03 WA1200-3 Shop Manual

SEBM018209
WA1200-3
MACHINE MODEL WA1200-3
SERIAL NO. 50001 and up
This shop manual may contain attachments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. WA1200-3 mount the Cummins QSK60 engine.
2004 1 All Rights Reserved Printed in Japan 10-04(01)
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CONTENTS
No. of page
01 10 20 30 40 90
GENERAL ........................................................................ STRUCTURE AND FUNCTION ...................................... TESTING AND ADJUSTING .......................................... DISASSEMBLY AND ASSEMBLY ................................. MAINTENANCE STANDARD ......................................... OTHERS...........................................................................
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WA1200-3
LIST OF REVISED PAGES
The affected pages are indicated by the use of the following marks. It is requested that necessary actions be taken to these pages according to the table below.
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Pages having no marks are those previously revised or made additions.
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10-197-1 (7) 10-198 10-199 10-200 10-201 10-202 10-203 10-204 10-205 10-206 10-207 10-208 10-209 10-210 10-211 (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7)
10-246 10-247 10-248 10-249 10-250 10-251 10-252 10-253 10-254 10-255 10-256 10-257 10-258 10-259 10-260 10-261 10-262 10-263 (7) (7)
10-211-1 (7) 10-212 10-213 10-214 10-215 10-216 10-217 10-218 10-219 10-220 10-221 10-222 10-223 10-224 (7) (7) (7) (7) (7) (7)
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20-119-1 (4) 20-120 20-121 20-122 20-123 20-124 20-125 20-126 20-127 20-128 20-129 20-130 20-131 20-132 20-133 20-134 20-135 20-136 20-137 20-138 20-139 20-140 20-141 20-142 20-143 20-144 (8) (1) (1) (1) (1) (1) (1) (8) (8) (1) (1) (1) (1) (8) (1) (8) (8) (1) (1) (1) (1) (1) (1) (6) (6)
20-199-1 (8) 20-199-2 (8) 20-199-3 (8) 20-199-4 (8) 20-199-5 (8) 20-199-6 (8) 20-199-7 (8) 20-199-8 (8) 20-199-9 (8) 20-199-10 (8) 20-199-11 (8) 20-199-12 (8)
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30-070-1 (5) 30-071 30-072 30-073 30-074 30-075 30-076 (5) (5) (5) (5) (5) (5)
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30-040 30-041 30-042 30-043 30-044 30-045 30-046 30-047 30-048 30-049
30-076-1 (5) 30-076-2 (5) 30-076-3 (5) 30-076-4 (5) 30-076-5 (5) 30-076-6 (5) 30-076-7 (5) 30-076-8 (5) 30-076-9 (5) 30-076-10 (5) 30-077 30-078 (5) (5)
30-006-1 (9) 30-007 30-008 30-009 30-010 30-011 30-012 30-013 (5) (5) (5) (5) (5) (5) (5)
30-049-1 (5) 30-049-2 (5) 30-049-3 (5) 30-049-4 (5)
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(6) (6) (6) (6) (6) (6) (6) (6) (6)
40-33 40-34 40-35 40-36 40-37 40-38 40-39 40-40 40-41 40-42 40-43
90- 7 90- 9 90-11 90-13 90-15 90-17 90-19 90-21 90-23 (7) (7) (7) (7) (7) (7) (7)
30-079-1 (5) 30-079-2 (5) 30-079-3 (5) 30-079-4 (5) 30-079-5 (5) 30-079-6 (5) 30-079-7 (5) 30-079-8 (5) 30-079-9 (5) 30-079-10 (5) 30-079-11 (5) 30-079-12 (5) 30-079-13 (5) 30-079-14 (5) 30-080 30-081 30-082 30-083 30-084 30-085 30-086 (5) (5) (5) (5) (5) (5) (5)
30-099-1 (5) 30-099-2 (5) 30-099-3 (5) 30-099-4 (5) 30-100 30-101 30-102 30-103 30-104 30-105 30-106 30-107 30-108 30-109 30-110 30-111 30-112 30-113 30-114 30-115 30-116 30-117 30-118 30-119 30-120 30-121 30-122 30-123 30-124 30-125 30-126 30-127 30-128 30-129 30-131 30-132 30-133 (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (5) (6) (6) (6)
40- 1 40- 2 40- 4 40- 5 40- 6 40- 7 40- 8 40- 9 40-10 40-11 40-12 40-13 40-14 40-16 40-17 40-18 40-19 40-20 40-21 40-22 40-23 40-24 40-25 40-26 40-27 40-28 40-29 40-30 40-32
40-44 40-45 40-46 40-47 40-48 40-49 40-50 40-51 40-52 40-53 40-54 40-55 40-56 40-57 40-58 40-59 40-60 40-61 40-62 40-63 40-64 40-65 40-66
30-086-1 (9) 30-086-2 (9) 30-087 30-088 (5) (5)
30-088-1 (5) 30-089 30-090 (5) (5)
30-090-1 (5) 30-091 30-092 30-093 30-094 30-095 (5) (5) (5) (5) (5)
30-095-1 (5) 30-095-2 (5) 30-095-3 (5) 30-095-4 (5) 30-096 (5)
90- 1 90- 2 90- 3 90- 4 90- 5 (6) (6) (6) (6)
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WA1200-3
SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10.Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, hand shield, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
00-3
SAFETY
SAFETY NOTICE
PRECAUTIONS DURING WORK 11.When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12.The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13.Before starting work, remove the leads from the battery. Always remove the lead from the negative () terminal first. 14.When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15.When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16.When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. 17.When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. 18.As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
19.Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20.When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21.When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22.When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23.When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24.Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
00-4
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 judgements. 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 further divided into the each main group of components.
STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" with "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. MAINTENANCE STANDARD This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. OTHERS This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: Attachments volume: volume to cover all models
REVISED EDITION MARK When a manual is revised, an edition mark ((1)(2)(3)....) is recorded on the bottom of the pages.
REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-todate information before you start any work.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
Symbol
Item Safety
Remarks Special safety precautions are necessary when performing the work. Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants, etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water must be drained, and quantity to be drained.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 12-203 10-4 12-203-1 10-4-1 Added pages 12-203-2 10-4-2 12-204 10-5
Caution
Weight
3 2 5 6
Tightening torque
Coat
Oil, water
Drain
00-6
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING k Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol 4 If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
100%
88%
79%
71%
41%
SAD00479
WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing)
Rope diameter mm 10 11.5 12.5 14 16 18 20 22.4 30 40 50 60 Allowable load kN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2 tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN {1000 kg} when two ropes make a 120 hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 39.2 kN {4000 kg} if they sling a 19.6 kN {2000 kg} load at a lifting angle of 150.
The allowable load value is estimated to be onesixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.
00-7
FOREWORD
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank.
Type 1
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container. Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) The adapter can be pushed in about 3.5 mm. Do not hold rubber cap portion (4). 3) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) 4) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) Since some hydraulic oil flows out, prepare an oil receiving container. Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00-8
FOREWORD
Type 2 1) Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise).
Disassembly
2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it.
Hold the mouthpiece of the tightening portion and push body (2) in straight until sliding prevention ring (1) contacts contact surface a of the hexagonal portion at the male end to connect it.
Connection
00-9
FOREWORD
COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code LT-1A Part No. 790-129-9030 Q'ty 150 g Container Tube Main applications, features Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polyprophylene, tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal. Features: Resistance to heat and chemicals Used for anti-loosening and sealant purpose for bolts and plugs. Used as adhesive or sealant for metal, glass and plastic. Can
LT-1B
790-129-9050
20 g (2 pcs.)
Polyethylene container
LT-2
09940-00030
50 g Adhesive: 1 kg Hardening agent: 500 g 250 g 75 g
LT-3 Adhesives LT-4 Holtz MH 705 Three bond 1735
790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120
Polyethylene container Tube Polyethylene container
Used as sealant for machined holes. Used as heat-resisting sealant for repairing engine. Quick hardening type adhesive Cure time: within 5 sec. to 3 min. Used mainly for adhesion of metals, rubbers, plastics and woods. Quick hardening type adhesive Quick cure type (max. strength after 30 minutes) Used mainly for adhesion of rubbers, plastics and metals. Resistance to heat, chemicals Used at joint portions subject to high temperatures. Used as adhesive or sealant for gaskets and packing of power train case, etc. Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc. Used as heat-resisting sealant for repairing engine. Features: Silicone type, heat resistant, vibration resistant, and impact resistant sealing material Used as sealing material for transfer case
790-129-9140
50 g
Aron-alpha 201 Loctite 648-50 LG-1
790-129-9130
2g
Polyethylene container Polyethylene container Tube
79A-129-9110 790-129-9010
50 cc 200 g
LG-5
790-129-9080
1 kg
Can
LG-6 Gasket sealant LG-7
790-129-9020
200 g
Tube
790-129-9070
1 kg
Tube
Three bond 1211 Three bond 1207B
790-129-9090
100 g
Tube
419-15-18131
100 g
Tube
00-10
FOREWORD
COATING MATERIALS
Category
Komatsu code LM-G
Part No. 09940-00051
Q'ty 60 g
Container Can
Main applications, features Used as lubricant for sliding portion (to prevent from squeaking). Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc. General purpose type
Molybdenum disulphide lubricant
LM-P
09940-00040
200 g
Tube
G2-LI
SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA SYG2-400M SYG2-400M-A SYGA-16CNM SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*) SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*)
Various
Various
G2-CA
Various
Various
Used for normal temperature, light load bearing at places in contact with water or steam.
Grease
Molybdenum disulphide grease LM-G (G2-M) Hyper White Grease G2-T G0-T (*) *: For use in cold district Biogrease G2B G2-BT (*) *: For high temperature and large load SUNSTAR PAINT PRIMER 580 SUPER SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PENGUINE SEAL 580 SUPER "S" or "W" Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE SEAL No. 2505 SEKISUI SILICONE SEALANT
400 g 10 Bellows type 400 g 20 Bellows type 16 kg Can
Used for heavy load portion
400 g 16 kg
Seizure resistance and heat resistance higher than molybdenum diBellows type sulfide grease Can Since this grease is white, it does not stand out against machine body. Bellows type Can Since this grease is decomposed by bacteria in short period, it has less effects on microorganisms, animals, and plants. Used as primer for cab side (Using limit: 4 months) Used as primer for glass side (Using limit: 4 months) Adhesive for cab glass "S" is used for high-temperature season (April - October) and "W" for low-temperature season (November - April) as adhesive for glass. (Using limit: 4 months) Used as adhesive for glass. (Using limit: 6 months) Used to seal joints of glass parts. (Using limit: 4 months) Used to seal front window. (Using limit: 6 months)
400 g 16 kg
20 ml
Glass container Glass container
Primer
20 ml 417-926-3910
320 ml
Adhesive
20Y-54-39850 417-926-3920
310 ml 320 ml
Polyethylene container Polyethylene container Polyethylene container
Caulking material
20Y-54-55130
333 ml
00-11
FOREWORD
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below.
Tightening torque Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 Nm 11.8 14.7 27 34 59 74 98 123 153 190 235 285 320 400 455 565 610 765 785 980 1150 1440 1520 1910 1960 2450 2450 3040 2890 3630 Tightening torque Thread diameter of bolt mm 6 8 10 12 Width across flats mm 10 13 14 27 Nm 5.9 9.8 13.7 23.5 34.3 46.1 74.5 90.2 kgm 0.6 1.0 1.4 2.4 3.5 4.7 7.6 9.2 kgm 1.2 1.5 2.8 3.5 6 7.5 10 12.5 15.5 19.5 23.5 29.5 33 41 46.5 58 62.5 78 80 100 118 147 155 195 200 250 250 310 295 370
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter mm 14 18 22 24 30 33 36 42 Width across flat mm 19 24 27 32 36 41 46 55 Nm 24.5 4.9 49 19.6 78.5 19.6 137.3 29.4 176.5 29.4 196.1 49 245.2 49 294.2 49 Tightening torque
SAD00483
kgm 2.5 0.5 52 82 14 3 18 3 20 5 25 5 30 5
00-12
FOREWORD
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below.
Thread diameter mm 10 12 16
Width across flat mm 14 17 22 Nm 59 74 98 123 235 285
Tightening torque kgm 6 7.5 10 12.5 23.5 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Norminal No. mm 02 03, 04 05, 06 10, 12 14 14 20 24 33 42
Width across flat mm
Tightening torque (Nm {kgm}) Range 35 63 84 132 128 186 363 480 746 1010 {3.5 6.5} {8.5 13.5} {13.0 19.0} {37.0 49.0} {76.0 103} Target 44 {4.5} 103 {10.5} 157 {16.0} 422 {43.0} 883 {90.0}
Varies depending on type of connector.
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Norminal No. mm 08 10 12 14 16 18 20 24 30 33 36 42 52 08 10 12 14 16 18 20 24 30 33 36 42 52
Width across flat mm 14 17 19 22 24 27 30 32 32 36
Tightening torque (Nm {kgm}) Range 5.88 8.82 9.8 12.74 14.7 19.6 19.6 24.5 24.5 34.3 34.3 44.1 44.1 53.9 58.8 78.4 93.1 122.5 107.8 147.0 127.4 176.4 181.3 240.1 274.4 367.5 {0.6 0.9} {1.0 1.3} {1.5 2.0} {2.0 2.5} {2.5 3.5} {3.5 4.5} {4.5 5.5} {6.0 8.0} {9.5 12.5} {11.0 15.0} {13.0 18.0} {18.5 24.5} {28.0 37.5} Target 7.35 {0.75} 11.27 {1.15} 17.64 {1.8} 22.54 {2.3} 29.4 {3.0} 39.2 {4.0} 49.0 {5.0} 68.6 {7.0} 107.8 {11.0} 124.4 {13.0} 151.9 {15.5} 210.7 {21.5} 323.4 {33.0}
00-13
FOREWORD
TIGHTENING TORQUE FOR 102 ENGINE SERIES 1) BOLT AND NUTS Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter mm 6 8 10 12 10 0 2 24 0 4 43 0 6 77 0 12 Nm Tightening torque 1.02 0 0.20 2.45 0 0.41 4.38 0 0.61 7.85 0 1.22 kgm
2) EYE JOINTS Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter mm 6 8 10 12 14 802 10 0 2 12 0 2 24 0 4 36 0 5 Nm Tightening torque 0.81 0 0.20 1.02 0 0.20 1.22 0 0.20 2.45 0 0.41 3.67 0 0.51 kgm
3) TAPERED SCREWS Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter inch 1 / 16 1/8 1/4 3/8 1/2 3/4 1 301 802 12 0 2 15 0 2 24 0 4 36 0 5 60 0 9 Nm Tightening torque 0.31 0 0.10 0.81 0 0.20 1.22 0 0.20 1.53 0 0.41 2.45 0 0.41 3.67 0 0.51 6.12 0 0.92 kgm
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {kgm}) Nominal size Width across of hose flats Range 34 54 {3.5 5.5} 34 63 {3.5 6.5} 03 22 24 04 05 06 (10) (12) (14) 27 32 36 41 46 55 54 93 {5.5 9.5} 59 98 {6.0 10.0} 84 132 {8.5 13.5} 128 186 {13.0 19.0} 177 245 {18.0 25.0} 177 245 {18.0 25.0} 197 294 {20.0 30.0} 246 343 {25.0 35.0} Target 44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0} Taper seal type Face seal type
Nominal thread Thread size size Root diameter - Threads per (mm) inch, Thread series (mm) (Reference) 14 18 22 24 30 33 36 42 9 18UN 16 11 16UN 16 13 16UN 16 1 14UNS 3 1 12UN 16 14.3 17.5 20.6 25.4 30.2
02
19
00-14
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire Norminal number Number of strands 11 26 65 84 85 127 217 Dia. of strands (mm2) 0.32 0.32 0.32 0.45 0.80 0.80 0.80 Cross section (mm2) 0.88 2.09 5.23 13.36 42.73 63.84 109.1 Cable O.D. (mm) Current rating (A) Applicable circuit
0.85 2 5 15 40 60 100
2.4 3.1 4.6 7.0 11.4 13.6 17.6
12 20 37 59 135 178 230
Starting, lighting, signal etc. Lighting, signal etc. Charging and signal Starting (Glow plug) Starting Starting Starting
CLASSIFICATION BY COLOR AND CODE

Circuits Priority Classification Primary Code Color Code 2 Color White & Red Code 3 Color White & Black Code 4 Auxiliary WL Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow BR RY YG Yellow & Green YL GY Green & Yellow GB LY Blue & Yellow LB WB White & Black Red & White Rellow & Red Green & White Blue & White BY RB YB GR LR
Charging
Ground
Starting
Lighting
Instrument
Signal
Other
W White WR
B Black
B Black BW
R Red RW
Y Yellow YR
G Green GW
L Blue LW
Color White & Blue Code WG
Black & Red Red & Yellow RG
5 Color White & Green Code 6 Color Red & Blue Yellow & White Green & Blue Red & Green Yellow & Blue Green & Black Blue & Black RL YW GL n n
00-15
FOREWORD
CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below.
EXAMPLE Method of using the Conversion Table to convert from millimeters to inches 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line from A. (2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down from B. (3) Take the point where the two lines cross as C. This point C gives the value when converting from 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. B Millimeters to inches
1 mm = 0.03937 in
0 0 10 20 30 40 A 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543
1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583
2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622
3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661
4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 C 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780
7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819
8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858
9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898
00-16
FOREWORD
CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 0 10 20 30 40 50 60 70 80 90 0 0.394 0.787 1.181 1.575 1.969 2.362 2.756 3.150 3.543
1 0.039 0.433 0.827 1.220 1.614 2.008 2.402 2.795 3.189 3.583
2 0.079 0.472 0.866 1.260 1.654 2.047 2.441 2.835 3.228 3.622
3 0.118 0.512 0.906 1.299 1.693 2.087 2.480 2.874 3.268 3.661
4 0.157 0.551 0.945 1.339 1.732 2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780
7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819
8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858
9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 0 10 20 30 40 50 60 70 80 90 0 22.05 44.09 66.14 88.18 110.23 132.28 154.32 176.37 198.42
1 2.20 24.25 46.30 68.34 90.39 112.44 134.48 156.53 178.57 200.62
2 4.41 26.46 48.50 70.55 92.59 114.64 136.69 158.73 180.78 202.83
3 6.61 28.66 50.71 72.75 94.80 116.85 138.89 160.94 182.98 205.03
4 8.82 30.86 51.91 74.96 97.00 119.05 141.10 163.14 185.19 207.24
5 11.02 33.07 55.12 77.16 99.21 121.25 143.30 165.35 187.39 209.44
6 13.23 35.27 57.32 79.37 101.41 123.46 145.51 167.55 189.60 211.64
7 15.43 37.48 59.53 81.57 103.62 125.66 147.71 169.76 191.80 213.85
8 17.64 39.68 61.73 83.78 105.82 127.87 149.91 171.96 194.01 216.05
9 19.84 41.89 63.93 85.98 108.03 130.07 152.12 174.17 196.21 218.26
00-17
FOREWORD
CONVERSION TABLE
Liter to U.S. Gallon 0 0 10 20 30 40 50 60 70 80 90 0 2.642 5.283 7.925 10.567 13.209 15.850 18.492 21.134 23.775 1 0.264 2.906 5.548 8.189 10.831 13.473 16.115 18.756 21.398 24.040 2 0.528 3.170 5.812 8.454 11.095 13.737 16.379 19.020 21.662 24.304 3 0.793 3.434 6.076 8.718 11.359 14.001 16.643 19.285 21.926 24.568 4 1.057 3.698 6.340 8.982 11.624 14.265 16.907 19.549 22.190 24.832 5 1.321 3.963 6.604 9.246 11.888 14.529 17.171 19.813 22.455 25.096 6 1.585 4.227 6.869 9.510 12.152 14.795 17.435 20.077 22.719 25.361 7 1.849 4.491 7.133 9.774 12.416 15.058 17.700 20.341 22.983 25.625
1l = 0.2642 U.S. Gal
8 2.113 4.755 7.397 10.039 12.680 15.322 17.964 20.605 23.247 25.889
9 2.378 5.019 7.661 10.303 12.944 15.586 18.228 20.870 23.511 26.153
Liter to U.K. Gallon 0 0 10 20 30 40 50 60 70 80 90 0 2.200 4.399 6.599 8.799 10.998 13.198 15.398 17.598 19.797 1 0.220 2.420 4.619 6.819 9.019 11.281 13.418 15.618 17.818 20.017 2 0.440 2.640 4.839 7.039 9.239 11.438 13.638 15.838 18.037 20.237 3 0.660 2.860 5.059 7.259 9.459 11.658 13.858 16.058 18.257 20.457 4 0.880 3.080 5.279 7.479 9.679 11.878 14.078 16.278 18.477 20.677 5 1.100 3.300 5.499 7.969 9.899 12.098 14.298 16.498 18.697 20.897 6 1.320 3.520 5.719 7.919 10.119 12.318 14.518 16.718 18.917 21.117 7 1.540 3.740 5.939 8.139 10.339 12.528 14.738 16.938 19.137 21.337
1l = 0.21997 U.K. Gal
8 1.760 3.950 6.159 8.359 10.559 12.758 14.958 17.158 19.357 21.557
9 1.980 4.179 6.379 8.579 10.778 12.978 15.178 17.378 19.577 21.777
00-18
FOREWORD
CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 0 72.3 144.7 217.0 289.3 361.7 434.0 506.3 578.6 651.0 723.3 795.6 868.0 940.3 1012.6 1084.9 1157.3 1129.6 1301.9 1374.3
1 7.2 79.6 151.9 224.2 296.6 368.9 441.2 513.5 585.9 658.2 730.5 802.9 875.2 947.5 1019.9 1092.2 1164.5 1236.8 1309.2 1381.5
2 14.5 86.8 159.1 231.5 303.8 376.1 448.5 520.8 593.1 665.4 737.8 810.1 882.4 954.8 1027.1 1099.4 1171.7 1244.1 1316.4 1388.7
3 21.7 94.0 166.4 238.7 311.0 383.4 455.7 528.0 600.3 672.7 745.0 817.3 889.7 962.0 1034.3 1106.6 1179.0 1251.3 1323.6 1396.0
4 28.9 101.3 173.6 245.9 318.3 390.6 462.9 535.2 607.6 679.9 752.2 824.6 896.9 969.2 1041.5 1113.9 1186.2 1258.5 1330.9 1403.2
5 36.2 108.5 180.8 253.2 325.5 397.8 470.2 542.5 614.8 687.1 759.5 831.8 904.1 976.5 1048.8 1121.1 1193.4 1265.8 1338.1 1410.4
6 43.4 115.7 188.1 260.4 332.7 405.1 477.4 549.7 622.0 694.4 766.7 839.0 911.4 983.7 1056.0 1128.3 1200.7 1273.0 1345.3 1417.7
7 50.6 123.0 195.3 267.6 340.0 412.3 484.6 556.9 629.3 701.6 773.9 846.3 918.6 990.9 1063.2 1135.6 1207.9 1280.1 1352.6 1424.9
8 57.9 130.2 202.5 274.9 347.2 419.5 491.8 564.2 636.5 708.8 781.2 853.5 925.8 998.2 1070.5 1142.8 1215.1 1287.5 1359.8 1432.1
9 65.1 137.4 209.8 282.1 354.4 426.8 499.1 571.4 643.7 716.1 788.4 860.7 933.1 1005.4 1077.7 1150.0 1222.4 1294.7 1367.0 1439.4
00-19
FOREWORD
CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 0 142.2 284.5 426.7 568.9 711.2 853.4 995.6 1138 1280 1422 1565 1707 1849 1991 2134 2276 2418 2560 2702 2845 2987 3129 3271 3414
1 14.2 156.5 298.7 440.9 583.2 725.4 867.6 1010 1152 1294 1437 1579 1721 1863 2005 2148 2290 2432 2574 2717 2859 3001 3143 3286 3428
2 28.4 170.7 312.9 455.1 597.4 739.6 881.8 1024 1166 1309 1451 1593 1735 1877 2020 2162 2304 2446 2589 2731 2873 3015 3158 3300 3442
3 42.7 184.9 327.1 469.4 611.6 753.8 896.1 1038 1181 1323 1465 1607 1749 1892 2034 2176 2318 2460 2603 2745 2887 3030 3172 3314 3456
4 56.9 199.1 341.4 483.6 625.8 768.1 910.3 1053 1195 1337 1479 1621 1764 1906 2048 2190 2333 2475 2617 2759 2901 3044 3186 3328 3470
5 71.1 213.4 355.6 497.8 640.1 782.3 924.5 1067 1209 1351 1493 1636 1778 1920 2062 2205 2347 2489 2631 2773 2916 3058 3200 3343 3485
6 85.3 227.6 369.8 512.0 654.3 796.5 938.7 1081 1223 1365 1508 1650 1792 1934 2077 2219 2361 2503 2646 2788 2930 3072 3214 3357 3499
7 99.6 241.8 384.0 526.3 668.5 810.7 953.0 1095 1237 1380 1522 1664 1806 1949 2091 2233 2375 2518 2660 2802 2944 3086 3229 3371 3513
8 113.8 256.0 398.3 540.5 682.7 825.0 967.2 1109 1252 1394 1536 1678 1821 1963 2105 2247 2389 2532 2674 2816 2958 3101 3243 3385 3527
9 128.0 270.2 412.5 554.7 696.9 839.2 981.4 1124 1266 1408 1550 1693 1835 1977 2119 2262 2404 2546 2688 2830 2973 3115 3257 3399 3542
00-20
FOREWORD
CONVERSION TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, 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.
1C = 33.8F
C 40.4 37.2 34.4 31.7 28.9 28.3 27.8 27.2 26.7 26.1 25.6 25.0 24.4 23.9 23.3 22.8 22.2 21.7 21.1 20.6 20.0 19.4 18.9 18.3 17.8 17.2 16.7 16.1 15.6 15.0 14.4 13.9 13.3 12.8 12.2 40 35 30 25 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10
F 40.0 31.0 22.0 13.0 4.0 2.2 0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0
C 11.7 11.1 10.6 10.0 9.4 8.9 8.3 7.8 7.2 6.7 6.1 5.6 5.0 4.4 3.9 3.3 2.8 2.2 1.7 1.1 0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
F 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0
C 7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 48 49 50 51 52 53 54 55 56 57 58 59 0 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80
F 114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0
C 27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175
F 117.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0
00-21
FOREWORD
UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI). As for reference, conventionally used Gravitational System of units are indicated in parentheses { Example: N {kg} Nm {kgm} MPa {kg/cm2} kPa {mmH2O} kPa {mmHg} kW/rpm {HP/rpm} g/kWh {g/HPh}
}.
00-22
10-04
01
GENERAL
General assembly drawing . .. . . . .. . . . . . . .. . . . . . . . .. . . 01-2 Specifications . . .. . .. . . . . . .. . . . . .. .. . . . .. . .. .. . . . . . . .. . . . . .. . . .. 01-3 Weight table . . . . . . .. . . . .. . . . . . .. . . . . . . .. .. . . . . . . . . . .. . . . . . .. . . 01-6 List of lubricant and water .. . . . . . . .. .. . . . . . . .. . . .. . . 01-8
WA1 200-3
01-l
GENERAL
GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY
DRAWING
Dimensions in ( 1 are for vehicles equipped with 65/65-57-62PR tires. Dimensions marked with % are for vehicles for handling rocks and those marked with *X are for vehicles for handling lime.
SJWO4720
01-2
WA1 200-3
GENERAL
SPECIFICATIONS
Machine model Serial No. Operating weight Distribution (front) Distribution (rear) Bucket capacity (piled) Rated load Travel speed FORWARD 1st FORWARD 2nd FORWARD 3rd REVERSE 1st REVERSE 2nd REVERSE 3rd Max. rimpull Gradeability Min. turning radius
WA1 200-3 50001 and up
kg
205,200 [210,4001 122,220 [ 124,840l 82,950 I85,5601 20.0 36,000 6.3 i6.51 11.5 [Il.91 19.8 120.41 7.4 17.71 13.4 113.91 22.6 i23.21 1,127 {115,000~ [1,088 ~lll,OOO~l 25 12,000 14,300 18,210 5,7 10 [5,9701 6,400 (Cutting edge) 6,550 (Tire guard) 6,865 !6,9301 11,865 [I I,9301 7,100 4,300 650 [7151 8,830 [8,8951 6,735 [6,8001 2,665 49.5 (Max. height) 50 590 [5251
kg
kg
m3 kg km/h km/h km/h km/h km/h km/h kN {kg) deg
Overall length
Center of outside wheel Outside portion of chassis
mm mm mm mm mm
Overall width (chassis) Bucket width
Overall height
(top of ROPS cab) (Bucket raised)
mm mm mm mm mm mm mm mm deg deg mm
Wheelbase Tread Min. ground clearance Height of bucket hinge pin Dumping clearance (tip of edge) Dumping reach (tip of edge) Bucket dump angle Bucket tilt angle (SAE carrying position) Digging depth (IO dump) (tip of edge) I I: with 65/65-57-62PR tires WA1 200-3
01-3
GENERAL
SPECIFICATIONS
Machine model Serial No. Model Type
WA1 200-3 50001 and up Cummins QSK60 4-cycle, water-cooled, V type, 16-cylinder direct injection, with turbocharger, after-cooler mm e {cc) Wrpm IHP/rpml lmlrpm Ikgmlrpml 16-159x190 60 (60,360) 1,I 60/l ,900 {I ,558/l ,900) 7,830/l ,500 {798/l ,500) 214 {ISO} (at rated output, gross) 2,050 650 24 V 9.0 kW x 2 24V140A 12 V 200 Ah x 6 3-element, l-stage, single-phase (TCA51-3)
No. of cylinders - bore x stroke Piston displacement
Fuel consumption i High idling speed Low idling speed Starting motor Alternator Battery Torque converter
ratio
g/kW-h {g/HP-h} wm wm
Transmission Reduction gear Differential Final drive Drive type Front axle Rear axle Tire Wheel rim Inflation pressure Main brake
Planetary gear, multiple-disc, hylraulically actuated, modulation type Spiral bevel gear Straight bevel gear Planetary gear, 2 reduction, oil bath Front/rear-wheel drive
Fixed-frame, full-floating Center pin support type, full-floating 55.5/80-57-68PR(L-5) [65/65-57-62PR(L-511 kPa {kg/cm21 44.00 x 57i6.0 [52.00 x 57i6.01 588 (6.01 Front/rear wheel braking, separate front/rear wheel, wet disc, hydraulically actuated
1 ? a
Parking brake
Drive shaft (Transmission output shaft) braking, multiple wet disc, hydraulically release spring apply
r I: with 65/65-57-62PR tires
01-4
WA1 200-3
GENERAL
SPECIFICATIONS
Machine model Serial No.
WA1 200-3 50001 and up Articulated type Fully hydraulically power steering
Type
Structure Torque converter, transmission pump Steering pump Umin
817 (Gear type: SAR(4)200+SAR(4)200) 630 (Fixed capacity piston pump: HPF160+160) 630 Variable + fixed capacity piston pump: HPV160+HPF160) 95 (Gear type: SAR(2)50) 54 (Gear type: SAR(2)28) 630 (Variable capacity piston pump: HPV160+160) 383 (Variable capacity piston pump: H PV95+95) 2.65 127) (Spool type, electric control) 31.4 {320} (Spool type) 3.7 08) (2-lever type) 31.4 (320) (2-spool type) Reciprocating piston 2 - 225 x 660 Reciprocating piston 2-360x 1,835 Reciprocating piston 2-300x 1,025 Double Z bar link Spade nose bucket with teeth
Umin
Switch pump
Umin
Hydraulic pump Delivery
PPC pump
4Ymin
Brake pump
Urnin
Work equipment pump (I)
Urnin
Work equipment pump (2)
l?/min
Transmission valve
MPa {kg/cm?
Control valve Set pressure
Steering valve PPC valve
VlPa {kg/cm21
VlPa {kg/cm?
Main control valve
VlPa {kg/cm)
Steering cylinder No. - bore x stroke Cylinder 3oom cylinder No. - bore x stroke 3ucket cylinder No. - bore x stroke -ink type 3ucket edge type
mm
mm
mm
WA1 200-3
01-5
GENERAL
WEIGHT TABLE
WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components. Unit: kg Machine model Serial No. Engine Radiator (including hydraulic oil cooler) Torque converter Torque converter oil cooler Fuel cooler Transmission Damper Upper drive shaft Center drive shaft Front drive shaft Rear drive shaft Center support Front axle Rear axle Front differential assembly Rear differential assembly Planetary carrier assembly (each) Planetary hub assembly (each) Axle pivot (Rear axle) (front/rear) Wheel (55.5 tire/65 tire) (each) Tire (55.5 tire/65 tire) (each) Steering valve Steering cylinder (each) Hydraulic tank (tank unit) Work equipment pump (No.VNo.2) Torque converter charging + PPC pump Switch pump Steering pump Fender (one side) PPC valve I I I I I I I I I WA1 200-3 50001 and up 7,250 2,750 1,404 285 338 3,690 359 112 184 209 215 154 16,500 16,500 1,570 1,800 880 710 6251960 1,913/2,051 5,930/7,150 68 589 1,366 ( 1,230) 193/I 66 70.3 189 191 140 4
01-6
WA1 200-3
GENERAL
WEIGHT TABLE
Unit: kg Machine model Serial No. Main control valve (each) Boom cylinder (each) Bucket cylinder Radiator guard Front frame Rear frame Bucket link (including bushing) (each) Bellcrank (including bushing) (each) Boom (including bushing) Bucket (with teeth) Rear bumper (including fuel tank) Fuel tank (side x 2, center x 1) Battery (each) Cab assembly Air conditioner unit Operators seat Floor plate ROPS support assembly I 3,238 I 646 I WA1 200-3 50001 and up 95 2,943 1,380 905 15,160
r
I I
2,440 18,430 23,840 6,470 side: 520 x 2, center: 609 59 539 55
WA1 200-3
01-7
GENERAL
LIST OF LUBRICANT AND WATER

RESERVOIR <IND OF FLUID AMBIENT TEMPERATURE -40 -22 -4 14 32 50 88 88 104
-40 -30 -20 -10 0 10 20 30 40
CAPACITY
122F 50C
Specified
Refill
Engine oil pan
260 Q
Transmission case Engine oil Hydraulic system
380 k!
350 Q
1,200 e 60 Q 280 Q See Note 1 45 Q 270 Q
Brake tank
Brake Cooling
Axle (Front and rear) (each) Auto-grease Grease
670 Q
670 Q
Work equipment pir
Gear oil
Fuel tank
Gear -
5,100 Q
Cooling system
Water
Add antifreeze
510 Q
% ASTM 0975 No.1 Note 1: For axle oil, use only recommended oil as follows. DONAX TT or TD SHELL: RPM TRACTOR HYDRAULIC FLUID CALTEX: TRACTOR HYDRAULIC FLUID CHEVRON: TDH OIL TEXACO: MOBILAND SUPER UNIVERSAL MOBIL: 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. In cold areas when the hydraulic oil temperature is low, if the steering wheel is turned and the machine is stopped in that position, there may be a time lag before the machine turns and stops. If this happens, turn the steering wheel slowly to the left and right (repeat for about 10 minutes) and the oil inside the steering valve will be warmed up. [xl]: When working in particularly severe conditions, use a multi-purpose grease containing 3 - 5% molybdenum. b+21: For machines equipped with an autogrease system, if the machine is operated in temperatures below -2OC, use lithiumbased grease No. 0 for the grease. *
01-8
WA1 200-3
GENERAL
REMARK
When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%.
Fuel sulphur
content
Change interval of oil in engine oil pan l/2 of regular l/4 of regular interval interval
0.5 to 1.0% Above 1.0%
When starting the engine in an atmospheric temperature of lower than OC, be sure to use engine oil of SAEIOW, SAEIOW-30 and SAE15W40, even though an atmospheric temperature goes up to 10C more or less in the day time. Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table. We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine and hydraulic work equipment applications. Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance. ASTM: SAE: API: American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute
WA1 200-3
01-9
10
STRUCTURE AND FUNCTION
Outline ......................................................... 10- 2 Radiator and hydraulic oil cooler ............. 10- 4 Damper ........................................................ 10- 5 Torque converter and transmission piping ............................. 10- 6 Torque converter ........................................ 10- 8 Main relief valve and torque converter relief valve ............................................ 10- 17 Torque converter regulator valve ............. 10- 20 ECMV ........................................................... 10- 22 Transmission .............................................. 10- 28 Transmission control valve ....................... 10- 38 Lubricating oil relief valve ......................... 10- 49 Transfer ....................................................... 10- 50 Torque converter oil cooler ...................... 10- 52 Center support ............................................ 10- 53 Axle .............................................................. 10- 54 Final drive ................................................... 10- 59 Axle mount ................................................. 10- 60 Center hinge pin ......................................... 10- 62 Arrangement of steering equipment ........ 10- 63 AJSS (Advanced Joystick Steering System) ................................................. 10- 64 Steering pump ............................................ 10- 65 Switch pump .............................................. 10- 68 Servo valve ................................................. 10- 71 Steering demand valve ............................. 10- 75 Rotary valve ................................................ 10- 86 EPC valve .................................................... 10- 89 Diverter valve ............................................. 10- 90 Arrangement of brake equipment ............ 10- 94 Brake valve ................................................. 10- 96 Charge valve ............................................... 10-101 Accumulator (for brake) ............................ 10-105 Slack adjuster ............................................. 10-106
Brake ............................................................ 10-109 Parking brake .............................................. 10-110 Arrangement of hydraulic equipment ...... 10-112 Work equipment lever linkage .................. 10-114 Hydraulic tank ............................................. 10-115 Work equipment pump No. 1 ................... 10-118 Work equipment pump No. 2 ................... 10-131 PPC valve .................................................... 10-148 PPC relief valve .......................................... 10-152 Accumulator (for PPC valve) ..................... 10-153 Main control valve ..................................... 10-154 Work equipment linkage ........................... 10-168 Operation of proximity switch .................. 10-170 Air conditioner ............................................ 10-172 Machine monitor system........................... 10-175 Main monitor .............................................. 10-177 CGC monitor ............................................... 10-181 All-range electronic control automatic transmission (ATM) system ................ 10-218 Modulated clutch (MOD/C) control system ..................................... 10-233 Work equipment and joystick steering control system ..................................... 10-237 Work equipment and joystick steering controller .............................................. 10-243 Engine starting circuit ................................ 10-244 Engine stopping circuit .............................. 10-248 Ether injection circuit ................................. 10-249 Electric parking brake control ................... 10-250 Parking brake solenoid valve .................... 10-260 Emergency parking brake reset solenoid valve ............................ 10-261 Kick-down switch and auto shift/ manual shift selector switch ............... 10-262
WA1200-3
10-1
(7)
STRUCTURE
AND FUNCTION
OUTLINE
OUTLINE
SWWO4721
OUTLINE The power of engine (16) is transmitted through the engine flywheel to damper (15). The damper output shaft is connected to modulated clutch (13) through upper drive shaft (14). The output of the modulated clutch is connected to the pump of torque converter (11). The turbine of the torque converter is connected to input shaft of transmission (IO). The transmission has five hydraulically operated clutches and generates three gear speeds each in forward and reverse directions which are selected with an electric control switch. The transmission output shaft is connected to the gear of transfer (91, then the power is transmitted to the transfer output shaft. Then, the power is transmitted from the transfer output shaft through center drive shaft (71, center support (321, front drive shaft (61, and rear drive shaft (31) to front axle (5) and rear axle (281, then transmitted through the wheels to the tires.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Front differential Front brake Front final drive Front tire Front axle Front drive shaft Center drive shaft Emergency steering pump Transfer (Output) Transmission Torque converter Transfer (Input) Modulated clutch Upper drive shaft Damper Engine Work equipment pump No. 1 Work equipment pump No. 2 Switching pump Steering pump Control pump PPC pump
o-2
WA1 200-3
STRUCTURE
AND
FUNCTION
OUTLINE
23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.
Torque converter, transmission Brake cooling pump Brake pump Rear final drive Rear tire Rear axle Rear differential Rear brake Rear drive shaft Center support Parking brake
pump
SWW04722
WA1 200-3
1o-3
RADIATOR AND HYDRAULIC OIL COOLER
RADIATOR
AND HYDRAULIC
OIL COOLER
,______----I
Y
SJW04723
1. Fan guard 2. Water level sensor 3. Radiator cap 4. Sub-tank 5. Upper tank 6. Hydraulic oil cooler 7. Radiator (LTC) 8. Radiator (HTC) 9. Lower tank
Specification LTC Core type Total heat dissipating m* area I I Cross-sectional area of water tubes /cm 1
I
HTC
Modular core Modular core 211.6 59,042 1

I
414.8 88,690 /
I
1o-4
WA1 200-3
DAMPER
DAMPER
SJW04724
1. Shaft
2. 3. 4. 5. 6.
Breather Rubber cushion Inner body Rubber cushion Outer body
FUNCTION . The damper reduces the caused by changes in the acts to protect the units beyond the engine from sional vibration.
torsional vibration engine torque, and of the power train the effects of tor-
OPERATION . The power of the engine is transmitted from the flywheel to outer body (6). The torsional vibration of the engine is absorbed by rubber cushions (3) and (51, passes through inner body (4) and shaft (I), and is transmitted to the upper drive shaft between the torque converter.
WA1 200-3
1o-5
TORQUE CONVERTER AND TRANSMISSION
PIPING
TORQUE CONVERTER
AND TRANSMISSION
PIPING
SWW04725
1. 2. 3. 4. 5. 6. 7. 8. 9.
Transmission Transmission control valve Transfer (input) Torque converter oil cooler Torque converter charging pump Torque converter Torque converter oil filter Transmission oil level gauge Transfer (output)
10-6
WA1 200-3
TORQUE CONVERTER
TORQUE CONVERTER
(INPUT TRANSFER,
PTO, MODULATED CLUTCH, TORQUE CONVERTER)
lZ
W
7
9JA00061
1O-8
WA1 200-3
TORQUE CONVERTER
. . \.. F
v
IO
9JBOOO62
A: Torque converter outlet port B: Outlet oil pressure pick-up port of torque converter c: Torque converter inlet port D: Lubrication port for PTO, input transfer, and modulated clutch E: Interconnection port F: Torque converter inlet port G: Inlet oil pressure pick-up port of torque converter H: Main oil pressure pick-up port J: Torque converter relief port K: Drain port
1. Mounting port for steering pump, control pump, and PPC pump 2. Mounting port for switch pump 3. Mounting port for transmission charging pump, torque converter charging pump, brake cooling pump, and brake pump 4. Regulator valve of torque converter outlet 5. Mounting port for work equipment pump 6. Mounting port for work equipment pump 7. Output rotation sensor of modulated clutch 8. ECMV for modulated clutch 9. Torque converter valve 10. Input rotation sensor of input transfer
WA1 200-3
1o-9
TORQUE CONVERTER
14
A-A
9JB00063
10-10
WA1 200-3
STRUCTURE
AND
FUNCTION
TORQUE
CONVERTER
9JBOOO64
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Coupling Drive gear (Number of teeth: 74) PTO gear (Number of teeth: 68) PTO gear (Number of teeth: 68) Idler gear (Number of teeth: 68) Modulated clutch output shaft Modulated clutch piston Modulated clutch outer drum Modulated clutch inner drum Coupling
21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Torque converter input shaft Drive case Turbine Stator Pump Torque converter case Transmission input shaft Driven gear (Number of teeth: 58) Modulated clutch disc Modulated clutch plate
WA1 200-3
10-11
TORQUE CONVERTER
Specifications Model: 42C-13-11002 Type: 3-elemet, single stage, single phase Stall torque ratio: 2.23 (T3/Tl) 2.84 (T3/T2)
T3
10-12
WA1 200-3
STRUCTURE
AND
FUNCTION
TORQUE
CONVERTER
Operation
Power transmission route
9JBOOO66
The torque converter is installed between the damper and transmission. The power from the damper is transmitted through the upper drive shaft to coupling (II). The speed of the rotation is heightened with drive gear (121, idler gear (151, and driven gear (28) of the input transfer, then transmitted to modulated clutch inner drum (19). If oil pressure is applied to the back of modulated clutch piston (171, modulated clutch piston (171 presses modulated clutch disc (29) against modulated clutch plate (30) to transfer the power to modulated clutch outer drum (18).
The power transmitted to modulated clutch outer drum (18) is further transmitted through modulated clutch output shaft (16) and coupling (20) to torque converter input shaft (21). Since torque converter input shaft (211, drive case (22). and pump (25) are secured with bolts, they are rotated with the power from the modulated clutch. The power of pump (25) rotates turbine (23) to drive transmission input shaft (271, using the oil as medium. The power of coupling (11) is used to drive the pump, too, through drive gear (121, PTO gear (131, or idler gear (15).
10-14 0
WA1 200-3
TORQUE CONVERTER
Flow of oil
9JBOOO67
The oil flows through the main relief valve and its pressure is regulated below the set pressure by the torque converter relief valve, then it flows in inlet port A and merges with the oil sent from the torque converter charging pump through torque converter case (26), then the merged oil flows in pump (25). Set pressure: 1.05 MPa (IO.7 kg/cm*} The oil is given centrifugal force by pump (251, then it flows in turbine (23) and gives its energy to turbine (23).
The oil from turbine (23) flows to stator (24) and flows in pump (25) again. At this time, a part of the oil flows through stator (24) and outlet port B to the torque converter outlet regulator valve. The oil that flows in the torque converter outlet regulator valve flows further through the oil cooler to cool itself, then it is used to lubricate the transmission.
WA1 200-3
10-M
TORQUE CONVERTER
Outline The modulated clutch is installed between the input transfer and torque converter. The clutch can be engaged or slipped by adjusting the clutch oil pressure with ECMV. The power transmitted to the torque converter can be reduced by slipping the clutch.
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Operation When clutch is engaged The oil sent from ECMV (1) for the modulated clutch flows through the oil passage of modulated clutch case (2) to piston (3) and moves piston (3) to the right. If piston (3) moves and the clutch oil pressure rises, the pressure of piston (3) increases and presses disc (4) against plate (5) to engage inner drum (6) with outer drum (7). Accordingly, all of the power transmitted from inner drum (6) is transmitted to outer drum (7).
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When clutch is slipped . If the controller outputs the signal to lower the clutch oil pressure, ECMV (I) for the modulated clutch lowers the clutch oil pressure. If the clutch oil pressure lowers, the pressure of piston (3) lowers and disc (4) slips on plate (51, then outer drum (7) rotates slower than inner drum (6). As a result, the transmitted power is reduced.
l
9JBOOO68
The transmitted power depends on the slip ratio of the clutch and the speed ratio of the torque converter. Slip ratio = (I - Output rpm/lnput rpm) x 100 (%)
10-16
WA1 200-3
MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE

