mz 3) Connect T-adapter.
normal. OFF.
T01
Solenoid (2nd) 2) Disconnect
(male) Between (G) – (B) 5 – 15 z
connectors.
Between (G), (B) – chassis Max. 1 Mz 3) Connect T-adapter.
normal. OFF.
T01
Solenoid (3rd) 2) Disconnect
(male) Between (F) – (B) 5 – 15 z
connectors.
Between (F), (B) – chassis Max. 1 Mz 3) Connect T-adapter.
normal. OFF.
T01
Solenoid (4th) 2) Disconnect
(male) Between (E) – (B) 5 – 15 z
connectors.
Between (E), (B) – chassis Max. 1 Mz 3) Connect T-adapter.
normal. OFF.
T01
Solenoid (F) 2) Disconnect
(male) Between (D) – (B) 5 – 15 z
connectors.
Between (D), (B) – chassis Max. 1 Mz 3) Connect T-adapter.
normal. OFF.
T01
Solenoid (R) 2) Disconnect
(male) Between (C) – (B) 5 – 15 z
connectors.
Between (C), (B) – chassis Max. 1 Mz 3) Connect T-adapter.
WA700-3 20-21
(10)
Testing and adjusting Standard value table for electrical parts
resistance
Measure
normal. OFF.
Engine speed E13
2) Disconnect
sensor (male) Between (1) – (2) 500 – 1000 z
connectors.
Between (1), (2) – chassis Max. 1 Mz 3) Connect T-adapter.
Measure
voltage
Engine speed 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
Adjust
Engine speed
— contacts the ring gear, then turn it back 1 turn. —
sensor
2) It works normally by adjustment above.
If the condition is as shown in the table below, it is 1) Turn starting switch
resistance
Measure
normal. OFF.
T05
Speed sensor 2) Disconnect
(male) Between (1) – (2) 500 – 1000 z
connectors.
Between (1), (2) – chassis Max. 1 Mz 3) Connect T-adapter.
2) Insert T-adapter.
voltage
2) Insert T-adapter.
voltage
Measure
2) Insert T-adapter.
voltage
2) Insert T-adapter.
voltage
2) Insert T-adapter.
voltage
20-22 WA700-3
(10)
Testing and adjusting Standard value table for electrical parts
Measure
2) Insert T-adapter.
voltage
Directional Directional lever at
20 – 30 V 3) Turn starting switch
lever (R) R Between
ON.
Directional lever (6) – chassis
Max. 1 V
not at R
If the condition is as shown in the table below, it is 1) Turn starting switch
Controller
normal. OFF.
Measure
2) Insert T-adapter.
voltage
Directional C3B Directional lever at
20 – 30 V 3) Turn starting switch
lever (N) N Between
ON.
Directional lever (13) – chassis
Max. 1 V
not at N
System If the condition is as shown in the table below, it is 1) Turn starting switch
network normal. OFF.
Measure
voltage
Kick-down switch
& shift-down Max. 1 z connectors.
at ON Between
switch 3) Connect T-adapter.
Kick-down switch (1) – (2)
Min. 1 Mz
at OFF
L15
(male) If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
resistance
Measure
2) Disconnect
Shift-up switch at
Shift-up switch Max. 1 z connectors.
ON Between
3) Connect T-adapter.
Shift-up switch at (3) – (4)
Min. 1 Mz
OFF
If the condition is as shown in the table below, it is 1) Turn starting switch
normal. OFF.
resistance
Measure
2) Insert T-adapter.
voltage
OFF.
Measure
WA700-3 20-23
(10)
Testing and adjusting Standard value table for electrical parts
Measure
When joystick FNR
voltage
Joystick gear 17 –30 V 2) Insert T-adapter.
switch is in “R” Between
shift switch R 3) Turn starting switch
When joystick FNR (6) – chassis
Max. 1 V ON.
switch is not in “R”
Normal ranges are as follows. 1) Turn starting switch
OFF.
Measure
When joystick FNR
voltage
Neutralizer 17 –30 V 2) Insert T-adapter.
switch is in “N” Between
relay signal 3) Turn starting switch
When joystick FNR (14) – chassis ON.
Max. 1 V
switch is not in “N”
Normal ranges are as follows. 1) Turn starting switch
OFF.
Measure
20-24 WA700-3
(10)
Testing and adjusting Standard value table for electrical parts
Measure
0.5 – 1.5 V 2) Insert T-adapter.
voltage
Frame angle is RIGHT. Between
C3A 3) Start engine.
sensor When frame angle (13) – (16)
3.5 – 4.5 V 4) Move joystick to
is LEFT. left or right stoke
end.
Controller
not in neutral
a Set machine in straight travel position.
Normal ranges are as follows. 1) Turn starting switch
OFF.
When steering
2) Insert T-adapter.
lever angle is 3.5 – 4.5 V
3) Start engine.
RIGHT. Between
4) Move joystick to
When steering (1) – (3)
left or right stoke
Measure
voltage
WA700-3 20-25
(10)
Testing and adjusting
[Related to VHMS]
Basic precautions........................................................................................................................................ 20-157
Outline......................................................................................................................................................... 20-160
Setting up VHMS controller......................................................................................................................... 20-166
Collection, transmission of data .................................................................................................................. 20-168
Inspection and maintenance ....................................................................................................................... 20-173
Replacing parts ........................................................................................................................................... 20-173
a For the functions and structures of the controllers, sensors, etc., see Structure and function.
WA700-3 20-101
(11)
Testing and adjusting Table of tools for testing, adjusting, and troubleshooting
20-102 WA700-3
(10)
Testing and adjusting Table of tools for testing, adjusting, and troubleshooting
Commercially
Valve clearance F Feeler gauge
available
799-201-1504 Blow-by checker
Blow-by pressure G 799-201-1590 Gauge —
6162-23-4500 Barring device 0 – 98 kPa {0 – 1,000mm H2O}
Air supply pressure –101.3 to + 199.9 kPa
H 799-201-2202 Pressure gauge
(boost pressure) {–760 to + 1,500 mmHg}
1 793-520-1805 Brake tester kit —
Brake oil pressure I 2 • 793-520-1851 Nipple —
3 790-301-1230 Elbow Kit part No.: 799-101-5002
1 79A-264-0020 0 – 294.2 N {0 – 30 kg}
Operating effort J Push-pull scale
2 79A-264-0090 0 – 490.3 N {0 – 50 kg}
Commercially
Stroke, hydraulic drift K Scale
available
Commercially
Work equipment speed L Stop watch —
available
Measuring brake disc Commercially
M Caliper gauge —
wear available
Measuring voltage,
N 79A-264-0211 Tester —
resistance value
Adjusting fuel injection
P 795-471-1200 Gauge ass’y (Dial gauge is commercially available)
timing
WA700-3 20-103
(10)
Testing and adjusting Table of tools for testing, adjusting, and troubleshooting
20-104 WA700-3
(10)
Testing and adjusting Adjusting valve clearance
WA700-3 20-105
(10)
Testing and adjusting Adjusting valve clearance
Serial No.: 51001 and up 5. Tighten locknut (4) to hold adjustment screw (3)
3. Using barring device F1, rotate the crankshaft in 6. Turn the crankshaft 120° each time in the nor-
the normal direction to set the No. 1 cylinder at mal direction and repeat the procedure in Steps
compression top dead center, and align pointer 3 to 5 to adjust the valves of each cylinder
b with the [1.6TOP] line a on the crankshaft pul- according to the firing order.
ley. a Firing order : 1 – 5 – 3 – 6 – 2 – 4
a At compression top dead center, the valve
rocker arm can be moved by hand by the 7. After completing the measurement, set to the
20-106 WA700-3
(10)
Testing and adjusting Testing and adjusting injector lift
Testing and adjusting injector 5. Crank the crankshaft and measure the lift of the
plunger at the point where the deviation of the
lift dial gauge is the maximum.
a Max. lift c: 20.00 mm
Serial No.: 51001 and up
Inspection
1. Remove the cover of the flywheel housing, then
install barring device F1.
4. Set dial gauge to the head of the plunger of 2. Fully loosen adjustment screw (1) of the injector
the injector to be inspected. to be adjusted, then tighten it by hand.
a Use a dial gauge with a stroke of at least 30 a Check that the socket at the tip of the rocker
mm. arm and the ball of the push rod are both
fitted securely into the injector and push rod,
respectively.
WA700-3 20-107
(10)
Testing and adjusting Testing and adjusting injector lift
3 Adjustment screw:
ing operation, then tighten finally.
20-108 WA700-3
(10)
Testing and adjusting Measuring compression pressure
Measuring compression
pressure
Serial No.: 50001 – 51000
WA700-3 20-109
(10)
Testing and adjusting Measuring compression pressure
Serial No.: 51001 and up 4. Fit adapter of compression gauge D1, then
k When measuring the compression pressure, be
connect to the compression gauge.
a Hold the adapter in position with an injector
careful not to touch the exhaust manifold or
3 Mounting bolt:
holder.
muffler, or to get caught in rotating parts.
a Measure the compression pressure with the
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
engine warmed up.
(Oil temperature: 40°C – 60°C)
3 Mounting bolt:
Engine oil (EO30CD)
20-110 WA700-3
(10)
Testing and adjusting Measuring compression pressure
WA700-3 20-111
(10)
Testing and adjusting Measuring blow-by pressure
Note:
a Blow-by varies greatly according to the condition
of the engine. Therefore, if the blow-by value is
considered abnormal, check for problems
connected with defective blow-by, such as
excessive oil consumption, defective exhaust
gas color, and prematurely dirty or deteriorated
oil.
20-112 WA700-3
(10)
Testing and adjusting Testing and adjusting fuel injection timing
WA700-3 20-113
(10)
Testing and adjusting Testing and adjusting fuel injection timing
20-114 WA700-3
(10)
Testing and adjusting Measuring exhaust gas color
20-109
WA700-3 20-115
(10)
Testing and adjusting Testing and adjusting alternator belt tension
Testing
• Measure deflection a of the belt when each belt is
pushed with a force of approx. 59 N {approx. 6 kg} at
a point midway between the alternator pulley and the
drive pulley.
a Deflection a of belt (standard value):
approx. 10 – 15 mm
Adjusting
Testing
• Measure deflection a when the belt is pressed with a
finger at a point midway between the alternator
pulley and drive pulley.
a Pushing force when measuring:
Approx. 98 Nm {approx. 10 kg}
a Deflection a: 10 – 15 mm
Adjusting
a If the deflection is not within the specified range,
adjust as follows.
1. Loosen 2 mounting bolts of alternator (1) and the
lock bolt of the bar.
2. Loosen locknut (2), move alternator (1) with adjust-
ment nut (3), and adjust the tension of belt (4).
a Deflection: 10 – 15 mm
20-116 WA700-3
(10)
Testing and adjusting Testing and adjusting air conditioner compressor belt tension
1. Testing
• Measure deflection b of the belt when it is
pushed with a finger force of approx. 58.8 N
{approx. 6 kg} at a point midway between the
compressor pulley and the engine drive pulley.
a Deflection b of V-belt (standard value):
10 – 15 mm
2. Adjusting
1) Loosen compressor mount bolt (1) and
adjustment bolt (2).
2) Move the position of compressor (3) to adjust
the tension of belt (4).
3) After adjusting the belt tension to the standard
value, tighten adjustment bolt (2) and mount
bolt (1).
1. Testing
• Measure deflection b of the belt when it is
pushed with a finger force of approx. 58.8 N
{approx. 6 kg} at a point midway between the
compressor pulley and the engine drive pulley.
a Deflection b of V-belt (standard value):
10 – 15 mm
2. Adjusting
1) Loosen air compressor mounting bolts (1) and
(2), nut (3) and adjusting bolt lock nut (4) and
adjusting bolt (5).
2) Adjust the tension of fan belt (7) by shifting the
position of compressor (6).
3) After adjusting the fan belt tension to the
specified value, tighten adjusting bolt lock nut
WA700-3 20-117
(10)
Handling equipment in fuel circuit
Testing and adjusting Measuring fuel pump outlet port pressure
a Precautions when carrying out inspection and a Measure the outlet port pressure of the fuel
maintenance of fuel system. pump with the signal voltage of the fuel pump
With the HPI type fuel injection system, more pressure sensor.
precise equipment is used than on the conven-
tional fuel injection pump and nozzle. Problems 1. Insert a T-adapter into the connector of fuel
may occur if dirt or dust get in, so always be pump pressure sensor (1), then connect to T-
careful of the following points. adapter box Q.
When carrying out inspection or maintenance of
the fuel line, pay more attention than usual to
prevent dirt or dust from getting in. If there is any
dirt stuck to any part, use clean fuel to wash it off
completely.
a Precautions when replacing fuel filter cartridge.
Always use a genuine Komatsu part for the fuel
filter cartridge.
With the HPI type fuel injection system, more
precise equipment is used than on the conven-
tional fuel injection pump and nozzle. Problems
may occur if dirt or dust get in, so a special filter
with highly efficient filtering performance is
used.
For this reason, do not use imitation filters. If 2. Start the engine and measure the power source
they are used, there is danger of problems voltage of the fuel pump pressure sensor.
occurring in the fuel line. a Check that the power source voltage is
within the following range.
a Sensor power source voltage (between (A)
and (B)): 4.75 – 5.25 V.
20-118 WA700-3
(10)
Testing and adjusting Bleeding air from fuel circuit
a Bleed the air from the fuel circuit as follows if the a Fill with fuel through the 8 inlet port portions
engine does not start or is difficult to start after a of the filter. Portion b is the outlet port
the following operations. (clean side) after filtering, so fuel must not be
• When starting the engine for the first time added from here.
• When the fuel filter has been replaced
• When the fuel tank has been cleaned
• When fuel has been added after the engine
stopped
WA700-3 20-119
(10)
Testing and adjusting Bleeding air from fuel circuit
20-120 WA700-3
(10)
Testing and adjusting Measuring exhaust temperature
Measurement procedure
1. When measuring the maximum value during trou-
bleshooting
Carry out actual work and measure the maximum
value during operation.
a Use the PEAK mode (it can store the maximum
value in memory) of the temperature gauge
function.
Note:
The exhaust temperature varies greatly according
to the ambient temperature (temperature of the
engine intake air), so if any abnormal value is
obtained, carry out temperature compensation.
a Compensation = Measured value + 2 ×
(converted ambient temperature – actual
ambient temperature).
a The converted ambient temperature is
taken as 20°C.
2. When measuring periodically (during preventive
maintenance, etc.)
1) Raise the exhaust temperature by using full
stall (torque converter stall + hydraulic pump
relief).
(Standard value: Approx. 700°C)
2) From the above condition, cancel the hydraulic
pump relief and continue only the torque
converter stall. (The temperature will start to go
down. If it does not go down, but goes up,
increase the set temperature at point shown
in the diagram on the right.)
3) Note the stable temperature when the
temperature starts to go down.
a If only torque converter stall is used when
measuring the exhaust temperature, torque
converter will overheat before a stable value
is obtained.
WA700-3 20-121
(10)
Testing and adjusting Measuring exhaust temperature (overall engine)
20-122 WA700-3
(10)
Testing and adjusting Measuring exhaust gas temperature (each cylinder)
4. Compensate the measured value for each cylin- No cylinder is more than 20°C lower than the aver-
der and judge if there is any cylinder with a prob- age value, so judge all cylinders as normal.
lem.
a Compensation value
Unit: °C
Cylinder No.1 No.2 No.3 No.4 No.5 No.6
Compensation
+20 +5 0 0 +5 +20
value
WA700-3 20-123
(10)
Testing and adjusting Measuring air supply pressure (boost pressure)
Note: Operate the engine at midrange speed or Serial No.: 51001 and up
above, and use the self-seal portion of the
gauge to bleed the oil inside the hose.
• Insert the gauge about half way, repeat the
action to open the self-seal portion, and
bleed the oil.
20-124 WA700-3
(10)
Testing and adjusting Measuring accelerator pedal
m
0m
15
Operating force of accelerator pedal
a
Measuring Top surface of floor
1. Set push-pull scale J at a position 150 mm from
pedal fulcrum a.
a Put the center of push-pull scale J in contact with
a point 150 mm from the pedal fulcrum.
TEW00056
2. Start the engine, then measure the maximum value
when the pedal is moved from the pushed position
(low idling) to the end of its travel (high idling).
WA700-3 20-125
(10)
Testing and adjusting Adjusting accelerator pedal travel, potentiometer
1. Measuring
Accelerator pedal travel
1) Stop the engine.
LY
B
Depress pedal
LR
CNL13
Potentiometer connection diagram
TEW00060
Potentiometer
TEW00061
20-126 WA700-3
(10)
Testing and adjusting Adjusting accelerator pedal travel, potentiometer
2. Adjusting
Adjusting output voltage of potentiometer
1) Check that punch mark (2) made on
intermediate connector (1) between the case
and potentiometer is on the side where it can be
seen.
Insert the protruding part of the potentiometer
into the groove in the intermediate connector, 1
WA700-3 20-127
(10)
Testing and adjusting Adjusting accelerator pedal micro switch
Contact Spring
TEW00065
4. Installation of case
7 TEW00066
20-128 WA700-3
(10)
Testing and adjusting Measuring torque converter, transmission oil pressure
Method of measuring
a The following work is necessary before measuring
the hydraulic pressure.
• Open inspection cover (1) at the rear of the cab.
• Turn transmission cut-off switch (2) OFF, and
use the left brake. (Check that the pilot lamp
goes out.)
WA700-3 20-129
(10)
Testing and adjusting Measuring torque converter, transmission oil pressure
5. Modulating pressure
1) Measurement port (P1)
2) Place the directional lever at neutral, operate
the speed lever, and measure the pressure.
a Do not measure at F3 or R3.
20-130 WA700-3
(10)
Testing and adjusting Method for operation of emergency manual spool
Operation
WA700-3 20-131
(10)
Testing and adjusting Method for operation of emergency manual spool
20-132 WA700-3
(10)
Testing and adjusting Testing and adjusting steering oil pressure
Measuring
1. Measuring steering relief pressure
Adjusting
WA700-3 20-133
(10)
Testing and adjusting Adjusting steering stopper bolt
Adjusting
1. Set the stopper bolt to the minimum length.
20-134 WA700-3
(10)
Testing and adjusting Adjusting joystick steering
WA700-3 20-135
(10)
Testing and adjusting Adjusting joystick steering
20-136 WA700-3
(10)
Testing and adjusting Adjusting joystick lever neutral detection switch
Adjusting
1) Set so that the tip of the roller of the neutral
detection switch contacts the concave portion of
the cam plate, then tighten the switch mounting
bolts.
a Never make the roller of the neutral
detection switch push into the concave
portion of the cam plate.
WA700-3 20-137
(10)
Testing and adjusting Testing brake oil pressure
20-138 WA700-3
(10)
Testing and adjusting Measuring wear of brake disc
Measurement method
1. Remove plug (1).
WA700-3 20-139
(10)
Testing and adjusting Measuring brake performance
Measurement method
1. Start the engine and move the machine.
20-140 WA700-3
(10)
Testing and adjusting Testing and adjusting parking brake
Measuring pad
1. Turn the starting switch ON, then turn the parking
brake switch OFF to release the brake.
Measuring clearance
1. Turn the parking brake switch OFF to release the
brake.
WA700-3 20-141
(10)
Testing and adjusting Testing and adjusting parking brake
Adjusting
a If the measurement is not within the standard value,
adjust as follows.
20-142 WA700-3
(10)
Testing and adjusting Testing and adjusting accumulator charge pressure
Adjusting
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 nut for the cut-in
pressure.
WA700-3 20-143
(10)
Testing and adjusting Measuring PPC relief valve hydraulic pressure
Measuring
1. Measuring PPC relief valve pressure
1) Remove plug (2) for measuring the hydraulic
pressure in the dump cylinder circuit of the main
control valve.
20-144 WA700-3
(10)
Testing and adjusting Measuring PPC relief valve hydraulic pressure
Adjusting
1. Adjusting PPC relief valve
WA700-3 20-145
(10)
Testing and adjusting Testing and adjusting work equipment hydraulic pressure
Measuring
1. Measuring work equipment relief pressure
1) Set the bucket so that portion a is raised 30 mm
– 50 mm, then lower portion b to the ground.
20-146 WA700-3
(10)
Testing and adjusting Testing and adjusting work equipment hydraulic pressure
Adjusting
WA700-3 20-147
(10)
Testing and adjusting Bleeding air from piston pump
3. Let oil flow out in turn from plugs (1) and (2), and
when the air is completely bled from the piston
pump, tighten the plugs. After that, in order to fill the
inside of the pump with the hydraulic oil, leave it for
10 minutes.
20-148 WA700-3
(10)
Testing and adjusting Adjusting work equipment lever linkage
WA700-3 20-149
(10)
Testing and adjusting Adjusting work equipment lever linkage
3. Installation of solenoid
• Do as follows to set boom kickout solenoid (13)
and bucket positioner solenoid (14) at the pulled
(electricity flowing) condition.
i) Disconnect wiring connectors (F05) (15) and
(F06) (16).
a F05 (15): Proximity switch for bucket
positioner
F06 (16): Proximity switch for boom kick-
out
ii) Connect a T-adapter and short circuit the
terminals between connectors (1) and (2).
a Check that the solenoid is pulled 12 mm.
20-150 WA700-3
(10)
Testing and adjusting Testing and adjusting bucket positioner
Testing
1. With the engine stopped, check that clearance a
between proximity switch (1) and detector bar (2) is
the standard value.
a Clearance a: 3 – 5 mm
Adjusting
1. Lower the bucket to the ground, set the bucket to
the desired digging angle, return the lever to the
HOLD position, and stop the engine.
WA700-3 20-151
(10)
Testing and adjusting Testing and adjusting boom kick-out
Testing
1. With the engine stopped, check that clearance a
between proximity switch (1) and sensor plate (2) is
the standard value.
a Clearance a: 3 – 5 mm
Adjusting
1. Raise the boom to the desired height, then mark the
boom to show the position where the center of prox-
imity switch (1) is at the top of sensor plate (2).
20-152 WA700-3
(10)
Testing and adjusting Testing proximity switch actuation pilot lamp
Proximity switch
Lights up Goes out
actuation pilot lamp
When detector is positioned at detection When detector has moved away from
Detector position
surface of proximity switch detection surface of proximity switch
Bucket positioner
Boom kick-out
WA700-3 20-153
(10)
Testing and adjusting Adjusting main monitor (speedometer module)
Adjustment procedure
• Turn off the power, then remove the machine
monitor and adjust the switches at the back of the
speedometer.
Reference
Amount of correction for switch (2)
Switch position 0 1 2 3 4 5 6 7
Amount of
+14 +12 +10 +8 +6 +4 +2 0
correction (%)
Switch position 8 9 A B C D E F
Amount of
0 –2 –4 –6 –8 –10 –12 –14
correction (%)
20-154 WA700-3
(10)
Testing and adjusting Bleeding air
Bleeding air
1. Bleeding air from brake system
WA700-3 20-155
(10)
Testing and adjusting Releasing remaining pressure in hydraulic circuit
20-156 WA700-3
(10)
Testing and adjusting Basic precautions
Basic precautions
always supplies electricity (permanent
1. Handling machine, safety, inspection and power source) in addition to the power
maintenance source (switch power source) that is cut
For details of safety items, operation, inspection, when the starting switch is turned OFF or
and maintenance of the machine, see the Oper- the engine is stopped.
ation and Maintenance Manual for the machine. Because this switch power source and per-
manent power source are provided, the
2. Handling monitoring system period needed for collecting data is clearly
Always obey the following precautions when known and it becomes possible to store this
handling the monitoring system. data in the internal memory.
1) When disassembling, repairing, or modifying In other words, the VHMS uses the perma-
the machine or system, follow the nent power source to save to memory the
instructions in the manual. data accumulated from the moment the
2) Do not touch the system (equipment) when starting switch is turned ON to the moment
operating the machine. the starting switch is turned OFF. Then the
3) Do not damage or get the wiring harnesses, VHMS controller itself turns off the perma-
connectors, or sensors of the system nent power source.
(equipment) caught or pulled by force. This 2) Precautions when turning the permanent
may cause short circuits or disconnections power source OFF
that will lead to failure or fire on the machine When the starting switch is turned OFF, the
or system (equipment). power supply is maintained for at least 3
4) Do not get water, dirt, or oil on the system minutes (the VHMS system shut-down time:
(equipment). the time taken for the VHMS system to save
the data to memory and switch off), and
3. Permanent power source for VHMS (battery then the permanent power source is turned
direct power source) OFF.
1) Meaning and need of permanent power If the VHMS system shut-down time is
source shorter than 3 minutes, the accumulated
The VHMS has the function of checking data may be damaged.
and collecting data on the condition of the i) When removing VHMS from permanent
machine from the moment the starting power source
switch is turned ON to the moment the start- When removing the VHMS from the per-
ing switch is turned OFF. Therefore, its manent power source (for example,
power supply is different from many of the when carrying out repairs), check that
electronic equipment and electrical parts. the monitor display (7-segment LED in
For the system to provide the above func- the diagram below) of the VHMS con-
tions, it is necessary to have a power supply troller is out.
that is connected directly to the battery and
WA700-3 20-157
(11)
Testing and adjusting Basic precautions
20-158 WA700-3
(11)
Testing and adjusting Basic precautions
WA700-3 20-159
(11)
Testing and adjusting Outline
Outline
a It is also possible to add this system to a machine that has already been shipped.
20-160 WA700-3
(11)
Testing and adjusting Outline
WA700-3 20-161
(11)
Testing and adjusting Outline
3. Position of equipment
Install monitoring controller (VHMS controller)
(1) on the machine, and collect the operation
data for the engine, transmission, and PLM.
1) Data collection function
i) Data from connected sensors
• Engine oil temperature {Sensor (2)}
• Exhaust temperature {Sensor (3)}
• Blow-by pressure {Sensor (4)}
• Transmission pump oil pressure
{Sensor (5)}
• Atmospheric temperature
{Sensor (6)}
• Work equipment pump oil pressure
{Sensor (7)}
• Steering pump oil pressure
{Sensor (8)}
• Work equipment oil temperature
{Sensor (9)}
• Brake oil pressure {Sensor (10)}
• Brake oil temperature {Sensor (11)}
20-162 WA700-3
(11)
Testing and adjusting Outline
WA700-3 20-163
(11)
Testing and adjusting Outline
ii)
Data from controller mounted on machine
• Engine speed
• Fuel injection amount
• Engine oil pressure
• Data from transmission controller
• SMR (service meter)
2) Saving data
• The above data is saved to memory.
20-164 WA700-3
(11)
Testing and adjusting Outline
2 Antenna mount:
(14): Communications antenna/pole
WA700-3 20-165
(11)
Testing and adjusting Setting up VHMS controller
Turn starting switch ON Check that no error is generated by the VHMS controller or other
1 • Check for generation of errors controller
• Start setup tool If there is any error, repair or correct to return condition to normal
• Calendar (data, time, time difference from GMT, summer time
(daylight saving time))
2 Setting up VHMS • Machine model, Serial No., variation code
• Engine model, Serial No.
• Transmission Serial No.
3 Starting switch OFF • Saving settings
4 Starting switch ON • Checking VHMS functions
Start engine • Performing test (quick PM)
5 Test (quick PM) • Downloading
Starting switch OFF • Checking data (content of data)
• Checking operation of Orbcomm
Starting switch ON
• Setting up communications
6 • Check for errors
(need for communications file, communications frequency, GCC
• Start setup tool
code)
• Setup completion report, content of setup (data), sending checksheet
7 Starting switch OFF
• Sending download data
20-166 WA700-3
(11)
Testing and adjusting Setting up VHMS controller
Start
Display Display
VHMS controller starts up, LEDs flash
Engine, transmission controllers show
(see diagram below) and aggregate
Normal past errors, then give [00] display (no Normal
numerals are displayed in order (no
error exists)
error exists)
No display No display
Turn starting switch [OFF], then check connection of wiring harnesses again
Display Display
VHMS controller starts up, LEDs flash
Engine, transmission controllers show
(see diagram below) and aggregate
Normal past errors, then give [00] display (no Normal
numerals are displayed in order (no
error exists)
error exists)
No display No display
5. Collection of data
a If there is no abnormality in the system, the machine will operate and the operation data for the machine
will automatically be saved by the VHMS controller.
WA700-3 20-167
(11)
Testing and adjusting Collection, transmission of data
20-168 WA700-3
(11)
Testing and adjusting Collection, transmission of data
<Downloading from connector inside cab> <Downloading from ground level connector>
1) Remove the connected wiring harness and 1) Remove the clamp at the top of the download
install the download cable. box.
2) Connect the other end of the download wiring 2) Use the engine key to open the cover at the
harness to the PC. front of the box.
3) Turn the machine starting switch ON, check that 3) Remove the cap of the download connector (12)
the monitor controller is working, then download and install the download cable.
to the PC. 4) When turn (wake-up) switch (15) is turned, the
a To check that the VHMS controller is VHMS is actuated and pilot lamp (16) lights up.
working, check that the VHMS controller 5) Check that pilot lamp (16) is lighted up, then
starts up, LEDs flash (see diagram below), carry out the PC download.
and aggregate numerals are displayed in 6) When [complete] is displayed on the download
order. PC, the download operation is completed.
4) When [complete] is displayed on the download 7) Return the turn switch to its original position,
PC, the download operation is completed. remove the download cable, then install the cap.
5) Turn the machine starting switch OFF, then turn 8) Check that pilot lamp (16) is out, then close the
the PC power OFF, remove the download cable, box cover. If the turn switch is not off, the cover
and return the wiring harness to its original will not close.
condition. 9) Turn the engine key and lock the front cover.
Close the clamps at the top of the box also.
WA700-3 20-169
(11)
Testing and adjusting Collection, transmission of data
20-170 WA700-3
(11)
Testing and adjusting Collection, transmission of data
WA700-3 20-171
(11)
Testing and adjusting Collection, transmission of data
20-172 WA700-3
(11)
Inspection and maintenance
Testing and adjusting Replacing parts
3. Remedy
If there is any abnormality, repair, replace, or
reinstall (tighten).
WA700-3 20-173
(11)
Troubleshooting
WA700-3 20-201
(11)
Troubleshooting Points to remember when troubleshooting
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3) Check the travel of the control levers.
hurry to disassemble the components. 4) Check the stroke of the control valve spool.
If components are disassembled immediately 5) Other maintenance items can be checked
any failure occurs: ex t ern al l y, s o ch eck a ny i t e m t h at i s
• Parts that have no connection with the failure considered to be necessary.
or other unnecessary parts will be
disassembled. 4. Confirming failure
• It will become impossible to find the cause of • Confirm the extent of the failure yourself, and
the failure. judge whether to handle it as a real failure or
It will also cause a waste of manhours, parts, or as a problem with the method of operation,
oil or grease, and at the same time, will also lose etc.
the confidence of the user or operator. a When operating the machine to reenact
For this reason, when carrying out troubleshoot- the troubleshooting symptoms, do not
ing, it is necessary to carry out thorough prior carry out any investigation or measure-
investigation and to carry out troubleshooting in ment that may make the problem worse.
accordance with the fixed procedure.
5. Troubleshooting
2. Points to ask user or operator • Use the results of the investigation and
1) Have any other problems occurred apart inspection in Items 2 – 4 to narrow down the
from the problem that has been reported? causes of failure, then use the
2) Was there anything strange about the troubleshooting flowchart to locate the
machine before the failure occurred? position of the failure exactly.
3) Did the failure occur suddenly, or were there a The basic procedure for troubleshooting
problems with the machine condition before is as follows.
this? 1) Start from the simple points.
4) Under what conditions did the failure occur? 2) Start from the most likely points.
5) Had any repairs been carried out before the 3) Investigate other related parts or
failure? information.
When were these repairs carried out?
6) Has the same kind of failure occurred 6. Measures to remove root cause of failure
before? • Even if the failure is repaired, if the root
cause of the failure is not repaired, the same
3. Check before troubleshooting failure will occur again.
1) Check the oil level To prevent this, always investigate why the
2) Check for any external leakage of oil from problem occurred. Then, remove the root
the piping or hydraulic equipment. cause.
20-202 WA700-3
(10)
Troubleshooting Sequence of events in troubleshooting
WA700-3 20-203
(10)
Troubleshooting Points to remember when carrying out maintenance
TEW00191
TEW00192
TEW00193
20-204 WA700-3
(10)
Troubleshooting Points to remember when carrying out maintenance
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
TEW00194
WA700-3 20-205
(10)
Troubleshooting Points to remember when carrying out maintenance
• Disconnecting connectors
1) Hold the connectors when disconnecting.
Press lightly
When disconnecting the connectors, hold when removing
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw Lock stopper
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 TEW00197
the connectors apart.
a Never pull with one hand.
TEW00212
Stopper
TEW00213
TEW00198
20-206 WA700-3
(10)
Troubleshooting Points to remember when carrying out maintenance
• Connecting connectors
1) Check the connector visually.
i) Check that there is no oil, dirt, or water
stuck to the connector pins (mating
portion).
ii) Check that there is no deformation,
defective contact, corrosion, or damage Cliks into position
to the connector pins.
iii) Check that there is no damage or
breakage to the outside of the
connector.
a If there is any oil, water, or dirt stuck to TEW00199
the connector, wipe it off with a dry cloth.
If any water has got inside the
connector, warm the inside of the wiring
with a dryer, but be careful not to make it
too hot as this will cause short circuits.
a If there is any damage or breakage,
replace the connector.
WA700-3 20-207
(10)
Troubleshooting Points to remember when carrying out maintenance
TEW00202
TEW00203
20-208 WA700-3
(10)
Troubleshooting Points to remember when carrying out maintenance
TEW00204
TEW00205
TEW00206
WA700-3 20-209
(10)
Troubleshooting Points to remember when carrying out maintenance
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
TEW00208
TEW00209
20-210 WA700-3
(10)
Troubleshooting Points to remember when carrying out maintenance
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Flushing oil
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.
TEW00210
7) Cleaning operations
After repairing the hydraulic equipment (pump,
c ont r ol v al v e , et c . ) or w he n r un ni ng t h e
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.
TEW00211
WA700-3 20-211
(10)
Troubleshooting Checks before troubleshooting
Judgement
Item Remedy
standard
4. Check hydraulic filter (Torque converte, Transmission hydraulic oil) — Clean, drain
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
21. Check for water leaking on wiring (be particularly careful attention to Disconnect
—
water leaking on connectors or terminals) connector and dry
20-212 WA700-3
(10)
Troubleshooting Connector types and mounting locations
CNB10 X 2 Air conditioner condenser left C5 CNE21 X 1 Air conditioner magnet clutch b6
CNC01 X 2 Torque converter oil filter sensor L5 CNF01 M 4 Lamp intermediate connector Y2
Turn signal, side lamp intermediate
CNC03 X 2 Brake pressure switch L6 CNF02 M 3 connector Y2
Turn signal, side lamp intermediate
CNC04 X 2 Brake pressure switch L6 CNF03 M 3 connector b2
CNE03 X 2 Connector for starting motor F6 CNF12 X 2 Parking brake display switch H1
20-214 WA700-3
(10)
Troubleshooting Connector types and mounting locations
CNG07 M 2 Rear working lamp left Z9 CNL78 — — Emergency engine stop switch T3
CNG08 M 2 Rear working lamp left Y7 CNL79 — — Emergency engine stop switch S3
WA700-3 20-215
(10)
Troubleshooting Connector types and mounting locations
A03 Terminal 1 Battery relay (E) — C01 X 2 Torque converter oil filter sensor L5
A6 SWP 6 Air conditioner air mixing motor Q3 C04 M 2 Low pressure switch 2 L7
Air conditioner blower motor,
A7 M 6 resistor Q1 C04 M 2 Front working lamp (L.H.) —
Intermediate connector
A8A S 10 (air conditioner) R1 C05 Kyouritsu 4 Beacon lamp switch (OP) —
Intermediate connector
A8B S 8 (air conditioner) R1 C06 KES 1 2 Room lamp —
A9 Yazaki 4 Air conditioner blower relay (M) — C07 M 4 Rear wiper motor —
A10 Yazaki 4 Air conditioner blower relay (Hi) — C07 X 2 Emergency brake switch 1 L6
A11 Yazaki 4 Air conditioner blower relay (M2) — C08 Connector 1 Cigar lighter —
A12 Yazaki 4 Air conditioner condenser relay — C08 X 2 Emergency brake switch 1 L6
A13 Yazaki 4 Air conditioner blower relay (M1) — C09 Terminal 1 Cigar lighter —
B02 KES 1 2 Window washer (front) C6 C16 M 2 Side working lamp (L.H.) (OP) —
B03 KES 1 2 Diode (window washer) — C17 M 2 Side working lamp (R.H.) (OP) —
20-216 WA700-3
(10)
Troubleshooting Connector types and mounting locations
E05 Terminal 1 Alternator (B) AB5 F06 X 3 Boom kick-out proximity switch C2
E14 KES 1 2 Diode (heater relay) — F13 Terminal 1 GND (front frame) F2
E15 KES 1 2 Diode (heater relay) — FLTP Connector 2 Fuel temperature sensor —
E23 KES 1 2 Diode (starting motor) — FSO- Terminal 1 Fuel shutoff valve (–) —
E24 KES 1 2 Diode (starting motor) — FSO+ Terminal 1 Fuel shutoff valve (+) —
ECMA DRC 40 Engine controller — G01 M 6 Rear combination lamp (R.H.) AB9
ECMB DRC 40 Engine controller — G02 M 2 Working lamp (R.H.) (OP) AB8
ER1 SWP 12 Intermediate connector B7 G03 M 2 Radiator water level sensor AA9
(engine harness)
ER2 X 4 Intermediate connector A8 G04 Terminal 1 Back buzzer AB8
(engine harness)
ER3 SWP 14 Intermediate connector A7 G05 Terminal 1 Back buzzer AB7
WA700-3 20-217
(10)
Troubleshooting Connector types and mounting locations
G08 M 2 Working lamp (L.H.) (OP) Y9 L14 DT-T 3 Accelerator limit switch L3
G09 M 6 Rear combination lamp (L.H.) Y9 L15 M 2 Kick-down switch & hold T8
GND Terminal 1 Engine block GND — L18 AMP040 16 Maintenance monitor (sub motor) R9
GND M 1 Front combination lamp — L19 AMP040 8 Maintenance monitor (sub motor) R9
GND1 Terminal 1 GND (OP) G5 L22 KES 1 2 Maintenance monitor (sub motor) Q8
IMTP Connector 2 Suction air temperature sensor — L46 KES 1 3 Flasher unit W7
L01 SWP 6 Parking brake switch P4 L60 — 6 Front working lamp relay —
L02 SWP 6 Light & dimmer switch N5 L61 — 6 Rear working lamp relay —
L04 SWP 14 Transmission switch N4 L64 — 5 Engine oil pressure switch relay —
L12 X 2 Transmission cut off switch L3 L76 — 5 2nd – 1st selector relay —
20-218 WA700-3
(10)
Troubleshooting Connector types and mounting locations
L80 — 5 Power window relay (right raise) — R07 Terminal 1 Slow blow fuse (30A) —
L81 X 2 Stop lamp switch H5 R08 Terminal 1 Slow blow fuse (80A) —
L89 Connector 1 LED (red) M9 RPR Connector 3 Fuel rail pressure sensor —
LR3 SWP 14 Intermediate connector (engine) B1 SL6 — 1 Step light switch (auto-return) —
LR4 SWP 14 Intermediate connector (engine) A3 SP1 Connector 2 Engine revolution sensor (master) —
LR5 X 4 Intermediate connector (GND) B2 SP2 Connector 2 Engine revolution sensor (backup) —
OLPR Connector 3 Engine oil pressure sensor — T03 KES 1 2 Diode (transmission control valve) —
OP1 Connector 1 Connector for connecting H5 T04 KES 1 2 Diode (transmission control valve) —
windshield heater (OP) V2
OP2 Connector 1 Connector for connecting 24V W2 T05 X 2 Speed sensor L4
OP3 Connector 1 Connector for connecting 24V W2 T06 X 2 Torque converter temperature —
sensor (monitor)
PMPR Connector 3 Fuel pump pressure sensor — TAC — 1 Tachograph (OP) G5
PWR1 Connector 1 Power window regulator — TPR Connector 3 Timing rail pressure sensor —
WA700-3 20-219
(10)
Troubleshooting Connector arrangement diagram
20-220 WA700-3
(10)
Troubleshooting Connector arrangement diagram
WA700-3 20-221
(10)
Troubleshooting Connector arrangement diagram
(2/3)
20-222 WA700-3
(10)
Troubleshooting Connector arrangement diagram
WA700-3 20-223
(10)
Troubleshooting Connector arrangement diagram
(3/3)
20-224 WA700-3
(10)
Troubleshooting Connector arrangement diagram
(1/3)
Serial No.: 51001 and up
20-226 WA700-3
(10)
Troubleshooting Connector arrangement diagram
WA700-3 20-227
(10)
Troubleshooting Connector arrangement diagram
(2/3)
20-228 WA700-3
(10)
Troubleshooting Connector arrangement diagram
WA700-3 20-229
(10)
Troubleshooting Connector arrangement diagram
(3/3)
20-230 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
2 799-601-7020
3 799-601-7030
4 799-601-7040
WA700-3 20-231
(10)
Troubleshooting Connection table for connector pin numbers
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
20-232 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
16 799-601-7320
WA700-3 20-233
(10)
Troubleshooting Connection table for connector pin numbers
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
20-234 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
WA700-3 20-235
(10)
Troubleshooting Connection table for connector pin numbers
10
—
(Blue)
— —
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
20-236 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
5 799-601-2710
9 799-601-2950
13 799-601-2720
WA700-3 20-237
(10)
Troubleshooting Connection table for connector pin numbers
17 799-601-2730
21 799-601-2740
20-238 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
WA700-3 20-239
(10)
Troubleshooting Connection table for connector pin numbers
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
20-240 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
2 —
— —
9 —
— —
10 799-601-3460
— —
WA700-3 20-241
(10)
Troubleshooting Connection table for connector pin numbers
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
20-242 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
8 —
Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
WA700-3 20-243
(10)
Troubleshooting Connection table for connector pin numbers
5 799-601-7360
— —
6 799-601-7370
— —
20-244 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
4 —
— —
WA700-3 20-245
(10)
Troubleshooting Connection table for connector pin numbers
[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
799-601-9210
799-601-9220
799-601-9220
20-246 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
[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)
799-601-9230
799-601-9230
799-601-9240
799-601-9240
WA700-3 20-247
(10)
Troubleshooting Connection table for connector pin numbers
[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)
799-601-9250
799-601-9250
799-601-9260
799-601-9260
20-248 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
[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)
799-601-9270
799-601-9270
799-601-9280
799-601-9280
WA700-3 20-249
(10)
Troubleshooting Connection table for connector pin numbers
[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)
799-601-9290
799-601-9290
20-250 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
[The pin No. is also marked on the connector (electric wire insertion end)]
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
WA700-3 20-251
(10)
Troubleshooting Connection table for connector pin numbers
[The pin No. is also marked on the connector (electric wire insertion end)]
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820 (normal type) Part No.: 08192-1810 (normal type)
08192-2820 (fine wire type) 08192-2810 (fine wire type)
12GR:799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920 (normal type) Part No.: 08192-1910 (normal type)
08192-2920 (fine wire type) 08192-2910 (fine wire type)
20-252 WA700-3
(10)
Troubleshooting Connection table for connector pin numbers
[The pin No. is also marked on the connector (electric wire insertion end)]
2 799-601-9010
[The pin No. is also marked on the connector (electric wire insertion end)]
1 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
WA700-3 20-253
(10)
Troubleshooting Electric engine throttle controller system
20-254 WA700-3
(10)
Troubleshooting Electric engine throttle controller system
WA700-3 20-255
(10)
Troubleshooting Electric engine throttle controller system
20-256 WA700-3
(10)
Troubleshooting Method of displaying action code and failure code
WA700-3 20-257
(10)
Troubleshooting Method of displaying action code and failure code
20-258 WA700-3
(10)
Troubleshooting Chart of action codes and failure codes, and re-enaction
a E59 and E60 cannot be distinguished, so they are issued at the same time.
Disconnection cannot be detected for E56. It is always ON and is called up when there is a failure warning.
WA700-3 20-259
(10)
Troubleshooting Chart of action codes and failure codes, and re-enaction
Disconnection in Automatic
travel speed sensor gearshifting not
Normal operation
system carried out — —
possible at manual
(changes to manual
gearshifting)(OP)
Disconnection in Gearshifting not
engine speed carried out in Auto
Normal operation
E00 sensor system mode. (OP) — — No
possible at manual
20-260 WA700-3
(10)
Troubleshooting Transmission controller LED display
WA700-3 20-261
(10)
Troubleshooting Method of using troubleshooting charts
20-262 WA700-3
(10)
Troubleshooting Method of using troubleshooting charts
<Example>
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.
3) a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)
b) Buzzer always sounds
4)
Cause Remedy
WA700-3 20-263
(10)
Troubleshooting of engine body
(S mode)
Method of using troubleshooting charts ...................................................................................................... 20-302
S-1 Starting performance is poor (Starting always takes time).................................................................. 20-306
S-2 Engine does not start.......................................................................................................................... 20-308
a) Engine turns but no exhaust smoke comes out (fuel is not being injected) ................................. 20-308
b) Exhaust smoke 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 .......................................................................................................... 20-312
S-5 Engine does not rotate smoothly (Hunting) ........................................................................................ 20-314
S-6 Engine lacks output (or lacks power).................................................................................................. 20-315
S-7 Exhaust smoke is black (Incomplete combustion).............................................................................. 20-316
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................. 20-317
S-9 Oil becomes contaminated quickly ..................................................................................................... 20-318
S-10 Fuel consumption is excessive........................................................................................................... 20-319
S-11 Oil is in cooling water, or water spurts back, or water level goes down.............................................. 20-320
S-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................................. 20-321
S-13 Oil level rises ...................................................................................................................................... 20-322
S-14 Water temperature becomes too high (Overheating) ......................................................................... 20-323
S-15 Abnormal noise is made..................................................................................................................... 20-324
S-16 Vibration is excessive ......................................................................................................................... 20-326
WA700-3 20-301
(10)
Troubleshooting Method of using troubleshooting charts
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in (B) are items that can be
obtained from the user, depending on the user’s
level.
(1) (2) (3)
[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
(a)
Questions
own inspection.
(A) (b)
[Troubleshooting] (c)
Troubleshooting is carried out in the order of proba- (d)
bility, starting with the causes that have been (e)
marked as having the highest probability from infor- (B)
Check items
i
shooting
Trouble-
ii
iii
20-302 WA700-3
(10)
Troubleshooting Method of using troubleshooting charts
)
tion
ence for [Degree of use (Operated for long
njec
period)] in the [Questions] section as refer-
ve i
ence.
si
e
renc
xces
zzle
As a rule, do not use it when calculating the
ent
n no
erfe
p (e
points for locating the cause, but it can be
der
ing
lem
, int
ctio
pum
cylin
included if necessary to determine the order
m
er e
i
rger
inje
on t
for troubleshooting.
ion
,
lean
ring
cha
ecti
zed
ject
air c
urbo
, sei
ston
r inj
e in
rope
ged
ged
ctiv
n pi
ed t
Clog
Clog
Defe
Wor
Seiz
Imp
WA700-3 20-303
(10)
Troubleshooting Method of using troubleshooting charts
d)
ad
ion)
eize
d he
ject
er s
r an
e in
lung
seat
arge
ssiv
ck, p
elem rence
alve
zzle
och
exce
p (ra
ent
n no
e, v
terfe
turb
(
der
r
ed m ce
mp
uffle
valv
pum
timin
io
r, in
een
ran
ylin
t
u
c
p
rope ized inje
clea
t of
etw
n pis cleaner
arge
ion
ion
rope jection
ing,
ntac
ject
air b
ject
e
logg
Clog urboch
valv
r
Legend
e in
to n
e co
, se
in
e in
air
e of
: Possible causes (judging from Questions and check items)
d, c
r
ectiv
ged
ged
ctiv
ctiv
ed t
: Most probable causes (judging from Questions and Check items)
she
kag
: Possible causes due to length of use (used for a long period)
Clog
Defe
Defe
Wor
Seiz
Deff
Imp
Imp
Cru
Lea
: Items to confirm the cause.
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Questions
on reduced cylinders
Replace
Replace
Replace
Replace
Replace
Repair
Adjust
Adjust
Adjust
Clean
Remedy
20-304 WA700-3
(10)
Troubleshooting Method of using troubleshooting charts
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Add up the total of and marks where the
horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1) Clogged air cleaner element:
(2) Air leakage between turbocharger
and head:
(3) Clogged, seized injection nozzle:
(4) Defective contact of valve, valve seat:
(5) Worn piston ring, cylinder:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked . The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
WA700-3 20-305
(10)
Troubleshooting S- 1
iner
a Battery charging rate
stra
t
elem alve sea
Charging rate
ump
Ambient 100% 90% 80% 75% 70%
)
temperature
er (
p
ve, v
ent
g
r
heat
20°C 1.28 1.26 1.24 1.23 1.22
imin
inde
f val
0°C 1.29 1.27 1.25 1.24 1.23
vice
r, pr
, cyl
ner
r
act o
–10°C 1.30 1.28 1.26 1.25 1.24
lato
e
filte
ring
clea
d
• The specific gravity should exceed the value for the charging rate of 70% in the above table.
regu
cont
APS
fuel
ston
r
• In cold areas the specific gravity must exceed the value for the charging rate
a i
ctive
ctive
ctive
ged
ged
n pi
of 75% in the above table.
Defe
Defe
Defe
Clog
Clog
The item marked ( ) is applicable for serial No.: 50001 – 51000.
Wor
Confirm recent repair history
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When check is made using delivery method, injection timing is found to be incorrect
When control rack is pushed, it does not return (when rack stopper
bolt at rear of pump is removed, and rack piston is pushed with a
screwdriver during cleaning, rack does not move)
When fuel tank cap is inspected directly, it is found to be clogged
Inspect governor oil pump directly
Inspect governor spool valve directly
When governor oil supply pipe is inspected directly, it is found to be clogged
When governor oil strainer is inspected directly, it is found to be clogged
When overflow valve is inspected, it is found to be stiff or open
Legend
Q : Possible causes (judging from Questions and check items)
Replace
Replace
Replace
Correct
E : Possible causes due to length of use (used for a long period) Remedy
q : Items to confirm the cause.
20-306 WA700-3
(10)
Replace Defe
ctive
Replace Defe alter
nato
ctive
o r
Replace Defe r de
WA700-3
ctive terio
rate
Adjust Defe injec
tion d ba
tive n ozzl
ttery
Replace Defe
injec
ti o e
tive n timi
Correct injec ng
Leak tion
Troubleshooting
age, pum
Clean Clog clog
ging p (rack
ged , air , plu
nger
Replace Stuc air b
reat
in in
jecti stuc
k go her on s k)
vern yste
Adjust Seiz or s
hole
in fu m
ed g poo el ta
l val nk
Replace Defec
over
nor ve
tive o oil p
Replace Defec
perat
ion o
ump
gear
Causes
(10)
20-307
S- 1
Troubleshooting S-2
ump
Ambient temprature
ed)
oil p
t)
Type of fuel
f
seiz
–22 –4 –14 32 50 68 86 104°F
a
r, sh
nor
–30 –20 –10 0 10 20 30 140°C
ger
over
key
gea
haft
nk
ASTM D975 No.2
plun
el ta
aft,
g
on (
Diesel oil
ipe
ar, s
e of
r
ASTM D975A
e sh
ack,
in fu
p
pist
No.1
rain
iner
valv
p ge
ply
ng
alve
r
driv
er
(
mp
p st
stra
sup
e
pipi
a In winter, if No. 3 diesel oil is not available, a 50-50
f
ump
m
prim r, strain
relie
ol
ol v
u
u
mp
h
pum
p
oil p
mixture of No. 2 diesel oil and kerosene can be used.
r oil
r oil
fuel
her
p
n of
spo
eed
n pu
d
ion
use
erno
erno
reat
lte
ing
king
ratio
rnor
Legend en f
r
ject
ctio
o
el fi
l
air b
vern
r fue
Q : Possible causes (judging from Questions and check items)
gov
gov
, lea
e
ove
brok
e in
el
p
inje
u
w : Most probable causes (judging from Questions and check items)
o
of fu
f
k go
ed g
rope
ctive
ged
ged
ged
ged
ged
ged
ctiv
Clog
Clog
Defe
Clog
Stuc
Clog
Clog
Lack
Clog
Defe
Seiz
Seiz
Imp
Bro
2) No fuel comes out even when fuel filter air bleed plug is
loosened
3) No fuel spurts out even when injection pipe sleeve nut is
loosened
Rust and water are found when fuel is drained
to be clogged
When priming pump strainer is inspected directly, it is found
to be clogged
When fuel cap is inspected directly, it is found to be clogged
Inspect governor oil pump directly
Inspect governor spool valve directly
When governor oil supply pipe is inspected directly, it is found
to be clogged
When governor oil strainer is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Remedy
Add
20-308 WA700-3
(10)
Troubleshooting S-2
, etc.)
does not start
uck)
lever
• Lack of rotating force due to defective electrical system
t
• Insufficient supply of fuel
ocker
er s
ray
• Insufficient intake of air
e sp
ung
lve, r
em
• Improper selection of fuel and oil
tank
ctiv
l
syst
m (va
k, p
tter y
r
line
defe
(rac
fuel
syste
fuel
high
ent
iner
d ba
a The item marked ( ) is applicable for
ump iner
der
le in
zle,
m
mp
( )
valve
ir in
stra
serial No.: 50001 – 51000.
r ate
too
e
a
n
noz
n pu
o
i
er e
vice
, cyl
h
amic
terio
sity
d
ing,
her
lter,
u se
ion
lean
o
S de
ring
n dyn
isco
reat
ject
ed p
e
ogg
Legend
el fi
ject
d
fuel
air c
e AP
ston
air b
broke
Q : Possible causes (judging from Questions and check items)
e or
oil v
e in
e, cl
n
u
f e
i
f
w : Most probable causes (judging from Questions and check items)
r
rope
ged
ged
ged
ged
ctiv
ctiv
ctiv
n pi
ged
tive,
kag
ine
E : Possible causes due to length of use (used for a long period)
Clog
Defe
Clog
Clog
Clog
Defe
Defe
Clog
Defec
Wor
Imp
Eng
q : Items to confirm the cause.
Lea
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly failed to start
Questions
1) Little fuel comes out even when injection pump sleeve nut
is loosened
2) Little fuel comes out even when fuel filter air bleed plug is
loosened
There is leakage from fuel piping
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
to be clogged
When feed pump strainer is inspected directly, it is found to be clogged
When air cleaner element is inspected directly, it is found to be clogged
Glow plug mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, operation is too light or too heavy
Speed does not change when operation of certain cylinders is stopped
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
WA700-3 20-309
(10)
Troubleshooting S-3
ap
ray
seat
nk c
• Insufficient supply of fuel
e sp
lve
el ta
• Improper condition of fuel injction
e
ctiv
d va
renc
r
• Improper fuel used
in fu
line
nge
defe
e an
ent
g
terfe
iner
n
r
u
der
aine
pipi
e
hole
lem
zle,
p pl
valv
anc
stra
r, in
cylin
noz
r
er e
fuel
pum
r, st
r
her
clea
t of
ump
arge
n
lean
ng,
reat
filte
king
ntac
ctio
tion
lve
ed p
h
Legend
i
c
r
air b
air c
urbo
uel
, lea
inje
r va
Q : Possible causes (judging from Questions and check items)
ston
e co
njec
e
f
f
w : Most probable causes (judging from Questions and check items)
rope
ged
ged
ged
ged
ged
ged
ctiv
ed t
ed i
n pi
E : Possible causes due to length of use (used for a long period)
Clog
Clog
Clog
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
q : Items to confirm the cause.
Imp
Confirm recent repair history
Degree of use of machine Operated for long period
Replacement of filters has not been carried out according to
Questions
Operation Manual
Non-specified fuel is being used
Engine oil must be added more frequently
Rust and water are found when fuel tank is drained
Dust indicator caution is red
Noise of interference is heard from around turbocharger
Engine pick-up suddenly became poor
Blue under light load
Color of exhaust gas
Black
Clanging sound is heard from around cylinder head
Mud is stuck to fuel tank cap
Check items
clogged
Speed does not change when operation of certain cylinders
is stopped
When control rack is pushed, it is found to be heavy, or does not return
When compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be
outside standard value
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
20-310 WA700-3
(10)
Troubleshooting S-4
c.)
• Insufficient supply of fuel
r, e t
• Overheating
leve
a If there is overheating and the engine stops, carry out
cker
ey
troubleshooting for overheating.
rod
ent
e , ro
aft,k
m
g
ting
arin
valv
quip
er
e sh
• Failure on machine
rain
nec
ft be
m (
a If the machine stopped because of a failure on the
ry e
driv
er
con
p st
yste
train
in
ksha
a
machine, carry out troubleshooting for the chassis.
p
r tra
pum
on,
l
pum
lve s
i
aux
s
cran
,
gea
pist
r
filte
ic va
ing
p or
tion
zed
ze d
zed
Legend
prim
y na m
fuel
c
pum
l
inje
Q : Possible causes (judging from Questions and check items)
, sei
, sei
, sei
e
of fu
ged
w : Most probable causes (judging from Questions and check items)
ged
en d
ken
ken
ken
ken
ken
E : Possible causes due to length of use (used for a long period)
Clog
Clog
Lack
Brok
Bro
Bro
Bro
Bro
Bro
q : Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Abnormal noise was heard and
engine stopped suddenly
Condition when engine
Engine overheated and stopped
stopped
Questions
Clean
Clean
Remedy
Add
20-312 WA700-3
(10)
Replace Bro
ken
, sei
Correct Clog zed
ged gea
r, sh
Clean , lea aft
WA700-3
Clog king
ged fuel
Replace Defe a i r brea p i ping
ctiv ther
— Carry out troubleshooting for the chassis. e in
Fail
ure j ec tion
hole
in fu
at c pum el ta
Replace p nk
Troubleshooting
(10)
20-313
S-4
Troubleshooting S-5
ump
zzle
• Defective governor mechanism
ol)
e
, pip
, spo
ing p
no
and
ilter
prim
noid
ilter
ort f
m p
tank
(sole
k and
pum creen f
d pu
let p
rack
l t an
l
rnor
nor
e
iner
n fee
in fu
p in
trol
s
n fue
over
ove
low
ump
stra
twee
er
con
e
t wee
rain
of g
l
of g
r ho
o
ump
p
it be
is to
n of
l
r oil
r, st
it be
i
ent
or o
athe
ion
ng p
circu
o
eed
erno
stm
u
filte
i
erat
erat
n
e
in cir
Legend
r
r br
rimi
e
g sp
adju
air in
gov
gov
fuel
e op
e op
Q : Possible causes (judging from Questions and check items)
e l
i
, air
p
a
of fu
w : Most probable causes (judging from Questions and check items)
idlin
ctive
ged
ged
ged
ged
ged
ged,
ctiv
ctiv
ging
E : Possible causes due to length of use (used for a long period)
Lack
Defe
Clog
Clog
Clog
Clog
Defe
Clog
Low
Defe
Clog
q : Items to confirm the cause.
Clog
Confirm recent repair history
Degree of use of machine Operated for long period
Occurs at a certain speed range
Questions
Clean
Clean
Clean
Clean
Remedy
Add
20-314 WA700-3
(10)
Troubleshooting S-6
noid
• Improper fuel used
ray
seat
sole
(if non-specified fuel is used, output drops)
e sp
nk
lve
el ta
ool
• Lack of output due to overtaking
ctiv
e
d va
enc
e sp
a If there is overheating and lack of output, carry out
in fu
er
defe
e an
rfer
ung
ng
ent
er
trok
troubleshooting for overheating.
pum ainer
r
rain
ole
pipi
e
e
inde
zle,
lem
p pl
valv
anc
, int
re-s
h
p st
noz
tr
fuel
er e
pum
, cyl
ther
lear
rger
er, s
le p
t of
ion
lean
king
ring
brea
ntac
ri a b
cha
tion
t
lve
l
ject
i
Legend
f
feed
air c
fuel
urbo
, lea
e va
e co
r va
ston
njec
Q : Possible causes (judging from Questions and check items)
r
n
a i
i
w : Most probable causes (judging from Questions and check items)
rope
ged
ged
ged
ged
ged
ctiv
ged
ctiv
ed t
n pi
ed i
E : Possible causes due to length of use (used for a long period)
Clog
Clog
Clog
Defe
Defe
Clog
Clog
Clog
Seiz
Seiz
Wor
Imp
q : Items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly
Power was lost
Gradually
Questions
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
—
WA700-3 20-315
(10)
Troubleshooting S-7
sole zed)
ad
)
• Excessive injection of fuel
tion
d he
noid
i
e sp nger se
njec
seat
ray
r an
e sp
ve i
e
arge
valv
ool
lu
essi
e
ctiv
k, p
renc
och
and
(exc
defe
(rac
ent
turb
erfe
trok
r
lve
g
r
ce
inde
mp
p
lem
zle,
e
imin
, int
pum
re-s
l
een
aran
f va
f f
u
z
u
er e
, cyl
n no
ed m
rger
le p
on t
w
ct o
e cle
ion
ion
t
lean
ir be
ring
riab
ctio
cha
ecti
onta
ject
ject
logg
Legend
valv
air c
a
inje
urbo
e va
r inj
Q : Possible causes (judging from Questions and check items)
ston
e in
e in
c
e of
d, c
w : Most probable causes (judging from Questions and check items)
e
r
rope
rope
ged
ctiv
ctiv
ged
ctiv
ctiv
n pi
ed t
she
kag
E : Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Defe
Clog
Clog
q : Items to confirm the cause.
Wor
Seiz
Imp
Imp
Cru
Lea
Confirm recent repair history
Degree of use of machine Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
is stopped
When check is made using piston displacement method,
injection timing is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust color returns to normal
When control rack is pushed, it is found to be heavy, or
does not return
Inspect sliding of spool valve solenoid for variable pre- stroke
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
—
20-316 WA700-3
(10)
Troubleshooting S-8
a Do not run the engine at idling for more than 20 minutes Causes
continuously. (Both low and high idling)
r
arge
General causes why oil consumption is excessive
och
• Abnormal combustion of oil
Turb
• External leakage of oil
al
d
hea
n se
ce
• Wear of lubrication system
em
e
ping l cooler
urfa
hos
der
oke
syst
er
s
r lin
cylin
her
), br
seal
plug
i
e
or o
reat
k
inde
nd
nd
uide
inta
n or
eal,
ain
e
roke ower e
or b
ilter
, cyl
bine
m, g
om
ar s
il pa
il dr
il pi
ing
oil f
ther
r
ring
in fr
n re
oole
t tur
(ste
mo
mo
mo
l
on r
Legend
at b
m
brea
ston
Q : Possible causes (judging from Questions and check items)
cked
al a
e fro
oil c
e fro
e fro
e fro
lve
pist
al
w : Most probable causes (judging from Questions and check items)
n va
n se
n se
ged
n, b
n pi
t su
kag
kag
ken
kag
kag
E : Possible causes due to length of use (used for a long period)
ken
Clog
Wor
Wor
Wor
Wor
Wor
q : Items to confirm the cause.
Dus
Lea
Lea
Bro
Lea
Lea
Bro
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
WA700-3 20-317
(10)
Troubleshooting S-9
end
bine
r tur
pipe
ose
er
e
r lin
er h
harg
rain
inde
er d
uide
t
boc
lack
a
, bre
e
, cyl
valv
harg
ded
t tur
g
is b
r
e
ther
oole
ring
valv
ilter
l ad
fety
al a
rboc
oke
Legend
brea
oil c
h oi
oil f
Q : Possible causes (judging from Questions and check items)
ston
e se
e sa
lve,
t sm
t u
w : Most probable causes (judging from Questions and check items)
muc
ged
n va
ged
ged
ged
ctiv
ctiv
n pi
aus
E : Possible causes due to length of use (used for a long period)
Clog
Defe
Defe
Clog
Clog
Clog
Wor
Wor
q : Items to confirm the cause.
Too
Exh
Confirm recent repair history
Questions
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
—
20-318 WA700-3
(10)
Troubleshooting S-10
)
tion
ge
ter
on)
njec
linka
el fil
(pist
ive i
g, fu
trol
ump
r
ger
ce ss
cove
l con
pipin
p
plun
ng
y
p (ex
eed
spra
f fue
head
timi
fuel
ump
ide f
pum
lder
nt o
tion
from
side
l ins
on p
le ho
stme
injec
tion
el in
Legend
age
a
jecti
e
injec
nozz
adju
oil s
Q : Possible causes (judging from Questions and check items)
fuel
of fu
leak
n
w : Most probable causes (judging from Questions and check items)
i
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
E : Possible causes due to length of use (used for a long period)
Defe
Defe
Leak
Defe
Defe
Defe
Defe
q : Items to confirm the cause.
Exte
Confirm recent repair history
Questions
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
WA700-3 20-319
(10)
Troubleshooting S-11
S-11 Oil is in cooling water, or water spurts back, or water level goes down
)
gged
ting
y pit
r clo
de b
athe
et
in
gask
s ma
(bre
k
r tra
bloc
r
ing
e
of lin
head
hole
seal
o we
, O-r
der
mp
fo r p
ing,
cylin
sion
core
ead,
r pu
r
rotru
-
er h
Legend
oler
oler
O
s in
wate
liner
Q : Possible causes (judging from Questions and check items)
ylind
rack
il co
il co
nt p
w : Most probable causes (judging from Questions and check items)
aged
aged
nal c
fficie
en o
en o
en c
E : Possible causes due to length of use (used for a long period)
Dam
Dam
Brok
Brok
Brok
Inter
q : Items to confirm the cause.
Insu
Confirm recent repair history
Questions
Remedy
20-320 WA700-3
(10)
Troubleshooting S-11
ng
Type of oil –22 –4 –14 32 50 68 86 104°F
pipi
n
pan
–30 –20 –10 0 10 20 30 140°C
l pa
sor
ing
ulic
sen
l
SAE30
e oi
r
alve
o
braz
nso
ydra
e
l
d
sure
d
urna
e
tor v
el se
insi
SAE10W
insi
pipe
valv
ed h
mp
Engine oil
pres
n oi
g, jo
il
ilter
iner
gula
pipe
l lev
l pu
SAE10W-30
in o
lief
ion
ush
il pa
stra
oil f
l
arin
e re
e re
e oi
e oi
e oi
suct
l
uel
i
SAE15W-40
c
o
of o
n be
,
ctiv
ctiv
ctiv
ged
ged
ged
ctiv
ctiv
king
er, f
ken
Defe
Defe
Defe
Defe
Defe
Lack
Clog
Clog
Clog
Wor
Wat
Lea
Bro
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
—
Legend
Q : Possible causes (judging from Questions and check items)
w : Most probable causes (judging from Questions and check items)
E : Possible causes due to length of use (used for a long period)
q : Items to confirm the cause.
WA700-3 20-321
(10)
Troubleshooting S-13
)
mber
er
aids
eath
er
n cha
General causes why oil level rises
cov
ting
p br
g
bustio
• Water in oil
ittin
ead
star
m
• Fuel in oil (diluted, and smells of diesel fuel)
recom
by p
u
h
mp
ter p
ther
e
• Oil leaking in from other component
ce
nsid
n pu
ing p
ade
urfa
or o
a
e
-ring
includ
w
leev
ng i
les m
ctio
k
s
ged
bloc
mp
l
pipi
(
er s
inje
re, O
, ho
r se
gaske
clog
f pu
der
hold
from
stat
side
-ring
a
r co
head
ng o
e
cylin
ng,
r
rmo
rt in
ged
zzl e
oole
er O
fuel
head,
i
l
Legend
l
a
side
e
e se
ama
e no
e pa
e se
d lin
oil c
e th
Q : Possible causes (judging from Questions and check items)
e of
nder
ks in
w : Most probable causes (judging from Questions and check items)
ctiv
n, d
ctiv
ctiv
ctiv
ctiv
age
n cyli
kag
ken
E : Possible causes due to length of use (used for a long period)
Defe
Defe
Defe
Defe
Defe
Dam
Wor
Crac
Broke
Lea
Bro
q : Items to confirm the cause.
Confirm recent repair history
Questions
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Remedy
20-322 WA700-3
(10)
Troubleshooting S-14
re
ratu
)
pen
e
a Carry out troubleshooting for chassis.
ket
mpe
g
lley
ot o
gau
gas
ns
n pu
il te
es n
ure
or fi
ead
oler
er o
n fa
erat
t (do
alve
diat
d, h
o
vert
g
e
wor
p
r
oil c
ittin
r
v
osta
d ra
hea
ump
tem
o
wat
e
c
con
r
ng,
ator
by p
u
ken
she
erm
der
ater
er p
s
ling
Legend
rque
ippi
e
, bro
radi
, cru
cylin
Q : Possible causes (judging from Questions and check items)
e pr
e th
ade
ew
wat
o
l
o
s
in to
w : Most probable causes (judging from Questions and check items)
of c
ged
ged
ged
sm
ctiv
ctiv
ctiv
belt
ken
ken
E : Possible causes due to length of use (used for a long period)
Clog
Defe
Hole
Clog
Defe
Clog
Defe
Lack
Rise
q : Items to confirm the cause.
Bro
Bro
Fan
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly overheated
Condition of overheating
Always tends to overheat
Water temperature Rises quickly
gauge Does not go down from red range
Radiator water level caution lamp is lighted up
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
Check items
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
Add
WA700-3 20-323
(10)
Troubleshooting S-15
.)
, et c
d)
n)
General causes why abnormal noise is made
eize
ever
ctio
r
line
• Abnormality due to defective parts
er s
ker l
inje
ce
der
• Abnormal combustion
aran
lung
, roc
ive
e
ylin
• Air sucked in from intake system
enc
e
e cle
cess
alve
ck, p
renc
pum ozzle
g, c
rfer
m (v
x
valv
p (ra
erfe
n rin
p (e
inte
on n
yst e
, int
ing
t of
pum
isto
belt
ecti
lve s
ush
men
rger
of p
ion
ion
n
n
ic va
b
n, fa
i
cha
just
d
ject
ject
ear
zed
Legend
ynam
z
urbo
d fa
e ad
, sei
Q : Possible causes (judging from Questions and check items)
ve w
e in
, sei
e in
w : Most probable causes (judging from Questions and check items)
rme
ctiv
ged
ctiv
en d
ctiv
ed t
sing
essi
E : Possible causes due to length of use (used for a long period)
Defe
Defo
Defe
Defe
Clog
Brok
Seiz
q : Items to confirm the cause.
Mis
Exc
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Replace
Correct
Adjust
Adjust
Remedy
20-324 WA700-3
(10)
Correct Imp
rope
Correct Lea r ge
ar tr
kag ain
e of
Replace a bac
WA700-3
Defe ir be klas
ct in twe h
Replace side
m
en t
Leak
age u ffler urbo
cha
Replace from (divi rger
Seiz air c ding and
ed c o m b o hea
rank pres ard o d
Troubleshooting
shaf sor p ut of
t bea iping posi
ring tion)
Causes
(10)
20-325
S-15
Troubleshooting S-16
uck)
made”.
tc. st
ion
)
tion
d
gne
er, e
ush
General causes why vibration is excessive
njec
r)
r lev
isali
e
en c
• Defective parts (abnormal wear, breakage)
ve i
(dam
ocke
ring
in m
brok
• Improper alignment
essi
r
bea
,
r tra
e
• Abnormal combustion
haft
(valv
lts,
(exc
h
ing
klas
ain
per
s
e
g bo
stem
h
mp
utpu
d, m
bus
zle
d po
dam
bac
ntin
y
u
noz
s
p
de o
am
g ro
n
train
alve
ion
mou
ion
a
tion
er, c
gine
mic v
ctin
insi
brat
ject
Legend
ear
njec
e
lanc
nne
ngin
f en
dyna
Q : Possible causes (judging from Questions and check items)
e in
part
e vi
g
i
r
w : Most probable causes (judging from Questions and check items)
n ba
n co
rope
ter o
ged
ctiv
ctiv
se e
ctive
ken
E : Possible causes due to length of use (used for a long period)
Defe
Clog
Defe
Wor
Wor
Imp
Cen
Loo
q : Items to confirm the cause.
Defe
Bro
Confirm recent repair history
Degree of use of machine Operated for long period
Questions
Suddenly increased
Condition of vibration
Gradually increased
Non-specified oil is being used
Metal particles are found in oil filter
Metal particles are found when oil is drained
Oil pressure is low at low idling
Check items
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-326 WA700-3
(10)
Troubleshooting of main monitor system
(M mode)
Electrical circuit diagram for M mode system ............................................................................................. 20-354
M-1 Main monitor does not work ............................................................................................................... 20-358
M-2 When starting switch is turned ON and engine is started immediately,
all lamps stay lighted up..................................................................................................................... 20-359
M-3 Speedometer display does not work properly .................................................................................... 20-360
M-4 Abnormality in shift indicator .............................................................................................................. 20-361
a) Displays N even when directional lever is at F ............................................................................ 20-361
b) Displays N even when directional lever is at R ............................................................................ 20-361
c) Does not display N even when directional lever is at N, and displays E when
directional lever is at F................................................................................................................. 20-361
d) Does not display N even when directional lever is at N, and displays E when
directional lever is at R ................................................................................................................ 20-362
e) Does not display 1st even when speed lever is at 1 (directional lever at F or R) ........................ 20-362
f) Does not display 2nd even when speed lever is at 2 (directional lever at F or R) ........................ 20-362
g) Does not display 3rd even when speed lever is at 3 (directional lever at F or R) ........................ 20-363
h) Does not display 4th even when speed lever is at 4 (directional lever at F or R) ........................ 20-363
M-5 Turn signal display does not light up.................................................................................................. 20-365
a) L.H. turn signal display does not light up ..................................................................................... 20-365
b) R.H. turn signal display does not light up .................................................................................... 20-365
M-6 Abnormality in parking display ........................................................................................................... 20-366
a) Parking lamp display does not light up ........................................................................................ 20-366
b) Parking lamp display stays lighted up.......................................................................................... 20-366
M-7 Night lighting does not light up........................................................................................................... 20-367
M-8 Abnormality in front working lamp...................................................................................................... 20-368
a) Neither monitor display nor front working lamp light up ............................................................... 20-368
b) Working lamp lights up but monitor display does not light up ...................................................... 20-368
c) Monitor display lights up but working lamp does not light up ....................................................... 20-368
M-9 Abnormality in rear working lamp....................................................................................................... 20-370
a) Neither monitor display nor rear working lamp light up................................................................ 20-370
b) Working lamp lights up but monitor display does not light up ...................................................... 20-370
c) Monitor display lights up but working lamp does not light up ....................................................... 20-370
M-10 Abnormality in transmission cut-off .................................................................................................... 20-372
Standard specification
a) When transmission cut-off switch is pressed, cut-off function is not switched
and display does not change ....................................................................................................... 20-372
b) When transmission cut-off switch is turned OFF, cut-off function is always actuated. ................. 20-372
c) Transmission cut-off switch turned ON, but cut-off function is not actuated ................................ 20-373
WA700-3 20-351
(10)
Auto-shift specification
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is
not switched and display does not change 5 ............................................................................... 20-374
b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out
but cut-off function is actuated when pedal is depressed ............................................................ 20-374
c) When monitor display is turned off (transmission cut-off switch turned OFF),
cut-off function is always actuated ............................................................................................... 20-374
d) Cut-off function is always actuated regardless of monitor display
(transmission cut-off switch ON or OFF)...................................................................................... 20-374
e) Monitor display lights up (transmission cut-off switch turned ON),
but cut-off function is not actuated ............................................................................................... 20-375
M-11 Abnormality in parking brake dragging warning ................................................................................. 20-376
a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp flashes even when
directional lever is at N................................................................................................................. 20-376
b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when
directional lever is at position other than N .................................................................................. 20-376
M-12 When parking brake dragging warning is given, buzzer and caution lamp are actuated
continuously, or they are not actuated ............................................................................................... 20-378
a) Actuated continuously.................................................................................................................. 20-378
b) Not actuated................................................................................................................................. 20-378
M-13 Abnormality in buzzer ........................................................................................................................ 20-379
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check) ......... 20-379
b) Buzzer always sounds ................................................................................................................. 20-379
M-14 Condition of monitor switches is not stored in memory...................................................................... 20-380
M-15 Abnormality in failure display mode ................................................................................................... 20-381
a) Does not enter failure display mode ............................................................................................ 20-381
b) Count for time elapsed since failure in failure display mode does not advance........................... 20-381
M-16 Abnormality in electric engine throttle controller error display ........................................................... 20-382
a) There is no abnormality on machine but error code [91] is displayed.......................................... 20-382
b) There is no abnormality on machine but error code [92] is displayed.......................................... 20-382
c) Problem is error code [90(94)] but error code [91(93)] is displayed ............................................. 20-382
d) Problem is error code [90(96)] but error code [92(95)] is displayed............................................. 20-383
M-17 Abnormality in emergency steering actuation display........................................................................ 20-384
a) Emergency steering actuation display does not light up .............................................................. 20-384
b) Emergency steering actuation display stays lighted up ............................................................... 20-384
M-18 Abnormality in auto-greasing system................................................................................................. 20-385
a) Forced greasing cannot be carried out ........................................................................................ 20-385
b) Monitor display flashes rapidly (2 times/sec) ............................................................................... 20-385
c) When no more grease remains, monitor display flashes rapidly (2 times/sec) ............................ 20-385
d) Monitor display flashes slowly (1 time/sec) .................................................................................. 20-386
e) Monitor display goes out .............................................................................................................. 20-386
M-19 Abnormality in low idling select system.............................................................................................. 20-387
a) Display does not change when switch is pressed........................................................................ 20-387
b) Monitor display lights up but low idling select function does not work ......................................... 20-387
20-352 WA700-3
(10)
Troubleshooting Electrical circuit diagram for M mode system
20-354 WA700-3
(10)
Troubleshooting Electrical circuit diagram for M mode system
WA700-3 20-355
(10)
Troubleshooting Electrical circuit diagram for M mode system
20-356 WA700-3
(10)
Troubleshooting Electrical circuit diagram for M mode system
WA700-3 20-357
(10)
Troubleshooting M-1
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
YES
Defective main monitor Replace
1
Is voltage
between L05 (1), Defective contact or discon-
(2) – (3) normal? 2 YES nection in wiring harness Repair or
Is resistance bet- between L05 (female) (1), replace
• 20 – 30 V ween L05 (female) (2) and FS2 (female) (9)
• Turn starting NO (3) and chassis Defective contact or discon-
switch ON. ground normal? Repair or
nection in wiring harness
• Turn starting NO between L05 (female) (3) replace
switch OFF. and LR5 (male) (3)
• Disconnect L05.
• Max. 1 z
20-358 WA700-3
(10)
Troubleshooting M-2
M-2 When starting switch is turned ON and engine is started immediately, all lamps
stay lighted up
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage between
L05 (4) and chassis
ground normal? Defective contact or discon-
nection in wiring harness Repair or
• 20 – 30 V NO between L05 (female) (4) replace
• Turn starting switch and L57 (female) (3)
to START.
WA700-3 20-359
(10)
Troubleshooting M-3
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Check that the gap between the speed sensor and gear is normal.
Cause Remedy
2 YES
Defective main monitor Replace
Is resistance
YES between L07
1 (female) (1) and (2) Defective contact or discon-
normal? nection in wiring harness
Is resistance Repair or
between L07 (female) (1),
between T05 • 500 z – 1 kz NO replace
(2) – TL1 (11), (12) – T05
(male) (1) and (2) • Turn starting switch (female) (1), (2)
normal? OFF.
• 500 z – 1 kz • Disconnect L07.
• Turn starting switch NO Defective speed sensor Replace
OFF.
• Disconnect T05.
20-360 WA700-3
(10)
Troubleshooting M-4
a Before carrying out troubleshooting, check that all the related connectors are properly inserted..
a Always connect any disconnected connectors before going on the next step.
a Check that the transmission shifts.
a Check that the output of the directional lever and speed lever is normal before starting troubleshooting.
a Check that the steering is in the steering wheel mode.
1 YES
Defective main monitor Replace
Is voltage
between L08 (7)
Defective contact or
and chassis
disconnection in wiring
ground normal? Repair or
harness between L08
• 20 – 30 V NO (female) (7) and L04 replace
• Turn starting (female) (2)
switch ON.
• Directional lever: F
1 YES
Defective main monitor Replace
Is voltage
between L08 (8)
Defective contact or
and chassis
disconnection in wiring
ground normal? Repair or
harness between L08
• 20 – 30 V NO (female) (8) and L04 replace
• Turn starting (female) (4)
switch ON.
• Directional lever: R
1 YES
Defective main monitor Replace
Is voltage
between L08 (7)
and chassis Short circuit with power
ground normal? source in wiring harness Repair or
•0– 5V NO between L08 (female) (7) replace
• Turn starting and L04 (female) (2)
switch ON.
• Directional lever: N
WA700-3 20-361
(10)
Troubleshooting M-4
1 YES
Defective main monitor Replace
Is voltage
between L08 (8)
and chassis Contact of power source
ground normal? with wiring harness Repair or
•0– 5V NO between L08 (female) (8) replace
• Turn starting and L04 (female) (4)
switch ON.
• Directional lever: N
1 YES
Defective main monitor Replace
Is voltage between
L05 (female) (12) <Standard specification>
and chassis Defective contact or
ground normal? Repair or
disconnection in wiring
• 20 – 30 V NO harness between L05 replace
• Turn starting (female) (12) and L04
switch ON. (female) (5)
<Auto-shift specification>
Defective contact or
disconnection in wiring Repair or
harness between L05 replace
(female) (12) and TL1 (1)
(female)
1 YES
Defective main monitor Replace
Is voltage between
L05 (female) (13) <Standard specification>
and chassis Defective contact or
ground normal? Repair or
disconnection in wiring
• 20 – 30 V NO harness between L05 replace
• Turn starting (female) (13) and L04
switch ON. (female) (6)
<Auto-shift specification>
Defective contact or
disconnection in wiring Repair or
harness between L05 replace
(female) (13) and TL1 (2)
(female)
20-362 WA700-3
(10)
Troubleshooting M-4
1 YES
Defective main monitor Replace
Is voltage between
L05 (female) (14) <Standard specification>
and chassis Defective contact or
ground normal? Repair or
disconnection in wiring
• 20 – 30 V NO harness between L05 replace
• Turn starting (female) (14) and L04
switch ON. (female) (7)
<Auto-shift specification>
Defective contact or
disconnection in wiring Repair or
harness between L05 replace
(female) (14) and TL1 (3)
(female)
1 YES
Defective main monitor Replace
Is voltage between
L05 (female) (15) <Standard specification>
and chassis Defective contact or
ground normal? Repair or
disconnection in wiring
• 20 – 30 V NO harness between L05 replace
• Turn starting (female) (15) and L04
switch ON. (female) (8)
<Auto-shift specification>
Defective contact or
disconnection in wiring Repair or
harness between L05 replace
(female) (15) and TL1 (4)
(female)
WA700-3 20-363
(10)
Troubleshooting M-4
Auto-shift specification
20-364 WA700-3
(10)
Troubleshooting M-5
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not
blown
1 YES
Defective main monitor Replace
Is voltage between
L06 (14) and
chassis ground
Defective contact or discon-
normal? Repair or
nection in wiring harness
• Repeats 0V and NO between L06 (female) (14) replace
20 – 30V. and L03 (female) (4)
• Turn starting switch ON.
• Turn L.H. turn signal ON.
1 YES
Defective main monitor Replace
Is voltage between
L06 (15) and
chassis ground
Defective contact or discon-
normal? Repair or
nection in wiring harness
• Repeats 0V and NO between L06 (female) (15) replace
20 – 30V. and L03 (female) (3)
• Turn starting switch ON.
• Turn R.H. turn signal ON.
WA700-3 20-365
(10)
Troubleshooting M-6
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
3 YES
Defective main monitor Replace
Is resistance
YES between F12
(female) (2) and
2 chassis ground Defective contact or discon-
Is voltage between normal? nection in wiring harness Repair or
YES L06 (11) and replace
• Max. 1 z NO between F12 (female) (1)
chassis ground • Turn starting switch and chassis ground
1 normal? OFF.
Is resistance Defective contact or discon-
• 20 – 30 V • Disconnect F12. nection in wiring harness Repair or
between F12
(male) (1) and (2) • Turn starting switch NO between L06 (female) (11) – replace
normal? ON. LR2 (14) – FR2 (6) – F12
• Turn parking switch (female) (1)
• Max. 1 z ON.
• Disconnect F12. Defective parking brake Replace
• Turn starting switch NO indicator switch
ON.
• Turn parking switch
ON.
2 YES
Defective main monitor Replace
Is voltage between
YES F12 (1) and chassis
1 ground normal?
Short circuit with power
Is resistance source in harness between Repair or
between F12 •0– 2V NO L06 (female) (11) – LR2 (14) replace
(male) (1) and (2) • Turn starting switch – FR2 (6) – CN19 (female)
normal? ON. (1)
• Max. 1 z • Turn parking switch OFF. Defective parking brake
• Disconnect F12. Replace
NO indicator switch
• Turn starting switch
ON.
• Turn starting switch
OFF.
20-366 WA700-3
(10)
Troubleshooting M-7
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the lamp bulbs are not blown.
a Check that fuse I-6 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring
harness between FS2 (female) (5) and L05 (female) (16).
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage between
L05 (16) and
chassis ground
Defective contact or
normal? Repair or
disconnection in wiring
• 20 - 30 V NO harness between L05 replace
• Turn starting switch (female) (16) and FS2 (5)
ON.
• Turn small lamp switch
ON.
WA700-3 20-367
(10)
Troubleshooting M-8
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the monitor lighting is lighted up.
1 YES
Defective main monitor Replace
Is voltage between
L05 (17) and
chassis ground
Defective contact or discon-
normal? Repair or
nection in wiring harness
• 20 – 30 V NO between L05 (female) (17) replace
• Turn starting switch and L60 (female) (1)
ON.
20-368 WA700-3
(10)
Troubleshooting M-8
WA700-3 20-369
(10)
Troubleshooting M-9
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Before starting troubleshooting, check that the monitor lighting is lighted up.
Defective contact or
YES disconnection in wiring
Repair or
harness between L61
(female) (1) – L05 (female) replace
(18), LR1 (female) (8)
1 YES
Defective main monitor Replace
Is voltage between
L05 (18) and
chassis ground
Defective contact or discon-
normal? Repair or
nection in wiring harness
• 20 – 30 V NO between L05 (female) (18) replace
• Turn starting switch and L61 (female) (1)
ON.
20-370 WA700-3
(10)
Troubleshooting M-9
WA700-3 20-371
(10)
Troubleshooting M-10
Standard specification
a) When transmission cut-off switch is pressed, cut-off function is not switched and display does not
change
Cause Remedy
b) When transmission cut-off switch is turned OFF, cut-off function is always actuated.
Cause Remedy
YES
Defective monitor panel Replace
Defective contact or
20-372 WA700-3
(10)
Troubleshooting M-10
c) Transmission cut-off switch turned ON, but cut-off function is not actuated
Cause Remedy
3 YES
Defective monitor panel Replace
YES Does cut-off
2 function work? Short circuit with chassis
Is voltage ground in harness Repair or
YES between L65 (5) • Disconnect L06 NO between L06 (female) (3) replace
and chassis • Turn starting and L65 (female) (2)
1 ground normal? switch ON.
• Turn parking switch OFF.
•0– 3V Defective cut-off relay Replace
Does cut-off NO
• Turn starting
function work?
switch ON.
• Turn parking switch
• Turn starting Short circuit between L65
OFF. Repair or
switch ON. (female) (3) and (5) or
NO defective cut-off switch replace
• Remove cut-off
relay.
• Turn parking
switch OFF.
WA700-3 20-373
(10)
Troubleshooting M-10
Auto-shift specification
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
20-374 WA700-3
(10)
Troubleshooting M-10
WA700-3 20-375
(10)
Troubleshooting M-11
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 With or without auto-shift, use the flowchart below when in the steering wheel mode.
a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp flashes even when
directional lever is at N
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage between
L05 (8) and chassis
ground normal? Defective contact or discon-
nection in wiring harness Repair or
• 20 – 30 V NO between L05 (female) (8) – replace
L04 (female) (3)
• Turn starting switch
ON.
• Directional lever: N
b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even
when directional lever is at position other than N
a Check that the synchronous flash signal is normal.
Cause Remedy
YES
Defective main monitor Replace
1
Is voltage between Short circuit with power
L05 (8) and chassis source in wiring harness
ground normal? 2 YES Repair or
between L05 (female) (8)
replace
Is resistance bet- – L04 (female) (3), or
•0– 5V
ween L05 (male) defective directional lever
• Turn starting NO (8) and (3) normal?
switch ON.
• Directional lever: Defective main monitor Replace
• 3 kz – 4 kz NO
Other than N • Turn starting switch
OFF.
• Disconnect L05.
20-376 WA700-3
(10)
Troubleshooting M-11
WA700-3 20-377
(10)
Troubleshooting M-12
M-12 When parking brake dragging warning is given, buzzer and caution lamp are
actuated continuously, or they are not actuated
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a) Actuated continuously
Cause Remedy
b) Not actuated
Cause Remedy
20-378 WA700-3
(10)
Troubleshooting M-13
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
YES
Defective main monitor Replace
1
Does buzzer stop
when L06 is YES Go to Troubleshooting
disconnected? —
2 for maintenance monitor
WA700-3 20-379
(10)
Troubleshooting M-14
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage between
L07 (10) and
chassis ground
Defective contact or discon-
normal? Repair or
nection in wiring harness
• 20 – 30 V NO between L07 (female) (10) replace
• Turn starting switch and L09 (female) (2)
ON.
20-380 WA700-3
(10)
Troubleshooting M-15
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
1 YES
Defective main monitor Replace
Is voltage between
L05 (5) and chassis Short circuit with power
ground normal? source in wiring harness
between L05 (female) (5) – Repair or
•0– 5V NO LR4 (6) – ER1 (9) – replace
• Turn starting switch alternator terminal R, or
defective alternator
ON.
1 YES
Defective main monitor Replace
Is voltage between
L05 (5) and chassis Defective contact or discon-
ground normal? nection in wiring harness
between L05 (female) (5) – Repair or
• 20 – 30 V NO LR4 (6) – ER1 (9) – replace
• Start engine. alternator terminal R, or
defective alternato
WA700-3 20-381
(10)
Troubleshooting M-16
YES
Defective main monitor Replace
1
Is voltage
between L07 (9)
See Troubleshooting (G
and chassis 2 YES mode) of electric engine —
ground normal?
Is voltage between throttle controller
• 20 – 30 V EC1 (female) (15)
• Turn starting NO and chassis Short circuit with chassis
switch ON. ground normal? ground in wiring harness Repair or
• 20 – 30 V between L07 (female) (9) replace
NO
• Disconnect EC1. and EC1 (female) (15)
• Turn starting
switch ON.
YES
Defective main monitor Replace
1
Is voltage
between L07 (5)
See Troubleshooting (G
and chassis 2 YES mode) of electric engine —
ground normal?
Is voltage between throttle controller
• 20 – 30 V EC1 (female) (6)
• Turn starting NO and chassis Short circuit with chassis
switch ON. ground normal? ground in wiring harness Repair or
• 20 – 30 V between L07 (female) (5) replace
NO
• Disconnect EC1 and EC1 (female) (6)
(female).
• Turn starting
switch ON.
YES
Defective main monitor Replace
1
Is voltage
Defective contact or
between L07 (5)
disconnection in wiring
and chassis 2 YES Repair or
harness between L07
ground normal? replace
Is voltage between (female) (5) and EC1
• Max. 3 V EC1 (female) (6) (female) (6)
• Turn starting NO and chassis
switch ON. ground normal? See Troubleshooting (G
• Max. 3 V mode) of electric engine —
NO
• Turn starting throttle controller
switch ON.
20-382 WA700-3
(10)
Troubleshooting M-16
YES
Defective main monitor Replace
1
Is voltage
between L07 (9) Defective contact or
and chassis disconnection in wiring
2 YES harness between L07 Repair or
ground normal?
Is voltage between (female) (9) and EC1 replace
• Max. 3 V EC1 (female) (15) (female) (15)
• Turn starting NO and chassis
switch ON. ground normal? See Troubleshooting (G
mode) of electric engine —
• Max. 3 V NO throttle controller
• Turn starting
switch ON.
WA700-3 20-383
(10)
Troubleshooting M-17
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L05 (11) Short circuit with chassis
and chassis ground in wiring harness
ground normal? between L05 (female) (11)
Repair or
– LR4 (13) – R01 (female)
• 20 – 30 V NO replace
(1) or defective
• Turn starting emergency steering
switch ON. actuation sensor
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage
between L05 (11) Defective contact or Repair or
and chassis disconnection in wiring replace
ground normal? harness between L05
(female) (11) – LR4 (13) –
•0– 2V NO R01 (female) (1)
• Turn starting or defective emergency Replace
switch ON. steering actuation sensor
20-384 WA700-3
(10)
Troubleshooting M-18
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
YES
Defective main monitor Replace
1
Is voltage between
L07 (11) and
Defective contact or discon-
chassis ground 2 YES nection in wiring harness Repair or
normal? between L07 (female) (11)
Is voltage between replace
• 20 – 30 V GRE (2) and and GRE (2)
• Turn starting NO chassis ground
switch ON. normal? See “ Handling auto-greasing
system” in Operation and —
• 20 – 30 V NO Maintenance Manual
• Turn starting switch
ON.
WA700-3 20-385
(10)
Troubleshooting M-18
YES
Defective main monitor Replace
1
Is voltage between
L07 (11) and
Short circuit with power
chassis ground 2 YES source in wiring harness Repair or
normal? between L07 (female) (11)
Is voltage between replace
• Max. 3 V GRE (female) (2) and GRE (female) (2)
• Turn starting NO and chassis
switch ON. ground normal? See “ Handling auto-greasing
system” in Operation and —
•2– 3V NO Maintenance Manual
• Turn starting switch
ON.
• Disconnect GRE.
20-386 WA700-3
(10)
Troubleshooting M-19
See Troubleshooting (G
2 YES mode) of electric engine —
Is voltage throttle controller
YES between EC5A (5)
1 and chassis Defective contact or
Is voltage ground normal? disconnection in wiring Repair or
between L06 (7) • Max. 3 V NO harness between L06 replace
and chassis • Turn starting (female) (7) and EC5A (5)
ground normal? switch ON.
• Max. 3 V
• Turn starting Defective main monitor Replace
NO
switch ON.
WA700-3 20-387
(10)
Troubleshooting M-19
20-388 WA700-3
(10)
Troubleshooting of maintenance
monitor system
(K mode)
Electrical circuit diagram for K mode system .............................................................................................. 20-402
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up
for 3 seconds, maintenance monitor does not work ........................................................................... 20-404
a) No lamps on maintenance monitor light up................................................................................... 20-404
b) Some lamps do not light up .......................................................................................................... 20-404
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but
do not go out (even after 3 seconds) .................................................................................................. 20-405
K-3 When engine is started immediately after starting switch is turned ON (within 3 seconds), no lamps on
maintenance monitor go out ............................................................................................................... 20-406
K-4 When starting switch is turned ON (engine stopped), CHECK items flash......................................... 20-407
a) Engine oil level display flashes ..................................................................................................... 20-407
b) Engine water level display flashes ................................................................................................ 20-408
K-5 When starting switch is turned ON (engine started), CAUTION items flash....................................... 20-410
a) Engine oil pressure display flashes (Check that the engine oil pressure is correct.) .................... 20-410
b) Battery charge level display flashes.............................................................................................. 20-412
c) Brake oil pressure display flashes (Check that the brake oil pressure is correct.)........................ 20-413
d) Air cleaner (L.H.) display flashes .................................................................................................. 20-414
e) Air cleaner (R.H.) display flashes.................................................................................................. 20-415
f) Air cleaner display flashes ............................................................................................................. 20-416
K-6 CAUTION items are flashing but caution buzzer does not sound ...................................................... 20-417
K-7 There is no abnormality in monitor display but caution buzzer sounds .............................................. 20-418
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not flash....... 20-419
a) CHECK lamp................................................................................................................................. 20-419
b) CAUTION lamp............................................................................................................................. 20-419
K-9 There is no abnormality in maintenance monitor display but warning lamp
(CHECK lamp, CAUTION lamp) lights up........................................................................................... 20-420
a) CHECK lamp................................................................................................................................. 20-420
b) CAUTION lamp............................................................................................................................. 20-420
K-10 Night lighting does not light up when lamp switch is turned ON
(only lighting of maintenance monitor does not light up)..................................................................... 20-421
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up....................... 20-422
K-12 Service meter does not work.............................................................................................................. 20-423
K-13 Service meter is running even when engine is stopped ..................................................................... 20-423
K-14 Abnormality in gauge items ................................................................................................................ 20-425
a) Abnormality in fuel gauge ............................................................................................................. 20-425
b) Abnormality in engine water temperature gauge .......................................................................... 20-426
c) Abnormality in torque converter oil temperature gauge ................................................................ 20-427
WA700-3 20-401
(10)
Troubleshooting Electrical circuit diagram for K mode system
20-402 WA700-3
(10)
Troubleshooting Electrical circuit diagram for K mode system
WA700-3 20-403
(10)
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 does not work
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
20-404 WA700-3
(10)
Troubleshooting K-2
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up
but do not go out (even after 3 seconds)
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA700-3 20-405
(10)
Troubleshooting K-3
K-3 When engine is started immediately after starting switch is turned ON (within 3
seconds), no lamps on maintenance monitor go out
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1 YES
Defective monitor module Replace
When starting engine,
is voltage between
of maintenance monitor
L19 (female) (1) and
chassis ground Defective contact or discon-
normal? nection in wiring harness Repair or
• 20 – 30 V NO between L19 (female) (1) replace
• Disconnect L19. and neutral relay
• Start engine.
• Measure when starting
motor is turning
(starting switch at START).
20-406 WA700-3
(10)
Troubleshooting K-4
K-4 When starting switch is turned ON (engine stopped), CHECK items flash
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA700-3 20-407
(10)
Troubleshooting K-4
Cause Remedy
20-408 WA700-3
(10)
Troubleshooting K-4
Cause Remedy
WA700-3 20-409
(10)
Troubleshooting K-5
K-5 When starting switch is turned ON (engine started), CAUTION items flash
Serial No.: 50001 – 51000
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
20-410 WA700-3
(10)
Troubleshooting K-5
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Check that Error Code [527] is not displayed in the engine controller.