I E 23
D
A-A P4
A4
Pi
9JB00069
A: B: C: D: E: F: G: PI:
From pump To torque converter To transmission lubricating circuit Drain Drain Drain Drain Inlet oil pressure pick-up port of torque converter P4: Main oil pressure pick-up port
1. 2. 3. 4. 5. 6. 7. 8. 9. IO.
Valve body Valve spring (Small) Valve spring (Large) Main relief valve spool Piston spring Piston Valve spring Torque converter relief valve spool Piston spring Piston
Outline . Main relief valve The main relief valve keeps the transmission oil pressure at the set level. Set pressure: 2.65 MPa (27 kg/cm21 (At the rated engine speed) Torque converter relief valve The torque converter relief valve is installed
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to the torque converter inlet circuit, and it keeps the oil pressure at the torque converter inlet circuit below the set pressure to protect the torque converter from abnormally high pressure. Set pressure: 1.05 MPa 110.7 kg/cm*) (Cracking pressure)
WA1 200-3
10-17
Operation Operation of main relief valve

l
The oil from the torque converter charging pump flows through the filter into port A of spool (41, then flows through orifice a into port B. If the circuit is filled with the oil from the pump, the oil pressure starts rising.
From
Pump
To torque converter
To transmission lubrication
SXW04736
As the oil pressure in the circuit rises, the oil in chamber B presses piston (6) and its reaction force compresses springs (2) and (3) to move spool (4) to the left to open ports A and C. Then, the oil from the pump flows through port A and port C into the torque converter. At this time, the oil pressure at port A is 2.65 MPa 127 kg/cm21 (at the rated engine speed).
To torque converter
sxwo4737
lo-18
WA 1200-3
Operation of torque converter relief valve The oil from the main relief valve flows through port C into the torque converter. It also flows through orifice b of spool (8) into chamber D. If the torque converter is filled with the oil, the oil pressure starts rising. As the oil pressure in the torque converter rises, the oil in chamber D presses piston (10) and its reaction force compresses valve spring (7) to move spool (8) to the right to open ports C and E. Then, the oil in port C flows through port E into the transmission lubricating circuit. At this time, the oil pressure at port C is 1.05 MPa 110.7 kg/cm? (cracking pressure).
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To toraue converter
sxwo473a
WA1 200-3
10-19
TORQUE CONVERTER REGULATOR VALVE
9JBOOO73
A: From torque converter B: To oil cooler 1. 2. 3. 4. 5. 6. Valve body Valve spring (Small) Valve spring (Large) Spool Piston spring Piston
Outline The torque converter regulator valve is installed to the torque converter outlet circuit to extract the full performance of the torque converter by keeping the oil pressure in the torque converter at the set level. Set pressure: 0.88 2 0.10 MPa 19 -c 1 kg/cm?
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1O-20 0
WA1 200-3
Operation The oil from the torque converter flows through port A and orifice a into chamber B. Since the oil pressure in chamber B is lower than the tension of valve springs (2) and (31, spool (4) does not move.
From torque converter
sxwo4739
If oil pressure in chamber B rises above the tension of valve springs (2) and (31, the oil in chamber B presses piston (6) and its reaction force compresses valve springs (2) and (3) to move spool (4) to the left to open ports A and C.
/
A
ii
From torque converter sxwo4740
WA1 200-3
1o-21
ECMV
ECMV
(For modulated clutch)
9JBOOO76
A: B: C: P:
To clutch Drain From pump Clutch oil pressure pick-up port
1. 2. 3. 4. 5. 6. 7. 8. 9.
Connector Spring Flow sensor valve spool Spring Fill switch Proportional solenoid Pressure control valve spool Load piston Spring
1o-22
WA1 200-3
ECMV
Outline Outline of ECMV ECMV (Electronic Control Modulated Valve) consists of one pressure control valve and one flow sensor valve. . Pressure control valve This valve receives the current sent from the controller with a proportional solenoid, then converts it into oil pressure. Flow sensor valve This valve operates according to the trigger signals sent from the pressure control valve and has the following functions. 1) Keeps open untilthe clutch is filled with oil to shorten the time to fill the clutch with oil (filling time). 2) Closes and outputs a signal (a filling signal) to the controller to notify that filling is completed when the clutch is filled with oil. 3) Keeps outputting signals (filling signals) to the controller to notify that oil pressure is applied or not while oil pressure is applied to the clutch. Range A: Before shifting gear (when draining) Range B: Fill starts (during trigger) Range C: Fill completed Range D: Pressure adjustment Range E: During filling
MPa! _ to/cm) _
0
t
I I
Time
w3ec
c al .zz .-al
/-
,;I
Time
*Set
t-l o 1
OFF
ON Time
*Set
sxwo474
Characteristics of ProPortional solenoid current-propulsion force N (ka)
ECMV and proportional solenoid . For each ECMV, one proportional solenoid is installed. The proportional solenoid generates propulsion force according to the command current from the controller as shown in the figure at right. The propulsion force generated by the proportional solenoid is applied to the pressure control valve spool to generate the oil pressure shown in the figure at right. Accordingly, the propulsion force is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil. ECMV and fill switch For each ECMV, one fill switch is installed. If the clutch is filled, the flow sensor valve
turns on the fill switch. When this signal output, oil pressure starts building up. is
Current proportional Pressure Characteristics of solenoid propulsion-oil
(A)
MPa( kg/cm)
N(kel Propulsion force
SXW04742
WA1 200-3
1 O-23
ECMV
Operation Operation of ECMV ECMV is controlled with the command current sent from the controller to the proportional solenoid and the fill switch output signal. The relationship among the proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal is shown at right.
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Range A: Before shifting gear (when draining) Range B: Fill starts (during trigger) Range C: Fill completed Range D: Pressure adjustment Range E: During filling i;;
Set
4
Time t-l 1 OFF 1 ON Time
,Sec
esec
sxwo474
1.
Before shifting gear (when draining) (Range A in chart) While any current is not flowing in proportional solenoid (6). proportional solenoid (6) is pushed back by the reaction force of pressure control valve spring (9) through pressure control valve spool (7). Accordingly, pressure control valve spool (7) drains the oil from clutch port C through drain port E. At this time, since any oil pressure is not applied to flow sensor valve spool (3), flow sensor valve spool (3) is separated from fill switch (5) by the reaction force of fill switch spring (4) and stopped at a position where fill switch spring (4) is balanced with flow sensor valve return spring (2).
9JEOOO77
1O-24
WA1 200-3
ECMV
2.
When fill starts (During trigger) (Range B in chart) 1) If a trigger current (the maximum current) is given to proportional solenoid (6) while there is not oil in the clutch, proportional solenoid (6) moves through its stroke and pressure control valve spool (7) moves to the left. As a result, pump port A and pressure control valve output port B open, then the oil starts flowing into the clutch through orifice a of flow sensor valve spool (3).
9JBOOO78
2)
At this time, differential pressure is generated between the upstream side and downstream side of orifice a of flow sensor valve spool (3). Because of this differential pressure, flow sensor valve spool (3) compresses flow sensor valve return spring (2) and moves to the left. Then, flow sensor valve spool (3) opens pump port D and oil flows through orifice a into clutch port C.
9JBOOO79
WA1 200-3
1o-25
STRUCTURE
AND FUNCTION
ECMV
3.
When fill is completed (When pressure trol valve is set to initial pressure) (Range C in chart) I)
con-
If pump port D of the flow sensor valve opens and oil starts flowing, differential between the uppressure is generated side of oristream side and downstream fice a of flow sensor valve spool (31, and this pressure keeps pressing flow sensor valve spool (3) to the left. At this time, if the current flowing in proportional solenoid (61 is lowered to the alinitial pressure level for a moment, most all the pump pressure is applied to load piston (8) and pressure control valve spool (7) is pushed back to the right, then a little oil flows from pressure control valve output port B to drain port E. Since the quantity of this oil is not much, almost all the oil from the pump flows into the clutch and flow sensor valve spool (3) is kept pressed to the left.
9JBOOO80
2)
If the clutch is filled with oil, the oil from pressure control valve port B does not flow into clutch port C. The pressure receiving area of the left side of flow sensor valve spool (3) is larger than that of if the same the right side. Accordingly, oil pressure is applied to both sides, flow sensor valve spool (3) is moved by the oil pressure to the right. As a result, pump port D and clutch port C are closed. At this time, flow sensor valve spool (3) is pushed to the right further by the difboth sides and ferential area between the tension of flow sensor valve return spring (21, and it compresses fill switch spring (4). Then, flow sensor valve spool (3) touches fill switch (5) and notifies the controller of completion of filling. At this time, a current of the initial pressure level solenoid (6) and flows in proportional pressure control valve (71 is set to the initial pressure.
9JROOORl
1O-26
WA1 200-3
ECMV
4.
Pressure adjustment (Range D in chart) If a current flows in proportional solenoid (61, the solenoid generates a propulsion force in proportion to the current. This propulsion force of the solenoid is balanced with the sum of the propulsion force of load piston (8) generated by the oil pressure in clutch port C and the reaction force of pressure control valve spring (91, then the pressure is settled. Flow sensor valve spool (3) is pressed to the right by the differential oil pressure between both sides of itself and it continues outputting the fill signal to the controller.
9JBOOO82
WA1 200-3
lo-27
TRANSMISSION
TRANSMISSION
(Transmission, transfer, and parking brake)
9JB00083
1. Transmission valve 2. Transmission input shaft 3. Transmission 4. Transfer 5. Output coupling (Front side) 6. Drain plug
7. 8. 9. 10. 11.
Parking brake Output coupling (Rear side) Travel speed sensor adapter Oil filler adapter Strainer
1O-28
WA1 200-3
STRUCTURE AND FUNCTK)N
TRANSMISSION
9JBOO
004
A: B: c: D: E: F:
From oil filter From oil cooler Lubricating oil pressure pick-up port To parking brake valve To modulated clutch ECMV To main relief valve and torque converter relief valve G: Drain port H: From torque converter case J: To transmission charging pump and torque converter charging pump
K: From torque converter case L: To modulated clutch (Lubrication) and input transfer (Lubrication) M: To parking brake piston N: To transmission lubricating circuit P: To transmission lubricating circuit Q: To 1st speed clutch R: To 2nd speed clutch S: To 3rd speed clutch T: To forward clutch U: To reverse clutch
WA1 200-3
1O-29
TRANSMISSION
44
x-x
+
SJBOOOB5
1O-30
WA1 200-3
TRANSMISSION
9JROOO86
Transmission inout shaft Pinion shaft Clutch disc Clutch plate Planetary pinion No. 1 (for reverse) (Number of teeth: 31) 6. Clutch No. 1 housing (for reverse) 7. Ring gear No. 1 (for reverse) (Number of teeth: 88) 8. Clutch No. 2 housing (for forward) 9. Ring gear No. 2 (for forward) (Number of teeth: 165, 94) 10. Planetary pinion No. 2 (for forward) (Number of teeth: 28) 11. Pinion shaft 12. Planetary pinion No. 3 (for 3rd speed) (Number of teeth: 28) 13. Ring gear No. 3 (for 3rd speed) (Number of teeth: 165, 94) 14. Clutch No. 3 housing (for 3rd speed) 15. Pinion shaft 16. Planetary pinion No. 4 (for 2nd speed) (Number of teeth: 22) 17. Clutch No. 4 housing (for 2nd speed) 18. Ring gear No. 4 (for 2nd speed) (Number of teeth 165, 94) 19. Piston No. 5 return spring (for 1st speed) 20. Clutch No. 5 piston (for 1st speed) 21. Rear housing 22. Transmission output shaft 23. Clutch No. 5 housing (for 1st speed) 24. Carrier No. 4 (for 2nd speed) (Number of teeth: 94) Clutch No. 5 drum (for 1st speed) (Number of teeth: 164) 25. Clutch No. 5 hub (for 1st speed) 26. Sun gear No. 4 (for 2nd speed) (Number of teeth: 50) 27. Clutch No. 4 piston (for 2nd speed) .28. Piston No.4 return spring (for 2nd speed) 29. Sun gear No. 3 (for 3rd speed) (Number of teeth: 38) 30. Clutch No. 3 piston (for 3rd speed) Piston No. 3 return spring (for 3rd speed) 3:: Carrier No. 2, 3 (for forward, 3rd speed) (Number of teeth: 88) 33. Clutch No. 2 piston (for forward) 34. Sun gear No. 2 (for forward) (Number of teeth: 38) 35. Piston No. 2 return spring (for forward) 36. Clutch No. 1 piston (for reverse) 37. Sun gear No. 1 (for reverse) (Number of teeth: 26) 38. Ring gear No. 1 (for reverse) (Number of teeth: 165, 94) 39. Carrier No. 1 (for reverse) (Number of teeth: 94) 40. Piston No. 1 return spring (for reverse) 41. Pin 42. Washer spring 43. Tie bolt 44. Front housing
I. 2. 3. 4. 5.
WA1 200-3
1o-31
TRANSMISSION
Outline The transmission system consists of a forward 3-gear speed and reverse 3-gear speed+ transmission consisting of planetary gear mechanisms and disc clutches, transfer, parking brake, and transmission control valve. Among the five sets of a planetary gear mechanism and a disc clutch, 2 clutches are operated with a control valve and fixed hydraulically to select one rotation direction and one rpm. Clutch No. 1 is fixed for reverse travel, clutch No. 2 for forward travel, clutch No. 3 for travel at 3rd speed, clutch No. 4 for travel at 2nd speed, and clutch No. 5 for travel at 1st speed.
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Gear speeds and operated clutches Gear speed Forward Forward Forward Reverse Reverse Reverse 1st speed 2nd speed 3rd speed 1st speed 2nd speed 3rd speed Operated (Engaged) clutch No.2 No.2 No.2 No.1 No.1 No.1 . . . . . No.5 No.4 No.3 No.5 No.4 No.3
Number of plates and discs used Clutch No. Clutch Clutch Clutch Clutch Clutch No. No. No. No. No. 1 2 3 4 5 Number of plates Number of discs 7 8 4 3 8 8 9 5 4 9
lo-32
WA1 200-3
TRANSMISSION
Operation
Operation of clutch The clutch consists of piston (361, plate (41, disc (3), pin (411, piston return spring (401, washer spring (421, etc. to secure ring gear (38). The inside teeth of disc (3) are engaged with the outside teeth of ring gear (38). The cut part of the outside of plate (4) is engaged with pin (41) fixed to clutch housing (6).
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9J800087
Clutch ON (Fixed) The oil sent from the transmission valve flows through the oil passage in the transmission to the back side of piston (36) to move piston (36) to the left. Piston (36) presses plate (4) against disc (3) to stop rotation of disc (3) with friction force and fixes ring gear (38) engaged with the inside teeth.
9J800088 Clutch OFF (Released) . If the oil sent from the transmission valve is shut off, piston (36) is returned by piston return spring (401, then the friction force between plate (4) and disc (3) is released and ring gear (38) is set in neutral. Washer spring (42) installed between plates (4) at the pin section returns piston (36) quickly and separates plate (4) from disc (3) sharply to prevent drag turning when the clutch is disengaged.
95800089
WA1 200-3
1o-33
TRANSMISSION
Power train Forward 1st speed
9J 800090
When the transmission is set in the forward 1st speed, clutches No. 2 and No. 5 are connected and ring gear No. 2 (9) is fixed and clutch No. 5 hub (25) is directly coupled with output shaft (22) to output the power. The power from the torque converter is transmitted to input shaft (I), then transmitted through sun gear No. 2 (34) to planetary pinion No. 2 (10). Since ring gear No. 2 (9) is fixed, planetary pinion No. 2 (10) rotates and revolves along ring gear No. 2 (9) around sun gear No. 2 (34) simultaneously.
At this time, rotation of carriers No. 2 and No. 3 (32) is transmitted as rotary power in the rotation direction of sun gear No. 2 (34). Since clutch No. 5 is engaged, ring gear No. 3 (13), carrier No. 4, clutch No. 5 drum (24), and clutch No. 5 hub (25) are fixed as one unit. Since carriers No. 2 and No. 3 (32) rotate under this condition, the whole unit of ring gear No. 3 (13), carrier No. 4, clutch No. 5 drum (24), and clutch No. 5 hub (25) rotates, and the rotary power is output through output shaft (22) in the rotation direction of sun gear No. (2) (34).
1o-34
WA1 200-3
TRANSMISSION
Forward 2nd speed
9JB00091
When the transmission is set in the forward 2nd speed, clutches No. 2 and No. 4 are connected and ring gears (9) and (18) are fixed to output the power. The power from the torque converter is transmitted to input shaft (I), then transmitted through sun gear No. 2 (34) to planetary pinion No. 2 (IO). Since ring gear No. 2 (9) is fixed, planetary pinion No. 2 (IO) rotates and revolves along ring gear No. 2 (9) around sun gear No. 2 (34) simultaneously. At this time, rotation of carriers No. 2 and No. 3 (32) is transmitted as rotary power in the rotation direction of sun gear No. 2 (34).
Since clutch No. 4 is engaged, ring gear No. 4 (18) is fixed. Since carriers No. 2 and No. 3 (32) rotate under this condition, the power is transmitted from ring gear No. 3 (13) through carrier No. 5 to clutch No. 5 drum (24). Planetary pinion No. 4 (16) rotates and revolves along ring gear No. 4 (18) around sun gear No. 4 (261, and its rotary power is output to output shaft (22) in the rotation direction of sun gear No. 2 (34).
WA1 200-3
1o-35
TRANSMISSION
Forward 3rd speed
QJBOOO!32
When the transmission is set in the forward 3rd speed, clutches No. 2 and No. 3 are connected and ring gears No. 2 (9) and No. 3 (13) are fixed to output the power. The power from the torque converter is transmitted to input shaft (I), then transmitted through sun gear No. 2 (34) to planetary pinion No. 2 (IO). Since ring gear No. 2 (9) is fixed, planetary pinion No. 2 (10) rotates and revolves along ring gear No. 2 (9) around sun gear No. 2 (34) simultaneously.
At this time, rotation of carriers No. 2 and No. 3 (32) is transmitted as rotary power in the rotation direction of sun gear No. 2 (34). Since ring gear No. 3 (13) is fixed, as carriers No. 2 and No. 3 (32) rotate, planetary pinion No. 3 (12) rotates along ring gear No. 3 (13) and revolves around sun gear No. 3 (291. Under this condition, the rotary power of carriers No. 2 and No. 3 (32) rotates sun gear No. 3 (29) and is output to output shaft (22) in the rotation direction of sun gear No. 2 (34).
1O-36
WA1 200-3
TRANSMISSION
Reverse 1st speed
9JEOOO93
When the transmission is set in the reverse 1st speed, clutches No. 1 and No. 5 are con-
nected and ring gear No. 1 (38) is fixed and clutch No. 5 hub (25) is directly coupled with output shaft (22) to output the power. The power from the torque converter is transmitted to input shaft (I), then transmitted through sun gear No. 1 (36) and planetary pinion No. 1 (5) to ring gear No. 1 (7). Since ring gear No. 1 (38) is fixed, planetary pinion No. 1 (5) rotates and revolves around sun gear No. 1 (36) simultaneously.
At this time, since clutch No. 1 fixes carrier No. 1 (391, the rotary power of planetary pinion No. 1 (5) is transmitted to carriers No. 2 and No. 3 (32) to rotate ring gear No. 1 (7) in the opposite direction to sun gear No. 1 (36). As a result, the power in the reverse direction is transmitted to output shaft (22). The power train after this point in the reverse lst, 2nd, or 3rd speed is similar to that in the forward Ist, 2nd, or 3rd speed described before.
WA1 200-3
1o-37
TRANSMISSION
CONTROL VALVE
TRANSMISSION
CONTROL VALVE
9JBOOO94
1O-38
WA1 200-3
TRANSMISSION
CONTROL VALVE
A: B: c: D: E: F: G: H:
Reverse clutch oil pressure pick-up port Forward clutch oil pressure pick-up port 3rd speed clutch oil pressure pick-up port 2nd speed clutch oil pressure pick-up port Lubricating oil pressure pick-up port 1st speed clutch oil pressure pick-up port To parking brake valve To modulated clutch ECMV
1. By-pass fill valve and by-pass drain valve (for reverse clutch) 2. ECMV (for reverse clutch) 3. By-pass fill valve (for forward clutch) 4. ECMV (for forward clutch) 5. Lubricating oil relief valve 6. By-pass fill valve (for 1st speed clutch) 7. ECMV (for 1st speed clutch) 8. ECMV (for 2nd speed clutch) 9. ECMV (for 3rd speed clutch) 10. Pilot filter
ECMV operations table
When the transmission is set in neutral in the manual operation mode, the clutch of the gear speed in which the gear shift lever is set is turned ON.
WA1 200-3
1o-39
TRANSMISSION
CONTROL VALVE
By-pass fill valve Outline When the piston volume of a clutch is large, if only ECMV is used, it takes long time to fill the clutch, that is, the fill time is lengthened and the operator feels time lag in gear shifting operation. To solve this problem, by-pass valves are installed, which are operated simultaneously with ECMV to fill the large-piston volume clutches with oil quickly. The by-pass fill valves are installed to the reverse clutch, forward clutch, and 1st speed clutch circuits.
Relationship between by-pass fill valve and ECMV Each bv-oass fill valve is controlled with the , . command current from the transmission controller. The relationship between ECMV and operation of this valve is shown at right. Range A: Before shifting gear (when draining) Range B: Fill starts (both by-pass fill valve and ECMV are opened simultaneously and oil is filled at large flow rate) Range C: During filling (only ECMV is opened and oil is filled at medium flow rate) Range D: Fill completed (only ECMV is opened and filling is completed at low flow rate) Range E: Pressure adjustment by ECMV Range F: During filling
Set)
Time
1O-40
WA1 200-3
TRANSMISSION
CONTROL VALVE
Operation
When solenoid valve is Da-energized
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Since spool (2) in solenoid valve (11 is pressed to the right by return spring (31, chamber A and port T are opened and no oil pressure is applied to chamber A. Accordingly, spool (4) of the by-pass fill valve is pressed to the right by return spring (5) and ports P and C are closed.
C4PA
T32
I 9JEIOOO96
When solenoid valve is Energized . If a current flows in solenoid valve (I), spool
(2) is pressed to the left and port P and chamber A are opened and pressurized oil is supplied to chamber A. Accordingly, spool (4) is moved to the left by the pressurized oil to open ports P and C, then the oil is supplied to the clutch.
ECMV
9JB00097
WA1 200-3
10-41
TRANSMISSION
CONTROL VALVE
By-pass drain valve Outline

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When a clutch is disengaged, the oil in the clutch piston is drained through ECMV into the transmission case. When the piston volume of the clutch is large, if only ECMV is operated as past, it takes long time to discharge the oil. If the next gear shifting operation starts before the all oil is discharged, a shock may be generated. To prevent this, a by-pass drain valve is installed to discharge the oil quickly from a large-piston volume clutch without through ECMV. The by-pass drain valve reverse clutch circuit. is installed to the
Operation When solenoid valve is De-energized (When normal)

l
Since spool (2) in solenoid valve (1) is pressed to the right by return spring (3), chamber A and port T are opened and no oil pressure is applied to chamber A. Accordingly, spool (4) of the by-pass fill valve is pressed to the right by return spring (5) and ports C and T are closed.
9JBOOO98
When solenoid valve is Energized (When clutch oil is discharged) . If a current flows in solenoid valve (I), spool (2) is pressed to the left and port P and
chamber A are opened and pressurized oil is supplied to chamber A. Accordingly, spool (4) is moved to the left by the pressurized oil to open ports C and T, then the oil from the clutch is drained. c!r Z This valve is operated for a set time just after the clutch is disengaged. Accordingly, it does not operate under the normal condition (while the clutch oil pressure is being adjusted or the clutch is being filled with oil or after a set time has passed after the clutch is disengaged). A P2
1 9JBOOO99
1o-42
WA1 200-3
STRUCTURE
AND FUNCTION
TRANSMISSION
CONTROL
VALVE
ECMV
(For transmission)
SJBOOlOO
A: B: C: P:
To clutch Drain From pump Clutch oil pressure
pick-up port
1. 2. 3. 4. 5. 6. 7. 8. 9.
Connector Spring Flow sensor valve spool Spring Fill switch Proportional solenoid Pressure control valve spool Load piston Spring
WA1 200-3
1o-43
TRANSMISSION
CONTROL VALVE
Outline Outline of ECMV ECMV (Electronic Control Modulated Valve) consists of one pressure control valve and one flow sensor valve. . Pressure control valve This valve receives the current sent from the transmission controller with a proportional solenoid, then converts it into oil pressure. . Flow sensor valve This valve operates according to the trigger sinnals sent from the pressure control valve and has the following functions. I) Closes and outputs a signal (a filling signal) to the controller to notify that filling is completed when the clutch is filled with oil. 2) Keeps outputting signals (filling signals) to the controller to notify that oil pressure is applied or not while oil pressure is applied to the clutch. Range A: Before shifting gear (when draining) Range B: Fill starts (during trigger) Range C: Fill completed Range D: Pressure adjustment Range E: During filling
-L !k=i z-a LC zg z 5s: a. u-
Time
(Set)
ECMV and proportional solenoid For each ECMV, one proportional solenoid is installed. The proportional solenoid generates propulsion force according to the command current from the transmission controller as shown in the figure at right.
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Characteristics of proportional solenoid current-propulsion N (ke)
force
The propulsion force generated by the proportional solenoid is applied to the pressure control valve spool to generate the oil pressure shown in the figure at right. Accordingly, the propulsion force is changed by controlling the command current to operate the pressure control valve to control the flow and pressure of the oil. ECMV and fill switch . For each ECMV, one fill switch is installed. If the clutch is filled, the flow sensor valve turns on the fill switch. When this signal is output, oil pressure starts building up.
0' Current proportional pressure
(A)
MPa ( ks/cml
Characteristics of solenoid propulsion-oil
Niksl __c Propulsion force
sxwo4742
1o-44
WA1 200-3
TRANSMISSION
CONTROL VALVE
Operation Operation of ECMV . ECMV is controlled with the command current sent from the transmission controller to the proportional solenoid and the fill switch output signal. The relationship among the proportional solenoid command current of ECMV, clutch input pressure, and fill switch output signal is shown at right. Range A: Before shifting gear (when draining) Range B: Fill starts (during trigger) Range C: Fill completed Range D: Pressure adjustment Range E: During filling
Tine (Sec)
1.
Before shifting gear (when draining) (Range A in chart) While any current is not flowing in proportional solenoid (61, proportional solenoid (6) is pushed back by the reaction force of pressure control valve spring (9) through pressure control valve spool (7). Accordingly, pressure control valve spool (7) drains the oil from clutch port C through drain port E. At this time, since any oil pressure is not applied to flow sensor valve spool (31, flow sensor valve spool (3) is separated from fill switch (5) by the reaction force of fill switch spring (4) and stopped at a position where fill switch spring (4) is balanced with flow sensor valve return spring (2).
9JBOOlOl
WA1 200-3
1o-45
TRANSMISSION
CONTROL VALVE
2.
When fill starts (During trigger) (Range B in chart) If a trigger current (the maximum current) is given to proportional solenoid (6) while there is not oil in the clutch, proportional solenoid (6) moves through its stroke and pressure control valve spool (7) moves to the left. As a result, pump port A and pressure control valve output port B open, then the oil starts flowing into the clutch through orifice a of flow sensor valve spool (3).
7
9JBOOlO2
1O-46
WA1 200-3
TRANSMISSION
CONTROL VALVE
3.
When fill is completed (When pressure control valve is set to initial pressure) (Range C in chart) 1) After the set time, the current in proportional solenoid (6) is lowered to the initial pressure level to move pressure control valve spool (7) to the right to throttle the passage between pump port A and pressure control valve output port B. As a result, the oil flow rate into the clutch is lowered. By this operation, generation of peak pressure in clutch port C at the end of oil filling process is prevented and the gear speed is changed smoothly.
9JBOO103
2)
If the clutch is filled with oil, the oil from pressure control valve port B does not flow into clutch port C. The pressure receiving area of the left side of flow sensor valve spool (3) is larger than that of the right side. Accordingly, if the same oil pressure is applied to both sides, flow sensor valve spool (3) is moved by the oil pressure to the right. At this time, flow sensor valve spool (3) is pushed to the right further by the differential area between both sides and the tension of flow sensor valve return spring (21, and it compresses fill switch spring (4). Then, flow sensor valve spool (3) touches fill switch (5) and notifies the controller of completion of filling. At this time, a current of the initial pressure level flows in proportional solenoid (6) and pressure control valve (7) is set to the initial pressure.
95800104
WA1 200-3
1o-47
TRANSMISSION
CONTROL VALVE
4.
Pressure adjustment (Range D in chart) If a current flows in proportional solenoid (61, the solenoid generates a propulsion force in proportion to the current. This propulsion force of the solenoid is balanced with the sum of the propulsion force of load piston (8) generated by the oil pressure in clutch port C and the reaction force of pressure control valve spring (91, then the pressure is settled. Flow sensor valve spool (3) is pressed to the right by the differential oil pressure between both sides of itself and it continues outputting the fill signal to the controller.
9JB00105
lo-48
WA1 200-3
LUBRICATING OIL RELIEF VALVE
LUBRICATING
OIL RELIEF VALVE
A-A
9JBOO106
P: Lubricating
1. Spool 2. Valve body
oil pressure
pick-up port
Function
l
This valve is installed to the transmission valve and prevents the pressure of the transmission lubricating oil from rising abnormally. Set pressure: 0.26 MPa 12.7 kg/cm*) (Cracking pressure)
WA1 200-3
1o-49
TRANSFER
TRANSFER
9JBOO107
1. Transmission
2. 3. 4. 5. 6. 7. 8.
output shaft Transfer input shaft (Number of teeth: 38) Transfer idler gear (Number of teeth: 57) Transfer output gear (Number of teeth: 40) Output shaft Front coupling Rear coupling Parking brake
Outline The transfer is installed on the output side of the transmission and secured to the transmission case with bolts.
l
1O-50
WA1 200-3
TRANSFER
Operation Power train Since transmission output shaft (I) and transfer input gear (2) are fixed with the spline, the power is transmitted through transfer idler gear (3) to transfer output gear (41, then transmitted to output shaft (5). One part of the power transmitted to output shaft (5) is further transmitted through the center drive shaft and front drive shaft to the front axle. The other part of the power is transmitted through the rear drive shaft to the rear axle.
9JEIOOlO8
WA1 200-3
10-51
TORQUE CONVERTER OIL COOLER
TORQUE CONVERTER
OIL COOLER
1. Torque converter oil cooler A. Oil inlet port (From torque converter regulator valve) B. Oil outlet port (To transmission lubricating) C. Water inlet port (From water pump) D. Water outlet port (To engine block)
OUTLINE . The oil which comes out from the torque converter outlet port is at a high temperature because of the energy used in transmitting the motive force. This torque converter oil passes through oil cooler port A and enters the oil cooler. Here it is cooled by the engine cooling water. The oil then flows out from oil outlet port B, lubricates the transmission and returns to the transfer case.
1O-52
WA1 200-3
CENTER SUPPORT
CENTER SUPPORT
1. 2. 3. 4.
Front coupling Case Grease nipple Rear coupling
FUNCTION The center support is installed to the front frame between the center drive shaft and the front drive shaft. With the articulating frame, this part is constantly twisting from side to side, so there is liable to be large stress on the drive shaft. Therefore, the center support is used to transmit the power smoothly, to reduce the stress on the drive shafts, and in this way improve the durability of the drive shafts.
WA1 200-3
1o-53
AXLE
AXLE
FRONT AXLE
SJW04727
1. 2. 3. 4. 5.
Front axle Final drive Brake Front differential Drain plug
1o-54
WA1 200-3
AXLE
FRONT DIFFERENTIAL
SJWO4728
1. 2. 3. 4.
Housing Bevel gear (Teeth 39) Differential side gear (Teeth 28) Differential pinion gear (Teeth 22)
5. 6. 7.
Shaft Bevel pinion (Teeth Coupling
IO)
WA1 200-3
1o-55
AXLE
REAR AXLE
lZ
\
b---=-t
5
SJWO4729
1. 2. 3. 4. 5.
Rear axle Rear differential Brake Final drive Drain plug
lo-56
WA1 200-3
AXLE
REAR DIFFERENTIAL
SJWO4730
1. 2. 3. 4. 5. 6. 7.
Bevel pinion (Teeth IO) Bevel gear (Teeth 39) Shaft Differential pinion gear (Teeth 22) Differential side gear (Teeth 28) Differential housing Coupling
WA1 200-3
1o-57
AXLE
Outline The power of the engine is transmitted through the damper, upper drive shaft, modulated clutch, torque converter, transmission, and drive shaft to the front and rear axles. In the axle, the rotation is transmitted from pinion gear (I) to bevel gear (5) and its direction is changed by 90 degrees and its speed is reduced, then it is transmitted through differential (4) to axle shaft (2). The rotation speed of the axle shaft is further reduced by the final drive of planetary gear type, then transmitted to the wheels.
sEwooo77
When driving straight forward When the machine is driven straight forward, the rotating speed of the left and right wheels is the same, so pinion gear (4) inside carrier (6) is sent through pinion gear (4) and side gear (3) and is transmitted equally to the left and right axle shafts (2).
l
SEW00078
When turning When turning, the rotating speed of the left and right wheels is different, so pinion gear (4) and side gear (3) inside the differential assembly rotate in accordance with the difference between the rotating speed of the left and right wheels. The motive force of carrier (6) is then transmitted to axle shafts (2).
l
lo-58
WA1 200-3
FINAL DRIVE
FINAL DRIVE
SJW04731
1. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Axle shaft
Ring gear (Number of teeth: 81) Ring gear (Number of teeth: 76) Sun gear (Number of teeth: 21) Sun gear (Number of teeth: 28) Drain plug Planetary gear (Number of teeth: 23) Planetary gear (Number of teeth: 29) Housing Wheel
Outline
l
2. Brake
The final drive reduces the rotation speed to obtain a large drive force by using a planetary gear mechanism and transmits the obtained drive force to the tires. The power is transmitted from the differential through axle shaft (I) to sun gear (5) of the first stage, then transmitted to planetary gear (9). The planetary gear rotates inside fixed ring gear (3) to transmit the power to sun gear (6) of the second stage. Then, the reduced rotation is transmitted to the planetary carrier as in the first stage, then further transmitted to wheels (II) installed to the carrier.
WA1 200-3
1o-59
AXLE MOUNT
AXlE MOUNT
A-A
B-B
SJWO4732
1O-60
WA1 200-3
AXLE MOUNT
SJWO4733
1. 2. 3. 4. 5.
Front frame Rear frame Rear axle Front axle ROPS support
Front axle . Front axle (4) receives the force directly during operations, so it is fixed directly to front frame (I) by axle mounting bolts. Rear axle . Rear axle (3) has a structure which allows the center of the rear axle to float, so that all tires can be in contact with the ground when traveling over soft ground.
WA1 200-3
lo-61
STRUCTURE
AND
FUNCTION
CENTER
HINGE
PIN
CENTER HINGE PIN
A-A
B-0
SJW04734
1. 2. 3. 4. 5. 6.
Front frame Rear frame Rear axle Front axle Upper hinge pin Lower hinge pin
OUTLINE The front frame and rear frame are joined by the center hinge pin through a bearing. The steering cylinders adjust the angle of curvature to the left and right of the front and rear frame (in other words, they adjust
l
the turning
radius).
1O-62
WA1 200-3
ARRANGEMENT
OF STEERING EQUIPMENT
ARRANGEMENT
OF STEERING
EQUIPMENT
3 \
1. Steering demand valve 2. Rotary valve 3. Hydraulic tank 4. Steering pump 5. EPC valve 6. Steering cylinder
WA1 200-3
1O-63
AJSS (ADVANCED JOYSTICK STEERING SYSTEM)
AJSS (ADVANCED
JOYSTICK
STEERING SYSTEM)
1. 2. 3. 4. 5. 6.
Steering lever Potentiometer (Lever operating angle) Joint Joint Joint Joint
7. 8. 9. 10. 11. 12.
Rotary valve Potentiometer (Frame angle) Front frame Bracket Joint Lever
1O-64
WA1 200-3
STEERING PUMP
STEERING
PUMP
Model: HPV160+ 160

l
This pump consists of 2 fixed-displacement swash plate piston pumps, 2 gear pumps and 1 impeller pump between them.
For the operation of this pump, see the section of work equipment pump.
PS
PGSl
PGSP
PD12
PA1
PA2
PD22
PAD1
PAD2
9JYOO227
PAI: PA2: PADI: PAD2: PDII: PD12: PD21: PD22:
Front pump discharge Rear pump discharge Gear pump discharge Gear pump discharge Drain port Drain port Drain port Drain port
port port port port
PGSI : Gear pump suction Port PGSS: Gear pump suction Port PS: Pump suction port 1. 2. 3. 4. Front pump Rear pump Gear pump Gear pump
WA1 200-3
1O-65
STEERING PUMP
STEERING PUMP
c-c
2 3 4
B-0
I!
9JYOO228
1O-66
WA1 200-3
STEERING PUMP
1. Front shaft 2. Front cradle 3. Front case 4. Rocker cam 5. Piston 6. Cylinder block 7. Valve plate
8. 9. 10. 11. 12. 13. 14.
Front end cap Impeller Coupling Rear end cap Valve plate Cylinder block Piston
15. 16. 17. 18. 19.
Rocker cam Rear case Rear cradle Rear shaft Servo piston
WA1 200-3
lo-67
SWITCH PUMP
SWITCH PUMP
Model HPV160+ HPF160
l
This pump consists of 1 variable-displacement swash plate piston pump, 1 fixed-displacement swash plate piston pump, and 1 impeller pump built in between the front
pump and rear pump. For the operation of this pump, see the section of work equipment pump.
PIN
PDl
PSV
PD21
PD12
PA1
PA2
PD22
9JYOO229
PAI: PA2: PDll: PD12: PD21: PD22: PIN:
Front pump discharge port Rear pump discharge port Drain port Drain port Drain port Drain port Main pump pressure input port
PS: Pump suction port PSV: Servo main pressure supply port 1. 2. 3. 4. Front pump Front servo valve Front CO + NC valves Rear pump
1O-68
WA1 200-3
SWITCH PUMP
SWITCH PUMP
PSVl
PSI1
PSVlA
PSVPA
PSVP
PSV2B
Y 9JYOO230
PSVI : PSVIA: PSVlB:
Servo valve main pressure port Servo valve output port Servo valve output port
PSVP: Servo valve main pressure port PSV2A: Servo valve output port PSVSB: Servo valve output port
WA1 200-3
1O-69
SWITCH PUMP
SWITCH PUMP
Cd
A-A
18
c-c
9JYOO231
8. 9. 10. 11. 12. 13. 14.
Front end cap Coupling Impeller Rear end cap Valve plate Cylinder block Piston
15. 16. 17. 18. 19.
1O-70
WA1 200-3
SERVO VALVE
SERVO VALVE
1. Servo valve assembly (For front of switch)
PA ,c2
AC1
Pl
P2
\
PECN
9JYOO232
Main pump pressure IN pot-t Main pump pressure IN port PACl: Servo actuator port PACS: Servo actuator port PDR: Servo drain OUT port PECN: CO + NC valves output pressure
PI:
P2:
PIN: Main pump pressure input port PPO: Servo main pressure IN port
1. 2. 3. CO + NC valves Servo valve Plate
OUT port
WA1 200-3
1o-71
SERVO VALVE
2.
Servo valve
(For front of switch)
Pl
P2 I
CN
A-A
D-D
E-E
F-F
G-G
H-H
J-J
K-K
9JYOO233
Pll:
PlO: P21: P20:
Main Main Main Main
pump pressure pump pressure pump pressure pump pressure
IN port OUT port IN port OUT port
PDR:
PPO:
CO + NC valves drain IN pot-t

Servo main pressure OUT port IN port
PECN: CO + NC valves output pressure
lo-72
WA1 200-3
SERVO VALVE
CO + NC valves
(For front
of switch)
PECN
PPO
PDR
P2
Pl
9JYOO234
Main pump pressure front IN port Pl: P2: Main pump pressure rear IN port PDR: CO + NC valves drain OUT port
PPO: Servo main pressure IN port PECN: CO + NC valves output pressure OUT port
WA1 200-3
1o-73
SERVO VALVE
PEO
,PDR
A-A
SJYOO235
PI: P2: PDR: PEO: PPO:
Main pump pressure rear OUT port Main pump pressure rear OUT port TVC valve drain IN port Servo main pressure IN port Servo main pressure OUT port
CO 1. 2. 3. 4. 5. 6. 7.
valve Cover Sleeve Piston Spool Spring Seat Plug
NC 8. 9. 10. 11. 12. 13.
valve Cover Sleeve Piston Spool Spring Cover
1o-74
WA1 200-3
STEERING DEMAND VALVE
PB
PI
PI
1. 2. 3. 4. 5.
Overload relief valve Surge cut relief valve Steering spool Demand spool Main relief valve
A. To steering cylinder 6. To steering cylinder PI. From steering pump P2. From switch pump PB. To main control valve T. To hydraulic tank (through hydraulic oil cooler)
5
A-A
i
SEW01395
WA1 2003
1o-75
OVERLOAD RELIEF VALVE
1. 2. 3. 4. 5.
Poppet Relief valve poppet Check valve poppet Pilot poppet Spring
SDW01396
FUNCTION
l
The overload relief valve is installed in the cylinder circuit of the steering demand valve. When the demand valve is at neutral and any impact is applied to the steering cylinder and abnormal pressure is generated, this valve functions as a safety valve to relieve the circuit to prevent breakage of the cylinder or hydraulic piping. It also functions to prevent any vacuum if any at the cylinder negative pressure is generated end.
OPERATION 1. Operation of relief valve Port A is connected to the cylinder circuit and port B is connected to the drain circuit. The
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oil passes through the hole in poppet (1) and dl and d2. acts on the area of diameters Checkvalve poppet (3) and relief valve poppet (2) are securely seated.
SDW01397
When the pressure at port A reaches the set pressure of the relief valve, pilot poppet (4) opens and the oil goes around pilot poppet (4) and flows to port B.
SDW0139S
1O-76
WA1 200-3
When pilot poppet (4) opens, the pressure at the rear of poppet (I) drops, poppet (1) moves to the right, and it is seated with pilot poppet (4).
SDW01399
Compared with the pressure at port A, the pressure on the inside is low, so relief valve poppet (2) opens and the oil flows from port A to port B to prevent any abnormal pressure.
SDW01400
2.
Operation of suction valve Negative pressure is generated at port A, the difference in the area of diameters d3 and d4 opens check valve poppet (31,and the oil flows from port B to port A to prevent a vacuum from forming in the circuit.
l
SDWO1401
WA1 200-3
1o-77
MAIN RELIEF VALVE

1. Adjustment screw 2. Spring 3. Plug 4. Pilot poppet 5. Valve seat
FUNCTION
l
The main relief valve of the steering demand valve is inside the valve and sets the maximum pressure in the steering circuit when it is operated. In other words, when the valve is being operated and the steering circuit goes above the set pressure of this valve, it relieves the oil and actuates the flow control spool of the demand valve to drain the oil to the steering circuit.
1 O-78
WA1 200-3
OPERATION OF STEERING RELIEF VALVE
To main control
valve
sxwo4904
When the pressure in the circuit rises and reaches the pressure set by spring (2) and adjustment screw (I), pilot poppet (3) opens and drains the oil. When this happens, the balance of the pressure in pressure receiving chamber (I) and pressure receiving chamber (II) is lost, and demand spool (4) moves to the left.
When demand spool (4) moves, the oil from the steering pump is drained and the oil from the switch pump is relieved to the main control valve, so the steering circuit pressure is prevented from going above the set value.
WA1 200-3
1o-79
STRUCTURE
AND
FUNCTION
STEERING
DEMAND
VALVE
OPERATION OF DEMAND VALVE

When steering spool is at neutral
From switch
sxwo4905
The oil from the steering pump enters port A

and the oil from the switch pump enters port B. When steering spool (2) is at the neutral position, pressure receiving pressure chamber (II) is connected to the drain circuit through orifice b, and notch c is closed. 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 (I) to the left.
When the pressure in pressure receiving chamber (I) reaches a certain value (set by spring (3)), notch f opens and the oil from the steering pump goes to the drain circuit. Notch g is closed, so the oil from the switch pump all flows to the main control valve.
1 O-80
WA1 200-3
WHEN STEERING SPOOL IS OPERATED

Engine running at low speed
From switch
SXWO4906
When the steering is operated, oil flows from the rotary valve to steering spool (2) and pushes steering spool (2) to the right. The circuit between pressure receiving chamber (II) and the drain circuit is shut off, and at the same time, notch c opens. As a result, the pressure in pressure receiving chamber (II) rises, and demand spool (I) moves to the right until notch h closes. The passage from port B to the main control valve is shut off, so the oil from the switch pump pushes up pump merge-divider check valve (4) and merges with the oil from the steering pump at port A.
The merged oil passes through notches c and d, pushes load check valve (51, and flows to the cylinder. The return oil from the cylinder passes through notch e and flows to the drain circuit. When this happens, the pressure before passing through notch c is sent to pressure receiving chamber (I) and the pressure after passing through notch c is sent to pressure receiving chamber (II). Demand spool (I) is actuated so that the difference in pressure on both sides of notch c is kept constant. Therefore, an oil flow corresponding to the opening of notch c is supplied to the cylinder port. These pressure differences (control pressure) are set by spring (3).
WA1 200-3
lo-81
Engine running at high speed
% %
From Porno
To main control
valve
steering sxwo4907
There is no need for supply of extra oil from the switch pump, so the steering pump pressure rises until notch g closes and shuts off the merge passage from port B. The pressure difference on both sides of notch c is controlled only by notch f, and the excess oil from the steering pump is drained from notch f to the drain circuit. (At this point, notch g is completely closed.)
The oil from the steering pump passes through notches c and d, pushes load check valve (51, and flows to the cylinder. The return oil from the cylinder passes through notch e and flows to the drain circuit. Notch g is closed, so the oil from the switch pump all flows from port B and is sent to the main control valve.
1O-82
WA1 200-3
OPERATION OF STEERING VALVE

Neutral
SXWO4908
The steering wheel is not being operated, so steering spool (2) does not move. The oil from the steering pump enters port A. The oil from the switch pump enters port B.
When the pressure at ports A and B rises, demand spool (I) moves to the left, so the oil from the steering pump passes through port C of the spool and is drained. The oil from the switch pump passes through port D and all flows to the main control valve.
WA1 200-3
lo-83
Turning to right
From
ro
From
steerin sxwo4909
If the steering lever is moved to the right, the rotary valve operates and the steering spool (2) moves to the left. The oil from the steering pump flows in port A, then flows through flow control spool (I) to steering spool (2) and pushes load check valve (6) of the spool open to supply oil to the bottom side of the left cylinder and rod
side of the right cylinder to turn the machine to the right. The oil from both cylinders is drained through load check valve (5) of the steering spool. The oil from the switch pump flows in port 6, then flows through flow control spool (I) to push check valve (4) open and merges with the steering pump oil.
1O-84
WA1 200-3
Turning to left
From valve
rotary
control
valve
sxw04910
If the steering lever is moved to the left, the rotary valve operates and the steering spool (2) moves to the right. The oil from the steering pump flows in port A, then flows through flow control spool (1) to steering spool (2) and pushes load check valve (5) of the spool open to supply oil to the rod side of the left cylinder and bottom
side of the right cylinder to turn the machine to the left. The oil from both cylinders is drained through load check valve (6) of the steering spool. The oil from the switch pump flows in port B, then flows through flow control spool (I) to push check valve (41 open and merges with the steering pump oil.
WA1 200-3
lo-85
STRUCTURE
AND
FUNCTION
ROTARY
VALVE
.b
swwa94
1. 2. 3. 4. 5. 6. 7. 8. 9. IO. 11.
Neutral position spring Valve body Check valve Spool Sleeve Feedback spool Feedback sleeve Loose spring Drive shaft Center pin Body
a. b. c. d.
To hydraulic tank To port Pb of steering To pot-t Pa of steering From PPC pump
demand demand
valve valve
1O-86
WA1 200-3
ROTARYVALVE
Outline The steering lever is connected to the top of the rotary valve. The direction of the oil sent from the PPC pump through the EPC valve to this valve is changed with the steering lever to move the spool of the steering demand valve. As a result, the steering cylinder is operated to set the steering direction of the machine. The link installed to the front frame is connected to the bottom of the rotary valve to feed back the steering angle of the machine. Accordingly, the position of the steering lever is matched to the steering angle of the machine.
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Structure Spool (4) is connected through pin (IO) (which is not in contact with the spool while the steering lever is in neutral) and neutral position spring (II to sleeve (5). The top and bottom of drive shaft (9) are engaged with pin (IO) and assembled into one unit together with sleeve (5) and feedback sleeve (7). . Feedback spool (6) is connected through pin (IO) (which is not in contact with the spool while the steering lever is in neutral) and loose spring (8) to feedback sleeve (7). Valve body (2) has four ports, which are connected to the pump circuit, tank circuit, and pilot circuit of the steering demand valve respectively.
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Steerina
lever
Link
WA1 200-3
lo-87
ROTARY VALVE
Operation . If the steering
lever is operated, spool (4) rotates along sleeve (5), against neutral position spring (I). By this rotation, the port of spool (4) is matched to that of sleeve (5) to form an oil passage, then the oil flows in the steering demand valve. If the steering lever is operated more than the allowable displacement of neutral position spring (I), loose spring (8) absorbs the displacement through drive shaft (9). If the oil flows in the steering cylinder and steering operation starts, the link installed to the front frame turns sleeve (5) through feedback spool (6) and drive shaft (9) so that the deviation of sleeve (5) from spool (4) will be offset. If the machine is steered to the position matched to the operating distance of the steering lever, deviation of spool (4) from sleeve (5) is eliminated and the oil passage is closed.
1O-88
WA1 200-3
EPC VALVE
EPC VALVE
_I
e
r---------7
,_+_______AD
I
11 T
T
P2
Ii
Pl
i:--_.____i
SJWO4896
1. 2. Pl. P2. C. D.
Min. pressure assurance pressure reducing valve Electromagnetic proportional valve From PPC pump From diverter valve To rotary valve TO hydraulic tank
Outline The EPC valve controls the oil flow to the rotary valve with the electromagnetic proportional valve controlled with the command current from the work equipment and joystick controller.
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Even if the electromagnetic proportional valve does not work because of a controller trouble, the minimum pressure assurance pressure reducing valve supplies the minimum oil pressure to the rotary valve.
WA1 200-3
1O-89
DIVERTER VALVE
DIVERTER VALVE
1. Check valve 2. Check valve 3. Check valve 4. Check valve 5. Spool 6. Valve body
A. 6. C. D. E. F.
To emergency pump Sensor mounting port To hydraulic oil tank To steering valve From hydraulic tank From steering circuit
FUNCTION The diverter valve is a selector valve which senses the pilot pressure from the steering pump and if there is no abnormality in the steering circuit, it drains the oil from the emergency pump to the tank. If no pilot pressure from the steering pump reaches the diverter valve, the oil from the emergency pump is switched to the steering circuit and flows to enable the machine to be steered.
1O-90
WA1 200-3
DIVERTER
VALVE
EMERGENCY STEERING RELIEF VALVE
1. 2. 3. 4. 5.
Main valve Valve seat Pilot poppet Spring Adjustment screw
Kzr
SDW01420
FUNCTION Compared to the steering valve relief pressure of 31.4 MPa 1320 kg/cm*}, the rated pressure of the emergency steering pump and diverter valve are both 20.6 MPa (210 kg/cm*). 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 pressure generated by the steering exceeds 20.6 MPa (210 kg/cm*}, 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 (I) and fills port B. Pilot poppet (3) is in contact with valve seat (2).
I
l
When the pressure inside port A and B reaches the pressure set by the poppet spring (set pressure), pilot poppet (3) opens and the hydraulic pressure at port B escapes from port D to port C. This lowers the pressure at port B. When the pressure at port B drops, the orifice of main valve (I) generates a difference in pressure between port A and port B. Main valve (I) is opened by the pressure at port A and the oil at port A is relieved.
WA1 200-3
10-91
DIVERTER VALVE
HYDRAULIC
CIRCUIT
SCHEMATICS
FOR EMERGENCY
STEERING
To steering cylinder 6 From
CY I
Pump, engine working normally
steering inder
When the steering pump and engine are working normally, the main pump, steering pump, and switch pump are rotated by the engine. Therefore, oil is sent to the steering valve, and the machine can be steered. In addition, the emergency steering pump is rotated by the transmission, so oil from port A of the diverter valve pushes open check valve (2) and enters port B. Pressure oil from the steering pump is flowing to port D, so it pushes spool (3) in the direction of the arrow. As a result, the oil from port B flows to port C and is drained to the hydraulic tank.
1 O-92
WA1 200-3
DIVERTER VALVE
When pump or engine has trouble while machine is traveling
To steering cylinder 6
From
CYI
steering inder 6
If the pump or engine has a trouble while the machine is traveling, the rotation of the tires is transmitted through the transmission to the emergency pump. Since the steering pump is not rotating, any pressure is not generated in port D. Accordingly, spool (3) is pressed to the right by spring (4). The oil from the emergency pump flows through port A and port 6 to the rotary valve, and the machine can be steered. % The emergency pump can rotated in either forward or reverse direction.
Emergency steering
ourno
WA1 200-3
1o-93
ARRANGEMENT
OF BRAKE EQUIPMENT
ARRANGEMENT
OF BRAKE EQUIPMENT
1. Front brake (right) 2. Brake valve (right) 3. Parking brake switch 4. Rear brake (right) 5. Slack adjuster (rear) 6. Torque converter + transmission, brake cooling, brake pump 7. Rear brake (left) 8. Brake oil tank
9. IO. 11. 12. 13. 14. 15. 16.
Parking brake (Built in transmission) Accumulators Brake valve (left) Front brake (left) Slack adjuster (front) Charge valve Strainer Parking brake solenoid valve
1o-94
WA1 200-3
BRAKE VLAVE
BRAKE VALVE
BRAKE VALVE (RIGHT)
swwo4aa5
1. Brake pedal (left, right brake) 2. Rod (right brake) 3. Pilot piston (right brake) 4. Spool (right brake) 5. Upper cylinder (right brake) 6. Spool (right brake) 7. Lower cylinder (right brake) 8. Rod (left brake)
9. Spool (left brake) 10. Cylinder (left brake) A. B. C. D. E. Pilot port (right brake) To rear brake (right brake) To front brake (right brake) Drain (left, right brake) To pilot port (left brake)
1O-96
WA1 200-3
BRAKE VLAVE
BRAKE VALVE (LEFT)
II\_J
SDWOO108
Outline There are two brake valves installed in parallel under the front of the operators 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.
l l l
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.
WA1 200-3
1o-97
BRAKE VLAVE
Operation
Brake applied (right brake valve) Upper portion When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, drain port a is closed, and the oil from the pump and accumulator flows from port A to port C and actuates the rear brake cylinders.
l
Lower portion When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, spool (5) is also pushed down by plunger (6). When this happens, drain port b is closed, and the oil from the pump and accumulator flows from port B to port D and actuates the front brake cylinders.
Brake applied (left brake pedal) When pedal (7) is depressed, spool (10) is pushed up by rod (8) and spring (9), and drain port c is closed. The oil from the pump and the accumulator flows from port E to port F. . Port F of the left brake valve and port PP of the right brake valve are connected by a hose, so the oil flowing to port F flows to pilot port PP of the right brake valve. The oil entering pilot port PP enters port G from orifice d, and pushes piston (11). The spring pushes spool (3) down, so the operation is the same as when the right brake valve is depressed.
l
Left brake valv
To front brake
1O-98
WA1 200-3
STRUCTURE
AND
FUNCTION
BRAKE VLAVE
Applying brake when upper valve fails (right brake valve) . Even if there is leakage of oil in the upper piping, spool (5) is moved down mechanically when pedal (I) is depressed, and the lower portion is actuated normally. The upper brake is not actuated. Applying brake when lower valve fails (right brake valve) l Even if there is leakage of oil in the lower piping, the upper portion is actuated normally.
When actuation is balanced Upper portion l When oil fills the rear brake cylinder and the pressure between port A and port C becomes high, the oil entering port H from orifice e of spool (3) pushes against spring (4). It pushes up spool (3) and shuts off the circuit between port A and port C. When this happens, drain port a stays closed, so the oil entering the brake cylinder is held and the brake remains applied. Lower portion When spool (3) in the upper portion moves up and the circuit between port A and port C is shut off, oil also fills the 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 the brake is applied. l The pressure in the space in the upper portion is balanced with the operating force of the pedal, and the pressure in the space in the lower portion is balanced with the pressure in the space in the upper portion. When spools (3) and (5) move to the end of their stroke, the circuits between ports A and C and between ports B and D are fully opened, so the pressure in the space in the upper and lower portions and the pressure in the left and right brake cylinders is the same as the pressure from the pump. Therefore, up to the point where the piston moves to the end of its stroke, the effect of the brake can be adjusted by the amount that the pedal is depressed.
l
From pump M
From pump -&
From
pump
To front brake
From
pump
WA1 200-3
1o-99
BRAKE VLAVE
Brake released (right brake valve) Upper portion When pedal (I) is released and the operating force is removed from the top of the spool, the back pressure from the brake cylinder and the force of the spool return spring move spool (3) up. Drain port a is opened and the oil from the brake cylinder flows to the hydraulic tank return circuit to release the rear brake.
l
Lower portion When the pedal is released, spool (3) in the upper portion moves up. At tlie same time, the back pressure from the brake cylinder and the force of the spool return spring move spool (5) up. Drain port b is opened and the oil from the brake cylinder flows to the hydraulic tank return circuit to release the front brake.
l
From pump
From rear brake
From pump
rom front brake

SEW00113
10-100
WA1 200-3
CHARGE VALVE
CHARGE VALVE
PP
ACC
_-_-_~-_---_----_-,
I
ACC
PP
i_
-__--__________~I
SXWO4764
ACC. Plug PP. To brake valve P. From pump T. To brake oil tank
Function The charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and to store it in the accumulator. When the oil pressure reaches the specified pressure, the oil from the pump is connected to the drain circuit to reduce the load on the pump.
WA1 200-3
10-101
CHARGE VALVE
A-A
1. Main relief valve (R3)
2. 3. 4. 5. 6.
Valve body Relief valve (RI) Relief valve (HI) Filter Filter
10-102
WA1 200-3
CHARGE VALVE
Operation 1. When no oil is being supplied to accumulator (cut-out condition)

l
The pressure at port B is higher than the set pressure of the relief valve (RI), so piston (8) is forcibly pushed up by the oil pressure at port B. Poppet (6) is opened, so port C and port T are short circuited. The spring chamber at the right end of spool (15) is connected to port C of the relief valve (RI), so the pressure becomes the brake oil tank pressure. The oil from the pump enters port P, pushes spool (15) to the right at a low pressure equivalent to the load on spring (14). It also passes through orifices (171, (181, and (16), and flows to the brake oil tank.
Front pi
lot
accumulator ~rasaura
2. I)
l
When oil is supplied to accumulator Cut-in condition When the pressure at port B is lower than the set pressure of the relief valve (RI), 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.
rant accumulator i lot oresaura
WA1 200-3
10403
CHARGEVALVE
2) When cut-out pressure is reached When the pressure at port B (accumulator pressure) reaches the set pressure of the relief valve (RI), poppet (6) separates from valve seat (7), so an oil flow is generated and the circuit is relieved. When the circuit is relieved, a pressure difference is generated above and below piston (8), so piston 18) moves up, poppet (6) is forcibly opened, and port C and port T are short circuited. The spring chamber at the right end of spool (15) is connected to port C of the relief valve (Rl), so the pressure becomes the brake oil tank pressure. The pressure at port P drops in the same way to a pressure equivalent to the load on spring (14, so the supply of oil to port 6 is stopped.
rant accumulator
ilot ~reawre
3. .
Main relief valve (R3) If the pressure at port P (pump pressure) goes above the set pressure of the relief valve (R3), the oil from the pump pushes spring (3). Ball (11) is pushed up and the oil flows to the brake oil tank circuit, so this sets the maximum pressure in the brake circuit and protects the circuit.
10-104
WA1 200-3
ACCUMULATOR
(FOR BRAKE)
ACCUMULATOR (FOR BRAKE)
1. Valve
2. 3. 4.
Top cover Cylinder Piston
sxwo4770
Function The accumulator is installed between the charge valve and the brake valve. It is charged with nitrogen gas between cylinder (3) and free piston (41, and uses the compressibility of the gas to absorb the pulse of the hydraulic pump or to maintain the braking force and to make it possible to operate the machine if the engine should stop.
Specifications Gas used: Nitrogen gas Charge amount: 20 e Charging pressure: 11.8 f 0.49 MPa 020 * 5 kg/cm21
WA1 200-3
10-105
SLACK ADJUSTER
SLACK ADJUSTER
sxwo4771
1. 2. 3. 4. 5.
Bleeder Cylinder Check valve Piston Spring
A. Inlet port B. Outlet port
SPECIFICATIONS Piston operating oil pressure: O.O1~oo MPa {O.l~ kg/cm*) Check valve cracking pressure: 17.4 r 0.05 MPa (17.8 -c 0.5 kg/cm*}) Check valve closing pressure: 1.09 + 0.05 MPa (11.1 + 0.5 kg/cm9 FUNCTION The slack adjuster is installed in the brake oil line from the brake valve to the brake piston. It acts to keep the clearance between the brake piston and discs constant even when the brake discs are worn. In this way it acts to keep a constant time lag when the brake is operated.
10-106
WA1 200-3
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 (21, where it moves piston (4) by stroke S to the left and right.
Right brake c To bra
From brake valve
SEW00122
When this is done, brake piston (7) moves by a distance of stroke S. In this condition, the closer the clearance between the brake piston and disc is to 0, the greater the braking force becomes.
From brake valve
SEW00123
If the brake pedal is depressed further, and the oil pressure discharged from the brake valve goes above the set pressure, check valve (3) opens and the pressure is applied to port C to act as the braking force. Therefore, when the brake is applied, the time lag is a fixed value.
From brake valve
Right brake
SEW00124
WA1 200-3
10407
SLACK ADJUSTER
2. .
When brake pedal is released When the brake is released, piston (4) is returned by brake return spring (8) by an amount equivalent to the oil for stroke S, and the brake is released. In other words, return stroke T of brake piston (7) is determined by the amount of oil for stroke S of the slack adjuster. The time lag of the brake is always kept constant regardless of the wear of the brake disc.
Fro lef bra
I)
SEW00125
lo-108
WA 1200-3
BRAKE
BRAKE
I VT) I JJ.-J I \:I i
3 ;:7, _~_____________ ------_s; 9
\1 i
SXW04772
1. 2. 3. 4. 5. 6.
Guide pin Brake piston Return spring Floating seal Disc Plate
FUNCTION The brakes are wet-type multiple disc brakes, and are fitted to all four wheels.
l
Operation When the brake pedal is depressed, moves brake piston (2) to the right, and presses disc (5) and plate (6) together to hold them in position. Disc (5) is rotating together with the wheel, so when it is held in position, the rotation stops, the brake is actuated, and the machine is stopped. When the brake pedal is released, the pressure at the rear face of piston (2) is released, and the piston is moved to the left by the force of return spring (3) to release the brake.
l
WA1 200-3
10409
PARKING BRAKE
PARKING BRAKE
9JEIOO109
A: Piston chamber 1. 2. 3. 4. 5. 6. 7. Rear coupling Output shaft Spring Piston Disc Plate Front coupling
Outline The parking brake is a multiple-wet disc brake, which is operated mechanically with spring (3) to brake output shaft (2). The tension of spring (3) presses discs (5) and plates (6) with piston (4) to lock output shaft (2). This brake is released by supplying pressurized oil to piston chamber A to move piston (4) against the tension of spring (3) to set discs (5) and plates (6) free.
l l l
10-l10
WA1 200-3
ARRANGEMENT OF HYDRAULICEQUIPMENT
ARRANGEMENT
OF HYDRAULIC
EQUIPMENT
-/
swwo4773
10-l 12
WA1 200-3
ARRANGEMENT
OF HYDRAULIC EQUIPMENT
1. Bucket cylinder
2. 3.
4. 5. 6. 7.
8. 9. 10.
PPC valve Main pump 3A. No.1 main pump 3B. No.2 main pump Switch pump Accumulator Hydraulic oil cooler 4th gear pump (Torque converter + transmission + brake cooling + brake) Transmission Boom cylinder Main control valve (x 3)
The work equipment system consists of the hydraulic circuit and steering circuit. The hydraulic circuit controls the operation of the bucket and attachment. The oil from hydraulic tank is sent from main pumps (3A) and (381, and switch pump (4) through the steering valve to two main control valves (IO). If the bucket and boom spools of the main control valve are both in neutral, the oil passes through the drain circuit of the main control valve, is filtered by the filter inside the hydraulic tank, and returns to the tank. The bucket or boom spool in PPC valve is activated by operating the work equipment control lever, causing each spool in the work equipment valve to be hydraulically activated. Thereby, the oil is allowed to flow from the work equipment valve to boom cylinder (9) or bucket cylinder (I), thus operating the boom or the bucket. The maximum pressure of the hydraulic circuit is regulated by the relief valve inside the main control valve. There are two safety valves (with suction valve) and an unloader valve in the bucket cylinder circuit to protect the circuit. Even when engine is at rest, the boom can be lowered to the ground because accumulator (5) is provided in the circuit. Hydraulic tank is a pressurized, sealed type and has a breather with a relief valve. This acts to pressurize the tank and at the same time prevents negative pressure. This protects the pump from cavitation. A port is made on the hydraulic tank to pressurize the hydraulic tank with air to bleed air from the piston pump after removing and installing the piston pump and its piping.
WA1 200-3
10-113
HYDRAULIC TANK
HYDRAULIC
TANK
A-A
SJWO4782
1. 2. 3. 4. 5. 6. 7. A. B. C. D. E. F.
Strainer Oil filler Oil filler strainer Filter bypass valve Filter Breather Drain valve Steering return port Loader return port Emergency steering return port Main suction port Emergency steering suction port PPC, control suction port
OUTLINE Oil is sent from the hydraulic tank through the work equipment valve to each cylinder. Then, it merges with the oil from various parts in the return circuit, and a part of it is cooled by the oil cooler and filtrated by the oil filter, then returned to the hydraulic tank. The oil filter filtrates the all oil in the return circuit from the work equipment valve. If this filter is clogged, the bypass valve operates to let the oil return to the tank directly for prevention of breakage of the filter. The bypass valve also operates when negative pressure is generated in the circuit. Strainer (I 1 is installed to the suction port of the hydraulic tank.
l l
WA1 200-3
10-l 15
HYDRAULIC TANK
OPERATION VALVE
OF OIL FILTER BYPASS
When the filter is clogged. Bypass valve (1) opens and the oil returns directly to the tank without passing through the filter. Bypass valve set pressure: 125 kPa (1.27 kg/cm21
From main control
To hvdrailic
tank
SDW02312
When negative pressure is formed in the return circuit. Valve (2) moves up and acts a check valve. Check valve set pressure: 25.5 kPa IO.26 kg/cm21
To main
control
From
hydraulic
tank
SDW02313
10-116
WA1 200-3
STRUCTURE
AND
FUNCTION
HYDRAULIC
TANK
BREATHER
1. 2. 3. 4.
Body Filter element Poppet Sleeve
SEW00141
FUNCTION Preventing negative pressure inside the tank
The tank is pressurized, sealed type, so negative pressure is formed inside the hydraulic tank when the oil level drops during operations. When this happens, the difference in pressure between the tank and the outside atmospheric pressure opens poppet (31, and air from the outside is let into the tank to prevent negative pressure.
Preventing rise in pressure inside the tank
When the hydraulic cylinder are being used, the oil level in the hydraulic circuit changes and the temperature rises. If the hydraulic pressure rises above the set pressure, sleeve (4) is actuated to release the hydraulic pressure inside the tank.
WA1 200-3
10417
WORK EQUIPMENT
PUMP No. 1
WORK EQUIPMENT PUMP No. 1

Model: HPV160+ 160
PA1 PA2
PDl
PESl
PSV
PESP
PD21
PS
CZ
9JYOO236
P: PAI: PA2: PDII: PD21: PESI: PESS: PS: PSV:
Main pump pressure IN port Front pump discharge port Rear pump discharge port Drain port Drain port ES valve output pressure IN port ES valve output pressure IN port Pump suction port Servo main pressure supply port
1. 2. 3. 4. 5.
Front pump Front servo valve Rear servo valve Rear CO + NC valves Rear pump
lo-118
WA1 200-3
WORK EQUIPMENT
PUMP No. 1
Work equipment pump No. 1
f
A
PSVlA
PSVl
PSVlB
PSVPB
PSVP
PSVPA
Y
9JYOO237
PSVI: Servo valve main pressure port PSVIA: Servo valve output port PSVIB: Servo valve output port
PSV2: Servo valve main pressure PSVPA: Servo valve output port PSVPB: Servo valve output port
port
WA1 200-3
10419
c-l
A-A
I8
c-c
9JYOO238
1. 2. 3. 4. 5. 6. 7.
Front shaft Front cradle Front case Rocker cam Piston Cylinder block Valve plate
8. 9. 10. 11. 12. 13. 14.
Front end cap Coupling Impeller Rear end cap Valve plate Cylinder block Piston
15. 16. 17. 18. 19.
10-120
WA1 200-3
STRUCTURE
AND
FUNCTION
WORK EQUIPMENT
PUMP No. 1
Servo valve
1. Servo valve (For front No. 1)
PACl
PPO
P2
PACP
PDR
A-A
D-D
E-E
F-F
G-G
H-H
9JYOO239
P2: Main pump pressure PACI: Servo actuator port

PAC2: PDR:
IN port
1. Servo valve
PESI:
PPO:
Servo actuator port Servo valve drain OUT port ES valve output pressure IN port Servo valve main pressure IN port
WA1 200-3
10421
2.
Servo valve assembly (For rear No. 1)
PPO
PAC
PES
PEbN
p: PACI: PAC2: PDF?: PECN: PES: PESP: PPO:
Main pump pressure IN port Servo actuator port Servo actuator port Servo valve drain OUT port CO + NC valves output pressure OUT port ES valve output pressure pick-up pot-t ES valve output pressure IN port Servo main pressure IN port
1. CO + NC valves
2. 3.
Servo valve Plate
10422
WA1 200-3
WORK EQUIPMENT
PUMP No. 1
3.
Servo valve (For rear No. I)
D-D
E-E
F-F
G-G
H-H
J-J
K-K
9JYOO241
PII: PIO: PZI: P20:
Main Main Main Main
pump pump pump pump
pressure pressure pressure pressure
IN port OUT port IN port OUT port
PDR: CO + NC valves drain IN port PPO: Servo main pressure OUT port PECN: CO + NC valves output pressure IN port
WA1 200-3
lo-123
Structure
9JYOO242
1. 2. 3. 4. 5. 6.
Locknut Cover Plug Spring Valve body Arm
7. 8. 9. IO. 11. 12.
Pin Piston Locknut Plug Locknut Cover
13. 14. 15. 16. 17. 18.
Sleeve Piston Spring Plug Cover Locknut
Function Discharge amounts Ql and 02 of main pumps Pl and P2 are controlled individually by the respective servo valves. The relationship between pump discharge amount 0 and input signal PECN to the servo valve is as shown in the graph on the right. 0 varies in proportion to PECN.
(cc/rev1
a z = E
(MPa(kdcml) CWNC valve

output pressure
PECN
SWP06953
lo-124
WA1 200-3
STRUCTURE
AND FUNCTION
WORK
EQUIPMENT
PUMP
No. 1
1)
Operation
in direction
of increase
of pump
discharge
amount
(max. angle)
J SWPO6954
Operation
The control, pump pressure PPO is taken to port a. \ Signal pressure PECN from the NC valve is taken from port b to chamber c. When signal pressure PECN rises, piston (8) is pushed to the right by the pressure in chamber c, and stops at a point where it balances the pressure of springs (4) and (4A). At the same time, arm (6) uses servo piston (19) as a fulcrum and sways to the right in the same way as piston (8). This moves guide spool (13) to the right. When guide spool (13) moves, port a and port d are closed and port d is connected to drain chamber e. As a result, servo piston chamber f is also interconnected with drain chamber e through port g and port d.
At the same time, port a is interconnected with port h, so the pressure oil flows through port i to servo piston chamber j, pushes servo piston (19) to the right, increases the swash plate angle in the main piston pump and increases the pump discharge amount. When servo piston (19) moves, arm (6) rotates counterclockwise with its center at pin (7) and moves guide spool (13) to the left. Port a, port d and port h close, so the discharge increases by an amount that matches signal pressure PECN.
WA1 200-3
10-125
STRUCTURE
AND
FUNCTION
WORK EQUIPMENT
PUMP
No. 1
21
Operation
in direction
of decrease
of pump
discharge
amount
(min. angle)
1 NCvalve 1
TVC valve
SWPO6955
Operation
l
When signal pressure PECN goes down, piston (8) moves to the left and stops at a point where the pressure in chamber c balances the pressure of springs (4) and (4A). At the same time, arm (6) uses servo piston (19) as a fulcrum and sways to the left in the same way as piston (81. This moves guide spool (13) to the left. When guide spool (13) moves, port a and port h are closed and port h is connected to drain chamber e. As a result, servo piston chamber j is also interconnected with drain chamber e through port i and port h.
At the same time, port a is interconnected with port d, so the oil flows through port g to servo piston chamber f, pushes servo piston (19) to the left, decreases the swash plate angle in the main piston pump and decreases the pump discharge amount. When servo piston (19) moves, arm (6) rotates clockwise with its center at pin (7). Guide spool (13) is moved to the right and closes port a, port d and port h, so the discharge decreases by an amount that matches signal pressure PECN.
10-126
WA1 200-3
CO + NC valves
(For rear No. 1)
PECti
PDR
P2
9JYOO243
P2: Main pump pressure IN port PDR: CO + NC valves drain OUT port PECN: CO + NC valves output pressure OUT port
WA1 200-3
lo-127
9JYOO244
CO valve 1. Cover
NC valve
8. 9. 10. 11. 12. 13. Cover Sleeve Piston Spool Spring Cover
2. 3.
4. 5. 6. 7.
Sleeve
Piston Spool Spring Seat Plug
lo-128
WA1 200-3
WORK EQUIPMENT
PUMP No. 1
1.
CO valve
Function When the load becomes large during operations and the main pump discharge pressure rises to a point close to relief pressure, the cut-off function of the CO valve acts to reduce the pump discharge in order to reduce relief loss.
The CO valve is controlled by balancing the spring with the total of main pump discharge pressure P and CO valve output pressure PEC.
I)
When main pump discharge pressure is lower than relief pressure
Sma I I
w
Servo Piston
r)
Large
Operation . Spool (4) is being pushed down fully by spring (3). As a result, port a and port b are fully open and TVC valve output pressure PE and CO valve output pressure PEC are equal. In this way, CO valve output pressure PEC becomes the maximum and the main pump discharge amount also becomes the maximum.
WA1 200-3
1O-l 29
2)
When main pump discharge pressure becomes close to relief pressure
Servo
valve
Servo Smal
Piston Large
I+
sxwo4747
Operation . If the load increases and main pump discharge pressure P comes close to the relief pressure, main pump discharge pressure P pushes piston (5). At the same time, CO valve output pressure PEC pushes piston (51, and spool (4) moves up.
As a result, the flow of oil from port a to port b is throttled by the notch in the spool, and the area of the opening at port b and port c (drain port) becomes larger. In this way, CO valve output pressure PEC goes down, and the pump discharge amount becomes the minimum.
10-130
WA1 200-3
WORK EQUIPMENT
Model: HPV95 + 95
PUMP No. 2
3
J
L
Pyl 1 PE,S I
PA2
PA1 PL)21
PSV
PS
PSG
9JYOO247
P: PI: P2: PAl: PA2: PAG: PDII: PD21: PESI: PESO: PS: PSG: PSV:
Main pump input pressure IN port Orifice upstream pressure IN port Orifice downstream pressure IN port Front pump discharge port Rear pump discharge port Gear pump discharge port Drain port Drain port ES valve output pressure IN port ES valve output pressure OUT port Pump suction port Gear pump suction port Servo main pressure supply port
1. 2. 3. 4. 5. 6. 7. 8. 9.
Front pump Rear pump Fan driving gear pump Rear servo valve Plate ES valve (Engine sensing) CO + NC valves Plate Servo valve
WA1 200-3
10431
WORK EQUIPMENT
PUMP No. 2
Work equipment
pump No. 2
PSVlB
PSVl
PSVlA
PSVPA
PSVP
PSVPB
9JYOO248
PSVI: Servo valve main pressure port PSVIA: Servo valve output port PSVIB: Servo valve output port
PSV2: Servo valve main pressure port PSV2A: Servo valve output port PSVSB: Servo valve output port
1O-l 32
WA1 200-3
WORK EQUIPMENT
PUMP No. 2
A-A
9JYO0249
8. Front end cap

9. IO. 11. 12. Coupling Impeller Rear end cap
Valve plate 13. Cylinder block 14. Piston
15. 16. 17. 18. 19.
Rear case Rocker cam Rear cradle Rear shaft Servo piston
WA1 200-3
m-133
Servo valve
1. Servo valve assembly (For front No. 21
PEiN
PDR P2 PPO
PACl PAC2 Z
9JYOO250
P: P2: PACI: PAC2: PDR: PECN: PES: PPO:
Main pump pressure IN port Main pump pressure IN port Servo actuator port Servo actuator port Servo valve drain OUT port CO + NC valve output pressure OUT port ES valve output pressure IN port Servo main pressure IN port
1. CO + NC valves
2. 3.
Servo valve Plate
10-134
WA1 200-3
WORK EQUIPMENT
PUMP No. 2
2.
Servo valve (For front No. 21
PECN
PDR
pDP2
@ isiik!
H
0
CZ
QO
A-A k-E
D-D
E-E
F-F
G-G
H-H
9JYOO251
P2: Main pump pressure OUT port PDR: CO + NC valve drain IN port PECN: CO + NC valve output pressure IN port
WA1 200-3
10-135
3.
Servo valve assembly (For rear No. 2)
POkl
PCiRP
PES
PECN
PDR
P2
Pl PACl
PPO
PAC2
9JYOO252
Pl: P2: PACI: PAC2: PDR: PES: PECN: PPO: PORI: POR2:
Main pump pressure IN port Main pump pressure IN port Servo actuator port Servo actuator port Servo valve drain OUT port ES valve output pressure OUT port CO + NC valve output pressure IN port Servo main pressure IN port Orifice upstream pressure IN port Orifice downstream pressure IN port
1. ES valve
2. 3.
Servo valve Plate
lo-136
WA1 200-3
WORK EQUIPMENT
PUMP No. 2
4.
Servo valve (For rear No. 2)
H4
I--D
M-0 + Y
D-D
E-E
F-F
G-G
H-H
J-J
K-K
9JYOO253
PI: Main pump pressure OUT port P2: Main pump pressure OUT port PDR: ES valve drain IN port
PPO: Servo main pressure OUT port PECN: CO + NC valve output pressure IN port
WA1 200-3
10-137
Structure (For rear No. 21
9JYOO254
1. Locknut 2. Cover 3. Plug 4. Spring 5. Valve body 6. Arm
7. 8. 9. 10. 11. 12.
Pin Piston Locknut Plug Locknut Cover
13. 14. 15. 16. 17. 18.
Sleeve Piston Spring Plug Cover Locknut
Function Discharge amounts Ql and Q2 of main pumps PI and P2 are controlled individually by the respective servo valves. The relationship between pump discharge amount 0 and input signal PECN to the servo valve is as shown in the graph on the right. Q varies in proportion to PECN.
(MPa{ktdcm'l) CO+NC valve output oressure PECN SUP06953
10438
WA1 200-3
WORK EQUIPMENT
PUMP No. 2
I)
Operation to increase pump discharge (increase swash plate angle)
Control pump
Main
Pump
SXWO4748
Operation Signal pressure PI acts on chamber E of the control piston through port D. Control pump pressure PC is led in port B. If PI rises, the oil pressure applied to chamber E rises and control piston (9) moves to the right until the oil pressure force in chamber E is balanced with the force of spring (IO). At the same time, arm (4) rocks to the right, using servo piston (11) as a fulcrum, and moves guide spool (12) to the right. As guide spool (12) moves, port B is connected to port A, then control pump pressure PC is applied to chamber F of servo piston (I 1) to push servo piston (II) to the right. As a result, the swash plate angle of the main piston is increased to increase the discharge.
Consequently, arm (4) turns counterclockwise around pin (13) to move guide spool (12) to the left. Since ports B, A, and C are closed, the discharge is increased by the quantity corresponding to signal pressure PI.
WA1 200-3
10-139
2)
Operation to decrease pump discharge (reduce swash plate angle)
From servo valve
rear @
PI-
Control Pump
Main
Pump
sxwo4749
Operation . If PI lowers, piston (9) moves to the left until the oil pressure force in chamber E is balanced with the force of spring (IO). At the same time, arm (4) rocks to the left, similarly to piston (9) and using servo piston (I I) as a fulcrum, and moves guide spool (12) to the left. As guide spool (12) moves, port B is disconnected from port A, the port A is connected to drain chamber T. Accordingly, servo piston chamber F is connected through port A to drain chamber T.
l
At this time, port B is connected to port C and the pressurized oil flows in servo piston chamber H and pushes servo piston (11) to the left, together with the force of spring (14). As a result, the swash plate angle of the main pump is reduced to decrease the pump discharge. As servo piston (11) moves, arm (4) turns clockwise around pin (13) to move guide spool (12) to the right. Since ports B, C, and A are closed, the discharge is decreased by the quantity corresponding to signal pressure PI.
10-140
WA1 200-3
STRUCTURE
AND
FUNCTION
WORK EQUIPMENT
PUMP
No. 2
CO + NC valves
(For front
No. 2)
0/
Z
l--A
9JYOO257
P: Main pump pressure IN port PDR: CO + NC valve drain OUT port PECN: CO + NC valve output pressure
OUT port
WA1 200-3
10-141
A-A
9JYOO258
CO 1. 2. 3. 4. 5. 6. 7.
valve
Cover Sleeve Piston Spool Spring Seat Plug
NC 8. 9. IO. 11. 12. 13.
valve Cover Sleeve Piston Spool Spring Cover
lo-142
WA1 200-3
WORK EQUIPMENT
PUMP No. 2
1.
CO valve
Function When the load becomes large during operations and the main pump discharge pressure rises to a point close to relief pressure, the cut-off function of the CO valve acts to reduce the pump discharge in order to reduce relief loss.
The CO valve is controlled by balancing the spring with the total of main pump discharge pressure P and CO valve output pressure PEC.
1) When main pump discharge pressure is lower than relief pressure
Servo
piston
Operation Spool (4) is being pushed down fully by spring (3). As a result, port a and port b are fully open and TVC valve output pressure PE and CO valve output pressure PEC are equal. In this way, CO valve output pressure PEC becomes the maximum and the main pump discharge amount also becomes the maximum.
l
WA1 200-3
10-143
2)
When main pump discharge pressure becomes close to relief pressure
Servo
Piston
1 I
fl
IPPoy
,I f , ,,,,,/ I I I I , YI I, , , , , , , , , , , ,
sxwo4751
Operation . If the load increases and main pump discharge pressure P comes close to the relief pressure, main pump discharge pressure P pushes piston (5). At the same time, CO valve output pressure PEC pushes piston (51, and spool (4) moves up.
As a result, the flow of oil from port a to port b is throttled by the notch in the spool, and the area of the opening at port b and port c (drain port) becomes larger. In this way, CO valve output pressure PEC goes down, and the pump discharge amount becomes the minimum.
10-144
WA1 200-3
WORK EQUIPMENT
PUMP No. 2
ES valve (For rear No. 2)
PES
PPO
POR
9JYOO261
PDR: ES valve drain OUT port PE: NC valve output pressure front-rear connecting port
PES: ES valve output pressure OUT port PPO: Servo main pressure IN port
WA1 200-3
10-145
1,1
0 G
7 f
D-D
E-E
F-F
G-G
H-H
9JYOO262
1. Cover 2. Plug 3. Rod 4. Plug 5. Nut 6. Screw
7. Cover 8. Sleeve 9. Piston 10. Spool 11. Cover
lo-146
WA 1200-3
FUNCTION A variable displacement piston pump is used for the hydraulic pump to save energy by reducing the consumption of hydraulic pressure when the engine is running at low speed. At the same time, it is also used to increase the engine acceleration from low speed. For this reason, a pressure difference valve is used to detect the engine speed by using a pressure difference system. The delivery (delivery per rotation) is then adjusted to match the engine speed.
o.l4*oD1 {IA4*0.11
O-37*0.02 Pilot pressure (3.8*0.21difference
Approx.800
A~~t0~.1100 sxwo4752
Ensine speed(rpm)
OPERATION Oil from the PPC pump passes through pressure difference valve (I) and is sent to the PPC valve. Pilot pressure from the inlet and outlet ports (ports A and B) of the pressure differential valve is supplied to the ES valve (2). The difference in pilot pressure becomes larger as the flow from the PPC pump increases (in other words, as the engine speed increases). When the pilot pressure difference reaches point a (0.14 MPa 11.44 kg/cm*}), the ES valve starts to operate, and actuates the servo valve and servo cylinder to change the swash plate angle of the pump. When the swash plate angle is changed, the piston stroke also changes to change the delivery of the pump (delivery per rotation). Until the difference in pilot pressure reaches 0.37 MPa (3.8 kg/cm*}, the pump delivery (delivery per rotation) increases in proportion with the increase in the difference in pilot pressure (in other words, the increase in the engine speed). When the difference in pressure reaches 0.37 MPa (3.8 kg/cm*}, the pump delivery (delivery per rotation) reaches the maximum.
When the pilot pressure difference is below point a
SDW01720
When the pilot pressure difference is above point b
SDW01721
WA1 200-3
10-147
PPC VALVE
PPC VALVE (Proportional
Pressure Valve)
P2
P4
P3
P T PI P2 P3 P4
: From pump : To tank (drain) : To boom cylinder : To bucket cylinder : To boom cylinder : To bucket cylinder
(Raise) (Dump) (Lower) (Tilt)
SEW01483
lo-148
WA1 200-3
PPC VALVE
A-A
D-D
1. Bolt
2. 3. 4. 5. 6. 7. 8. 9.
Piston Plate Collar Retainer Center spring Metering spring Valve Body
c-c
SWWO3476
WA1 200-3
10-149
PPC VALVE
OPERATION 1. Control lever at neutral (Fig. 1): Ports PA,, P2, Pe, and P4 are connected to drain chamber D through fine control hole (f) in spool (10). Control lever operated slightly (fine control) (Fig. 2): When piston (4) starts to be pushed by plate (21, retainer (7) is pushed. Valve (IO) is also pushed by spring (9) and moves down. When this happens, fine control hole (f) is shut off from drain chamber D. At almost the same time it is connected to pump pressure chamber PP, and the pilot pressure of the control valve is sent through fine control hole (f) to port P2 and PA,. When the pressure at port P2 rises, valve (10) is pushed back. Fine control hole (f) is shut off from pump pressure chamber PP. At almost the same time it is connected to drain chamber D, so the pressure at port P2 escapes to drain chamber D. Valve (10) moves up and down until the force of spring (9) is balanced with the pressure of port P2. The position of valve (IO) and body (11) (when fine control hole (f) is midway between drain chamber D and pump pressure chamber PP) does not change until the head of valve (IO) contacts the bottom of piston (4). Therefore, spring (9) is compressed in proportion to the travel of the control lever, so the pressure at port P2 also rises in proportion to the travel of the control lever. The spool of the control valve moves to a position where the pressure of port PA, (same as pressure at port P2) and the force of the return spring of the control valve are balanced.
2.
PA1
(Fig. 2)
PBl
SDW01466
10-150
WA1 200-3
STRUCTURE
AND
FUNCTION
PPC VALVE
3.
Control lever moved back from slightly erated position to neutral (Fine control) (Fig. 3):
op-
When plate (2) starts to be pushed back, piston (4) is pushed up by a force corresponding to the force of centering spring (8) and the pressure at port P2. At the same time, fine control hole (f) of valve (IO) is connected to drain chamber D, so the oil at port P2 escapes. If the pressure at port P2 drops too far, valve (IO) is pushed down by spring (9). Fine control hole (f) is shut off from drain chamber D, and at almost the same time it is connected to pump pressure chamber PP. The pump pressure is supplied until the pressure at port P2 return to a pressure equivalent to the position of the lever. When the spool of the control valve returns, the oil in drain chamber D flows in from fine control hole (f) of the valve which has not moved. The extra oil then flows through port P4 to chamber PB,.
4.
Control lever operated (Fig. 4):
to end of travel
Plate (2) pushes piston (4) down, and piston (4) forcibly pushes in valve (IO). Fine control hole (f) is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, pressure oil from the charging pump passes through fine control hole (f), and flows from port P2 to chamber PA, to push the spool of the control valve. The oil returning from chamber A2 flows from port Pe, through fine control hole (f) to drain chamber D.
PA1
(Fig. 4)
PBl
SDWOl 488
WA1 200-3
PPC RELIEF VALVE
PPC RELIEF VALVE