Cause Remedy
WA700-3 20-411
(10)
Troubleshooting K-5
Cause Remedy
20-412 WA700-3
(10)
Troubleshooting K-5
Cause Remedy
WA700-3 20-413
(10)
Troubleshooting K-5
20-414 WA700-3
(10)
Troubleshooting K-5
WA700-3 20-415
(10)
Troubleshooting K-5
20-416 WA700-3
(10)
Troubleshooting K-6
K-6 CAUTION items are flashing but caution buzzer does not sound
a The buzzer does not sound for CHARGE or ENGINE OIL LEVEL.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Check that fuse I-10 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring
harness between fuse – FS2 (9) – L42 (1).
Cause Remedy
WA700-3 20-417
(10)
Troubleshooting K-7
a Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
(Note: When joystick steering is not installed)
Cause Remedy
20-418 WA700-3
(10)
Troubleshooting K-8
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp)
does not flash
a Before carrying out troubleshooting, check that there are no blown lamp bulbs.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a) CHECK lamp
Cause Remedy
b) CAUTION lamp
Cause Remedy
WA700-3 20-419
(10)
Troubleshooting K-9
a Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a) CHECK lamp
Cause Remedy
1 YES
Defective monitor module Replace
Is resistance bet- of maintenance monitor
ween L19 (female)
(2) and chassis Short circuit with chassis
ground normal? ground in wiring harness Repair or
between L19 (female) (2)
• Min. 1 Mz NO and L06 (female) (10)
replace
• Turn starting switch (contact with chassis
OFF. ground)
• Disconnect L06 and L19.
b) CAUTION lamp
Cause Remedy
1 YES
Defective monitor module Replace
Is resistance bet- of maintenance monitor
ween L19 (female)
(3) and chassis Short circuit with chassis
ground normal? ground in wiring harness Repair or
between L19 (female) (3)
• Min. 1 Mz NO and L06 (female) (9) (contact
replace
• Turn starting switch with chassis ground)
OFF.
• Disconnect L06 and L19.
20-420 WA700-3
(10)
Troubleshooting K-10
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of
maintenance monitor does not light up)
a Before carrying out troubleshooting, check that there are no blown lamp bulbs.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA700-3 20-421
(10)
Troubleshooting K-11
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays
lighted up
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Switch Continuity
ON YES
OFF NO
20-422 WA700-3
(10)
Troubleshooting K-12, 13
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
YES
Defective service meter Replace
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
YES
Defective service meter Replace
1
Is voltage bet-
ween L22 (female) Contact of +24V with wiring
(2) and (1) normal? 2 YES harness between L22 Repair or
Is voltage between (female) (2) – LR4 (6) – ER1 replace
• Max. 3 V alternator terminal (9) – alternator terminal R
• Turn starting NO R and chassis
switch ON. ground normal?
• Disconnect L22. Defective alternator Replace
• Max. 3 V NO
• Turn starting switch
ON.
WA700-3 20-423
(10)
Troubleshooting K-12, 13
20-424 WA700-3
(10)
Troubleshooting K-14
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
YES
Defective fuel sensor Replace
YES
Defective fuel sensor Replace
1
Do all display areas
on fuel gauge go
out when R05 is 2 YES Defective monitor module
disconnected? Replace
Is resistance bet- of maintenance monitor
• Disconnect R05. ween R05 (female)
• Turn starting NO (1) and chassis Short circuit with chassis
switch ON. ground normal? ground in wiring harness Repair or
• Min. 1 Mz NO between R05 (female) (1) – replace
• Turn starting switch LR4 (10) – L18 (female) (6)
OFF.
• Disconnect L18 and R05.
WA700-3 20-425
(10)
Troubleshooting K-14
20-426 WA700-3
(10)
Troubleshooting K-14
WA700-3 20-427
(10)
Troubleshooting of electrical system
(E mode)
Electrical circuit diagram for E mode system .............................................................................................. 20-454
E-1 Engine does not start.......................................................................................................................... 20-458
a) Starting motor does not turn......................................................................................................... 20-458
b) Starting motor turns...................................................................................................................... 20-464
E-2 Abnormality in APS system ................................................................................................................ 20-474
a) When preheating switch is turned AUTO, preheating lamp does not light up,
but no pilot LED on APS controller lights up. ............................................................................... 20-476
b) When preheating switch is turned AUTO and engine water temperature is below 20ºC,
preheating lamp flashes, but pilot LED on APS controller shows normal.................................... 20-477
c) After preheating, fuel is not injected from APS nozzle when starting switch is
turned START, but pilot LED on APS controller shows normal.................................................... 20-478
d) LED 1 of pilot LED on APS controller shows abnormal ............................................................... 20-479
e) LED 2 of pilot LED on APS controller shows abnormal ............................................................... 20-479
f) LED 3 of pilot LED on APS controller shows abnormal ................................................................ 20-480
g) LED 4 of pilot LED on APS controller shows abnormal ............................................................... 20-480
h) LED 5 of pilot LED on APS controller shows abnormal ............................................................... 20-481
i) LED 6 of pilot LED on APS controller shows abnormal ................................................................ 20-481
j) When preheating switch is OFF, preheating lamp lights up .......................................................... 20-482
E-3 Parking brake does not have effect .................................................................................................... 20-483
a) Parking brake has no effect when parking brake switch is turned ON......................................... 20-483
b) Parking brake has no effect and does not work as emergency brake when
parking brake pressure drops ...................................................................................................... 20-483
E-4 Parking brake is applied when machine is traveling........................................................................... 20-484
E-5 Parking brake is released when starting switch is turned ON............................................................. 20-486
E-6 Transmission does not change to neutral when parking brake is applied,
but parking brake works normally ...................................................................................................... 20-486
E-7 Transmission does not work properly ................................................................................................. 20-489
a) Abnormality in parking brake circuit, transmission cut-off switch circuit or
neutralizer relay circuit................................................................................................................. 20-490
b) No continuity in travel FORWARD solenoid circuit ...................................................................... 20-494
c) No continuity in travel REVERSE solenoid circuit........................................................................ 20-496
d) Short circuit to chassis ground in directional solenoid circuit....................................................... 20-498
e) Abnormality in shift solenoid circuit.............................................................................................. 20-504
f) Short circuit to chassis ground in shift solenoid circuit.................................................................. 20-507
E-8 Kick-down switch does not work......................................................................................................... 20-512
E-9 Kick-down works only when kick-down switch is being turned ON..................................................... 20-515
E-10 Kick-down always works .................................................................................................................... 20-516
WA700-3 20-451
(10)
E-11 Kick-down swich works even when traveling forward in 2nd .............................................................. 20-518
E-12 Boom Kick-out does not work............................................................................................................. 20-520
E-13 Defective bucket positioner ................................................................................................................ 20-522
E-14 Power window does not work ............................................................................................................. 20-524
a) Window does not go up ............................................................................................................... 20-524
b) Window does not go down........................................................................................................... 20-525
E-15 Abnormality in front working lamp ...................................................................................................... 20-527
E-16 Abnormality in rear working lamp ....................................................................................................... 20-527
E-17 Abnormality in transmission cut-off..................................................................................................... 20-527
E-18 Abnormality in parking brake dragging warning ................................................................................. 20-527
E-19 Abnormality in buzzer ......................................................................................................................... 20-527
20-452 WA700-3
(10)
Troubleshooting Electrical circuit diagram for E mode system
20-454 WA700-3
(10)
Troubleshooting Electrical circuit diagram for E mode system
WA700-3 20-455
(10)
Troubleshooting Electrical circuit diagram for E mode system
20-456 WA700-3
(10)
Troubleshooting Electrical circuit diagram for E mode system
WA700-3 20-457
(10)
Troubleshooting E-1
YES
3
5 YES
Is voltage between
YES starting motor Is voltage between
terminal (B) and YES battery relay
chassis normal? terminal M and
chassis normal?
• 20 -– 30 V
• Turn starting 4 • 20 – 30 V NO
switch OFF. Does battery • Turn starting
relay make sound switch ON.
NO of actuation? YES
2
• Starting switch 6
Is there continuity ON i o OFF. Is voltage between both
YES between starting connection terminals
motor terminal (E) A02 and A03 and
connection terminals
and chassis? NO A04 and A05 of battery
relay normal?
• Turn starting
switch OFF. • 20 – 30 V
• Turn starting
switch ON.
1 NO
Is voltage
between E03, E04
(female) (1) and
chassis normal?
• 20 – 30 V
• Disconnect E03
and E04. NO
• Directional lever:
Neutral
• Turn starting
switch to START.
NO
20-458 WA700-3
(10)
Troubleshooting E-1
Cause Remedy
Defective contact or
disconnection in cable Repair or
between battery relay replace
and starting motor
Defective battery relay,
or defective contact of Repair or
wiring harness between replace
battery and battery relay
Defective contact or
Repair or
disconnection in starting
replace
motor ground cable
Go to A on next page
WA700-3 20-459
(10)
Troubleshooting E-1
YES
YES
11
Is voltage
YES between L57 13 YES
9 (female) (5) and Is voltage between
Does starting chassis normal? YES starting switch
From A 12 terminal C and
motor rotate • 20 – 30 V chassis normal?
when neutral • Disconnect L57. Is voltage between
relay is replaced? • Turn starting starting switch • 20 – 30 V NO
• Replace neutral switch to START.NO terminal B and • Turn starting
chassis normal? switch to START.
relay (L57) with
stop lamp relay • 20 – 30 V
(L53). • Turn starting NO
• Directional lever: switch OFF.
Neutral
• Turn starting 16 YES
switch to START. 10
Is voltage
Is voltage YES between L04 (3)
between L57
and chassis
NO (female) (1) and normal?
(2) normal?
• 20 – 30 V NO
• Disconnect L57. • Connect T-
15
• Directional lever: adapter to L04.
Neutral Is voltage
YES between L04 • Directional lever: 18 YES
• Turn starting N
switch to START. (female) (1) and Is voltages between
• Turn starting YES battery relay
chassis normal?
switch ON. terminal M and
• 20 – 30 V chassis normal?
• Disconnect L04.
• Turn starting 17 • 20 – 30 V NO
switch ON. Does battery • Turn starting
relay make sound switch ON.
NO of actuation? YES
14
• Turn starting 19
Is resistance switch ON io Is voltage between both
between L57 OFF. connection terminals
NO (female) (2) and A02 and A03 and
chassis normal? connection terminals
NO A04 and A05 of battery
• Max. 1 z relay normal?
• Turn starting • 20 – 30 V
switch OFF. • Turn starting
• Disconnect L57. switch ON.
NO
NO
20-460 WA700-3
(10)
Troubleshooting E-1
Cause Remedy
WA700-3 20-461
(10)
Troubleshooting E-1
20-462 WA700-3
(10)
Troubleshooting E-1
YES
3
Is voltage
YES between EC5B
(female) (4) and YES
chassis normal? 4
When fuel cut
• 20 – 30 V switch is operated,
2 • Disconnect EC5B. is No-injection
NO cranking relay (L82)
5 YES
Is voltage • Turn starting
actuated? Does condition
YES between EC1 switch ON.
become normal
(female) (9), (17) • Turn starting
when No-injection
– chassis normal? switch ON. NO cranking relay (L82)
• Turn fuel cut is replaced?
• 20 – 30 V switch ON io
• Disconnect EC1. • Replace with NO
OFF. other relay.
1 • Turn starting
Is voltage switch ON. • Turn starting
between EC1 switch ON.
(female) (4) and NO
chassis normal?
• 20 – 30 V
• Disconnect EC1. YES
• Turn starting 6
switch ON. Does condition
become normal
when governor cut
NO relay (L30) is 7 YES
replaced? Is voltage
• Replace with between L30
other relay. NO (female) (1), (3) –
• Turn starting chassis normal?
switch ON. • 20 – 30 V NO
• Disconnect L30.
• Turn starting
switch ON.
20-464 WA700-3
(10)
Troubleshooting E-1
Cause Remedy
Defective contact or
disconnection in wiring
Repair or
harness between EC5B
replace
(female) (4) and L82
(female) (6)
Defective No-injection
Replace
cranking relay (L82)
Short circuit with wiring
harness between L82
(female) (1) – L73 (2) – fuel Repair or
cut switch, or defective fuel replace
cut switch
Defective contact or
disconnection in wiring
harness between EC1 Repair or
(female) (9), (17) – FS7 (2) – replace
fuse – FS7 (1) – L09
(female) (5)
WA700-3 20-465
(10)
Troubleshooting E-1
20-466 WA700-3
(10)
Troubleshooting E-1
YES
3
5 YES
Is voltage between
YES starting motor Is voltage between
terminal (B) and YES battery relay
chassis normal? terminal M and
chassis normal?
• 20 -– 30 V
• Turn starting 4 • 20 – 30 V NO
switch OFF. Does battery • Turn starting
relay make sound switch ON.
NO of actuation? YES
2
• Starting switch 6
Is there continuity ON i o OFF. Is voltage between both
YES between starting connection terminals
motor terminal (E) A02 and A03 and
connection terminals
and chassis? NO A04 and A05 of battery
relay normal?
• Turn starting
switch OFF. • 20 – 30 V
• Turn starting
switch ON.
1 NO
Is voltage
between E03, E04
(female) (1) and
chassis normal?
• 20 – 30 V
• Disconnect E03
and E04. NO
• Directional lever:
Neutral
• Turn starting
switch to START.
NO
20-468 WA700-3
(10)
Troubleshooting E-1
Cause Remedy
Defective contact or
disconnection in cable Repair or
between battery relay replace
and starting motor
Defective battery relay,
or defective contact of Repair or
wiring harness between replace
battery and battery relay
Defective contact or
Repair or
disconnection in starting
replace
motor ground cable
Go to A on next page
WA700-3 20-469
(10)
Troubleshooting E-1
YES
YES
11
Is voltage
YES between L57 13 YES
9 (female) (5) and Is voltage between
Does starting chassis normal? YES starting switch
From A 12 terminal C and
motor rotate • 20 – 30 V chassis normal?
when neutral • Disconnect L57. Is voltage between
relay is replaced? • Turn starting starting switch • 20 – 30 V NO
• Replace neutral switch to START.NO terminal B and • Turn starting
chassis normal? switch to START.
relay (L57) with
stop lamp relay • 20 – 30 V
(L53). • Turn starting NO
• Directional lever: switch OFF.
Neutral
• Turn starting 16 YES
switch to START. 10
Is voltage
Is voltage YES between L04 (3)
between L57
and chassis
NO (female) (1) and normal?
(2) normal?
• 20 – 30 V NO
• Disconnect L57. • Connect T-
15
• Directional lever: adapter to L04.
Neutral Is voltage
YES between L04 • Directional lever: 18 YES
• Turn starting N
switch to START. (female) (1) and Is voltages between
• Turn starting YES battery relay
chassis normal?
switch ON. terminal M and
• 20 – 30 V chassis normal?
• Disconnect L04.
• Turn starting 17 • 20 – 30 V NO
switch ON. Does battery • Turn starting
relay make sound switch ON.
NO of actuation? YES
14
• Turn starting 19
Is resistance switch ON io Is voltage between both
between L57 OFF. connection terminals
NO (female) (2) and A02 and A03 and
chassis normal? connection terminals
NO A04 and A05 of battery
• Max. 1 z relay normal?
• Turn starting • 20 – 30 V
switch OFF. • Turn starting
• Disconnect L57. switch ON.
NO
NO
20-470 WA700-3
(10)
Troubleshooting E-1
Cause Remedy
WA700-3 20-471
(10)
Troubleshooting E-1
20-472 WA700-3
(10)
Troubleshooting E-2
Water
Normal condition
abnormal
Lighted off Lighted up Lighted off
condition
APS water temprature sensor goes ON at below 20ºC and goes OFF at above 20ºC.
LED No. Color of LED Abnormal condition When normal When abnormal
1 Red Short circuit to GND in glow plug 1 circuit Q (Lighted off) q (Lighted up)
2 Green Bad contact in glow plug 1 circuit q (Lighted up) Q (Lighted off)
3 Red Short circuit to GND in glow plug 2 circuit Q (Lighted off) q (Lighted up)
4 Green Bad contact in glow plug 2 circuit q (Lighted up) Q (Lighted off)
5 Red Short circuit to GND in nozzle circuit Q (Lighted off) q (Lighted up)
6 Green Bad contact in glow nozzle circuit q (Lighted up) Q (Lighted off)
20-474 WA700-3
(10)
Troubleshooting E-2
WA700-3 20-475
(10)
Troubleshooting E-2
a) When preheating switch is turned AUTO, preheating lamp does not light up, but no pilot LED on APS
controller lights up.
a Check for power supply circuit.
a Check whether engine cranking is possible or not. In case cranking is impossible, check for E-1 then check
for E-4.
a Check whether fuse 9 is blown or not. If fuse 9 is blown, check for short circuit to GND in fuse 9 related circuit.
a When carrying out troubleshooting, turn preheating switch AUTO.
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance bet-
YES ween L71 (female) Defective contact or disco-
(1) and chassis nnection in wiring harness
ground normal? between L71 (female) (1), Repair or
• Max. 1 z NO CL1 (12) and chassis replace
• Turn starting ground
1
switch OFF. Defective contact or disco-
Is voltage between • Disconnect L71. 4 YES nnection in wiring harness Repair or
L72 (female) (1)
and chassis Is resistance between L74 (female) (4) replace
ground normal? YES between L74 and L72 (female) (1)
3 (male) (3) and (4)
• 20 – 30 V Defective preheater
normal?
• Turn starting Is voltage between switch Replace
switch ON. L74 (female) (3) • Max. 1 z NO
• Disconnect L72. NO and chassis • Turn starting Defective contact or disco-
ground normal? switch OFF. nnection in wiring harness
• Disconnect L74. between L74 (female) (3),
• 20 – 30 V Repair or
FS6 (3) and fuse II (9)
• Turn starting NO replace
switch ON.
• Disconnect L74.
20-476 WA700-3
(10)
Troubleshooting E-2
b) When preheating switch is turned AUTO and engine water temperature is below 20ºC, preheating
lamp flashes, but pilot LED on APS controller shows normal
a Check APS water temperature switch circuit.
a Check engine water temperature.
Cause Remedy
4 YES Replace
Defective APS controller
Is resistance
YES between L74
3 (male) (1) and (2)
Is resistance normal? Defective preheater
YES between L74 Replace
• Min. 1 z NO switch
(female) (1) and (2) • Turn starting
2 normal? Short circuit between L74
switch OFF. (female) (1) and L71
Is resistance bet- • Disconnect L74.
YES ween L74 (female) • Min. 1 z (female) (2) or between L74 Repair or
• Turn starting NO (female) (2) and chassis replace
(2) and chassis
switch OFF. ground
1 ground normal?
• Disconnect L74, Defective contact or
Is resistance • Turn starting L71 and E08. disconnection or short
between E08 switch OFF. circuit with chassis ground
Repair or
(male) and chassis • Disconnect L71 NO in wiring harness between replace
ground normal? and L74 L71 (female) (2), LR4 (2),
• Resistance must be ER1 (8) and E08 (female)
• Turn starting
the same as Section 1. Defective APS water
switch OFF. Replace
• Disconnect E08. NO temperature sensor
• When water temperature
is below 20 C: Max. 1 z
• When water temperature
is above 20 C: Min. 1 z
WA700-3 20-477
(10)
Troubleshooting E-2
c) After preheating, fuel is not injected from APS nozzle when starting switch is turned START, but pilot
LED on APS controller shows normal
a Check starting switch circuit.
Cause Remedy
20-478 WA700-3
(10)
Troubleshooting E-2
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance bet-
YES ween L72 (female)
1 (2) and chassis Short circuit with chassis
Is resistance ground normal? ground in harness between Repair or
between terminal of
glow plug 1 and • 0.8 – 1.3 z NO L72 (female) (2) and replace
chassis ground • Turn starting terminal glow plug 1
normal? switch OFF.
• 0.8 – 1.3 z • Disconnect L72.
Defective glow plug 1 Replace
• Turn starting NO
switch OFF.
• Disconnect plug
terminal.
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance bet-
YES ween L72 (female)
1 (2) and chassis Short circuit with chassis
Is resistance ground normal? ground in harness between Repair or
between terminal of
glow plug 1 and • 0.8 – 1.3 z NO L72 (female) (2) and replace
chassis ground • Turn starting terminal glow plug 1
normal? switch OFF.
• 0.8 – 1.3 z • Disconnect L72.
Defective glow plug 1 Replace
• Turn starting NO
switch OFF.
• Disconnect plug
terminal.
WA700-3 20-479
(10)
Troubleshooting E-2
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance bet-
YES ween L72 (female)
1 (3) and chassis Short circuit with chassis
Is resistance ground normal? ground in harness between Repair or
between terminal of
glow plug 2 and • 0.8 – 1.3 z NO L72 (female) (3) and replace
chassis ground • Turn starting terminal glow plug 2
normal? switch OFF.
• 0.8 – 1.3 z • Disconnect L72.
Defective glow plug 2 Replace
• Turn starting NO
switch OFF.
• Disconnect plug 2.
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance bet-
YES ween L72 (female)
1 (3) and chassis Short circuit with chassis
Is resistance ground normal? ground in harness between Repair or
between terminal of
glow plug 2 and • 0.8 – 1.3 z NO L72 (female) (3) and replace
chassis ground • Turn starting terminal glow plug 2
normal? switch OFF.
• 0.8 – 1.3 z • Disconnect L72.
Defective glow plug 2 Replace
• Turn starting NO
switch OFF.
• Disconnect plug
terminal.
20-480 WA700-3
(10)
Troubleshooting E-2
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance bet-
YES ween L72 (female)
1 (4) and chassis Short circuit with chassis
Is resistance ground normal? ground in harness Repair or
between each
nozzle terminal and • 1.5 – 2.5 z NO between L72 (female) (4) replace
chassis ground • Turn starting and each nozzle terminal
normal? switch OFF.
• 3– 5 z • Disconnect L72. Nozzle having improper
Replace
• Turn starting NO resistance
switch OFF.
• Disconnect nozzle
terminal.
Cause Remedy
2 YES Replace
Defective APS controller
Is resistance bet-
YES ween L72 (female)
1 (4) and chassis Short circuit with chassis
Is resistance ground normal? ground in harness Repair or
between each
nozzle terminal and • 1.5 – 2.5 z NO between L72 (female) (4) replace
chassis ground • Turn starting and each nozzle terminal
normal? switch OFF.
•3–5z • Disconnect L72. Nozzle having improper
Replace
• Turn starting NO resistance
switch OFF.
• Disconnect nozzle
terminal.
WA700-3 20-481
(10)
Troubleshooting E-2
Cause Remedy
20-482 WA700-3
(10)
Troubleshooting E-3
a When carrying out troubleshooting of the brake system, stop the machine on flat ground.
a Before disconnecting or connecting connectors, always turn starting switch OFF.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
b) Parking brake has no effect and does not work as emergency brake when parking brake pressure
drops
Cause Remedy
WA700-3 20-483
(10)
Troubleshooting E-4
a When carrying out troubleshooting of the brake system, stop the machine on flat ground.
a Before disconnecting or connecting connectors, always turn starting switch OFF.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
2 YES
Is resistance
YES between F11
(female) (2) and
chassis normal?
• Max. 1 z NO
• Turn starting
switch OFF.
YES
1
Is voltage between
4
F11 (female) (1)
Does condition YES
and chassis
normal? YES become normal
when parking brake
• 20 – 30 V safety relay is
• Start engine. replaced?
(Charge brake oil • Replace parking
pressure) brake safety relay
(L59) with stop
lamp relay (L53).
• Start engine.
(Charge brake oil
3 pressure)
5
Is continuity of Does condition
L01 (male) become normal
NO (1)(2)(3) as shown when C07 and C08
in Table 1? NO are connected to
short connector?
• Turn starting
• Connect short
switch OFF.
connector to C07 YES
• Operate parking
(female) and C08
brake switch
(female). 7
ON/OFF.
• Start engine.
• Disconnect L01. Is resistance
(Charge brake oil
pressure) YES between L59
(female) (1) and (3)
6 normal?
NO
Table 1)
Operation Between L01 (2) – (3) Between L01 (1) – (3)
ON (Parking) Min. 1 Mz Max. 1 z
OFF (Travel) Max. 1 z Min. 1 Mz
20-484 WA700-3
(10)
Troubleshooting E-4
Cause Remedy
Defective emergency
Replace
brake switch
WA700-3 20-485
(10)
Troubleshooting E-5, E6
Cause Remedy
E-6 Transmission does not change to neutral when parking brake is applied, but
parking brake works normally
Cause Remedy
20-486 WA700-3
(10)
Troubleshooting E-3, E-4, E-5, E-6
WA700-3 20-487
(10)
Troubleshooting E-7
Perform tester check of the transmission solenoid Table 1 Normal operation table of transmission
control circuit according to the following procedure. Pin No.
T01
FR lever
(F) Go to
Table 2.
1. Install a T-adopter (or socket adopter) to trans- Reverse
(R)
Q q Q
mission connector T01, then check the voltage
1st q Q Q Q Q
between the pins in Table 1 and chassis ground.
4th Q Q Q q Q
3. Turn the parking brake switch ON, then OFF Q: 0 – 0.5V (Continuity)
(release) again. q: 20 – 30V (Battery voltage)
4. If required, press the right-hand foot brake Table 2 Result of check during operation of
directional lever
pedal.
a If the left-hand brake pedal is pressed, the Trouble-
Check result Cause
shooting
transmiss ion is cut off and cannot be
Defective transmission cut-off
checked. q [Battery volt- switch, parking brake or neu- Go to E-7-a).
age] is zero. tralizer relay circuit
5. Check the voltage and continuity according to
Table 1. Then, go to the troubleshooting shown Q There is not Defective circuit on forward
[continuity] Go to E-7-b).
in the right columns of Table 2 and Table 3 side.
(Forward side).
according to the inspection result shown in
those tables.
Q There is not Defective circuit on reverse
[continuity] Go to E-7-c).
side.
(Reverse side).
WA700-3 20-489
(10)
Troubleshooting E-7
a) Abnormality in parking brake circuit, transmission cut-off switch circuit or neutralizer relay circuit
3 YES
Is resistance
YES between L12
(male) (1) and (2)
normal?
• Max. 1 z NO
2 • Turn starting
Does condition
switch OFF.
YES become normal • Disconnect L12.
when transmission YES
cut-off selector
switch to turn OFF?
• Start engine.
4
Does condition YES
become normal
when replacing
NO neutralizer relay is
replaced?
• Replace neutralizer YES
relay (L58) with stop 5
lamp relay (L53). Does condition 7
• Start engine. become normal
1 when parking brake Is voltage between
NO safety relay is YES L58 (fremale) (1)
Is resistance bet-
replaced? and chassis
ween L04 (female)
• Replace parking ground normal?
(10) and chassis
ground normal? brake relay (L59) • 20 – 30 V
with stop lamp 6
• Max. 1 z • Turn starting
relay (L53). Is resistance of L01 switch ON.
• Turn starting
• Start engine. (male) (1), (2) and • Disconnect L58.
switch OFF. NO
• Disconnect L04. NO (3) conformed to • Turn on parking
Table 1? brake switch, then
• Turn starting release it.
switch OFF.
• Disconnect L01.
NO
NO
Table 1)
Operation Terminals (1) – (3) Terminals (1) – (3)
ON (Parking) Max. 1 z Min. 1 z
OFF (Travel) Min. 1 z Max. 1 z
20-490 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
WA700-3 20-491
(10)
Troubleshooting E-7
20-492 WA700-3
(10)
Troubleshooting E-7
2 YES
Is resistance bet-
YES ween T01 (female)
(A) and chassis
ground normal?
• Max. 1 z NO
1 • Turn starting
Is voltage between switch OFF.
T01 (female) (D) • Disconnect T01.
YES
and chassis
ground normal?
• 20 – 30 V
• Turn starting 3 YES
switch ON. Does condition 5
• Disconnect T01. become normal
• Release parking NO when relay is Is voltage between
brake (Turn switch YES L66 (female) (5)
replaced?
and chassis 6 YES
ON, then OFF).
• Replace forward ground normal?
• Set directional Is voltage between
relay (L66) with 4 • 20 – 30 V L04 (female) (1)
lever to FORWARD.
reverse relay (L67).
Is resistance bet- • Turn starting NO and chassis
• Start engine. switch ON. ground normal?
ween L66 (female)
• Release parking NO • Disconnect L66.
(6) and chassis • 20 – 30 V NO
brake. ground normal? • Set directional
• Set directional lever • Turn starting
lever to FORWARD.
to FORWARD. • Max. 1 z switch OFF.
• Turn starting • Disconnect L04.
switch OFF.
NO
• Disconnect L66.
20-494 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
Defective forward
Replace
solenoid
See E-7-a). —
WA700-3 20-495
(10)
Troubleshooting E-7
2 YES
Is resistance bet-
YES ween T01 (female)
(A) and chassis
ground normal?
• Max. 1 z NO
1 • Turn starting
Is voltage between switch OFF.
T01 (female) (C) • Disconnect T01.
YES
and chassis
ground normal?
• 20 – 30 V
• Turn starting 3 YES
switch ON. Does condition 5
• Disconnect T01. become normal
• Release parking NO when relay is Is voltage between
brake (Turn switch YES L67 (female) (5)
replaced?
and chassis 6 YES
ON, then OFF).
• Replace reverse ground normal?
• Set directional Is voltage between
relay (L67) with 4 • 20 – 30 V L04 (female) (1)
lever to REVERSE.
forward relay (L66).
Is resistance bet- • Turn starting NO and chassis
• Start engine. switch ON. ground normal?
ween L67 (female)
• Release parking NO • Disconnect L67.
(6) and chassis • 20 – 30 V NO
brake. ground normal? • Set directional
• Set directional lever • Turn starting
lever to REVERSE.
to REVERSE. • Max. 1 z switch OFF.
• Turn starting • Disconnect L04.
switch OFF.
NO
• Disconnect L67.
20-496 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
Defective reverse
Replace
solenoid
See E-7-a). —
WA700-3 20-497
(10)
Troubleshooting E-7
YES
6
Is resistance bet-
YES ween L04 (male)
(2) and chassis
5 ground normal?
Is resistance bet- • Min. 1 Mz
YES ween L04 (male) • Turn starting NO
(2) and (4), (5), (6), switch OFF.
(7), (8) normal? • Disconnect L04.
4
Is resistance bet- • Min. 1 Mz
YES ween TL1 (male) • Turn starting
(5) and chassis switch OFF. NO
ground normal? • Disconnect L04.
3
• Set directional lever
Is resistance bet- • Min. 1 Mz
to N or F.
YES ween TL1 (female) • Turn starting
(5) and (1), (2), (3), switch OFF. NO
(4), (6), (7) normal? • Disconnect TL1,
2 L04 and L66.
Is resistance bet- • Min. 1 Mz
YES ween T01 (female) • Turn starting
1 (D) and connector switch OFF. NO
Is resistance bet- body normal? • Disconnect T01
ween T01 (male) (D) and TL1.
and chassis ground • Min. 1 Mz
normal? • Turn starting
Is resistance NO
between (A), (B), (C), switch OFF.
(E), (F), (G), (H) and • Disconnect T01
chassis ground and TL1.
normal?
• Min. 1 Mz
NO
• Turn starting
switch OFF.
• Disconnect T01.
20-498 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
WA700-3 20-499
(10)
Troubleshooting E-7
YES
6
Is resistance bet-
YES ween L04 (male)
(4) and chassis
5 ground normal?
Is resistance bet- • Min. 1 Mz
YES ween L04 (male) • Turn starting NO
(4) and (2), (5), (6), switch OFF.
(7), (8) normal? • Disconnect L04.
4
Is resistance bet- • Min. 1 Mz
YES ween TL1 (male) • Turn starting
(6) and chassis switch OFF. NO
ground normal? • Disconnect L04.
3
• Set directional lever
Is resistance bet- • Min. 1 Mz
to N or F.
YES ween TL1 (female) • Turn starting
(6) and (1), (2), (3), switch OFF. NO
(4), (5), (7) normal? • Disconnect TL1,
2 L04 and L67.
Is resistance bet- • Min. 1 Mz
YES ween T01 (female) • Turn starting
1 (C) and connector switch OFF. NO
Is resistance bet- body normal? • Disconnect T01
ween T01 (male) (c) and TL1.
and chassis ground • Min. 1 Mz
normal? • Turn starting
Is resistance NO
between (A), (B), (D), switch OFF.
(E), (F), (G), (H) and • Disconnect T01
chassis ground and TL1.
normal?
• Min. 1 Mz
NO
• Turn starting
switch OFF.
• Disconnect T01.
20-500 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
WA700-3 20-501
(10)
Troubleshooting E-7
20-502 WA700-3
(10)
Troubleshooting E-7
5 YES
Is voltage between
YES T01 (female) (H)
4 and chassis
ground normal?
Is voltage between
• 20 – 30 V NO
1st L04 (5) and chassis
• Turn starting switch ON.
ground normal?
• Disconnect T01.
• 20 – 30 V • Set gear shift lever to 1st.
• Turn starting NO
switch ON.
• Connect T-adapter to L04.
• Set gear shift lever to 1st.
YES
7
Is voltage between
YES L76 (female) (3)
and chassis
ground normal?
6
• 20 – 30 V
Is voltage between • Turn starting
2nd L04 (6) and chassis switch ON.
ground normal? • Disconnect L76.
Go to defective NO
• Set gear shift
transmission
• 20 – 30 V lever to 2nd.
YES range. • Turn starting
switch ON.
• Disconnect NO
T-adapter to L04.
• Set gear shift
lever to 2nd.
11 YES
Is voltage between
YES T01 (female) (F)
10 and chassis
ground normal?
Is voltage between
L04 (7) and chassis • 20 – 30 V NO
3rd
ground normal? • Turn starting switch ON.
3 • Disconnect T01.
• 20 – 30 V • Set gear shift lever to 3rd.
Is resistance bet-
YES ween T01 (female) • Turn starting NO
(B) and chassis switch ON.
ground normal? • Connect T-adapter
to L04.
• Max. 1 z • Set gear shift
13 YES
• Turn starting lever to 3rd. Is voltage between
switch OFF. YES T01 (female) (E)
• Disconnect T01. 12 and chassis
ground normal?
2 Is voltage between
L04 (8) and chassis • 20 – 30 V NO
Is voltage between 4th
YES L04 (female) (1) ground normal? • Turn starting switch ON.
and chassis • Disconnect T01.
ground normal? • 20 – 30 V • Set gear shift lever to 4th.
• Turn starting NO
• 20 – 30 V switch ON.
• Turn starting • Connect T-adapter to L04.
1 switch ON. • Set gear shift lever to 4th.
Is resistance be- • Disconnect L04.
tween L04 (female) NO
(10) and chassis
ground normal?
• Max. 1 z
• Turn starting NO
switch OFF.
• Disconnect L04.
NO
20-504 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
WA700-3 20-505
(10)
Troubleshooting E-7
20-506 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
YES
To A
4
Is resistance bet- Short circuit with harness
between following couples in
YES ween TL1 (male) harness between TL1 (male)
(1) and (2), (3), (4), (1) and L04 (female) (5); TL1
(5), (6), (7) normal? (male) (2) and L76 (female)
(6), TL1 (male) (3) and L04
3 • Min. 1 Mz (female) (7), TL1 (male) (4) Repair or
Is voltage between • Turn starting NO and L04 (female) (8), TL1 replace
YES TL1 (male) (1) and (male) (5) and L66 (female)
switch OFF. (2), TL1 (male) (6) and L67
chassis ground • Disconnect TL1, L04 (female) (2), TL1 (male) (7)
normal? and L76. and chassis ground
2 • 0 – 0.5V
Short circuit with power
Is resistance • Disconnect TL1, Repair or
source in wiring harness
between T01 L04 and L76.
YES NO bet-ween TL1 (male) (1), replace
(female) (H) and (A), • Turn starting
(B), (C), (D), (E), (F),
L04 (female) (5) and L76
(G) normal?
switch ON. (female) (5)
1
Is resistance • Min. 1 Mz Short circuit with harness
between T01 (male) • Turn starting between T01 (female) (H)
(H) and chassis switch OFF. and TL1 (female) (1) in
ground normal? Repair or
Is resistance • Disconnect T01 harness between T01 replace
NO (female) (A) – (G) and TL1
between (A), (B), (C), and TL1.
(D), (E), (F), (G) and (female) (2) – (7)
chassis ground
normal? Defective insulation
• Min. 1 Mz between T01 (male) (H) and
• Turn starting connector body, or short
circuit of harness and Repair or
switch OFF. replace
• Disconnect T01.
NO chassis ground with T01
(H) in control valve and
defective insulation among
pins of T01
WA700-3 20-507
(10)
Troubleshooting E-7
Cause Remedy
YES
To A
4
Is resistance bet- Short circuit with harness
between following couples in
YES ween TL1 (male) harness between TL1 (male)
(2) and (1), (3), (4), (2) and L76 (female) (6); TL1
(5), (6), (7) normal? (male) (1) and L76 (female)
(5), TL1 (male) (3) and L04
3 • Min. 1 Mz (female) (7), TL1 (male) (4) Repair or
Is voltage between • Turn starting NO and L04 (female) (8), TL1 replace
YES TL1 (male) (2) and (male) (5) and L66 (female)
switch OFF. (2), TL1 (male) (6) and L67
chassis ground • Disconnect TL1, L04 (female) (2), TL1 (male) (7)
normal? and L76. and chassis ground
2 • 0 – 0.5V Short circuit with power
Is resistance • Disconnect TL1 source in wiring harness Repair or
between T01 and L76. between TL1 (male) (2) and
YES NO replace
(female) (G) and (A), • Turn starting L76 (female) (6)
(B), (C), (D), (E), (F),
(H) normal?
switch ON.
1
Is resistance • Min. 1 Mz
Short circuit with harness
between T01 (male) • Turn starting
(G) and chassis between T01 (female) (G)
switch OFF. and TL1 (female) (2) in Repair or
ground normal?
Is resistance • Disconnect T01 harness between T01 replace
NO
between (A), (B), (C), and TL1. (female) (A) – (F), (H) and
(D), (E), (F), (H) and TL1 (female) (1), (3) – (7)
chassis ground
normal? Defective insulation
• Min. 1 Mz between T01 (male) (G) and
connector body, or short
• Turn starting Repair or
circuit of harness and
switch OFF. chassis ground with T01 replace
• Disconnect T01.
NO
(G) in control valve and
defective insulation among
pins of T01
20-508 WA700-3
(10)
Troubleshooting E-7
Cause Remedy
YES
To A
4
Is resistance bet- Short circuit with harness
between following couples in
YES ween TL1 (male) harness between TL1 (male)
(3) and (1), (2), (4), (3) and L04 (female) (7); TL1
(5), (6), (7) normal? (male) (1) and L76 (female)
(5), TL1 (male) (2) and L76
3 • Min. 1 Mz (female) (6), TL1 (male) (4) Repair or
Is voltage between • Turn starting NO and L04 (female) (8), TL1 replace
YES TL1 (male) (3) and (male) (5) and L66 (female)
switch OFF. (2), TL1 (male) (6) and L67
chassis ground • Disconnect TL1, L04 (female) (2), TL1 (male) (7)
normal? and L76. and chassis ground
2 • 0 – 0.5V Short circuit with power
Is resistance • Disconnect TL1, source in wiring harness Repair or
between T01 L04 and L76. between TL1 (male) (3) and
YES NO replace
(female) (F) and (A), • Turn starting L04 (female) (7)
(B), (C), (D), (E), (G),
(H) normal?
switch ON.
1 Short circuit with harness
Is resistance • Min. 1 Mz between T01 (female) (F)
between T01 (male) • Turn starting and TL1 (female) (3) in
(F) and chassis switch OFF. harness between T01
ground normal? Repair or
• Disconnect T01 (female) (A), (B), (C), (D),
Is resistance NO replace
between (A), (B), (C), and TL1. (E), (G), (H) and TL1
(D), (E), (G), (H) and (female) (1), (2), (4), (5), (6),
chassis ground (7)
normal?
• Min. 1 Mz Defective insulation
between T01 (male) (F) and
• Turn starting Repair or
connector body, or short
switch OFF. circuit of harness and replace
• Disconnect T01.
NO
chassis ground with T01 (F)
in control valve and
defective insulation among
pins of T01
WA700-3 20-509
(10)
Troubleshooting E-7
Cause Remedy
YES
To A
4
Is resistance bet- Short circuit with harness
between following couples in
YES ween TL1 (male) harness between TL1 (male)
(4) and (1), (2), (3), (4) and L04 (female) (8); TL1
(5), (6), (7) normal? (male) (1) and L76 (female)
(5), TL1 (male) (2) and L76
3 • Min. 1 Mz (female) (6), TL1 (male) (3) Repair or
Is voltage between • Turn starting NO and L04 (female) (7), TL1 replace
YES TL1 (male) (4) and (male) (5) and L66 (female)
switch OFF. (2), TL1 (male) (6) and L67
chassis ground • Disconnect TL1, L04 (female) (2), TL1 (male) (7)
normal? and L76. and chassis ground
2 • 0 – 0.5V
Short circuit with power
Is resistance • Disconnect TL1, Repair or
source in wiring harness
between T01 L04 and L76.
YES NO between TL1 (male) (4) and replace
(female) (E) and (A), • Turn starting
(B), (C), (D), (F), (G),
L04 (female) (8)
(H) normal?
switch ON.
1 Short circuit with harness
Is resistance • Min. 1 Mz between T01 (female) (E)
between T01 (male) • Turn starting and TL1 (female) (4) in
(E) and chassis switch OFF. harness between T01
ground normal? Repair or
Is resistance • Disconnect T01 (female) (A), (B), (C), (D), replace
NO (F), (G), (H) and TL1 (fe-
between (A), (B), (C), and TL1.
(D), (F), (G), (H) and male) (1), (2), (3), (5), (6), (7)
chassis ground
normal? Defective insulation
• Min. 1 Mz between T01 (male) (E) and
• Turn starting connector body, or short
circuit of harness and Repair or
switch OFF.
NO chassis ground with T01 (E) replace
• Disconnect T01. in control valve and
defective insulation among
pins of T01
20-510 WA700-3
(10)
Troubleshooting E-7
WA700-3 20-511
(10)
Troubleshooting E-8
YES
2 YES
Does condition
YES become normal
when kick-down
relay is replaced? YES
• Replace kick-down
relay (L68) with 3
reverse relay (L67).
Does condition
• Start engine. become normal
NO when forward
relay is replaced?
• Replace forward
relay (L66) with
reverse relay (L67).
• Start engine.
4
Does condition
become normal
when 2nd-1st
1 NO selector relay is
Is resistance replaced?
between L15 • Replace 2nd-1st
(male) (1) and (2) selector relay (L76) YES
normal? with stop lamp
• Max. 1 z relay (L53).
6
• Turn starting • Start engine.
Is resistance bet-
switch OFF. YES ween L15 (female)
• Press kick-down (2) and L68 (female)
switch (L15). (5) normal?
5
Is resistance bet- • Max. 1 z
ween L68 (female) • Turn starting
NO (6) and chassis switch OFF. NO
ground normal? • Disconnect L15
and L68.
• Max. 1 z
• Turn starting
switch OFF. NO
• Disconnect L68.
NO
11 YES
Is resistance bet-
From A ween L76 (female)
(5) and TL1 (male)
(1) normal?
• Max. 1 z NO
• Turn starting switch OFF.
• Disconnect L76 and TL1.
20-512 WA700-3
(10)
Troubleshooting E-8
Cause Remedy
10 YES
To A
Is resistance bet-
YES ween L68 (female)
9 (4) and L76 (female)
Defective contact or disco-
Is voltage between (1) normal? Repair or
nnection in wiring harness
YES L68 (female) (3) • Max. 1 z NO between L68 (female)(4) replace
and chassis • Turn starting and L76 (female) (1)
8 ground normal? switch OFF.
Is voltage between
• 20 – 30V • Disconnect L66 and L76. Defective contact or disco- Repair or
YES L66 (female) (3) nnection in wiring harness
and chassis ground • Turn starting NO between FS2 (female) (8) replace
normal? switch ON. and L68 (female) (3)
7
• Disconnect L68.
Is resistance • 20 – 30V Defective contact or disco-
between L66 • Turn starting nnection in wiring harness Repair or
(female) (4) and L68 switch ON. NO between L76 (female) (3) replace
(female) (1) normal? • Disconnect L66. and L66 (female) (3)
• Set gear shift lever 2nd.
• Max. 1 z Defective contact or disco-
• Turn starting nnection in wiring harness Repair or
switch OFF. NO between L66 (female) (4) replace
• Disconnect L66 and L68 (female) (1)
and L68.
Defective contact or disco-
nnection in wiring harness Repair or
between L15 (female) (2) replace
and L68 (female) (5)
WA700-3 20-513
(10)
Troubleshooting E-8
20-514 WA700-3
(10)
Troubleshooting E-9
Cause Remedy
WA700-3 20-515
(10)
Troubleshooting E-10
Cause Remedy
1
Does condition
2 YES
Kick-down is not Defective forward relay Replace
become normal reset when directio- Does condition
when 2nd-1st YES nal lever is returned become normal
selector relay is from FORWARD to when forward relay
eplaced? NEUTRAL or Short circuit in harness
is replaced? Repair or
• Replace 2nd-1st REVERSE. between L66 (female) (3)
• Replace forward NO replace
selector relay (L76) and (4)
with stop lamp Go to defective relay (L66) with
relay (L53). NO part. reverse relay (L67).
• Start engine. • Start engine. 3 YES
Defective kick-down relay Replace
Kick-down is not Does condition
reset when gear become normal
shift lever is set
NO from 2nd to another when replacing
speed. kick-down relay?
To A
• Replace kick-down NO
relay (L68) with
reverse relay (L67). Short circuit with harness
between L68 (female) (1)
5 YES • Start engine. and L66 (female) (4) in har- Repair or
Is resistance ness between L68 (female) replace
YES between L68 (4) and L76 (female) (1)
4 (female) (1) and (2) Short circuit with harness
normal? between L68 (female) (1) Repair or
Is resistance and L66 (female) (4) in har-
From A between L68 • Min. 1 Mz NO replace
ness between L68 (female)
(female) (3) and (4) • Turn starting (2) and L68 (female) (5)
normal? switch OFF. Short circuit with harness
• Min. 1 z • Disconnect L68. between L68 (female) (3) Repair or
• Turn starting and FS2 (female) (8) in har- replace
NO
ness between L68 (female)
switch OFF. (4) and L76 (female) (1)
• Disconnect L68.
20-516 WA700-3
(10)
Troubleshooting E-10
WA700-3 20-517
(10)
Troubleshooting E-11
Cause Remedy
• Min. 1 Mz
• Turn starting Defective kick-down
switch OFF. Replace
NO switch
• Disconnect L15.
• Do not press kick-down Short circuit with harness
switch. between L68 (female) (3)
5 YES Repair or
and FS2 (female) (8) in har-
Is resistance ness between L68 (female) replace
between L68 (4) and L76 (female) (1)
From A
(female) (1) and (2)
Short circuit with harness
normal? between L68 (female) (1) Repair or
• Min. 1 Mz NO and L15 (female) (1) in har- replace
• Turn starting ness between L68 (female)
(2) and L15 (female) (2)
switch OFF.
• Disconnect L68.
20-518 WA700-3
(10)
Troubleshooting E-11
WA700-3 20-519
(10)
Troubleshooting E-12
a Before carrying out troubleshooting, check that all related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Check that fuse (10) is not blown.
YES
YES
6
Is voltage between
YES F06 (female) (2)
1 and chassis
5 ground normal?
Does condition
become normal Is voltage between • 20 – 30 V
when boom relay YES F06 (female) (1) • Turn starting
with another relay is
NO
and chassis
replaced? switch ON.
4 ground normal?
• Disconnect F06.
• Replace boom relay • 20 – 30 V
Is resistance bet-
(L49) with bucket YES ween F06 (female) • Turn starting
relay (L48). (3) and chassis switch ON. NO
3 ground normal?
Is resistance • Max. 1 z
YES between L16 • Turn starting
(male) (1) and (2) switch OFF. NO
normal? • Disconnect F06.
2
Is voltage between • 19 – 23 z
each two pins of • Disconnect L16.
NO F06 conformed to NO
Table 1?
• See Table 1.
• Turn starting
switch ON. NO
Table 1)
When screw driver is When screw driver is not
approached to proxity switch approached to proxity switch
Between (1) and (2) 20 – 30 V below 3 V
Between (1) and (3) 20 – 30 V 0 – 30 V
Between (2) and (3) below 3 V 20 – 30 V
20-520 WA700-3
(10)
Troubleshooting E-12
Cause Remedy
Defective boom
proximity switch Replace
WA700-3 20-521
(10)
Troubleshooting E-13
a Before carrying out troubleshooting, check that all related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Check that fuse (10) is not blown.
YES
YES
6
Is voltage between
YES F05 (female) (2)
1 and chassis
5 ground normal?
Does condition
become normal Is voltage between • 20 – 30 V
when bucket relay YES F05 (female) (1) • Disconnect F05.
with another relay is
NO
and chassis
replaced? • Turn starting
4 ground normal?
switch ON.
• Replace bucket relay • 20 – 30 V
Is resistance bet-
(L48) with boom YES ween F05 (female) • Turn starting
relay (L49). (3) and chassis switch ON. NO
3 ground normal?
Is resistance • Max. 1 z
YES between L17 • Turn starting
(male) (1) and (2) switch OFF. NO
normal? • Disconnect F05.
2
Is voltage between • 19 – 23 z
each two pins of • Disconnect L17.
NO F05 conformed to NO
Table 1?
• See Table 1.
• Turn starting
switch ON. NO
Table 1)
When screw driver is When screw driver is not
approached to proxity switch approached to proxity switch
Between (1) and (2) 20 – 30 V below 3 V
Between (1) and (3) 20 – 30 V 0 – 30 V
Between (2) and (3) below 3 V 20 – 30 V
20-522 WA700-3
(10)
Troubleshooting E-13
Cause Remedy
Defective bucket
positioner solenoid Replace
Defective bucket
proximity switch Replace
WA700-3 20-523
(10)
Troubleshooting E-14
Cause Remedy
4 YES
Defective relay (L75) Replace
Is resistance
YES between L75 Defective contact or
3 (female) (6) and disconnection in wiring
Is resistance chassis normal? harness between L75 Repair or
YES between PWL2 • Max. 1 z NO (female) (6) – CL1 (12) – replace
(female) and L75 • Turn starting chassis ground
(female) (3) normal? switch OFF.
• Disconnect PWL2 Defective contact or
and L75. disconnection in wiring
• Max. 1 z Repair or
2 harness between PWL2
• Turn starting NO (female) – CL4 (2) – L75 replace
Is voltage switch OFF.
YES between PWL1 (female) (3)
• Disconnect PWL2
and chassis and L75. 6 YES
normal? Defective relay (L70) Replace
Does condition
• 20 – 30 V YES become normal
• Turn starting 5 when relay is
1
switch ON. replaced?
Is resistance
Is there continuity • Left power • Replace L70 (left UP NO Go to A
between PWL1
between PWL1 window switch: (male) and L70 relay) with L80
(female) and PWL2 UP NO (right UP relay).
(female) (3) normal? • Turn starting switch ON. Defective contact or
(male)? • Left power window disconnection in wiring
• Max. 1 z switch: UP harness between PWL1
Repair or
• Turn starting replace
• Turn starting NO (male) – CL4 (1) – L70
switch OFF.
switch OFF. (female) (3)
• Disconnect PWL1
• Disconnect PWL1
and PWL2.
and L70. Defective power window
Replace
NO motor
Defective contact or
disconnection in wiring
YES harness between L70 Repair or
(female) (2) – CL1 (12) – replace
chassis ground
Defective contact or
7 10 YES disconnection in wiring Repair or
Is voltage harness between L41 replace
Is voltage (female) (5) and L70 (female)
From A between L70 YES between L70
(1)
(female) (1) and 9 (female) (5) and
chassis normal? Defective contact or
chassis normal? Is voltage disconnection in wiring Repair or
YES between L41 • 20 – 30 V NO harness between FS8 (male) replace
• 20 – 30 V
(female) (1) and • Disconnect L70. (1) and L70 (female) (5)
• Disconnect L70. 8 chassis normal? • Turn starting
• Turn starting Defective contact or
Is resistance switch ON. disconnection in wiring
switch ON. • 20 – 30 V Repair or
between L41 harness between L41
• Left power • Disconnect L41. NO replace
(male) (1) and (5)
window switch: NO • Turn starting (female) (1) and FS8 (male)
normal? (1)
UP switch ON.
• Max. 1 z
• Turn starting Defective switch (L41) Replace
switch OFF.
NO
• Disconnect L41.
• Left power
window switch:
UP
20-524 WA700-3
(10)
Troubleshooting E-14
Cause Remedy
4 YES
Defective relay (L70) Replace
Is resistance
YES between L75 Defective contact or
3 (female) (6) and disconnection in wiring
chassis normal? harness between L70
Is resistance Repair or
(female) (6) – CL1 (12) –
YES between PWL1 • Max. 1 z NO chassis ground replace
(male) and L70 • Turn starting
(female) (3) switch OFF.
• Disconnect L70 Defective contact or
and L75. disconnection in wiring
• Max. 1 z harness between PWL1 Repair or
2
• Turn starting NO (male) – CL4 (1) – L70 replace
Is voltage switch OFF. (female) (3)
YES between PWL2 • Disconnect PWL1
and chassis and L70. 6 YES
normal? Defective relay (L75) Replace
Does condition
• 20 – 30 V YES become normal
• Turn starting 5 when relay is
1
switch ON. replaced?
Is resistance
Is there continuity • Left power • Replace L75 (left Go to A
between PWL2 NO
between PWL1 window switch: (male) and L75 DOWN relay) with
(female) and PWL2 DOWN NO L77 (right DOWN relay).
(female) (3) normal? • Turn starting switch ON. Defective contact or
(male)? • Left power window disconnection in wiring
• Max. 1 z switch: DOWN harness between PWL2
Repair or
• Turn starting replace
• Turn starting NO (female) – CL4 (2) – L75
switch OFF.
switch OFF. (female) (3)
• Disconnect PWL1
• Disconnect PWL2
and PWL2.
and L75. Defective power window
Replace
NO motor
Defective contact or
disconnection in wiring
YES harness between L75 Repair or
(female) (2) – CL1 (12) – replace
chassis ground
Defective contact or
7 10 YES disconnection in wiring Repair or
Is voltage harness between L41 replace
Is voltage (female) (6) and L75 (female)
From A between L75 YES between L75
(1)
(female) (1) and 9 (female) (5) and
chassis normal? Defective contact or
chassis normal? Is voltage disconnection in wiring Repair or
YES between L41 • 20 – 30 V NO harness between FS8 (male) replace
• 20 – 30 V
(female) (1) and • Disconnect L75. (1) and L75 (female) (5)
• Disconnect L75. 8 chassis normal? • Turn starting
• Turn starting Defective contact or
Is resistance switch ON. disconnection in wiring
switch ON. • 20 – 30 V Repair or
between L41 harness between L41
• Left power • Disconnect L41. NO replace
(male) (1) and (6)
window switch: NO • Turn starting (female) (1) and FS8 (male)
normal? (1)
DOWN switch ON.
• Max. 1 z
• Turn starting Defective switch (L41) Replace
switch OFF.
NO
• Disconnect L41.
• Left power
window switch:
DOWN
WA700-3 20-525
(10)
Troubleshooting E-14
20-526 WA700-3
(10)
Troubleshooting E-15, E-16, E-17, E-18, E-19
a Go to Troubleshooting M-8.
a Go to Troubleshooting M-9.
a Go to Troubleshooting M-10.
a Go to Troubleshooting M-13.
WA700-3 20-527
(10)
Troubleshooting of electric engine throttle
controller & APS controller system system
(G mode)
Serial No.: 50001 – 51000
Judgement table for engine controller and engine related parts ................................................................. 20-552
Action taken by controller and condition of machine when abnormality occurs .......................................... 20-554
Action taken by controller and conditions for resetting when abnormality occurs....................................... 20-560
Points to remember when carrying out troubleshooting of engine controller system.................................. 20-561
Judgement table for engine controller......................................................................................................... 20-563
G-1 [90] [OFF or 10] Abnormality in power source system ...................................................................... 20-564
G-2 [90] [11] Abnormality in controller system.......................................................................................... 20-564
G-3 [90] [21] Mistaken connection of connector ....................................................................................... 20-565
G-4 [90] [56] Abnormality in controller solenoid power source system..................................................... 20-565
G-5 [90] [58] Abnormality in back-up power source system ..................................................................... 20-566
G-6 [90] [59] Abnormality in switch power source system........................................................................ 20-567
G-7 [91] [14] Abnormality in governor solenoid system............................................................................ 20-568
G-8 [91] [16] Abnormality in governor cut relay system ........................................................................... 20-569
G-9 [91] [19] Abnormality in governor servo system ................................................................................ 20-570
G-10 [91] [1d] Abnormality in pre-stroke solenoid system ......................................................................... 20-571
G-11 [92] [12] Abnormality in rack sensor system...................................................................................... 20-572
G-12 [92] [18] Abnormality in rack sensor power source system ............................................................... 20-573
G-13 [93] [1b] Abnormality in engine speed sensor A system ................................................................... 20-574
G-14 [94] [1c] Abnormality in engine speed sensor B system ................................................................... 20-575
G-15 [93,94] [1b, 1c] Abnormality in engine speed sensor A, B system .................................................... 20-576
G-16 [95] [40] Abnormality in water temperature sensor system ............................................................... 20-576
G-17 [97] [31] Abnormality in accelerator sensor system .......................................................................... 20-577
G-18 [99] [22] Engine overrun.................................................................................................................... 20-579
G-19 Engine does not start (controller related only) ................................................................................... 20-579
G-20 Engine does not start ......................................................................................................................... 20-580
G-21 Engine does not stop ......................................................................................................................... 20-583
G-22 Defective actuation of APS ................................................................................................................ 20-584
a) Preheating lamp switch does not light up when APS switch is ON
(all APS controller LEDs are also OFF) ........................................................................................ 20-584
b) Preheating pilot lamp flashes when water temperature is below 20ºC when
APS switch is ON (controller LEDs all give normal display) ......................................................... 20-586
Preheating pilot lamp lights up when water temperature is above 20ºC when
APS switch is ON (controller LEDs all give normal display) ......................................................... 20-586
c) Nozzle does not inject fuel when starting switch is turned to START after completion
of preheating when APS switch is ON (controller LEDs all give normal display).......................... 20-586
d) APS controller LED 1 (short circuit in glow plug 1 system) gives abnormal display .................... 20-587
e) APS controller LED 2 (disconnection in glow plug 1 system) gives abnormal display................. 20-587
f) APS controller LED 3 (short circuit in glow plug 2 system) gives abnormal display ..................... 20-588
g) APS controller LED 4 (disconnection in glow plug 2 system) gives abnormal display................. 20-588
h) APS controller LED 5 (short circuit with ground in nozzle) gives abnormal display..................... 20-589
i) APS controller LED 6 (disconnection in nozzle) gives abnormal display ...................................... 20-589
WA700-3 20-551
(10)
Troubleshooting Judgement table for engine controller and engine related parts
Error code
Engine speed does not (1) Does not reach high idling
change to high idling (2) Reaches high idling but returns to low idling
Defective automatic warming-up operation
(1) Engine continues to run at high speed
Engine does not stop Engine continues to run at low idling even when start-
(2)
ing switch is turned OFF
(1) Engine rotation is unstable at low idling
There is hunting of engine
(2) Engine rotation is unstable at high idling
High oil consumption, or exhaust smoke is blue
Oil becomes dirty quickly
Oil in cooling water
Oil pressure lamp lights up
Oil level rises
Water temperature rises too high (overheating)
Abnormal noise is generated
Excessive vibration
Troubleshooting code when abnormality display is given G-1 G-2 G-3 G-4 G-5 G-6
q: Check the error code display. If there is no display, go to the right side; if there is a display, go to the bottom.
20-552 WA700-3
(10)
Troubleshooting Judgement table for engine controller and engine related parts
Engine overrun
93
91 91 91 91 92 92 93 94 95 97 99
94
1b
14 16 19 1d 12 18 1b 1c 40 31 22
1c
q q q q q q See engine shop manual
q q q q q
See engine shop manual
G-17
q q –
q G-17
G-21
WA700-3 20-553
(10)
Troubleshooting Action taken by controller and condition of machine when abnormality occurs
Main Engine
System with
monitor controller Nature of abnormality
abnormality
error code error code
1) Back–up power voltage has dropped more than 5V from switch power
voltage.
Abnormality in
2) Short circuit with ground, defective contact or disconnection in wiring
controller back-up
90 58 harness between fuse box – controller EC1 (7)
power source
3) Defective contact or disconnection in wiring harness between controller
system
EC1 (16) – chassis ground
4) Defective engine controller
1) Switch power voltage has dropped more than 5V from back–up power
voltage.
Abnormality in
2) Short circuit with ground, defective contact or disconnection in wiring
controller switch
90 59 harness between fuse box – controller EC1 (9)(17)
power source
3) Defective contact or disconnection in wiring harness between controller
system
EC1 (8)(16) – chassis ground
4) Defective engine controller
20-554 WA700-3
(10)
Troubleshooting Action taken by controller and condition of machine when abnormality occurs
Condition when
Action by controller when Problem that appears on machine
normal (voltage,
abnormality is detected when there is abnormality
current, resistance)
• Voltage between 1) Normal control (when 1) When traveling: same condition is maintained.
EC5A (1) – chassis: operating). 2) When starting: engine cannot be started.
Less than 0.5V 2) Stops engine (when engine is
started).
WA700-3 20-555
(10)
Troubleshooting Action taken by controller and condition of machine when abnormality occurs
Main Engine
System with
monitor controller Nature of abnormality
abnormality
error code error code
20-556 WA700-3
(10)
Troubleshooting Action taken by controller and condition of machine when abnormality occurs
Condition when
Action by controller when Problem that appears on machine
normal (voltage,
abnormality is detected when there is abnormality
current, resistance)
• Solenoid resistance 1) Sets output to prestroke 1) Feels that there is lack of power during operation.
value: 10 – 21 z control solenoid to 0. 2) Engine does not pick up smoothly.
2) Operates with restricted 3) Amount of black smoke increases.
output 4) Starting performance is poor.
• Voltage between 1) Operates under open control. 1) Feels that there is lack of power during operation.
EC3A (7) – (17): 0.1 – (limits output) 2) Engine does not pick up smoothly.
4.5V 3) Starting performance is poor.
• Voltage between EC2 1) Operates under open control. 1) Feels that there is lack of power during operation.
(16) – chassis: 4.6 – (limits output) 2) Engine does not pick up smoothly.
5.4V 3) Starting performance is poor.
WA700-3 20-557
(10)
Troubleshooting Action taken by controller and condition of machine when abnormality occurs
Main Engine
System with
monitor controller Nature of abnormality
abnormality
error code error code
99 22 Engine overrun
20-558 WA700-3
(10)
Troubleshooting Action taken by controller and condition of machine when abnormality occurs
Condition when
Action by controller when Problem that appears on machine
normal (voltage,
abnormality is detected when there is abnormality
current, resistance)
• Sensor resistance 1) Operates with restricted 1)Feels that there is lack of power during operation.
value: 500 – 1000 z output. 2)Engine does not pick up smoothly.
3) Engine stops during operation and cannot be started
again.
• Sensor resistance 1) Operates with restricted 1)Feels that there is lack of power during operation.
value: 500 – 1000 z output. 2)Engine does not pick up smoothly.
3)Engine stops during operation and cannot be started
again.
• Resistance value 1) Operates under normal 1)Does not carry out warming-up operation.
between EC3B (9) – control. 2)Does not stop warming-up operation.
EC3A (16): Below
several z or infinity is a If the abnormality is restored
abnormal by the vibration of the
machine, it resets
automatically.
WA700-3 20-559
(10)
Troubleshooting Action taken by controller and conditions for resetting when abnormality occurs
20-560 WA700-3
(10)
Troubleshooting Points to remember when carrying out troubleshooting of engine controller system
WA700-3 20-561
(10)
Troubleshooting Points to remember when carrying out troubleshooting of engine controller system
4. Controller
1. Case Outline
2. Self-diagnostic display window • This receives the signals from the accelerator
3. Printboard sensor, low idling selector switch, and other sen-
sors and switches mounted on the machine. It
then outputs the signals to control the fuel injec-
tion pump for the engine.
The controller has a self-diagnostic function. If
there is any abnormality, it sends the ON/OFF
signal to the main monitor and displays charac-
ters on the built-in segments.
20-562 WA700-3
(10)
Troubleshooting Judgement table for engine controller
G-7 [91] Displays abnormality in governor and [14] Abnormality in governor solenoid system
pre-stroke control system
G-8 [16] Abnormality in governor cut relay syst
G-11 [92] Displays abnormality in rack sensor [12] Abnormality in rack sensor system
system
G-12 [18] Abnormality in rack sensor power source system
G-13 [93] Displays abnormality in engine speed [1b] Abnormality in engine speed sensor A system
sensor A system
G-14 [94] Displays abnormality in engine speed [1c] Abnormality in engine speed sensor B system
sensor B system
G-15 [93,94] Displays abnormality in engine speed [1b,1c] Abnormality in engine speed sensor A, B system
sensor A, B system
G-16 [95] Displays abnormality in engine water [40] Abnormality in engine water temperature sensor
temperature sensor system system
G-17 [97] Displays abnormality in accelerator [31] Abnormality in accelerator sensor signal system
sensor system
G-18 [99] Displays engine overrun [22] Engine overrun
WA700-3 20-563
(10)
Troubleshooting G-1, G-2
Cause Remedy
1 YES
Defective controller Replace
Is voltage
between EC1 (9)
– (8), EC1 (17) – Check wiring harness.
(16) normal? For details, see section —
• 20 – 30 V NO on abnormality in power
• Turn starting source.
switch ON.
20-564 WA700-3
(10)
Troubleshooting G-3, G-4
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
Cause Remedy
1 YES
Defective controller Replace
Is voltage
between EC5A (1)
and GND less Defective contact or
than 0.5 V? Repair or
disconnection in wiring
replace wiring
• Turn starting NO harness between EC5A
harness
switch ON. (female) (1) and GND
• Disconnect
CN5A.
• Check that CN3A
(1) is OPEN
(wiring harness is
not connected).
WA700-3 20-565
(10)
Troubleshooting G-5
Cause Remedy
YES
Defective controller Replace
1
Defective contact or
Is voltage disconnection in wiring
between EC1 (7) YES harness between CNFS2 Repair or
and EC1 (16) (female) (11) – EC1 (female)
(7) or EC1 (female) (16) – replace
normal? 2
battery terminal (– )
• 20 – 30 V Is voltage Defective contact or
• Turn starting between CNFS2 YES disconnection in wiring
Repair or
switch ON. NO (female) (11) and harness between CNFS2
3 (male) (11) and CNFS3 replace
chassis normal?
Is voltage (female) (6)
• 20 – 30 V Defective contact or
between CNFS3
• Turn starting
NO (male) (6) and 4 YES disconnection in wiring Repair or
switch ON. harness between CNLR5
chassis normal? Is voltage (male) (1) and battery replace
• 20 – 30 V between CNLR5 terminal (+)
• Turn starting NO (male) (1) and Defective contact or
switch ON. chassis normal? disconnection in wiring Repair or
• 20 – 30 V NO harness between EC1 replace
• Turn starting (female) (16) and battery
switch ON. terminal (– )
20-566 WA700-3
(10)
Troubleshooting G-6
Cause Remedy
YES
Defective controller Replace
1
Defective contact or
Is voltage
disconnection in wiring
between EC1 (9) harness between CNFS7
YES Repair or
– (8), EC1 (17) – (female) (1) – EC1 (female)
(16) normal? 2 (9), (17) or EC1 (female) (8), replace
s voltage (16) – battery terminal (– )
• 20 – 30 V between CNFS7 Defective contact or
• Turn starting disconnection in wiring
switch ON. NO (female) (1) and 3 YES
harness between CNFS7 Repair or
chassis normal?
Is voltage (male) (1) and CNL09 replace
• 20 – 30 V between CNL09 (female) (5)
• Turn starting NO (male) (5) and Defective contact or
switch ON. chassis normal? disconnection in wiring
harness between CNL09 Replace
• 20 – 30 V NO (male) (5) – starting switch –
• Turn starting battery terminal (+)
switch ON.
WA700-3 20-567
(10)
Troubleshooting G-7
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective controller Replace
3
Is resistance Short circuit with chassis
between EC2 ground in wiring harness
YES (female) (4), (7) –
chassis and EC2 between EC2 (female) (4), (7)
4 YES – CNE15 (female) (2), CNE12 Repair or
(female) (15), (17) –
chassis normal? Is resistance replace
between CNE12 (female) (2) or EC2 (female)
2 • Min. 1 Mz (male) (1) – chassis (15), (17) – CNE15 (female)
(1), CNE12 (female) (1)
Is resistance • Turn starting NO and CNE12 (male)
(2) – chassis
YES between EC2 switch OFF. normal? Defective governor
Replace
(female) (4), (7) – • Disconnect EC2. • Min. 1 Mz NO solenoid
• Turn starting switch OFF. Defective governor solenoid
(15), (17) normal? • Disconnect CNE12 and Defective contact or
CNE15. disconnection in wiring
• 10 – 21 z harness between EC2
1 5 YES
• Turn starting (female) (4), (7) – CNE15 Repair or
switch OFF. Is resistance (female) (2), CNE12 (female) replace
Is voltage between (2) or EC2 (female) (15), (17) –
EC1 (4) – chassis, • Disconnect EC2. between CNE12 CNE15 (female) (1), CNE12
between EC2 (1) NO (male) (1) and (2) (female) (1)
and chassis normal? normal?
Defective governor
• 10 – 21 z NO solenoid Replace
• 20 – 30 V
• Turn starting • Turn starting
switch ON. switch OFF.
• Disconnect CNE15 and CNE12.
Go to G-8 —
NO
Engine controller
Between CNE2 (female) – chassis
Min. 1 Mz
Between CNE2 (female) (2) – chassis
20-568 WA700-3
(10)
Troubleshooting G-8
Cause Remedy
WA700-3 20-569
(10)
Troubleshooting G-9
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
Cause Remedy
20-570 WA700-3
(10)
Troubleshooting G-10
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
Cause Remedy
WA700-3 20-571
(10)
Troubleshooting G-11
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective controller Replace
2 Defective contact or
disconnection in wiring
YES Is voltage harness between EC3A
between EC3A (7) YES Repair or
and (17) normal? (female) (7) – CNE14
3 replace
(female) (3) or between
Is voltage EC3A (female) (17) –
• 0.1 – 4.5 V
between CNE14 CNE14 (female) (4)
1 • Turn starting
NO (3) and (4) 4 YES Replace
switch ON. Defective rack sensor
Is voltage normal? Is resistance
between EC2 (16) between CNE14 Short circuit with chassis
• 0.1 – 4.5 V
and EC3A (14) ground in wiring harness
• Turn starting NO (female) (2) – (3),
normal? (2) – (4) normal? between EC3A (female)
switch ON. Repair or
• 4.6 – 5.4 V (7) – CNE14 (female) (3)
• Disconnect EC3A. • 50 kz – 1 Mz NO or between EC3A replace
• Turn starting • Turn starting switch OFF.
switch ON. • Disconnect CNE14 (female) (17) – CNE14
and EC3A. (female) (4)
Go to G-12 —
NO
20-572 WA700-3
(10)
Troubleshooting G-12
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
Cause Remedy
3 YES
Defective rack sensor Replace
Is voltage
YES between CNE14
2 (female) (1) and Defective wiring harness
(2) normal? between EC2 (female)
Is voltage Repair or
(16) – CNE14 (female) (1)
YES between EC2 • 4.6 – 5.4 V NO replace
or EC3A (female) (14) –
(male) (16) and • Turn starting
CNE14 (female) (2)
GND normal? switch ON.
1
• 4.6 – 5.4 V Defective controller Replace
Is resistance
between EC2
• Turn starting NO
(female) (16) and switch ON. Defective wiring harness
EC3A (female) (14) • Disconnect EC2 and connect T-adapter to between EC2 (female)
normal? male end only. 4 YES (16) – CNE14 (female) (1) Repair or
• Min. 500 kz Is resistance and between EC1 replace
• Turn starting between CNE14 (female) (8) – CNE14
switch OFF. (female) (2)
NO (male) (1) and (2)
• Disconnect EC2 normal?
and EC3A. Defective rack sensor Replace
• Min. 500 kz NO
• Turn starting
switch OFF.
• Disconnect
CNE14.
WA700-3 20-573
(10)
Troubleshooting G-13
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
Cause Remedy
20-574 WA700-3
(10)
Troubleshooting G-14
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
Cause Remedy
WA700-3 20-575
(10)
Troubleshooting G-15, G-16
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective controller Replace
1
Is resistance Short circuit,
between EC3B disconnection between
(female) (9) and EC3B (female) (9) –
2 YES Repair or
EC3A (female) (16)
CNE11 (female) (1) or replace
normal? Is resistance
between EC3A (female)
• Abnormal if between CNE11
(16) – CNE11 (female) (2)
resistance is NO (male) (1) and (2)
below several z normal? Defective water
or infinity. Replace
• Abnormal if NO temperature sensor
• Turn starting resistance is
switch OFF. below several z
• Disconnect EC3A or infinity.
and EC3B. • Turn starting
switch OFF.
• Disconnect
CNE11.
20-576 WA700-3
(10)
Troubleshooting G-17
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective controller Replace
2
Does voltage
between EC3B (11)
YES and EC3A (16) change
according to angle of 3 YES Adjust (see
accelerator pedal as Defective adjustment of
shown in Fig. 1? In Item 2, does TESTING AND
accelerator sensor
voltage change ADJUSTING)
• Turn starting
1
switch ON. NO but is outside
Is voltage • Operate specified value?
between EC3A (6) accelerator Go to A
NO
and EC3A (16) pedal.
normal?
• 4.6 – 5.4 V YES
• Turn starting Defective controller Replace
8
switch ON. Is resistance Short circuit in wiring
between EC3A harness between EC3A
(female) (6) – (16), (female) (6) – CNL13
NO (6) – chassis 9 YES Repair or
(female) (3) (5V), CNL13 (1)
normal? Is resistance between replace
accelerator sensor (male) (GND) – EC3A (female)
• Between (6) – (16): (5V) and (GND) and (16), contact with other
4.6 – 5.4 kz resistance between wiring harness
NO accelerator sensor (male)
Between (6) – (5V) and chassis normal? Defective accelerator Replace
chassis: Min. 1 Mz • Between (5V) – NO sensor
• Turn starting (GND): 4.6 – 5.4 kz
switch OFF. Between (5V) –
• Disconnect EC3A. chassis: Min. 1 Mz
• Turn starting
switch OFF.
Defective contact or
• Disconnect sensor.
disconnection in wiring
YES harness between EC3B Repair or
(female) (11) and CNL13 replace
(female) (Sig)
5 Defective contact or
Does voltage between
accelerator sensor (Sig) 7 YES disconnection in wiring Repair or
YES and (GND) change Does resistance between harness between EC3B
according to angle of replace
accelerator sensor (Sig) (female) (11) and CNL13
accelerator pedal as YES and (GND) change (female) (Sig)
shown in Fig. 1? according to angle of
6
• Turn starting accelerator pedal as Disconnected accelerator
4 Is resistance shown in Fig. 2? Repair or
switch ON. sensor linkage or replace
between accelerator • Turn starting NO defective sensor
Is voltage between • Operate
From A accelerator sensor sensor (5V) – (GND) switch OFF.
accelerator NO
normal? • Disconnect
(5V) – (GND) pedal.
normal? • 4.6 – 5.4 kz sensor Defective accelerator
Replace
• 4.6 – 5.4 V • Turn starting NO sensor
• Turn starting switch OFF.
Defective contact or
switch ON. • Disconnect
disconnection in wiring
sensor. harness between EC3A Repair or
NO (female) (6) – CNL13 replace
(female) (3) (5V), CNL13 (1)
(GND) – EC3A (female) (16)
WA700-3 20-577
(10)
Troubleshooting G-17
20-578 WA700-3
(10)
Troubleshooting G-18, G-19
Cause Remedy
Carry out
Problem probably caused troubleshooting
1 YES
by abnormality that of abnormality
Did any other occurred at same time that occurred at
abnormality same time
occur at same Problem probably caused
time? by external abnormality Look for other
NO and not by electric cause
engine throttle controller
Cause Remedy
Carry out
Problem probably
YES troubleshooting
caused by abnormality of displayed
1 that is displayed abnormality
Is there any
abnormality
2 YES See Engine
display? See Engine shop manual
Is resistance shop manual
between EC5B (4) Defective fuel cut switch Repair or
NO and EC1 (16) or APS assister or relay replace
normal? Short circuit in wiring Repair or
• Min. 1 Mz NO harness between EC5B replace
• Turn starting (4) – relay – APS assister
switch ON. – fuel cut switch
WA700-3 20-579
(10)
Troubleshooting G-20
a Check that the fuse is not blown. (If it is blown, check for a short circuit with the ground in the circuit related
to the fuse.)
a Check that the wiring harness between battery relay terminal B – battery (+) – battery (–) – chassis is
connected securely.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
4 YES
Is voltage between
YES starting motor
terminal B and
chassis ground
normal?
• Turn starting NO
switch ON.
3 • 20 – 30 V
Is there sound of YES
YES 6
starting motor
pinion engaging? Is voltage between
YES starting motor
• Turn starting terminal R and
7 YES
chassis ground
switch ON io
normal? Is voltage between
START alternator terminal
5 • Turn starting
switch ON. R and chassis
Is voltage between NO
ground normal?
starting motor • Max. 1 V
terminal C and • Disconnect wiring. NO
NO chassis ground • Turn starting switch
2 normal? ON.
• Max. 1 V
Is sound of • Turn starting 8 YES
YES actuation heard switch to START. Is resistance
from battery • 20 – 30 V between starting
relay? switch terminal B
NO and terminal C
• Turn starting normal?
switch OFF io • Turn starting NO
ON switch to START.
• Disconnect CNL09.
• Max. 1 z
10 YES
Is resistance
YES between battery
relay terminal E and
chassis ground
1 9 normal?
Is voltage between • Turn starting NO
Are voltage and battery relay switch OFF.
specific gravity of terminal BR and • Max. 1 z
battery normal? NO chassis ground YES
normal?
11
• Turn starting • Turn starting
Is voltage between
switch OFF. switch ON. starting switch
• Voltage: Min. 24V • 20 – 30 V terminal BR and
• Specific gravity: NO chassis ground
12 YES
Min. 1.26 normal? Is resistance
between starting
• Turn starting
switch terminal B
switch ON. NO and terminal BR
• 20 – 30 V normal?
• Turn starting NO
switch to START.
• Disconnect CNL09.
• Max. 1 z
NO
20-580 WA700-3
(10)
Troubleshooting G-20
Cause Remedy
Defective contact or
disconnection in wiring
harness between starting Repair or
motor terminal B and replace
battery relay terminal
Defective contact or
disconnection in wiring
harness between starting Repair or
switch terminal C and replace
starting motor terminal C
Defective contact or
disconnection in wiring
harness between battery Repair or
relay terminal E and chassis replace
ground
Defective contact or
disconnection in wiring
harness between starting Repair or
switch terminal BR and replace
battery relay terminal BR
Defective contact or
disconnection in wiring Repair or
harness between starting replace
switch terminal B and
battery relay terminal B
Charge or
Lack of battery capacity replace
WA700-3 20-581
(10)
Troubleshooting G-20
20-582 WA700-3
(10)
Troubleshooting G-21
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
Cause Remedy
WA700-3 20-583
(10)
Troubleshooting G-22
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on the next step.
a) Preheating lamp switch does not light up when APS switch is ON (all APS controller LEDs are also
OFF)
a Carry out troubleshooting of the power system.
a Check that the engine can be cranked (if the engine cannot be cranked, carry out troubleshooting G-19 and
G-20 first).
a Check that the fuse is normal. (If it is blown, check for a short circuit with the ground in the related circuits
for the fuse).
a Carry out troubleshooting with the APS switch ON.
2 YES
Is resistance
YES between CNL71
(female) (1) and
chassis ground
normal?
• Turn starting NO
switch OFF.
1 • Disconnect
Is voltage CNL71. YES
between CNL72 • Max. 1 z
(1) and chassis
ground normal?
• Turn starting YES
switch ON. 6
• 20 – 30 V Is voltage
3
When No-injection YES between CNL82
cranking (CNL82) is (3) and chassis 7 YES
interchanged with ground normal?
other relay, does 5 Is there continuity
NO voltage in Item 1 • Turn starting between starting
become normal? Is there continuity
YES between CNL82 switch ON. NO switch terminals B
• Turn starting • 20 – 30 V and ACC?
switch ON. (female) (2) and
• 20 – 30 V chassis ground? • Turn starting NO
switch OFF.
• Turn starting
4 switch OFF.
• Disconnect
Is voltage NO
CNL82.
between CNL82
NO (1) and chassis
ground normal?
9 YES
• Turn starting
switch ON. Is there continuity
YES
• 20 – 30 V between CNL09
8 (male) (3) and (4)?
Is voltage between
CNL09 (female) (3) • Turn starting NO
NO and chassis switch OFF.
ground normal? • Disconnect CNL09.
• Turn starting . Turn heater switch ON.
switch ON. NO
• 20 – 30 V
20-584 WA700-3
(10)
Troubleshooting G-22
Cause Remedy
Defective contact or
disconnection in wiring
harness between CNL71 Repair or
(female) (1) and chassis replace
ground
Defective No-injection
cranking relay for APS Replace
controller
Defective contact,
disconnection, or short
circuit with chassis ground in Repair or
wiring harness between replace
CNL82 (female) (6) and
CNEC5B (female) (4)
Defective contact,
disconnection, or short Repair or
circuit with chassis ground in
wiring harness between
replace
starting switch terminal ACC
and CNL82 (female) (3)
Defective starting switch Replace
Defective contact or
disconnection in wiring
harness between CNL82 Repair or
(female) (2) and chassis replace
ground
Defective contact or
disconnection in wiring Repair or
harness between CNL09 replace
(female) (2) – CNL82
(female) (2)
Defective contact or
disconnection in wiring Repair or
harness between fuse replace
and CNL09 (female) (3)
WA700-3 20-585
(10)
Troubleshooting G-22
b) Preheating pilot lamp flashes when water temperature is below 20ºC when APS switch is ON (con-
troller LEDs all give normal display)
Preheating pilot lamp lights up when water temperature is above 20ºC when APS switch is ON (con-
troller LEDs all give normal display)
a Carry out troubleshooting of the APS water temperature sensor system.
a Check the engine water temperature.
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance
YES between CNL71 Defective contact,
(female) (2) and disconnection, or short
1 chassis ground
circuit with chassis
Is resistance normal? Repair or
ground in wiring harness
between CNE08 • Turn starting NO replace
(male) and chassis between CNL71 (female)
switch OFF.
ground normal? (2) and CNE08 (female)
• Disconnect CNL71.
• Turn starting • Same as Item 1. Defective APS water
Replace
switch OFF. NO temperature senso
• Disconnect
CNE08.
• Water temperature
below 20 C:
Max. 1z
• Water temperature
above 20 C:
Min. 1 Mz
c) Nozzle does not inject fuel when starting switch is turned to START after completion of preheating
when APS switch is ON (controller LEDs all give normal display)
a Carry out troubleshooting of the starting motor signal (terminal C) system.
a Check that the injection nozzle stop valve is open.
Cause Remedy
YES
1 Defective APS controller Replace
Is voltage
Defective contact or
between CNL71
disconnection in wiring
(3) and chassis 2 YES Repair or
harness between CNL71
ground normal? Is voltage between replace
starting switch
(female) (3) and starting
• Turn starting terminal C and switch terminal C
switch to NO chassis ground
START. normal?
Defective starting switch Replace
• 20 – 30 V • Turn starting NO
switch ON.
• 20 – 30 V
20-586 WA700-3
(10)
Troubleshooting G-22
d) APS controller LED 1 (short circuit in glow plug 1 system) gives abnormal display
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance
YES between CNL72
(female) (2) and Short circuit with chassis
1 chassis ground
Is resistance
ground in wiring harness
normal? between CNL72 (female) Repair or
between glow plug
• Turn starting NO (2) and glow plug 1 replace
1 terminal and
chassis ground switch OFF. terminal
normal? • Disconnect CNL72.
• Turn starting • 0.8 – 1.3 z
Defective glow plug 1 Replace
switch OFF. NO
• Disconnect plug
terminal.
• 0.8 – 1.3 z
e) APS controller LED 2 (disconnection in glow plug 1 system) gives abnormal display
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance
YES between CNL72
(female) (2) and Defective contact or
1 chassis ground
Is resistance
disconnection in wiring
normal? harness between CNL72 Repair or
between glow plug
• Turn starting NO (female) (2) and glow replace
1 terminal and
chassis ground switch OFF. plug 1 terminal
normal? • Disconnect CNL72.
• Turn starting • 0.8 – 1.3 z
Defective glow plug 1 Replace
switch OFF. NO
• Disconnect plug
terminal.
• 0.8 – 1.3 z
WA700-3 20-587
(10)
Troubleshooting G-22
f) APS controller LED 3 (short circuit in glow plug 2 system) gives abnormal display
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance
YES between CNL72
(female) (3) and Short circuit with chassis
1 chassis ground
Is resistance
ground in wiring harness
normal? between CNL72 (female) Repair or
between glow plug
• Turn starting NO (3) and glow plug 2 replace
2 terminal and
chassis ground switch OFF. terminal
normal? • Disconnect CNL72.
• Turn starting • 0.8 – 1.3 z
Defective glow plug 2 Replace
switch OFF. NO
• Disconnect plug
terminal.
• 0.8 – 1.3 z
g) APS controller LED 4 (disconnection in glow plug 2 system) gives abnormal display
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance
YES between CNL72
(female) (3) and Defective contact or
1 chassis ground
Is resistance
disconnection in wiring
normal? harness between CNL72 Repair or
between glow plug
• Turn starting NO (female) (3) and glow replace
2 terminal and
chassis ground switch OFF. plug 2
normal? • Disconnect CNL72.
• Turn starting • 0.8 – 1.3 z
Defective glow plug 2 Replace
switch OFF. NO
• Disconnect plug
terminal.
• 0.8 – 1.3 z
20-588 WA700-3
(10)
Troubleshooting G-22
h) APS controller LED 5 (short circuit with ground in nozzle) gives abnormal display
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance
YES between CNL72
(female) (4) and
1 chassis ground Short circuit with chassis
Is resistance normal? ground in wiring harness Repair or
between each • Turn starting NO between CNL72 (female) replace
nozzle and chassis switch OFF. (4) and each nozzle
ground normal? • Disconnect CNL72.
• Turn starting • 1.5 – 2.5 z Defective nozzle (nozzle
Replace
switch OFF. NO with defective resistance)
• Disconnect
nozzle terminal.
•3– 5z
Cause Remedy
2 YES
Defective APS controller Replace
Is resistance
YES between CNL72
(female) (4) and Defective contact or
1 chassis ground
disconnection in wiring
Is resistance normal? Repair or
harness between CNL72
between each • Turn starting NO replace
(female) (4) and each
nozzle and chassis switch OFF. nozzle
ground normal? • Disconnect CNL72.
• Turn starting • 1.5 – 2.5 z Defective nozzle (nozzle
Replace
switch OFF. NO with defective resistance)
• Disconnect
nozzle terminal.
•3– 5z
WA700-3 20-589
(10)
Troubleshooting G-22
20-590 WA700-3
(10)
Troubleshooting of hydraulic and
mechanical system (H mode)
Method of using matrix troubleshooting tables............................................................................................ 20-604
H-1 Machine does not start ....................................................................................................................... 20-606
H-2 Machine lacks power or speed when traveling (all speed ranges) ..................................................... 20-607
H-3 Time lag is excessive when starting or shifting gear .......................................................................... 20-608
H-4 Torque converter oil temperature is high ............................................................................................ 20-609
H-5 Steering does not turn ........................................................................................................................ 20-610
Steering wheel specification
H-6 Steering does not turn ........................................................................................................................ 20- 611
Steering wheel and joystick steering specification
H-7 Steering does not turn ........................................................................................................................ 20-612
AJSS (Advanced Joystick steering system) specification
H-8 Turning, response of steering is poor ................................................................................................. 20-613
Steering wheel specification
H-9 Turning, response of steering is poor ................................................................................................. 20-614
Steering wheel and joystick steering specification
H-10 Turning, response of steering is poor................................................................................................. 20-616
AJSS (Advanced Joystick steering system) specification
H-11 Steering is heavy ................................................................................................................................ 20-617
Steering wheel specification
H-12 Joystick lever is heavy ....................................................................................................................... 20-617
Steering wheel and joystick steering specification
H-13 Joystick lever is heavy ....................................................................................................................... 20-618
AJSS (Advanced Joystick steering system) specification
H-14 Steering wheel shakes or jerks .......................................................................................................... 20-619
Steering wheel specification
H-15 Steering shakes or there is excessive shock ..................................................................................... 20-620
Steering wheel and joystick steering specification
H-16 Steering wheel shakes or jerks .......................................................................................................... 20-621
AJSS (Advanced Joystick steering system) specification
H-17 Minimum turning radii to right and left are different ............................................................................ 20-622
Steering wheel specification, Steerig wheel and joystick steering specification
H-18 Minimum turning radii to right and left are different ............................................................................ 20-622
AJSS (Advanced Joystick steering system) specification
H-19 Wheel brakes do not work or braking effect is poor ........................................................................... 20-624
H-20 Wheel brakes are not released or brakes drag .................................................................................. 20-626
H-21 Parking brake does not work or braking effect is poor ....................................................................... 20-627
H-22 Parking brake is not released or brake drags .................................................................................... 20-628
WA700-3 20-601
(10)
H-23 Neither boom nor bucket move .......................................................................................................... 20-629
H-24 Both boom and bucket are slow or lack power................................................................................... 20-630
H-25 Boom does not move ......................................................................................................................... 20-631
H-26 Boom is slow or boom lacks power .................................................................................................... 20-632
H-27 Boom cannot be set to FLOAT or cannot be released from FLOAT................................................... 20-633
H-28 Boom drops momentarily when control lever is operated from HOLD to RAISE................................ 20-633
H-29 Excessive hydraulic drift of boom ....................................................................................................... 20-634
H-30 Bucket does not move........................................................................................................................ 20-635
H-31 Bucket is slow or lacks power ............................................................................................................ 20-636
H-32 Excessive hydraulic drift of bucket ..................................................................................................... 20-637
20-602 WA700-3
(10)
Troubleshooting Method of using matrix troubleshooting tables
Step 1. Questioning the operator 1. Steering does not work i Symptom [Example]
The questions to ask the operator are given
Ask the operator about the following points.
below the failure symptom. If the answers to the
• Did the steering suddenly stop working o
questions match the information given, follow Breakage in steering equipment
the arrow to reach the probable cause of the fail- • Had the steering gradually been becoming heavy?
ure. o Internal wear of steering equipment, defective
Consider the contents of the questions and con- seal
sult the table while proceeding to Steps 2 and 3
to grasp the true cause.
Checks before starting [Example]
Step 2. Checks before troubleshooting • Is the oil level in the hydraulic tank correct?
Before starting the main troubleshooting and • Is the type of oil correct?
measuring the hydraulic pressure, first check • Is there any leakage of oil from the steering valve
the Checks before Starting items, and check for or Orbit-roll?
oil leakage and loose bolts. These checks may • Has the safety bar been removed from the frame?
avoid time wasted on unnecessary trouble-
shooting.
The items given under Checks before Starting
[Example 1]
are items which must be considered particularly
for that symptom before starting troubleshoot- Remedy
No. Problems
ing.
1 Steering does not work to the left or right.
Step 3. Using cross-reference table Same as item 1, but abnormality in actuation of
1) Operate the machine to carry out the checks 2 work equipment
in the troubleshooting item column.
3 Steering can only be operated to one side.
Mark the items where the results match the
symptom. 4 Steering wheel is heavy and cannot be turned.
a It is not necessary to follow the
troubleshooting checks in order; follow
an order which is easiest to carry out
troubleshooting.
[Example 2]
2) Find the appropriate cause from the cause
column. If the symptom appears, the Q
marks on that line indicate the possible
ses
20-604 WA700-3
(10)
Troubleshooting Method of using matrix troubleshooting tables
ses
appears, mark that item. (In the chart on the
Cau
right, the symptom appears again for item a b c d e
5). Remedy
C A
Problems
4) Find the appropriate cause from the cause
1
column. In the same way as in Step 2), if the
symptom appears, the Q marks on that line 2
indicate the possible causes. (For item No. 3
5 in the table on the right, the possible 4
causes are b or e.) 5
Applicable troubleshooting item located in Step 3).
5) Narrow down the possible causes.
Applicable troubleshooting item located in Step 1).
There is one common cause among the
causes located in Steps 2) and 4). (One
cause marked Q appears on the line for Ignore these causes
ses
both items.) This cause is common to both
Cau
the symptoms in troubleshooting Steps 1)
and 3). a b c d e Common causes
a The causes which are not common to Remedy
both troubleshooting items (items which C A
Problems
are not marked Q for both symptoms) 1
are unlikely causes, so ignore them. 2
(In the example given on the right, the
3
causes for Troubleshooting Item 2 are c
or e, and the cause for Troubleshooting 4
Item 5 are b or e, so cause e is common 5
to both.)
remains.
a b c d e
a If the causes cannot be narrowed down
to one cause, narrow the causes down Remedy Action to take
C A
as far as possible. Problems
1
7) Remedy 2
If the causes are narrowed down to one 3
common cause, take the aciton given in the
4
remedy column.
5
The symbols given in the remedy column
indicate the following:
X: Replace, E: Repair, A; Adjust, C: Clean
WA700-3 20-605
(10)
Troubleshooting H-1
Power train
H-1 Machine does not start
Ask the operator the following questions
• Did the problem suddenly happen?
Yes = Internal seizure, damage
• When this happened, was there any abnormal
noise?
ring
Yes = Broken part
e sp
roov ng valv
Checks before troubleshooting
valv alve
ss)
uit
it
• Is the oil level in the transmission case correct?
ircu
circ
htne
i
• Is the monitor display correct?
duc
utch n of pil pool
ch c
lief
e
h
• Is the drive shaft broken?
il tig
ot re
lutc
n re
clut
,s
g, g
alve
o
ed c
lief
mai
ses
issio ) speed
e
ump
l rin
v
g re
ng v
spe
t i
of m ulating
Cau
alve
lve
e
a
latin
of p
tio
(def
e
3rd)
i
rd
t
id va
s
a
oid v
pera
sion
n
l
n (3
odu
u
side
tch
(
od
ch
leno
n
f mo
n
ve o
ng i
m
mis
n cl
u
clut
e
g
ion
nsm
l
c
n
of so
n of
s
on o
al ri
al ri
rans
issio
eed
ecti
suct
sion
f
ion
ation
ation
ft se
ft se
f
) sp
de t
i
e
nsm
erat
erat
mis
mp
n, d
n at
ope
(3rd
a
sha
i
oper
oper
e pu
s
e op
e op
e tra
rans
e sh
atio
ed i
e in
e in
e
e
ctive
ctiv
ctiv
suck
ctiv
ctiv
rior
ctiv
ctiv
ctiv
ed t
ctiv
kag
kag
Defe
Defe
Defe
Defe
Dete
Defe
Defe
Defe
Defe
Brea
Brea
Defe
Defe
Seiz
Air
Tank – Torque
Pump Transmission converter
a b c d e f g h i j k l m n o
Remedy A
No.
Problems
1 Abnormal noise comes from between pump and filter
2 Machine does not start in any speed range (Item 1 normal)
3 Machine starts normally in certain speed range
4 When torque converter oil temperature rises, machine stops moving
5 Transmission relief pressure is low
6 Low at every speed range
Transmission
7 modulation Becomes lower at certain speed range
8 pressure is low Indicator is unstable and fluctuates excesively
9 Lack of pilot pressure (Items 5 – 8 are normal)
10 Torque converter relief valve pressure is low (Items 5 – 9 are normal)
11 Torque converter outlet port pressure is low (Items 5 – 9 are normal)
20-606 WA700-3
(10)
Troubleshooting H-2
H-2 Machine lacks power or speed when traveling (all speed ranges)
Checks before troubleshooting
• Is the oil level in the transmission case correct?
ug)
• Is there any external oil leakage from the piping
ring
e pl
or valve joints?
d sp
loos
• Is there any dragging of the parking brake or
rate
ng,
ng
service brake?
erio
al ri
spri
roke
g va
v
ve v
ecti
• Engine high idling speed
et b
a
n
ief v
relie
f
• Torque converter stall speed
e
t
dula
er (d
r re l
• Machine travel speed
ain
rbin
f mo
vert
erte
• Transmission clutch (both high pressure and
ses
nm
p
r (tu
pum
con
o
onv
low pressure)
Cau
ssio
ion
erte
rque
• Pump outlet port pressure
tran e
ue c
f
erat
smi
o
in
lve
onv
side
e to
torq
n
g va
e op
of e
ue c
ion
d
n
v
n of
n of
s i
i
nce
i
c
torq
t
suct
e in
efec
edu
o
o
rma
i
i
akag
t
erat
mp
side
lot r
pera
n, d
n at
erfo
e pu
e op
e
atio
ed i
e pi
e in
o
ve l
p
e
ctiv
ctiv
suck
ctiv
rior
ctiv
kag
p in
essi
Defe
Defe
Defe
Dete
Defe
Brea
Dro
Exc
Air
Tank – En- Torque
Pump gine converter
a b c d e f g h i
Remedy A
No.