Pump control circuit relief valve
1. 2. 3. 4. 5. Main valve Valve seat Pilot poppet Spring Adjustment screw
9JYOO264
Set pressure: For PPC: 3.73 MPa 138.0 kg/cm*} For pump control circuit: 2.94 MPa (30.0 kg/cm*)
Function 1. PPC relief valve The PPC relief valve is installed between the PPC pump and PPC valve. While the PPC valve is not operating or when abnormally high pressure is generated, this valve relieves oil sent from the pump to prevent breakage of the pump and circuit. (It sets the maximum pressure in the circuit.)
2.
l
Pump control circuit relief valve The pump control circuit relief valve is installed between the main pump control pump and main pump. The oil sent from the control pump is relieved through this valve to keep the pressure in the main pump control circuit constant.
Operation . Ports A and C are connected to the pump circuit and drain circuit respectively. The oil is filled in port B through the orifice of main valve (I). Pilot poppet (3) is in contact with valve seat (2).
9JYOO265
If the pressure in ports A and B reaches the set pressure of the poppet spring, pilot poppet (3) opens to let the oil flow from port B through port D to port C, then pressure in port B lowers.
If the pressure in port B lowers, discharge pressure is generated between ports A and B because of the orifice of main valve (I), then main valve (I) is opened by the pressure of port A and the oil flows out of port A.
9JYOO266
9JYOO267
lo-152
WA1 200-3
ACCUMULATOR
ACCUMULATOR
(FOR PPC VALVE)
1. 2. 3.
Cap Nut Body
4. 5. 6.
Bladder Oil port Nut
Specifications Type of gas: Nitrogen gas Gas amount: 3,000 cc Max. actuation pressure: 2.9 MPa (30 kg/cm*) Min. actuation pressure: 1.6 MPa (16 kg/cm*)
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.
SEW0
OPERATION After the engine stops, when the PPC valve is a NEUTRAL, chamber A (volume of nitrogen gas: 3000 cc) inside the bladder is compressed by chamber B.
l l
Before operation
After operation
When the PPC valve is operated, the pressure in chamber B drops below 2.9 MPa (30 kg/cm*) and the pressure of the nitrogen gas in chamber A makes the bladder expand. The actuating pressure is 1.6 to 2.9 MPa (16 to 30 kg/cm*}.
t
From PPC
pump
SEW0 1494
+
To PPC valve
SE
WA1 200-3
10-153
MAIN CONTROL VALVE
MAIN CONTROL VALVE
Pl
PA2
.PB2
PA1 PBl
Al
61
9JYOO268
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Main relief valve Bucket spool return spring Boom spool return spring Boom spool Bucket spool Body Suction valve Unloader valve Float selector valve Safety valve (with suction)
PA1 : PA2 : PBI : PB2 : Al : A2 : Bl : 82 : : P PI : : T
From PA1 of PPC valve From PA2 of PPC valve From PBI of PPC valve From PB2 of PPC valve To bucket cylinder bottom side To boom cylinder bottom side To bucket cylinder rod side To boom cylinder rod side Pump port From PA2 of PPC valve Drain port (to hydraulic tank)
1o-1 54
WA1 200-3
MAIN CONTROL VALVE
7
A-A
D-D B-B
E-E
9JYOO269
FUNCTION The three main control valves control the actuation of the attachments and the bucket in the hydraulic system. It has a tandem circuit which gives priority to the bucket circuit. The oil from the pump enters port P. The maximum pressure is set by main relief valve (I). The oil passes through the bypass circuit of bucket spool (5) and boom spool (4). It then flows from port T to the drain circuit, passes through the filter and returns to the tank. If the bucket and boom spools are actuated, the oil flows to the bucket and boom cylinders. However, the circuit gives priority to the bucket, so when the bucket spool is being operated, even if the boom spool is operated, the boom will not move.
There are two safety valves (with suction valves) (IO) to protect the circuit if abnormal pressure is generated in the bucket circuit. If one of the two safety valves is acting as a relief valve, the other valve acts as a suction valve to make up any lack of oil.
WA1 200-3
10-155
MAIN CONTROL VALVE
RELIEF VALVE
I 2 3 45 6
1. Main valve
2. 3. 4. 5. 6.
Valve seat Pilot poppet Pilot poppet spring Adjustment screw Lock nut
Set pressure: 31.4 MPa 1320 kg/cm21
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 (I) 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 (41, 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. When the pressure at port B drops, the orifice effect of main valve (I) generates a difference in pressure between port A and port B. The main valve is pushed open and the oil from port A passes through port C and flows to the drain circuit to release the abnormal pressure.
SDW01500
SDWOlSOl
10456
WA1 200-3
MAIN CONTROL VALVE
SAFETY-SUCTION
VALVE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
9JYOO270
Suction valve Main valve Piston Piston spring Poppet Poppet spring Suction valve spring Sleeve Adjustment screw Locknut
Set pressure: 36.8 MPa 1375 kg/cm21
FUNCTION . If any impact is applied to the cylinder and abnormally high pressure is generated, that pressure is relieved through the safety-suction valve to protect the cylinder and other hydraulic devices. . If any negative pressure is generated in the cylinder circuit, the safety-suction valve functions as a suction valve. Operation as safety valve . Ports A and B are connected to the cylinder circuit and drain circuit respectively. The oil pressure in port A is led through the hole of piston (3) into port C. Main valve (2) is in contact with the left side since d2 < d3. The diameters (sectional areas) are set as follows; d5 > d4 > dl > d3 > d2
D
SJYOOP 71
If abnormal pressure in port A reaches the set pressure of spring (61, poppet (5) opens to drain the oil from chamber C through chamber D and periphery a of suction valve (1).
f\
\\\
60
9JYOO272
WA1 200-3
1o-1 57
MAIN CONTROL VALVE
If poppet (5) opens, the pressure in chamber C lowers and piston (3) moves to the right. Piston (3) touches the end of poppet (51, then the oil is drained from chamber D through throttle b.
9JYOO2
Since the pressure in chamber C is lower than that in port A, main valve (2) moves to the right and the oil flows from port A to port B to prevent generation of abnormal pressure. Even if abnormal pressure is generated, suction valve (1) having a larger diameter does not operate, since dl < d4.
12
6
9JYOO274
Operation as suction valve . If any negative pressure is generated in the cylinder circuit, the pressure in port A becomes negative, too, since port A is connected to chamber C. Since the tank pressure in port B is applied to port E, the oil pressure on suction valve (I) is increased by the degrees corresponding to the area difference between d5 and dl. Then, spring (6) is compressed to move suction valve (I) to the right. Accordingly, the oil flows from port B to port A to prevent generation of negative pressure in port A.
.B
9JYOO275
lo-158
WA1 200-3
MAIN CONTROL VALVE
FLOAT SELECTOR VALVE AND UNLOAD VALVE FUNCTION

l
The float selector valve and unload valve are inside the work equipment valve. If the boom lever is set to the FLOAT position, the float selector valve operates. As a result, the unload valve operates to set the boom to the floating position.
OPERATION 1. LOWER position

. In the figure at right, the boom to the LOWER position. lever is set
8
From valve steering
2. .
FLOAT position
If the boom lever is pushed further from the LOWER position, it is set to the FLOAT position. Boom spool (I) of the work equipment valve is kept under the same condition as at the LOWER position. Since oil pressure in port A becomes higher than that at the LOWER position, float selector valve (2) moves to the right and the back pressure on unload valve (3) is released. Accordingly, unload valve (3) opens and the boom is floated.
From steering va I ve
WA1 200-3
MAIN CONTROL VALVE
3. .
FLOAT position (Riding over) If the machine moves back and the boom is raised, the pressure on the cylinder rod side becomes higher. At this time, the oil is drained through port B and unload valve (3). Since the cylinder bottom side is evacuated, oil flows in this side from port C.
Pump
8
From valve steering
FLOAT position (Lowered by weight) If the machine moves back and the boom is lowered by its weight, the pressure on the cylinder bottom side becomes higher. At this time, the oil is drained through port C. Since the cylinder rod side is evacuated, oil flows in this side from port B.
8
From steering va I ve
10-160
WA1 200-3
STRUCTURE
AND FUNCTION
MAIN
CONTROL
VALVE
BOOM AND BUCKET SPOOLS IN NEUTRAL POSITION
I4
OPERATION Oil flows through the steering valve and work l equipment pumps 1 and 2 to port A, then its by relief pressure is regulated maximum valve (11). Since bucket spool (I) is in the neutral posil tion, the bypass circuit is open and the oil in port A flows through the periphery of the spool to port B. Since boom spool (2) is also in the neutral position, the bypass circuit is open and the oil in port B flows through the periphery of the spool to port C of the drain circuit, then it returns through the filter in the hydraulic tank.
The oil from the PPC pump flows through check valve (13) to port L of the PPC valve. Since the boom and bucket levers are in the the oil returns neutral position, however, through PPC relief valve (12) to the hydraulit tank.
WA1 200-3
10-161
MAIN CONTROL VALVE
BOOM
SPOOL IN RAISE
Hydraul tank
OPERATION When boom lever (3) is pulled, the oil flows from port L of the PPC valve to port N and port S. In addition, the oil at port T passes through port M and flows to the drain circuit. The oil pressure at port S pushes boom spool (2) and moves it to the RAISE position. The oil from the steering valve passes through the bypass circuit of the bucket spool
l
and flows to the bypass circuit of boom spool (2). The bypass circuit is closed by the spool, so the oil pushes open check valve (IO). The oil flows from 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.
10-162
WA1 200-3
MAIN CONTROL VALVE
BOOM SPOOL IN LOWER
tank
L1,,,,,,,,,,,,.,,,,........
r,
SXW,-,A7Fiq
OPERATION
l
When boom lever (3) is pushed, the oil flows from port L of the PPC valve to port M and port T. In addition, the oil at port S flows to the drain circuit. The oil pressure at port T pushes boom spool (2) and moves it to the LOWER position. The oil from the steering valve passes through the bypass circuit of the bucket spool and flows to the bypass circuit of boom spool
(2). The bypass circuit is closed by the spool, so the oil pushes open check valve (IO). The oil flows from 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.
WA1 200-3
10-163
MAIN CONTROL VALVE
BOOM SPOOL IN FLOAT
HYdrauI tank
ic
ii!&_
SXWO4760
OPERATION When boom lever (3) is pushed to the FLOAT position, the PPC valve spool moves beyond the LOWER position to the FLOAT position. The pressure oil at port L flows to port M, and at the same time, it also flows to port T and port W. In addition, the pressurized oil at port S flows to port N. The pressurized oil at port T pushes boom spool (2) to the LOWER position. . If a difference in pressure greater than the specified pressure is generated at port W and port X, valve (7) moves to the right,
l l
opens port Cl and port C, and connects to the drain circuit. When port Cl is connected to the drain circuit, unload valve (8) moves up and the oil from the pump flows to the drain circuit. Therefore, the oil at the cylinder rod end passes from port K through unload valve (8) and flows to the drain circuit. The oil at the cylinder bottom flows from port I to port C, and then flows to the drain circuit. Therefore, the boom is set to the FLOAT condition.
10-164
WA1 200-3
MAIN CONTROL VALVE
BUCKET SPOOL IN DUMP
OPERATION
l
When bucket lever (4) is pushed, the sure oil at port L of the PPC valve from port Q to port V. In addition, the port R flows to the drain circuit. The sure oil at port V moves bucket spool the DUMP position. The bypass circuit is closed by bucket (I), so the oil from port A pushes open
presflows oil at pres(1) to spool check
valve (IO). The oil from checkvalve (IO) flows from port F to port G, and then flows to the cylinder rod end. At the same time, the oil at the cylinder bottom flows from port D to drain port C, and returns to the tank, so the bucket is dumped.
WA1 200-3
10-165
MAIN CONTROL VALVE
BUCKET
SPOOL IN TILT BACK
PPC valve
lx
SXW04762
OPERATION When bucket lever (4) is pulled, the pressure oil at port L of the PPC valve flows from port P to port R. In addition, the oil at port V flows to the drain circuit. The pressure oil at port R moves bucket spool (I) to the TILT position. The bypass circuit is closed by bucket spool
l
(I 1, so the oil from port A pushes open check valve (IO). The oil from check valve (IO) flows from port E to port D, and then flows to the cylinder bottom. At the same time, the oil at the cylinder rod end flows from port G to drain port C, and returns to the tank, so the bucket is tilted.
lo-166
WA1 200-3
WORK EQUIPMENT
LINKAGE
WORK EQUIPMENT
LINKAGE
Ii Ii i~~_~___-,____.,_-il ;--..--____.__._.____,--
;;
I,
1. 2. 3. 4.
Bucket Bucket link Bellcrank Bucket cylinder
5. 6. 7. 8.
Boom Boom cylinder Tooth with tip Sweeper wing
lo-168
WA1 200-3
WORK EQUIPMENT
LINKAGE
B-B
D-D
E-E
F-F
G-G
H-H SJWO4764
WA1 200-3
lo-169
OPERATION OF PROXIMITY SWITCH
OPERATION
l
OF PROXIMITY
SWITCH
switch Proximity positioner bucket for
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.
SVW03369
Cam Bucket lever
\ Detector Proximity switch
Solenoid
SEW02327
When the bucket lever is moved to the TILT position, the bucket spool is held at the TILT position by the cam follower and cam on the lever, and the bucket tilts.
switch Proximity positioner bucket
for -To battery relay
II
Bucket lever
Positioner
relay
SVW03369
Detector
Proximity
switch +PPC valve SEW02326
10-170
WA1 200-3
OPERATION OF PROXIMITY SWITCH
When the bucket tilts and reaches the set position for the bucket leveler, in other words, the sensor (steel plate) separates from the detection surface of the proximity switch, electric current is sent to the solenoid by the action of the proximity switch and relay circuit. As a result, the solenoid is actuated, and the cam is pulled away from the cam detent, so the bucket spool is returned to the HOLD position by the return spring.
Proximity switch bucket positioner
for -To I battery relay
Cam Bucket lever
Detector
Proximity
switch SEW02329
Action of proximity switch

When sensor is in position at detection surface of proximity switch Lights up Current flows When sensor is separated from detection surface of proximity switch Goes out Current is shut off
Position Proximity actuation Positioner Solenoid switch display relay (for bucket)
I I
Current
is shut off
Current flows
WA1 200-3
10-171
STRUCTURE AND FUNCTlON
AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
SWWO4785
1. 2. 3. 4. 5. 6. 7.
Air vent Air vent Condenser (right) Dry reservoir Compressor Condenser (left) Air conditioner Unit
1o-172
WA1 200-3
AIR CONDITIONER
AIR CONDITIONER CONDENSER
1. 2. 3. 4.
Electric wiring Fan Refrigerant gas inlet port Refrigerant gas outlet port
SWWO4786
AIR CONDITIONER COMPRESSOR
1. 2. 3. 4.
Refrigerant outlet port Refrigerant inlet port Relief valve Clutch
Specifications
Type: Piston pump type Refrigerant used: R134a
4707
WA1 200-3
10-173
AIR CONDITIONER
DRY RESERVOIR
1. 2. 3.
Body Drier Filter
10-174
WA1 200-3
MACHINE MONITOR SYSTEM
OUTLINE The machine monitor system monitors the machine condition by means of the sensors installed to various parts of the machine and displays the result immediately on the monitor panel to notify the operator of the machine condition. The machine monitor system consists of a main monitor, CGC monitor, various sensors, switches, relays, an alarm buzzer, and a power supply unit. The displayed items are roughly classified into two groups; The items in one group are various caution items displayed on the monitor when any trouble occurs in the machine, and those in the other group are the machine conditions which are displayed constantly by the gauges, speedometer, service meter, pilot lamps, etc. There are various switches inside the monitor panel which are used to control the machine. WA1200-3
The main monitor has a function to send and receive signals through the network circuit to display the following items. 1 Shift indicator: 1st 3rd gear speeds, N, F, R 2 Remedy code, failure code, time after failure (failure history mode) The CGC monitor consists of a display and touch switches. The monitor screen to display the gauges, maintenance screen, fuel consumption screen, positioner screen, load meter screen, etc. can be selected on the display. If any trouble occurs, the CGC monitor receives signals from the VHMS controller and displays the warning screen. The VHMS controller monitors the data of the machine condition and maintenance condition, and saves them in itself.
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System configuration
INPUT I
1
Alternator R terminal voltage
D A D D D A
Small lamp ON voltage Boom cylinder bottom pressure Boom proximity sensor Sub total switch Cancel switch PPC relief pressure Torque converter inlet oil pressure
Torque converter outlet oil pressure Transmission main relief pressure Transmission lubricating oil pressure
A A A
Transmission modulation oil pressure Steering relief pressure Work equipment relief pressure Boom cylinder head pressure
OUTPUT
P: Pulse signal A: Analog signal D: ON-OFF signal
10476
WA1 200-3
MAIN MONITOR
MAIN MONITOR
5C
5D
SE
4F
4E
SWWO4789
2. 3.
1. Check lamp Caution lamp Caution item 3A. Operation of emergency steering system 4. Pilot items 4A.Turn signal lamp (Left) 4B. Turn signal lamp (Right) 4C. Shift indicator 4D. Tachometer/Speedometer 4E. Parking brake 4F. Remedy code 5. Switches 5A. Auto grease switch 5B. Tire slip control ON/OFF switch 5C. Working lamp (Front) switch 5D. Working lamp (Rear) switch 5E. Transmission cut-off switch
OUTLINE
l
The main monitor has functions to display travel speed, etc. and switch functions to control electrical equipment, controllers, etc. The main monitor has one CPU (Central Processing Unit) in itself to process, display, and output the signals from the sensors, etc. The main monitor uses LCD and LED to display various items. The switches are embossed (convex) sheet switches.
WA1 200-3
1o-177
MAIN MONITOR
DISPLAY FUNCTION OF MAIN MONITOR

Division of display Symbol Indicated item Display range When maintenance monitor trouble is displayed Display method Flashing of displayed items (For details, see display functions of maintenance monitor)
Check
CHECK
Check
Operation of emergency steeringI system
When system operates
Flashing of displayed items
Caution
0
3
When parking brake is applied while shift lever is not in N Caution When maintenance monitor trouble is displayed
Flashing of displayed items and sounding of buzzer Flashing of displayed items (Buzzer may sound) (For details, see display functions of maintenance monitor)
CAUTION
Turn signal lamps (Right, Left)
When lamp is turned on
Lighting of pilot lamp
Pilot
c
$w
Parking brake
When parking brake is applied
Lighting of pilot lamp If parking brake is applied while shift lever is not in N, buzzer sounds. Digital display (Selection of tachometer/speedometer)
Tachometer/ Speedometer Shift indicator
Travel speed
x 100 rpm 0 - 99 km/h MPH
Shift indicator
l-3,N
Digital display
Remedy code
Remedy code
If controller detects failure and operator must, take remedy, CALL is displayed, or CALL and E 0 0 (Remedy code) are displayed alternately.
Digital display Sounding of buzzer (For failure history mode, see failure history mode)
Shift indicator
LF/R dilrllr
SDW02342
Forward/Reverse (When joystick steering system is installed)
F, R
Digital display
lo-178
WA1 200-3
STFWCTUREAND FUNCTION
MAIN MONITOR
SWITCH FUNCTIONS OF MAIN MONITOR

Item Function Display Operation
Auto grease
When pilot lamp lights up, grease is supplied forcibly only while switch is pressed.
Flashing (Quick)
Auto grease controller has trouble. Auto grease controller is not installed. Tire slip control function is turned on Tire slip control function is turned off.
OFF
Tire slip control
Tire slip control function is turned on and off each time switch is pressed.
ON
OFF
Working lamps (Front)
While small lamp lights up, rear working lamp is turned on and off each time switch is pressed. head lamp, lamp in front of axle)
Working lamp (Rear)
While small lamp lights up, front working lamps are turned on and off each time switch is pressed.
ON
Rear working lamp lights up.
OFF
Rear working lamp goes off
Transmission cut-off
Transmission cut-off function is turned on and off each time switch is pressed.
ON
Cut-off function is turned on.
OFF
Cut-off function is turned off.
WA1 200-3
10-179
MAIN MONITOR
TROUBLE DATA DISPLAY MODE

Item Method of switching to trouble data display mode Switch operation With engine stopped and starting switch turned ON, press 2nd switch from top on left side of main monitor (switch below emergency steering display) and working lamp (front) switch simultaneously for at least 5 seconds. Actuation All switch displays (LEDs) go out, and failure code is displayed on speedometer display and time elapsed since failure is displayed on failure action code display. (I) Failure code is a two-digit display given in numbers or letters. The display for the failure now occurring flashes and the display for past failures lights up. If there is no failure, CC is displayed (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 displayed. Any time greater than 999H is displayed as 999H). (3) A maximum of 9 items are stored in memory for the failure code. Failure code and time elapsed since failure change to next item.
Method of sending failure code
Press working lamp (front) switch
SDW01254
swwo479 1
Clearing failure code
Press working lamp (rear) switch for at least 2 seconds
Failure code and time elapsed since failure being displayed are cleared. Failure code for problem now occurring (flashing display) cannot be cleared.
Resetting from travel data display mode
Press 2nd switch from top on left side of main monitor (switch below emergency steering display) and working lamp (front) switch simultaneously for at least 5 seconds, or start the engine.
Changes to normal display
lo-180
WA1 200-3
CGC MONITOR
CGC MONITOR
1: Use the PC tool to select the default setting and the setting when replacing the controller. Outline On the CGC monitor, the monitor screen to display gauges, maintenance screen, setting screen, fuel consumption screen, etc. can be selected with the buttons on the screens (touch switches). If any trouble occurs in the machine, the warning screen appears automatically.
In addition to the screen for operator which is normally displayed, the screen for serviceman is available to check and set the machine data and clear the saved data. (A special ID is required to open the screen for serviceman).
WA1200-3
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CGC MONITOR
Monitor screen
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
Engine water temperature gauge Torque converter oil temperature gauge Fuel gauge Clock Tachometer Brightness adjustment button Maintenance screen button Setting screen button Fuel consumption screen button Positioner screen button Load meter screen button Failure list screen button
After the initial screen disappears, the monitor screen appears automatically. This screen is composed of the following gauges and buttons (touch switches). Engine water temperature gauge: The display range is 60 108C. The red range is above 102C. If the pointer enters the red range, its color changes from green to red. Torque converter temperature gauge: The display range is 27 140C. The red range is above 120C. If the pointer enters the red range, its color changes from green to red. Fuel gauge: The display range is 555 3700 . The yellow range is below 1250 . If the pointer enters the yellow range, its color changes from green to yellow. Clock: This clock indicates the present time. For setting method of this clock, see the setting screen. Tachometer: This meter indicates the engine speed digitally. Brightness adjustment button: This button is used to select the brightness and contrast adjustment screen. Brightness button: Used to adjust brightness. Contrast button: Used to adjust contrast. EXIT button: Used to turn off the screen and display the monitor screen.
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WA1200-3
CGC MONITOR
Maintenance screen button:
This button is used to select the maintenance screen. See the maintenance screen. The color of this button changes to display the maintenance condition. Yellow: One or more parts need to be maintained in 30 hours. Red: One or more parts have passed the maintenance time.
Setting screen button: Fuel consumption screen button: Positioner screen button: Load meter screen button: Failure list screen button:
This This This This This
button button button button button
is is is is is
used used used used used
to to to to to
select select select select select
the the the the the
setting screen. fuel consumption screen. positioner screen. load meter screen. failure list screen
WA1200-3
10-183 10-183
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CGC MONITOR
Maintenance screen
1. Display of maintenance items (Maintenance item selector buttons) 2. Display of time before periodic maintenance 3. Page button 4. Monitor screen button
If the maintenance screen button is pressed on the monitor screen, the maintenance screen appears. Maintenance items are displayed. The buttons to select maintenance items are formed in this area. The color of each button changes to display the maintenance condition. Yellow:The time before periodic maintenance is shorter than 30 hours. Red: The displayed part has passed the maintenance time (The time before periodic maintenance is negative). Display of time before periodic maintenance: The time before the next periodic maintenance is displayed. If the displayed part has passed the planned maintenance time, a negative value is displayed. Page button: This button is used to turn over the displayed page. Monitor screen button: This button is used to select the monitor screen. Maintenance item selector button: If this button (one of displayed maintenance items) is pressed, it flashes. If it is pressed again, the following pop-up screen appears. When maintenance is executed, set the time before the next periodic maintenance to the initial value on this screen. YES button: Press this button if maintenance has been executed, and the time before the periodic maintenance is set to the initial value. NO button: Press this button if maintenance has not been executed, and the time before the periodic maintenance is kept as it is. If the YES or NO button is pressed, the popup screen disappears and the maintenance screen appears. Display of maintenance items:
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WA1200-3
CGC MONITOR
Maintenance No.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
items list
Interval Item Change Change Change Change Change Corrosion Fuel Filter Engine Oil Filter Engine Oil Oil Filter Resistor
250H I
250H 250H 250H 250H
Transmission
250H 1OOOH 1OOOH IOOOH
1 Change
Change
Brake Oil Filter Transmission Oil Breather Strainer
Clean Transmission Clean Transmission Change Change Change Change
I I
1OOOH
2000H 2000H 2000H 2000H 2000H
By-pass Engine Oil Filter Brake Oil Brake Oil Tank Breather Hyd. Tank Breather Element
Clean Hyd. Tank Strainer Change Brake Line Strainer
2000H 2000H 2000H 2000H 2000H
Clean Pilot Line Strainer Change Change Change Change Axle Oil Linkage Pin Lube Oil
Hyd. Oil Filter Hyd. Oil
WA1 200-3
lo-185
CGC MONITOR
Setting screen
1. 2. 3. 4. 5. 6. 7.
DATE button TIME button UNIT button USER ID button SET button Monitor screen button Language selection button
When the setting screen button is pressed on the monitor screen, the screen changes to the setting screen. This screen is used to set the unit for displaying the data and to set the user ID. To confirm or set the present time and date, use the PC tool (see TESTING AND ADJUSTING). DATE button: This button is used to check the date. (Do not set the date on the setting screen; use the PC tool to carry out the setting.) If the DATE button is pressed, the popup screen to select the year, month, or day appears. If the year, month, or day is selected (pressed), the data inputting screen appears, but if the Previous button is pressed, the screen returns to the confirmation screen.
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WA1200-3
CGC MONITOR
TIME button: This button is used to check the time. (Do not set the time on the setting screen; use the PC tool to carry out the setting.) If the TIME button is pressed, the popup screen to select the hour or minute appears. If the hour or minute is selected (pressed), the data inputting screen appears, but if the Previous button is pressed, the screen returns to the confirmation screen.
UNIT button: This button is used to set the unit for displaying the data. If the UNIT button is pressed, and the set language is English or Spanish, the pop-up screen to select the unit appears. The unit can be selected from METRIC, ENGLISH, and SI. If the set language is Japanese, the unit is set to SI. Even if the UNIT button is pressed, the pop-up screen does not appear. SUMMER (daylight saving time) button If the set language is English or Spanish, the SUMMER setting button appears. If the SUMMER setting button is pressed, a check mark is displayed on the button, and the time advances by one hour.
USER ID button: This button is used to set the user ID No. If this button is pressed, the pop-up screen to input the user ID No. appears. As the user ID No., any one of 1-digit 10-digit values can be input. If the user ID is changed, even if the failure history has been deleted with the failure history un-display button, the warning/failure display is displayed again. This makes it possible to check the condition of the machine even when the operator has changed.
WA1200-3
10-187 10-187
(7)
CGC MONITOR
SET button:
If this button is pressed, the input date, time, unit, and user ID are saved. If this button is not pressed, the input data are not saved, and the present data not updated. Monitor screen button: This button is used to select the monitor screen. Language selection button: This button is used to select the language used for the display. It is possible to select from Japanese, English, and Spanish. When the selection is made, the CGC monitor is automatically reset and the display switches to the selected language. Use this switch also for setting the time difference from GMT.
10-188 10-188
(7)
WA1200-3
CGC MONITOR
Fuel consumption screen
1. 2. 3. 4. 5. 6.
Display of data measurement period Display of productivity in Ton/Hour Fuel consumption ratio in Liter/Hour Display of kind of material Productivity history screen button Monitor screen button
If the fuel consumption screen button on the monitor screen is pressed, the fuel consumption screen appears. The fuel consumption is calculated from the data recorded on the load meter screen, then the data measurement period, productivity in Ton/Hour, and fuel consumption ratio in Liter/Hour are displayed. The displayed data are based on the kind or material (KIND) selected on the load meter screen. The unit set on the setting screen is used for the displayed data. Productivity history screen button: This button is used to select the productivity history screen. Monitor screen button: This button is used to select the monitor screen.
WA1200-3
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(7)
CGC MONITOR
Productivity history screen
1. 2. 3. 4. 5.
Display of kind of load (Memory clear button) Display of fuel consumption ratio Display of productivity Display of date when memory is cleared Fuel consumption screen button
If the productivity history screen button on the productivity screen is pressed, the productivity history screen appears. The fuel consumption ratio in Liter/Hour and productivity data in Ton/Hour for each kind of load (KIND) are calculated from the data recorded on the load meter screen, then displayed. The unit set on the setting screen is used for the displayed data. Memory clear button: This button is used to clear the data of the selected kind of load (KIND). If this button is pressed, the pop-up screen to ask if your are really clearing the data of the selected kind of load (KIND) appears. YES button: Press this button if you wish to clear the data. NO button: Press this button if you do not wish to clear the data. If the YES or NO button is pressed, the pop-up screen disappears, and the productivity history screen appears. Fuel consumption screen button: This button is used to select the fuel consumption screen.
10-190 10-190
(7)
WA1200-3
CGC MONITOR
Positioner screen
1. 2. 3. 4. 5.
UPPER STOP selector button UPPER STOP POSITION setting button LOWER STOP selector button LOWER STOP POSITION setting button Monitor screen button
If the positioner screen button on the monitor screen is pressed, the positioner screen appears. This screen is used to set ON/OFF and stopping positions of the remote positioner function. (The set condition is saved even if the starting switch is turned off.) UPPER STOP selector button: Each time this button is pressed, it lights up (green) and goes off alternately. While this switch is lighting up, the upper stopping function is effective. UPPER STOP POSITION setting button: After setting the upper stopping position according to the given procedure, press this button to save the set data. LOWER STOP selector button: Each time this button is pressed, it lights up (green) and goes off alternately. While this switch is lighting up, the lower stopping function is effective. LOWER STOP POSITION setting button:After setting the lower stopping position according to the given procedure, press this button to save the set data. Monitor screen button: This button is used to select the monitor screen.
WA1200-3
10-191 10-191
(7)
CGC MONITOR
Load meter screen (integration mode) 1. 2. 3. 4. 5. 6. 7. 8. 9. Display of kind of load Display of integrated load Display of bucket load Kind of load selector button Subtraction mode button Calibration screen button Total load screen button Monitor screen button Gauge display button
If the load meter screen button on the monitor screen is pressed, the load meter screen appears. The load is measured each time, and the bucket load and integrated load are displayed. The integrated load is added up and displayed for each of the seven kinds of load (KIND). Kind of load selector button: This button is used to select the kind of load (KIND). If this button is pressed, the pop-up screen to select the kind of load (KIND) appears. Select one of seven kinds A G.
Subtraction mode button: This button is used to select the load meter screen (subtraction mode).
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WA1200-3
CGC MONITOR
Calibration screen button: This button is used to select the calibration screen. Total load screen button: This button is used to select the total load screen. Monitor screen button: This button is used to select the monitor screen. Gauge display button: This button is used to display the gauges on the right side of the screen. If this button is pressed, the engine water temperature gauge, torque converter oil temperature gauge, and fuel gauge are displayed. If it is pressed again, the displayed gauges disappear.
WA1200-3
10-193 10-193
(7)
CGC MONITOR
Load meter screen (Subtraction mode) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Display of kind of load Display of remaining load Display of bucket load Kind of load selector button Subtraction standard value setting button Integration mode button Calibration screen button Total load screen button Monitor screen button Gauge display button
If the subtraction mode button on the load meter screen (Integration mode) is pressed, this screen appears. The load measured each time is subtracted from the subtraction standard value which is set in advance, and the bucket load and the remaining load are displayed. Kind of load selector button: This button is used to select the kind of load (KIND). If this button is pressed, the pop-up screen to select the kind of load (KIND) appears. Select one of seven kinds A G.
10-194 10-194
(7)
WA1200-3
CGC MONITOR
Subtraction standard value setting button: This button is used to set the subtraction standard value. If this button is pressed, the screen to input the subtraction standard value appears.
Integration mode button: This button is used to select the load meter screen (Integration mode). Calibration screen button: This button is used to select the calibration screen. Total load screen button: This button is used to select the total load screen. Monitor screen button: This button is used to select the monitor screen. Gauge display button: This button is used to display the gauges on the right side of the screen. If this button is pressed, the engine water temperature gauge, torque converter oil temperature gauge, and fuel gauge are displayed. If it is pressed again, the displayed gauges disappear.
WA1200-3
10-195 10-195
(7)
CGC MONITOR
Calibration screen
2
CALIBRATION I/cw
buctet 2. Raise
at carrl
mition.
1. 2. 3. 4. 5.
Display of calibration method Engine water temperature gauge Torque converter oil temperature Fuel gauge Load meter screen button
gauge
If the calibration screen button on the load meter screen in the integration mode or subtraction mode is pressed, the calibration screen appears. Operate the machine according to the displayed procedure for calibration, and the load meter is calibrated automatically.
Load meter screen button: This button
is used to select the load meter screen again. oil temperature gauge, and fuel gauge, see
(For the engine water temperature the monitor screen.)
gauge, torque converter
10-196
WA1 200-3
CGC MONITOR
Total load screen
1. 2. 3. 4. 5.
Display of kind of load (Data clear button) Display of number of loading times Display of load Display of date where data are cleared Load meter screen button
If the total load screen button on the load meter screen in the integration mode or subtraction mode is pressed, the total load screen appears. On this screen, the total number of loading times, load, and date when the data are cleared are displayed for each kind of load (KIND). The unit set on the setting screen is used for the displayed data. Data clear button: This button is used to clear the data of each kind of load (KIND) or the data of the total load. If the display area of a kind of load (KIND) is pressed, the pop-up screen to clear the data appears. YES button: Press this button if you wish to clear the data and update the display of the date when the data are cleared. NO button: Press this button if you do not wish to clear the data.
Load meter screen button: This button is used to select the load meter screen in the integration mode or subtraction mode.
WA1200-3
10-197 10-197
(7)
CGC MONITOR
FAILURE LIST SCREEN
1. 2. 3. 4. 5. 6. 7.
Detected failure total display Number display Error code display Failure occurrence detection start time display Display item UP/DOWN button Display page selector button Service menu selection screen button
If the failure list screen button is pressed on the service menu selection screen, the screen changes to this screen. The currently existing failures are displayed in turn starting from the newest. (Only the error codes displayed on the CGC monitor are displayed on the failure list screen.) If the problem is removed, the problem is automatically deleted. Display item UP/DOWN button: The display goes up or down one item Display page selector button: The display goes up or down one page Service menu selection screen button: The screen changes to the service menu selection screen
10-197-1
(7)
WA1200-3
CGC MONITOR
Warning screen 1. 2. 3. 4. 5. 6. 7. Display of warning item Display of warning message Display of error code Display of warning page Cancel switch Hold switch (cancel switch) Jump switch
If any trouble occurs, the CGC monitor automatically displays the warning screen. The CGC monitor then displays the currently used screens (displays in item order) and the warning screen alternately. Display of warning item: Each warning item is displayed in yellow or red, depending on its type. Display of warning page: The position of the currently detected trouble is displayed. (Example: 1/5 means the first of five troubles.) Cancel switch: If the cancel switch is displayed on a warning screen, this screen can be put out temporarily by pressing the cancel switch. (A warning screen which does not have the cancel switch on it cannot be put out.) If the trouble displayed on the warning screen is not repaired, it is detected again and displayed on the warning screen when the starting switch is turned on next time. It is possible to cancel any warning display that has been canceled with the cancel switch when the user ID has been changed. Hold switch: If the hold switch is pressed, the currently displayed warning item is held for 2 minutes. The hold switch changes into the cancel switch. Jump switch: If the cancel switch is pressed, the screen displays the next warning item. The cancel switch changes into the hold switch and the monitor screen is held for 2 minutes. If the trouble is not repaired, the screen returns to the warning display screen after 2 minutes.
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WA1200-3
CGC MONITOR
Warning items list

Warning output No. Item Display range Warning Main monitor output display Color on screen CHECK CAUTION on CGC lamp lamp Abnormal Red Red Red Yellow Yellow Red Red Red Yellow Red Yellow Red Yellow Yellow Yellow Yellow Red Yellow Red Yellow Yellow Yellow Yellow Yellow Yellow Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Buzzer Cancel switch Error code No. C253 Remarks
1 Engine oil level 2 Engine oil pressure 3 Engine water temperature 4 Fuel level
Below LOW level
ON ON ON ON ON ON ON
Displayed
Below specified pressure Abnormal Above 102C Abnormal
Not displayed C143 Displayed C151
Below specified level Insufficient Below specified level Insufficient
Displayed B@BFZK Before engine starts Displayed b@BFZK While engine is running Displayed B@CENS Displayed b@CENS Displayed B@HANS Displayed 2G41BM Not displayed 2G42ZG Displayed 2G41BM Not displayed 2G43ZG Displayed B@GAZK Displayed B@GBZK Displayed B@GCZK Displayed B@C5ZK Before engine starts Not displayed b@C5ZK While engine is running Displayed B@BCZK Before engine starts Not displayed b@BCZK While engine is running Displayed 15BONX Displayed AA1ANX Displayed AA1BNX Displayed AA1CNX Displayed AA1DNX Displayed AB00MA
5 Torque converter oil temperature 6 Hydraulic oil temperature 7 Brake oil pressure (F)
Above 120C Above 130C Above 105C Below 14.7 MPa {150 kg/cm2} Below 14.7 MPa {150 kg/cm2} Below LOW level Below LOW level Below LOW level
Abnormal Abnormal Abnormal Being raised Abnormal Being raised Abnormal Abnormal Abnormal Abnormal
8 Brake oil pressure (R) 9 Battery fluid level (1) 10 Battery fluid level (2) 11 Battery fluid level (3) 12 Brake oil level
Below specified level Abnormal Below specified level Abnormal
13 Engine water level 14 Clogging of transmission
Below LOW level Below LOW level
Abnormal Abnormal
Above specified pressure Abnormal
15 Clogging of air cleaner (1) Above specified pressure Abnormal 16 Clogging of air cleaner (2) Above specified pressure Abnormal 17 Clogging of air cleaner (3) Above specified pressure Abnormal 18 Clogging of air cleaner (4) Above specified pressure Abnormal 19 Abnormal charging voltage When charge is abnormal Abnormal
WA1200-3
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(7)
CGC MONITOR
Service ID inputting screen
1. Service ID inputting screen button (Lower) 2. Service ID inputting screen button (Upper)
The service ID inputting screen buttons are hidden at the right bottom and right top of the setting screen (They are not displayed on the screen). Press the lower button, then press the upper button, and the screen changes to the following service ID input screen.
1. Display of message 2. Operator display screen button
Input the correct service ID (the service ID is the VHMS controller part No. (with no hyphens), first nine digits + 0) through the keys and press the enter key, and the screen for serviceman appears. If a wrong service ID is input, the message changes to Please input Service ID. Operator display screen button: If this button is pressed, the serviceman display screen does not appear, but the operator display screen appears again.
10-200 10-200
(7)
WA1200-3
CGC MONITOR
Service menu selection screen
1. 2. 3. 4. 5. 6. 7. 8.
Real-time monitor screen button Maintenance time setting screen button Failure history screen button PM clinic screen button Machine serial No. setting screen button Snapshot operation screen button Memory clear ID inputting screen button Operator display screen button
If the correct ID is input on the service ID inputting screen, the service menu selection screen appears. If each screen button on this screen is pressed, the selected screen appears. If the operator display screen button is pressed, the operator display screen appears.
WA1200-3
10-201 10-201
(7)
CGC MONITOR
Real-time monitor screen
1. 2. 3. 4. 5. 6. 7.
Engine system display button Transmission system display button Load meter system display button Modulated clutch system display button Remote positioner system display button Joystick steering system display button Service menu selection screen button
If the real-time monitor screen button on the service menu selection screen is pressed, the real-time monitor screen appears. On this screen, select the data of a desired controller. If a display button is pressed, the data of the selected system are displayed. If the service menu selection screen button is pressed, the service menu selection screen appears again.
On the data display screen, the information of the selected controller is displayed in real time. Select the page to be displayed with the arrow keys. If the Previous screen key is pressed, the realtime monitor screen (for selection of a system) appears again.
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(7)
WA1200-3
CGC MONITOR
Real-time monitor display items Engine DISPLAYED PAGE 1/2 1/2 1/2 1/2 1/2 2/2 NAME OF SIGNAL ENGINE SPEED COOLANT TEMP. ENGINE OIL TEMP. FUEL RAIL PRESSURE ENGINE OIL LEVEL EXH GAS TEMP LIST SAMPLING TIME 2s 2s 2s 2s 2S 2s UNIT 1 rpm 1C 1C
0.01MPa {0.1kg/cm2}
DETECTED COMPONENT VHMS CENSE CENSE CENSE
ON/OFF: LOGIC
Normal: OK Insufficient: NG
(ON/OFF) CENSE 1C CENSE
Transmission DISPLAYED PAGE 1/4 1/4 1/4 1/4 1/4 2/4 2/4 2/4 2/4 2/4 2/4 3/4 3/4 3/4 3/4 3/4 3/4 4/4 4/4 4/4 4/4 4/4 NAME OF SIGNAL T/M DIRECTION SIG. F T/M DIRECTION SIG. N T/M DIRECTION SIG. R T/M UP SHIFT SW T/M DOWN SHIFT SW ENGINE SPEED FILL SIGNAL F FILL SIGNAL R FILL SIGNAL 1st FILL SIGNAL 2nd FILL SIGNAL 3rd ENGINE SPEED SOLENOID F SOLENOID R SOLENOID 1st SOLENOID 2nd SOLENOID 3rd ENGINE SPEED AUTO SHIFT SIGNAL MANUAL SHIFT SIGNAL T/M CUTOFF SIGNAL KICK DOWN SW SIGNAL SAMPLING TIME 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s UNIT (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1 rpm (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1 rpm 1 mA 1 mA 1 mA 1 mA 1 mA 1 rpm (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) DETECTED COMPONENT T/M T/M T/M T/M T/M VHMS T/M T/M T/M T/M T/M VHMS T/M T/M T/M T/M T/M VHMS T/M T/M T/M T/M
SW SW SW SW SW SW SW SW SW SW
ON/OFF: LOGIC
J/S lever OFF: OFF (OPEN) J/S lever ON: ON (24V) J/S lever OFF: OFF (OPEN) J/S lever ON: ON (24V) J/S lever OFF: OFF (OPEN) J/S lever ON: ON (24V) SW OFF: OFF (Others) SW ON: ON (2 inputs for detection are normal) SW OFF: OFF (Others) SW ON: ON (2 inputs for detection are normal)
OFF: OFF (OPEN) ON: ON (GND) OFF: OFF (OPEN) ON: ON (GND) OFF: OFF (OPEN) ON: ON (GND) OFF: OFF (OPEN) ON: ON (GND) OFF: OFF (OPEN) ON: ON (GND)