Problems
1 Abnormal noise comes from between pump and filter
2 Torque converter stall speed is low
3 Torque converter stall speed is high
4 Transmission main relief valve pressure is low
5 Transmission Low at every speed range (Item 2 abnormal)
modulation
6 pressure is low Indicator is unstable and fluctuate excessively
7 Pressure in pilot reducing pressure circuit is low (Items 4 – 6 are normal)
8 Torque converter relief valve pressure is low (Items 4 – 7 are normal)
9 Torque converter outlet port pressure is low (Items 4 – 7 are normal)
10 Pieces of iron and aluminium stuck to strainer os transmission case
11 When oil temperature rises, modulating pressure drops
WA700-3 20-607
(10)
Troubleshooting H-3
ng
spri
lve
g va
latin
ve
l
uit
s)
o o
groo
nes
circ
e sp
odu
ve
ight
utch
valv
l
ng,
of m
a
ses
v
ump
oil t
al ri
n
d cl
n
Cau
etur
tion
r
of p
tive
retu
e
pee
s
ick r
pera
utch
efec
in s
side
c k
u
i
o
u
in q
n cl
h (d
ring
q
e
ion
ctiv
f
ssio
on o
lutc
ole
suct
eal
defe
tle h
smi
c
i
aft s
erat
mp
eed
n at
ion,
tran
t
e pu
thro
e op
e sh
e sp
ed i
a t
e
rior
ctiv
ctiv
suck
ctiv
ctiv
ctiv
ked
Dete
Defe
Defe
Defe
Defe
Defe
Bloc
Air
Tank –
pump Transmission
a b c d e f g h
Remedy
No.
Problems
1 Abnormal noise comes from between pump and filter
2 There is time lag when transmission is placed in any speed range
3 Machine starts normally in certain speed range
4 Transmission modulating pressure is low ehn placed in any speed range
5 In Item 4, indicator is unstable and fluctuates excessively
6 Torque converter oil temperature goes above operating range
20-608 WA700-3
(10)
Troubleshooting H-4
)
• Does oil temperature go up when torque convert-
bine
er is stalled and go down when torque converter
r
in tu
is not stalled?
crack
Yes = Normal (incorrect selection of speed
mp (
range)
g, pu
lu
Checks before troubleshooting
ose p
alve
• Is oil level in transmission case correct?
g), lo
ief v
• Is filter clogged?
a l ri n
r rel
ve se
Checking for abnormalities
erte
ses
ump
a If oil temperature is normal but oil temperature
fecti
onv
Cau
of p
gauge on machine goes above operating range -
r (de
ue c
> defective oil temperature gauge
verte
ide
torq
s
e con
ion
n of
suct
orqu
ratio
p
ide t
n at
pum
ope
e ins
ed i
e
e
ctiv
suck
akag
ctiv
Defe
Defe
Oil le
Air
Tank – Trans-
pump mission
a b c d
Remedy
No.
Problems
1 Pump makes abnormal noise when oil temperature is low
2 High idling and low idling speeds are low
3 Transmission modulating pressure is low
4 Torque converter inlet port oil pressure is low
5 Torque converter outlet port oil pressure is low
WA700-3 20-609
(10)
Troubleshooting H-5
ses
l
ool
frame?
mp
p oo
Cau
g sp
h pu
nd s
e
erin
v
witc
ema
a l
e
on v
f ste
v
nd s
of d
v va
ucti
o
seal
mp
lve
ng a
ion
relie
ion
ll
ty-s
t-ro
C pu
ston
op v
tuat
tuat
eeri
PPC
safe
Defe ve orbi
e PP
e ac
e ac
e st
e pi
e st
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC Orbit- Stop
Hydraulic relief Steering Cylin-
pump valve roll valve valve der
a b c d e f g h i
Remedy
No.
Problems
1 Steering wheel does not turn in both directions (left and right)
2 Steering wheel turns in one direction (left or right)
3 Steering wheel 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 zero in both directions
8 When steering (left and right)
relief pressure
is measured Oil pressure is low or zero in one direction
9
(left or right)
10 Measured Orbit-roll output pressure is low or zero
11 When PPC valve (Orbit-roll) Oil pressure is low
12 basic pressure is measured Oil pressure is zero
a There is 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.
20-610 WA700-3
(10)
Troubleshooting H-6
e
valv
• Is the stop valve stopper properly adjusted?
• Has the safety bar been removed from the
oid
ses
mp
l
ool
poo
frame?
olen
Cau
f pu
g sp
e
• Is the operation of the steering and the steering
s
valv
ck s
alve
d
alve
nd o
man
erin
mode switch correct?
ysti
ston trictor v
top
on v
l ve
f ste
on e
f de
of jo
of s
f va
ucti
o
o
ucti
seal
p
pum
s
ion
n
n
tion
oll
relie
y re
atio
atio
ty-s
at s
bit-r
tuat
Defe e actua
Defe e 2-wa
suck TO
PPC
actu
actu
safe
C
r
d in
filte
e PP
e Or
e ac
e pi
eP
e
e
e
e
e
ctiv
ged
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Clog
Defe
Defe
Defe
Defe
Defe
Air
a b c d e f g h i j k l m
Remedy C
No.
Problems
1 When steering Steering does not move (steering wheel mode only)
2 mode switch Steering does not move (joystick mode only)
3 is switched Steering does not move in either mode
4 Steering wheel does not turn in both directions (left and right)
5 Steering wheel turns only in one direction (left or right)
6 Steering wheel is heavy in both directions (left and right)
7 Steering wheel is heavy in one direction (left or right)
8 Work equipment moves
9 Work equipment does not move
10 Abnormal noise comes from around PTO
11 Abnormal noise comes from around PPC pump or hydraulic tank
Oil pressure is low, or there is no pressure
12 When steering in both directions (left and right)
relief pressure
is measured Oil pressure is low, or there is no pressure
13
in one direction (left or right)
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.
WA700-3 20-611
(10)
Troubleshooting H-7
l
ol
poo
p
• Is steering valve open?
ses
spo
pum
nd s
Cau
ing
e
itch
valv
ema
teer
d sw
tio n
of d
of s
e
n
seal
valv
mp
-suc
ng a
ion
ion
C pu
ston
tuat
tuat
ary
fety
eeri
t
e PP
e ac
e ac
e sa
e ro
e pi
e st
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Hydraulic Rotary Cylin-
pump valve Steering valve der
a b c d e f g
Remedy
No. Problems
1 Steering wheel does not turn in both directions (left and right)
2 Steering wheel turns only in one direction (left or right)
3 Joystick lever is heavy in both directions (left and right)
4 Work equipment moves
5 Work equipment does not move
6 Abnormal noise comes from around PTO
7 Abnormal noise comes from around PPC pump or hydraulic tank
a There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality
is felt in the steering, check the operation of the work equipment also.
20-612 WA700-3
(10)
Troubleshooting H-8
ses
mp
ol
poo
spo
Cau
f pu
e
nd s
valv
ring
nd o
lve
ema
stop
n va
e
e
stee
valv
valv
on e
mp
of d
ump
ctio
n of
n of
u
i
seal
liefe
p
lief
suct
ng p
pum
ion
y-su
ll
ch p
atio
atio
n re
t-ro
C re
ston
tuat
n at
eeri
Defe e safet
suck TO
u
PPC
actu
swit
orbi
mai
t
e PP
e ac
e ac
e pi
ed i
e st
eP
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
a b c d e f g h i j k l m
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 Steering wheel is heavy in both directions (left and right)
4 Steering wheel is heavy in one direction (left or right)
5 Work equipment moves normally
6 Work equipment speed is low
7 Abnormal noise comes from around PTO
8 Abnormal noise comes from around steering pump or hydraulic tank
9 Abnormal noise comes from around switch pump or hydraulic tank
Oil pressure is low or zero in both directions
10 When steering (left and right)
relief pressure
is measured Oil pressure is low or zero in one direction
11 (left or right)
12 Measured Orbit-roll output pressure is low
13 Measured PPC valve (Orbit-roll) basic pressure is low
a There is 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.
WA700-3 20-613
(10)
Troubleshooting H-9
e
valv
• Is the oil level in the hydraulic tank correct? Is the
type of oil correct?
oid
ses
l
poo
olen
pum
Cau
lve
s
ck s
d of
and
p va
ysti
dem
lve
n en
f sto
mp
valv
of jo
f va
ump
o
n of
g pu
o
i
p
suct
relie
lief
pum
ion
n
l
ch p
atio
atio
it-ro
n
C re
tuat
n at
eeri
ain
suck TO
PPC
actu
swit
actu
ilter
Orb
e PP
e ac
em
ed i
e st
eP
f
e
e
e
e
ged
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Clog
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
a b c d e f g h i j k l
Remedy C
No.
Problems
1 When steering Abnormality only in steering wheel mode
2 mode switch is Abnormality only in joystick mode
3 switched Abnormality in both modes
4 Turning, response of steering is poor in both directions (left and right)
5 Turning, response of steering is poor in one direction (left or right)
6 Steering wheel is heavy in both directions (left and right)
7 Steering wheel is heavy in one direction (left or right)
8 Work equipment moves
9 Work equipment does not move
10 Abnormal noise comes from around PTO
11 Abnormal noise comes from around steering pump or hydraulic tank
12 Abnormal noise comes from around switch pump or hydraulic tank
13 When steering Oil pressure is low in both directions (left and right)
relief pressure
14 is measured Oil pressure is low in one direction (left or right)
15 When Orbit-roll output pressure is measured, oil pressure is found to be low
When joystick solenoid valve output pressure is measured,
16 oil pressure is found to be low
When PPC valve (Orbit-roll) basic pressure is measured,
17 oil pressure is found to be low
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.
20-614 WA700-3
(10)
valve
Defe
m n
ctiv
Steering
e ac
Defe tuat
WA700-3
ctiv ion
Valve
Defe e sa of s
fety teer
o p
ctiv - ing
der
e suct spo
Cylin-
Defe 2-w i on ol
ay r valv
ctiv
e pi estr
icto e
ston
Troubleshooting
r va
seal lve
(10)
20-615
H-9
Troubleshooting H-10
ses
ool
ol
ump
spo
d sp
Cau
of p
ing
e
man
valv
end
teer
alve
f de
mp
tion
of s
tion
ump
e ac relief v
e
u
o
valv
seal
mp
ng p
-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
e ro
e sa
e St
e pi
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
suck
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
Remedy
No. Problems
1 Turning, response of steering is poor in both directions (left and right)
2 Turning, response of steering is poor in one direction (left or right)
3 Joystick lever is heavy in both directions
4 Joystick lever is heavy in one direction (left or right)
5 Work equipment moves
6 Work equipment also speed is slow
7 Abnormal noise comes from around PTO
8 Abnormal noise comes from around steering pump or hydraulic tank
9 Abnormal noise comes from around switch pump or hydraulic tank
Oil pressure is low or there is no pressure in
10 When steering both directions (left and right)
relief pressure
is measured Oil pressure is low or there is no pressure in
11 one direction (left or right)
a There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality
is felt in the steering, check the operation of the work equipment also.
20-616 WA700-3
(10)
Troubleshooting H-11, H-12
ha f t
• Was there previously any symptom, such as
gs
erin
heavy steering?
ses
whe spool
Yes o Wear of related equipment, defective seal
r ste
Cau
lve
el o
ring
p va
Checks before troubleshooting
stee
f sto
• Is the oil level in the hydraulic tank correct? Is the
ring
n of
type of oil correct?
o
ion
stee
roll
• Is the tire inflation pressure correct?
atio
tuat
Defe e Orbit-
e of
actu
e ac
enc
e
ctiv
ctiv
ctiv
rfer
Defe
Defe
Inte
Orbit- Stop Stee-
ring Others
roll valve valve
a b c d
Remedy
No.
Problems
1 Steering is heavy in both directions (left and right)
2 Steering is heavy in one direction (left or right)
Steering is heavy even when joint between steering shaft and
3
Orbit-roll 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)
6 Measured Orbit-roll output pressure is low
WA700-3 20-617
(10)
Troubleshooting H-13
haft
heavy steering?
ng s
Yes = Wear of related equipment, defective seal
ri
ol
stee
ses
spo
Checks before troubleshooting
r or
Cau
ing
• Is the oil level in the hydraulic tank correct?
leve
teer
Is the type of oil correct?
of s
tick
• Is the tire inflation pressure correct?
e
valv
joys
ion
tuat
tary
e of
e ac
e ro
enc
ctiv
ctiv
rfer
Defe
Defe
Inte
Rotary Steering
valve valve Others
a b c
Remedy
No. Problems
1 Joystick lever is heavy when turned in both directions (left and right)
2 Joystick lever is heavy when turned in one direction (left or right)
4 When steering Oil pressure is low in both directions (left and right)
relief pressure
5 is measured Oil pressure is low in one direction (left or right)
20-618 WA700-3
(10)
Troubleshooting H-14
ses
ool
poo
Cau
g sp
e
nd s
valv
lve
erin
ema
stop
n va
e
e
valv
e
valv
t
of d
of s
ctio
n of
seal
lief
lief
ion
ion
oll
y-su
atio
n re
C re
bit-r
ston
tuat
tuat
Defe e safet
actu
mai
e PP
e Or
e ac
e ac
e pi
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC Orbit- Stop Cylin-
relief
roll valve Steering valve der
valve
a b c d e f g h
Remedy
No.
Problems
1 Steering wheel shakes or jerks in both directions (left and right)
2 Steering wheel shakes or jerks in one direction (left or right)
During operations or when traveling (when steering), steering
3
wheel shakes or jerks in both directions (left and right)
WA700-3 20-619
(10)
Troubleshooting H-15
e
valv
• Is there any abnormality in the connection be-
tween the steering shaft and the Orbit-roll?
noid
ses
l
• Is the tire inflation pressure correct?
poo
on v g spoo
sole
Cau
e
s
valv
lve
d
tick
alve
man
a
i
v
r
joys
top
e
stee
e
r
valv
f de
icto
valv
of s
n of
n of
ucti
o
r
seal
lief
rest
lief
ion
n
oll
atio
atio
s
atio
n re
-
C re
bit-r
ston
tuat
fety
way
actu
actu
actu
mai
e PP
e Or
e sa
e ac
e 2-
e pi
e
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC Orbit- Joy- Stop Cylin-
relief
stick valve
Steering valve Valve
der
valve roll
a b c d e f g h i j
Remedy
No.
Problems
1 When steering Abnormality only in steering wheel mode
2 mode switch is Abnormality only in joystick mode
3 switched Abnormality in both modes
4 Steering wheel shakes or jerks in both directions (left and right)
5 Steering wheel shakes or jerks in one direction (left or right)
During operations or when traveling (when steering), steering
6
wheel shakes or jerks in both directions (left and right)
20-620 WA700-3
(10)
Troubleshooting H-16
l
p oo
poo
ses
nd s
ng s
Cau
e
valv
ema
eeri
lve
t
tion
of d
f va
f s
e
on o
valv
seal
relie
-suc
ion
i
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)
WA700-3 20-621
(10)
Troubleshooting H-17, H-18
20-622 WA700-3
(10)
Troubleshooting H-19
a t or
see TESTING AND ADJUSTING, "Measuring
mul
brake performance"
a ccu
rom
Ask the operator the following questions.
• Did the problem suddenly start?
as f
Yes o Related equipment broken
of g
Was there any abnormal noise when this hap-
ding
pened? Where did the noise come from?
ses
blee
p
• Did the problem gradually appear?
lve
pum
Cau
ton
tive
Yes o Wear of related parts, defective seal
e va
efec
harg
al
n en
e
Checks before troubleshooting
or d
v
alve
n se
br
l
c
r
a
e
r
ke v
o
e
• Is the oil level in the hydraulic tank correct?
just
n of
o
ke v
o
i
eal
p
suct
t
a
pum
s
l
Is the type of oil correct?
t bra
k ad
i
umu
on s
atio
ke p
a
side
ft br
n at
• Is the brake pedal play correct?
suck TO
PPC
actu
c
righ
pist
c
a
e sla
e ac
e br
e in
ed i
e le
• Is there any leakage of oil from the brake tube? eP
e
ctiv
ctiv
ctiv
kag
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Is there any deformation of the tube? Defe
Defe
Defe
Brea
Defe
Defe
Defe
Defe
Defe
Defe
• Are the tire inflation pressure and tread pattern
Air
a b c d e f g h i j k
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 and steering do not work either
9 Movement of work equipment and steering is slow
10 Abnormal noise comes from around PTO
11 Abnormal noise comes from around hydraulic tank or PPC pump
12 Many metal particles are found in oil drained from axle case
13 Measured accumulator charge pressure is low
14 Braking effect is lost immediately after engine is stopped
15 There is time lag before brake takes effect
16 Measured brake oil pressure is low
17 Measured drop in brake piston pressure is excessive
18 Measured wear of brake disc is excessive
19 When air is bled from brake line, air comes out
a The PPC pump is used for the wheel brake actuation pressure in the same way as for the work equipment
circuit and steering circuit, so if any abnormality is felt in the wheel brake, check the condition of actuation of
the work equipment and steering, too (the circuit set pressure is different).
20-624 WA700-3
(10)
Troubleshooting H-19
sc
uit
il
e di
le o
circ
brak
e ax
rake
ctiv
r of
in b
Defe
Wea
Air
Wheel
brake
Others
l m n
WA700-3 20-625
(10)
Troubleshooting H-20
ses
er
ton
Cau
just
, pla ake pis
k ad
e
slac
valv
ve
br
te
e rig ake val
n of
n of
rake
atio
atio
disc
ht b
ft br
actu
Seiz ve actu
rake
e le
ed b
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe
Defe
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, break is released
20-626 WA700-3
(10)
Troubleshooting H-21
ston
e
e pi
ses
valv
brak
Cau
o i d
ing
olen
park
s
ake
ad
g
n of
n
or p
g br
r i
e sp
atio
rkin
disc
actu
brak
e pa
eak
e
e
ctiv
ctiv
n br
ctiv
Defe
Defe
Defe
Wor
SOL Parking brake
a b c d
Remedy
No.
Problems
1 Parking brake does not work when engine is stopped
Measured parking brake disc thickness is less than specified
2
value
WA700-3 20-627
(10)
Troubleshooting H-22
)
seat
d)
automatically to apply the parking brake.]
t pa
alve
ugh
e (V
a
nt
valv
eal)
c
tme
and
s
noid
djus
ton
aked
(Pis
ng a
sole
( F l
der
wro
ake
ake
ses
cylin
g br
g br
, or
Cau
age
n
rkin
ring
i
park
link
f pa
f sp
s of
o
rake
ts o
arts
part
r
ng b
a
al p
p
rnal
rnal
arki
tern
inte
inte
of p
e in
e
e
ctiv
age
ctiv
ctiv
Defe
Defe
Dam
Defe
a b c d
Remedy C
No.
Problems
When parking brake switch is OFF, oil leaks from spring
1 cylinder or cylinder rod does not return to end
2 When parking brake switch is OFF, parking brake is not released
Spring cylinder operates normally, and rod and lever return,
3
but brake drags
20-628 WA700-3
(10)
Troubleshooting H-23
ses
p
pum
Cau
d of
n en
lve
alve
f va
o
v
i
p
suct
relie
f
pum
relie
n at
ain
suck TO
PPC
Defe ve PPC
em
ed i
eP
e
ctiv
ctiv
ctiv
cti
Defe
Defe
Defe
Air
a b c d e
Remedy
No.
Problems
1 Steering also does not work
2 Abnormal noise comes from around PTO
3 Abnormal noise comes from around hydraulic tank or PPC pump
4 Measured PPC valve output pressure is normal
5 Measured PPC valve (Orbit-roll) basic pressure is low or zero
a There is close connection between the steering circuit and the work equipment circuit, so if any abnormality
is felt in the work equipment, check the operation of the steering, also.
WA700-3 20-629
(10)
Troubleshooting H-24
ses
l
poo
pum
Cau
mp
nd s
d of
t pu
ema
n en
e
men
alve
valv
of d
ump
o
ief v
p
i
p
lief
suct
i
pum
ion
equ
ch p
n re
l
C re
tuat
n at
ork
suck TO
PPC
swit
mai
e PP
e ac
ed i
ew
eP
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Air
a b c d e f g h
Remedy
No.
Problems
1 Boom and bucket movement takes approx. 1.5 times standard value
2 Boom and bucket movement takes approx. 3 times standard value
3 Steering works normally
4 Response of steering is also poor
5 Abnormal noise comes from around PTO
6 Abnormal noise comes from around hydraulic tank or hydraulic pump
7 Measured PPC valve output pressure is normal
8 Measured PPC valve (Orbit-roll) basic pressure is low
a There is close connection between the steering circuit and the work equipment circuit, so if any abnormality
is felt in the work equipment, check the operation of the steering, also.
20-630 WA700-3
(10)
Troubleshooting H-25
alve
ses
ck v
Cau
ol
spo
che
ge
om
nka
load
f bo
er li
e
e
al
valv
n of
v
o
r se
l
l lev
lve
a
n
ad v
atio
atio
ion
nde
C va
ntro
o
actu
actu
suct
i
l
l
e PP
e un
e cy
e co
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC
valve Control valve Boom Others
a b c d e f g
Remedy
No. A
Problems
1 Does not move in both directions (RAISE and LOWER)
2 Does not move in one direction (RAISE or LOWER)
Oil pressure is low or zero in both directions
3 When boom (RAISE and LOWER)
relief pressure
is measured Oil pressure is low or zero in one direction
4
(RAISE or LOWER)
5 Measured PPC valve output pressure is low or zero
6 Measured operating effort of boom control lever is heavy
7 Measured travel of boom control lever is short
WA700-3 20-631
(10)
Troubleshooting H-26
alve
ses
ck v
Cau
ol
spo
che
ge
om
nka
load
f bo
er li
e
e
al
valv
n of
v
o
r se
l
l lev
lve
a
n
v
atio
atio
ion
nde
C va
oad
ntro
actu
actu
suct
i
l
l
e PP
e un
e cy
e co
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
Defe
PPC Cylin-
valve Control valve der
Others
a b c d e f g
Remedy
No. A
Problems
1 Does not move normally in both directions (RAISE and LOWER)
2 Does not move normally in one direction (RAISE or LOWER)
3 When boom Oil pressure is low in both directions (RAISE and LOWER)
relief pressure
4 is measured Oil pressure is low in one direction (RAISE or LOWER)
5 Measured PPC valve output pressure is low
6 Measured hydraulic drift of boom is excessive
7 Measured operating effort of boom control lever is heavy
8 Measured travel of boom control lever is short
20-632 WA700-3
(10)
Troubleshooting H-27, H-28
alve
ses
or v
alve
Cau
lect
ad v
ge
t se
nka
unlo
floa
er li
n of
n of
l lev
lve
atio
atio
C va
ntro
a ctu
actu
e PP
e co
e
e
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
a b c d
Remedy
No. A
Problems
1 When PPC valve output pressure is measured Oil pressure is normal
2 (boom control lever at FLOAT position) Oil pressure is low
3 When PPC valve output pressure is measured Oil pressure is normal
4 (boom control lever at LOWER position) Oil pressure is low
5 Measured travel of boom control lever is short
H-28 Boom drops momentarily when control lever is operated from HOLD to RAISE
WA700-3 20-633
(10)
Troubleshooting H-29
ses
ol
spo
Cau
om
f bo
ss o
seal
htne
ston
l tig
e oi
e pi
ctiv
ctiv
Defe
Defe
Cont- Cylin-
rol
valve der
a b
Remedy
No.
Problems
1 When boom control lever is operated in Hydraulic drift increases
RAISE direction from boom maximum
2 raise with engine stopped (See Note) No change in hydraulic drift
NOTE: Before starting troubleshooting, the PPC accmulator must be charged, so run the engine at low idling
for 5 – 10 secound, the stop the engine.
20-634 WA700-3
(10)
Troubleshooting H-30
alve
ses
ol
ck v
Cau
spo
che
ge
e
cket
valv
nka
load
f bu
er li
ion
seal
n of
o
l lev
c
lve
n
u
atio
der
atio
ty-s
C va
ntro
cylin
actu
actu
f e
e PP
e co
e sa
e
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
Defe
PPC Cylin-
valve Control valve der Others
a b c d e f
Remedy
No. A
Problems
1 Does not move in both directions (TILT and DUMP)
2 Does not move in one direction (TILT or DUMP)
Oil pressure is low or there is no pressure in
3 When bucket both directions (TILT and DUMP)
relief pressure
is measured Oil pressure is low or there is no pressure in
4
one direction (TILT or DUMP)
WA700-3 20-635
(10)
Troubleshooting H-31
lve
ses
k va
ol
Cau
spo
hec
ge
e
ket
valv
ad c
nka
buc
er li
of lo
ion
seal
n of
l lev
c
lve
ion
u
atio
der
ty-s
C va
ntro
tuat
cylin
actu
f e
e PP
e co
e sa
e ac
e
e
ctiv
ctiv
ctiv
ctiv
ctiv
ctiv
Defe
Defe
Defe
Defe
Defe
PPC
Defe
valve
Cylin-
Control valve der Others
a b c d e f
Remedy
No. A
Problems
1 Does not move in both directions (TILT and DUMP)
2 Does not move in one direction (TILT or DUMP)
3 When bucket Oil pressure is low in both directions (TILT and DUMP)
relief pressure
4 is measured Oil pressure is low in one direction (TILT or DUMP)
When PPC valve output pressure is measured, oil pressure is
5 found to be low
6 When hydraulic drift of bucket is measured, it is found to be excessive
When operating effort of bucket control lever is measured,
7 lever is found to be heavy
8 When travel of bucket control lever is measured, it is found to be short
20-636 WA700-3
(10)
Troubleshooting H-32
ses
ol
spo
Cau
cket
f bu
ss o
seal
htne
ston
l tig
e oi
e pi
ctiv
ctiv
Defe
Defe
Cont- Cylin-
rol
valve der
a b
Remedy
No.
Problems
1 When bucket control lever is Hydraulic drift increases
operated in DUMP direction with
2 engine stopped (See Note) No change in hydraulic drift
NOTE: Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idling
for 5 – 10 seconds, then stop the engine.
WA700-3 20-637
(10)
Troubleshooting of transmission
control system
(T mode)
Judgement table for transmission controller system related parts .............................................................. 20-654
Action taken by controller when abnormality occurs and problems on machine......................................... 20-658
Electrical circuit diagram for transmission control system........................................................................... 20-668
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source
in backup lamp relay) is displayed...................................................................................................... 20-672
T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source
in F solenoid) is displayed................................................................................................................... 20-673
T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source
in R solenoid) is displayed .................................................................................................................. 20-674
T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source
in 1st solenoid) is displayed ................................................................................................................ 20-675
T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source
in 2nd solenoid) is displayed............................................................................................................... 20-676
T-6 Failure code [16] (Short circuit, disconnection, short circuit with power source
in 3rd solenoid) is displayed................................................................................................................ 20-677
T-7 Failure code [17] (Short circuit, disconnection, short circuit with power source
in 4th solenoid) is displayed................................................................................................................ 20-678
T-8 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed...... 20-679
Steering wheel and joystick steering specification
T-9 Failure code [20] (Short circuit, disconnection in directional switch system) is displayed................... 20-680
Steering wheel specification, Steering wheel and joystick steering specification
T-10 Failure code [20] (Short circuit or disconnection in joystick directional switch system) is displayed .. 20-683
AJSS (Advanced Joystick Steering System) specification
T-11 Failure code [21] (Short circuit, disconnection in range switch system) is displayed.......................... 20-684
Steering wheel specification, Steering wheel and joystick steering specification
T-12 Failure code [21] (Short circuit or disconnection in joystick shift-up/shift-down
switch system) is displayed................................................................................................................. 20-688
AJSS (Advanced Joystick Steering System) specification
T-13 Failure code [22] (Disconnection in travel speed sensor system) is displayed................................... 20-690
Steering wheel specification, Steering wheel and joystick steering specification
T-14 Failure code [22] (Disconnection in travel speed sensor system) is displayed................................... 20-691
AJSS (Advanced Joystick Steering System) specification
T-15 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is displayed ............ 20-692
T-16 Kickdown switch signal system and hold switch signal system .......................................................... 20-696
Steering wheel specification, AJSS (Advanced Joystick Steering System) specification
T-17 Shift-down switch signal system and shift-up switch signal system.................................................... 20-697
Steering wheel and joystick steering specification
WA700-3 20-651
(10)
T-18 Transmission cut-off signal system ..................................................................................................... 20-698
T-19 Neutralizer relay signal system ........................................................................................................... 20-699
Steering wheel specification, Steering wheel and joystick steering specification
T-20 Neutralizer relay signal system ........................................................................................................... 20-700
AJSS (Advanced Joystick Steering System) specification
T-21 Buzzer signal system .......................................................................................................................... 20-702
T-22 Network system .................................................................................................................................. 20-703
T-23 Transmission controller power source system .................................................................................... 20-704
Steering wheel specification, Steering wheel and joystick steering specification
T-24 Transmission controller power source system .................................................................................... 20-705
AJSS (Advanced Joystick Steering System) specification
T-25 Short circuit in travel speed sensor system ........................................................................................ 20-706
Steering wheel specification, Steering wheel and joystick steering specification
T-26 Short circuit in travel speed sensor system ........................................................................................ 20-707
AJSS (Advanced Joystick Steering System) specification
20-652 WA700-3
(10)
Troubleshooting Judgement table for transmission controller system related parts
20-654 WA700-3
(10)
Troubleshooting Judgement table for transmission controller system related parts
H-1
T-16
T-16, T-17, E-8
T-18
T-19, H-15, E-3
T-21
T-21, J-1
T-22
WA700-3 20-655
(10)
Troubleshooting Judgement table for transmission controller system related parts
20-656 WA700-3
(10)
Troubleshooting Judgement table for transmission controller system related parts
H-1
T-16
T-16, E-8
T-18
T-20, H-15, E-3
T-21
T-21, J-1
T-22
WA700-3 20-657
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
Failure
Abnormal system Nature of abnormality
code
1) Defective F solenoid
2) Short circuit with power source, short circuit with ground, defective contact,
disconnection in wiring harness between transmission & joystick controller
Short circuit, disconnection C1 (female) (2) – TL1 (5) – T01 (D)
12
in F solenoid system 3) Short circuit with ground, defective contact, disconnection in wiring harness
between T01 (A) – TL1 (7) – CL1 (12) – chassis ground
4) Defective transmission & joystick controller
1) Defective R solenoid
2) Short circuit with power source, short circuit with ground, defective contact,
disconnection in wiring harness between transmission & joystick controller
Short circuit, disconnection C1 (female) (9) – TL1 (6) – T01 (C)
13
in R solenoid system 3) Short circuit with ground, defective contact, disconnection in wiring harness
between T01 (A) – TL1 (7) – CL1 (12) – chassis ground
4) Defective transmission & joystick controller
20-658 WA700-3
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
WA700-3 20-659
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
Failure
Abnormal system Nature of abnormality
code
20-660 WA700-3
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
1) Voltage between combination switch L04 (1) and • Shifts to neutral imme- Travel impossible
chassis ground: 20 – 30 V diately when short cir-
2) Voltage for only 1 system in accordance with cuit with power source
position of directional lever: 20 – 30 V is detected
(Others: Less than 1 V) • When there is no signal
F: Between transmission & joystick controller (disconnection), holds T-9
C3B (5) – chassis ground previous signal condi-
N: Between transmission & joystick controller tion for 2 seconds
C3B (13) – chassis ground
R: Between transmission & joystick controller
C3B (6) – chassis ground
1) Voltage between combination switch L04 (1) and • If 2 signals are input, it 1) Auto–shift limit is
chassis ground: 20 – 30 V judges speed range different from range
2) Voltage for only 1 system in accordance with position in order of pri- position selected by
position of speed lever: 20 – 30 V ority 4 i 3 i 2 i 1 operator
(Others: Less than 1 V) • When there is no signal 2) Impossible to shift gear
1st: Between transmission & joystick controller (disconnection), holds in manual mode
C3B (7) – chassis ground previous signal condi- T-11
2nd: Between transmission & joystick controller tion (speed range posi-
C3B (15) – chassis ground tion
3rd: Between transmission & joystick controller
C3B (8) – chassis ground
4th: Between transmission & joystick controller
C3B (16) – chassis ground
1) Resistance between speed sensor T05 (1) and 1) Switches to manual 1) Does not carry out
(2): 500 – 1000 z mode auto–shift
2) Voltage between transmission & joystick 2) Shifts gear according to 2) Switches to manual
controller C5 (female) (2) and (10): Min. 0.5 V operation of speed shift T-13
(AC range) lever
WA700-3 20-661
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
Failure
Abnormal system Nature of abnormality
code
20-662 WA700-3
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
1) Resistance between engine speed sensor E10, 1) It is possible to travel There is gearshifting shock
E13 (1) and (2): 100 – 500 z with engine speed
2) Voltage between transmission & joystick control- taken as 2100 rpm
ler C4 (female) (2) and (9): Min. 0.5 V T-15
WA700-3 20-663
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
Failure
Abnormal system Nature of abnormality
code
1) Defective F solenoid
2) Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission & joystick
Short circuit, disconnection controller C1 (female) (2) – TL1 (5) – T01 (D)
12
in F solenoid system 3) Short circuit with chassis ground, defective contact, disconnection in wiring
harness between chassis – TL1 (7) – T01 (A)
4) Defective transmission & joystick controller
1) Defective R solenoid
2) Short circuit with power source, short circuit with chassis ground, defective
contact, disconnection in wiring harness between transmission & joystick
Short circuit, disconnection controller C1 (female) (9) – TL1 (6) – T01 (C)
13
in R solenoid system 3) Short circuit with chassis ground, defective contact, disconnection in wiring
harness between chassis – TL1 (7) – T01 (A)
4) Defective transmission & joystick controller
20-664 WA700-3
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
1) Resistance of relay coil: 200 – 400 z Neutral Back lamp is not actuated
2) Voltage between transmission & joystick control- (F, R, 1st, 2nd, 3rd, 4th when driving in reverse
ler C1 (8) and chassis ground at neutral: Less solenoid output: off)
than 1 V
3) Resistance in wiring harness between transmis-
T-1
sion & joystick controller C1 (female) (8) and L76
(female) (1): Max. 1 z
4) Resistance in wiring harness between back lamp
relay L76 (female) (2) and chassis ground: Max.
1z
WA700-3 20-665
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
Failure
Abnormal system Nature of abnormality
code
20-666 WA700-3
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
1) Voltage between transmission & joystick control- 1) When N signal is input: 1) When in F: Stops.
ler C3B (5) and chassis ground Shifts to N immediately. 2) When in N or R: Starts
When joystick forward-reverse switch is in "F": 2) When F/R signal is moving forward
17 – 30 V input: Shifts to N suddenly.
When joystick forward-reverse switch is not in immediately. 3) When in N: N signal is
"F": Max. 1 V 3) When there is no not output.
2) Voltage between transmission & joystick control- signal: Holds previous 4) When in F or R: Sets to
ler C3B (13) and chassis ground signal condition for 2 neutral suddenly.
When joystick forward-reverse switch is in "N": seconds, then shifts to 5) When in R: Stops.
T-10
17 – 30 V N. 6) When in N or F: Starts
When joystick forward-reverse switch is not in moving in reverse
"N": Max. 1 V suddenly.
3) Voltage between transmission & joystick control-
ler 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
2) Voltage between transmission & joystick
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
3) Voltage between transmission & joystick
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
4) Voltage between transmission & joystick
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 travel speed sensor X05 (1) 1) Switches to manual 1) Does not carry out
and (2): 500 – 1,000 z mode (OP) auto-shift (OP)
2) Voltage between transmission & joystick 2) Shifts gear according to 2) Switches to manual
controller C5 (female) (2) and (1): Min. 0.5 V operation of range shift T-14
lever
1) Resistance between engine speed sensor E13 1) Switches to manual 1) Does not carry out
(1) and (2): 100 – 500 z mode (OP) auto-shift (OP)
2) Voltage between transmission & joystick 2) Shifts gear according to 2) Switches to manual
controller C4 (female) (2) and (9) operation of range shift T-15
lever
WA700-3 20-667
(10)
Troubleshooting Electrical circuit diagram for transmission control system
20-668 WA700-3
(10)
Troubleshooting Electrical circuit diagram for transmission control system
a This circuit diagram is made by extracting the part of the transmission & joystick steering controller system
from the general circuit diagram.
WA700-3 20-669
(10)
Troubleshooting Electrical circuit diagram for transmission control system
20-670 WA700-3
(10)
Troubleshooting Electrical circuit diagram for transmission control system
a This circuit diagram is made by extracting the part of the transmission & joystick steering controller system
from the general circuit diagram.
WA700-3 20-671
(10)
Troubleshooting T-1
T-1 Failure code [10] (Short circuit, disconnection, short circuit with power source in
backup lamp relay) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 YES
Go to A
Is resistance bet-
YES ween L76 (female)
3 (1) and chassis Short circuit with chassis
Is resistance between ground normal? ground in wiring harness Repair or
YES C1 (female) (8) and • Min. 1 Mz NO between C1 (female) (8) replace
chassis normal when
• Turn starting switch and L76 (female) (1)
2 L76 (female) (1) is
grounded to chassis? OFF. Disconnection in wiring
Is resistance bet- • Disconnect C1 and L76
YES ween L76 (female) • Max. 1 z harness between C1 Repair or
(2) and chassis • Turn starting switch NO (female) (8) and L76 replace
ground normal? OFF. (female) (1)
1 • Disconnect C1 and L76
Is troubleshooting • Max. 1 z Disconnection in wiring
code 10 displayed • Turn starting switch harness between L76 Repair or
when the relay is inter- NO (female) (2) – LR5 (2) – replace
changed with other
OFF.
relay of same type? • Disconnect L76. chassis ground
• Turn starting switch
OFF. Defective backup lamp
Replace
• Interchange with NO relay
other relay of same type.
• Turn starting switch ON.
• Directional lever: R Defective transmission &
5 YES
joystick steering Replace
Is voltage between controller
From A C1 (female) (8) and
chassis normal? Short circuit with power
source in wiring harness
Replace
• Turn starting switch NO between C1 (female) (8)
OFF. and L76 (female) (1)
• Disconnect C1 and L76.
• Less than 0.1 V
20-672 WA700-3
(10)
Troubleshooting T-2
T-2 Failure code [12] (Short circuit, disconnection, short circuit with power source in
F solenoid) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA700-3 20-673
(10)
Troubleshooting T-3
T-3 Failure code [13] (Short circuit, disconnection, short circuit with power source in
R solenoid) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
20-674 WA700-3
(10)
Troubleshooting T-4
T-4 Failure code [14] (Short circuit, disconnection, short circuit with power source in
1st solenoid) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA700-3 20-675
(10)
Troubleshooting T-5
T-5 Failure code [15] (Short circuit, disconnection, short circuit with power source in
2nd solenoid) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
20-676 WA700-3
(10)
Troubleshooting T-6
T-6 Failure code [16] (Short circuit, disconnection, short circuit with power source in
3rd solenoid) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA700-3 20-677
(10)
Troubleshooting T-7
T-7 Failure code [17] (Short circuit, disconnection, short circuit with power source in
4th solenoid) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
20-678 WA700-3
(10)
Troubleshooting T-8
T-8 Failure code [19] (Short circuit, disconnection in joystick directional switch sys-
tem) is displayed
Steering wheel and joystick steering specification
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
Cause Remedy
connectors are properly inserted.
a Always connect any disconnected connectors before going on to
the next step.
Defective transmission &
4 YES joystick steering
Replace
Is voltage between controller
YES C5 (female) (7), (8), Short circuit, short circuit
(9), (15), (16), (17) and
chassis as shown in with chassis ground, defec-
3 tive contact, or disconnec-
Table 1? Repair or
Is resistance tion in wiring harness bet-
• Turn starting switch NO ween JL2 (female) (2), (3),
replace
YES between JL2
(female) (8) and ON. (4), (5), (6), (7) – C5 (female)
(7), (8), (9), (15), (16), (17)
2 chassis normal?
Defective contact or discon-
Is voltage between • Min. 1 Mz nection in wiring harness Repair or
YES • Turn starting between JL2 (female) (8) – replace
JL2 (1) and NO
chassis normal? switch OFF. LR5 (3) – chassis
1 • Disconnect JL2. Short circuit, short circuit
Is voltage between • 20 – 30 V with chassis ground, defec-
JL2 (8) and terminals tive contact, or disconnec- Repair or
• Turn starting switch
(2), (3), (4), (5), (6), tion in wiring harness bet- replace
and (7) as shown in ON. NO
ween C3A (male) (6) - JL2
Table 1? (1) - LR5 (3) - chassis
• Turn starting switch
ON. Defective joystick lever Replace
NO
When directional
switch is pressed F N R
Terminal
JL2 (male) (8) – (2) Between C5 (8) and chassis 20 – 30 V Max. 1 V Max. 1 V
JL2 (male) (8) – (3) Between C5 (16) and chassis Max. 1 V 20 – 30 V 20 – 30 V
JL2 (male) (8) – (4) Between C5 (7) and chassis Max. 1 V 20 – 30 V Max. 1 V
JL2 (male) (8) – (5) Between C5 (15) and chassis 20 – 30 V Max. 1 V 20 – 30 V
JL2 (male) (8) – (6) Between C5 (9) and chassis Max. 1 V Max. 1 V 20 – 30 V
JL2 (male) (8) – (7) Between C5 (17) and chassis 20 – 30 V 20 – 30 V Max. 1 V
WA700-3 20-679
(10)
Troubleshooting T-9
T-9 Failure code [20] (Short circuit, disconnection in directional switch system) is
displayed
Steering wheel specification,
Steering wheel and joystick steering specification
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
YES
2 5 YES
Is voltage between Is there continuity
C3B (female) (5), (6), between L04 (female) (2)
YES YES – C3B (female) (5), L04
(13) – chassis (female) (4) – C3B
ground as shown in 4 (female) (6), L04
Table 1? Is resistance (female) (3) – C3B
• Turn starting YES between C3B • Turn starting NO
(female) (5), (6), (13)
switch OFF. switch OFF.
3 and chassis ground
1 • Disconnect C3B. normal? • Disconnect C3B and L04.
• Turn starting Is voltage between • Max. 1z
Is voltage C3B (female) (5), • Turn starting
between L04 switch ON. switch OFF. NO
(female) (1) and
NO (6), (13) – chassis
ground normal? • Disconnect C3B
(10) normal? and L04.
• Turn starting • Min. 1 Mz
• Turn starting switch OFF.
switch OFF. • Disconnect C3B NO
• Disconnect L04. and L04.
• Turn starting • Turn starting switch ON.
switch ON. • Max. 1 V
• 20 – 30 V
NO
Table 1
Terminal
F N R
Directional position
C3B (female) (5) – chassis ground 20 – 30 V Max. 1 V Max. 1 V
C3B (female) (13) – chassis ground Max. 1 V 20 – 30 V Max. 1 V
C3B (female) (6) – chassis ground Max. 1 V Max. 1 V 20 – 30 V
20-680 WA700-3
(10)
Troubleshooting T-9
Cause Remedy
Defective directional
lever Replace
Defective contact or
disconnection in wiring
harness between L04
(female) (2) – C3B (female)
(5), L04 (female) (4) – C3B Repair or
(female) (6), L04 (female) (3) replace
– C3B (female) (13)
Short circuit with chassis
ground in wiring harness
between L04 (female) (2) –
C3B (female) (5), L04 (female) Repair or
(4) – C3B (female) (6), L04 replace
(female) (3) – C3B (female)
(13)
Short circuit with power
source in wiring harness
between L04 (female) (2) – Repair or
C3B (female) (5), L04 (female) replace
(4) – C3B (female) (6), L04
(female) (3) – C3B (female)
(13)
Defective contact,
disconnection, or short Repair or
circuit with chassis ground in replace
wiring harness between L04
(female) (1) and FS2 (8),
blown fuse
WA700-3 20-681
(10)
Troubleshooting T-9
20-682 WA700-3
(10)
Troubleshooting T-10
T-10 Failure code [20] (Short circuit or disconnection in joystick directional switch
system) is displayed
AJSS (Advanced Joystick Steering System) specification
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
a Check that fuse is normal.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective transmission
3 YES
and joystick steering Replace
Is voltage between
controller
YES C3B (5), (13), (6) and
chassis ground as Disconnection, defective
2 shown in Table 1? contact, short circuit with
Is voltage chassis ground, or short Repair or
YES between JS1 (1) circuit in wiring harness replace
• Turn starting NO between JS1 (female) (2), (3),
and chassis switch ON. (4) – C3B (female) (5), (13), (6)
1 ground normal?
Is voltage between • 20 – 30 V Disconnection or defective
JS1 (2), (3), (4) and contact in wiring harness Repair or
• Turn starting NO replace
chassis ground as between fuse – JS1
shown in Table 1? switch ON.
(female) (1)
• Turn starting
switch ON. Defective joystick
Replace
NO directional switch
WA700-3 20-683
(10)
Troubleshooting T-11
T-11 Failure code [21] (Short circuit, disconnection in range switch system) is dis-
played
Steering wheel specification,
Steering wheel and joystick steering specification
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
YES
2 5 YES
Is voltage between Is there continuity between
C3B (female) (7), L04 (female) (5) – C3B
YES YES (female) (7), L04 (female) (6) –
(15), (8), (16) – C3B (female) (15), L04
chassis ground as 4
(female) (7) – C3B (female)
shown in Table 1? Is resistance (8), L04 (female) (8) – C3B
• Turn starting YES between C3B • Turn starting NO
(female) (7), (15),
switch OFF. switch OFF.
3 (8), (16) and chassis
1 • Disconnect C3B. ground normal? • Disconnect C3B and L04.
Is voltage between
Is voltage • Turn starting C3B (female) (7), • Turn starting • Max. 1z
between L04 switch ON. (15), (8), (16) – switch OFF. NO
(female) (1) and
NO chassis ground • Disconnect C3B
(10) normal? normal?
and L04.
• Turn starting • Min. 1 Mz
• Turn starting switch OFF.
switch OFF. • Disconnect C3B NO
• Disconnect L04. and L04.
• Turn starting • Turn starting switch ON.
switch ON. • Max. 1 V
• 20 – 30 V
NO
Table 1
Terminal
1st 2nd 3rd 4th
Directional position
C3B (female) (7) – chassis ground 20 – 30 V Max. 1 V Max. 1 V Max. 1 V
C3B (female) (15) – chassis ground Max. 1 V 20 – 30 V Max. 1 V Max. 1 V
C3B (female) (8) – chassis ground Max. 1 V Max. 1 V 20 – 30 V Max. 1 V
C3B (female) (16) – chassis ground Max. 1 V Max. 1 V Max. 1 V 20 – 30 V
20-684 WA700-3
(10)
Troubleshooting T-11
Cause Remedy
Defective directional
lever Replace
Defective contact or
disconnection in wiring
harness between L04 (female)
(5) – C3B (female) (7), L04
(female) (6) – C3B (female) Repair or
(15), L04 (female) (7) – C3B
(female) (8), L04 (female) (8) – replace
C3B (female) (16)
Short circuit with chassis
ground in wiring harness
between L04 (female) (5) – C3B Repair or
(female) (7), L04 (female) (6) –
C3B (female) (15), L04 (female) replace
(7) – C3B (female) (8), L04
(female) (8) – C3B (female) (16)
Short circuit with power
source in wiring harness
between L04 (female) (5) – C3B Repair or
(female) (7), L04 (female) (6) – replace
C3B (female) (15), L04 (female)
(7) – C3B (female) (8), L04
(female) (8) – C3B (female) (16)
Defective contact,
disconnection, or short circuit Repair or
with chassis ground in wiring replace
harness between L04 (female)
(1) and FS2 (8), blown fuse
WA700-3 20-685
(10)
Troubleshooting T-11
20-686 WA700-3
(10)
Troubleshooting T-12
Cause Remedy
Defective transmission
3 YES
and joystick steering Replace
Is voltage between
controller
YES C3B (16), (8), (15), Disconnection, defective
(7) and chassis
2 ground as shown in
contact, short circuit with
chassis ground, or short
Is voltage Table 1? circuit in wiring harness Repair or
YES between JS1 (1) • Turn starting NO between JS1 (female) (5), (6), replace
and chassis (7), (8) – C3B (female) (16),
1 switch ON. (8), (15), (7)
ground normal?
Is voltage between
Disconnection or defective
JS1 (5), (6), (7), (8) • 20 – 30 V Repair or
and chassis ground contact in wiring harness
• Turn starting NO replace
as shown in Table between fuse – JS1
switch ON.
1? (female) (1)
• Turn starting
Defective joystick shift-
switch ON. Replace
NO up/shift-down switch
20-688 WA700-3
(10)
Troubleshooting T-12
WA700-3 20-689
(10)
Troubleshooting T-13
T-13 Failure code [22] (Disconnection in travel speed sensor system) is displayed
Steering wheel specification,
Steering wheel and joystick steering specification
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
20-690 WA700-3
(10)
Troubleshooting T-14
T-14 Failure code [22] (Disconnection in travel speed sensor system) is displayed
AJSS (Advanced Joystick Steering System) specification
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
WA700-3 20-691
(10)
Troubleshooting T-15
T-15 Failure code [23] (Short circuit, disconnection in engine speed sensor system) is
displayed
Serial No.: 50001 – 51000
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
2 YES
Is resistance
YES between C4
1 (female) (9) and
Is resistance chassis normal?
between C4 • Max. 1 z NO
(male) (2) and • Disconnect C4.
chassis normal? • Turn starting
• Min. 1 Mz switch OFF.
• Disconnect C4, NO
EC3A, and L07.
• Turn starting
switch OFF. 6 YES
Is resistance
YES between EC3A
5 (female) (2), (3) –
b) Electric engine throttle controller system (14)?
Is resistance
YES between EC3A • Min. 1 Mz NO
(female) (14) and • Disconnect EC3A,
4 chassis normal? E10, and E13.
Is resistance between • Turn starting switch
YES EC3A (female) (14) • Min. 1 Mz OFF.
and chassis normal • Disconnect EC3A, NO
when E10, E13
(female) (2) are E10, and E13.
3 grounded to chassis? • Turn starting
Is resistance • Max. 1 z switch OFF.
YES between EC3A • Disconnect EC3A,
(female) (2), (3) – E10, and E13. NO
2 chassis normal? • Turn starting
Is resistance between switch OFF.
EC3A (female) (2), (3) • Min. 1 Mz
YES – chassis normal • Disconnect EC3A,
when E10, E13 E10, and E13. NO
(female) (1) are
1 grounded to chassis? • Turn starting
Is resistance • Max. 1 z switch OFF.
between E10, E13 • Disconnect EC3A,
(male) (1) and (2) E10, and E13. NO
normal? • Turn starting
• 100 – 500 z switch OFF.
• Disconnect E10
and E13. NO
• Turn starting
switch OFF.
a Normally, the engine speed is detected from E13 Engine speed sensor A. When an abnormality occurs in
sensor A, it switches to E10 Engine speed sensor B.
20-692 WA700-3
(10)
Troubleshooting T-15
Cause Remedy
WA700-3 20-693
(10)
Troubleshooting T-15
20-694 WA700-3
(10)
Troubleshooting T-15
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 failure code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4 YES
Go to A
Is resistance
YES between C4 Defective contact or
3 (female) (9) and E13 disconnection in wiring
(female) (2) normal?
Is resistance harness between C4 Repair or
YES between C4 (female) • Max. 1 z NO (female) (9) and E13 replace
2
(2) and chassis • Disconnect C4 and E13. (female) (2)
ground normal? • Turn starting switch
Is resistance
Short circuit with chassis
• Min. 1 Mz OFF. ground in harness Repair or
YES between C4
(female) (2) and E13 • Disconnect C4, NO between C4 (female) (2) replace
(female) (1) normal? E13 and L07. and E13 (female) (1)
1
• Turn starting Defective contact or
Is resistance • Max. 1 z switch OFF. disconnection in wiring Repair or
between E13 • Disconnect C4,
NO harness between C4 replace
(male) (1) and (2) E13 and L07. (female) (2) and E13
normal? • Turn starting (female) (1)
• 100 – 500 z switch OFF.
• Disconnect E13. Defective engine speed Replace
• Turn starting NO sensor
switch OFF.
Defective transmission &
6 YES joystick steering Replace
Is resistance controller
YES between C4 Short circuit of harness
5 (female) (2) and between C4 (female) (2)
(9) normal? and E03 (female) (1) and Repair or
Is resistance harness between C4
between C4 (female) • Min. 1 Mz NO replace
From A (female) (9) and E13
(9) and chassis • Disconnect C4, (female) (2) with each
ground normal? E13 and L07. other
• Turn starting switch OFF. Short circuit with chassis Repair or
• Min. 1 Mz
• Disconnect C4 NO ground in harness replace
and E13. between C4 (female) (9)
• Turn starting and E13 (female) (2)
switch OFF.
WA700-3 20-695
(10)
Troubleshooting T-16
T-16 Kickdown switch signal system and hold switch signal system
Steering wheel specification,
AJSS (Advanced Joystick Steering System) specification
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).
Cause Remedy
Kickdown switch
Hold switch
Cause Remedy
a Hold switch is applied to only the auto-shift specification
20-696 WA700-3
(10)
Troubleshooting T-17
T-17 Shift-down switch signal system and shift-up switch signal system
Steering wheel and joystick steering specification
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).
Cause Remedy
Shift-down switch
Cause Remedy
Shift-up switch
WA700-3 20-697
(10)
Troubleshooting T-18
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).
Cause Remedy
20-698 WA700-3
(10)
Troubleshooting T-19
WA700-3 20-699
(10)
Troubleshooting T-20
Cause Remedy
20-700 WA700-3
(10)
Troubleshooting T-20
WA700-3 20-701
(10)
Troubleshooting T-21
a Check that the main monitor and alarm buzzer work normally.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).
Cause Remedy
20-702 WA700-3
(10)
Troubleshooting T-22
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or
socket).
Cause Remedy
WA700-3 20-703
(10)
Troubleshooting T-23
Cause Remedy
20-704 WA700-3
(10)
Troubleshooting T-24
Cause Remedy
WA700-3 20-705
(10)
Troubleshooting T-25
Cause Remedy
20-706 WA700-3
(10)
Troubleshooting T-26
Cause Remedy
WA700-3 20-707
(10)
Troubleshooting of joystick steering controller
system (J mode)
Judgement table for joystick controller system related parts ...................................................................... 20-752
Action taken by controller when abnormality occurs and problems on machine......................................... 20-754
Electrical circuit diagram for joystick steering system ................................................................................. 20-758
J-1 Failure code [56] (Short circuit, disconnection in caution relay output) is displayed ........................... 20-759
J-2 Failure code [57] (Short circuit in steering right solenoid (detected when output)) is displayed.......... 20-760
J-3 Failure code [58] (Short circuit in steering left solenoid (detected when output)) is displayed............ 20-761
J-4 Failure code [59] (Short circuit in steering right solenoid (HOT end)) is displayed ............................. 20-762
J-5 Failure code [60] (Short circuit in steering left solenoid (HOT end)) is displayed................................ 20-763
J-6 Failure code [61] (Short circuit, disconnection in steering solenoid cut relay output) is displayed...... 20-764
J-7 Failure code [62] (Short circuit, disconnection in joystick steering neutral signal) is displayed........... 20-765
J-8 Failure code [63] (Short circuit, disconnection in joystick steering lever potentiometer system)
is displayed.......................................................................................................................................... 20-766
J-9 Abnormality in power source, voltage ................................................................................................. 20-767
J-10 Abnormality in joystick steering ON-OFF signal system ..................................................................... 20-768
J-11 Disconnection in steering right solenoid.............................................................................................. 20-769
J-12 Disconnection in steering left solenoid................................................................................................ 20-770
WA700-3 20-751
(10)
Troubleshooting Judgement table for joystick controller system related parts
Location of failure
no abnormality display is
given
Failure
code
Transmission & joystick
Failure mode
steering controller
56 57 58 59 60 61 62 63 – –
1 Alarm buzzer does not stop Q T-17
2 Steering does not turn to left Q Q Q Q H-6,H-8,H-9,H-11,J-9,J-11
3 Steering does not turn to right Q Q Q Q H-6,H-8,H-9,H-11,J-9,J-12
4 Steering can be turned fully to left Q Q Q
5 Steering canlbe turned fully to right Q Q Q
6 Both steering and transmission do not work at all Q Q J-9,J-10
Troubleshooting code when error code is displayed J-1 J-2 J-3 J-4 J-5 J-6 J-7 J-8 – –
20-752 WA700-3
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
1) Defective R SOL
2) Defective steering solenoid cut relay
3) Short circuit in wiring harness between joystick steering control-
ler C2 (female) (2) and (13)
Short circuit with ground, defective contact, or disconnection in
the following wiring harnesses
Steering (R) (right) Sol. system
57 4) Wiring harness between joystick steering controller C2 (female)
(short circuit, disconnection)
(2) and L84 (2)
5) Wiring harness between joystick steering controller C2 (female)
(13) and L67 (3)
6) Wiring harness between steering solenoid cut relay L67 (5) and
L84 (1)
7) Defective joystick steering controller
1) Defective L SOL
2) Defective steering solenoid cut relay
3) Short circuit in wiring harness between joystick steering control-
ler C2 (female) (3) and (14)
Short circuit with ground, defective contact, or disconnection in
the following wiring harnesses
Steering (L) (left) Sol. system
58 4) Wiring harness between joystick steering controller C2 (female)
(short circuit, disconnection)
(3) and L83 (2)
5) Wiring harness between joystick steering controller C2 (female)
(14) and L67 (3)
6) Wiring harness between steering solenoid cut relay L67 (5) and
L83 (1)
7) Defective joystick steering controller
1) Defective R SOL
2) Short circuit with power source in wiring harness between joy-
Steering R (right) Sol. system stick steering controller C2 (female) (2) and L84 (2)
59
(short circuit with power source) 3) Defective joystick steering controller
1) Defective L SOL
2) Short circuit with power source in wiring harness between joy-
Steering L (left) Sol. system stick steering controller C2 (female) (3) and L83 (2)
60
(short circuit with power source) 3) Defective joystick steering controller
20-754 WA700-3
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
Steering R, L solenoid
output: OFF Impossible to use
1) Joystick lever at neutral
and steering solenoid joystick
Voltage between joystick steering controller C2 J-4
cut relay output: OFF and joystick caution
(female) (2) and chassis ground: Less than 1 V
and caution relay output: actuated
OFF
Steering R, L solenoid
output: OFF Impossible to use
1) Joystick lever at neutral
and steering solenoid joystick
Voltage between joystick steering controller C2 J-5
cut relay output: OFF and joystick caution
(female) (3) and chassis ground: Less than 1 V
and caution relay output: actuated
OFF
WA700-3 20-755
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
20-756 WA700-3
(10)
Troubleshooting Action taken by controller when abnormality occurs and problems on machine
Steering R, L solenoid
output: OFF Impossible to use
1) Resistance between joystick steering controller C1 and steering solenoid joystick
J-6
(female) (1) and chassis ground: 200 – 400 z cut relay output: OFF and joystick caution
and caution relay output: actuated
OFF
Steering R, L solenoid
1) Resistance between joystick steering controller C5
output: OFF Impossible to use
(female) (11) and chassis ground:
and steering solenoid joystick
Min. 1 Mz (when joystick is at neutral) J-7
cut relay output: OFF and joystick caution
Less than 1 z (joystick at angle of ± 5 – 15º from
and caution relay output: actuated
neutral)
OFF
Steering R, L solenoid
output: OFF Impossible to use
1) Voltage between joystick steering controller C3A
and steering solenoid joystick
(female) (3) and C3A (17): 0.5 – 4.5 V (voltage J-8
cut relay output: OFF and joystick caution
when joystick is at neutral: Approx. 2.5 V)
and caution relay output: actuated
OFF
WA700-3 20-757
(10)
Troubleshooting Electrical circuit diagram for joystick steering system
20-758 WA700-3
(10)
Troubleshooting J-1
J-1 Failure code [56] (Short circuit, disconnection in caution relay output)
is displayed
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting any connector.
Cause Remedy
WA700-3 20-759
(10)
Troubleshooting J-2
J-2 Failure code [57] (Short circuit in steering right solenoid (detected when output))
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 failure code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
Cause Remedy
20-760 WA700-3
(10)
Troubleshooting J-3
J-3 Failure code [58] (Short circuit in steering left solenoid (detected when output))
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 failure code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
Cause Remedy
WA700-3 20-761
(10)
Troubleshooting J-4
J-4 Failure code [59] (Short circuit in steering right solenoid (HOT end)) is displayed
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
20-762 WA700-3
(10)
Troubleshooting J-5
J-5 Failure code [60] (Short circuit in steering left solenoid (HOT end)) is displayed
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
a Always connect any disconnected connectors before going on to the next step.
a Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket
adapter).
Cause Remedy
WA700-3 20-763
(10)
Troubleshooting J-6
J-6 Failure code [61] (Short circuit, disconnection in steering solenoid cut relay
output) 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 failure code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
Cause Remedy
20-764 WA700-3
(10)
Troubleshooting J-7
J-7 Failure code [62] (Short circuit, disconnection in joystick steering neutral signal)
is displayed
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective joystick
YES controller or defective
joystick potentiometer Replace
mount
2
Defective contact or
Is resistance
YES between C5 4 YES disconnection in wiring Repair or
harness between JL1
(female) (11) and Is resistance replace
(male) (6) and C5 (female)
chassis normal? YES between JL1 (11)
3 (male) (7) and
• Disconnect C5. Defective contact or
chassis normal? Repair or
• Operate joystick Is resistance disconnection in wiring
1 lever fully to left between JL1 • Disconnect JL1. NO harness between JL1 replace
Is resistance or right. NO (female) (6) and • Max. 1 z (male) (7) – LR5 (3)
between C5 • Max. 1 z (7) normal? chassis ground
(female) (11) and • Disconnect JL1.
chassis normal? Defective neutral switch Replace
• Operate joystick NO
• Disconnect C5. lever fully to left or right.
• Min. 1 Mz • Max. 1 z Short circuit with chassis
5 YES ground in wiring harness Repair or
Is resistance between JL1 (male) (6) replace
between JL1 (male) and C5 (female) (11)
NO (6) and chassis
ground normal?
Defective neutral switch Replace
• Disconnect JL1 NO
and C5.
• Min. 1 Mz
WA700-3 20-765
(10)
Troubleshooting J-8
J-8 Failure code [63] (Short circuit, disconnection in joystick steering lever
potentiometer system) is displayed
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
a Always connect any disconnected connectors before going on to the next step.
a After connecting the T-adapter, turn the starting switch ON.
Cause Remedy
20-766 WA700-3
(10)
Troubleshooting J-9
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Check that fuse is normal.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA700-3 20-767
(10)
Troubleshooting J-10
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Check that fuse is normal.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
1
Is voltage
3 YES Defective system cut-off
between C3B Replace
Is voltage switch
(female) (14) and
chassis normal? YES between JL1
2 (male) (1) and Defective contact or
• 20 – 30 V Is resistance between chassis normal? Repair or
disconnection in wiring
• Turn starting C3B (female) (14) and replace
• 20 – 30 V NO harness between fuse –
switch ON. chassis normal when
• Turn starting FS2 (10) – JL1 (male) (1)
NO JL1 (male) (2) is
grounded to chassis? switch ON. Defective contact or
disconnection in wiring Replace
• Turn starting switch,
harness between C3B
switch OFF. NO or repair or
(female) (14) – L82 (1), (2) –
• Disconnect JL1 JL1 (male) (2), or defective replace
and C3B. joystick ON-OFF switch
• Max. 1 z
20-768 WA700-3
(10)
Troubleshooting J-11
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
Cause Remedy
WA700-3 20-769
(10)
Troubleshooting J-12
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering
selector switch ON.
Cause Remedy
20-770 WA700-3
(10)
Troubleshooting of
AJSS (advanced joystick steering system)
control system
(A mode)
AJSS (advanced joystick steering system) specification
Judgement table for AJSS (advanced joystick steering system) control system ........................................ 20-802
Operations of controller against abnormality and conditions of machine caused by abnormality............... 20-804
Electric circuit diagram related to AJSS (Advanced Joystick Steering System) control.............................. 20-808
A-1 Error code [56] (Disconnection or short circuit with chassis ground in
caution buzzer relay system) is displayed ...................................................................................... 20-810
A-2 Error code [57] (Disconnection or short circuit with chassis ground in
steering lever angle sensor system) is displayed ........................................................................... 20- 811
A-3 Error code [58] (Deviation of steering lever angle sensor and frame
angle sensor signals) is displayed .................................................................................................. 20-812
A-4 Error code [59] (Disconnection or short circuit with chassis ground in
frame angle sensor system) is displayed........................................................................................ 20-813
A-5 Error code [60] (Disconnection or short circuit with chassis ground in
steering lever lock pressure switch system) is displayed ............................................................... 20-814
A-6 Error code [62] (Disconnection or short circuit with chassis ground in
steering neutral interlock relay system) is displayed ...................................................................... 20-815
A-7 Error code [63] (Disconnection, short circuit with chassis ground, or
short circuit with power source in steering main pressure control EPC
solenoid system) is displayed ......................................................................................................... 20-816
A-8 Steering speeds in both directions are different.................................................................................. 20-817
A-9 Abnormality in console switch (adjustment of steering lever angle sensor
and frame angle sensor is impossible) ........................................................................................... 20-818
A-10 Abnormality in power source and voltage........................................................................................... 20-819
WA700-3 20-801
(10)
Judgement table for AJSS (advanced joystick steering
Troubleshooting system) control system
Disconnection, short circuit with chassis ground, or short circuit with power source in steering main pres-
Location of failure
Disconnection or short circuit with chassis ground in steering lever lock pressure switch system
Disconnection or short circuit with chassis ground in steering neutral interlock relay system
Disconnection or short circuit with chassis ground in steering lever angle sensor system
Deviation of steering lever angle sensor and frame angle sensor potentiometer signals
Disconnection or short circuit with chassis ground in caution buzzer relay system
Disconnection or short circuit with chassis ground in frame angle sensor system
Failure
code
Failure mode
56 57 58 59 60 62 63
Diagnosis code when failure code is displayed J-1 J-2 J-3 J-4 J-5 J-6 J-7
20-802 WA700-3
(10)
Operations of controller against abnormality and
Troubleshooting conditions of machine caused by abnormality
20-804 WA700-3
(10)
Operations of controller against abnormality and
Troubleshooting conditions of machine caused by abnormality
1) Voltage between relay L66 (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
400 z
3) Resistance between T/M and J/S controller C2
(female) (9) – L66 (female) (1): Max. 1 z
4) Resistance between T/M and J/S controller C2
(female) (19) – L66 (female) (2): Max. 1 z
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 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
voltage.
1) Voltage between T/M and J/S controller C3A Turns off steering main Steering speeds in both
(7) – (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
sensor JS2 (male) (1) – (2): 0 – 5 kz A-3
4) Resistance between frame angle sensor L84
(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 L84 EPC solenoid output.
(male) (1) – (2): 0 – 5 kz 2) Controls frame angle
sensor signal voltage A-4
as input voltage.
WA700-3 20-805
(10)
Operations of controller against abnormality and
Troubleshooting conditions of machine caused by abnormality
20-806 WA700-3
(10)
Operations of controller against abnormality and
Troubleshooting conditions of machine caused by abnormality
Voltage between T/M and J/S controller C3B (9) – Turns on caution buzzer. (In case of disconnection)
chassis ground: 1) Transmission is kept
• When steering lock lever is in LOCK: 20 – 30 V in N.
• When steering lock lever is in FREE: Max. 1 V 2) Steering system is
operable normally.
Voltage between T/M and J/S controller C2 (8) – Does not operate at all. 1) Engine can be started
chassis ground: while machine is
• When steering lock lever is in NEUTRAL: steered.
Max. 1 V 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 steering
(7) – (17): 600 ± 80 mA pressure control EPC system is lowered.
solenoid output. 2) Steering speed is
lowered.
3) Response of steering A-7
system is heightened
4) Steering speed is
heightened
WA700-3 20-807
(10)
Electric circuit diagram related to AJSS (Advanced
Troubleshooting Joystick Steering System) control
20-808 WA700-3
(10)
Electric circuit diagram related to AJSS (Advanced
Troubleshooting Joystick Steering System) control
a This circuit diagram is made by extracting the part of the transmission & joystick steering controller from the
general circuit diagram.
WA700-3 20-809
(10)
Troubleshooting A-1
A-1 Error code [56] (Disconnection or short circuit with chassis ground in caution
buzzer relay system) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
20-810 WA700-3
(10)
Troubleshooting A-2
A-2 Error code [57] (Disconnection or short circuit with chassis ground in steering
lever angle sensor system) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA700-3 20-811
(10)
Troubleshooting A-3
A-3 Error code [58] (Deviation of steering lever angle sensor and frame angle sensor
signals) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if
the error code is no longer displayed on the monitor display, the problem has been removed.
a Before carrying out troubleshooting, check that all the related
connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the Cause Remedy
neutral position.
a Always connect any disconnected connectors before going on to
the next step. Improper installation of
Replace or
YES steering lever angle
adjust neutral
sensor (Deviation of
position
neutral position)
2
Improper installation of
4 YES frame angle sensor Replace or
YES Does voltage adjust neutral
between C3A (3) (Deviation of neutral
and (16) change? Does voltage position
YES position)
between C3A (13)
3 and (16) change?
• Lean steering
1 Does resistance
lever to right or Go to A.
between JS2 • Change frame NO
Is voltage left
• 0.5 – 4.5 V NO (male) (1) and (3) angle
between C3A (7) change?
• Starting switch • 0.5 – 4.5 V
and (16) normal?
ON. • Lean steering • Start engine. Defective steerintg lever
Replace
• 4.9 – 5.1 V lever to right or NO angle sensor
• Starting switch left
ON. • 0.2 – 5 kz
• Starting switch OFF. Defective T/M and J/S Replace
NO • Disconnect JS2. controller
Disconnection, defective
contact, short circuit with
chassis ground, or short circuit Repair or
6 YES replace
with power source in wiring
Is harness between C3A
harness between C3A (female)
(female) (3) and JS2
YES (female) (1) normal (no (13) – L84 (female) (A)
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 L84 • Disconnect C3A, NO with power source in wiring replace
From A
(male) (A) and (C) JS2. harness between C3A (female)
change? (3) – JS2 (female) (1)
20-812 WA700-3
(10)
Troubleshooting A-4
A-4 Error code [59] (Disconnection or short circuit with chassis ground in frame
angle sensor system) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a When the joystick steering lever is not being used, leave it at the neutral position.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA700-3 20-813
(10)
Troubleshooting A-5
A-5 Error code [60] (Disconnection or short circuit with chassis ground in steering
lever lock pressure switch system) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the steering lock lever is in the LOCK position, the steering lock pressure switch is opened (since the
oil pressure is not heightened).
Cause Remedy
20-814 WA700-3
(10)
Troubleshooting A-6
A-6 Error code [62] (Disconnection or short circuit with chassis ground in steering
neutral interlock relay system) is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA700-3 20-815
(10)
Troubleshooting A-7
A-7 Error code [63] (Disconnection, short circuit with chassis ground, or short cir-
cuit with power source in steering main pressure control EPC solenoid system)
is displayed
a This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the error code is no longer displayed on the monitor display, the problem
has been removed.
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
a When the joystick steering lever is not being used, leave it at the neutral position.
Cause Remedy
4 YES
Go to A.
Is resistance
YES between C2 Short circuit of wiring
3 (female) (7) and harness between C2
Is resistance (17) normal? (female) (7) – L82 (female) Repair or
(2) with wiring harness replace
YES between C2 • Min. 1 Mz NO between C2 (female) (17)
(female) (17) and
chassis ground • Turn starting and L82 (female) (1)
2
normal? switch OFF.
Is resistance Short circuit with chassis
• Disconnect C2 and L82. Repair or
YES between C2 • Min. 1 Mz ground in wiring harness
(female) (7) and • Turn starting NO between C2 (female) (17) – replace
chassis ground switch OFF. L82 (female) (1)
1 normal?
If L82 is replaced • Disconnect C2 Short circuit with chassis
with other same • Min. 1 Mz and L82. Repair or
ground in wiring harness
EPC solenoid, • Turn starting between C2 (female) (7) – replace
does failure code switch OFF. NO
L82 (female) (2)
appear? • Disconnect C2
• Turn starting and L82. Defective steering main
switch OFF. pressure control EPC Replace
• Replace with NO solenoid
other same EPC
solenoid.
• Turn starting 5 YES Defective T/M and J/S
switch ON. Is resistance controller Replace
between C2
From A (female) (7) and
chassis ground Short circuit with power
normal? source in wiring harness Repair or
• Max. 1 V NO between C2 (female) (7) – replace
• Disconnect C2 L82 (female) (2)
and L82.
• Turn starting
switch ON.
20-816 WA700-3
(10)
Troubleshooting A-8
Cause Remedy
Deviation of steering
lever angle sensor or Repair or
frame angle sensor replace
potentiometer
WA700-3 20-817
(10)
Troubleshooting A-9
A-9 Abnormality in console switch (adjustment of steering lever angle sensor and
frame angle sensor is impossible)
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
20-818 WA700-3
(10)
Troubleshooting A-10
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Check that fuse is normal.
a When the joystick steering lever is not being used, leave it at the neutral position.
a Always connect any disconnected connectors before going on to the next step.
Cause Remedy
WA700-3 20-819
(10)
Troubleshooting of engine control system
(EA mode)
Serial No.: 51001 an up
Method of error code display ...................................................................................................................... 20-853
Action taken by controller and condition of machine when error code is displayed .................................... 20-856
Electrical circuit diagram for engine control system .................................................................................... 20-864
EA-1 Error code [111] (Abnormality in controller memory) ........................................................................ 20-866
EA-2 Error code [112] (Abnormality in timing rail actuator) ....................................................................... 20-866
EA-3 Error code [113] (Abnormality with electric current in timing rail actuator system)........................... 20-867
EA-4 Error code [115] (Abnormality in engine speed sensor 2 system).................................................... 20-868
EA-5 Error code [116] (Abnormality [high level] in timing rail pressure sensor system)............................ 20-870
EA-6 Error code [117] (Abnormality [low level] in timing rail pressure sensor system) ............................. 20-871
EA-7 Error code [118] (Abnormality [high level] in fuel pump pressure sensor system) ........................... 20-872
EA-8 Error code [119] (Abnormality [low level] in fuel pump pressure sensor system)............................. 20-873
EA-9 Error code [121] (Abnormality in engine speed sensor 1 system).................................................... 20-874
EA-10 Error code [122] (Abnormality [high level] in boost pressure sensor system) .................................. 20-875
EA-11 Error code [123] (Abnormality [low level] in boost pressure sensor system).................................... 20-876
EA-12 Error code [131] (Abnormality [high level] in accelerator sensor system) ........................................ 20-877
EA-13 Error code [132] (Abnormality [low level] in accelerator sensor system) ......................................... 20-878
EA-14 Error code [135] (Abnormality [high level] in oil pressure sensor system) ....................................... 20-879
EA-15 Error code [141] (Abnormality [low level] in oil pressure sensor system)......................................... 20-880
EA-16 Error code [143] (Abnormal drop in oil pressure (level 1)) ............................................................... 20-881
EA-17 Error code [144] (Abnormality [high level] in water temperature sensor system)............................. 20-882
EA-18 Error code [145] (Abnormality [low level] in water temperature sensor system) .............................. 20-883
EA-19 Error code [151] (Abnormal rise in water temperature).................................................................... 20-883
EA-20 Error code [153] (Abnormality [high level] in intake air temperature sensor system)....................... 20-884
EA-21 Error code [154] (Abnormality [low level] in intake air temperature sensor system) ........................ 20-884
EA-22 Error code [221] (Abnormality [high level] in atmospheric pressure sensor system) ....................... 20-885
EA-23 Error code [222] (Abnormality [low level] in atmospheric pressure sensor system)......................... 20-886
EA-24 Error code [234] (Overspeed) .......................................................................................................... 20-888
EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage) ............................................... 20-889
EA-26 Error code [259] (Abnormality in fuel shut-off valve) ........................................................................ 20-890
EA-27 Error code [261] (Abnormal rise in fuel temperature)....................................................................... 20-890
EA-28 Error code [263] (Abnormality [high level] in fuel temperature sensor system)................................ 20-891
EA-29 Error code [265] (Abnormality [low level] in fuel temperature sensor system) ................................. 20-891
EA-30 Error code [316] (Abnormality in fuel pump actuator system current).............................................. 20-892
EA-31 Error code [318] (Abnormality in fuel pump actuator) ...................................................................... 20-893
EA-32 Error code [343] (Abnormality in controller internal communication) ............................................... 20-893
EA-33 Error code [346] (Abnormality in controller power down) ................................................................. 20-894
WA700-3 20-851
(10)
EA-34 Error code [384] (Abnormality in preheating heater control system)................................................ 20-895
EA-35 Error code [415] (Abnormal drop in oil pressure (level 2)) ............................................................... 20-896
EA-36 Error code [423] (Abnormality [in range] in timing rail pressure sensor system).............................. 20-896
EA-37 Error code [431] (Abnormality [1] in idling validation switch system) ............................................... 20-898
EA-38 Error code [432] (Idling validation process error) ............................................................................. 20-900
EA-39 Error code [441] (Abnormality [low level] in battery voltage) ............................................................ 20-902
EA-40 Error code [442] (Abnormality [high level] in battery voltage) .......................................................... 20-902
EA-41 Error code [451] (Abnormality [high level] in fuel rail pressure sensor system) ............................... 20-903
EA-42 Error code [452] (Abnormality [low level] in fuel rail pressure sensor system)................................. 20-904
EA-43 Error code [455] (Abnormality in fuel rail actuator system current) .................................................. 20-905
EA-44 Error code [467] (Abnormality in timing rail actuator control) ........................................................... 20-906
EA-45 Error code [468] (Abnormality in fuel rail actuator control)............................................................... 20-906
EA-46 Error code [514] (Abnormality in fuel rail actuator)........................................................................... 20-906
EA-47 Error code [527] (Abnormality in dual output solenoid A system) .................................................... 20-907
EA-48 Error code [551] (Abnormality [2] in idling validation switch system) ............................................... 20-907
EA-49 Error code [554] (Abnormality [in range] in fuel rail pressure sensor) .............................................. 20-908
a This section gives an outline of the troubleshooting procedures for the electrical systems related to the
engine proper and the engine controller (for construction equipment).
When carrying out troubleshooting of the electrical system with the engine mounted on the machine, use this
section and the shop manual for the machine.
20-852 WA700-3
(10)
Troubleshooting Method of error code display
WA700-3 20-853
(10)
Troubleshooting Method of error code display
20-854 WA700-3
(10)
Action taken by controller and condition of machine
Troubleshooting when error code is displayed
20-856 WA700-3
(10)
Action taken by controller and condition of machine
Troubleshooting when error code is displayed
• Red lamp lights up • Engine speed goes down • Excessive negative pressure at inlet port of
• Limits engine speed to 1500 rpm fuel pump
• Defective timing rail actuator or clogged
screen
• Broken injector O-ring
• Defective engine controller
• Yellow lamp lights up • Engine output goes down • Defective timing rail actuator
• Engine emits white smoke • Defective wiring harness and connector of
timing rail actuator circuit
• Defective engine controller
• Red lamp lights up • Engine makes abnormal • Defective timing rail pressure sensor
• Carries out open control of timing rail explosion sound or emits white • Defective wiring harness and connector of
• Limits engine speed to 1500 rpm smoke, then engine speed timing rail pressure sensor circuit
becomes 1500 rpm • Defective engine controller
• No lamps light up • Engine output goes down • Defective boost pressure sensor
• Defective wiring harness and connector of
boost pressure sensor circuit
• Defective engine controller
WA700-3 20-857
(10)
Action taken by controller and condition of machine
Troubleshooting when error code is displayed
Abnormality in water • Abnormality has occurred in water • Resistance of water temperature sensor
temperature sensor temperature sensor circuit Between CLTP (A) – (B): 600 – 36 kz
145
system low level ECMA (22): 0.21 V or less detected
20-858 WA700-3
(10)
Action taken by controller and condition of machine
Troubleshooting when error code is displayed
WA700-3 20-859
(10)
Action taken by controller and condition of machine
Troubleshooting when error code is displayed
20-860 WA700-3
(10)
Action taken by controller and condition of machine
Troubleshooting when error code is displayed
• Red lamp lights up • Engine cannot stop • Defective fuel shut-off valve
• Shuts off power supply to fuel shut-off valve • Defective injector
• Defective engine controller
• Orange lamp lights up • Defective engine
• After 30 seconds limits engine speed to 800 — • Defective fuel temperature sensor
rpm • Defect on machine
• Yellow lamp lights up • Defective fuel temperature sensor
• Defective wiring harness and connector of fuel
—
temperature sensor circuit
• Defective engine controller
• Yellow lamp lights up • Defective fuel temperature sensor
• Defective wiring harness and connector of fuel
—
temperature sensor circuit
• Defective engine controller
• Yellow lamp lights up • Defective fuel pump actuator
• Defective wiring harness and connector of fuel
pump actuator circuit
—
• Defective engine controller
• Yellow lamp lights up • Engine speed becomes • Defective fuel pump actuator
unstable • Excessive negative pressure at inlet port of
fuel pump
• Defective fuel temperature sensor
• Defective injector
• Defective engine controller
WA700-3 20-861
(10)
Action taken by controller and condition of machine
Troubleshooting when error code is displayed
• Abnormality has occurred in fuel rail • Voltage of fuel rail pressure sensor
pressure sensor circuit Between ECMA (5) – (18) (power source):
Abnormality in fuel rail
ECMA (31): 4.78 V or more detected 4.75 – 5.25 V
451 pressure sensor system
Between ECMA (31) – (18) (signal):
high level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in fuel rail • Voltage of fuel rail pressure sensor
pressure sensor circuit Between ECMA (5) – (18) (power source):
Abnormality in fuel rail
ECMA (31): 0.15 V or less detected 4.75 – 5.25 V
452 pressure sensor system
Between ECMA (31) – (18) (signal):
low level
0.42 – 0.58 V
(engine stopped)
• Abnormality has occurred in fuel rail • Resistance of fuel rail actuator
Abnormality in fuel rail actuator circuit Between RAIL (A) – (C): 7 – 9 z
455
actuator system current Between ECMA (1) – (20) (reference
value): 0.40 ± 0.35 A (engine stopped)
• Excessive difference between timing rail
command fuel value and actual timing fuel,
Abnormality in timing rail
467 does not reach target value —
actuator control
20-862 WA700-3
(10)
Action taken by controller and condition of machine
Troubleshooting when error code is displayed
• Defective battery
• Blown fuse
— — • Defective wiring harness and connector of
controller power source circuit
• Defective engine controller
• Defective battery
• Blown fuse
— — • Defective wiring harness and connector of
controller power source circuit
• Defective engine controller
• Red lamp lights up • Defective fuel rail pressure sensor
• Carries out open control of fuel rail • Defective wiring harness and connector of fuel
rail pressure sensor circuit
—
• Defective engine controller
WA700-3 20-863
(10)
Troubleshooting Electrical circuit diagram for engine control system
20-864 WA700-3
(10)
Troubleshooting Electrical circuit diagram for engine control system
WA700-3 20-865
(10)
Troubleshooting EA-1, EA-2
Cause Remedy
1
• Turn starting switch OFF
and wait for 5 minutes. Is error code [111] re-enacted?
NO
• Run engine at low idling.
YES
Defective engine controller Replace
2
Has error code [111] already It has probably been reset, so
NO operate for a short time and watch —
been generated 3 or more
times? for any change in symptoms
YES
Defective engine controller Replace
Cause Remedy
1
Is another error code displayed NO
• Turn starting switch ON. at same time?
Go to trouble-
YES shooting for
— service code
displayed
2
When engine is run at rated
speed, does output go up or NO
• Start engine
down, or does exhaust
temperature go up?
YES
Defective timing rail actuator Replace
3
Is there clogging, looseness,
breakage, or leakage from fuel NO
filter, piping?
YES
Clogging, looseness, breakage, or Repair or
leakage from fuel filter, piping replace
4
Is screen of timing rail actuator NO
clogged with dirt?
YES
Clogged timing rail actuator screen Clean or
replace
5
Is engine oil diluted with fuel? NO Defective timing rail actuator or de- Replace
fective engine controller
YES
Broken injector O-ring Replace
20-866 WA700-3
(10)
Troubleshooting EA-3
EA-3 Error code [113] (Abnormality with electric current in timing rail actuator system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between TIMG NO Replace
Defective timing rail actuator
• Disconnect TIMG. (male) (A) and (C) 7 – 9 z?
YES
2
Is resistance between TIMG NO
• Turn starting switch OFF. Defective timing rail actuator
(male) (A)(C) and ground more Replace
• Disconnect TIMG.
than 100 kz?
YES
3
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (1) and TIMG (female) Repair or
(A), and between ECMA (female) NO short circuit in wiring harness
• Disconnect ECMA and replace
(1) and surrounding wiring between ECMA (female) (1) and
TIMG.
harnesses as shown in Table 1? TIMG (female) (A)
YES
4
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (20) and TIMG (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and (C), and between ECMA (female)
(20) and surrounding wiring between ECMA (female) (20) and replace
TIMG.
harnesses as shown in Table 2? TIMG (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), TIMG (female) Resistance value ECMA (female), TIMG (female) Resistance value
Between ECMA (1) and TIMG (A) Max. 10 z Between ECMA (20) and TIMG (C) Max. 10 z
Between ECMA (1) and Between ECMA (20) and
Min. 1 Mz Min. 1 Mz
surrounding wiring harnesses surrounding wiring harnesses
WA700-3 20-867
(10)
Troubleshooting EA-4
Cause Remedy
1
• Turn starting switch OFF. Is resistance between SP1
NO Defective engine speed sensor Replace
• Disconnect SP1 and SP2. (male) (A) and (B), and between
SP2 (male) (A) and (B) 1k – 2kz?
YES
2
Is resistance between SP1
• Turn starting switch OFF. (male) (A) and ground, and NO
Defective engine speed sensor Replace
• Disconnect SP1 and SP2. between SP2 (male) (A) and
ground more than 10 Mz?
YES
3
Is resistance between SP1 (male)
• Turn starting switch OFF. (A) and SP2 (male) (A), and NO Replace
between SP1 (male) (B) and SP2 Defective engine speed sensor
• isconnect SP1 and SP2.
(male) (B) less than 10 z?
YES
4
• Remove engine speed Is engine speed sensor NO Defective engine speed sensor Replace
sensor. damaged?
YES
5
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (37) and SP2 (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and SP1. (A), and between ECMA (female)
(37) and surrounding wiring between ECMA (female) (37) and replace
harnesses as shown in Table 1? SP2 (female) (A)
YES
6
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (38) and SP2 (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and SP1. (B), and between ECMA (female) between ECMA (female) (38) and replace
(38) and surrounding wiring
harnesses as shown in Table 2? SP2 (female) (B)
YES
7
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (27) and SP1 (female) NO short circuit in wiring harness Repair or
(A), and between ECMA (female)
• Disconnect ECMA and SP2. (27) and surrounding wiring between ECMA (female) (27) and replace
harnesses as shown in Table 3? SP1 (female) (A)
YES
8
Is resistance between ECMA Defective contact, disconnection, or
(female) (28) and SP1 (female) Repair or
• Turn starting switch OFF. (B), and between ECMA (female) NO short circuit in wiring harness
between ECMA (female) (28) and replace
• Disconnect ECMA and SP2. (28) and surrounding wiring
harnesses as shown in Table 4? SP1 (female) (B)
YES
Defective engine controller Replace
20-868 WA700-3
(10)
Troubleshooting EA-4
Table 1 Table 2
ECMA (female), SP2 (female) Resistance value ECMA (female), SP2 (female) Resistance value
Between ECMA (37) and SP2 (A) Max. 10 z Between ECMA (38) and SP2 (B) Max. 10 z
Between ECMA (37) and Between ECMA (38) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
Table 3 Table 4
ECMA (female), SP1 (female) Resistance value ECMA (female), SP1 (female) Resistance value
Between ECMA (27) and SP1 (A) Max. 10 z Between ECMA (28) and SP1 (B) Max. 10 z
Between ECMA (27) and Between ECMA (28) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
WA700-3 20-869
(10)
Troubleshooting EA-5
EA-5 Error code [116] (Abnormality [high level] in timing rail pressure sensor system)
Cause Remedy
1
• Disconnect TPR. When TPR is disconnected, NO
• Turn starting switch ON. does error code [116] go out?
YES
Defective timing rail pressure Replace
2
Is resistance between ECMA
(female) (5) and TPR (female) (A), Defective contact, disconnection, or
•Turn starting switch OFF.
• Disconnect ECMA and TPR. and between ECMA (female) (5) NO short circuit in wiring harness Repair or
and surrounding wiring between ECMA (female) (5) and TPR replace
harnesses as shown in Table 1? (female) (A)
YES
3
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (18) and TPR (female)
(B), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and TPR. between ECMA (female) (18) and
(18) and surrounding wiring replace
harnesses as shown in Table 2? TPR (female) (B)
YES
4
Is resistance between ECMA Defective contact, disconnection, or
(female) (33) and TPR (female) NO short circuit in wiring harness Repair or
• Turn starting switch OFF. (C), and between ECMA (female)
• Disconnect ECMA and TPR. between ECMA (female) (33) and replace
(33) and surrounding wiring
harnesses as shown in Table 3? TPR (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), TPR (female) Resistance value ECMA (female), SP1 (female) Resistance value
Between ECMA (5) and TPR (A) Max. 10 z Between ECMA (18) and TPR (B) Max. 10 z
Between ECMA (5) and Between ECMA (18) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
Table 3
20-870 WA700-3
(10)
Troubleshooting EA-6
EA-6 Error code [117] (Abnormality [low level] in timing rail pressure sensor system)
Cause Remedy
1
Is voltage between TPR (A) and
• Insert T-adapter to TPR. NO Defective timing rail pressure Replace
(B), and between (C) and (B) as
• Turn starting switch ON.
shown in Table 1?
YES
2
Is resistance between ECMA Defective contact, disconnection, or
(female) (5) and TPR (female) (A), NO
• Turn starting switch OFF. and between ECMA (female) (5) short circuit in wiring harness Repair or
• Disconnect ECMA and TPR. and surrounding wiring between ECMA (female) (5) and TPR replace
harnesses as shown in Table 2? (female) (A)
YES
3
Is resistance between ECMA E. Defective contact, disconnection,
• Turn starting switch OFF. (female) (18) and TPR (female)
(B), and between ECMA (female) NO or short circuit in wiring harness Repair or
• Disconnect ECMA and TPR. (18) and surrounding wiring between ECMA (female) (18) and replace
harnesses as shown in Table 3? TPR (female) (B)
YES
4
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (33) and TPR (female) NO short circuit in wiring harness Repair or
(C), and between ECMA (female)
• Disconnect ECMA and TPR. (33) and surrounding wiring between ECMA (female) (33) and replace
harnesses as shown in Table 4? TPR (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
TPR Voltage ECMA (female), TPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (5) and TPR (A) Max. 10 z
Between (C) and (B) 0.42 – 0.58 V Between ECMA (5) and
surrounding wiring harnesses Min. 1 Mz
Table 3 Table 4
ECMA (female), TPR (female) Resistance value ECMA (female), TPR (female) Resistance value
Between ECMA (18) and TPR (B) Max. 10 z Between ECMA (33) and TPR (C) Max. 10 z
Between ECMA (18) and Between ECMA (33) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
WA700-3 20-871
(10)
Troubleshooting EA-7
EA-7 Error code [118] (Abnormality [high level] in fuel pump pressure sensor system)
Cause Remedy
1
• Disconnect PMPR. When PMPR is disconnected, NO
• Turn starting switch ON. does error code [118] go out?
YES
Defective fuel pump pressure Replace
2
Is resistance between ECMA
• Turn starting switch OFF. (female) (5) and PMPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (A), and between ECMA (female) NO short circuit in wiring harness Repair or
PMPR. (5) and surrounding wiring between ECMA (female) (5) and replace
harnesses as shown in Table 1? PMPR (female) (A)
YES
3
Is resistance between ECMA
• Turn starting switch OFF. (female) (18) and PMPR (female) Defective contact, disconnection, or
NO Repair or
• Disconnect ECMA and (B), and between ECMA (female) short circuit in wiring harness
(18) and surrounding wiring replace
PMPR. between ECMA (female) (18) and
harnesses as shown in Table 2? PMPR (female) (B)
YES
4
Is resistance between ECMA
• Turn starting switch OFF. (female) (32) and PMPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (C), and between ECMA (female) NO short circuit in wiring harness Repair or
PMPR. (32) and surrounding wiring between ECMA (female) (32) and replace
harnesses as shown in Table 3? PMPR (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), PMPR (female) Resistance value ECMA (female), PMPR (female) Resistance value
Between ECMA (5) and PMPR (A) Max. 10 z Between ECMA (18) and PMPR (B) Max. 10 z
Between ECMA (5) and Between ECMA (18) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
Table 3
20-872 WA700-3
(10)
Troubleshooting EA-8
EA-8 Error code [119] (Abnormality [low level] in fuel pump pressure sensor system)
Cause Remedy
1
• Insert T-adapter to PMPR. Is voltage between PMPR (A)
NO
and (B), and between (C) and Defective fuel pump pressure sensor Replace
• Turn starting switch ON.
(B) as shown in Table 1?
YES
2
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (5) and PMPR (female)
(A), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and
(5) and surrounding wiring between ECMA (female) (5) and replace
PMPR.
harnesses as shown in Table 2? PMPR (female) (A)
YES
3
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (18) and PMPR (female)
NO short circuit in wiring harness Repair or
• Disconnect ECMA and (B), and between ECMA (female)
(18) and surrounding wiring between ECMA (female) (18) and replace
PMPR.
harnesses as shown in Table 3? PMPR (female) (B)
YES
4
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (32) and PMPR (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and (C), and between ECMA (female)
(32) and surrounding wiring between ECMA (female) (32) and replace
PMPR.
harnesses as shown in Table 4? PMPR (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
PMPR Voltage ECMA (female), PMPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (5) and PMPR (A) Max. 10 z
Between (C) and (B) 0.42 – 0.58 V Between ECMA (5) and
surrounding wiring harnesses Min. 1 Mz
Table 3 Table 4
ECMA (female), PMPR (female) Resistance value ECMA (female), PMPR (female) Resistance value
Between ECMA (18) and PMPR (B) Max. 10 z Between ECMA (32) and PMPR (C) Max. 10 z
Between ECMA (18) and Between ECMA (32) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
WA700-3 20-873
(10)
Troubleshooting EA-9
20-874 WA700-3
(10)
Troubleshooting EA-10
EA-10 Error code [122] (Abnormality [high level] in boost pressure sensor system)
Cause Remedy
1
• Disconnect IMPR. When IMPR is disconnected, NO
• Turn starting switch ON. does error code [122] go out?
YES
Defective boost pressure sensor Replace
2
Is resistance between ECMA
• Turn starting switch OFF. (female) (6) and IMPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (A), and between ECMA (female) NO short circuit in wiring harness Repair or
IMPR. (6) and surrounding wiring between ECMA (female) (6) and replace
harnesses as shown in Table 1? IMPR (female) (A)
YES
3
Is resistance between ECMA
• Turn starting switch OFF. (female) (17) and IMPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (B), and between ECMA (female) NO short circuit in wiring harness Repair or
IMPR. (17) and surrounding wiring between ECMA (female) (17) and replace
harnesses as shown in Table 2? IMPR (female) (B)
YES
4
Is resistance between ECMA
• Turn starting switch OFF. (female) (35) and IMPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (C), and between ECMA (female) NO short circuit in wiring harness Repair or
IMPR. (35) and surrounding wiring between ECMA (female) (35) and replace
harnesses as shown in Table 3? IMPR (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), IMPR (female) Resistance value ECMA (female), IMPR (female) Resistance value
Between ECMA (6) and IMPR (A) Max. 10 z Between ECMA (17) and IMPR (B) Max. 10 z
Between ECMA (6) and Between ECMA (17) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
Table 3
WA700-3 20-875
(10)
Troubleshooting EA-11
EA-11 Error code [123] (Abnormality [low level] in boost pressure sensor system)
Cause Remedy
1
Is voltage between IMPR (A)
• Insert T-adapter to IMPR. NO Defective boost pressure sensor Replace
and (B), and between (C) and
• Turn starting switch ON.
(B) as shown in Table 1?
YES
2
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (6) and IMPR (female)
(A), and between ECMA (female)
NO short circuit in wiring harness Repair or
• Disconnect ECMA and
(6) and surrounding wiring between ECMA (female) (6) and replace
IMPR.
harnesses as shown in Table 2? IMPR (female) (A)
YES
3
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (17) and IMPR (female)
(B), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and replace
(17) and surrounding wiring between ECMA (female) (17) and
IMPR.
harnesses as shown in Table 3? IMPR (female) (B)
YES
4
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (35) and IMPR (female) Repair or
NO short circuit in wiring harness
• Disconnect ECMA and (C), and between ECMA (female)
(35) and surrounding wiring between ECMA (female) (35) and replace
IMPR.
harnesses as shown in Table 4? IMPR (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
IMPR Voltage ECMA (female), IMPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (6) and IMPR (A) Max. 10 z
Between (C) and (B) 0.42 – 0.58 V Between ECMA (6) and
surrounding wiring harnesses Min. 1 Mz
Table 3 Table 4
ECMA (female), IMPR (female) Resistance value ECMA (female), IMPR (female) Resistance value
Between ECMA (17) and IMPR (B) Max. 10 z Between ECMA (35) and IMPR (C) Max. 10 z
Between ECMA (17) and Between ECMA (35) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
20-876 WA700-3
(10)
Troubleshooting EA-12
EA-12 Error code [131] (Abnormality [high level] in accelerator sensor system)
Cause Remedy
1
Is resistance between L13 (male)
• Turn starting switch OFF. NO Defective accelerator sensor Replace
(3) and (2), and between L13 (1)
• Disconnect L13.
and L13(2) as shown in Table 1?
YES
2
Is resistance between ECMB Defective contact, disconnection, or
• Turn starting switch OFF. (female) (11) and L13 (female) (2), NO
and between ECMB (female) (11) short circuit in wiring harness Repair or
• Disconnect ECMB and L13. and surrounding wiring between ECMB (female) (11) and replace
harnesses as shown in Table 2? L13(female) (2)
YES
3
Is resistance between ECMB Defective contact, disconnection, or
(female) (29) and L13 (female) (1),
• Turn starting switch OFF. and between ECMB (female) (29) NO short circuit in wiring harness Repair or
• Disconnect ECMB and L13. and surrounding wiring harnesses between ECMB (female) (29) and replace
as shown in Table 3? L13 (female) (1)
YES
4
Is resistance between ECMB Defective contact, disconnection, or
• Turn starting switch OFF. (female) (26) and L13 (female) (3), NO short circuit in wiring harness Repair or
and between ECMB (female) (26)
• Disconnect ECMB and L13. and surrounding wiring between ECMB (female) (26) and replace
harnesses as shown in Table 4? L13 (female) (3)
YES
Defective engine controller Replace
Table 1 Table 2
L13 (male) Resistance value ECMB (female), L13 (female) Resistance value
Between L13(3) and L13(2) 2,000 – 3,000 z Between ECMA (11) and L13(2) Max. 10 z
Between L13(1) and L13(2) 200 – 3,000 z Between ECMB (11) and
surrounding wiring harnesses Min. 1 Mz
Table 3 Table 4
ECMB (female), L13 (female) Resistance value ECMB (female), L13 (female) Resistance value
Between ECMB (29) and L13(1) Max. 10 z Between ECMB (26) and L13(3) Max. 10 z
Between ECMB (29) and Between ECMB (26) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
WA700-3 20-877
(10)
Troubleshooting EA-12, EA-13
EA-13 Error code [132] (Abnormality [low level] in accelerator sensor system)
20-878 WA700-3
(10)
Troubleshooting EA-14
EA-14 Error code [135] (Abnormality [high level] in oil pressure sensor system)
Cause Remedy
1
• Disconnect CLPR. When CLPR is disconnected, NO
• Turn starting switch ON. does error code [135] go out?