AUTO: ON MANUAL: OFF MANUAL: ON AUTO: OFF When normal: ON (GND) When cut off: OFF (OPEN) SW OFF: OFF (OPEN) SW ON: ON (GND)
WA1200-3
10-203 10-203
(7)
CGC MONITOR
Load meter DISPLAYED PAGE 1/1 1/1 1/1 1/1 1/1 NAME OF SIGNAL BOOM BOTTOM PRESSURE MEASURED PRESSURE CAL. PRESSURE NO LOAD PRESSURE MEASURED LOAD SAMPLING TIME 2s 2s 2s 2s 2s UNIT
0.01MPa {0.1kg/cm2} 0.01MPa {0.1kg/cm2} 0.01MPa {0.1kg/cm2} 0.01MPa {0.1kg/cm2}
DETECTED COMPONENT VHMS VHMS VHMS VHMS VHMS
ON/OFF: LOGIC
1 TON
Modulated clutch DISPLAYED PAGE 1/6 1/6 1/6 1/6 1/6 2/6 2/6 2/6 2/6 2/6 2/6 3/6 3/6 3/6 3/6 3/6 3/6 4/6 4/6 4/6 4/6 4/6 4/6 5/6 5/6 5/6 5/6 5/6 6/6 6/6 6/6 6/6 6/6 6/6 NAME OF SIGNAL T/M CUTOFF SIGNAL TRACTION CONT. SIGNAL SPEED CONT. SIGNAL VEHICLE SPEED SETTING VEHICLE SPEED ENGINE SPEED MOD/C OUTPUT SPEED VEHICLE SPEED MOD/C SLIP RATE MOD/C SOLENOID MOD/C FILL SIGNAL ENGINE SPEED BOOM RAISE SIGNAL BOOM LOWER SIGNAL BUCKET TILT SIGNAL BUCKET DUMP SIGNAL NC SOL OUTPUT SIGNAL ENGINE SPEED TIRE REV. SPEED VEHICLE SPEED MOD/C SOLENOID TRACTION TIRE SLIP SIGNAL BOOM RAISE SIGNAL BUCKET TILT SIGNAL FILL SIGNAL F FILL SIGNAL 1st TIRE SLIP SIGNAL ENGINE SPEED RH BRAKE PROXIMITY SW ACCELERATOR SIGNAL CONT. OUTPUT SIGNAL SET/ACCEL RESUME/DECEL SAMPLING TIME 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s UNIT DETECTED COMPONENT ON/OFF: LOGIC
When normal: ON (GND) When cut off: OFF (OPEN)
(ON/OFF) T/M 0.1 V MOD 0.1 V MOD 0.1 km/h MOD 0.1 km/h MOD 1 rpm VHMS 1 rpm MOD 0.1 km/h MOD 1% MOD 1 mA MOD (ON/OFF) MOD 1 rpm VHMS (ON/OFF) J/S (ON/OFF) J/S (ON/OFF) MOD (ON/OFF) MOD (ON/OFF) MOD 1 rpm VHMS 1 rpm MOD 0.1 km/h MOD 1 mA MOD 1 TON MOD (ON/OFF) Main monitor (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) J/S MOD T/M T/M
1% (VHMS is calculated from outlet rpm)

Fill switch ON: ON (GND) ELSE: OFF (OPEN)
RAISE: ON (OPEN) N: OFF (GND) LOWER: ON (OPEN) N: OFF (GND) TILT: ON (OPEN) N: OFF (GND) LOWER: ON N: OFF When output: ON ELSE: OFF (GND)

Data are updated only when drive force is controlled. ON: Tire slip is controlled. OFF: Tire slip is not controlled. (Turned on and off each time switch is pressed) RAISE: ON (OPEN) N: OFF (GND) TILT: ON (OPEN) N: OFF (GND) Switch OFF: OFF (OPEN) Switch ON: ON (GND) Switch OFF: OFF (OPEN) Switch ON: ON (GND) ON: Tire slip is controlled. OFF: Tire slip is not controlled. (Turned on and off each time switch is pressed)
(ON/OFF) Main monitor 1 rpm VHMS (ON/OFF) MOD 0.1 V MOD 0.1 V MOD (ON/OFF) MOD (ON/OFF) MOD
Switch ON: ON (GND) Switch OFF: OFF (OPEN)
0.1 V (Command value of electronic governor)

Switch Switch Switch Switch ON: ON (GND) OFF: OFF (OPEN) ON: ON (GND) OFF: OFF (OPEN)
10-204 10-204
(7)
WA1200-3
CGC MONITOR
Remote positioner DISPLAYED PAGE 1/1 1/1 1/1 1/1 1/1 1/1 NAME OF SIGNAL BOOM ANGLE SIGNAL BOOM RAISE SIGNAL BOOM LOWER SIGNAL DETENT SIGNAL UPPER SET SIGNAL LOWER SET SIGNAL SAMPLING TIME 2s 2s 2s 2s 2s 2s UNIT 0.1 V (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) DETECTED COMPONENT J/S J/S J/S J/S VHMS VHMS ON/OFF: LOGIC
RAISE: ON (OPEN) N: OFF (GND) LOWER: ON (OPEN) N: OFF (GND) DETENT ON: ON DETENT OFF: OFF Positioner UPPER switch ON: ON Positioner UPPER switch OFF: OFF Positioner LOWER switch ON: ON Positioner LOWER switch OFF: OFF
Joystick steering DISPLAYED PAGE 1/2 1/2 1/2 1/2 1/2 2/2 2/2 2/2 2/2 NAME OF SIGNAL J/S ON/OFF SIGNAL S/T LEVER POTENTIO ARTICULATE ANG. J/S SOL OUTPUT STEERING LOCK T/M DIRECTION SIGNAL F T/M DIRECTION SIGNAL N T/M DIRECTION SIGNAL R S/T N SIGNAL OUTPUT SAMPLING TIME 2s 2s 2s 2s 2s 2s 2s 2s 2s UNIT (ON/OFF) 0.1 V 0.1 V 1 mA (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) DETECTED COMPONENT J/S J/S J/S J/S J/S T/M T/M T/M J/S ON/OFF: LOGIC
LOCK: ON (OPEN) FREE: OFF (GND) Joystick lever OFF: OFF (OPEN) Joystick lever ON: ON (24 V) Joystick lever OFF: OFF (OPEN) Joystick lever ON: ON (24 V) Joystick lever OFF: OFF (OPEN) Joystick lever ON: ON (24 V) N: ON (Relay output OFF) ELSE: OFF (Relay output ON)
WA1200-3
10-205 10-205
(7)
CGC MONITOR
Maintenance
time setting screen
1. 2. 3. 4. 5.
Display of maintenance items (Maintenance item selector button) Display of time before periodic maintenance Display of maintenance period (Maintenance period setting button) Page button Service menu selection screen button
If the maintenance
time
setting
screen
button
on the service
menu
selection
screen is pressed,
this
screen appears. l Display of maintenance
items:
The maintenance items are displayed. The buttons to select maintenance items are formed in this area. The color of each button changes to display the maintenance condition. Yellow:The time before periodic maintenance is shorter than 30 hours. The displayed part has passed the mainRed: tenance time (The time before periodic maintenance is negative). maintenance: The time before the next periodic maintenance is displayed. If the displayed part has passed the planned maintenance time, a negative value is displayed. The maintenance period set for each maintenance item is displayed. The buttons to set the maintenance period are formed in this area. This button is used to turn over the displayed page. This button is used to select the service menu selection screen. If this button is pressed, it flashes. If it is pressed again, a pop-up screen appears, and the time before periodic maintenance is displayed again. (This function is the same with the maintenance screen.)
Display
of time before periodic
Display
of maintenance
period:
.
l
Page button: Service menu selection Maintenance
screen button: button:
item selector
1O-206
WA1 200-3
CGC MONITOR
Maintenance period setting button: If this button is pressed, the screen to set the maintenance period appears. If a new maintenance period is input and the enter button is pressed, the maintenance period is updated. Then, the time before the next periodic maintenance is calculated again on the basis of the new maintenance period. For the maintenance items and maintenance period, see the maintenance screen.
WA1200-3
10-207 10-207
(7)
CGC MONITOR
Failure history screen 1. Display of number of detected failures 2. Display of history No. (History un-display button) 3. Display of error code 4. Display of failure occurrence time 4A. Time when detection was started 4B. Time when detection was finished 5. Display item UP/DOWN button 6. Page button 7. Service menu selection screen button 8. Display of number of failure occurrences
If the failure history screen button on the service menu selection screen is pressed, this screen appears. On this screen, the failures are displayed in the order of the time from the newest one. If a trouble has not been repaired, the time when detection was finished is not displayed for that trouble. History un-display button: If this button is pressed, the corresponding history is not displayed. Once a history is set un-displayed, it cannot be displayed on the CGC monitor any more. (The memory of the VHMS controller is kept, however.) If a history is set un-displayed, it is not counted in the detected failures. (If one history is set un-displayed, the number of the detected failures is reduced by one.) Display item UP/DOWN button: This button is used to move the displayed items up or down one by one. Page button: This button is used to turn over the displayed page. Service menu selection screen button: This button is used to select the service menu selection screen. Display of number of failure occurrences: If the same failure occurs repeatedly within a short time, the number of occurrences is displayed. If more than 30 minutes passes after the failure was canceled, the display is added to a different column and the number of occurrences is fixed.
10-208 10-208
(7)
WA1200-3
CGC MONITOR
PM clinic screen 1. 2. 3. 4. 5. 6. Display of items Display of page Display of data Page button Service menu selection screen button Hold button (cancel button)
If the PM clinic screen button on the service menu selection screen is pressed, this screen appears. On this screen, the data necessary to the PM clinic are displayed. Page button: This button is used to turn over the displayed page. Service menu selection screen button: This button is used to select the service menu selection screen. Hold button (cancel button): If the hold switch is pressed, the data for the display is held. The hold switch changes into the cancel switch. If the cancel switch is pressed, the latest data is displayed, and the cancel switch changes into the hold switch. PM clinic items
DISPLAYED PAGE 1/4 1/4 1/4 1/4 2/4 2/4 2/4 2/4 2/4 2/4 3/4 3/4 3/4 3/4 3/4 3/4 4/4 4/4 4/4 4/4 4/4 4/4 NAME OF SIGNAL ENGINE SPEED ENGINE OIL PRESSURE ENGINE OIL TEMP COOLANT TEMP ENGINE SPEED BLOW-BY PRESSURE BOOST PRESSURE EXH GAS TEMPERATURE AMBIENT AIR TEMP FUEL RAIL PRESSURE T/C TEMP T/C IN PRESSURE T/C OUT PRESSURE T/M MAIN PRESSURE T/M LUB PRESSURE T/M MOD PRESSURE HYD. OIL TEMP PPC. OIL PRESSURE HYD. OIL PRESSURE S/T PUMP PRESSURE F BRAKE OIL PRESSURE R BRAKE OIL PRESSURE SAMPLING TIME 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s 2s UNIT rpm kPa C C rpm Pa kPa C C kPa C MPa MPa MPa MPa MPa C MPa MPa MPa MPa MPa DETECTED COMPONENT VHMS Quantum CENSE Quantum VHMS Quantum Quantum CENSE VHMS Quantum VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS
WA1200-3
10-209 10-209
(7)
CGC MONITOR
Machine serial No. setting screen 1. 2. 3. 4. Machine serial No. button Component serial No. setting screen button Service menu selection screen button Confirmation screen button for satellite communications ground station (GCC)
If the machine serial No. setting screen button on the service menu selection screen is pressed, this screen appears. Confirmation is carried out for the serial No. display and the setting, or for the machine model, specification, and type. Use the PC tool to set the machine model, specification, and type. (See TESTING AND ADJUSTING) Machine serial No. button: If the button is pressed, the serial No. input screen is displayed. If the serial No. is input and the input button is pressed, the serial No. is set. The screen then returns to the machine serial No. set screen. If the Previous screen button is pressed, the screen returns immediately to the machine serial No. set screen and the serial No. is not set. A maximum of 10 digits can be set for the serial No. If the machine serial No. is set, the popup screen for clearing the VHMS memory appears when the screen returns to the service menu. The machine serial No. is important for the VHMS record data, so if it is changed, it is necessary to clear all the data. If necessary, download the internal data to the PC tool. Component serial No. setting screen button: If this button is pressed, the component serial No. setting screen appears. Service menu selection screen button: This button is used to select the service menu selection screen. Confirmation screen button for satellite communications ground station (GCC): This button is used to select the confirmation screen for the satellite communications ground station (GCC).
10-210 10-210
(7)
WA1200-3
CGC MONITOR
Component serial No. setting screen
1. 2. 3. 4. 5.
Engine serial No. button Transmission serial No. button Machine serial No. setting screen button Service menu selection screen button Confirmation screen button for satellite communications ground station (GCC)
If the component serial No. setting screen button on the machine serial No. setting screen is pressed, this screen appears. Confirmation is carried out for the component serial No. display and the setting, or for the engine model. Use the PC tool to set the engine model. (See TESTING AND ADJUSTING) Engine serial No. button, transmission serial No. button: If the button is pressed, the serial No. input screen is displayed. If the serial No. is input and the input button is pressed, the serial No. is set. The screen then returns to the component serial No. setting screen. If the Previous screen button is pressed, the screen returns immediately to the component serial No. setting screen and the serial No. is not set. A maximum of 10 digits can be set for the serial No. Machine serial No. setting screen button: If this button is pressed, the machine serial No. setting screen appears. Service menu selection screen button: This button is used to select the service menu selection screen. Confirmation screen button for satellite communications ground station (GCC): This button is used to select the confirmation screen for the satellite communications ground station (GCC).
WA1200-3
10-211 10-211
(7)
CGC MONITOR
Confirmation screen button for satellite communications ground station (GCC)
1. Machine serial No. setting screen button, component serial No. setting screen button 2. Message display
If the confirmation screen button for satellite communications ground station (GCC) is pressed on the machine serial No. setting screen or component serial No. setting screen, the screen changes to this screen. The present set value is displayed. If no setting has been made in the VHMS, the value displayed is 248 to show that the satellite communications ground station (GCC) is not effective. Use the confirmation screen for satellite communications ground station (GCC) for checking the set value. Use the PC tool to carry out the setting. (See TESTING AND ADJUSTING)
10-211-1
(7)
WA1200-3
CGC MONITOR
Snapshot operation screen
1. 2. 3. 4. 5. 6.
Clock Snapshot start button Tachometer Torque converter oil temperature gauge Display of message Service menu selection screen button
If the snapshot operation screen button on the service menu selection screen is pressed, this screen appears. This screen is used to take in the snapshot data and save them manually. (Normally, the snapshot data are taken in automatically by using an error as the trigger. See Snapshot items.) When a manual snapshot has been taken, the error code is recorded as MFAO.
Snapshot start button: If this button is pressed, the system gets ready to take in the data. If YES in the message area is pressed, the snapshot data are taken in.
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(7)
WA1200-3
CGC MONITOR
While the data are being taken in, the snapshot start button is not displayed, and the snapshot stop button, the message Executing . . ., the time elapsed, and the progress bar are displayed. If the snapshot cancel button is pressed, the data take-in operation is canceled.
If the data take-in operation is completed, the snapshot start button is displayed again and the message of Snapshot finished is displayed.
Snapshot cancel button: This button is used to cancel the data take-in operation. Service menu selection screen button: This button is used to select the service menu selection screen.
WA1200-3
10-213 10-213
(7)
CGC MONITOR
Snapshot items If an error is made, the data in set time before and after that error (5 minutes 30 seconds before the error and 2 minutes after the error) are saved. The cause of the error can be found out easily by checking the data of the sensors concerned to the error. 1) This system can be applied to an error which cannot be reproduced. 2) Troubleshooting can be executed by collecting the data freely with the manual trigger function. Sampling period of data Every 10 seconds in the period from 5 minutes 30 seconds to 30 seconds before the error Every 1 second in the period from 30 seconds before the error to 2 minutes after the error
Engine related Engine oil level Engine oil temperature Engine oil pressure Engine overrun Coolant level Coolant temperature Trigger item/memory, data item Coolant pressure Intake temperature Fuel temperature Blow-by pressure Cylinder exhaust gas temperature
MOD/C related MOD/C system
Transmission, torque converter related Transmission system Torque converter oil temperature
Hydraulic related Hydraulic oil temperature
Manual trigger (manual operation) (trigger items only)
(Number of saved errors: 9 errors max. 1 of them can be saved manually.)
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WA1200-3
CGC MONITOR
Memory clear ID inputting screen
1. Display of message 2. ID inputting button 3. Service menu selection screen button
If the memory clear screen button on the service menu selection screen is pressed, this screen appears. The memory clear screen appears only when the person of the input ID is proved to be qualified for clearing the memory. Input the memory clear ID with the ID inputting button, then press the enter button. If a wrong ID is input, the message changes to Please Input Memory Clear ID. If the correct ID is input, the memory clear screen appears. If the service menu selection screen button is pressed, the service menu selection screen appears again.
WA1200-3
10-215 10-215
(7)
CGC MONITOR
Memory clear screen 1. Display of message 2. Memory clear buttons 2A. Failure history data 2B. Trend data 2C. Snapshot data 2D. Maintenance data 2E. Load map data 3. Service menu selection screen button
If the correct ID is input on the memory clear ID inputting screen, this screen appears. This screen is used to clear various saved data. Memory clear buttons: These buttons are used to select the data to be cleared. If the memory clear button is pressed, the button flashes. If the memory clear button is pressed again, the YES and NO buttons are displayed. YES: Press this button if you wish to clear the data. NO: Press this button if you do not wish to clear the data. If the YES button is pressed, the selected data are cleared. If the selected data are cleared, the message that those data have been cleared is displayed.
Service menu selection screen button: This button is used to select the service menu selection screen.
10-216 10-216
(7)
WA1200-3
CGC MONITOR
SMR confirmation screen
1. SMR confirmation screen button
On the memory clear screen, the SMR confirmation screen button is hidden at the bottom right of the screen (it is not displayed on the screen). If the SMR confirmation button is pressed, it is possible to change to the next SMR confirmation screen. Use the SMR confirmation screen for checking the set value. Use the PC tool to carry out the setting. (See TESTING AND ADJUSTING)
1. Service meter display 2. Service meter input button 3. Service menu selection screen button
Service meter input button: If this button is pressed, the service meter input screen is displayed, but if the Previous screen button is pressed, the screen returns to the confirmation screen. Service menu selection screen button: If this button is pressed, the screen changes to the service menu selection screen.
WA1200-3
10-217 10-217
(7)
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM

OUTLINE OF SYSTEM
Auto gear shift ECMV control of all gear speeds Kickdown function L Safety functions Manual shift Kickdown function t Safety functions Travel control function (Forward/Reverse travel, gear shift range)
Self-diagnosis function Display of condition (Output, failure code) t Troubleshooting (Detection of system trouble, Communicating function
wire breakage
and short circuit in system)
The electronically controlled full-automatic transmission system consists of a transmission controller, FNR switch, shift-up and shift-down switches, engine rotation sensor, modulated clutch outlet rotation sensor, speed sensor, transmission oil temperature sensor, and ECMV (transmission clutch modulation valve) for the all gear speeds. The transmission controller selects the proper gear speed according to the operation signals of the operator and travel speed. Modulation control is applied to the all-gear speed ECMV to reduce the shocks made when the gear is shifted (when the clutch is engaged). This system prevents the machine from starting when the engine is started and protects the transmission when the travel direction is changed at high travel speed and the gear is shifted down (Priority shift control). With these functions, the transmission and clutch are protected and their durability is heightened. The self-diagnosis system monitors the input and output conditions constantly and displays them on the two 7-segment LEDs of the transmission controller. If it detects any failure, it displays the failure code, and displays the remedy code on the main monitor and turns on the alarm for higher safety, depending on the degree of the failure. The transmission controller has a communicating function and transmits the gear speed information (F, N, R, 1 M - 3) to the main monitor during travel, and the main monitor displays it.
1O-218
WA1 200-3
SYSTEM
CONFIGURATION
Input signals
J/S N SW 1 J/S F SW J/S R SW J/S SHIFT UP SW
D D
b b b
1+
Output signals
ECMV F
1 1 1
D Dx2
ECMV 1 Dx2
1J/S SHIFT DOWN SW
Transmission cut-off SW KDS (Kick Down SW) ID Manual/Auto gear shift selector SW
1 1
D D
+ b b
ECMV 3
D Engine speed Modulated clutch outlet rotation signal IP Travel speed Neutralizer relay signal
1 1
P P
b b b
b s
<Display> Monitor ---_-.-.-.-_-_-_-_-_-_-_-,
-1 Steering lever lock signal
j I I
I+ I
Shift indicator (Actual gear speed)
I I
I
b s Main monitor F.N.R
I
I
I i \
I I
I I i I
I <Display> Monitor ___________-_-_-_-_-_-_-_-_-_Tire correction Troubleindicating buzzeroutput
i S
I I ~__________________-_-_-_-_-_-A
Memory clear signal Fill SW F Fill SW R Fill SW 1 Fill SW 2 Fill SW 3 Transmission oil temperature
I I I I 1 1 1
A D D D
L_-_-_-_-_-_-_-_-_-_-_-__J
b b b R clutch drain valve b b b J/S: Joystick S: S-NET signal D: Digital signal A: Analog signal P: Pulse signal steering Fl output
Auto gear shift call display
1 1 I
D D A
WA1 200-3
10-219
FUNCTIONS 1. Auto gear shift function

When the modulated clutch outlet speed is 1,450 rpm or higher, shifting up and shifting down operations of the transmission are controlled with the signals of the travel direction, gear shift range, and travel sensor, according to the automatic gear shift change points table (Table 1) stored in the transmission controller. See combination of gear speeds and output ECMV (Table 4), auto gear shift operation table (Table 21, and the section of contents of control by transmission controller. 1) Gear shift range (I - 3) The highest gear speed (gear shift range) for the auto gear shift is limited. Example: Gear shift range 3: Between 2nd and 3rd gear speeds Gear shift lever 2: Only 2nd gear speed Gear shift lever 1: Only 1st gear speed 2) When direction switch is in N position If the direction switch is in the neutral position, only the gear speed clutch of the transmission is operated. 3) When direction switch is in F position If the direction switch is set from the N position to F position, ECMV of F of the transmission is turned on. If the gear shift range is 2 or 3 at this time, the machine starts with the 2nd gear. a) When the gear is shifted up (when gear shift range is 3) When the accelerator pedal is pressed to accelerate the machine and the modulated clutch outlet speed is 1,450 rpm or higher, if the travel speed reaches about 10.4 km/ h, the 3rd gear speed of ECMV is turned ON and the second gear speed is turned OFF. (The transmission is set in the F3 position.) b) When the gear is shifted down (when gear shift range is 3) If the accelerator pedal is released and the travel speed lowers to about 9.8 km/h while traveling in the 3rd gear speed, the second gear speed of ECMV is turned ON and the 3rd gear speed is turned OFF. (The transmission is set in the F2 position.)
If the modulated clutch outlet speed is below 1,450 rpm, however, ECMV is kept in the 3rd gear speed. (Coast4) ing) When direction switch is in R position Similarly to the operation in the F position, the 2nd or 3rd gear speed (when the gear shift range is 3) is selected automatically according to the travel speed when the modulated clutch outlet speed is 1,450 rpm or higher. Skip shift If the accelerator pedal is pressed while the machine is coasting in the 3rd gear speed at speed below 8 km/h (with the auto gear shift function turned OFF), the 2nd gear speed is selected immediately so that the machine can be accelerated easily. If the travel speed is 8 km/h or higher, however, the present gear speed is maintained. Period in which gear speed cannot be changed A certain period to keep each gear speed after gear shifting operation is set to prevent gear shift hunting. This period depends on the gear shifting pattern. See automatic gear shift change points table (Table I).
5)
6)
2.
Modulation
control
The modulation control system controls the clutch oil pressure (including the rising characteristics) matched to the condition of the hydraulic circuit in the all gear speeds according to the engine speed, transmission oil temperature, gear shifting pattern, and data stored in the transmission controller to reduce the shocks made when the gear speed is changed (when the clutch is en-
gaged).
The modulation control system is also applied to ECMV to be turned off to prevent lowering of the torque.
1O-220
WA1 200-3
3.
Kickdown function
If the operation (the operation of turning ON the kickdown switch) by the operator satisfies the conditions (travel mode, gear speed, and travel speed), the transmission is shifted down to the 1st gear forcibly. The transmission controller outputs the cutoff signal to the engine (electronic governor) controller in the kickdown mode (while the 1st gear signal is output). See the section of contents of control by transmission controller. 1) Auto gear shift mode The kickdown system becomes effective when the forward or reverse travel speed is below 13 km/h. It is also effective while the gear speed is held (while the auto gear shift function is turned off). The resetting condition is either rise of the travel speed or change of the travel direction. If either condition is satisfied, the transmission is set in the 2nd gear speed. See the auto gear shift operation table (Table 2) in the section of the protective functions of the transmission (gear speed control table). 2) Manual gear shift mode The kickdown system becomes effective when the machine travels forward in the 2nd gear speed. The resetting condition is either operation of the shift up/down switch or change of the travel direction. If either condition is satisfied, the transmission is set in the 2nd gear speed.
2)
3)
4)
5)
Neutral safety When the engine is started, if the direction switch is not in the N position, the transmission controller keeps itself in the neutral state and the machine cannot start (Prevention of abrupt start). This function is reset if the N signal is input once after the engine is started. Shift-down switch priority The transmission can be shifted immediately with the gear shift-down switch and the engine can be used as a brake when the machine travels downhill. Protective function of transmission If the gear is shifted down or the travel direction is changed while the machine is traveling in the 3rd or 2nd gear speed, the gear speed and warning buzzer are controlled to protect the transmission. See the section of the protective functions of the transmission (gear speed control table). Manual gear shift mode If the travel speed data cannot be obtained because of a travel speed sensor trouble, the manual gear shift mode is selected.
Table 1 Automatic gear shift change

Applicable item Solenoic signal orward (F) Speed (km/h) 5.4 10.4 3+2 9.8 Reverse (8) Speed (km/h) 5.4 10.4 9.8
Dints table
eriod to keep ear speed af. ?r gear shift lg operatior
XC)
1. 3asic gear shift :hange
2 2 2
4.
Travel mode
The auto or manual gear shift mode can be selected with the travel mode selector switch. In the manual gear shift mode, the gear speed is changed with the shift up/down switch.
2. IModulated clutch outlet speed signal OFF (Below 1,450 rpm) 3. Modulated clutch outlet speed signal OFF (Below 1,450 rpm) + ON (1,450 rpm or higher) 4. When direction switch is changed F-+N+F R-+N-+R
3+2
1.0
1.0
5.
Safety functions
I) Transmission neutralizer function This function sets the transmission in the neutral position when the steering lock lever is operated (set in the LOCK position) or when the machine is stopped and the engine has not been started.
3-2
8.0
8.0
+3
10.4 -
10.4 -
+2
- 10.4
- 10.4
WA1 200-3
1o-22 1
Table 2 Auto gear shift operation table

Gear shift range Period to keep Remarks
1. Basic gear shift change Modulated clutch outlet speed is 1,450 rpm or higher. Operation accelerator of only pedal @ 5.4 2. Modulated clutch outlet speed is below 1,450 rpm. (During coasting braked to stop) or until 0
Basic gear shift in auto
Gear can be shifted to 1st gear speed with shift-down switch or by KDS
1.0 --@
Basic gear shift when auto mode is turned off
3. Modulated clutch outlet speed is below 1,450 rpm + above 1,450 rpm. Operation of only
Gear shift just after auto mode is turned on
accelerator pedal (During coasting or acceleration after braking)
4. Kickdown Only in moment operation
after
of switch
* Kickdown system operates at any engine speed. Travel speed is limited, however, to prevent overrun. * If accelerator pedal is pressed and travel speed rises, gear is shifted up in auto mode.
5. When direction switch changed (Part 1)
is
-When direction
is changed or machine starts in neutral in another case than the left, gear
Lever is changed or machine starts in neutral. (F+)N+R, (R+)N-tF
o_
All range
@ protection of transmission.
6. When
direction (Part 2)
switch
is
changed
Lever is returned position. F+N+F, R+N+R Gear is shifted
to same
according
to travel speed at time when lever is changed. A rase below s.3

All range below 9.3
1o-222
WA1 200-3
6.
Self-diagnosis function
The transmission controller constantly monitors the input and output signals of the travel control system, and executes self-diagnosis and displays the result with the LED of the controller. The transmission controller also transmits the following data to the main monitor. I) Normal display: The output gear speed is displayed with the LED of the transmission controller. 2) Display of failure code: If any trouble is detected, its contents are displayed by the code (See the table below).
Table 3 Failure codes table
WA1 200-3
1 O-223
7.
Communicating
function
Power source of transmission
controller
The transmission controller has a communicating function through S-NET, and it receives the tire correction data from the main monitor. If the transmission controller has a signal trouble in its control system, it displays the remedy code on the main monitor to notify the operator for higher safety, depending on the degree of the trouble.
When the starting switch is turned on and the source voltage is 20 V or higher and a voltage of +20 V or higher is applied to the transmission controller solenoid, drive of each solenoid valve can be controlled. If the source voltage lowers below 19 V, all
The failure code saved in the main monitor can be checked in the failure history mode of the main monitor.
the outputs are turned off and control is not executed. (The machine cannot travel.) If the source voltage rises to 20 V, the neutral safety function works, and the machine can travel.
1O-224
WA1 200-3
ALL-RANGE STRUCTURE AND FUNCTION
ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
INPUT SIGNALS
1. Steering lever lock signal This signal is a GND/OPEN digital signal, which becomes OPEN when the steering lever is stopped (locked) and becomes GND when the steering lever is operated (free). If the steering lever is operated, the direction switch becomes effective. 2. Neutralizer relay signal This signal is a +24V/OPEN digital signal. If the parking brake switch is turned off, +24 V is input. When this signal is OPEN, the transmission controller keeps itself in neutral state. (The machine cannot travel.) Transmission cut-off switch signal This signal is a GND/OPEN digital signal, which becomes OPEN when the left brake is used (pressed) while the transmission cutoff switch is effective, and becomes GND when the left brake is released. If the left brake is used, the transmission controller outputs the neutral signal. If the transmission controller is reset, the gear speed matched to the current travel speed is set. Manual/Auto gear shift selector switch signal This signal is a GND/OPEN digital signal, which becomes GND when the switch is pressed and becomes OPEN when the switch is released. If this signal changes from OPEN to GND, the manual and auto travel modes are selected alternately. Direction switch (F, N, RI signal This signal is a +24V/OPEN digital signal. When the machine is normal, one of the F (Forward), N (Neutral), and R (Reverse) signals is input (+24 V). Shift-up/Shift-down switch signal This signal is a +24V/OPEN digital signal. If the switch is pressed, its N.C side is opened and its N.0 side becomes +24 V. If the switch is released, its N.C side becomes +24 V and its N.0 side is opened. The operation of the switch is judged by these signals. If both shift-up switch and shift-down switch are operated simultaneously, their operations are judged as follows. . After either switch is turned ON, the turnon operation of the shift-up switch or shift-down switch is not accepted for 0.2 seconds. . If the shift-up and shift-down switches are operated simultaneously (for 0.01 second), the operation of the shift-down switch is accepted. 7. Fill switch (F, R, 1st gear, This signal is which becomes turned ON and ECMV is turned
3.
2nd gear, 3rd gear) signal a GND/OPEN digital signal, GND when each ECMV is becomes OPEN when each OFF.
8.
Engine rotation sensor signal This signal is a pulse signal. The number of pulses sent from the electromagnetic pickup sensor is converted into rpm and used for control. Modulated clutch outlet rotation sensor signal This signal is a pulse signal. The number of pulses sent from the electromagnetic pickup sensor is converted into rpm and used for control. The mode where the engine speed is 1,450 rpm or higher is called the auto-shift ON mode, and the mode where the engine speed is below 1,450 rpm is called the auto-shift OFF mode.
9.
4.
5.
10. Travel speed sensor signal This signal is a pulse signal. The number of pulses sent from the electromagnetic pickup sensor is converted into rpm and used for control. When this signal is converted into the travel speed, the tire correction data (sent from the main monitor) are added to it. 11 Communication signal (S-NET) The tire correction data set in the main monitor are received and used for control. The accurate travel speed is obtained by adding the correction value (ranging from 0.86 to 1.14) to the rpm data sent from the travel speed sensor.
6.
WA1 200-3
1o-225
OUTPUT SIGNALS
1. Transmission modulation valve (ECMV) Command current
This signal is a current output (0 - 1 A). There are five types of ECMV for directions of R and F, and for gear speeds of Ist, 2nd, and 3rd. This valve is a pressure control valve which converts the current supplied to the solenoid into the pressure. Accordingly, the oil pressure on the clutch selected for each gear speed is controlled to control the engagement of the clutches independently. When the transmission is in neutral, only the gear speed clutch is turned on. (The gear speed is selected according to the gear shift range and travel speed in the auto mode. In the manual mode, the gear speed before the transmission is set in neutral is maintained. When the engine is started, the 2nd gear speed is selected.) 4.
Fl (Cut-off) signal
This signal is a Lo side output, which becomes GND when the forward 1st gear (Fl) is selected by the kickdown operation, etc.
5.
Gear shift range display LED

I) This LED indicates the gear shift range (range of auto gear shift operation) in the auto mode. Gear shift range 1: LED 1 is turned on and only the 1st gear speed is selected. Gear shift range 2: LED 2 is turned on and only the 2nd gear speed is selected. (If the gear is shifted down to the 1st gear speed by the kickdown operation, the 2nd gear speed is selected, depending on the travel speed.) Gear shift range 3: LED 3 is turned on and the 2nd or 3rd gear speed is selected automatically. This LED goes off in the manual mode.
Table 4 Combination of gear speed and drive ECMV (Holding state)

2) 6.
Backup lamp relay signal

This signal is a digital (ON/OFF) output of +24 V, which is turned ON when the direction switch is in the R position to turn on the backup lamp and backup alarm.
7.
Communication signal (Data of disolav on main monitor)
I)
t R3
2)
0: ON AZ One of 1 - 3 is turned on according to the condition.
2.
Bypass valve (For F, R, and 1st gear speed)

This signal is a digital (ON/OFF) output of +24 V, which is turned ON for the stored period (data) when each ECMV is turned ON.
Display of gear speed 1st gear speed output: I 2nd gear speed output: 2 3rd gear speed output: 3 In neutral: N Display of F and R When travel direction is forward: When travel direction is reverse: In neutral: Nothing is displayed.
F R
3.
R clutch drain valve

This signal is a digital (ON/OFF) output of +24 V, which is turned ON for the stored period (data) when the R ECMV is turned OFF.
1 O-226
WA1 200-3
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION IATM) SYSTEM
LED DISPLAY
When the engine is started, the LED is set in 1. Program
speed display mode. If any trouble is detected, however, part No. display mode, then 2. Output gear
the LED is set in the Troubleshooting are displayed A, ti 1, hl 0,
display mode
immediately.
1.
Program part No. display mode When the power is turned on, the following
-0 -0 Al 70 80 Al 20 30 Al 1, 9,
in order at the interval 1, w
of 1 second.
+ To display mode 2
2.
Output gear speed display mode

LED display X 0 Y 0 (Dots of both are turned off.) X: Drive condition of direction ECMV Forward F: F, Reverse R: A, Neutral: 0 Y: Drive condition of gear speed ECMV l-4 Example Display 0 0 2 0 F o 1 0 A 0 2 0 F o F 0 Neutral, Forward, Reverse, Neutral Contents 2nd gear speed 1st gear speed 2nd gear speed safety state + If trouble is detected, Display mode 3 is selected. I N Gear shifting (Gear speed F2 is displayed continuously)
3.
Troubleshooting display mode (Trouble currently detected) E - (2 set) and Code (2 set) are repeated as one routine. 1) When there is only one trouble
-+ Repeat +=I=% 2) When there are two trouble E, -0 hl 20 30 Ll E, -0 Ll items 1, 80 ti + Repeat item
WA1 200-3
1O-227
CONTENTS OF CONTROL BY TRANSMISSION

1. Devices used and display on monitor
Section Steering Device Joystick steering lever Manual/Auto shift selector switch
CONTROLLER
Auto 0 0 0 0 0 0 0 1 0 0
Manual 0 0 0 0 0 0 0 1 0 OFF Main monitor 1 Main monitor
Remarks
FNR seesaw switch (Joystick knob) Transmission Shift-up switch (Joystick knob) Shift-down KDS Display of setting of FNR Display switch (Joystick knob)
1 Display of actual gear speed

Display of gear shift range (In AT)
Displayed with LED (Only in auto shift mode)
2.
Actual gear speed (II, gear shift range (III, and travel mode (Auto shift/Manual)
I) Actual gear speed (1) and gear shift range changed to each other (II) when manual
(Ill)
are
shift and auto shift modes
Manual/Auto shift selector switch @ Auto shift [Auto shift1
Before change
After change
[Manuall
--------------------b b (1)Actual gear speed is the same as that in auto shift mode. x (II)Gearshiftrangeisnotapplied,andisturnedoff. b [Auto shift] (1) [In F or RI Actual gear speed is set according to travel speed. IIn N12nd gear speed 6%) ---+ (II) Gear shift range is the same as actual gear speed in manual mode (~4): When gear shift range is [ll, 1st gear speed is selected.
J
Manual @ Manual L Auto shift
(1)Actual gear speed (II) Gear shift range [Manual] (1) Actual gear speedT
2)
Initial condition after power is turned on : (I) Actual gear speed [In manual mode] : [In auto shift model (II) Gear shift range [Only in auto shift model: : (III) Travel mode (Auto shift/Manual)
Actual gear speed before key is turned to OFF 2nd Gear shift range before key is turned to OFF Travel mode before key is turned to OFF
3.
Solenoid output when FNR signal is changed

The FNR signal is constantly Manual mode monitored prior to the other controls. Auto shift mode
Joystick knob switch F 0 0 EWhen N R 0 gear shift range is 111, 1st gear speed is selected. Solenoid F 0 0 R output 2nd gear %
Joystick knob switch F N R
Solenoid F 0 R
output before N is selected
Gear speed
1O-228
WA1 200-3
ALL-RANGE STRUCTURE AND FUNCTION
ELECTRONIC CONTROL AUTOMATIC TRANSMISSION (ATM) SYSTEM
4.
Gear shifting pattern I) Manual mode l The gear is shifted shift-down switch.
Gear shift mode Gear shift operation
with
the shift-up
switch
and
Actual gear speed 1 2
Initial value (When power is turned on) Actual gear speed (Solenoid output) .Gear speed before key is turned to OFF
Conditions
for resetting
kickdown
function
(Kickdown
is effective
only
in F2) Remarks
Resetting operation
Condition before resetting

Fl Fl Fl I
Condition after resetting

N2 R2 F2 I
1 1Jovstick knob switch F + N 1 2 Joystick knob switch F -+ R

3 Shift-up switch
-1
Actual gear speed is shifted up only when kickdown is applied
4 Shift-down
switch
Fl Fl
Fl -
Gear speed is shifted down from 2 to 1, too.
5 Turn-off of power 2)
Auto shift mode l The shift-up switch and shift-down

Gear shifting operation g g I I@Ei5q
switch function
as gear shift range selector

Initial value (When power is turned on)
Sear shifting mode
Actual gear speed 1 2 3
Range 1
& h
E r 4
I I I
! I I I
3,: *, 0
- Actual gear speed (Solenoid output) . .2nd (s) 1%) . . When gear shift range is [ll, 1st gear speed is selected. - Gear shift range..
Gear shift range before power is turned o
5 1
i an~2~
$z$&
01
KICK DOWN SW
O
I I b
,AUtmlBflC reset when Liirenion

i* changed between F and FL)
Resetting condition (Operation) 1 Joystick knob switch F+ N 2 Joystick knob switch F -+ R 3 Joystick knob switch R + N
I
Condition before resetting Kickdown in F 1Kickdown in R Fl Fl I
Condition after resetting N2 R2 N2

I
Remarks
RI RI Rl RI RI RI
4 Joystick knob switch R + F 5 Shift-up switch 6 Shift-down switch 7 Turn-off of power 8 Rise of travel speed
Fl Fl Fl Fl
F2 Shifting up to 2
As per auto gear shift operation table
WA1 200-3
1 O-229
PROTECTIVE 1.
FUNCTIONS
OF THE TRANSMISSION
(GEAR SPEED CONTROL
TABLE)
Protection functions in auto shift mode

I) Control of kickdown
Gear speed before kickdown
Command
from controller
Brd+lst
1st
3rd is held (Kickdown signal is ignored). 2nd is held (Kickdown signal is ignored). \t
2nd+lst
1st
Travel speed (km/h)
9
5
13
15 20
Period in which gear speed cannot be changed (5 set)
2)
Control
of shift-down
operation
Operation of shift-down switch
Command
from controller 14
3rd-12nd
2nd
3rd &caution When travel speed is 14 km/h or higher and shih-down switch is accepted 2 times
3rd+lst
2nd
3rd &caution
2nd+lst
1st
2nd & caution
Travel speed (km/h
5 9
1314
20
3)
Control when
direction
is changed
Gear speed after change of direction (Command from controller)
Gear speed before change of direction
3rd
2nd
3rd &caution
2nd
2nd
3rd &caution
When gear shift range is 2nd, 3rd When gear shift range is 1st
1st
2nd
3rd &caution
Restoration from kickdown 1st is held and direction is changed. \ (2 set)
1st
@I
1st
@ E$$n
3rd &caution
Travel speed (km/h
14
20
Period in which gear speed cannot be changed
Gear speed is changed according to operation. Range 0: Range @J: Gear speed is controlled according to travel speed and caution
signal is output.
1 O-230
WA1 200-3
4)
Control after change of direction
When 9ear shift range
3rd+lst
@I
3rd &caution
is 1 and travel speed is 14 km/h or higher
j
Pnd-tlst
1 @ IstI
1
@ 2nd &caution
1a&diiction
is
Travel speed (km/h)
Range 0:
Range @:
Gear speed is changed according to operation. Gear speed is controlled according to travel speed and caution
signal is output.
2. Protective functions in manual shift mode 1) Control of shift-down

operation
Command from controller 14
3rd+2nd
3rd+lst / 1 Znd+lst 1 accepted2 times