YES
Defective oil pressure sensor Replace
2
Is resistance between ECMA
• Turn starting switch OFF. (female) (6) and CLPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (A), and between ECMA (female) NO short circuit in wiring harness Repair or
CLPR. (6) and surrounding wiring between ECMA (female) (6) and replace
harnesses as shown in Table 1? CLPR (female) (A)
YES
3
Is resistance between ECMA
• Turn starting switch OFF. (female) (17) and CLPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (B), and between ECMA (female) NO short circuit in wiring harness Repair or
CLPR. (17) and surrounding wiring between ECMA (female) (17) and replace
harnesses as shown in Table 2? CLPR (female) (B)
YES
4
Is resistance between ECMA
• Turn starting switch OFF. (female) (24) and CLPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (C), and between ECMA (female) NO short circuit in wiring harness Repair or
(24) and surrounding wiring between ECMA (female) (24) and replace
CLPR. harnesses as shown in Table 3? CLPR (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), CLPR (female) Resistance value ECMA (female), CLPR (female) Resistance value
Between ECMA (6) and CLPR (A) Max. 10 z Between ECMA (17) and CLPR (B) Max. 10 z
Between ECMA (6) and Between ECMA (17) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
Table 3
WA700-3 20-879
(10)
Troubleshooting EA-15
EA-15 Error code [141] (Abnormality [low level] in oil pressure sensor system)
Cause Remedy
1
Is voltage between CLPR (A)
• Insert T-adapter to CLPR. NO Defective oil pressure sensor Replace
and (B), and between (C) and
• Turn starting switch ON.
(B) as shown in Table 1?
YES
2
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (6) and CLPR (female) NO
(A), and between ECMA (female) short circuit in wiring harness Repair or
• Disconnect ECMA and between ECMA (female) (6) and
(6) and surrounding wiring replace
CLPR. CLPR (female) (A)
harnesses as shown in Table 2?
YES
3
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (17) and CLPR (female)
(B), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and replace
(17) and surrounding wiring between ECMA (female) (17) and
CLPR.
harnesses as shown in Table 3? CLPR (female) (B)
YES
4
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (24) and CLPR (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and (C), and between ECMA (female)
(24) and surrounding wiring between ECMA (female) (24) and replace
CLPR.
harnesses as shown in Table 4? CLPR (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
CLPR Voltage ECMA (female), CLPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (6) and CLPR (A) Max. 10 z
Between (C) and (B) 0.42 – 0.58 V Between ECMA (6) and
surrounding wiring harnesses Min. 1 Mz
Table 3 Table 4
ECMA (female), CLPR (female) Resistance value ECMA (female), CLPR (female) Resistance value
Between ECMA (17) and CLPR (B) Max. 10 z Between ECMA (24) and CLPR (C) Max. 10 z
Between ECMA (17) and Between ECMA (24) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
20-880 WA700-3
(10)
Troubleshooting EA-16
EA-16 Error code [143] (Abnormal drop in oil pressure (level 1))
Cause Remedy
1
Is another error code displayed NO
• Turn starting switch ON.
at same time?
Go to trouble-
YES shooting for
— service code
displayed
2
When troubleshooting for error Investigate
codes [135] and [141] is carried NO Defective engine cause and
out, does any problem occur in repair damage
electrical system? to engine
YES Defective electrical system for oil Repair or
pressure sensorDefective electrical replace
WA700-3 20-881
(10)
Troubleshooting EA-17
EA-17 Error code [144] (Abnormality [high level] in water temperature sensor system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between CLTP NO Defective water temperature sensor Replace
• Disconnect CLTP. (male) (A) and (B) 600 – 36kz?
YES
2
Is resistance between ECMA (fe- Defective contact, disconnection, or
• Turn starting switch OFF. male) (22) and CLTP (female) (A),
• Disconnect ECMA and and between ECMA (female) (22) NO short circuit in wiring harness be- Repair or
and surrounding wiring harnes- tween ECMA (female) (22) and CLTP replace
CLTP.
ses as shown in Table 1? (female) (A)
YES
3
Is resistance between ECMA (fe- Defective contact, disconnection, or
• Turn starting switch OFF. male) (17) and CLTP (female) (B), NO short circuit in wiring harness be- Repair or
• Disconnect ECMA and and between ECMA (female) (17) tween ECMA (female) (17) and CLTP replace
CLTP. and surrounding wiring harnes-
ses as shown in Table 2? (female) (B)
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), CLTP (female) Resistance value ECMA (female), CLTP (female) Resistance value
Between ECMA (22) and CLTP (A) Max. 10 z Between ECMA (17) and CLTP (B) Max. 10 z
Between ECMA (22) and Between ECMA (17) and sur-
surrounding wiring harnesses Min. 1 Mz rounding wiring harnesses Min. 1 Mz
20-882 WA700-3
(10)
Troubleshooting EA-18, EA-19
EA-18 Error code [145] (Abnormality [low level] in water temperature sensor system)
Cause Remedy
1
Is another error code displayed NO
• Turn starting switch ON.
at same time?
Go to trouble-
YES shooting for
— service code
displayed
2
When troubleshooting for error Investigate
codes [144] and [145] is carried NO Defective engine cause and re-
out, does any problem occur in pair damage
electrical system? to engine
YES Defective electrical system for oil Repair or
pressure sensor replace
WA700-3 20-883
(10)
Troubleshooting EA-20, EA-21
EA-20 Error code [153] (Abnormality [high level] in intake air temperature
sensor system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between IMTP NO Defective intake air temperature Replace
• Disconnect IMTP (male) (A) and (B) 600 – 36kz? sensor
YES
2
Is resistance between ECMA (fe- Defective contact, disconnection, or
male) (23) and IMTP (female) (A),
• Turn starting switch OFF. and between ECMA (female) (23) NO short circuit in wiring harness be- Repair or
• Disconnect ECMA and IMTP. and surrounding wiring harnes- tween ECMA (female) (23) and IMTP replace
ses as shown in Table 1? (female) (A)
YES
3
s resistance between ECMA (fe- Defective contact, disconnection, or
• Turn starting switch OFF. male) (17) and IMTP (female) (B), NO short circuit in wiring harness Repair or
and between ECMA (female) (17) between ECMA (female) (17) and replace
• Disconnect ECMA and IMTP. and surrounding wiring harnes-
ses as shown in Table 2? IMTP (female) (B)
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), IMTP (female) Resistance value ECMA (female), IMTP (female) Resistance value
Between ECMA (23) and IMTP (A) Max. 10 z Between ECMA (17) and IMTP (B) Max. 10 z
Between ECMA (23) and Between ECMA (17) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
EA-21 Error code [154] (Abnormality [low level] in intake air temperature
sensor system)
20-884 WA700-3
(10)
Troubleshooting EA-22
Cause Remedy
1
• Disconnect AAPR. When AAPR is disconnected, NO
• Turn starting switch ON. does error code [221] go out?
2
Is resistance between ECMA
• Turn starting switch OFF. (female) (6) and AAPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (A), and between ECMA (female) NO short circuit in wiring harness Repair or
AAPR. (6) and surrounding wiring between ECMA (female) (6) and replace
harnesses as shown in Table 1? AAPR (female) (A)
YES
3
Is resistance between ECMA
• Turn starting switch OFF. (female) (17) and AAPR (female) Defective contact, disconnection, or
• Disconnect ECMA and (B), and between ECMA (female) NO short circuit in wiring harness Repair or
AAPR. (17) and surrounding wiring between ECMA (female) (17) and replace
harnesses as shown in Table 2? AAPR (female) (B)
YES
4
Is resistance between ECMA
• Turn starting switch OFF. (female) (34) and AAPR (female) Defective contact, disconnection, or
(C), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and
(34) and surrounding wiring between ECMA (female) (34) and replace
AAPR. harnesses as shown in Table 3? AAPR (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), AAPR (female) Resistance value ECMA (female), AAPR (female) Resistance value
Between ECMA (6) and AAPR (A) Max. 10 z Between ECMA (17) and AAPR (B) Max. 10 z
Between ECMA (6) and Between ECMA (17) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
Table 3
WA700-3 20-885
(10)
Troubleshooting EA-23
Cause Remedy
1
Is voltage between AAPR (A) Defective atmospheric pressure
• Insert T-adapter to AAPR. NO Replace
and (B), and between (C) and sensor
• Turn starting switch ON.
(B) as shown in Table 1?
YES
2
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (6) and AAPR (female)
(A), and between ECMA (female)
NO short circuit in wiring harness Repair or
• Disconnect ECMA and
(6) and surrounding wiring between ECMA (female) (6) and replace
AAPR.
harnesses as shown in Table 2? AAPR (female) (A)
YES
3
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (17) and AAPR (female)
(B), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and
(17) and surrounding wiring between ECMA (female) (17) and replace
AAPR.
harnesses as shown in Table 3? AAPR (female) (B)
YES
4
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (34) and AAPR (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and (C), and between ECMA (female)
(34) and surrounding wiring between ECMA (female) (34) and replace
AAPR.
harnesses as shown in Table 4? AAPR (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
AAPR Voltage ECMA (female), AAPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (6) and AAPR (A) Max. 10 z
Between (C) and (B) 0.42 – 0.58 V Between ECMA (6) and
surrounding wiring harnesses Min. 1 Mz
Table 3 Table 4
ECMA (female), AAPR (female) Resistance value ECMA (female), AAPR (female) Resistance value
Between ECMA (17) and AAPR (B) Max. 10 z Between ECMA (34) and AAPR (C) Max. 10 z
Between ECMA (17) and Between ECMA (34) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
20-886 WA700-3
(10)
Troubleshooting EA-23
WA700-3 20-887
(10)
Troubleshooting EA-24
Cause Remedy
1
Is another error code displayed NO
• Turn starting switch ON.
at same time?
Go to
YES
troubleshooting
—
for service code
displayed
2
Has machine been used is way NO
which would cause overspeed?
Investigate
YES cause and
Defective engine repair damage
to engine
3 Investigate
Can engine speed be read NO cause and
• Turn starting switch ON. Defective engine repair damage
correctly?
to engine
YES Investigate
Defective engine cause and
repair damage
to engine
20-888 WA700-3
(10)
Troubleshooting EA-25
EA-25 Error code [254] (Abnormality in fuel shut-off valve system voltage)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between FSO+ NO Defective fuel shut-off valve Replace
• Disconnect FSO+ and FSO-. and FSO- (valve end) 23 – 40 z?
YES
2
Is resistance between FSO+
• Turn starting switch OFF. NO
and FSO- (valve end) more Defective fuel shut-off valve Replace
• Disconnect FSO+ and FSO-.
than 100 kz?
YES
3
Is resistance between ECMA Defective contact, disconnection, or
(female) (8) and FSO-, and
• Turn starting switch OFF. between ECMA (female) (8) and NO short circuit in wiring harness Repair or
• Disconnect ECMA and FSO-. surrounding wiring harnesses between ECMA (female) (8) and replace
as shown in Table 1? FSO-
YES
4
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (30) and FSO+, and NO short circuit in wiring harness Repair or
• Disconnect ECMA and between ECMA (female) (30)
and surrounding wiring between ECMA (female) (30) and replace
FSO+.
harnesses as shown in Table 2? FSO+
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), FSO- Resistance value ECMA (female), FSO+ Resistance value
Between ECMA (8) and FSO- Max. 10 z Between ECMA (30) and FSO+ Max. 10 z
Between ECMA (8) and Between ECMA (30) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
WA700-3 20-889
(10)
Troubleshooting EA-26, EA-27
Cause Remedy
3
Is there clogging, looseness,
NO
breakage, or leakage from fuel
filter, piping?
YES
Clogging, looseness, breakage, or Repair or
leakage from fuel filter, piping replace
4
Is there problem with internal NO
Defective engine controller Replace
parts of injector?
YES
Defective injector Replace
Cause Remedy
1
Is another error code displayed NO
• Turn starting switch ON.
at same time?
Go to trouble-
YES shooting for
— service code
displayed
2
When troubleshooting for error Investigate
codes [263] and [264] is carried NO Defective engine cause and
out, does any problem occur in repair damage
electrical system? to engine
YES Defective electrical system for fuel Repair or
temperature sensor replace
20-890 WA700-3
(10)
Troubleshooting EA-28, EA-29
EA-28 Error code [263] (Abnormality [high level] in fuel temperature sensor system)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between FLTP NO Defective fuel temperature sensor Replace
• Disconnect FLTP. (male) (A) and (B) 600 – 36 kz?
YES
2
Is resistance between ECMA Defective contact, disconnection, or
(female) (26) and FLTP (female)
•Turn starting switch OFF. (A), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and FLTP. (26) and surrounding wiring between ECMA (female) (26) and replace
harnesses as shown in Table 1? FLTP (female) (A)
YES
3
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (17) and FLTP (female) NO short circuit in wiring harness Repair or
(B), and between ECMA (female) between ECMA (female) (17) and replace
• Disconnect ECMA and FLTP. (17) and surrounding wiring
harnesses as shown in Table 2? FLTP (female) (B)
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), FLTP (female) Resistance value ECMA (female), FLTP (female) Resistance value
Between ECMA (26) and FLTP (A) Max. 10 z Between ECMA (17) and FLTP (B) Max. 10 z
Between ECMA (26) and Between ECMA (17) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
EA-29Error code [265] (Abnormality [low level] in fuel temperature sensor system)
WA700-3 20-891
(10)
Troubleshooting EA-30
EA-30 Error code [316] (Abnormality in fuel pump actuator system current)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between PUMP NO Defective fuel pump actuator Replace
• Disconnect PUMP. (male) (A) and (C) 7 – 9 z?
YES
2
Is resistance between PUMP
• Turn starting switch OFF. NO
(male) (A)(C) and ground more Defective fuel pump actuator Replace
• Disconnect PUMP.
than 100 kz?
YES
3
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (11) and PUMP (female) short circuit in wiring harness
(A), and between ECMA (female) NO Repair or
• Disconnect ECMA and between ECMA (female) (11) and replace
PUMP. (11) and surrounding wiring
harnesses as shown in Table 1? PUMP (female) (A)
YES
4
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (40) and PUMP (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and (C), and between ECMA (female)
(40) and surrounding wiring between ECMA (female) (40) and replace
PUMP.
harnesses as shown in Table 2? PUMP (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), PUMP (female) Resistance value ECMA (female), PUMP (female) Resistance value
Between ECMA (11) and PUMP (A) Max. 10 z Between ECMA (40) and PUMP (C) Max. 10 z
Between ECMA (11) and Between ECMA (40) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
20-892 WA700-3
(10)
Troubleshooting EA-31, EA-32
Cause Remedy
1
Is another error code displayed NO
• Turn starting switch ON.
at same time?
Go to trouble-
YES shooting for
— service code
displayed
2
When engine is run at rated
• Start engine speed, does output go up or NO
down, or does exhaust
YES
Defective fuel pump actuator Replace
3
Is there clogging, looseness,
breakage, or leakage from fuel NO
filter, piping?
YES Clogging, looseness, breakage, or Repair or
leakage from fuel filter, piping replace
4
Is negative pressure at suction NO
• Start engine. side (tank side) of fuel filter
more than 27kPa{203mmHg}?
YES
Excessive suction resistance of fuel Repair or
filter replace
5
When troubleshooting for error
codes [118] and [119] is carried NO
out, does any problem occur in
electrical system?
YES Defective electrical system for fuel Repair or
pump pressure sensor replace
6
Is there problem with internal NO
Defective engine controller Replace
parts of injector?
YES
Defective injector Replace
Cause Remedy
1
• Turn starting switch OFF.
Is error code [343] re-enacted?
NO
• Wait for 5 minutes, then
turn starting switch ON.
YES
Defective engine controller Replace
WA700-3 20-893
(10)
Troubleshooting EA-33
Cause Remedy
1
Is battery terminal connected NO Defective connection of battery Repair
normally? terminal
YES
2
• Turn starting switch OFF.
Is voltage of battery 17.3 – 34.7 V ?
NO Drop in battery voltage Charge or
• Disconnect battery terminal. replace
YES
3
Is slow blow fuse blown? NO
YES
Blown slow blow fuse Replace
4
• Turn starting switch OFF. Is resistance between slow
blow fuse inlet and battery (+), Defective contact, disconnection, or
• Disconnect slow blow fuse NO Repair or
and between slow blow fuse short circuit in wiring harness
inlet terminal and battery replace
(+) terminal. inlet and surrounding wiring between slow blow fuse inlet and
harnesses as shown in Table 1? battery (+)
YES
5
Is resistance between ECMB Defective contact, disconnection, or
• Turn starting switch OFF. (female) (3)(4)(5) and slow blow fuse NO
• Disconnect ECMB and short circuit in wiring harness Repair or
outlet, and between ECMB (female)
slow blow fuse outlet (3)(4)(5) and surrounding wiring between ECMB (female) (3)(4)(5) replace
harnesses as shown in Table 2? and slow blow fuse outlet
YES
Defective engine controller Replace
Table 1 Table 2
Slow blow fuse inlet, battery (+) Resistance value ECMB (female), C slow blow fuse outlet Resistance value
Between slow blow fuse inlet and Between ECMB (3)(4)(5) and
Max. 10 z Max. 10 z
battry (+) slow blow fuse outlet
Between slow blow fuse inlet Between ECMB (3)(4)(5) and
and surrounding wiring harness Min. 1 Mz surrounding wiring harness Min. 1 Mz
20-894 WA700-3
(10)
Troubleshooting EA-34
Cause Remedy
1
• Turn starting switch OFF.
Is resistance between L82 NO Defective heater relay Replace
• Disconnect preheating
(male) (1) and (2) 200 – 400 z?
relay L82.
YES
2
Is the wiring harness resistance Defective contact, disconnection
• Turn starting switch OFF. value between ECMA(female) NO short circuit wiring harness between Repair or
• Disconnect L82. (2) and L82 (female) (1) as ECMA (female) (2) – L82 (female) (1) replace
indicated in Table 1?
YES
3
Is the resistance value between There is ground fault or short-
• Turn starting switch OFF. the chassis and ECMA (female) NO circuiting in the wiring harness Repair or
• Disconnect ECMA, L82. (2) or L82 (female) (1) as between ECMA (female) (2) and L82 replace
indicated in Table 1? (female) (1).
YES
4
Is the resistance value in the There is a disconnection or
wiring harness between L82 NO connection fault in the wiring Repair or
(female) (2) and the chassis as harness between L82 (female) (2) replace
indicated in Table 1? and the chassis.
YES
Defective engine controller Replace
Table 1
WA700-3 20-895
(10)
Troubleshooting EA-35, EA-36
EA-35 Error code [415] (Abnormal drop in oil pressure (level 2))
EA-36 Error code [423] (Abnormality [in range] in timing rail pressure sensor system)
Cause Remedy
2
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (5) and TPR (female) (A), NO short circuit in wiring harness Repair or
and between ECMA (female) (5)
• Disconnect ECMA and TPR. and surrounding wiring between ECMA (female) (5) and TPR replace
harnesses as shown in Table 1? (female) (A)
YES
3
Is resistance between ECMA Defective contact, disconnection, or
(female) (18) and TPR (female) NO short circuit in wiring harness Repair or
• Turn starting switch OFF. (B), and between ECMA (female) between ECMA (female) (18) and replace
• Disconnect ECMA and TPR. (18) and surrounding wiring TPR (female) (B)
harnesses as shown in Table 2?
YES
4
Is resistance between ECMA Defective contact, disconnection, or
(female) (33) and TPR (female)
• Turn starting switch OFF. (C), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and TPR. (33) and surrounding wiring between ECMA (female) (33) and replace
harnesses as shown in Table 3? TPR (female) (C)
YES
5
Is negative pressure at suction
NO
• Start engine. side (tank side) of fuel filter Defective engine controller Replace
more than 27kPa{203mmHg}?
YES
Excessive suction resistance of fuel Repair or
filter replace
Table 1 Table 2
ECMA (female), TPR (female) Resistance value ECMA (female), TPR (female) Resistance value
Between ECMA (5) and TPR (A) Max. 10 z Between ECMA (18) and TPR (B) Max. 10 z
Between ECMA (5) and Between ECMA (18) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
Table 3
20-896 WA700-3
(10)
Troubleshooting EA-36
WA700-3 20-897
(10)
Troubleshooting EA-37
EA-37 Error code [431] (Abnormality [1] in idling validation switch system)
Cause Remedy
1
Is resistance between L14
• Turn starting switch OFF. NO Defective idling validation switch Replace
(female) (1) – (2) and (1) – (3)
• Disconnect L14.
shown in Table 1?
YES
2
Is resistance between ECMB Defective contact, disconnection, or
• Turn starting switch OFF. (female) (21) and L14 (male) (1), NO short circuit in wiring harness Repair or
• Disconnect ECMB and L14. and between ECMB (female)
(21) and surrounding wiring between ECMB (female) (21) and replace
harnesses as shown in Table 2? L14 (male) (1)
YES
3
Is resistance between ECMB Defective contact, disconnection, or
• Turn starting switch OFF. (female) (13) and L14 (male) (2), NO short circuit in wiring harness Repair or
and between ECMB (female) between ECMB (female) (13) and replace
• Disconnect ECMB and L14. (13) and surrounding wiring
harnesses as shown in Table 3? L14 (male) (2)
YES
4
Is resistance between ECMB (fe- Defective contact, disconnection, or
• Turn starting switch OFF. male) (12) and L14 (male) (3), NO
and between ECMB (female) (12) short circuit in wiring harness Repair or
• Disconnect ECMB and L14. and surrounding wiring harnes- between ECMB (female) (12) and replace
ses as shown in Table 4? L14 (male) (3)
YES
Defective engine controller Replace
Table 1 Table 2
L14 (male) Pedal Resistance value ECMB (female), L14 (male) Resistance value
Between (1) and (2) Released (idling ON) Max. 125 z Between ECMB (21) and L14 (1) Max. 10 z
Between (1) and (3) Depressed (idling OFF) Max. 125 z Between ECMB (21) and
surrounding wiring harnesses Min. 1 Mz
Table 3 Table 4
ECMB (female), L14 (male) Resistance value ECMB (female), L14 (male) Resistance value
Between ECMB (13) and L14 (2) Max. 10 z Between ECMB (12) and L14 (3) Max. 10 z
Between ECMB (13) and Between ECMB (12) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
20-898 WA700-3
(10)
Troubleshooting EA-37
WA700-3 20-899
(10)
Troubleshooting EA-38
Cause Remedy
1
Is resistance between L14
• Turn starting switch OFF. NO Replace
(female) (1) and (3), and between Defective idling validation switch
• Disconnect L14. (2) and (3) as shown in Table 1?
YES
2
Is resistance between ECMB Defective contact, disconnection, or
• Turn starting switch OFF. (female) (21) and L14 (male) (1), NO
and between ECMB (female) short circuit in wiring harness Repair or
• Disconnect ECMB and L14. (21) and surrounding wiring between ECMB (female) (21) and replace
harnesses as shown in Table 2? L14 (male) (1)
YES
3
Is resistance between ECMB Defective contact, disconnection, or
• Turn starting switch OFF. (female) (13) and L14 (male) (2), NO short circuit in wiring harness Repair or
and between ECMB (female) between ECMB (female) (13) and replace
• Disconnect ECMB and L14. (13) and surrounding wiring
harnesses as shown in Table 3? L14 (male) (2)
YES
4
Is resistance between ECMB Defective contact, disconnection, or
• Turn starting switch OFF. (female) (12) and L14 (male) (3), NO short circuit in wiring harness Repair or
and between ECMB (female)
• Disconnect ECMB and L14. (12) and surrounding wiring between ECMB (female) (12) and replace
harnesses as shown in Table 4? L14 (male) (3)
YES
Defective engine controller Replace
Table 1 Table 2
L14 (male) Pedal Resistance value ECMB (female), L14(male) Resistance value
Between (1) and (3) Released or depressed 2,000 – 3,000 z Between ECMB (21) and L14 (1) Max. 10 z
Released (idling ON) 1,500 – 3,000 z Between ECMB (21) and
Min. 1 Mz
Between (2) and (3) surrounding wiring harnesses
Depressed (idling OFF) 200 – 1,500 z
Table 3 Table 4
ECMB (female), L14 (male) Resistance value ECMB (female), L14 (male) Resistance value
Between ECMB (13) and L14 (2) Max. 10 z Between ECMB (12) and L14 (3) Max. 10 z
Between ECMB (13) and Between ECMB (12) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
20-900 WA700-3
(10)
Troubleshooting EA-38
WA700-3 20-901
(10)
Troubleshooting EA-39, EA-40
20-902 WA700-3
(10)
Troubleshooting EA-41
EA-41 Error code [451] (Abnormality [high level] in fuel rail pressure sensor system)
Cause Remedy
1
• Disconnect RPR. When RPR is disconnected, NO
• Turn starting switch ON. does error code [451] go out?
YES
Defective fuel rail pressure sensor Replace
2
Is resistance between ECMA
(female) (5) and RPR (female) (A), Defective contact, disconnection, or
• Turn starting switch OFF.
and between ECMA (female) (5) NO short circuit in wiring harness Repair or
• Disconnect ECMA and RPR. and surrounding wiring between ECMA (female) (5) and RPR replace
harnesses as shown in Table 1? (female) (A)
YES
3
Is resistance between ECMA
(female) (18) and RPR (female) Defective contact, disconnection, or
• Turn starting switch OFF. NO
(B), and between ECMA (female) short circuit in wiring harness Repair or
• Disconnect ECMA and RPR. (18) and surrounding wiring between ECMA (female) (18) and replace
harnesses as shown in Table 2? RPR (female) (B)
YES
4
Is resistance between ECMA
(female) (31) and RPR (female) Defective contact, disconnection, or
• Turn starting switch OFF. (C), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and RPR. (31) and surrounding wiring between ECMA (female) (31) and replace
harnesses as shown in Table 3?
RPR (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), RPR (female) Resistance value ECMA (female), RPR (female) Resistance value
Between ECMA (5) and RPR (A) Max. 10 z Between ECMA (18) and RPR (B) Max. 10 z
Between ECMA (5) and Between ECMA (18) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
Table 3
ECMA (female), RPR (female) Resistance value
Between ECMA (31) and RPR (C) Max. 10 z
Between ECMA (31) and
surrounding wiring harnesses Min. 1 Mz
WA700-3 20-903
(10)
Troubleshooting EA-42
EA-42 Error code [452] (Abnormality [low level] in fuel rail pressure sensor system)
Cause Remedy
1
Is voltage between RPR (A) and
• Insert T-adapter to RPR. NO Replace
(B), and between (C) and (B) as Defective fuel rail pressure sensor
• Turn starting switch ON.
shown in Table 1?
YES
2
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (5) and RPR (female) NO
(A), and between ECMA (female) short circuit in wiring harness Repair or
• Disconnect ECMA and RPR. (5) and surrounding wiring between ECMA (female) (5) and RPR replace
harnesses as shown in Table 2? (female) (A)
YES
3
Is resistance between ECMA Defective contact, disconnection, or
(female) (18) and RPR (female)
• Turn starting switch OFF. (B), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and RPR. (18) and surrounding wiring between ECMA (female) (18) and replace
harnesses as shown in Table 3? RPR (female) (B)
YES
4
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (31) and RPR (female) NO short circuit in wiring harness Repair or
(C), and between ECMA (female) replace
• Disconnect ECMA and RPR. (31) and surrounding wiring between ECMA (female) (31) and
harnesses as shown in Table 4? RPR (female) (C)
YES
Defective engine controller Replace
Table 1 Table 2
RPR Voltage ECMA (female), RPR (female) Resistance value
Between (A) and (B) 4.75 – 5.25 V Between ECMA (5) and RPR (A) Max. 10 z
Between (C) and (B) 0.42 – 0.58 V Between ECMA (5) and
surrounding wiring harnesses Min. 1 Mz
Table 3 Table 4
ECMA (female), RPR (female) Resistance value ECMA (female), RPR (female) Resistance value
Between ECMA (18) and RPR (B) Max. 10 z Between ECMA (31) and RPR (C) Max. 10 z
Between ECMA (18) and Between ECMA (31) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
20-904 WA700-3
(10)
Troubleshooting EA-43
EA-43 Error code [455] (Abnormality in fuel rail actuator system current)
Cause Remedy
1
• Turn starting switch OFF. Is resistance between RAIL NO Replace
Defective fuel rail actuator
• Disconnect RAIL. (male) (A) and (C) 7 – 9 z?
YES
2
Is resistance between RAIL
• Turn starting switch OFF. (male) (A)(C) and ground more
NO
Defective fuel rail actuator Replace
• Disconnect RAIL. than 100 kz?
YES
3
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (3) and RAIL (female)
(A), and between ECMA (female) NO short circuit in wiring harness Repair or
• Disconnect ECMA and RAIL. (3) and surrounding wiring between ECMA (female) (3) and replace
harnesses as shown in Table 1? RAIL (female) (A)
YES
4
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (10) and RAIL (female) Repair or
NO short circuit in wiring harness
• Disconnect ECMA and (B), and between ECMA (female) replace
(10) and surrounding wiring between ECMA (female) (10) and
RAIL.
harnesses as shown in Table 2? RAIL (female) (B)
YES
Defective engine controller Replace
Table 1 Table 2
ECMA (female), RAIL (female) Resistance value ECMA (female), RAIL (female) Resistance value
Between ECMA (3) and RAIL (A) Max. 10 z Between ECMA (10) and RAIL Max. 10 z
Between ECMA (3) and Between ECMA (10) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
WA700-3 20-905
(10)
Troubleshooting EA-44, EA-45, EA-46
Cause Remedy
3
Is there clogging, looseness,
breakage, or leakage from fuel NO
filter, piping?
YES Repair or
Clogging, looseness, breakage, or
leakage from fuel filter, piping replace
4
Is fuel rail actuator screen NO
clogged with dirt?
YES
Clogged fuel rail actuator screen Clean or
replace
5
NO Defective fuel rail actuator or Replace
Is engine oil diluted with fuel?
defective engine controller
YES
Broken injector O-ring Replace
20-906 WA700-3
(10)
Troubleshooting EA-47, EA-48
Cause Remedy
1
• Turn starting switch OFF. Is resistance of relay L64 (male) NO Defective engine oil pressure relay Replace
• Disconnect L64. (1) and (2) 200 – 400 z?
YES
2
Is resistance between ECMB Defective contact or disconnection
• Turn starting switch OFF. NO in wiring harness between ECMB Repair or
• Disconnect ECMB and L64. (female) (1) and L64 (female) replace
(1) less than 1 z? (female) (1) and L64 (female) (1)
YES
3
There is a disconnection or
Is the resistance value between
• Turn starting switch OFF. NO connection fault in the wiring Repair or
L64(frmale) (2) and the chassis
• Disconnect L64. harness between L64 (female) (2) replace
less than 1 z?
and the chassis.
YES
4
Is resistance between ECMB
Short circuit in wiring harness
(female) (1) and surrounding NO Repair or
• Turn starting switch OFF. between ECMB (female) (1) and L64
wiring harnesses more than 100 replace
• Disconnect ECMB and L64. (female) (1)
kz?
YES
Defective engine controller Replace
EA-48 Error code [551] (Abnormality [2] in idling validation switch system)
WA700-3 20-907
(10)
Troubleshooting EA-49
EA-49 Error code [554] (Abnormality [in range] in fuel rail pressure sensor)
Cause Remedy
2
Is resistance between ECMA Defective contact, disconnection, or
• Turn starting switch OFF. (female) (5) and RPR (female) NO short circuit in wiring harness Repair or
(A), and between ECMA (female)
• Disconnect ECMA and RPR. (5) and surrounding wiring between ECMA (female) (5) and replace
harnesses as shown in Table 1? RPR (female) (A)
YES
3
Is resistance between ECMA Defective contact, disconnection, or
(female) (18) and RPR (female) NO short circuit in wiring harness Repair or
• Turn starting switch OFF. (B), and between ECMA (female) between ECMA (female) (18) and replace
• Disconnect ECMA and RPR. (18) and surrounding wiring RPR (female) (B)
harnesses as shown in Table 2?
YES
4
4. Is resistance between ECMA Defective contact, disconnection, or
(female) (31) and RPR (female) NO short circuit in wiring harness Repair or
• Turn starting switch OFF. (C), and between ECMA (female)
• Disconnect ECMA and RPR. (31) and surrounding wiring between ECMA (female) (31) and replace
harnesses as shown in Table 3? RPR (female) (C)
YES
5
Is negative pressure at suction
NO Defective engine controller Replace
• Start engine. side (tank side) of fuel filter
more than 27kPa{203mmHg}?
YES
Excessive suction resistance of fuel Repair or
filter replace
Table 1 Table 2
ECMA (female), RPR (female) Resistance value ECMA (female), RPR (female) Resistance value
Between ECMA (5) and RPR (A) Max. 10 z Between ECMA (18) and RPR (B) Max. 10 z
Between ECMA (5) and Between ECMA (18) and
surrounding wiring harnesses Min. 1 Mz surrounding wiring harnesses Min. 1 Mz
Table 3
20-908 WA700-3
(10)
Troubleshooting EA-49
WA700-3 20-909
(10)
Troubleshooting of VHMS controller system
(VHMS mode)
Electrical system diagram related VHMS controller .................................................................................. 20-1004
Information given in troubleshooting chart ................................................................................................ 20-1006
Phenomenon type code list....................................................................................................................... 20-1007
[DBB0KK] (or VHMS_LED indicates "n901") Abnormality in source voltage......................................... 20-1008
[DBB5KP] (or VHMS_LED indicates "n904") Abnormality in sensor power source (5 V) system.......... 20-1010
[DBB6KP] (or VHMS_LED indicates "n902") Abnormality in sensor power source (24 V) system........ 20-1012
[DBBRKR] (or VHMS_LED displays [n801]) Defective CAN communications: Defective
communications (KR) (between engine controller and VHMS controller)............................. 20-1014
[DGE1KB] (or VHMS_LED displays [n242]) Disconnection, short circuit with chassis ground
in engine oil temperature sensor system (KB) {30 min. (at 500 rpm or above) after
starting engine}..................................................................................................................... 20-1016
[DGE1KY] (or VHMS_LED displays [n242]) Short circuit with power source (hot short) in engine oil
temperature sensor system (KY) .......................................................................................... 20-1017
[DGE5KX] (or VHMS_LED displays [n401]) Failure in ambient temperature sensor system:
Input signal outside range (KX) ............................................................................................ 20-1018
[DGT4KA] (or VHMS_LED displays [n312]) Disconnection, short circuit with chassis ground
in No. 1, 2, 3 (front) exhaust temperature sensor system (KA) ............................................ 20-1020
[DGT4KB] (or VHMS_LED displays [n311]) Short circuit with power source (hot short)
in No. 1, 2, 3 (rear) exhaust temperature sensor system (KB) ............................................. 20-1022
[DGT5KA] (or VHMS_LED displays [n322]) Disconnection, short circuit with chassis ground
in No. 4, 5, 6 (front) exhaust temperature sensor system (KA) ............................................ 20-1024
[DGT5KB] (or VHMS_LED displays [n321]) Short circuit with power source (hot short)
in No. 4, 5, 6 (front) exhaust temperature sensor system (KB) ............................................ 20-1026
[DHE5KB] (or VHMS_LED displays [n332]) Disconnection, short circuit with chassis ground
in engine blow-by pressure sensor system (KA) .................................................................. 20-1028
[DHE5KY] (or VHMS_LED displays [n331]) Short circuit with power source (hot short) in engine
blow-by pressure sensor system (KY) .................................................................................. 20-1030
[DHT3KX] (or VHMS_LED displays [n614]) Trouble in transmission oil pressure sensor system:
Out of input signal range (KX) .............................................................................................. 20-1032
[DHP2KX] (or VHMS_LED displays [n531]) Trouble in main pump oil pressure sensor system:
Out of input signal range (KX) .............................................................................................. 20-1034
[DHT8KX] (or VHMS_LED displays [n533]) Trouble in steering oil pressure sensor system:
Out of input signal range (KX) .............................................................................................. 20-1036
[DGH2KX] (or VHMS_LED displays [n537]) Trouble in hydraulic oil temperature sensor system:
Out of input signal range (KX) .............................................................................................. 20-1038
[DHU2KX] (or VHMS_LED displays [n711]) Trouble in front brake oil pressure sensor system:
Out of input signal range (KX) .............................................................................................. 20-1040
WA700-3 20-1001
(11)
Troubleshooting
[DHU3KX] (or VHMS_LED displays [n712]) Trouble in rear brake oil pressure sensor system:
Out of input signal range (KX) .............................................................................................. 20-1042
[DGR4KX] (or VHMS_LED displays [n717]) Trouble in front brake oil temperature sensor system:
Out of input signal range (KX) .............................................................................................. 20-1044
[F@BBZL] (or VHMS_LED displays [n338]) Engine blow-by pressure is high: (ZL) .............................. 20-1045
[F@BYNR] (or VHMS_LED displays [n362]) No. 1, 2, 3 (rear) exhaust temperature is high (2): (NR) ... 20-1046
[F@BYNS] (or VHMS_LED displays [n361]) No. 1, 2, 3 (rear) exhaust temperature is high (1): (NS) ... 20-1047
[F@BZNR] (or VHMS_LED displays [n372]) No. 4, 5, 6 (front) exhaust temperature is high (2): (NR) .. 20-1048
[F@BZNS] (or VHMS_LED displays [n371]) No. 4, 5, 6 (front) exhaust temperature is high (1): (NS) .. 20-1049
VHMS-1 Abnormality in satellite data communication......................................................................... 20-1050
a) Satellite communication data are not transmitted............................................................. 20-1050
b) Abnormality in downloading into PC or setting of PC ....................................................... 20-1054
VHMS-2 Abnormality in saving data in VHMS controller (Data are not saved) ................................... 20-1056
VHMS-3 Engine blow-by pressure indicated by monitor is low (When blow-by pressure measured
with measuring instrument is normal) ................................................................................... 20-1058
20-1002 WA700-3
(11)
Troubleshooting Electrical system diagram related VHMS controller
20-1004 WA700-3
(11)
Troubleshooting Electrical system diagram related VHMS controller
WA700-3 20-1005
(11)
Troubleshooting Information given in troubleshooting chart
a The following type of information is given in the troubleshooting charts and related circuit diagrams, so make
sure that you understand the content fully before starting troubleshooting.
20-1006 WA700-3
(11)
Troubleshooting Phenomenon type code list
This is the section of the circuit diagram that shows the parts related to the failure.
• Connector No.: (type – No. of pins) (color).
• Arrows ( ): Shows approximate mounting position on machine.
a For phenomenon type codes marked "See list", refer to this list.
Phenomenon Phenomenon
Contents Contents
code code
Fill signal for non-existent combination of clutches ON
KA Disconnection L0
simultaneously for 2 or more channels.
KB Short circuit L1 Fill signal ON when command current to ECMV is OFF.
KK Drop in power source voltage, input L2 Fuel pressure is higher than max. specified value.
KQ Mismatch in model selection signal L3 Target components cannot be controlled.
KR Defective communications L4 ON/OFF signals from 2 systems do not match.
Engine speed signal, C terminal signal, oil pressure
KT Abnormality inside controller L6 switch, coolant temperature sensor signals do not
match operating condition or stopped condition.
KX Input signal outside range L8 Analog signals of 2 systems do not match.
Short circuit with power source
KY LC Speed signals of 2 systems do not match.
(Hot short)
Switch remains pressed for length of time unthinkable
KZ Disconnection or short circuit LD
for normal operations .
Fill signal is turned OFF when command current to
MA Defective function LH
ECMV is ON.
MB Drop in function
MW Slippage
NS Overheat
ZG Drop in oil pressure
ZK Drop in level
WA700-3 20-1007
(11)
Troubleshooting [DBB0KK]
20-1008 WA700-3
(11)
Troubleshooting [DBB0KK]
WA700-3 20-1009
(11)
Troubleshooting [DBB5KP]
20-1010 WA700-3
(11)
Troubleshooting [DBB5KP]
WA700-3 20-1011
(11)
Troubleshooting [DBB6KP]
20-1012 WA700-3
(11)
Troubleshooting [DBB6KP]
WA700-3 20-1013
(11)
Troubleshooting [DBBRKR]
Action code Failure code Controller code Defective CAN communications: Defective communications
Trouble
Not set DBBRKR Not set (KR) (between engine controller and VHMS controller)
Contents of
• Communications (CAN) data from engine controller cannot be obtained.
trouble
Action of
• Maintains condition existing when abnormality occurred.
controller
Problem that
appears on • VHMS function for obtaining data from engine controller not working.
machine
• LED display is [n801]
Related
• If failure code [DASRKR] related to CAN communications is displayed, carry out troubleshooting first for
information
the applicable code.
20-1014 WA700-3
(11)
Troubleshooting [DBBRKR]
WA700-3 20-1015
(11)
Troubleshooting [DGE1KB]
[DGE1KB] (or VHMS_LED displays [n242]) Disconnection, short circuit with chassis
ground in engine oil temperature sensor system (KB) {30 min. (at 500 rpm
or above) after starting engine}
Action code Failure code Controller code Disconnection, short circuit with chassis ground in engine
Trouble oil temperature sensor system (KB)
Not set DGE1KB Not set {30 min. (at 500 rpm or above) after starting engine}
Contents of
• Signal voltage of engine oil temperature sensor has dropped below 0.3V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine oil temperature cannot be monitored with monitoring function.
machine
Related • Engine oil temperature can be checked with monitoring function (code: 42700).
information • LED display is [n242]
20-1016 WA700-3
(11)
Troubleshooting [DGE1KY]
[DGE1KY] (or VHMS_LED displays [n242]) Short circuit with power source (hot short)
in engine oil temperature sensor system (KY)
Action code Failure code Controller code Short circuit with power source (Hot short) in engine oil
Trouble
Not set DGE1KY Not set temperature sensor system (KY)
Contents of
• Signal voltage of engine oil temperature sensor has risen above 4.9V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Engine oil temperature cannot be monitored with monitoring function.
machine
Related • Engine oil temperature can be checked with monitoring function (code: 42700).
information • LED display is [n242]
WA700-3 20-1017
(11)
Troubleshooting [DGE5KX]
Action code Failure code Controller code Failure in ambient temperature sensor system: Input signal
Trouble
Not set DGE5KX Not set outside range (KX)
Contents of
• Input signal voltage of ambient temperature sensor is more than 4.9V or less than 0.3V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Ambient temperature cannot be monitored with monitoring function.
machine
Related • Ambient temperature can be checked with monitoring function (code: 37501).
information • LED display is [n401]
20-1018 WA700-3
(11)
Troubleshooting [DGT4KA]
[DGT4KA] (or VHMS_LED displays [n312]) Disconnection, short circuit with chassis
ground in No. 1, 2, 3 (front) exhaust temperature sensor system (KA)
Action code Failure code Controller code Disconnection, short circuit with chassis ground in No. 1, 2,
Trouble
Not set DGT4KA Not set 3 (front) exhaust temperature sensor system (KA)
Contents of
• Signal voltage of less than 0.3V detected from No. 1, 2, 3 (front) exhaust temperature sensor.
trouble
Action of
• None in particular.
controller
Problem that
appears on • No. 1, 2, 3 (front) exhaust temperature cannot be monitored with monitoring function.
machine
Related • No. 1, 2, 3 (front) exhaust temperature can be checked with monitoring function (code: 42600).
information • LED display is [n312].
20-1020 WA700-3
(11)
Troubleshooting [DGT4KA]
WA700-3 20-1021
(11)
Troubleshooting [DGT4KB]
[DGT4KB] (or VHMS_LED displays [n311]) Short circuit with power source (hot short)
in No. 1, 2, 3 (rear) exhaust temperature sensor system (KB)
Action code Failure code Controller code Short circuit with power source (Hot short) in No. 1, 2, 3
Trouble
Not set DGT4KB Not set (rear) exhaust temperature sensor system (KB)
Contents of
• Signal voltage of more than 4.9V detected from No. 1, 2, 3 (rear) exhaust temperature sensor.
trouble
Action of
• None in particular.
controller
Problem that
appears on • No. 1, 2, 3 (rear) exhaust temperature cannot be monitored with monitoring function
machine
Related • No. 1, 2, 3 (rear) exhaust temperature can be checked with monitoring function (code: 42600).
information • LED display is [n311]
20-1022 WA700-3
(11)
Troubleshooting [DGT4KB]
WA700-3 20-1023
(11)
Troubleshooting [DGT5KA]
[DGT5KA] (or VHMS_LED displays [n322]) Disconnection, short circuit with chassis
ground in No. 4, 5, 6 (front) exhaust temperature sensor system (KA)
Action code Failure code Controller code Disconnection, short circuit with chassis ground in No. 4, 5,
Trouble
Not set DGT5KA Not set 6 (front) exhaust temperature sensor system (KA)
Contents of
• Signal voltage of less than 0.3V detected from No. 4, 5, 6 (front) exhaust temperature sensor.
trouble
Action of
• None in particular.
controller
Problem that
appears on • No. 4, 5, 6 (front) exhaust temperature cannot be monitored with monitoring function
machine
Related • No. 4, 5, 6 (front) exhaust temperature can be checked with monitoring function (code: 42601).
information • LED display is [n322]
20-1024 WA700-3
(11)
Troubleshooting [DGT5KA]
WA700-3 20-1025
(11)
Troubleshooting [DGT5KB]
[DGT5KB] (or VHMS_LED displays [n321]) Short circuit with power source (hot short)
in No. 4, 5, 6 (front) exhaust temperature sensor system (KB)
Action code Failure code Controller code Short circuit with power source (Hot short) in No. 4, 5, 6
Trouble
Not set DGT5KB Not set (front) exhaust temperature sensor system (KB)
Contents of
• Signal voltage of more than 4.9V detected from No. 4, 5, 6 (front) exhaust temperature sensor.
trouble
Action of
• None in particular.
controller
Problem that
appears on • No. 4, 5, 6 (front) exhaust temperature cannot be monitored with monitoring function.
machine
Related • No. 4, 5, 6 (front) exhaust temperature can be checked with monitoring function (code: 42601).
information • LED display is [n321]
20-1026 WA700-3
(11)
Troubleshooting [DGT5KB]
WA700-3 20-1027
(11)
Troubleshooting [DHE5KB]
[DHE5KB] (or VHMS_LED displays [n332]) Disconnection, short circuit with chassis
ground in engine blow-by pressure sensor system (KA)
Action code Failure code Controller code Disconnection, short circuit with chassis ground in engine
Trouble
Not set DHE5KB Not set blow-by pressure sensor system (KA)
Contents of
• Signal voltage of blow-by pressure sensor has dropped below 0.1V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Blow-by pressure cannot be monitored with monitoring function.
machine
Related • Blow-by pressure can be checked with monitoring function (code: 42800).
information • LED display is [n332]
20-1028 WA700-3
(11)
Troubleshooting [DHE5KB]
WA700-3 20-1029
(11)
Troubleshooting [DHE5KY]
[DHE5KY] (or VHMS_LED displays [n331]) Short circuit with power source (hot short)
in engine blow-by pressure sensor system (KY)
Action code Failure code Controller code Short circuit with power source (Hot short) in engine blow-
Trouble
Not set DHE5KY Not set by pressure sensor system (KY)
Contents of
• Signal voltage of blow-by pressure sensor has risen above 4.7V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Blow-by pressure cannot be monitored with monitoring function.
machine
Related • Blow-by pressure can be checked with monitoring function (code: 42800).
information • LED display is [n331]
20-1030 WA700-3
(11)
Troubleshooting [DHT3KX]
Action code Failure code Controller code Transmission oil pressure sensor: Out of input signal range
Trouble
Not set DHT3KX Not set (KX)
Contents of
• The signal circuit voltage of the transmission oil pressure sensor is below 0.3 V or above 4.7 V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • The transmission oil pressure is not displayed and recorded normally.
machine
Related
• The LED indicates [n614].
information
20-1032 WA700-3
(11)
Troubleshooting [DHT3KX]
WA700-3 20-1033
(11)
Troubleshooting [DHP2KX]
[DHP2KX] (or VHMS_LED displays [n531]) Trouble in main pump oil pressure sensor
system: Out of input signal range (KX)
Action code Failure code Controller code Main pump oil pressure sensor: Out of input signal range
Trouble
Not set DHP2KX Not set (KX)
Contents of
• The signal circuit voltage of the main pump oil pressure sensor is below 0.3 V or above 4.7 V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • The main pump oil pressure is not displayed and recorded normally.
machine
Related
• The LED indicates [n531].
information
20-1034 WA700-3
(11)
Troubleshooting [DHP2KX]
WA700-3 20-1035
(11)
Troubleshooting [DHT8KX]
[DHT8KX] (or VHMS_LED displays [n533]) Trouble in steering oil pressure sensor
system: Out of input signal range (KX)
20-1036 WA700-3
(11)
Troubleshooting [DHT8KX]
WA700-3 20-1037
(11)
Troubleshooting [DGH2KX]
Action code Failure code Controller code Hydraulic oil temperature sensor: Out of input signal range
Trouble
Not set DGH2KX Not set (KX)
Contents of
• The input signal voltage of the hydraulic oil temperature sensor is above 4.9 V or below 0.3 V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • The hydraulic oil temperature cannot be monitored with the monitoring function.
machine
Related
• The LED indicates [n537].
information
20-1038 WA700-3
(11)
Troubleshooting [DHU2KX]
[DHU2KX] (or VHMS_LED displays [n711]) Trouble in front brake oil pressure sensor
system: Out of input signal range (KX)
Action code Failure code Controller code Front brake oil pressure sensor: Out of input signal range
Trouble
Not set DHU2KX Not set (KX)
Contents of
• The signal circuit voltage of the front brake oil pressure sensor is below 0.3 V or above 4.7 V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • The front brake oil pressure is not displayed and recorded normally.
machine
Related
• The LED indicates [n711].
information
20-1040 WA700-3
(11)
Troubleshooting [DHU2KX]
WA700-3 20-1041
(11)
Troubleshooting [DHU2KX]
[DHU3KX] (or VHMS_LED displays [n712]) Trouble in rear brake oil pressure sensor
system: Out of input signal range (KX)
Action code Failure code Controller code Rear brake oil pressure sensor: Out of input signal range
Trouble
Not set DHU3KX Not set (KX)
Contents of
• The signal circuit voltage of the rear brake oil pressure sensor is below 0.3 V or above 4.7 V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • The rear brake oil pressure is not displayed and recorded normally.
machine
Related
• The LED indicates [n712].
information
20-1042 WA700-3
(11)
Troubleshooting [DHU2KX]
WA700-3 20-1043
(11)
Troubleshooting [DGR4KX]
[DGR4KX] (or VHMS_LED displays [n717]) Trouble in front brake oil temperature
sensor system: Out of input signal range (KX)
Action code Failure code Controller code Front brake oil temperature sensor: Out of input signal
Trouble
Not set DGR4KX Not set range (KX)
Contents of
• The input signal voltage of the front brake oil temperature sensor is above 4.9 V or below 0.3 V.
trouble
Action of
• None in particular.
controller
Problem that
appears on • The front brake oil temperature cannot be monitored with the monitoring function.
machine
Related
• The LED indicates [n717].
information
20-1044 WA700-3
(11)
Troubleshooting [F@BBZL]
[F@BBZL] (or VHMS_LED displays [n338]) Engine blow-by pressure is high: (ZL)
WA700-3 20-1045
(11)
Troubleshooting [F@BYNR]
20-1046 WA700-3
(11)
Troubleshooting [F@BYNS]
WA700-3 20-1047
(11)
Troubleshooting [F@BZNR]
20-1048 WA700-3
(11)
Troubleshooting [F@BZNS]
WA700-3 20-1049
(11)
Troubleshooting VHMS-1
Action code Failure code Controller code Abnormality in satellite data communication
Trouble
Not set Not set Not set a) Satellite communication data are not transmitted
Contents of
• Satellite communication data are not transmitted.
trouble
Action of
• None in particular.
controller
Problem that
appears on • Satellite communication data are not transmitted.
machine
Related
information
20-1050 WA700-3
(11)
Troubleshooting VHMS-1
WA700-3 20-1051
(11)
Troubleshooting VHMS-1
20-1052 WA700-3
(11)
Troubleshooting VHMS-1
WA700-3 20-1053
(11)
Troubleshooting VHMS-1
Action code Failure code Controller code Abnormality in satellite data communication
Trouble
Not set Not set Not set b) Abnormality in downloading into PC or setting of PC
Contents of
• PC cannot download or cannot be set.
trouble
Action of
• None in particular.
controller
Problem that
appears on • PC cannot download or cannot be set.
machine
Related
information
20-1054 WA700-3
(11)
Troubleshooting VHMS-1
WA700-3 20-1055
(11)
Troubleshooting VHMS-2
VHMS-2 Abnormality in saving data in VHMS controller (Data are not saved)
Action code Failure code Controller code Abnormality in saving data in VHMS controller
Trouble (Data are not saved)
Not set Not set Not set
aLED of VHMS counts up and operates normally
Contents of • Data are not saved in the VHMS controller.
trouble aPower is kept turned off.