@ I I I I I 1314 2nd &caution I
1st I
9
Travel speed (km/h)
I I I I I I I I
5
I I
I I
I I I I
20
Range Range
0: @:
Gear Gear
speed speed
is changed is controlled
according according
to operation.
to travel speed and caution signal is output.
WA1 200-3
lo-231
2)
Control when
direction
is changed when the direction is changed to F or R while the machine is
(The following control is also applied coasting with the gear is in NJ
Gear speed after change of direction (Command from controller)
3rd
2nd
3rd &caution
2nd I. When range is judged to be 1st
2nd
3rd &caution
1st
1st
@ z2$!&
3rd &caution \
1st is held and direction is changed.
Travel (km/h)
speed
14
20
(2 set)
Period in which gear speed cannot be changed
Range 0: Range @:
Gear speed is changed according to operation. Gear speed is controlled according to travel speed and caution of direction
signal is output.
3)
Control
after change
I
I
Command from controller
Pnd-+lst
I
1Olst
1
1
,
2nd &caution
Travel (km/h)
speed
10 5 20 15
Range 0: Range @: Control
Gear speed is changed according to operation. Gear speed is controlled according to travel speed and caution auto shift mode is in neutral
Gear speed selected when in neutral (Co2myd from con_lerl 3rd
signal is output.
of gear speed when
kI:Tnge
1st
2nd
3rd
Travel speed (km/h)
14
20
WA1 200-3
lo-232
MODULATED
CLUTCH (MOD/C) CONTROL SYSTEM
MODULATED
CLUTCH (MOD/C)
CONTROL SYSTEM
SYSTEM CONFIGURATION
Modulated clutch controller

-o ___________________________________. g;
Travel
speed control
8:
0, g:
oi
2i
Modulated clutch ECMV current
Engine speed signal (output)
RPM set ON/OFF switch signal SET/ACCEL switch signal RESUME/DECEL switch signal
D D D D ? E 8 :: S 2
Electronic governor voltage command
Low idle switch signal
D 5 A e
A: Analog signal D: Digital signal P: Pulse signal S: S-NET signal
WA1 200-3
1O-233
STRUCTURE
AND
FUNCTION
MODULATED
CLUTCH
(MOD/C)
CONTROL
SYSTEM
Control function Modulated clutch control
Travel speed control function Drive force control function ITire slip control function
RPM set control function I Troubleshooting function
Modulated clutch control The modulated clutch control system has the following functions. I) Travel speed control function Since the travel speed can be limited to the maximum speed set with the travel speed control lever, the operator can keep the travel speed low without releasing the accelerator pedal when approaching a dump truck. As a result, the operator can work easily. This function can be applied with the travel speed control ON/OFF switch only when it is required. <Operating conditions> The travel speed control ON/OFF switch is turned ON. The transmission is set in the Fl, F2, RI, or R2 position. The travel speed is 1.5 km/h or higher. The maximum travel speed can be set as shown below according to the gear speed of the transmission and the position of the travel speed control lever.
l l l
2)
3)
Drive force control function Since the drive force set with the drive force control lever can be set at a properly low level, slip of the tires can be prevented on a clayey ground (red clay), in mud, etc. Accordingly, the operator can work without paying attention to the acceleration work. The maximum drive force can be changed to 20% - 100% with the drive force control lever. <Operating condition> . The transmission is set in the Fl position. (If the travel speed control function is turned on, however, it is applied first.) Tire slip control function Even if the drive force is lowered with the drive force control function, the tires may still slip. If slip of the tires is detected in this case, the drive force is further lowered to minimize the slip. <Operating conditions> The tire slip control switch is turned ON. The transmission is set in the Fl position. The work equipment is not operated.
l l l
1 O-234
WA1 200-3
STRUCTURE
AND
FUNCTION
MODULATED
CLUTCH
(MOD/C)
CONTROL
SYSTEM
RPM SET CONTROL FUNCTION

Since the operator can set the idling speed of the engine freely, unnecessary lowering of the engine speed can be prevented while the operator is working with the accelerator, and the engine is accelerated sharply and the cycle time is shortened. Since the travel speed can be kept constant during load-and-carry operation, the operator is less fatigued and the machine consumes less fuel. How to set engine speed 1) Turn on the RPM set ON/OFF switch. 2) The RPM set pilot LED lights up. 3) Press the accelerator pedal until the engine speed rises to the desired level. 4) Press the SET/ACCEL switch to save the engine speed data. Then, even if the accelerator pedal is released, the engine runs at the saved speed. How to change set engine speed Use the following method to change the save engine speed. 1) How to raise set engine speed i) Setting with accelerator pedal a) Press the accelerator pedal until the engine speed rises to the desired level. b) Press the SET/ACCEL switch to save the new engine speed data. Then, even if the accelerator pedal is released, the engine runs at the saved speed. ii) Setting with switch a) Press and hold the SET/ACCEL switch for more than 0.5 seconds, and the engine speed rises. b) When the engine speed rises to the desired level, release the SET/ACCEL switch, and the new engine speed data is saved. 2) How to lower set engine speed i) Setting with accelerator pedal a) Press the right brake pedal, and the memory of the engine speed is canceled temporarily and the engine speed is lower to the low idling level. b) Press the accelerator pedal until the engine speed rises to the desired level. c) Press the SET/ACCEL switch to save the new engine speed data. Then, even if the accelerator pedal is released, the engine runs at the saved speed. ii) Setting with switch a) Press and hold the RESUME/DECEL switch for more than 0.5 seconds, and the engine speed lowers. b) When the engine speed lowers to the desired level, release the RESUME/ DECEL switch, and the new engine speed data is saved.
How to cancel memory of engine speed temporarily Press the right brake pedal, and the memory of the engine speed is canceled temporarily and the engine speed lowers to the low idling level. How to restore canceled engine speed Press the RESUME/DECEL switch, and the engine speed rises to the saved level again. (Note) If the engine starting switch or the RPM set ON/OFF switch is turned OFF, the saved engine speed is cleared, then the engine runs at the low idling speed. In this case, repeat the above procedure to set the engine speed again.
WA1 200-3
lo-235
MODULATED
CLUTCH (MOD/C) CONTROL SYSTEM
Troubleshooting
function
The controller constantly monitors the electronic devices such as the potentiometers to receive input signals, solenoid valves to receive output signals, etc. If any one of those devices has a trouble, the controller detects it and displays is as a failure code on the main monitor to notify the operator.
1O-236
WA1 200-3
WORK EQUIPMENT AND JOYSTICK STEERING CONTROL SYSTEM
WORK EQUIPMENT SYSTEM

SYSTEM CONFIGURATION
AND JOYSTICK
STEERING CONTROL
Work equipment and joystick steering controller
D +/ Boom raising switch (Pressure switch)
Boom lever kick-out SOL
Boom lowering
switc Remotepositionerswitch input checkbuzzeroutput Engine rotation signal P Display of lower setting of remote positioner S
Display of upper setting of remote positioner
-1 Lower setting switch of remote positioner
Upper setting switch of Display of lower stop of remote positioner Lower selection switch o Pilot LED of upper stop of remote positioner
J Upper selection switch of remote positioner
s
Pilot LED of lower stop of remote positioner
Selection of remote positioner
function
x:: j
Steering lever potentiometer calibration reset switch
Joystick main pressure control EPC SOL
Joystick caution buzzer relay
Joystick neutral caution buzzer relay Steering potentiometer
A: D: P: S:
Analog signal Digital signal Pulse signal S-NET signal
WA1 200-3
1o-237
COMPOSITION OF WORK EQUIPMENT (REMOTE POSITIONER) CONTROL CIRCUIT
10-238 10-238
(7)
WA1200-3
COMPOSITION
OF JOYSTICK STEERING CONTROL CIRCUIT
Steer lever Travel

Speed
ins
Steering lever Potentiometer

L
Work eauipment h joystick steerino controller : Steer in0 lever lock switch Rotary valve
,_____-_____________-__-,
I I I I
I I I I ______--__-___--I
I I I
f I I I I
Frame angle Potentiometer
I
0
i -
sxw0491.3
Control function Remote positioner control Boom raising and lowering position stop Boom raising and lowering position setting E Sensor adjustment function Joystick steering control Potentiometer calibrating function t Neutral interlock function Troubleshooting function
Outline With the remote positioner control function, the operator can set the boom stopping (lever kick-out) position freely so that the boom will stop smoothly. As a result, the operator can operate the machine safely and easily when driving in reverse, digging the earth, or approaching a dump truck.
l
With the joystick steering control function, the flow gain in the steering hydraulic system is controlled according to the deviation of the frame angle from the operating angle of the joystick steering lever to improve the narrow steering characteristics and response to high-speed steering for higher maneuverability.
WA1 200-3
1 O-239
REMOTE POSITIONER CONTROL

Functions of remote positioner 1. Stopping boom at raising and lowering oositions . The boom is decelerated and stopped at the set raising and lowering positions. The controller constantly detects the operating direction signal of the lever sent from the pressure switch installed to the PPC valve of the boom. It also detects the boom angle (position) signal sent from the boom angle potentiometer. I) Raising kick-out (When UPPER button lights up) If the boom lever is set to the RAISE DETENT position, the boom rises to the set position, then decelerates and stops. The detent is reset at this position. When the boom lever is not in the RAISE DETENT position, the boom is raised as the operator operates. lowering boom (When 2) Stopping LOWER button lights up) If the boom lever is in the FLOAT or MAX. LOW position, the boom lowers to the set position, then decelerates and stops. If the lever is held as it is, the boom is fixed. If the lever is returned to the neutral and set to the LOWER position, the boom lowers again. The operator can freely set the positions at which the boom stops when it rises and lowers. Setting range of stop position
(2) Each time the LOWER button is

pressed, it lights up and goes off alternately. While it is lighting up, the lowering stop function is effective. (The setting is maintained even if the starting switch is turned off.) There is an indicator on the right console, in addition to the UPPER and LOWER buttons on the CGC monitor screen, so that the operator can see the setting condition.
2.
Setting of raising stop position of remote positioner 1) Press the UPPER button to light it up. 21 Operate the boom lever to move the boom to the stop position, then set it in neutral. (The boom must be higher than the level position.) 3) Press the raising stop position setting button. 4) The UPPER button flashes (for 2.5 seconds). 5) If the UPPER button lights up again, the raising stop position is saved. Setting of lowering stop position of remote positioner 1) Press the LOWER button to light it up. 2) Operate the boom lever to move the boom to the stop position, then set it in neutral. (The boom must be lower than the level position.) 3) Press the lowering stop position setting button. 4) The LOWER button flashes (for 2.5 seconds). 5) If the LOWER button lights up again, the lower stop position is saved.
3.
(
(Angle is 0 degree when boom is horizontal.) Setting of the control can be changed as explained below. (1) Each time the UPPER button is pressed, it lights up and goes off alternately. While it is lighting up, the raising stop function is effective.
l
Sensor adjustment function This function is used to offset the error caused by installation of the potentiometer so that the correct position data of the work equipment can be obtained. Be sure to adjust the sensors with this function after the controller, potentiometer, or work equipment is replaced. (For the setting method, see TESTING AND ADJUSTING, Initial setting procedure for remote positioner.)
1 O-240 0
WA1 200-3
WORK EQUIPMENT
AND JOYSTICK STEERING CONTROL SYSTEM
JOYSTICK STEERING CONTROL

Potentiometer calibrating function This function is used to measure the difference between the steering lever angle and the frame angle sensing potentiometer (offset angle), and correct it automatically.
Neutral interlock function . Interlock relays are installed to the engine and the starting line of the starting motor so that the frame will not articulate and the machine will not start abruptly when the engine is started. If the difference between the operating angle of the steering lever and the frame angle is 6 degrees or wider, the interlock operates so that the engine will not start. At this time, the buzzer sounds, If the steering lever is set in neutral and the FNR switch is set to the N position, the interlock is reset and the engine can start. . If the FNR switch is not in the N position, the neutral safety function prevents the engine from starting.
Troubleshooting function The controller constantly monitors the electronic devices such as the potentiometers to receive input signals, solenoid valves to receive output signals, etc. If any one of those devices has a trouble, the controller detects it and displays is as a failure code on the main monitor to notify the operator.
Failure codes table Failure code on
58 59 61 62 63
frame angle sensor, and potentiometer signal from each other Frame angle sensor Steering lever lock switch Joystick neutral interlock relay Joystick main pressure control EPC SOL E44 and E45 cannot be distinguished,
0 0 0 0
0 0 0 0
EOl + CALL EOI + CALL EOl + CALL EOO EOI + CALL
and they are turned on simultaneously.
WA1 200-3
1O-241 0
POTENVOMETER
A-A
A4
SW04882
1. 2. 3. 4.
Connector Case Shaft Element
5. 6. 7.
Bearing Contact Mold
Potentiometer
output
Potentiometer
anole
f1
sxwo4919
Function The potentiometer senses the operating angle. In the potentiometer, the source voltage of 5 V is converted with a variable resistor into a signal voltage according to the angle, then sent to the controller. The hatched area in the above figure is the abnormality detection area. If the controller receives
the above signal in this area, it judges that the potentiometer system has a trouble such as wire breakage, short circuit, etc. Since the correct position cannot be sensed in this case, the control output is turned off and the failure code is displayed on the main monitor.
1 O-242
WA1 200-3
WORK EQUIPMENT AND JOYSTICK STEERING CONTROLLER
WORK EQUIPMENT
AND JOYSTICK
STEERING CONTROLLER
CN,l
cy2
C.N3
Connector signal CNI CN2 Cl 1 3
CN3
Pin No. / i Name of signal 1Frameangleiometer Input/ output
In:
I SOL2 (+)I Output
I 121
1 I
6
1Boom
PPC dumping
I -1 I - I
I Input Input
I41
5 6
Boom PPC dumping J/S EPC SOL (+) SOL1 (t)
Output output
I 5 I Boom RAISE pressure switch Boom LOWER pressure switch
I I
1 , ~:;,9:~;,s,p,e,e,,s:gnal (+) 1;;w;;1

6 I 7 1 8 Remote positioner UPPERstop LED Output
I I
I I -
I I
I101 I 11 I
12 13 S-NET (+)
I I
(+24V) SOL2 H SOL1 H
Input
I I
12 13 14 15 16 Sir potentio CAL. reset switch Input 12
I
I Pulse I I J/S
input
GND
I I
Input
1Sensor
power
( output
Output Output
13
caution buzzer output
14
Boom PPC dumping Boom PPC dumpmg
1 14 1 Remote positioner LOWERstop LED/ Output I 15 16
15
I Output
output
I I I
Buzzer output
I 17 I 18
I SOL
power input
input (+24V)
I Input I I but I
output relay
17
I Power I Boom
1 19 1 GND I 20 lever kick-out interlock
I 21 I S/T neutral
I but I I Output I I Output I
WA1 200-3
1O-243
ENGINE STARTING CIRCUIT
ENGINE STARTING
CIRCUIT
tiler xrv~ce meter Main monitor
Starting
switch
Slow fuse
blow 30A Battervl
Work equipment
Cummins
engine
inject ion solenoid
Alternator _-__r----r
Voltage regulator
1 I
Prelub timer
l___
-.-
__-__
IE
E: !I -___I
&
rreluu 0 Pressure ,. swltcn
Conventional starter
sxwo4920
Function
l
When the direction switch and the joystick steering lever are in the N (Neutral) position, the neutral safety circuit prevents the engine from starting to secure the safety when the engine is started. If the starting switch is set to the START position, the engine oil is circulated first by the pre-lubricating function. After the oil pressure has risen, the engine is started.
Operation . If the starting
switch is turned to the ON position, a current flows from the BR terminal of the starting switch to the battery relay, then the battery relay contacts are closed. The power is supplied to the machine by this operation. If the direction switch is set to the N (Neutral) position, a current flows in the neutral relay, then the contacts 5 and 3 of this relay are connected to each other. On the other hand, when the joystick steering lever is set to the N (Neutral) position, contacts 6 and 3 of the steering neutral relay are connected to each other, and the contacts 6 and 3 of the alternator hold relay are also connected to each other. At this time, if the starting switch is set to the START position, the current flows through the following route.
1o-244
WA1 200-3
Positive terminal of the battery + Terminal B of the starting switch + Terminal C of the starting switch + Terminals 5 - 3 of the neutral relay + Terminals 6 - 3 of the steering neutral relay + Terminals 6 - 3 of the alternator hold relay + Pre-lubrication hold relay coil + Ground. As a result, contacts 1 and 2, and contacts 3 and 4 of the pre-lubrication hold relay are connected to each other respectively, and the following circuit is formed and the current flows through it. Terminal BR of the starting switch + Terminals 1 - 2 of the pre-lubrication hold relay + Terminal 3 of the pre-lubrication timer. As a result, the contacts of the pre-lubrication timer are closed. Then, the current flows from the positive terminal of the battery through the battery relay to the prelubrication starting motor to circulate the engine oil. At this time, the following circuit is formed, too; Terminal BR of the starting switch + Terminals 3 - 4 of the pre-lubrication hold relay + Neutral relay + Steering neutral relay + Alternator hold relay -_j Pre-lubrication hold relay coil + Ground. Accordingly, the current flows in the coil of the pre-lubrication hold relay continuously to hold the circuit from the starting switch through the pre-lubrication hold relay to the pre-lubrication timer. Accordingly, even after the starting switch is returned from the START position to the ON position, the engine starting operation is continued. That is, it is not necessary to keep the starting switch at the START position until the engine starts successfully. The star-ting operation of the engine is stopped by returning the starting switch to the OFF position. If the oil is supplied all over the engine and the oil pressure rises, the contacts of the pre-lubrication oil pressure switch are opened. Upon receiving the signal from this oil pressure switch, the pre-lubrication timer opens its own contacts. As a result, the current flowing in the prelubrication starting motor is turned off and pre-lubrication is completed.
WA1 200-3
1 O-245
Start
ine
switch
-VHMS -Service -Main
controller meter monitor
Slow fuse
blow 30A
r
Prelub hold relay
Battery
r
Alternator _
starter Pr club oil pr essure switch :
t Conventional starter
i-.---c____-3
sxwo4921
Several seconds after pre-lubrication is completed, a current flows from terminal 5 of the pre-lubrication timer to terminal 1 of the safety relay to close the contacts of the safety relay, then the electric power is supplied to the pre-lubrication starting motor and conventional starting motor. At this time, the current flows in both holding coil and pull-in coil of each starting motor to close the contacts. Since the current also flows through the pull-in coil to the motor, the starting motor starts slowly.
If the starting motor rotates slowly and meshes with the gear of the engine, the contacts of the starting motor are closed by the suction force of the pull-in coil, then the starting motor starts quick rotation to start the engine. The current does not flow in the pull-in coil any more, but the contacts of the starting motor are kept closed by the current flowing in the holding coil.
1 O-246
WA1 200-3
Sta rtins
switch 3 3 3
VHMS controller Service meter Main monitor Slow blow
------I
LLllrl
injection
&
11
Battery
Cummins controller
Ether injection solenoid
engine
9
SafZ relay T
:i c
+
pressure switch = Conventional starter
sxwo4922
If the engine starts, the alternator starts generation and outputs the power through terminal B. At this time, the same voltage is generated at terminals B and L, and a current flows into terminal 2 of the safety relay to open the contacts of this relay to break the power for the starting motor. The current flows from terminal L of the alternator through the alternator hold relay coil to the ground, and the circuit to the prelubrication hold relay is broken to break the
connection between terminals 6 and 3 of the alternator hold relay, then the starting circuit is not held any more. The current from terminal L of the alternator is supplied as the signal that the engine is rotating to the service meter, etc. If the direction switch and/or the joystick steering lever is not in the N (Neutral) position, the circuit is broken by the steering neutral relay and the engine does not start.
WA1 200-3
lo-247
ENGINE STOPPING CIRCUIT
ENGINE STOPPING CIRCUIT
Starting
switch
VHMS controller Service meter Main monitor
Cummins
engine
Alternator ----__-__-_B
Voltage reeulato
+
IE E:
111; -__-
Prelub Pressure switch
oi
sxwo4923
Operation . If the starting switch
is turned to the OFF position, the signal from terminal BR of the starting switch to the CUMMINS electronic governor controller is turned off, and the fuel supply to the engine is stopped to stop the engine. If the engine speed lowers, the alternator does not generate the voltage at its termi-
nals B and L any more, and the signal that the engine is rotating is stopped. The power is not supplied from terminal BR of the starting switch to the battery relay any more, and the contacts of the battery relay are opened to turn off the power supplied to the machine.
lo-248
WA1 200-3
ETHER INJECTION CIRCUIT
ETHER INJECTION
CIRCUIT
Starting
switch
VHMS controller Service meter Main monitor
Cummins
engine
Ether
injection solenoid
Alternator -__-__-__--8
Voltage regulator
Prelub oil Pressure switch
sxwo4924
Operation The ether injection system can operate only while the starting switch is at the START position. If the ether injection switch is turned
l
on while the starting switch is at the START position, a current flows as follows. The current flows from terminal R2 of the starting switch through ether injection switch and ether start relay coil to the ground, and terminals 3 and 5 of the ether start relay are closed. As a result, the circuit from terminal R2 of the starting switch through terminals
3 and 5 of the ether start relay, and ether injection solenoid to the ground is formed, then the ether is injected. If the ether injection switch is turned to the OFF position, the current flowing in the ether start relay coil is broken to stop injection of ether. If the starting switch is not at the START position, the current does not flow from terminal R2 of the starting switch, and ether is not injected accordingly.
WA1 200-3
1 O-249
ELECTRIC PARKING BRAKE CONTROL
Y
SWWO4852
OUTLINE
l
The parking brake is a wet multi-disc brake built in the transmission. If the current flows in the parking brake solenoid valve, the oil pressure from the transmission pump is applied to the parking brake cylinder to release the parking brake. If the current is broken, the oil pressure from the transmission pump is shut off and the pressurized oil in the parking brake is drained through the parking brake valve, then the parking brake is operated with the spring force.
1. 2. 3. 4. 5. 6. 7. 8. 9.
Parking brake switch Emergency parking brake reset switch Parking brake display switch Accumulator Emergency brake switch Parking brake solenoid valve Emergency parking brake reset solenoid valve Neutralizer relay Parking safety relay
1O-250
WA1 200-3
STRUCTURE
AND
FUNCTION
ELECTRIC PARKING
BRAKE CONTROL
FUNCTION 1. Applying and releasing parking brake The parking brake is applied or released using the parking brake switch. 2.
6. by
Automatic parking brake When the engine stops (when the starting switch is OFF), the parking brake is automatically applied to prevent the machine from running away when the operator is away from his seat. Emergency brake If the pressure in the oil pump should drop because of damage to the hydraulic circuit and the braking force can not be ensured, the parking brake is applied automatically to act as an emergency brake. Parking brake safety It is dangerous if the parking brake can be released simply by turning the starting switch ON after the automatic parking brake has been applied. Therefore, to ensure safety, the system is designed so that the brake cannot be released unless the starting switch is turned ON and then the parking brake switch is also turned ON. 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 neutral to make it impossible to drive the machine. However, the braking distance will become longer if the transmission is shifted to neutral when the emergency brake is applied. It may also be necessary to move the machine if it stops in places where it is prohibited to stop (such as on railway crossings). To overcome this, the circuit is designed so that the transmission is not shifted to neutral when the emergency brake is applied.
Parking brake emergency release solenoid valve If the supply of pressure oil from the transmission pump should stop because of some failure, it is possible to actuate the emergency relief solenoid valve with the parking brake emergency release switch in the operators compartment. This sends the accumulator charge pressure in the brake piping to the parking brake cylinder to release the parking brake.
3.
4.
5.
WA1 200-3
10-251
OPERATION 1. Starting switch OFF
Parking OFF -
brake (manual) -
switch (Applied)
ON
Parking brake seftv relay
Neutralizer relay
Start ins switch
To transmission controller Emergency (installed brake switch to accumulator)

sxwo4925
When the starting switch is turned OFF, the battery relay is opened, so electricity does not flow to the parking brake circuit. For this reason, if the starting switch is at the OFF position, no electric current flows to the parking brake solenoid valve, regardless of whether the parking brake switch is ON (applied) or OFF (released), so the parking brake is actuated. (Automatic parking brake)
1o-252
WA1 200-3
STRUCTURE
AND
FUNCTION
ELECTRIC PARKING
BRAKE CONTROL
2. When
starting
switch
is turned
ON ON (operated) before starting switch is turned
2-l.ln case where ON
parking brake switch has been turned
Parking OFF -
brake (manua I) -
switch ON (Applied)
Battery
Battery
Parking seftu
brake relay
Neutralizer relay
Battery
_--!i%~~-~l L---A
Battery
L-_ t -
Starting switch
Emergency (installed
brake switch to accumulator)
SXWO4926
@ Since the current flows from the positive (+I terminal of the battery through the starting switch and battery relay coil to the ground, the battery relay is closed. Then, @ the current flows from the positive (+) terminal of the battery through the battery relay, terminals 1 - 2 of the parking brake switch, and terminals 1 - 2 of the parking safety relay to the ground. As a result, the parking safety relay operates and its terminals 3 and 5 are closed. Then, @the following circuit is formed; Positive (+) terminal of the battery + Battery
relay + Terminals 5 - 3 of the parking safety relay + Terminals 1 - 2 of the parking safety relay + Ground. From this time on, the parking safety relay is kept in the circuit of @ until the starting switch is turned to the OFF position. Under this condition, since the current does not flow in the parking brake solenoid valve, the parking brake is applied. Under this condition, since the terminals 3 and 5 of the neutralizer are opened, the transmission is set in neutral by the transmission controller.
WA1 200-3
lo-253
2-2.ln case where parking brake switch has been turned OFF (released) before starting switch is turned ON
Parking
brake (manua I)
switch
@ Start switch ins
To t.an!mission controller Emergency (installed brake switch to accumulator) sxwo4927
@ Since the current flows from the positive (+I terminal of the battery through the starting switch and battery relay coil to the ground, the battery relay is closed. Since the parking brake switch is turned off (released), however, the parking safety relay does not operate. Accordingly, the current does not flow in the parking brake solenoid
valve. Even if the starting switch is turned to the ON position after the automatic parking brake is operated, the parking brake is not released automatically. Since the current does not flow in the transmission controller, the machine does not move.
1O-254
WA1 200-3
STRUCTURE
AND
FUNCTION
ELECTRIC PARKING
BRAKE CONTROL
3.
When parking brake switch is turned OFF (released) In case where parking brake switch is turned OFF after starting switch is turned ON
Parking
brake (manua I)
switch
Battery
Battery relay
(Applied)
Parking seftu
brake relay
Neutral relay
izer
Battery
Battery y R Alternator terminal L
@ Start
To
!ran!nission
switch
ine
controller Emergency (installed brake switch to accumulator)
SXWO4928
If the parking brake switch is turned OFF (released), its terminals 2 and 3 are connetted to each other. Since the parking brake safety relay is turned on at this time, @ the current flows from positive (+I terminal of the battery through the battery relay and parking brake safety relay to parking brake switch, then it flows as follows.
The circuit of the emergency brake switch through the parking brake solenoid valve to the ground is formed, and the parking brake is released. The signal flows from terminal 3 of the neutralizer to the transmission controller, and the machine can travel.
WA1 200-3
1o-255
STRUCTURE
AND
FUNCTION
ELECTRIC PARKING
BRAKE CONTROL
4.
When
parking
brake switch
is turned
ON (operated)
Parking
brake (manual)
switch
Bat terv
Battery relay
y n
Alternator terminal
@ Start switch ina
To !ran!mission controller Emergency (installed brake switch to accumulator)
SXWO4926
If the parking brake switch is turned ON (operated) after operating the machine with the parking brake switch turned OFF, the above circuit is formed. Since the current does not flow in the parking brake solenoid valve, the pressurized oil supplied to the parking brake cylinder is shut off and the pressurized oil in the parking brake cylinder is drained through the parking brake valve. As a result, the parking brake is operated with the spring force.
Since the neutralizer is reset at this time, the circuit of 3 and 5 is opened and the signal does not flow from terminal 3 of the neutralizer to the transmission controller, then the transmission is set in neutral. In this way, the transmission is set in neutral while the parking brake is operated to prevent the machine from traveling with the parking brake applied to seizure of the parking brake.
1 O-256
WA1 200-3
STRUCTURE
AND FUNCTION
ELECTRIC PARKING
BRAKE CONTROL
5.
When
main brake oil pressure
lowers
(When
emergency
brake operates)
Parking
brake (manua I)
switch
Battery
Neutralizer relay
Battery
Battery
Starting switch
controller Emergency (installed brake switch to accumulator)

sxwo4930
Operation . If the oil pressure in the main brake line lowers, the emergency brake switch installed to the accumulator is opened. Accordingly, the current does not flow in the parking brake solenoid valve and the pressurized oil in the parking brake cylinder is drained and the parking brake operates. In this case, however, the current is still flowing in the neutralizer coil, unlike the case where the parking brake is turned ON (operated).
As a result, the signal flows to the transmission controller and the transmission clutch can be engaged. By this operation, the engine can be used as a brake when the emergency brake is operated. Consequently, the braking distance can be shortened. In addition, when the emergency brake operates but the machine needs to be moved (e.g. when the emergency brake operates while the machine is traveling through a railroad crossing), the machine can be moved by operating the transmission switch.
WA1 200-3
lo-257
6.
Parking brake emergency release
(Re
I eased)
ON
Parking brake emergency release switch_-.-_ l&Z c -7-l 1
Main
monitor
____ --@J+--0
Battery
Battery _--
OFF
I Battery relay_
--
Buzzer
III
B
IOA
BR
8-
Start switch
ins
Parking emergency solenoid
brake release valve sxwo4931
Operation . If the machine should stop because of engine trouble, the oil pressure form the transmission pump to the parking brake cylinder is shut off and the parking brake is applied. When this happens, the oil pressure in the main brake line is stored in the accumulator. When the emergency release switch is turned on (released), the buzzer sounds, and at the same time, electric current flows to the emergency parking brake release solenoid valve.
The oil pressure stored in the accumulator in the main brake line then flows to the parking brake cylinder to release the parking brake. The emergency release switch should normally be kept at the OFF position and should be returned to the OFF position after the emergency release.
lo-258
WA1 200-3
PARKING SAFETY RELAY NEUTRALIZER RELAY
3 6
5
1
2
Relay
connection Terminal
chart No. 1
Relay actuation
table
EMERGENCY BRAKE SWITCH
0
0
0
:a @g--D
SWWO4860
PARKING BRAKE EMERGENCY RELEASE SWITCH

Connection table
OFF
If
3
SEW00319
WA1 200-3
1O-259
PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID
VALVE
SWWO486 I
1. 2.
Solenoid valve assembly Block
Outline . This solenoid valve is turned on and off ac-
B. Outlet port P. Inlet port (From transmission) T. Drain port

l
cording to the ON-OFF operation of the parking brake switch to supply or stop the pressurized oil from the transmission to the parking brake spring cylinder to apply or release the parking brake. When the parking brake solenoid valve is turned on: Parking brake is released. When the parking brake solenoid valve is turned off: Parking brake is applied.
1O-260
WA1 200-3
EMERGENCY PARKING BRAKE RESET SOLENOID VALVE
EMERGENCY
PARKING BRAKE RESET SOLENOID
VALVE
1. Valve assembly 2. Solenoid valve
A. B. C. T. P.
To parking brake From parking brake solenoid valve From transmission Drain From brake (Accumulator circuit)
SWWO4862
Function
l
The emergency parking brake reset solenoid valve is installed between the transmission and brake circuit. When the transmission pump cannot supply oil pressure because of an engine trouble, etc., the solenoid of the parking brake reset switch on the operators seat is turned on to apply the accumulator charge pressure of the brake circuit to the parking brake cylinder.
To Parking brake
From brake
parking solenoid
Operation . If emergency
parking brake reset switch @ is turned ON, solenoid valve @ operates. As a result, the pressurized oil in accumulator @ flows in port P to change the circuit with the pilot pressure, then flows through port A to the parking brake to reset the parking brake.
WA1 200-3
1O-261
KICK-DOWN SWITCH AND AUTO SHIFT/MANUAL SHIFT SELECTOR SWITCH
Kick-down switch
1. 2. 3. 4. 5. Kick-down switch Spring Spring Auto shift/Manual shift selector switch Harness Operation The kick-down switch is installed to the boom lever. While the conditions of the travel mode, gear speed, and travel speed are satisfied, if this switch is turned ON (pressed), the gear is shifted down to the 1st gear speed. In the manual shift mode, the kick-down switch is effective only when the transmission is in the forward 2nd gear position. If it is pressed at this time, the gear is shifted down to the 1st gear speed. In the auto shift mode, if the kick-down switch is pressed when the machine is traveling forward or in reverse at a speed below 13 km/h, the gear is shifted down to the 1st gear speed.
10-262 10-262
(7)
WA1200-3
Resetting (In manual shift mode) When the direction switch is set to the N or R position When the shift-up switch or shift-down switch is pressed (When the shift-down switch is pressed, the gear is kept in the 1st gear speed.) When the starting switch is turned off (In auto shift mode) When the direction switch is set to the N position When F or R of the direction switch is changed to the opposite direction When the shift-up switch or shift-down switch is pressed When the travel speed rises When the starting switch is turned off
Auto shift/Manual shift selector switch

Operation The auto shift/manual shift selector switch is installed to the boom lever. Each time it is pressed, the travel mode (auto shift/manual shift) is changed. In the auto shift mode, the indicator (one of the three) under the main monitor lights up. When the starting switch is turned ON, the travel mode (auto shift/manual shift) saved when the starting switch was turned off last time is selected.
WA1200-3
10-263 10-263
3 (7)
20
TESTING AND ADJUSTING
Standard value table Standard value table for engine ........................................................................................................ Standard value table for chassis .......................................................................................................
Standard value table for electrical parts .......................................................................................... Testing and adjusting ............................................................................................................................ Troubleshooting ......................................................................................................................................
20- 2 20- 3 20- 9 .20-101 20-201
Note the following troubleshooting.
when making judgements using the standard value tables for testing, adjusting, or
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. 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. These standard values are not the standards used in dealing with claims. a g g g When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety pins, and use blocks to prevent the machine from moving. When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine. When checking the water level, always wait for the water to cool down. If the radiator cap is removed when the water is still hot, the water will spurt out and cause burns. Be careful not to get caught in the fan, fan belt or other rotating parts.
WA1 200-3
20-l 0
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Machine model I WA1200-3
Item
1 Measurement conditions /
Low idling
Unit
( f~~~~~r~~$~e
650 + 50
Se~~~~mit
650 f 75 2,050 + 100 130 11,000~ Max. 4.5 * 0.5 Max. 1.0 f 0.5 3.29 I3301
Rotation speed
High idling Rated rotation speed
rpm
2,050 f 50 1,900
Intake air pressure (Boost pressure) Torque converter stall At sharp acceleration Exhaust gas color At high idling Blow-by pressure (15W-40 oil) (Watertemperature in operatingrange) Torque converter stall
kPa
165.6 & 15 11,293 r 1131 Max. 4.5 f 0.5 Max. 1.0 f 0.5 1.25 {I271
ImmHgI
Bosch index
Oil pressure (I 5W-40 oil)
h-
(Watertemperaturein operatingrange) {k;::? )
Oil temperature
All rotation range (In oil pan)
"C
I
I
80 - 110
Min. 120
Tension of fan belt
When new (~1 When re-tensed t-i
Measure belt tension with belt tension gauge.
N {kg1 N (kg)
4,893 1498.951 4,893 1498.951
4,893 1498.951 4,893 (498.95)
Tension of air conditioner compressor belt
Press intermediate point I between drive pulley and air conditioner compressor pulley with force of about 98 N (IO kg}.
I
9 - 12.5 9 - 12.5
mm
%: If new one is installed, be sure to readjust
it after operating
24 hours.
20-2 0
WA1 200-3
STANDARD VALUE TABLE FOR CHASSIS

Machine / model Unit WA1 200-3 Standard value for new machine 13.7 f 2.0 (1.4 * 0.2) Ser$tdmit 13.7 + 2.0 (1.4 * 0.2) 4.9 +: (0 .5+q 0 N{kgI 6.9 + 1.0 (0.7 f 0.11 6.9 f 1.0 IO.7 f 0.11
;;:zrting
wi
l l
Stop engine. Measure at center of lever knob.
HOLD+RAISE
Max. 23.52 (2.41
Max. 35.28 (3.61
RAISE+HOLD
Max. 15.68 Il.61
Max. 23.52 (2.41
E 8 m
HOLD-+LOWER
Max. 24.5 (2.5)

I
Max. 37.24 (3.81
LOWER+HOLD
l
Run engine at low idling. Hydraulic oil temperature: 45 - 55C
N{kgI
Max. 34.3 13.5)
Max. 51.94 (5.31
FLOAT-tHOLD
Max. 14.7 (1.5)
Max. 23.54 (2.31
HOLD+DUMP
Max. 23.52 (2.4)
Max. 35.28 (3.61
Max. 23.52 (2.41
Max. 35.28 I3.6)
Max. 14.7 (I.51
Max. 23.54 (2.31
HOLD-tRAISE
67_+ 15
67 ?I 30
t 8
I
HOLD+LOWER
l
53_+ 15 Run engine at low idling. Hydraulic oil temperature: 45 - 55C
53 + 30
HOLD-FLOAT
mm
672
15
67 ?I 30
z 5 m3
HOLD-DUMP
60+_ 15
60 + 30
HOLD-TILT
60f
15
60 + 30
WA1 200-3
20-3 0
STANDARD
VALUE TABLE FOR CHASSIS
Machine
model
deg. On flat, level, straight, dry, paved road. Run engine at high idling. Left lock position - Right lock position. Start engine. Hydraulic oil temperature: 45 - 55C Left lock position - Right lock position. NIkgl
Max. 8 13.7 f 5.0 (I.4 f 0.51
Max. 10
Operating effort
Wgl
23.5 (2.41
Operating angle
deg.
80 k 8
Max. 90
I
Operating time
l---i
Low idling
l l
High idling
Pressing force
58.8 f 2.45 IS.0 + 0.25)
Max. 88.2 (9.0)
Neutral (a I) Pressing angle Max. (a 2)
*See
l l
Fig. A. Run engine at low idling. Hydraulic oil temperature: 45 - 55C
*See
Pressing angle
Fig. B. Run engine at low idling. Hydraulic oil temperature: 45 - 55C
45
tTq--Tdeg.
Play
2 i=
Fitting condition of wheel lock ring
y--e+-+
l
B c
*See Fig. C. Tire inflation pressure: Specified pressure
mm
Max. 4.0
Clearance of wheel rock ring
2 - 10
-0 8
Torque converter stall speed
z .w
,P
. Coolant: ln operating range Torque converter oil temperal
1,950 k 100
1,950 k 200
rpm Torque converter stall speed + Hydraulic stall speed

l
1,990 * 100
1,990 + 200
Gear shift lever: F4 or R4
1,745 f 200
1,745 _+300
20-4 0
WA1 200-3
Machine
model
Measurement conditions
WA1 200-3
Standard value Servf$imit
Item
I
l
21 + 0.2 {27 C 2.8 2.8 + 0.2 127 + 2) 1.05 + 0.1 (IO.7 * 1.0)
21 f 0.2 (27 + 2.8 2.8 + 0.2 (27 f 2) 1.05 + 0.1 I10.7 + 1.0) 0.88 f 0.1 {9f 11 2.25 + 0.15 (23 f 1.51 2.45 + 0.15 (25 f 1.51 0.1 f 0.05 11.o * 0.5)
Torque converter relief (inlet) pressure Torque converter outlet oil pressure 1st 2nd, 3rd MOD/C, F-R
Torque converter oil temperature: 60 - 80C Run engine at high idling. MPa @cm9
0.89 + 0.1 19+ 11 2.25 i 0.15 I23 f 1.51 2.45 + 0.15 {25 + I.51 0.1 c 0.05 11.o c 0.5)
ECMV output (clutch) oil pressure
Torque converter oil temperature: 60 - 80C Run engine at high idling. Turn ON manual switch. Torque converter oil temperature: 60 - 80C Run engine at high idling.
Lubricating oil (oil cooler outlet) pressure
Steering relief pressure

l
Orbit roll output pressure
Hydraulic oil temperature: 45 - 55C Run engine at high idling. When brake oil 17.6 % {180+,6) MPa :g/cm3 20.6 ;. I210 $5, 20.6 % (210 +o,
Charge cut-in pressure
Charge cut-out pressure
. Run engine at low idling. Hydraulic oil temperature: 45 - 55C

l
+I.47 17.6 o 1180 +;I
When rising oil pressure starts
I
Forward 2nd 3rd Travel speed :m/h
6.3 f 0.3
6.3 + 0.3
11.5 + 0.6
11.5 f 0.6
19.8 + 1.0
19.8 k 1.0
7.4 f 0.4
7.4 * 0.4
WA1 200-3
20-5 0
Machine Item Brake oil pressure
model
I
Unit
WA1200-3 Setvic&tmit
Standard value for new machine
- Hydraulic oil temperature: 45 - 55C

l
Brake oil pressure drop
Stop engine. Continue pressing brake pedal to 4.9 MPa 150 kg/cm3 and measure oil pressure drop after 5 minutes. Tire inflation pressure: Specified pressure On flat, level, straight, dry, paved road. Set initial speed for braking to 20 km/h. Delay in pressing must be 0.1 set max. Pressing force of brake pedal: Specified pressing force 294 +- 29.4 N (30 f 3 kg} Measure braking distance.
Performance
l
Max. 6
Max. 6
Wear of disc
*See Fig. D. Measure wear of disc by measuring piston stroke.
mm
7.0
I Parkina I I
High idling
l
2.65 + 0.2 47 + 21 Torque converter oil temperature: 80 - 80C Run engine at high idling. MPa kdcm3 2.94 It 0.29 130 f 31 2.65 f 0.2 (27 + 2) *See Fig. E. Tire inflation pressure: Specified pressure On flat, paved, dry road having gradient of l/5 (1120). Set machine in operating state.
2.65 + 0.2 (27 rf 2) 2.94 * 0.29 {30 + 31 2.65 f 0.2 07 + 2)
Parking brake pilot pressure ,
Performance
stop
stop
Thickness of disc
l
mm Hydraulic oil temperature: 45 - 55C Run engine at high idling. Hydraulic oil temperature: 45 - 55C Run engine at high idling.
3.2 + 0.1
2.77
PPC pump pressure

l
PPC valve main pressure

l
PPC valve 3utput Jressure
Raising/Floating of boom and dumping/tilting of bucket Lowering of i boom
MPa :Qlcm3
3.72 2 I38,1
3.72 + 0.2 i38+21
Hydraulic oil temperature: 45 - 55C Run engine at high idling. Operate work equipment control lever full stroke.
3.72 T 08: 1
3.72 f 0.2 138 f 2)
2.54 T!Z 0.05 (26 z!z 0.51
2.54 + 0.05 126 + 0.51
20-6 0
WA1 200-3
Machine
model
WA1 ZOO-3
Work equipment relief pressure
Hydraulic oil temperature: 45 - 55C Run engine at high idling.
MPa
Ikg/cm3
I
31.36%: {320+ -3 )
I
3 1.36 %;; f320 -13 ) Max. 14.0

I
12.5 f 0.5
set When tilted through
I }I
5.0 f 0.5
Max. 7.0
I
l
3.7 * 0.3
Max. 5.0
2.3 + 0.3 *See Fig. H. Hydraulic oil temperature: 45 - 55C Stop engine and leave it for 15 min, then measure for I5 min. Empty bucket and set boom and bucket level.
Max. 3.4
C g
Hydraulic drift of bucket hinge pin
Max. 250 mm
Max. 250
!-----I Hydraulic drift of 5 bucket tooth edge s
Max. 100 Max. 100 (Excluding (Excluding hydraulic drift of hydraulic drift of bucket hinge pin) bucket hinge pin)
WA1 200-3
20-7 0
Illustration
of components
related to standard
values table
*Fie.A
face
*Fig.
*Fig.
*Fig.
) f
Fio. F
*Fig.G When fully
*Fig.
I
Horizontal
Work equipment Posture
rim
TWW0243
20-B 0
WA1 200-3
STANDARD VALUE TABLE FOR ELECTRICAL PARTS

Systen n
Name of comioonent
(Zonnector No.
Judgement
table
Measurement conditions I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows.
SW power supply
-1
1 Between C2(1), (12) -(II), (21) 1 Normal ranges are as follows. Between (6) - (17)
20_30
Sensor power supply
20C3A Between (6) - chassis
30 v
1) Turn starting switch OFF. 2) Inset-t Tadapter. 3) Ts;cpo;ng 4) Turn parking brake switch OFF.
Normal ranges are as follows. S-NET 1 Between (4). (12) - chassis
1 4- 8V
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows. C3B Manual shift switch
Normal ranges are as follows. Transmission cut-off switch C3A Normal ranges are as follows. Kickdown switch
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. II Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows. Joystick FNR button switch F C3B Normal ranges are as follows. Joystick FNR button switch N
WA1 200-3
20-9
Syste:m
Name of comDonent
Connect0 No.
Judgement
table
Measurement conditions 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) T~;c~ort$g
Normal ranges are as follows. Joystick gear shift switch R C3B

L
I I
Normal ranges are as follows. Neutralizer relay signal C3A
Normal ranges are as follows. Joystick shift-up switch (N.0 c5 Joystick shift-down switch (N.0
Normal ranges are as follows. Joystick shift-up switch (N.CI c5 Normal ranges are as follows. Joystick shift-down switch (N.C) When joystick shiftup switch is ON When joystick shiftup switch is OFF Between ,.i.$& 17 -30 v Max. 1 V
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Ts;c,staOrt$g
Normal ranges are as follows. Steering lock signal C3B
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Normal ranges are as follows. Transmission oil temperature C3A
20-10
0
WA1 200-3
Syste!m
Name of comeonent Engine rotation sensor
Connectc No.
iOll
Od
Judgement Measure in AC range.
table
Measurement conditions 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine 1) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON.
:, j
1 Between (1) - (9)
Min. 0.5 V
Backup lam relay signal
~~
Normal ranges are as follows. Sl
Buzzer signal ON
>
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.