Action of
• None in particular.
controller
Problem that
appears on • None in particular.
machine
Related • If fuse box 1 (14) is broken, check the wiring harness between fuse and CN-V01 (6), (7) for grounding
information fault.
20-1056 WA700-3
(11)
Troubleshooting VHMS-2
WA700-3 20-1057
(11)
Troubleshooting VHMS-3
Action code Failure code Controller code Engine blow-by pressure indicated by monitor is low
Trouble (When blow-by pressure measured with measuring
Not set Not set Not set
instrument is normal)
Contents of
• The engine blow-by pressure indicated by the monitor is low.
trouble
Action of
• None in particular.
controller
Problem that
• The engine blow-by pressure indicated by the monitor is low.
appears on
(The blow-by pressure measured with a measuring instrument is normal.)
machine
Related • The blow-by pressure can be checked with the monitoring function (Code: 42800).
information • If failure code "DHE5KA" is indicated, carry out the troubleshooting for it.
20-1058 WA700-3
(11)
30 DISASSEMBLY AND ASSEMBLY
WA700-3 30-1
3
7
FRONT DIFFERENTIAL WORK EQUIPMENT VALVE
Removal ................................................ 30-130 Removal ................................................ 30-197
Installation ............................................ 30-131 Installation ............................................ 30-198
REAR AXLE WORK EQUIPMENT CONTROL VALVE
Removal ................................................ 30-132 Disassembly ......................................... 30-199
Installation ............................................ 30-136 Assembly .............................................. 30-201
REAR DIFFERENTIAL DUMP CYLINDER
Removal ................................................ 30-137 Removal & Installation ....................... 30-203
Installation ............................................ 30-138 LIFT CYLINDER
Disassembly ......................................... 30-139 Removal ................................................ 30-204
Assembly .............................................. 30-143 Installation ............................................ 30-205
FINAL DRIVE STEERING, LIFT, DUMP CYLINDER
Disassembly ......................................... 30-152 Disassembly ......................................... 30-206
Assembly .............................................. 30-156 Assembly .............................................. 30-208
ORBIT ROLL CENTER HINGE PIN
Removal & Installation ....................... 30-160 Removal ................................................ 30-210
STEERING CYLINDER Installation ............................................ 30-216
Removal ................................................ 30-161 WORK EQUIPMENT
Installation ............................................ 30-163 Removal ................................................ 30-220
STEERING DEMAND VALVE Installation ............................................ 30-223
Removal ................................................ 30-164 BULKHEAD
Installation ............................................ 30-166 Removal ................................................ 30-225
BRAKE VALVE Installation ............................................ 30-226
Removal & Installation ....................... 30-166 FLOOR FRAME
BRAKE VALVE (RIGHT) Removal ................................................ 30-227
Disassembly ......................................... 30-167 Installation ............................................ 30-229
Assembly .............................................. 30-169 COUNTERWEIGHT
BRAKE VALVE (LEFT) Removal & Installation ....................... 30-230
Disassembly ......................................... 30-171 FUEL TANK
Assembly .............................................. 30-173 Removal ................................................ 30-231
SLACK ADJUSTER Installation ............................................ 30-232
Removal & Installation ....................... 30-175 CAB
Disassembly ......................................... 30-176 Removal ................................................ 30-233
Assembly .............................................. 30-177 Installation ............................................ 30-235
BRAKE STOP VALVE
Removal ................................................ 30-178 Removal & Installation ....................... 30-236
Installation ............................................ 30-179 ACCUMULATOR CHARGE VALVE
Disassembly ......................................... 30-180 Removal & Installation ....................... 30-237
Assembly .............................................. 30-184 Disassembly ......................................... 30-238
HYDRAULIC PUMP Assembly .............................................. 30-239
Removal ................................................ 30-190 PARKING BRAKE SOLENOID VALVE,
Installation ............................................ 30-191 PRESSURE SWITCH
PISTON PUMP Removal & Installation ....................... 30-241
Disassembly ...................................... 30-191-1 DIVERTER VALVE
Assembly ........................................... 30-191-7 Removal & Installation ....................... 30-242
HYDRAULIC TANK Disassembly ......................................... 30-243
Removal ................................................ 30-192 Assembly .............................................. 30-244
Installation ............................................ 30-193 EMERGENCY STEERING PUMP
PPC VALVE Removal & Installation ....................... 30-246
Removal ................................................ 30-194 PARKING BRAKE
Installation ............................................ 30-195 Removal & Installation ....................... 30-247
Disassembly & Assembly ................... 30-196
30-2 WA700-3
3
7
PARKING BRAKE CALIPERS AIR CONDITIONER UNIT
Disassembly ......................................... 30-248 Removal ................................................ 30-257
Assembly .............................................. 30-250 Installation ............................................ 30-258
PARKING BRAKE PAD MAIN MONITOR
Removal & Installation ....................... 30-252 Removal ................................................ 30-259
REAR TIRE Installation ............................................ 30-260
Removal & Installation ....................... 30-253 MAINTENANCE MONITOR
AIR CONDITIONER COMPRESSOR Removal & Installation ....................... 30-261
Removal & Installation ....................... 30-254 ENGINE, APS CONTROLLER
AIR CONDITIONER CONDENSER Serial No.: 50001 – 51000
Removal & Installation ....................... 30-255 Removal & Installation ....................... 30-262
RECEIVER TANK
Removal & Installation ....................... 30-256
WA700-3 30-2-1
7
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
fl After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and
installing any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equip-
ment piping, always bleed the air as follows after completion of installation.
1. Run the engine at low idling, and extend and retract the steering, bucket, and lift arm cylinders
4 – 5 times without going to the end of this stroke. (Stop approx. 100 mm before the end of the
stroke.)
2. Operate the steering, bucket, and lift arm cylinders 3 – 4 times to the end of the stroke, then
stop the engine and bleed the air from the plugs at the top of the hydraulic tank filter.
3. Raise the engine speed and repeat Step 2. to bleed the air. Repeat this procedure until no more
air comes out from the plugs.
4. After completing bleeding the air, tighten the plugs.
3 Plug: 11.3 ± 1.5 Nm {1.15 ± 0.15 kgm}
fl If the engine is run at high speed from the start, or the cylinders are operated to the end of
this stroke, the air inside the cylinder will cause damage to the piston packing.
fl After repair or long storage, follow the same procedure.
WA700-3 30-7
3
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
01050-32235 Bolt ■ 3
2
795-902-1430 Push tool ■ 1
01050-32240 Bolt ■ 3
795-902-1450 Bolt ■ 2
3 01582-02016 Nut ■ 2
01050-32050 Bolt ■ 4
Disassembly,
assembly of A 4 790-331-1110 Wrench ■ 1 Tightening of cylinder head
engine assembly Removal, installation
5 795T-871-1110 Adapter ■ 2 of fuel injection pump
6 795-601-1110 Push tool ■ 1 Removal of water tube
8 795-902-1460 Bolt ■ 3
01582-02218 Nut ■ 3
10 Commercially
available Filler gauge ● 1 Assembly of engine
30-8 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
· 01010-51240 · Bolt ■ 1
Check of operation of
1 799-301-1600 Oil leak tester kit ■ 1 clutch piston
Disassembly, Centering of transmission
assembly of 2 793-615-1200 Centering tool ■ 1 and center support
transmission D
793-615-1100 Wrench assembly ■ 1 Adjustment of pre-load
assembly 3 on transfer bearing
793-615-1130 Spline wrench ■ 1
· 01010-51240 Bolt ■ 1
· 01010-51240 · Bolt ■ 1
Unit repair ■ 1 Differential repair stand
790-501-5000 stand (100V)
or
Unit repair ■ 1
4 790-501-5200 stand (110-120V
or 220-240V)
790-901-5110 Bracket ■ 1
· 01010-51240 · Bolt ■ 1
· 01010-51240 · Bolt ■ 1
WA700-3 30-9
3
7
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
· 01010-51240 · Bolt ■ 1
Adjustment of pre-load
9 790-425-1660 Wrench ■ 1 on side bearing
Positioning of pinion
Disassembly, 10 793-623-1120 Plate ■ 1 gear of differential
assembly of Holding of brake assem-
H 11 793-623-1130 Fixture ■ 2 bly and wheel hub
differential
assembly 791-585-1510 Installer ■ 1 Installation of floating
12 seal
792-530-1700 Push tool ■ 1
· 01010-51240 · Bolt ■ 1
Check of brake oil for
14 793-520-1805 Brake tester ■ 1 leakage
790-101-2501 Push tool kit ■ 1 Installation of center
hinge bearing
· 790-101-2510 · Plate 1
· 790-101-2520 ·Screw 1
· 791-112-1180 · Nut 1
1 · 790-101-2540 · Washer 1
· 790-101-2610 · Leg 2
· 790-101-2570 · Plate 4
Installation of · 790-101-2560 · Nut 2
center hinge K
bearing · 790-101-2740 · Adapter 2
790-201-1310 Spacer ■ 1
4
790-101-2102 Puller (30 ton) ■ 1
30-10 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Component Symbol Part No. Part Name Neces- Q’ty New/ Sketch Nature of work,
sity remodeled remarks
· 790-201-1881 · Push tool 1 Boom cylinder
· 01010-51240 · Bolt ■ 1
· 01010-50816 · Bolt 1
790-201-1980 Plate ■ 1
Disassembly, 3
· 790-101-5021 · Grip ■ 1 Steering cylinder
assembly of
U
hydraulic cylinder · 01010-50816 · Bolt ■ 1
assembly
790-201-1920 Plate ■ 1
07281-02429 Clamp ■ 1
07281-02909 Clamp ■ 1
793T-870-1110 Sleeve ■ 1
793T-870-1120 Plate ■ 1
791-745-2110 Adapter ■ 1
790-703-1120 Vacuum ■ 1
pump (240 V)
799-703-1401 Gas leak detector ■ 1
WA700-3 30-11
(10)
3
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Component Symbol Part No. Part Name Neces- Q’ty New/ Sketch Nature of work,
sity remodeled remarks
1 790-501-5000 Unit repair stand 1
2 790-901-2110 Bracket 1
Y
3 790-901-1330 Plate 1
4 790-345-1020 Plate 1
1 796-720-3520 Cap 1
AA 2 796-720-2220 Socket 1
3 796-730-2120 Screwdriver 1
30-11-1 WA700-3
4
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
H6 PLATE
30-12 WA700-3
3
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
H7, H8 PLATE
H8 SPACER
WA700-3 30-13
(10)
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
V1 PLATE
WA700-3 30-15
3
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
INSTALLATION OF STARTING
MOTOR
• Carry out installation in the reverse order to
removal.
30-16 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
Serial No.: 50001 – 51000
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
4 Alternator assembly: 12 kg
INSTALLATION OF
ALTERNATOR ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to
removal.
1
3 Lock bolt:
53.9 – 122.6 Nm {5.5 – 12.5 kgm}
2
fl Adjust the drive belt tension. For details,
see TESTING AND ADJUSTING, Testing and
adjusting alternator drive belt.
WA700-3 30-17
3
7
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
Serial No.: 51001 and up
¤ Stop the machine on level ground and lower
the work equipment completely to the ground,
then put blocks under the wheels to prevent the
machine from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
4 Alternator: 12 kg
INSTALLATION OF
ALTERNATOR ASSEMBLY
Serial No.: 51001 and up
• Carry out installation in the reverse order to
removal.
1
fl Adjust the deflection of the belt to the speci-
fied value. For details, see TESTING AND
ADJUSTING ALTERNATOR BELT TENSION.
30-17-1 WA700-3
7
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
1
3 Mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
30-18 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
WA700-3 30-18-1
7
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
WA700-3 30-19
3
7
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to
removal.
1
3 Eyebolt: 9.8 – 12.7 Nm {1.0 – 1.3 kgm}
2
3 Hose adapter:
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
3
3 Eyebolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
4
3 Eyebolt: 24.5 – 34.3 Nm {2.5 – 3.5 kgm}
5
3 Sleeve nut:
53.9 ± 4.9 Nm {5.5 ± 0.5 kgm}
6
fl Adjust the fuel injection timing. For details,
see TESTING AND ADJUSTING, Testing and
adjusting fuel injection timing.
• Bleeding air
Bleed air from fuel circuit. For details, see TEST-
ING AND ADJUSTING, Bleeding air from each
part.
30-20 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY WATER PUMP
INSTALLATION OF WATER
PUMP ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to
removal.
1
fl Tighten the upper and lower mounting bolts
alternately and evenly.
WA700-3 30-21
3
7
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
Serial No.: 50001 – 51000
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to
removal.
1
3 Spill tube:
13.8 – 17.7 Nm {1.4 – 1.8 kgm}
2
3 Head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
3
3 Flange mounting bolt:
24.5 – 29.4 Nm {2.5 – 3.0 kgm}
30-22 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLIES
Serial No.: 50001 – 51000
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
4 Turbocharger assembly: 17 kg
WA700-3 30-23
3
7
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
4 Turbocharger assembly: 17 kg
INSTALLATION OF
TURBOCHARGER ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to
removal.
1
3 Turbocharger mounting bolt:
44.1 – 53.9 Nm {4.5 – 5.5 kgm}
30-24 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
WA700-3 30-25
3
7
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
30-26 WA700-3
3
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REPLACEMENT OF ENGINE
REAR SEAL
Serial No.: 50001 – 51000
¤ Stop the machine on level ground and lower
the work equipment completely to the ground,
then put blocks under the wheels to prevent the
machine from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
4 Flywheel: 48 kg
WA700-3 30-27
3
(9)
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
4. Installation of flywheel
1) Using bar 1, fix the flywheel.
2) For the tightening order, see the diagram on
the right.
2 Mounting bolt: Lubricant (LM-P)
3 Mounting bolt:
1st step: 98.0 ± 20.0 Nm {10.0 ± 2 .0 kgm}
2nd step: 294.0 ± 20.0 Nm {30.0 ± 2.0 kgm}
3rd step: 539.0 ± 20.0 Nm {65.0 ± 2.0 kgm}
3) Measure the radial runout and face runout
of the flywheel.
Radial runout: Max. 0.15 mm
Face runout: Max. 0.20 mm
30-28 WA700-3
3
(9)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
WA700-3 30-29
3
7
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
30-30 WA700-3
3
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
39. Remove snap ring (52), then pull out water tube
(53) with push tool A6.
WA700-3 30-31
3
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to
removal.
1
2 Exhaust manifold mounting bolt:
Lubricant (LM-P)
3 Exhaust manifold mounting bolt:
98.1 – 122.6 Nm {10.0 – 12.5 kgm}
fl For tightening order, see the figure at right.
2
3 Intake manifold mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
fl For tightening order, see the figure at right.
3
3 Head cover mounting bolt:
29.4 – 34.3 Nm {3.0 – 3.5 kgm}
4
fl Check that the push rod is securely fitted in
the cam follower and adjustment screw ball.
3 Rocker arm mounting bolt:
93.1 – 102.9 Nm {9.5 – 10.5 kgm}
5
fl Adjust the cross head according to the fol-
lowing procedure.
i) Loosen the locknut and return the ad-
justment screw.
ii) Pressing the top of the cross head lightly,
tighten the adjustment screw.
iii) After the adjustment screw comes in
contact with the valve stem, tighten it
further by 20 degrees. Tighten the
locknut at this position.
3 Locknut:
33.3 – 45.1 Nm {3.4 – 4.6 kgm}
30-32 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
6
fl Assemble the nozzle holder with the match
marks directed toward the front side of the
engine.
3 Flange mounting bolt:
24.5 – 29.4 Nm {2.5 – 3.0 kgm}
fl For tightening order, see the figure at right.
7
fl Before setting the cylinder head gasket, check
that there is not dust or foreign matter on
the fitting face of the cylinder head and in
the cylinder.
fl When fitting the gasket, check that the grom-
met is installed normally.
fl For tightening order, see the figure at right.
WA700-3 30-33
3
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
Serial No.: 50001 – 51000
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the ve-
hicle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
INSTALLATION OF
THERMOSTAT ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to
removal.
30-34 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER
WA700-3 30-35
3
7
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER, RADIATOR, AFTERCOOLER
4 Aftercooler assembly: 65 kg
INSTALLATION OF HYDRAULIC
OIL COOLER, RADIATOR,
AFTERCOOLER ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to
removal.
30-36 WA700-3
3
7
HYDRAULIC OIL COOLER, RADIATOR,
DISASSEMBLY AND ASSEMBLY AFTERCOOLER, FUEL COOLER
WA700-3 30-36-1
7
HYDRAULIC OIL COOLER, RADIATOR,
DISASSEMBLY AND ASSEMBLY AFTERCOOLER, FUEL COOLER
4 Aftercooler assembly: 50 kg
Fuel cooler assembly: 12 kg
30-36-2 WA700-3
7
HYDRAULIC OIL COOLER, RADIATOR,
DISASSEMBLY AND ASSEMBLY AFTERCOOLER, FUEL COOLER
INSTALLATION OF HYDRAULIC
OIL COOLER, RADIATOR,
AFTERCOOLER, FUEL COOLER
ASSEMBLY
Serial No.: 51001 and up
• Carry out installation in the reverse order to
removal.
WA700-3 30-36-3
7
DISASSEMBLY AND ASSEMBLY ENGINE, DAMPER
REMOVAL OF ENGINE,
DAMPER ASSEMBLY
Serial No.: 50001 – 51000
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the ve-
hicle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
WA700-3 30-37
3
7
DISASSEMBLY AND ASSEMBLY ENGINE, DAMPER
4 Drive shaft: 52 kg
30-38 WA700-3
3
DISASSEMBLY AND ASSEMBLY ENGINE, DAMPER
19. Using tool A1, lift off engine and damper as-
sembly (24).
fl Checking that the all hoses, harnesses, etc.
are disconnected, sling the assembly slowly.
INSTALLATION OF ENGINE,
DAMPER ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to
removal.
1
3 Mounting bolt:
156.9 – 196.1 Nm {16.0 – 20.0 kgm}
2
3 Mounting bolt:
824.0 – 1030.0 Nm {84.0 – 105.0 kgm}
• Bleeding air
Bleed air from the fuel circuit. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
WA700-3 30-39
3
7
DISASSEMBLY AND ASSEMBLY ENGINE, DAMPER
REMOVAL OF ENGINE,
DAMPER ASSEMBLY
Serial No.: 51001 and up
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the ve-
hicle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
30-39-1 WA700-3
7
DISASSEMBLY AND ASSEMBLY ENGINE, DAMPER
4 Drive shaft: 52 kg
WA700-3 30-39-2
7
DISASSEMBLY AND ASSEMBLY ENGINE, DAMPER
16. Using tool A1, lift off engine and damper as-
sembly (21).
fl Checking that the all hoses, harnesses, etc.
are disconnected, sling the assembly slowly.
INSTALLATION OF ENGINE,
DAMPER ASSEMBLY
Serial No.: 51001 and up
• Carry out installation in the reverse order to
removal.
1
3 Mounting bolt:
156.9 – 196.1 Nm {16.0 – 20.0 kgm}
2
3 Mounting bolt:
824.0 – 1030.0 Nm {84.0 – 105.0 kgm}
• Bleeding air
Bleed air from the fuel circuit. For details, see
TESTING AND ADJUSTING, Bleeding air from
each part.
30-39-3 WA700-3
7
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
INSTALLATION OF DAMPER
ASSEMBLY
• Carry out installation in the reverse order to
removal.
1
Mounting bolt:
156.9 – 196.1 Nm {16.0 – 20.0 kgm}
2
flApply grease to the oil seal lip.
2 Shaft spline: Lubricant (LM-P)
3 Mounting bolt:
110.8 ± 11.8 Nm {11.3 ± 1.2 kgm}
3
3 Mounting bolt:
277.5 ± 31.4 Nm {28.3 ± 3.2 kgm}
30-40 WA700-3
3
DISASSEMBLY AND ASSEMBLY FRONT AXLE
3. Brake hose
1) Disconnect parking brake cylinder hose (3).
3
2) Disconnect both front brake hoses (4).
4
4. Front axle
1) Sling front axle assembly temporarily and
remove both mounting bolts (5). 5
INSTALLATION OF FRONT
AXLE ASSEMBLY
• Carry out installation in the reverse order to
removal.
1
3 Hub nut:
823.8 ± 88.3 Nm {84.0 ± 9.0 kgm}
2
3 Drive shaft mounting bolt:
176.5 ± 19.6 Nm {18.0 ± 2.0 kgm}
34
fl Bleed air from the parking brake cylinder
and front brake. For details, see TESTING
AND ADJUSTING, Bleeding air from each
part.
5
3 Front axle mounting bolt:
3521.0 ± 353.0 Nm {350.0 ± 36.0 kgm}
WA700-3 30-129
3
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
REMOVAL OF FRONT
DIFFERENTIAL ASSEMBLY
Serial No.: 50001 – 50044
1. Remove front axle assembly. For details, see
REMOVAL OF FRONT AXLE ASSEMBLY.
4 Drive shaft: 70 kg
30-130 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
INSTALLATION OF FRONT
DIFFERENTIAL ASSEMBLY
Serial No.: 50001 – 50044
• Carry out installation in the reverse order to
removal.
1
3 Cover mounting bolt:
98.0 – 123.0 Nm {10.0 – 12.5 kgm}
2
fl Adjustment of tension bolt
Press tension bolt (14) end against the back
of the gear, then return it by 1/2 turn.
3 Locknut:
343.0 – 441.0 Nm {35.0 – 45.0 kgm}
34
2 Plate mounting bolt: Adhesive (LT-2)
3 Plate mounting bolt:
824.0 – 1030.0 Nm {84.0 – 105.0 kgm}
5
2 Disc mounting bolt: Adhesive (LT-2)
3 Disc mounting bolt:
490.0 – 608.0 Nm {50.0 – 62.0 kgm}
6
3 Differential mounting bolt:
490.0 – 608.0 Nm {50.0 – 62.0 kgm}
WA700-3 30-131
3
7
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
REMOVAL OF FRONT
DIFFERENTIAL ASSEMBLY
Serial No.: 50045 and up
1. Remove front axle assembly. For details, see
REMOVAL OF FRONT AXLE ASSEMBLY.
4 Drive shaft: 70 kg
30-131-1 WA700-3
7
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
INSTALLATION OF FRONT
DIFFERENTIAL ASSEMBLY
Serial No.: 50045 and up
• Carry out installation in the reverse order to
removal.
1
3 Cover mounting bolt:
98.0 – 123.0 Nm {10.0 – 12.5 kgm}
2
fl Adjustment of tension bolt
Press tension bolt (16) end against the back
of the gear, then return it by 1/2 turn.
3 Locknut:
343.0 – 441.0 Nm {35.0 – 45.0 kgm}
3
3 Bracket mounting bolt:
98 – 122 Nm {10 – 12.5 kgm}
45
2 Plate mounting bolt: Adhesive (LT-2)
3 Plate mounting bolt:
824.0 – 1030.0 Nm {84.0 – 105.0 kgm}
6
2 Disc mounting bolt: Adhesive (LT-2)
3 Disc mounting bolt:
490.0 – 608.0 Nm {50.0 – 62.0 kgm}
7
3 Differential mounting bolt:
490.0 – 608.0 Nm {50.0 – 62.0 kgm}
WA700-3 30-131-2
7
DISASSEMBLY AND ASSEMBLY REAR AXLE
3. Tire • wheel
Lift off tire • wheels (6) on both sides. 2
4. Drive shaft
Disconnect rear drive shaft (7). 3
30-132 WA700-3
3
DISASSEMBLY AND ASSEMBLY PISTON PUMP
DISASSEMBLY OF PISTON
(HPF90+90)
PUMP ASSEMBLY
HPV90+HPF90, HPF90+90
Preparatory work
Set pump assembly to tool Y1.
(HPV90+HPF90)
1. ES valve assembly, hoses (HPV90+HPF90 only)
1) Remove ES valve assembly (3).
2) Remove hoses (4) and (5).
Disassembly of pump
30-191-1 WA700-3
(9)
DISASSEMBLY AND ASSEMBLY PISTON PUMP
3. Impeller
1) Remove bolt (15), then remove plate (9) and
shim (17).
fl Check the number and thickness of the
shims, and keep in a safe place.
2) Remove impeller (8).
5. End cap
1) Remove snap ring (13), then remove washer
(14).
WA700-3 30-191-2
(9)
DISASSEMBLY AND ASSEMBLY PISTON PUMP
6. Valve plate
Remove valve plate (45).
fl It is stuck to the cylinder block, so be careful
not to scratch or damage it.
7. Pump sub-assembly
Support cylinder block and shaft, and remove
pump sub-assembly (49).
8. Servo piston
1) Using forcing screw 1 (Thread dia.=10 mm,
Pitch=1.5 mm) and nut 2, remove cap (27)
and shim (28).
2) Remove spring (31).
fl The spring and forcing screw are for the
HPV090+090 only.
30-191-3 WA700-3
4
DISASSEMBLY AND ASSEMBLY PISTON PUMP
9. Cylinder, shaft
1) Set pump sub-assembly (49) in vice.
fl Be careful not to damage the flange sur-
face of the cradle.
2) Remove slider (38) and cylinder block (35).
10. Piston
Remove 4 screws (56), then remove retainer
bearing (57), shoe retainer (58), spacer (59), and
piston (60).
WA700-3 30-191-4
(9)
DISASSEMBLY AND ASSEMBLY PISTON PUMP
30-191-5 WA700-3
4
DISASSEMBLY AND ASSEMBLY PISTON PUMP
WA700-3 30-191-6
4
DISASSEMBLY AND ASSEMBLY PISTON PUMP
30-191-7 WA700-3
(9)
DISASSEMBLY AND ASSEMBLY PISTON PUMP
3. Cylinder block
Align with drive shaft and piston, and install
cylinder block (35).
fl The valve plate forms a set with the cylinder
block, so always mark with a distinguishing
mark and keep as a set.
fl Install the spring and washer inside the cyl-
inder block after adjusting the bearing
preload.
30-191-11 WA700-3
(9)
DISASSEMBLY AND ASSEMBLY PISTON PUMP
WA700-3 30-191-12
4
DISASSEMBLY AND ASSEMBLY PISTON PUMP
30-191-13 WA700-3
(9)
DISASSEMBLY AND ASSEMBLY PISTON PUMP
fl HPV90+HPF90 only
7. End cap
1) Assemble spring (37) and washer (36) to cyl-
inder block (35), then install snap ring (34).
fl Be careful not to damage the contact
surface of the valve plate.
2) Install end cap.
fl For details, see Steps 6-1)-iii), iv), and 2).
30-191-17 WA700-3
(9)
DISASSEMBLY AND ASSEMBLY PISTON PUMP
(HPV90+HPF90)
12. ES valve assembly, hoses (HPV090+090 only)
1) Fit O-ring and install ES valve assembly (3).
2) Install hoses (4) and (5).
(HPF90+90)
WA700-3 30-191-20
(9)
DISASSEMBLY AND ASSEMBLY BULKHEAD
REMOVAL OF BULKHEAD
ASSEMBLY
Serial No.: 50001 – 51000
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
4. Lift off both side covers (3) and (4) and engine
hood (5).
WA700-3 30-225
3
7
DISASSEMBLY AND ASSEMBLY BULKHEAD
INSTALLATION OF BULKHEAD
ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to
removal.
12
fl Do not twist the hoses.
fl Do not let dirt, dust, water, etc. in the hoses.
fl Using tool X1, charge the air conditioner
circuit with new refrigerant (R134a).
30-226 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY BULKHEAD
REMOVAL OF BULKHEAD
ASSEMBLY
Serial No.: 51001 and up
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
4. Lift off both side covers (3) and (4) and engine
hood (5).
WA700-3 30-226-1
7
DISASSEMBLY AND ASSEMBLY BULKHEAD
30-226-2 WA700-3
7
DISASSEMBLY AND ASSEMBLY BULKHEAD
INSTALLATION OF BULKHEAD
ASSEMBLY
Serial No.: 51001 and up
• Carry out installation in the reverse order to
removal.
12
fl Do not twist the hoses.
fl Do not let dirt, dust, water, etc. in the hoses.
fl Using tool X1, charge the air conditioner
circuit with new refrigerant (R134a).
WA700-3 30-226-3
7
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
WA700-3 30-227
(10)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
30-228 WA700-3
(10)
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
INSTALLATION OF FLOOR
FRAME ASSEMBLY
• Carry out installation in the reverse order to
removal.
1
fl Install each hose so that it will not be twisted.
fl When installing the air conditioner hoses,
take care that dirt, dust, water, etc. will not
enter them.
fl When tightening each joint of the air condi-
tioner hose, check that O-ring is fitted to it.
fl Apply sufficient compressor oil for R134a
(DENSO: ND-OIL8, ZEXEL: ZXL100PG (appli-
cable to PAG46)) to each O-ring.
2
3 Mounting nut:
245.0 – 308.7 Nm {25.0 – 31.5 kgm}
1. Drain fuel.
WA700-3 30-231
3
7
DISASSEMBLY AND ASSEMBLY FUEL TANK
1
Adjust the shims so that the clearance between
the fuel tank and rear frame will be 0.5 mm
maximum.
3 Fuel tank mounting bolt:
1,520.1 – 1,912.4 Nm {155.0 – 195.0 kgm}
• Bleeding air
After installing the fuel tank, bleed air from the
fuel circuit. For details, see TESTING AND AD-
JUSTING, Bleeding air from each part.
30-232 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY FUEL TANK
1. Drain fuel.
WA700-3 30-232-1
7
DISASSEMBLY AND ASSEMBLY FUEL TANK
1
Adjust the shims so that the clearance between
the fuel tank and rear frame will be 0.5 mm
maximum.
3 Fuel tank mounting bolt:
1,520.1 – 1,912.4 Nm {155.0 – 195.0 kgm}
• Bleeding air
After installing the fuel tank, bleed air from the
fuel circuit. For details, see TESTING AND AD-
JUSTING, Bleeding air from each part.
30-232-2 WA700-3
7
DISASSEMBLY AND ASSEMBLY PARKING BRAKE CALIPERS
WA700-3 30-251
3
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD
INSTALLATION OF PARKING
BRAKE PAD
Serial No.: 50001 – 50044
• Carry out installation in the reverse order to
removal.
1
fl Adjust the parking brake pad. For details,
see TESTING AND ADJUSTING PARKING
BRAKE of TESTING AND ADJUSTING.
2
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
824.0 – 1030.0 Nm {84.0 – 105.0 kgm}
30-252 WA700-3
3
7
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD
WA700-3 30-252-1
7
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD
INSTALLATION OF PARKING
BRAKE PAD
Serial No.: 50045 and up
• Carry out installation in the reverse order to
removal.
1
fl Adjust the parking brake pad. For details,
see TESTING AND ADJUSTING PARKING
BRAKE of TESTING AND ADJUSTING.
2
3 Mounting bolt:
98 – 122 Nm {10 – 125 kgm}
3
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
824.0 – 1030.0 Nm {84.0 – 105.0 kgm}
30-252-2 WA700-3
7
DISASSEMBLY AND ASSEMBLY REAR TIRE
1
3 Hub nut:
736.0 – 912.0 Nm {75.0 – 93.0 kgm}
fl Match the holes for the stud bolts by turn-
ing the tire on the opposite side.
WA700-3 30-253
3
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
Serial No.: 50001 – 51000
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
30-254 WA700-3
(10)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to
removal.
1
fl Do not twist the hoses.
fl Do not let dirt, dust, water, etc. in the hoses.
fl When tightening each joint of the air condi-
tioner hose, check that O-ring is fitted to it.
fl Apply sufficient compressor oil for R134a
(DENSO: ND-OIL8, ZEXEL: ZXL100PG (appli-
cable to PAG46)) to each O-ring.
WA700-3 30-254-1
(10)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
Serial No.: 51001 and up
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Collect air conditioner gas (R134a).
2. Disconnect wiring connector (1) (E21).
3. Disconnect hose (2) between condenser and air
conditioner compressor and hose (3) between
air conditioner unit and air conditioner compres-
sor. 1
4. Loosen mounting bolt (4) of air conditioner com-
pressor bracket.
5. Remove adjustment bolt (5) and slant compres-
sor toward engine to remove drive belt (6).
6. Remove 2 mounting bolts (7) to remove cover (8).
7. Remove 2 mounting bolts (9) to remove air con-
ditioner compressor assembly (8).
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
Serial No.: 51001 and up
• Carry out installation in the reverse order to
removal.
1
fl Do not twist the hoses.
fl Do not let dirt, dust, water, etc. in the hoses.
fl When tightening each joint of the air condi-
tioner hose, check that O-ring is fitted to it.
fl Apply sufficient compressor oil for R134a
(DENSO: ND-OIL8, ZEXEL: ZXL100PG (appli-
cable to PAG46)) to each O-ring.
• Compressor oil
(When using new compressor or refill com-
pressor oil.)
5 Compressor oil (DENSO: ND-OIL8, ZEXEL:
ZXL100PG (applicable to PAG46)) : 220 m¬
3 Tightening torque of air conditioner re-
frigerant piping:
Thread size Tightening torque
16 x 1.5 11.8 – 14.7 Nm {1.2 – 1.5 kgm}
22 x 1.5 19.5 – 24.5 Nm {2.0 – 2.5 kgm}
24 x 1.5 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
30-254-2 WA700-3
(10)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLIES
Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
Disconnect the cable from the negative (–) ter-
minal of the battery.
WA700-3 30-255
(10)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
• Carry out installation in the reverse order to
removal.
1
fl Do not twist the hoses.
fl Do not let dirt, dust, water, etc. in the hoses.
fl When tightening each joint of the air condi-
tioner hose, check that O-ring is fitted to it.
fl Apply sufficient compressor oil for R134a
(DENSO: ND-OIL8, ZEXEL: ZXL100PG (appli-
cable to PAG46)) to each O-ring.
30-255-1 WA700-3
(10)
DISASSEMBLY AND ASSEMBLY RECEIVER TANK
INSTALLATION OF RECEIVER
TANK ASSEMBLY
• Carry out installation in the reverse order to
removal.
1
fl Do not twist the hoses.
fl Do not let dirt, dust, water, etc. in the hoses.
fl When tightening each joint of the air condi-
tioner hose, check that O-ring is fitted to it.
fl Apply sufficient compressor oil for R134a
(DENSO: ND-OIL8, ZEXEL: ZXL100PG (appli-
cable to PAG46)) to each O-ring.
30-256 WA700-3
(10)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR
CONDITIONER UNIT
ASSEMBLY
Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
Disconnect the cable from the negative (–) ter-
minal of the battery.
WA700-3 30-257
(10)
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
INSTALLATION OF AIR
CONDITIONER UNIT
ASSEMBLY
• Carry out installation in the reverse order to
removal.
1
fl Do not twist the hoses.
fl Do not let dirt, dust, water, etc. in the hoses.
fl When tightening each joint of the air condi-
tioner hose, check that O-ring is fitted to it.
fl Apply sufficient compressor oil for R134a
(DENSO: ND-OIL8, ZEXEL: ZXL100PG (appli-
cable to PAG46)) to each O-ring.
30-258 WA700-3
(10)
DISASSEMBLY AND ASSEMBLY MAINTENANCE MONITOR
REMOVAL OF MAINTENANCE
MONITOR ASSEMBLY
¤ Stop the vehicle on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the vehi-
cle from moving.
¤ Disconnect the cable from the negative (–) ter-
minal of the battery.
INSTALLATION OF
MAINTENANCE MONITOR
ASSEMBLY
• Carry out installation in the reverse order to
removal.
WA700-3 30-261
3
DISASSEMBLY AND ASSEMBLY ENGINE, APS CONTROLLER
INSTALLATION OF ENGINE,
APS CONTROLLER ASSEMBLY
Serial No.: 50001 – 51000
• Carry out installation in the reverse order to
removal.
30-262 WA700-3
3
7
40 Maintenance standard
WA700-3 40-1
(10)
Maintenance standard Engine and tansmission mount
Unit: mm
WA700-3 40-3
(10)
Maintenance standard Damper
Damper
40-4 WA700-3
(10)
Maintenance standard Damper
Unit: mm
WA700-3 40-5
(10)
Maintenance standard Torque converter and PTO
Unit: mm
40-6 WA700-3
(10)
Maintenance standard Torque converter regulator valve
Unit: mm
WA700-3 40-7
(10)
Maintenance standard Transmission
Transmission (1/2)
Unit: mm
40-8 WA700-3
(10)
Maintenance standard Transmission
Unit: mm
WA700-3 40-9
(10)
Maintenance standard Transmission
Transmission (2/2)
Unit: mm
40-10 WA700-3
(10)
Maintenance standard Transmission control valve
Relief valve
Serial No.: 50001 — 51000 Serial No.: 51001 and up
40-12 WA700-3
(10)
Maintenance standard Transmission control valve
Unit: mm
WA700-3 40-13
(10)
Maintenance standard Transmission control valve
Lower valve
40-14 WA700-3
(10)
Maintenance standard Transmission control valve
Unit: mm
WA700-3 40-15
(10)
Maintenance standard Transmission control valve
Solenoid valve
40-16 WA700-3
(10)
Maintenance standard Transfer
Transfer
40-18 WA700-3
(10)
Maintenance standard Transfer
Unit: mm
WA700-3 40-19
(10)
Maintenance standard Drive shaft
Drive shaft
40-20 WA700-3
(10)
Maintenance standard Center support
Center support
Unit: mm
WA700-3 40-21
(10)
Maintenance standard Differential
Differential
40-22 WA700-3
(10)
Maintenance standard Differential
Unit: mm
0
11 Wear of oil seal surface 160 —
–0.100
WA700-3 40-23
(10)
Maintenance standard Final drive
Final drive
40-24 WA700-3
(10)
Maintenance standard Final drive
Unit: mm
WA700-3 40-25
(10)
Maintenance standard Axle mount
Axle mount
40-26 WA700-3
(10)
Maintenance standard Axle mount
Unit: mm
–0.21
6 Thickness of thrust plate 33 —
–0.35 Replace
WA700-3 40-27
(10)
Maintenance standard Center hinge pin
40-28 WA700-3
(10)
Maintenance standard Center hinge pin
Unit: mm
WA700-3 40-29
(10)
Maintenance standard Steering column
Steering column
Unit: mm
40-30 WA700-3
(10)
Maintenance standard Steering demand valve
40-32 WA700-3
(10)
Maintenance standard Steering demand valve
Unit: mm
WA700-3 40-33
(10)
Maintenance standard Diverter valve
Diverter valve
Unit: mm
40-34 WA700-3
(10)
Maintenance standard Steering cylinder mount
Unit: mm
Standard clearance
Width of boss Width of hinge Replace
Connection of steering (Clearance a + b)
3
cylinder and front frame 0 +1
88 –0.2 96 0 1.2 – 3.2
WA700-3 40-35
(10)
Maintenance standard Emergency steering pump
Unit: mm
40-36 WA700-3
(10)
Maintenance standard Brake valve
Brake valve
(Left)
Serial No.: 50001 – 50055
40-38 WA700-3
(10)
Maintenance standard Brake valve
Unit: mm
WA700-3 40-39
(10)
Maintenance standard Brake valve
(Left)
Serial No.: 50056 and up
Unit: mm
40-40 WA700-3
(10)
Maintenance standard Brake valve
(Right)
Serial No.: 50001 – 50055
40-42 WA700-3
(10)
Maintenance standard Brake valve
Unit: mm
WA700-3 40-43
(10)
Maintenance standard Brake valve
(Right)
Serial No.: 50056 and up
Unit: mm
40-44 WA700-3
(10)
Maintenance standard Slack adjuster
Slack adjuster
Unit: mm
WA700-3 40-45
(10)
Maintenance standard Brake
Brake
Serial No.: 50001 – 50045
40-46 WA700-3
(10)
Maintenance standard Brake
Unit: mm
WA700-3 40-47
(10)
Maintenance standard Brake
40-48 WA700-3
(10)
Maintenance standard Brake
Unit: mm
WA700-3 40-49
(10)
Maintenance standard Parking brake
Parking brake
Unit: mm
–0.10
3 Wear of rod connecting pin 12.7 — Rebuild
–0.17
Thickness of plate
Wear of disc must be under 23 mm
4 25 ±0.7
(Thickness of disc plate)
Less than 23 mm Replace
Clearance between pad and disc
5 1.06 ±0.18 2.1
(Total of both sides)
Adjust
Clearance between brake
6 0.36 – 1.0
body and plate
40-50 WA700-3
(10)
Maintenance standard Control pump
Control pump
Model: BAR025
Unit: mm
Replace
2 Side clearance of gear 0.055 – 0.075 0.105
WA700-3 40-51
(10)
Maintenance standard Steering and switch pump
40-52 WA700-3
(10)
Maintenance standard Main piston pump
WA700-3 40-53
(10)
Maintenance standard Main control valve
40-54 WA700-3
(10)
Maintenance standard Main control valve
Unit: mm
WA700-3 40-55
(10)
Maintenance standard Main control valve
40-56 WA700-3
(10)
Maintenance standard Main control valve
Unit: mm
WA700-3 40-57
(10)
Maintenance standard PPC valve
PPC valve
40-58 WA700-3
(10)
Maintenance standard PPC valve
Unit: mm
WA700-3 40-59
(10)
Maintenance standard PPC relief valve
Unit: mm
40-60 WA700-3
(10)
Maintenance standard Hydraulic cylinder
Hydraulic cylinder
Unit: mm
WA700-3 40-61
(10)
Maintenance standard Work equipment linkage
40-62 WA700-3
(10)
Maintenance standard Work equipment linkage
Unit: mm
11 Joint of boom and frame 214 ± 0.8 210 ± 2.1 1.1 – 6.9
No. 10. 11 and
15 only:
+1.5 254 ± 4 Insert shims on
12 Joint of boom and bucket 259 0 1.0 – 10.5
(After installing flange) both sides so
+3 that clearance
+1.5 254 –5 on both left and
13 Joint of bucket link and bucket 259 0 2.0 – 11.5
(After installing flange) right is less than
1.5 mm.
Joint of bellcrank and bucket +1.5 +1
14 203 0 200 –3 2.0 – 7.5
link
Joint of boom cylinder and +0.8
No. 12 and 13
15 229 ± 0.8 225 0 2.4 – 4.8 only:
frame
Insert shims so
that clearance is
16 Joint of bellcrank and boom 358 ± 0.5 355 ± 0.5 2.0 – 4.0
1.5 mm on both
left and right.
Joint of bellcrank and bucket +1.5 +0.8
17 213 0 210 0 2.2 – 4.5
cylinder
Joint of boom cylinder and
18 184 ± 1.5 180 ± 2.1 0.4 – 7.6
boom
WA700-3 40-63
(10)
Maintenance standard Bucket
Bucket
Unit: mm
40-64 WA700-3
(10)
Maintenance standard Bucket positioner and boom kick-out
Unit: mm
WA700-3 40-65
(10)
90 Others
WA700-3 90-1
(10)
Electric circuit diagram (1/5)
Serial No.: 50001 – 51000
WA700-3 90-3
(10)
Electric circuit diagram (2/5)
Serial No.: 50001 – 51000
WA700-3 90-5
(10)
Electric circuit diagram (3/5)
Serial No.: 50001 – 51000
WA700-3 90-7
(10)
Electric circuit diagram (4/5)
Serial No.: 50001 – 51000
WA700-3 90-9
(10)
Electric circuit diagram (5/5)
Serial No.: 50001 – 51000
WA700-3 90-11
(10)
Electric circuit diagram (1/6)
Serial No.: 51001 and up
WA700-3 90-13
(10)
Electric circuit diagram (2/6)
Serial No.: 51001 and up
WA700-3 90-15
(10)
Electric circuit diagram (3/6)
Serial No.: 51001 and up
WA700-3 90-17
(10)
Electric circuit diagram (4/6)
Serial No.: 51001 and up
WA700-3 90-19
(10)
Electric circuit diagram (5/6)
Serial No.: 51001 and up
WA700-3 90-21
(10)
Electric circuit diagram (6/6)
Serial No.: 51001 and up
WA700-3 90-23
(10)
Electric circuit diagram (1/3)
with auto shift and joystick steering
Serial No.: 50001 – 51000
WA700-3 90-25
(10)
Electric circuit diagram (2/3)
with auto shift and joystick steering
Serial No.: 50001 – 51000
WA700-3 90-27
(10)
Electric circuit diagram (3/3)
with auto shift and joystick steering
Serial No.: 50001 – 51000
WA700-3 90-29
(10)
Electric circuit diagram (AJSS (Advanced joystick steering system) specification) (1/3)
Serial No.: 51001 and up
WA700-3 90-31
(10)
Electric circuit diagram (AJSS (Advanced joystick steering system) specification) (2/3)
Serial No.: 51001 and up
WA700-3 90-33
(10)
Electric circuit diagram (AJSS (Advanced joystick steering system) specification) (3/3)
Serial No.: 51001 and up
WA700-3 90-35
(10)