I
1 signal XJtput
II Turn starting switch OFF. 2) Insert Tadapter. 3) Turn manual shift switch ON. 4) Start engine 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Set directional lever in F or FL j) Turn manual shift switch OFF. I) Turn starting switch OFF. !I Insert Tadapter. I) Turn starting switch ON. 1) Set directional lever in F or R. i) Turn manual shift switch OFF.
Jut0 range 1st LED rignal
I t If shift-down switch is kept pressed, gear is shifted down to 1st.
kit0 range
!nd LED #ignal
* Do not operate shift-up switch or shiftdown switch when default mode is in 2nd (Leave as set when engine was started). Normal ranges are as follows.
) Turn starting
switch OFF. !I glsepsee;-
Uto range :rd LED ignal Ir If shift-up switch is kept pressed, gear is shifted up to 3rd.
I) Turn st&ing switch ON. ,I Set directional lever in F or R. 1)Turn manual shift switch OFF.
WA 1200-3
20-11 0
Syste
Name of component
r Connect0 No.
Judgement
table
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Manual shift switch
L15 (Male)
Normal ranges are as follows. 1 When FORWARD F: T14 (Male) I measuring point
R: Tl2 (Male) ECMV fill switch
~~
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 4) Start engine. 5) Turn transmission cut-off switch OFF. 6) Turn parking brake switch OFF. 7) Press brake pedal to prevent machine from moving. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. %)Start engine. 5) Set directional lever in N. 6) Turn manual shift switch ON.
1st: T4 (Male) 2nd: T6 (Male) 3rd: T8 (Male)
~~
* When default after starting of engine is 2nd, if shift-down switch is kept pressed, gear is shifted down to lst, and if shift-up switch is kept pressed, gear is shifted up to 3rd. Normal ranges are as follows.
Transmission cut-off switch
L12 (Male)
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
f
Kickdown switch L15 (Male)
Normal ranges are as follows. Transmission oil temperature sensor T19 (Male)
Normal ranges are as follows. Speedometer sensor T15 (Male) 1 Between (1) - (2) 1 Between (11, (2) -chassis I500-1,OOOR 1
1 Min. 1 MR
20-12 0
WA1 200-3
System
Name of component Speedometer sensor
Connectc No.
Judgement
table
1) Screw in speed sensor until it touches ring gear, then return it by l/2 - 1 turn. 2) Speed sensor must operate normally after above adjustment. Normal ranges are as follows. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Engine rotation sensor
T17 (Male)
Between (1) - (2) Between (1). (2) - chassis
500 - 1,000 R Min. 1 MR
1) Screw in engine rotation sensor until it touches ring gear, then return it by l/2 1 turn. 2) Engine rotation sensor must operate normally after above adjustment. Normal ranges are as follows. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Modulated clutch outlet rotation sensor
T16 (Male)
Between (1) - (2) Between (11, (2) - chassis
500 - 1,000 R Min. 1 MR
1) Screw in modulated clutch outlet rotation sensor until it touches ring gear, then return it by 314 - 1 turn. 2) Modulated clutch outlet rotation sensor must operate normally after above adiustment. Normal ranges are as follows.
Parking brake switch
LO1
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. I) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Normal ranges are as follows. F bypass solenoid T22 (Male) 1 Between (1) - (2) Between (1). (2) - chassis Normal ranges are as follows. R bypass solenoid T21 (Male) Between (1) - (2) Between (11, (2) - chassis Normal ranges are as follows. R drain solenoid T23 (Male) 5-15n Min. 1 MR
5-15R Min. 1 MR
1 Between (1) - (2)
5-15R
Min. 1 MB
I 1
1 Between (11, (2) - chassis I Normal ranges are as follows.
1st bypass solenoid
T20 (Male)
Between (1) - (2) Between (11, (2) - chassis
5-15R Min. 1 MQ
WA1 200-3
20-13 0
Syste
Name of comoonent
Zonnectc No.
Judgement
table
Measurement conditions 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. I) Turn starting switch OFF. 21 Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) ~;;anp~ T1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. U Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. !) Insert Tadapter_ 3) Start engine
Normal ranges are as follows. FFFMV solenoid T13 (Male) Between (1) - 12) Between (I), (2) - chassis Normal ranges are as follows. ECMV solenoid (R) Tll (Male) Between (1) - (2) Between (l), (2) - chassis Normal ranges are as follows. ECMV solenoid (1st) Between (I) - (2) Between (11, (2) - chassis Normal ranges are as follows. ECMV solenoid (2nd) Between (1) - (2) (Mze) Between (l), (2) - chassis Normal ranges are as follows. ECMV solenoid (3rd) Between (1) - (2) (M;e) Between (l), (2) - chassis Normal ranges are as follows. SW power supply Between (8) - chassis Between (18) - chassis Normal ranges are as follows. Solenoid power supply MO1 Between (17) - chassis 20 - 30 v 20 - 30 v 5-15R Min. 1 MR 5-I5R Min. 1 MQ 5-15R Min. 1 MR 5-15R Min. 1 MR 5-15n Min. 1 MfZ
Normal ranges are as follows. S-NET Between (11, (12) - chassis 4-8V
sure switch
(Raise boom)
PPC pres-
M02A
Operate lever just a little (to degree that work equipment does not move) (for only detection PPC pressure signal).
20-14 0
WA1 200-3
TESTING
AND
ADJUSTING
STANDARD
VALUE
TABLE FOR ELECTRICAL
PARTS
Systern
Name of comDonent
-I-
(Ionnectoi No.
Judgement
table
Measurement conditions 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine

I Work equipment
PPC pressure switch &:)r * Operate lever just a little (to degree that work equipment does not move) (for only detection PPC pressure signal). Normal ranges are as follows.
PPC pressure switch (Tilt bucket) * Operate lever just a little (to degree that work equipment does not move) (for only detection PPC pressure signal). Normal ranges are as follows.
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
PPC pressure switch [Dump bucket) M02A
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine
+ Operate lever just a little (to degree that work equipment does not move) (for only detection PPC pressure signal). Normal ranges are as follows. I) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON.
I) Turn starting
Right brake pedal signal
11
??a
-1 signal input H
24 :%
switch OFF. !I Insert Tadapter. s) Turn manual shift switch ON. C) Start engine Normal ranges are as follows. I) Turn starting switch OFF. !) Insert Tadapter. 1) Turn starting switch ON. 1 Turn starting switch OFF. t) Insert Tadapter. 1) Turn starting switch ON.
Transmission cut-off switch signal
Normal ranges are as follows. RPM set DLE-UP signal
WA1 200-3
20-15 0
TESTING
AND ADJUSTING
STANDARD
VALUE
PAFfTS
Systern
I-
Name of lmponent
Connector No.
Xl
Judgement
table
Measurement conditions 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows. RPM set IDLE-DOWN signal
Normal ranges are as follows. Low idling (Li) switch signal When accelerator
M02A Normal ranges are as follows. Between M02A(lO) - M02A(9) 14.75 - 5.25 V Between M02Al19) - M02A(9) 1 0.5 - 4.75 V 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Between M02A(19) - M02A(9) Accelerator pedal signal * Above table shows standard value of potentiometer voltage at which controller can recognize dial range normally. When potentiometer is readjusted, set margin of error judging area. y3100w,i$$rg, set voltage in range from (Error jddging area is potentiometer voltage < 0.5 V or potentiometer voltage > 4.5 V.) Normal ranges are as follows. Between M02AUO) - M02A(9) 14.75 - 5.25 ~1 Between M02BU) - M02A(9) Between M02BH) - M02A(9) IMAXI Drive force control dial Between M02BU) - M02A(9) (MINI 0.5 - 4.75 v 0.5 - 1.6 V 3.5 - 4.75 v 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
M02A M02B
rlr When potentiometer is readjusted, set margin of error judging area. At MIN, set voltage in range from 1.3 to 1.6 V. (Error judging area is potentiometer voltage c 0.3 V or potentiometer voltage > 4.7 V.)
20-16 0
WA1 200-3
TESTING
AND
ADJUSllNG
STANDARD
VALUE
PARTS
Syste m
Name of comoonent
Connector No.
Judgement
table
Measurement conditions 1) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows. Between M02A(lO) - M02A(9) Between M02BHO) - M02A(9)
Travel speed control dial
M02A M02B
Between M02B(lO) - M02A(9) (MINI
3.5 - 4.75 v
f When potentiometer is readjusted, set margin of error judging area. At MIN, set voltage in range from 1.3 to 1.6 V. (Error judging area is potentiometer voltage c 0.3 V or potentiometer voltage > 4.7 V.)
Normal ranges are as follows. RPM set ON/OFF switch signal
1) Turn starting switch OFF. 2) Insert Tadapter. 31 Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Measure in AC range. Engine .otation iensor M02B Between (5) - (12) Min. 0.5 V
Measure in AC range. Engine -0tation signal .output) Between (14) - chassis Min. 0.5 V
leutral-cut NC) solenoid
~~
I) Turn starting switch OFF. !) Insert Tadapter. $1 Start engine. 1) Travel in F3 at 10 km/h or higher.
MO1
Operate lever just a little (to degree that work equipment does not move) (for only detection PPC pressure signal).
Normal ranges are as follows. Electronic governor voltage :ommand signal
WA1 200-3
20-17 0
Name of comoonent
RPM set ON/OFF switch indicator MO1 Normal ranges are as follows. Travel speed switch indicator 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine. Conner% No. ion od
Judgement table
1) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON.
:,
3 5 .
Normal ranges are as follows. Travel speed set switch signal M02A When travel speed set switch is ON When travel speed set switch is OFF Between (26) - (8) Max. 1 V Min 2 6 v
. .
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 4) Start engine. 5) Turn transmission cut-off switch OFF. 6) Turn parking brake switch OFF. 7) Press brake.
Normal ranges are as follows. 1 When FORWARD F: T14 (Male)
Normal ranges are as follows. 1 When REVERSE R: T12 (Male)
ECMV fill switch
1When set to measur- 1

1st: T4 (Male) 2nd: T6 (Male) 3rd: T8 (Male)
* When default after starting of engine is 2nd. if shift-down switch is kept pressed, gear is shifted down to lst, and if shift-up switch is kept pressed, gear is shifted up to 3rd. Normal ranges are as follows.
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 4) Start engine. 5) Set directional lever in N. 5) Turn manual shift switch ON.
M%C (Male)
~~
I) Turn starting switch OFF. !I Disconnect connector. $1 Connect Tadapter.
20-l 8 0
WA1 200-3
Syster n
Name of component
Wheel rotation sensor (on left side of front wheels)
Connect0 No.
Judgement table
I) Screw in wheel rotation sensor (on left side of front wheels) until it touches flange, and measure clearance between rotation sensor flange and housing. 2) Adjust clearance to +{0.6 + 0.11 mm with shims. Normal ranges are as follows.
IF151
T16 (Male)
Between (I) - (2) Between (11, (2) - chassis
500 - 1,000 R Min. 1 MR
I) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
1) Screw in modulated clutch outlet rotation sensor until it touches ring gear, then return it by l/2 - 1 turn. 2) Modulated clutch outlet rotation sensor must operate normally after above adjustment. Normal ranges are as follows.
T17 (Male)
Between (I) - (2) Between (I 1, (2) - chassis
500 - 1,000 R Min. 1 MQ
I) Screw in engine rotation sensor until it touches ring gear, then return it by l/2 1 turn. 2) Engine rotation sensor must operate normally after above adjustment. Normal ranges are as follows.
Speedometer sensor
T15 (Male)
Between (1) - (2) Between (I), (2) - chassis
500 - 1,000 R Min. 1 ML2
Speedometer sensor
I) Screw in speed sensor until it touches ring gear, then return it by II2 - 1 turn. 2) Speed sensor must operate normally after above adjustment. Normal ranges are as follows. Between (1) - (2) Between (I), (2) - chassis 5-15R Min. 1 MQ 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
WA1 200-3
20-19 0
Syste m
Name of )mponent
-T
Connector NO.
m d
Judgement
table
Measurement conditions 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
I
Normal ranges are as follows. SW power supply Between (8) - chassis Between (18) - chassis 20 - 30 v
Normal ranges are as follows. Solenoid power supply L26 Between (17) - chassis
I 20 - 30 v I
Normal ranges are as follows. S-NET Between (11, (12) - chassis 4-8V
Normal ranges are as follows. Workequipment PPC pressure switch (Raise boom)
* Operate lever just a little (to degree that work equipment does not move) (for only detection PPC pressure signal). Normal ranges are as follows. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
I
PPC pressure switch !CZ%r L27

I
* Operate lever just a little (to degree that -work equipment does not move) (for only detection PPC pressure signal). Normal ranges are as follows. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Remote positioner function switch
)I
Normal ranges are as follows. Steering rock pressure switch Normal ranges are as follows. Steering potentiomete calibration reset switch
20-20 0
WA1 200-3
m System
Name of mponent
(Zonnector No.
Judgement
table
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Normal ranges are as follows. Boom angle sensor L27 Normal ranges are as follows. Steering lever angle sensor When boom angle is UPPER. When boom angle is LOWER. 4.33 ?:0.33 V Between (19) - (9) o 66 + o 33 V
Normal ranges are as follows. Frame angle sensor L28 L27
Normal ranges are as follows. Joystick lever neutral interlock relay
~~
* L26
Set machine in straight travel position. 1) Turn starting switch OFF. 2) insert Tadapter. 3) Start engine.
1 When boom
Boom raising kick-out solenoid relay
used * Use remote positioner function.

Normal ranges are as follows. When joystick caution buzzer relay is output When joystick caution buzzer relay is not output 17 - 30 v 1) Turn starting switch OFF. 2) Insert Tadapter. 3) T~;cyort$g
Joystick caution buzzer relay
L28
Between (15) chassis
Max. 1 V
+ Signals are output to joystick caution buzzer relay when machine is set in straight travel position and joystick steering lever is set in position other than neutral. Normal ranges are as follows. When boom positioner function is turned on When boom positioner function is not turned on * Min. 5 V Between (3) - (14) Max. 1 V 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Boom dumping solenoid (1)
L26
Lower boom lever fully by lowering operation of remote positioner.
WA1 200-3
20-21
0
STANDARD
VALUE TABLE FOR ELECTRICAL PARTS
Syster
Name of bmponent
Connect01 No.
Judgement
table
Measurement conditions 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Normal ranges are as follows. Boom dumping solenoid (21 When boom positioner function is turned on Between (5) - (15) When boom positioner function is not turned on t * Min. 5 V Max.
I
L26
L
1 V
Lower boom lever fully and hold it by lowering operation of remote positioner.
Joystick main pressure contra EPC
CGC monitor screen
Normal ranges are as follows. When joystick lever switch is 466k ,00 mA in neutral Normal ranges are as follows.
1) Turn starting switch ON.
Boom angle sensor
F04 Normal ranges are as follows. Between (1) - (2) Between (3) - (2) Normal ranges are as follows. o-5kQ 4-5kQ 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
Steering lever angle sensor
JS2 Normal ranges are as follows. 1 Between (1) - (2) Between (3) - (2) Normal ranges are as follows. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
o-5ks2
4-5kQ
Frame angle sensor
L30 Normal ranges are as follows.
1 Between (1) - (2)

Between (3) - (2)
o-5kQ
1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Normal ranges are as follows. Speedometer sensor T15 (Male)
1 Between (1) - (2)
I 500 - 1,000 kQ (
1 Between (11, (2) - chassis 1 Min. 1 MR
Speedometer sensor
1) Screw in speed sensor until it touches ring gear, then return it by l/2 - 1 turn. 2) Speed sensor must operate normally after above adjustment.
20-22 0
WA1 200-3
TESTING
AND ADJUSTING
STANDARD
VALUE
PARTS
Systen
Name of comDonent Boom lever kick-out solenoid
Eonnector No.
n&hod
Judgement
table
Measurement conditions 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. :3) Turn starting switch ON.
Normal ranges are as follows. L16 Between (1) - (2) 19-23R
Normal Boom dumping solenoid (I 1 HR8
ranges are as follows. (I) - (2) 15-25R
Between
Normal Boom dumping solenoid (2) HR9
ranges are as follows. (1) - (2) 15-250
Between
Normal NSW power supply Between Between Normal SW power supply Between Between Normal Sensor power supply
VI
ranges are as follows. (6) - chassis (7) - chassis ranges are as follows. (8) - chassis (9) - chassis ranges are as follows. 22 - 25 V 20 - 30 v 20 - 30 v
Between (2) - chassis
Normal Sensor power =$PlY
ranges are as follows. (3) - chassis 1113v
Between
Normal Sensor power &PPIY Between Between Normal S-NET V3A
ranges are as follows. (4) - chassis (5) - chassis 4-6V
ranges are as follows. 4-8V
Between (8), (18) - chassis
Normal Boom bottom pressure sensor

VI
ranges are as follows. (1) - (12) 0.7 - 5.3 v
Between
(Reference) When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. (IO) - (12) 0.7 - 5.3 v 0.5 - 1.5 V
Boom head pressure sensor
Between
(Reference) When open to atmosphere:
WA1 200-3
20-23 0
Systern
l-
Name of comcronent Flashing synchronizing signal (For main monitor)
IZonnector No. Normal
Judgement
table
Measurement conditions I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 4) Satisfv condition for turning on check lamp. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 4) Satisfy condition for turning on buzzer. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter.
ranges are as follows. Between (13) chassis Max. 1 V 20 - 30 v
Whenflashingsynchronizingsignalis ON Whenflashingsynchronizingsignalis OFF Normal
ranges are as follows.
Check lamp (For main monitor)
Vl
Ir Disconnect connector of battery fluid level sensor to output low fluid level alarm. Normal ranges are as follows. Between (16) chassis Max. 1 V 20 - 30 v
Buzzer output *
When buzzer is turned on When buzzer is stopped
Disconnect connectors of coolant level sensor, brake fluid level sensor, etc. to output low fluid level alarm. ranges are as follows.
Normal PPC relief pressure
1 Between (1) - (12)
0.7 - 5.3 v 0.5 - 1.5 V
Ir When open to atmosphere: Normal ranges are as follows.
Alternator terminal R voltage Ir If battery is deteriorated or in cold district, voltage may not rise for a while after engine is started. Normal Torque converter outlet oil pressure 1 Between V2A Ir When open to atmosphere: Normal Transmission main relief pressure ranges are as follows. 0.5 - 1.5 V ranges are as follows. (5) - (3)
1 0.7 - 5.3 v
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. WA1 200-3
1 Between (6) - (3)
0.7 - 5.3 v 0.5 - 1.5 V
1: When open to atmosphere: Normal ranges are as follows. (7) - (3)
Brake pressure (F)
Between
0.7 - 5.3 v 0.5 - 1.5 V
Ir When open to atmosphere: Normal Brake pressure (R) ranges are as follows. (8) - (3)
Between
0.7 - 5.3 v 0.5 - 1.5 V
* When open to atmosphere:
20-24 0
Syster n
Name of
lmponent
(lonnector
No.
Judgement
table
Measurement conditions 1) Turn starting switch OFF. 2) Disconnect connector. 3. Insert Tadapter. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows. Hydraulic oi temperature 1ooc 25C Normal ranges are as follows. Transmissior lubricating oil pressure sensor 1 Between (14) - (12)
0.2 - 4.8 v
Ir When open to atmosphere: 0.2 - 0.8 V Normal ranges are as follows.
Transmissior modulating oil pressure sensor
V2A
1 Between (15) - (12)
1 0.7 - 5.3 v
F;;;;ing
pressure sensor Between (16) - (12) 0.7 - 5.3 v Ir When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. Between (18) - (12) 0.7 - 5.3 v
Work equipment relief pressure sensor
* When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows.
Battery fluid level (1)
Between (1) - chassis
5.5 - 6.5 V
Normal ranges are as follows. Battery fluid level (2) V2B Normal ranges are as follows. Battery fluid level (3) Between (3) - chassis 5.5 - 6.5 V Between (2) - chassis 5.5 - 6.5 V
Torque converter inlet oil pressure sensor
Normal ranges are as follows. Between (IO) - (9) 0.7 - 5.3 v
Brake fluid level (RI
V3A
WA1 200-3
20-25 0
TESTING
AND ADJUSTING
STANDARD
VALUE
PARTS
n Systen
Name
of
co mponent
Tc
lonnector No.
Kp.40
nethoc
Judgement
table
Measurement conditions 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Coolant
u Ir When coolant level is low, sensor is OPENED. Normal ranges are as follows.
Transmission oil filterr differential pressure Klogging)
V3A
* When filter is clogged, sensor is OPENED. Normal ranges are as follows. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON.
Boom positioner proximity switch (For :oad meter)
Bemeeni Max.lV 1
17 - 30 V
receives rated load (16) - (17) Normal ranges are as follows.
Just ndicator I li When air cleaner is clogged, dust indicator 1 is CLOSED and dust indicator relay 1 is OPENED. Normal ranges are as follows.
Dust indicator 2 t When air cleaner is clogged, dust indicator 2 is CLOSED and dust indicator relay 2 is OPENED.
I) Turn starting switch OFF. 2) Insert Tadapter. 3) Start engine.
V3B
Dust indicator 3 t When air cleaner is clogged, dust indicator 3 is CLOSED and dust indicator relay 3 is OPENED
3ust
ndicator 4 * When air cleaner is clogged, dust indicator 4 is CLOSED and dust indicator relay 4 is OPENED.
L
20-26 0
WA1 200-3
Systen
Name of component
:onnectoi No.
Judgement
table
Measurement conditions 11 Turn starting switch OFF. 21 InsertTadapter. 3) Start engine.
Normal ranges are as follows. V3B When brake fluid level is normal When brake fluid level is low Between (5) chassis Max. 1 V I7 - 30 V
Normal ranges are as follows. Boom bottom pressure sensor FO6 Between (3) - 111 0.7 - 5.3 V
Ir When open to atmosphere: 0.5 - I.5 V Normal ranges are as follows. Boom head pressure sensor F14 Between (3) - (I) 0.7 - 5.3 v ~
1) Turn starting switch OFF. 21 Insert Tadapter. 3) $;c~ort$g 11 Turn starting switch OFF. 2) Insert Tadapter. 31 Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 31 T$;cFort$g 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 21 Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
* When open to atmosphere: 0.5 - 1.5 V

Normal ranges are as follows. PPC relief pressure sensor HS4
1 Between (3) - (1)
I 0.7 - 5.3 v ~
f When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. Transmission main relief pressure sensor MT2 Between (3) - (1) 0.7 - 5.3 v
* When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. MT3 1 Between (3) - (1) 1 0.7 - 5.3 v /
Torque converter outlet oil pressure sensor
* When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. MT4
Torque converter inlet oil pressure sensor
1 Between (3) - (1)
I 0.7 - 5.3 v I
t When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows.
Transmission lubricating oil pressure sensor
MT1
1 Between (3) - (1)
10.2 - 4.8 V 1
t When open to atmosphere: 0.2 - 0.8 V Normal ranges are as follows. Transmission modulating oil oressure sensor MT5 Between (3) - (1) 0.7 - 5.3 v
f When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. Steering oil lressure sensor HS3 ) Between (3) - (I)
I 0.7 - 5.3 v I
* When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. Nork equipment .elief pressure sensor HS2 1 Between (3l(1)
I 0.7 - 5.3 v I
f When open to atmosphere: 0.5 - 1.5 V
WA1 200-3
20-27 0
Syster
Name of component
Connector No.
Judgement
table
Measurement conditions 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Insert Tadaoter. 3) Turn starting switch ON. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) CZ;;;;e;t T1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadauter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Set fuel level sensor as shown at left. 4) Connect TadaDter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Cb;gt T1) Turn starting switch OFF. 2) Disconnect connector. 3) Cbmgrt T1) Turn starting switch OFF. 2) Disconnect connector. 3) Insert Tadapter. WA1 200-3
Normal ranges are as follows. Brake fluid level (R) HR6
Normal ranges are as follows. Brake fluid level (F) HRlO
Normal ranges are as follows. Brake pressure sensor (F) HR15 Between (3) - (1) 0.7 - 5.3 v
f- When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. Brake pressure sensor (RI HR16 Between (3) - (1) 0.7 - 5.3 v
t When open to atmosphere: 0.5 - 1.5 V Normal ranges are as follows. Atmospheric temperature sensor PHI
Normal ranges are as follows. Hydraulic oil temperature sensor HSl 100C 25C Between (1 - 12) Approx. 3.5 - 4 kQ Approx. 37 - 50 kQ
Torque converter oil temperature sensor
Normal ranges are as follows. T24 Normal (25C) 130C Between (1) - (2) Approx.40 kQ Approx.1.7 161
Normal ranges are as follows. FULL (100%) Fuel level sensor R05 l/2 (50%) l/4 (25%) EMPTY (0%) Normal ranges are as follows, Battery fluid level (1) RA7 Between RA7 chassis ground 5.6 - 6.5 V Between (1 - (2) Approx.10R Approx. 32 R Approx.49.5R Approx.85 R
Normal ranges are as follows. Battery fluid level (2) RAB Between RA8 chassis ground 5.6 - 6.5 V
Normal ranges are as follows. Battery fluid level (3)
I
RA9
I
Between RA9 chassis ground

I
5.6 - 6.5 V
1
STANDARD
VALUE TABLE FOR ELECTRICAL PARTS
Syster
Name of component
Zonnectoi No. &ha
Judgement
table
Measurement conditions 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. 11 Turn starting switch OFF. 2) Insert Tadapter.
Normal ranges are as follows. Power supply
Normal ranges are as follows. LO5 Charge (Alternator) * If battery is deteriorated or in cold district, voltage may not rise for a while after engine is started.
Normal ranges are as follows. Starting switch terminal C LO9 (Male)
1) Turn starting switch OFF. 2) Connect Tadapter.
2w
PRE-LUBE LO5
i:
2P WZ
1) Turn starting switch OFF. 2) Insert Tadapter.
Normal ranges are as follows. Starting switch terminal BR LO7
1) Turn starting switch OFF. 2) Insert Tadapter.

,
Normal ranges are as follows. Parking brake indicator switch T18 (Male)
1) Turn starting switch OFF. 2) Disconnect connector. 3) CXI;~~ T-
Normal ranges are as follows. FNR switch (N) LO5
1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. !I Insert Tadapter. 3) Turn starting switch ON. I) Turn starting switch OFF. 3) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows. FNR switch (F) When FNR switch is in F When FNR switch is not in F LO8 Normal ranges are as follows. FNR switch (R) Between (7) chassis 20 - 80 V Max. 1 V
WA1 200-3
20-29 0
STANDARD VALUE TABLE FOR ELECTRICAL PAFiTS
Systen
Name of comoonent
Connect01 No.
Judgement
table
Measurement conditions 7) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. 1) Turn starting switch OFF. 2) Insert Tadapter. 3) Turn starting switch ON.
Normal ranges are as follows. Parking brake solenoid HR14 Between (I) - (2) Between (I), (2) - chassis Normal ranges are as follows. Parking brake emergency reset solenoid HRl9 Between (2) - (I 1 Between (1). (2) - chassis Normal ranges are as follows. Parking brake emergency reset switch 20 - 60 R Min. 1 MR IO-40R Min. 1 MR
. L89
~1
Normal ranges are as follows. Bucket positioner solenoid L17 Between (I) - (2) Between (I), (2) - chassis 19-23R Min. 1 MD
I) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter. I) Turn starting switch OFF. 2) Disconnect connector. 3) Connect Tadapter.
Normal ranges are as follows. When accumulator pressure is 3.92 f 0.49 MPa {40 f 5 kg/cm3 or higher ,,,&~~dk;opeda lower accumulator pressure to below 3.63 + 0.49 MPa (37 k 5 kg/cm% HT;y8:;[Min 1 MR
Max. 1 R
Emergency brake switch
HR17, HR18 (Male)
20-30 0
WA1 200-3

ITEMS TO BE PREPARED List of devices for troubleshooting ................... 20-102 ITEMS RELATED TO ENGINE Measuring engine speed .................................... 20-103 Measuring exhaust gas color ............................ 20-106 Measuring blow-by pressure ............................. 20-107 Measuring engine oil pressure ......................... 20-108 Measuring exhaust temperature ....................... 20-109 Measuring boost pressure ................................. 20-110 Testing and adjusting fan belt tension ............ 20-111 Testing and adjusting belt tension of air conditioner compressor ........................... 20-111 Adjusting rotation sensor .................................. 20-112 POWER TRAIN Testing and adjusting torque converter and transmission oil pressure ...................... 20-114 Flushing procedure for hydraulic circuit of torque converter and transmission .............. 20-117 How to move machine when transmission valve is broken ............................................... 20-118 STEERING SYSTEM Testing and adjusting steering oil pressure .... 20-120 Testing and adjusting emergency steering oil pressure ...................................... 20-121 Bleeding air from steering circuit ..................... 20-123 Adjusting steering stopper bolt ........................ 20-124 BRAKE SYSTEM Testing drop of wheel brake oil pressure ........ 20-125 Testing wheel brake function ............................ 20-126 Measuring wear of wheel brake disc ............... 20-127 Testing and adjusting charge cut-in and cut-out pressure of accumulator .................. 20-128 Testing parking brake performance .................. 20-129 Testing wear of parking brake disc .................. 20-130 How to reset parking brake manually .............. 20-131 Measuring parking brake oil pressure .............. 20-132 HYDRAULIC EQUIPMENT Testing and adjusting work equipment oil pressure ..................................................... 20-133 Testing and adjusting PPC oil pressure ........... 20-135 Adjusting PPC valve linkage .............................. 20-136 Bleeding air from each part ............................... 20-137 Releasing residual pressure from hydraulic circuit .............................................. 20-140 WORK EQUIPMENT SYSTEM Adjusting work equipment lever linkage ......... 20-141 ELECTRICAL SYSTEM Testing and adjusting bucket proximity switch ............................................. 20-143 Testing and adjusting boom potentiometer .... 20-144 Adjusting boom horizontal detection switch .......................................... 20-144-1 Procedure for setting initial value for remote boom positioner (Method of inputting base point) .................................. 20-144-2 Checking proximity switch actuation pilot lamp ............................................................. 20-145 Initial learning method of transmission controller ......................................................... 20-146 Adjusting main monitor (Speedometer module) .................................. 20-147 Adjusting steering lever angle and frame angle sensors ...................................... 20-148 Procedure for checking diode ........................... 20-149 Method of adjusting auto-grease injector discharge amount .......................................... 20-150 Method of setting auto-grease timer ................ 20-151 VHMS CONTROLLER Basic precautions ................................................ 20-153 Setting up VHMS controller .............................. 20-156 Collecting and transmitting VHMS controller data ................................................ 20-158 Testing and maintaining VHMS controller ...... 20-163 Setup procedure for VHMS controller .............. 20-164 Operating procedure for quick PM clinic ......... 20-174 Setting procedure for replaced VHMS controller ............................................. 20-178 Operating procedure for quick PM clinic ......... 20-188 Outline of measurement procedure for PM clinic .......................................................... 20-192 Preparation for measurement for PM clinic .... 20-193 Measurement procedure by CGC monitor ....... 20-194 Measurement procedure by downloading data in VHMS controller ................................ 20-196 Operating procedure for quick PM clinic ......... 20-198 PM clinic check sheet ...................................... 20-199-1 Method of displaying remedy codes and error codes ........................................... 20-199-4 Error codes table ............................................ 20-199-11
WA1200-3
20-101 20-101
1 (8)
TESTING
AND
ADJUSTING
ITEMS
TO BE PREPARED
ITEMS TO BE PREPARED
LIST OF DEVICES FOR TROUBLESHOOTING
inspection/Adjustment item
Symbol
B
Part
No.
Digital
Part
Name set -99.9
Remarks - 1,299C
Coolant/Oil/Exhaust temperature
799-101-1502 799-101-5002 1
thermometer tester
Hydraulic
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa {25,60, 400, 600 kg/cm21 tester Pressure gauge: 68.6 MPa 1700kg/cm21 1.0 MPa {lo kg/cm21
Oil pressure
C 2 1
790-261-I
203
Digital
hydraulic gauge
799-401-2320 799-201-9000 Purchase Purchase 793-520-1805
Hydraulic Handy Smoke Angle
smoke meter gauge kit
checker
Exhaust Pedal Brake
gas color pressing angle
G H I
Pollution degree: 0 - 70%(Withstandard color) (Pollution degree x l/10 4 Bosch index)
Brake test Nipple
0 - 294.2 N IO - 30 kg} N IO - 50 kg1
oil pressure
793-520-1851
1 Operating effort drift speed J 2 K L
79A-264-0020 Push-Pull 79A-264-0090 Purchase Purchase Rule Stopwatch scale
0 - 490.3
Stroke/Hydraulic Work equipment
Measurement of wear of brake disc
1
l
Purchase
1Slide calipers
Fixed Cover Spacer
I
I
assembly
Note: This kit is for dump trucks, so the following parts are included, but they are not used on the WA1200-3. 792-415-1130 (Soacer. with 3rd. H stamp) 792-415-1140 . (Spacer, with 4th, L stamp) -
792-415-1200 792-415-l 110
valve
1 Movement transmission of machine valve with broken N
792-415-1120 175-15-15540 238-15-12930 792-415-1150 792-415-1160
Valve Spring Wrench Adapter Tester T-adapter assembly
2
l
Measurement of voltage/resistance
0 1
79A-264-0211 799-60 I-7400 799-601-7500

l
AMP070connectoradapterassembly For AMP07010 For AMP07012 Adapter For AMP07014 For AMP07018 For AMP07020 DTSeriesconnectoradapterassembly For DT Series For DT Series For DT Series Adapter For DT Series For DT Series For DTM Series P-pin 3-pin 4-pin 5-pin B-pin 2-pin
799-601-7510
. 799-601-7520 2
l
799-601-7530 799-601-7540 799-601-7550
Check of sensors/harnesses
P 799-601-7600
l
799-601-7610 799-601-7620 799-601-7630 799-601-7640 799-60 I-7650 799-601-7660
20- 102 0
WA1 200-3
ITEMS TO BE PREPARED
Inspection/Adjustment item Symbol
Part No.
799-601-7710 799-601-7720
Part Name
Remarks
Contact size #20 (Used for both DT Series and HD31 Series) Contact size #16 (Used for both DT Series and HD31 Series) Contact size #12 (Used for both DT Series and HD31 Series) Contact size #8 (Used for both DT Series and HD31 Series) Contact size #4 (Used for both DT Series and HD31 Series)
Check of sensors/harnesses
799-601-7730 Contact 799-601-7740 799-601-7750
Flushing torque converter, transmission hydraulic circuit
07063-41210 799-608-3211 799-608-3220 Commercially available 21T-06-64590 21T-06-64392
Element (for flushing) VHMS analysis tool Wiring harness Notebook computer Coupling assembly Wiring harness
Standard element part number 07063-01210
Setup of VHMS controller and setting of its replacement interval
2 Q 3 4
(OS: Windows 98/2000) PM Clinic
WA1200-3
20-102-1
(8)
ITEMS RELATED TO ENGINE

MEASURING ENGINE SPEED
Be
careful not to touch any hot part when removing or installing the measuring tools. When measuring, confirm that there is nobody around the machine. Put blocks under the wheels to prevent the machine from moving. Measure the engine speed under the following condition. Coolant temperature: Within operating range Hydraulic oil temperature: 45 55C Power train oil temperature: 70 90C
Measuring low idling and high idling speeds

1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press Real Time Monitor button (1) to select the REAL TIME MONITOR screen. 3. Select the screen of the system of the items corresponding to ENGINE SPEED of the real time monitor list (See Preface of STRUCTURE AND FUNCTION or TROUBLESHOOTING). (In this example, select the screen of Engine, Transmission, or MOD/C). 4. Display the items of ENGINE SPEED. 5. Start the engine and measure its low idling and high idling speeds. Check that the engine speed is in the standard range. If not, ask CUMMINS distributor for adjustment. 6. If the PAUSE button is pressed while the engine speed is being measured, the engine speed is held. If the PAUSE button is pressed again, holding of the engine speed is reset.
WA1200-3
20-103 20-103
1 (8)
Measuring
1.
torque
converter
stall speed
Similarly to Measuring low idling and high idling speeds, display the items of ENGINE SPEED on the REAL TIME MONITOR screen. Start the engine. Turn transmission cut-off switch (2) OFF and press the left brake pedal securely. (Check that the transmission cut-off pilot lamp goes off.) Turn the auto/manual shift selector switch ON (Turn it to MANUAL position). * At this time, the gear shift mode should be in 2nd. Press the shift-up 3rd. Set the directional Reset the parking switch to shift up the gear to
2. 3.
4.
5.
6. 7. 8.
(FNR) switch to F or R. brake.
Run the engine at full speed and stall the torque converter, and measure the engine speed at this time.
L
Measuring
1.
9JFOO366
hydraulic
stall speed
Similarly to Measuring low idling and high idling speeds, display the items of ENGINE SPEED on the REAL TIME MONITOR screen. Start the engine. Run the engine at full speed and extract the boom cylinder or bucket cylinder to relieve the oil, and measure the engine speed at this time.
2. 3.
20-104 0
WA1 200-3
Measuring torque converter hydraulic stall speed 1.
stall speed +
Similarly to Measuring low idling and high idling speeds, display the items of ENGINE SPEED on the REAL TIME MONITOR screen. Start the engine. Turn transmission cut-off switch (2) OFF and press the left brake pedal securely. (Check that the transmission cut-off pilot lamp goes off.) Turn the auto/manual shift selector switch ON (Turn it to MANUAL position). Sr At this time, the gear shift mode should be in 2nd. Press the shift-up switch to shift up the gear to 3rd. Set the directional (FNR) switch to F or R. Reset the parking brake. Run the engine at full speed and stall the torque converter and extract the boom cylinder or bucket cylinder to relieve the oil, and measure the engine speed at this time.
2. 3.
4.
5.
6. 7. 8.
9JFOO386
WA1 200-3
20-105 0
TESTING
AND ADJUSTING
MEASURING COLOR
l
EXHAUST
GAS
A Be
When measuring the exhaust gas color in the field without compressed air and power source, use handy smoke checker Gl. When taking records of official data, use smoke meter G2. Before measuring, heighten the coolant temperature to the operating range. careful not to touch any hot part when removing or installing the measuring tools.
1.
Measuring with handy smoke checker 1) Install filter paper to tool Gl. 2) Insert exhaust gas suction adapter in the exhaust pipe. Heighten the engine speed sharply and operate the handle of tool Gl simultaneously to have the filter paper absorb the exhaust gas. 3) Remove the filter paper and compare it with the attached scale.
2.
Measuring with smoke meter G2 1) Insert probe in the outlet of exhaust pipe and secure it to the exhaust pipe with the clip. 2) Connect the probe hose, accelerator switch outlet, and air hose to tool G2. * Limit the applied air pressure to 1.5 MPa 115 kg/cm21. 3) Connect the power cable to an AC 100 V outlet. * When connecting the power cable, check that the power switch of tool 62 is turned
Off.
4)
5) 6)
7)
Loosen the cap nut of the suction pump and set the filter paper. * Set the filter paper securely so that the exhaust gas will not leak. Turn on the power switch of tool G2. Heighten the engine speed sharply and press the accelerator pedal of tool G2 simultaneously to have the filter paper absorb the exhaust gas. Remove the contaminated filter paper and place it on clean filter paper (at least IO sheets) in the filter paper holder and read the indicated value.
TLD00140
20- 106 co
WA1 200-3
MEASURING BLOW-BY PRESSURE

Before measuring the blow-by pressure, increase the coolant temperature to the operating range. Check the coolant temperature on the PMClinic screen (1/4). 1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press PM-Clinic button (1) to select the PMCLINIC MENU screen. 3. Select the screen of the BLOW-BY PRESSURE (PM-CLINIC MENU screen 2/4). 4. Run the engine at full speed and operate the bucket. When the relief valve operates, measure the blow-by pressure. Take care not to touch a hot part or rotating part during measurement. The blow-by pressure may vary largely with the engine condition. If the measured value is judged abnormal, check for increase of oil consumption, bad exhaust gas color, deterioration of oil, high deterioration speed of oil, etc. which are related to the abnormal blow-by pressure. 5. If the PAUSE button is pressed while the blowby pressure is being measured, the currently measured value is held. If the PAUSE button is pressed again, holding of the blow-by pressure is reset.
WA1200-3
20-107 20-107
1 (8)
MEASURING ENGINE OIL PRESSURE

Before measuring the engine oil pressure, increase the coolant temperature to the operating range. Check the coolant temperature on the PMClinic screen (1/4). 1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press PM-Clinic button (1) to select the PMCLINIC MENU screen. 3. Select the screen of the ENGINE OIL PRESSURE (PM-CLINIC MENU screen 1/4). 4. Start the engine and measure the engine oil pressure while the engine is running at high idling. Take care not to touch a hot part or rotating part during measurement. 5. If the PAUSE button is pressed while the engine oil pressure is being measured, the currently measured value is held. If the PAUSE button is pressed again, holding of the engine oil pressure is reset.
20-108 20-108
1 (8)
WA1200-3
MEASURING EXHAUST TEMPERATURE

Before measuring the exhaust temperature, increase the coolant temperature to the operating range. Check the coolant temperature on the PMClinic screen (1/4). 1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press PM-Clinic button (1) to select the PMCLINIC MENU screen. 3. Select the screen of the EXHAUST TEMPERATURE (PM-CLINIC MENU screen 2/4). 4. If the PAUSE button is pressed while the exhaust temperature is being measured, the currently measured value is held. If the PAUSE button is pressed again, holding of the exhaust temperature is reset. Measuring 1. When measuring maximum value for troubleshooting Operate the machine actually and measure the maximum exhaust temperature. (Note) The exhaust temperature largely depends on the outside air temperature (intake air temperature of the engine). Accordingly, if any abnormal value is obtained, correct it by the following calculation. Corrected value = Measured value + 2 x (Converted outside air temperature Outside air temperature) Set the converted outside air temperature to 20C. 2. When measuring periodically for preventive and safety service 1) Stall the torque converter fully (Relieve the torque converter and work equipment pump) and raise the exhaust temperature (Approx. 700C: Standard value) 2) Stop relieving the hydraulic circuit and keep stalling the torque converter. (At this time, the temperature starts lowering. If the temperature does not lower but rises, increases the temperature at (1) in the figure at right.) 3) After the temperature lowers and is stabilized, measure it. If only the torque converter is stalled, it will be overheated before the exhaust temperature is stabilized.
WA1200-3
20-109 20-109
1 (8)
MEASURING BOOST PRESSURE

Before measuring the boost pressure, increase the coolant temperature to the operating range. Check the coolant temperature on the PMClinic screen (1/4). 1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press PM-Clinic button (1) to select the PMCLINIC MENU screen. 3. Select the screen of the BOOST PRESSURE (PM-CLINIC MENU screen 2/4). 4. Run the engine and measure the oil pressure while the torque converter is stalled. Normally, the blow-by pressure should be measured while the engine is operated at the rated output. In the field, however, an approximate value can be obtained by stalling the torque converter. 5. If the PAUSE button is pressed while the boost pressure is being measured, the currently measured value is held. If the PAUSE button is pressed again, holding of the boost pressure is reset.
20-110 20-110
1 (8)
WA1200-3
TESTING AND ADJUSTING FAN BELT TENSION

Testing . Using belt tension gauge (I), measure the tension of fan belt (2) at the intermediate point between the pulleys. Standard belt tension: 4,893 N (498.95 kg}
Ir
Adjusting 1. Loosen 7 bolts (3) and adjust tension with rod (4). Sr Do not loosen the bolt marked with %. -k If rod (2) is turned in the direction of the arrow, the tension is heightened.
TESTING AND ADJUSTING BELT TENSION OF AIR CONDITIONER COMPRESSOR

Testing . Press the intermediate point of the belt between drive pulley (I) and air conditioner compressor pulley (2) with the force of about 98 N {IO kg), and measure deflection b of the belt. Deflection of belt (Standard value) b: 9 - 12.5 mm
Adjusting
1.
9JFOO391
Loosen mounting bolts and nuts (31, (41, and (51, and locknut (6). Loosen locknut (8) of adjustment bolt (71, and adjust the tension of air conditioner compressor belt (9) with adjustment bolt (7). After positioning air conditioner compressor, tighten locknut (8) and mounting bolts and nuts (31, (41, (51, and (6). After adjusting the belt tension, check that it is in the standard range according to the above procedure.
2.
3.
4.
9JFOO392
WA1 200-3
20-111 0
ADJUSTING SENSOR
Engine 1. rotation
ROTATION
sensor
Screw in rotation sensor (1) until its tip touches gear (21, then return it by l/2 - 1 turn. Tighten locknut (3). m Locknut: 34.3 - 39.2 Nm 13.5 - 4.0 kgm} Handle the wires of the rotation sensor very * carefully so that an excessive force will not applied to them. * Take care that steel chips will not stick to the tip of the rotation sensor and the latter will not be scratched.
2.
Transmission 1.
output
shaft rotation
sensor
Screw in transmission output shaft rotation sensor (4) until its tip touches gear (51, then return it by l/2 - 1 turn. Tighten locknut (6). m Locknut: 49.0 - 68.6 Nm I5.0 - 7.0 kgm}
2.
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WA1 200-3
Modulated 1.
clutch
outlet
rotation
sensor
Screw in modulated clutch outlet rotation sensor (7) until its tip touches gear (81, then return it by l/2 - 1 turn.
Tighten locknut (9). w Locknut: 49.0 - 66.6 Nm 15.0 - 7.0 kgm1
2.
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WA1 200-3
20413 0
POWER TRAIN
POWER TRAIN
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE
Measuring Engine coolant: In operating range Torque converter oil temperature: 60 80C chine from moving. 1. Main relief pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (1) to select the PM-CLINIC MENU screen. 3) Display the items of Transmission main relief pressure (A) (3/4 of PM-CLINIC MENU screen). 4) Start the engine and measure the oil pressure when the engine speed is 1,900 rpm. 2. Modulating oil pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (1) to select the PM-CLINIC MENU screen. 3) Display the items of Transmission modulating oil pressure (B) (3/4 of PM-CLINIC MENU screen). 4) Turn drive force control dial (2) and travel speed control dial (3) to the right end. 5) Set the directional lever in Neutral and run the engine at full speed, then measure the oil pressure. 3. Torque converter inlet oil pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (1) to select the PM-CLINIC MENU screen. 3) Display the items of Torque converter inlet oil pressure (C) (3/4 of PM-CLINIC MENU screen). 4) Start the engine and measure the oil pressure while the engine is running at full speed. 4. If the PAUSE button is pressed while the oil pressure is being measured, the currently measured value is held. If the PAUSE button is pressed again, holding of the oil pressure is reset.
Put blocks under the wheels to prevent the ma-
20-114 20-114
1 (8)
WA1200-3
TESTING
AND ADJUSTING
POWER TRAIN
4.
Torque converter outlet oil pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (I) to select the PM-CLINIC MENU screen. 3) Display the items of Torque converter outlet oil pressure (2/4 of PM-CLINIC MENU screen). 4) Start the engine and measure the oil pressure while the engine is running at full speed. Lubricating valve oil pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (I) to select the PM-CLINIC MENU screen. 3) Display the items of Transmission lubricating valve oil pressure (2/4 of PM-CLINIC MENU screen). 4) Start the engine and measure the oil pressure while the engine is running at full speed. ECMV clutch oil pressure 1) Remove the oil pressure pickup plug of the clutch to be measured. . Pickup plug for 1st gear speed clutch: (I) . Pickup plug for 2nd gear speed clutch: (2) . Pickup plug for 3rd gear speed clutch: (3) . Pickup plug for reverse clutch: (4) . Pickup plug for forward clutch: (5) 2) Install oil pressure gauge Cl i5.88 MPa (60
5.
6.
kg/cm2H.
3) Star-t the engine and measure the oil pressure of the Ist, 2nd, and 3rd clutches under the following condition. 11 Keep the FNR (Forward/Reverse) switch in N (Neutral). 21 Set the auto shift/manual shift switch to ON (Manual) position. 31 Select each gear speed with the shift-up/ -down switches 41 Measure while the engine is running at full speed. Start the engine and measure the oil pressure of the forward and reverse clutches under the following condition. 11 Set the transmission cut-off switch to OFF position (to turn the light off). 21 Set the parking brake switch to OFF position. 31 Press the brake pedal.
4)
WA1 200-3
20415 0
TESTING
AND ADJUSTING
POWER TRAIN
Set the auto shift/manual shift switch to ON (Manual) position, and set the shiftup switch to 3rd. 51 Keep pressing the brake pedal, set the FNR (Forward/Reverse) switch to F (Forward) or R (Reverse). 61 Measure while the engine is running at full speed. Heighten the engine speed gradually + to the maximum. 41 Adjusting
a
* *
Adjust the oil pressure while the engine is stopped. When the main relief pressure cannot be measured accurately, do not adjust it. If the main relief pressure is out of the standard range, adjust it according to the following procedure. Adjusting transmission main relief pressure 1) Remove cover (1) and change the number of shims (2) to adjust the oil pressure. * Loosen the bolts of cover (I) gradually, lowering the tension of springs (3) and li + Ir (41. Standard thickness of shims: 2.0 mm Pressure changed with 1 shim (t = 0.5 mm): 42.17 Pa (0.43 kg/cm*) The set pressure is heightened by increasing the shims, and lowered by decreasing the shims.
1.
1.
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20-116 0
WA1 200-3
POWER TRAIN
FLUSHING PROCEDURE FOR HYDRAULIC CIRCUIT OF TORQUE CONVERTER AND TRANSMISSION

*
Metal chips, etc. in the hydraulic circuit of the torque converter and transmission shorten the lives of the torque converter and transmission and can cause an internal breakage. Accordingly, flush the hydraulic circuit to remove the metal chips, etc. from them. Flush the 1) When sion, 2) When circuit in the following cases. metal chips are sent to the circuit because of a damage of torque or hydraulic equipment. torque converter or transmission is overhauled or repaired.
1.
converter,
transmis-
2.
Install the flushing elements. 1) Drain the oil from the filters. 2) Remove the 2 transmission oil filters, then install 2 flushing * Clean the inside of the case and removed parts. Refill transmission case with oil. Add new oil through the oil filler to the specified level. through the system. Then, check the oil level again. Transmission case: Approx. 350 t
elements.
3.
Run the engine
to circulate
the oil
4.
Flush the circuit according to the following procedure. 1) Start the engine, then run it at low idling without operating the gear shift lever or directional lever for about 20 minutes. -)r Heighten the engine speed to about 1,500 rpm at intervals. Jr If the engine water temperature gauge does not rise to the green range because of low ambient temperature, continue the warm-up operation further. 2) Perform actual work or travel for at least 20 minutes. Sr Use the all gear speeds (Forward, reverse, and 1st - 3rd gears). 3) Run the engine at low idling for about 20 minutes similarly to 4-I) above. Replace the flushing elements. 1) Replace the flushing elements with the standard elements similarly to 2-I) above. If the flushing elements are used for long hours, they are clogged. Accordingly, replace them with the standard ones. 2) Supply oil and check the oil level again.
5.
be sure to
6.
Replace the transmission last-chance filter. 1) Turn part A of last-chance filter case (I) with a wrench * If there is dirt in the filter case, clean it. Remove element (2) and install a new element. 2) 3) Fit new O-ring (3) to the rim of the case. * Apply a little quantity of grease to the periphery of the O-ring. 4) Install the case. w Case mounting bolt: 58.8 - 73.55 Nm 16 - 7 kgm1
to remove
the case.
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WA1 200-3
20-117 0
TESTING
AND ADJUSTING
POWER TRAIN
HOW TO MOVE MACHINE WHEN TRANSMISSION VALVE IS BROKEN

If the machine cannot be moved because of a trouble of the transmission valve parts (electric system, solenoid valve, spool, etc.), it can be moved again by installing fixed valve assembly (tool Nl). AInstallation of fixed valve assembly (tool Nl) to ECMV is a measure to move the machine from a dangerous work site to a safety place when it cannot be moved at any gear speed because of a transmission valve trouble. Use this method only when the transmission valve has a trouble. AWhen moving the machine, observe the procedure and take care of safety. A Lower the work equipment to the ground, apply the parking brake, and put blocks under the wheels to prevent the machine from moving. When working, stop the engine. *
Take care not to get burned perature is high.
when
the oil tem-
1. 2.
Open the transmission
top cover.
Remove the valve cover. Ir Clean around ECMV thoroughly soil and dirt.
and remove
3.
Disconnect wiring connectors (I) - (14) (CN-T3, T4, T5, T6, T7, T8, Tll, T12, T13, T14, T20, T21, T22, T23). * For the precautions for removal of the wiring connectors, see DISASSEMBLY AND ASSEMBLY, Removing transmission control valve assembly.
20-118 0
WA1 200-3
TESTING
AND ADJUSTING
POWER TRAIN
4.
2 ECMV solenoids (15) Remove the following according to the moving direction of the maor reverse), then install fixed chine (Forward valve assembly (tool Nl). . When moving forward: Remove the F solenoid and 2nd solenoid. . When moving in reverse: Remove the R solenoid and 2nd solenoid. * If a wrong solenoid is removed, the transmission may be broken. Be careful. * Install plate N with the projected side directed to ECMV. Check that the O-ring is fitted to the fitting face. * Take care that soil and dirt will not enter the removed solenoids and valves.
TWWO2612
TWW02613
1) Assembly
i) ii)
of fixed valve assembly Assemble spring (17) to cover Assemble the following spacers 415-1120, stamped mark R, 1, Spacer (18) to use
(tool Nl) (16). (18) (7922)
TWW02614
Fixed valve assembly (tool Nl) the following parts, but they are on the WA1200-3. (Spacer, with 3rd, 792-415-1130 (Spacer, with 4th, 792-415-1140
includes not used H stamp) L stamp)
iii) Assemble valve (19). iv) Assemble O-ring on ECMV matching sursolenoid to the face and proportional fixed valve cover.
I
WA1 200-3
i9
17
TWW02615
POWER TRAIN
2)
Using tool N2, install fixed valve assembly (20) to the ECMV. w Fixed valve assembly mounting bolt: 13.2 f 1.5 Nm Il.35 f 0.15 kgml
5. 6. 7.
Press the left brake pedal securely. Start the engine and release the parking brake.
Release the brake pedal gradually to start the machine. A Put blocks under the wheels to prevent the machine from moving. If the engine is started, the transmission is engaged immediately and the machine starts. Accordingly, when starting the engine, check the travel direction and safety around the machine, and be sure to press the brake pedal.
20-119-l 0
WA1 200-3
STEERING SYSTEM
STEERING SYSTEM
TESTING AND ADJUSTING STEERING OIL PRESSURE
Measuring Hydraulic oil temperature: 45 55C the front frame and rear frame with the safety bar.
Lock
1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press PM-Clinic screen button (1) to select the PM-CLINIC MENU screen. 3. Display the items of Steering oil pressure (4/4 of PM-CLINIC MENU screen). 4. Run the engine and turn the joystick lever to the left or right, and measure the oil pressure when the relief valve operates. 5. If the PAUSE button is pressed while the oil pressure is being measured, the currently measured value is held. If the PAUSE button is pressed again, holding of the oil pressure is reset. Adjusting
If
the relief pressure is not normal, adjust the steering relief valve according to the following procedure. When adjusting, stop the engine. 1. Loosen locknut (3) and turn adjustment screw (4) to adjust the relief pressure. Pressure changed with adjustment screw Pressure changed by 1 turn: Approx. 3.5 MPa {Approx. 35.7 kg/cm2} If the adjustment screw is tightened, the set pressure is heightened. If the former is loosened, the latter is lowered. When the relief pressure cannot be measured accurately, do not adjust it.
20-120 20-120
1 (8)
WA1200-3
TESTING
AND ADJUSTING
STEERING
SYSTEM
TESTING AND ADJUSTING EMERGENCY STEERING OIL PRESSURE

Measuring Hydraulic a oil temperature: 45 - 55C
Lock the front frame and rear frame with the safety bar. the oil filler cap to release the residual ALoosen pressure from the hydraulic tank. 1. Disconnect drive shaft (I 1 between transmission and center support from the transmission. Disconnect drive shaft (2) between transmission and rear axle from the transmission. Disconnect diverter valve pilot hose (3). Replace elbow (4) with an oil passage shut-off elbow (See the next page), then install hose (3). (By this work, the oil pressure applied to the pilot port of the diverter valve is shut off and the emergency steering system can operate.)
9JFOO448
2.
3.
4.
Remove oil pressure pickup plug (5) (PT l/8) between the diverter valve and steering valve, then install nipple C2 and oil pressure gauge Cl (39.2 MPa (400 kg/cm21). Start the engine and shift the gear to FORWARD (or REVERSE) 3rd. Heighten the travel speed to 24 km/h and turn the steering wheel to the right or left. Measure the oil pressure when the relief valve operates.
5.
WA1 200-3
STEERING SYSTEM
Adjusting
A
1.
2.
When adjusting,
Remove
stop the engine.
cap nut (6) of the relief valve.
Loosen locknut (7) and turn adjustment screw (8) to adjust the pressure. * Pressure changed with adjustment screw Pressure changed by 1 turn: Approx. 3.5 MPa {Approx. 35.7 kg/cm21 t If the adjustment screw is tightened, the set pressure is heightened. If the former is loosened, the latter is lowered. * When the relief pressure cannot be measured accurately, do not adjust it.
Preparation of oil pressure shut-off elbow Prepare elbow (07236-10210) and drive a pin having diameter of 5 mm into the drilled hole and weld it to shut off the oil passage.
TKWOllt8
WeI
20-122 0
WA1 200-3
STEERING SYSTEM
BLEEDING AIR FROM STEERING CIRCUIT

Ir If the steering valve or the steering cylinder is removed and installed, bleed air from its circuit according to the following procedure. Run the engine utes. Running chine to + Stop each at low idling for about 5 min-
1.
2.
the engine at low speed, steer the mathe right and left 4 - 5 times. the piston rod about 100 mm before stroke end, and never relief the oil. perform the
9JFOO396
3.
Running the engine at full speed, operation in 2 above.
4.
Running the engine at low speed, move the piston rod to the stroke end to relief the oil.
WA1 200-3
20- 123 0
STEERING SYSTEM
ADJUSTING STEERING STOPPER BOLT

1. Running the engine at low speed, steer the machine and measure clearance a between frame end stopper (2) of front frame (I 1 and rear frame (3). If clearance a is out of the standard range, adjust it according to the following procedure. * Clearance a: 37 - 40 mm 1) Loosen locknut (4) and adjust clearance a to the standard range with steering angle adjustment bolt (5). the engine at low speed and operARun ate the joystick steering lever slowly. care not to catch your body, arm, ATake etc. between the front frame and rear frame. Adjust the stopper bolts on both sides * by the above method. 2) Start the engine and check that the clearance between frame end stopper (2) of front frame (1) and rear frame (3) is normal when the machine stops turning.
9JFOO397
I\
9JFOO399
20-124 0
WA1 200-3
TESTING
AND ADJUSTING
BRAKE SYSTEM
BRAKE SYSTEM
TESTING DROP OF WHEEL BRAKE OIL PRESSURE
Put blocks under the wheels A the machine from moving. 1. securely to prevent
I!
Testing wheel brake oil pressure 1) Remove bleeder screw (I), then install oil pressure gauge 139.22 MPa I400 kg/cm211 of tool I, joint, bleeder screw, and nipple. 2) Connect hose (2) to the bleeder screw to bleed air from the brake circuit. For details, see BLEEDING AIR FROM EACH PART. 3) Press the left brake pedal and measure the brake oil pressure. Measuring drop of brake piston pressure 1) Remove bleeder screw (I), then install oil pressure gauge i39.22 MPa 1400 kg/cm211 of tool I, joint, bleeder screw, and nipple. 2) Connect hose (2) to the bleeder screw to bleed air from the brake circuit. For details, see BLEEDING AIR FROM EACH PART. 3) Stop the engine, then press the left brake pedal so that the brake oil pressure becomes 15.5 MPa 1158 kg/cm21 and leave it for 5 minutes. Then, measure the pressure drop. * Take care not to move the brake pedal for 5 minutes. * After finishing the above work, bleed air from the brake circuit again.
2.
WA1 200-3
20- 125 0
BRAKE SYSTEM
TESTING WHEEL BRAKE FUNCTION

* .
l . .
Test the wheel brake function under following condition. Road surface: Flat, level, straight, paved, and dried road Speed: Initial braking speed of 20 km/h Tire inflation pressure: Specified pressure (588 kPa (6 kg/cm211 Delay in pressing pedal: 0.1 set Start the engine and drive the machine with the directional lever in F (Forward) and the gear shift lever in 3rd. Keep the travel speed at 20 km/h, then press the brake pedal with the specified force. * Set the run-up path and the point to start measurement in advance. Keep the travel speed at 20 km/h on the run-up path and press the brake pedal when the machine passes the point to start measurement. * Perform this test with the transmission cut-off switch turned ON. Measure the distance between the point to start measurement and the stopping point of the machine. Ir Perform the above measurement 3 times, then obtain the average.
1.
2.
3.
+
Stoooino Point
Point effect
where braking started
--
Point where operator foot on brake Pedal looeration Point1
Put
Stoooine
distance
Run-up
path
TWW02433
20- 126
0
WA1 200-3
BRAKE SYSTEM
MEASURING WEAR OF WHEEL BRAKE DISC

Stop the machine on a level place, and put blocks
under the wheels to prevent the machine from moving. Brake oil pressure: 15.49 1.37 MPa {158 14 kg/cm2} 1. Remove cap (1). 2. Press the brake pedal to the stroke end.
3. Using slide calipers M, measure depth a from the end of shaft (2) to guide (3). Keep pressing the brake pedal during measurement. Wear limit: a = Max. 7.0 mm After the disc has been worn to near the wear limit, test it frequently, regardless of the maintenance period.
WA1200-3
20-127 20-127
1 (8)
BRAKE SYSTEM
TESTING AND ADJUSTING CHARGE CUT-IN AND CUT-OUT PRESSURE OF ACCUMULATOR

Measuring Brake oil temperature: 45 55C While the engine is stopped, press the brake pedal at least 100 times to release the pressure from the accumulator circuit. 1. Select the SERVICE MENU SELECT screen on the CGC monitor. 2. Press PM-Clinic screen button (1) to select the PM-CLINIC MENU screen. 3. Display the items of F brake or R brake (4/4 of PM-CLINIC MENU screen). 4. Measure the charge cut-in pressure of the accumulator. Run the engine at low speed, check that the oil pressure rises, then when the rise in the oil pressure becomes slow, measure the oil pressure (read the front brake pressure or rear brake pressure on the CGC monitor). 5. Measure the charge cut-out pressure of the accumulator. After the cut-in of the accumulator, the oil pressure starts lowering. At this time, measure the oil pressure. 6. If the PAUSE button is pressed while the oil pressure is being measured, the currently measured value is held. If the PAUSE button is pressed again, holding of the oil pressure is reset. Adjusting Charge cut-out and cut-in pressure of accumulator If the charge cut-out pressure of the accumulator is adjusted, the valve area ratio cut-in pressure is changed. Accordingly, a cut-in pressure adjustment screw is not installed. 1. Loosen locknut (5) of cut-out valve (4) and turn adjustment screw (6) to adjust the cut-out pressure. If the adjustment screw is turned to the right, the pressure is heightened. turned to the left, the pressure is lowered. Pressure changed by 1 turn of adjustment screw: 5.59 MPa {57 kg/cm2} 3 Locknut: 9.8 11.8 Nm {1 1.2 kgm} After adjusting, check the cut-in and cut-out pressure of the accumulator again according to the above testing procedure.
20-128 20-128
1 (8)
WA1200-3
BRAKE SYSTEM
TESTING PARKING BRAKE PERFORMANCE

* Test the parking brake function under following condition. Tire inflation pressure: Specified pressure Road surface: Flat, paved, dry road having gradient of l/5 (11 20) Machine: Operating state Start the engine and drive straight up a slope having gradient of l/5. Press the brake pedal and set the directional lever in neutral, then stop the engine. Turn on the parking brake switch and release the brake pedal gradually. At this time, the machine must stop. j, Test the parking brake on an uphill road and a downhill road.
. . .
1.
TWW02434
2.
3.
TWW02435
WA1 200-3
20-129 0
BRAKE SYSTEM
TESTING WEAR OF PARKING BRAKE DISC

When the parking brake does not work sufficiently, check the parking brake disc for wear according to the following procedure. the work equipment to the ground and ALower put blocks under the wheels to prevent the machine from moving. AWhen 1. checking the wear, stop the engine.
Drain oil from the transmission case. & Transmission case: Approx. 350 e
2. 3.
Remove 1 of 2 plugs (I). Measure depth a from end of cage (2) to the piston with slide calipers M. Standard depth: a = 41.2 mm max.
4.
If depth a is larger than the standard value, remove parking brake (4) and measure disc thickness W. For details, see DISASSEMBLY AND ASSEMBLY, Removing parking brake disc. Standard thickness: W = 3.2 + 0.1 mm
l
5.
If the thickness of the parking brake disc is below the standard value, replace the disc.
20- 130 0
WA 1200-3
BRAKE SYSTEM
HOW TO RESET PARKING BRAKE MANUALLY *

The parking brake is controlled hydraulically. If it cannot be reset because of a trouble in the transmission, emergency reset solenoid valve, etc., it can be reset manually to move the machine.
Manual resetting of the parking brake is a measA ure to move the machine from a dangerous work site to a safety place. Use this method only in
an emergency A
Lower the work equipment to the ground and put blocks under the wheels to prevent the machine from moving. When resetting the parking brake, stop the engine. Drain oil from the transmission case. & 2. 3. Transmission case: Approx. 350 I?
A
1.
Remove 2 plugs (I). Remove 2 cage mounting bolts (21, then screw them in the slug holes alternatelv. * Remove 2 bolts (2) in the diagonal positions, together with the washers. * Tighten bolts (2) to pull piston (3) and reset the parking brake. * Tighten the 2 bolts evenly little by little. * If the bolts are tightened about -(3 + l/4) turns farther after they and washers touch the seat, the brake is reset.
9JFOO452
Refilling with oil . Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
WA1 200-3
20431 0
BRAKE SYSTEM
MEASURING PARKING BRAKE OIL PRESSURE

Measuring * parking brake inlet pressure
A
1.
Torque converter oil temperature: 60 - 80C Put blocks under the wheels to prevent the machine from moving.
Remove oil pressure pickup plug (PT l/8) (I), and install oil pressure gauge Cl (5.88 MPa 160 kg/cm21). Turn the parking Run the engine oil pressure. brake switch OFF. at high idling and measure the
2.
3.
A-A
9JFOO413
Measuring pressure
parking
brake solenoid
inlet
A chine
Torque
converter
oil temperature:
60 - 80C
Put blocks under the wheels to prevent the ma-
A
1.
from moving. While the engine is stopped, press the brake pedal at least 100 times to release the pressure from the accumulator circuit.
2.
3.
Turn the starting switch to the ON position and the parking brake switch to OFF position to reset the brake. Disconnect hose (21, and install the adapter and oil pressure gauge Cl (5.88 MPa {SO kg/cm211 of tool Cl. Run the engine at high idling and measure the oil pressure.
9JFOO414
20-132 0
WA1 200-3
HYDRAULIC EQUIPMENT
HYDRAULIC EQUIPMENT
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
Hydraulic oil temperature: 45 55C Measuring 1. Measuring work equipment relief pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (1) to select the PM-CLINIC MENU screen. 3) Display the items of Work equipment relief pressure (4/4 of PM-CLINIC MENU screen). 4) Start the engine and raise the boom, then run the engine at full speed and dump the bucket. When the relief valve operates, measure the oil pressure. 2. If the PAUSE button is pressed while the oil pressure is being measured, the currently measured value is held. If the PAUSE button is pressed again, holding of the oil pressure is reset.
WA1200-3
20-133 20-133
1 (8)
HYDRAULIC EQUIPMENT
Adjusting 1. Adjusting work equipment relief valve adjusting the oil pressure, stop the &hen engine. I) Loosen locknut (3) of work equipment relief valve (21, then turn adjustment screw (4) to adjust the oil pressure. * If the adjustment screw is . turned to the right, the pressure is heightened. . turned to the left, the pressure is lowered. * Pressure changed by 1 turn of adjustment screw: 1.02 MPa (10.39 kg/cm21 * After adjusting, measure the work equipment relief pressure again according the procedure described above.
.21 '004 QJF
9JFOO417
20-134 0
WA1 200-3
HYDRAULIC EQUIPMENT
TESTING AND ADJUSTING PPC OIL PRESSURE

Hydraulic oil temperature: 45 55C the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Operate the work equipment control lever 2 3 times to release the pressure from the PPC accumulator circuit.
Loosen
Measuring 1. Measuring PPC relief pressure 1) Select the SERVICE MENU SELECT screen on the CGC monitor. 2) Press PM-Clinic screen button (1) to select the PM-CLINIC MENU screen. 3) Display the items of PPC relief pressure (4/4 of PM-CLINIC MENU screen). 4) Run the engine at full speed and measure the oil pressure. 5) If the PAUSE button is pressed while the oil pressure is being measured, the currently measured value is held. If the PAUSE button is pressed again, holding of the oil pressure is reset.
2. Measuring PPC valve output pressure 1) Remove the work equipment valve cover. 2) Remove oil pressure pickup plugs (PT 1/8) (1) (4) from each circuit, then install nipples C2 and oil pressure gauges C1 (5.9 MPa {60 kg/cm2}). 1. For raising boom 2. For lowering boom 3. For dumping bucket 4. For digging with bucket 3) Start the engine and operate each circuit to the stroke end, then run the engine at full speed and operate each circuit. When the relief valve operates, measure the oil pressure.
WA1200-3
20-135 20-135
1 (8)
HYDRAULIC EQUIPMENT
Adjusting 1. Adjusting PPC relief valve
When
adjusting the oil pressure, stop the engine.
1) Open the transmission top cover. 2) Loosen locknut (6) of PPC relief valve (5), then turn adjustment screw (7) to adjust the oil pressure. If the adjustment screw is turned to the right, the pressure is heightened. turned to the left, the pressure is lowered. Pressure changed by 1 turn of adjustment screw: 1.02 MPa {10.39 kg/cm2}
ADJUSTING PPC VALVE LINKAGE

1. Remove the underside cover of the work equipment control lever. 2. Adjust distance a from nut (1) of the PPC valve linkage to the floor top. Distance a (Target value): 54 mm 3. Loosen nuts (2) and (3), then adjust the installed height of trunnion (5) to eliminate the play of lever (4). 4. After adjusting, tighten nuts (2) and (3).
20-136 20-136
1 (8)
WA1200-3
HYDRAULIC EQUIPMENT
BLEEDING AIR FROM EACH PART

Bleeding air from wheel brake circuit
I\
i i !!!
I!
Sr If any brake circuit hose is disconnected for removal and installation of the brake valve, axle, etc., bleed air from the circuit according to the following procedure. A~pply the parking brake put and blocks under the wheels to prevent the machine from moving. Awhile the engine is running, never bleed air from the slack adjuster, since the drive shaft is rotating. 1. Start the engine and heighten the pressure in the accumulator. (The pressure is heightened in about 30 set, if the engine runs at high idling.) Start the engine. Insert one end of a vinyl hose in bleeder (I), and put the other end in a container. Press the brake pedal and loosen the bleeder screw to bleed the air. Tighten the bleeder screw, then release the brake pedal slowly. Sr This work shall be done by two persons. One person shall press the brake pedal, and the other shall bleed air through the bleeder screw. * Use the left brake pedal. It Keep the brake oil tank full. Repeat this operation until any bubble does not come out any more through the vinyl hose. Then, press the pedal fully and tighten the bleeder screw while the oil is flowing out. Similarly to the above procedure, bleed air from the slack adjuster on the opposite side and bleeder (3) of each wheel. * If the pressure in the accumulator lowers, start the engine to heighten it. * After bleeding the air, run the engine at low idling and check the oil level in the brake oil tank, then supply oil, if necessary. * After bleeding the air, perform Testing wheel brake performance.
2.
3.
4.
5.
WA1 200-3
20- 137 0
TESTING
AND ADJUSTING
HYDRAULIC
EQUIPMENT
Bleeding air from piston pump

*
If the hydraulic oil is replaced or the piston pump is replaced or the piston pump piping is removed, bleed air to prevent seizure of the pump according to the following procedure. Check that the hydraulic its top level. tank is filled with oil to
6.
7.
Loosen plugs (I), (21, (3), and (4) of the suction tubes of the piston pump. Loosen the adapter on the block side of case drain hose (5) of the piston pump. Oil flows out of plugs (I), (21, (31, (41, and hose (5) in order. After the all air is bled, tighten the
8.
9.
plugs and hose adapter. * Since the oil level in the hydraulic tank is
higher than (I), (21, (31, (41, and (5) above, oil can be bled easily.
20- 138 0
WA1 200-3
HYDRAULIC EQUIPMENT
Bleeding *
air from work
equipment
circuit
If the work equipment control valve or the work cylinder is removed and installed, equipment bleed air according to the following procedure. Run the engine idle for about 5 minutes.
1.
2.
Running the engine at low speed, raise and lower the boom 4 - 5 times repeatedly. Ir Stop the piston rod about 100 mm before each stroke end, and never relief the oil. Running the engine at full speed, operation of 2 above. perform the
9JFOO425
3.
4.
Running the engine at low speed, operate the piston rod to the stroke end to relief the oil. Repeat the operations bucket cylinder. of 2 and 3 above for the
5.
9JFOO426
WA1 200-3
20-139 0
TESTING
AND ADJUSTING
HYDRAULIC
EQUIPMENT
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT

Releasing residual pressure from piping between a hydraulic cylinder and control valve * When disconnecting the piping between a hydraulic cylinder and the control valve, release the pressure from the circuit according to the following procedure. Stop the engine. Loosen the oil filler cap gradually to release the pressure from the tank. Operate the control lever. * After the control lever is operated 2 - 3 times, the pressure in the accumulator is lost. Run the engine at low idling for about 5 seconds, then stop it and operate the control lever. * Repeat the operations of 3) and 4) above 2 3 times to release the residual pressure completely.
1. 2.
3.
4.
Releasing residual pressure accumulator circuit *
from brake
When disconnecting the piping between cumulator and accumulator check valve tween the accumulator and brake valve, the pressure from the circuit according following procedure.
the acor berelease to the
1. Stop the engine.
2.
Press the brake pedal at least 100 times to release the pressure from the brake accumulator circuit.
Releasing residual pressure accumulator circuit *
from PPC
When disconnecting the piping between the PPC accumulator and PPC valve, release the pressure from the circuit according to the following procedure. Operate the control lever 2 - 3 times to release the pressure from the circuit.
20- 140 a
WA1 200-3
WORK EQUIPMENT
ADJUSTING EQUIPMENT *
SYSTEM
WORK LEVER LINKAGE
If the operating effort or stroke of a work equipment control lever is out of the standard range, or if the work equipment control lever, PPC valve assembly, or boom/bucket solenoid is removed, adjust the operating effort and stroke of the control lever according to the following procedure.
When adjusting, stop the engine. A f Check that the operating effort of the work ment control lever is in the standard
equiprange.
1. Remove the side cover of the work equipment control levers. 2. Operate boom lever (I) and adjust the length of rod (4) so that cam follower (2) for the boom lever will be put in the detents on both ends of cam (3) evenly and clearance a will be 0.2 - 1 Tm&stance b between pins of rod (4): 337 mm (Reference
value)
I-
1i? /
9JFOO427
3.
Operate bucket lever (5) and adjust the length of rod (8) so that cam follower (6) for the bucket lever will be put in the detents on both ends of cam (7) evenly and clearance c will be 0.2 - 1 mm. * Distance b between pins of rod (4): 337 mm (Reference value)
48
lr)l
9JFOO428
I
WA1 200-3
9JFOO429
20-141 0
4.
procedure to set boom Perform the following kick-out solenoid (9) and bucket positioner solenoid (10) in the pull state (to turn them on) (See the illustration on the previous page). 1) Remove relay (L45) (117 and (L48) (12) in the operators cab. L45: Boom kick-out relay + L48: Bucket positioner relay 2) Connect a T-adapter to short @ and @ of relay 45 (Female) to each other, and short @ and @ of relay 48 (Female) to each other. -k Check that each solenoid is in pull state of 12 mm.
m---9;FOO430
5.
Move boom kick-out solenoid (9) so that clearance d between boom lever cam (3) and cam follower (2) will be 0 - 0.5 mm when the solenoid is in the pull state. When adjusting, keep the boom lever in neu* tral. go
+
I
3 7
0
d
6
00
6.
solenoid (IO) so that Move bucket positioner clearance e between bucket lever cam (7) and cam follower (6) will be 0 - 0.5 mm when the solenoid is in the pull state. If the boom lever canceling force and the bucket lever canceling force are not 19.6 N (2 kg) and 9.8 N (1 kg) respectively, adjust them by changing installing holes d (at 4 places) of spring (13). Ir When the machine is shipped, the spring is installed to the second installing hole from the top.
%
9JFOO431
7.
8.
operate the bucket lever and After adjusting, boom lever and check that they are held in TILT, DUMP, and FLOAT positions.
9JFOO437
20-142 0
WA1 200-3
ELECTRICAL EQUIPMENT
TESTING AND ADJUSTING BUCKET PROXIMITY SWITCH
Testing 1. Run the engine and operate the bucket to have proximity switch (1) operate. Stop the engine and measure clearance a between the proximity switch and angle (2). Standard clearance: a = 3 5 mm 2. Run the engine at medium speed (about 1500 rpm) and have the proximity switch operate and lower the bucket to the ground. At this time, check that the bucket angle is directed down by 0 1.
Adjusting 1. If clearance a is not within the standard value, adjust as follows. 2. Lower the bucket completely to the ground on a horizontal ground surface. 3. Adjust proximity switch (1) so that clearance b from the switch detection surface to the tip of protector (3) is the standard value, then tighten nut (4) to hold it in position. Standard clearance: b = 0.5 1.0 mm 3 Mounting nut: 14.7 19.6 Nm {1.5 2.0 kgm} 4. Angle (2) moves to the side in relationship to the switch detection surface, so adjust the clearance so that it is a = 3 5 mm at all surfaces that it passes. 5. Run the engine at a mid-range speed (1500 rpm), and adjust mounting bracket (5) of the proximity switch so that the bucket angle is directed down by 0 1 degrees when the bucket is lowered to the ground and the positioner is actuated. Set the nominal position of the bracket so that c = 139 mm standard. The relationship between the bucket angle and the length of the cylinder when the bucket is at the horizontal position above the ground is 12 mm/1. 6. The variation caused by the engine speed when the bucket is actuated must be within 4 when the bucket is just above the ground. If it cannot be adjusted correctly, repeat Steps 1 to 4 again.
WA1200-3
20-143 20-143
1 6
TESTING AND ADJUSTING BOOM POTENTIOMETER

After installing the boom, adjust the boom proximity switch. 1. Remove bolts (1) and cover (2). 2. Raise the boom to the stroke end of the boom cylinder, then stop the engine. 3. Loosen 2 screws (3). 4. Insert a T-adapter between the front harness and potentiometer. Turn the starting switch to the ON position and turn the potentiometer to the right or left slowly so that the voltage between terminals No. 2 and 3 of CN-F04 will be 4.3 0.1 V. 5. After adjusting the potentiometer, tighten screws (3) temporarily and turn the starting switch to OFF position, then turn it to the ON position again. 6. Start the engine and lower the boom, then raise it to the top. Check again that the voltage is in the range of 4 above. If the voltage is in the range of 4 above, tighten screws (3) securely, then install cover (2) and bolts (1). If the voltage is out of the range of 4 above, adjust it again according to 4.
20-144 20-144
1 6
WA1200-3
ADJUSTING BOOM HORIZONTAL DETECTION SWITCH

Adjusting in lateral direction 1. Lower the bucket completely to the ground on a horizontal ground surface. 2. Adjust proximity switch (1) so that clearance d from the switch detection surface to cover (2) is the standard value, then tighten nut (3). Standard clearance: d = 3 5 mm 3 Mounting nut: 14.7 19.6 Nm {1.5 2.0 kgm} 3. Cover (2) moves in relationship to the switch detection surface, so adjust the clearance so that it is standard value d at all surfaces that it passes.
Adjusting boom in rotating direction 4. Set the boom to the horizontal position. 5. Loosen 2 lock bolts (5) of the switch mounting bracket. 6. When the boom is horizontal, use the oblong hole of bracket (4) to adjust the position so that cover (2) covers half the detection surface of proximity switch (1). See Fig. Y. 7. After completing the adjustment, tighten lock bolts (5).
WA1200-3
20-144-1
6
PROCEDURE FOR SETTING INITIAL VALUE FOR REMOTE BOOM POSITIONER (METHOD OF INPUTTING BASE POINT)
Carry out this setting after adjusting the boom potentiometer. 1. Operate the boom cylinder to the end of its stroke to raise. 2. Switch the CGC screen to the positioner screen. 3. Check both the UPPER stop position set display and LOWER stop position set display to make sure that they are not at the stop condition. Check that UPPER stop position set indicator (5) and LOWER stop position set indicator (6) are both OFF. 4. Press UPPER stop position set button (1) and LOWER stop position set button (2) within 10 seconds at least two times each. The buttons can be pressed in any order. 5. If the mounting position of the potentiometer is correct, UPPER stop position set display (3), LOWER stop position set display (4), UPPER stop position set indicator (5), and LOWER stop position set indicator (6) light up for 2.5 seconds and the buzzer sounds.
20-144-2
(8)
WA1200-3
CHECKING PROXIMITY SWITCH ACTUATION PILOT LAMP

Proximitv . switch actuation Dilot IamD (Red1
nn
fctuation Pilot lamp
The proximity switch has a pilot lamp to indicate its operating condition. Use it for adjustment. Condition of proximity switch actuation pilot lamp When the detector is at (near) the detecting face of the proximity switch: Lamp is turned on. When the detector is apart from the detecting face of the proximity switch: Lamp is turned off.
* . .
TEWDOl66
Proximity switch actuation Pilot lamp
Lights
UP
Goes
out
Detector
positior
When detector is detectian surface
positioned at of Proximity
switch
When detector has detection surface
moved away of Proximity
from switch
~--r--L_
I
__-_____-
_-______j
.-_-___A j
Bucket positioner
II
j
+__-._-__-
l-l_-__
Detector
Proximiiu
switch
Deteitor
=7=---T
Proximiiv switch Proximity \ switch \
Reading of load-meter
Detector
TWW02436
WA1 200-3
20- 145
0
TESTING
AND ADJUSTING
ELECTRICAL
EQUIPMENT
INITIAL LEARNING METHOD OF TRANSMISSION CONTROLLER

Ir The transmission controller has a learning function to correct itself so that the gear shift feeling will be kept constant even if the transmission clutch is worn. If the transmission controller is overhauled or transferred to another machine, the control command values which the transmission controller have learned from the former transmission are used. As a result, gear shift shocks or abnormal sounds may be made. As the machine is operated, the transmission controller learns the condition of the new transmission and corrects the command values properly. If you wish to reset the current data and have the transmission controller learns the new data immediately, however, reset the collected control data and perform initial learning according to the following procedure. How to reset collected control data * The all control data collected in the past can be reset to the initial values by the following procedure. I) Check that the starting switch is at the OFF position. 2) Remove the right cover of the work equipment control lever box. wiring connector (CN-CSB) 3) Disconnect and connect a T-adapter P. 4) Turn the starting switch to the ON position. * Do not start the engine. 5) Short @ and @ of T-adapter P to each other, then open them again. How to perform initial learning * When correcting the initial control data of each clutch in the controller to proper values, perform the following procedure after resetting the collected control data as explained above. * Start the engine and perform the following gear shifting operation to stabilize the fill time of each clutch. 1) Perform one cycle of the following gear shifting operation; N + Fl + F2 ~ F3 ~ F2 ~ UN --) MR., --j N_ When performing the above operation, run the engine at low idling and turn the transmission cut-off switch off, and turn the manual shift switch on. Keep the gear at each gear speed for the following time. Hold in F3 for 5 seconds, and in the other gear speeds for 3 seconds. Heighten the torque converter oil temperature to the second segment from the bottom (Torque converter may be stalled for this purpose), then lower the engine speed to low idling. * The target transmission oil temperature is 40 - 50C. There will be no troubles even if the torque converter oil temperature lowers to the first segment during the following gear shifting operation. Perform following cycles @ and @ 2 times each; @ N + Fl + F2 + F3. @ F3 ~ F2 ~ N ~ R, ~ N. When performing the above operation, run the engine at low idling and turn the transmission cut-off switch off, and turn the manual shift switch on. * Keep the gear at each gear speed for the following time. . Hold in F3 for 5 seconds, and in the other gear speeds for 3 seconds. * If the engine is stopped before performing the operations of 2) and 31, start with I) again. Raise the engine speed to 1,000 rpm, and repeat the operations of 2 and 3). Raise the engine speed to 1,500 rpm, and repeat the operations of 2 and 3). (Reference) The above gear shifting operations can be performed with the brake turned ON, and it is not necessary to drive the machine.
2)
1.
3)
2.
4) 5)
20-146 0
WA1 200-3
TESTING
AND ADJUSTING
ELECTRICAL
EQUIPMENT
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)

Monitor Panel (rear)
l
Ir
The speedometer of the main monitor is common to various models, and different models input different travel speed signals. Accordingly, the speedometer needs to be adjusted for each model. The speedometer is normally used as the tachometer. procedure
TWW01722
Adjusting
Turn off the power and remove the main monitor, then adjust the adjustment section of the rear side of the speedometer. Adjusting for each model I) Remove the rubber caps of DIP switches 1, 2, and 3 (SWI, SW2, and SW3) on the rear side of the main monitor. 2) There are rotary switches under the rubber caps. Adjust these rotary switches with a flat-head screwdriver according to the following table. Ir To change the tachometer to the speedometer, set switch 3 to 0.
1.
:I
>dswitch
TWW01723
DIP
SW
1.2.3 DIP SW 4
ON
piigq Switch posisiton
OFF
TWW02437
3)
4)
Remove the cap of DIP switch 4 (SW41 on the rear side of the main monitor, and set the inside ON-OFF switches according to the table at right. After adjusting, fit the rubber caps securely, then install the main monitor.
3 ON ON
(Reference)
Correction
ratio of switch 01234567

+14 +I2 +lO +8
(2)
Position of switch Correction ratio (%I
+6
+4
+2
WA1 200-3
20-147 a
ADJUSTING STEERING LEVER ANGLE AND FRAME ANGLE SENSORS

1.
Set the machine angle (measuring Set steering position. body and lever (1) at a right with eye).
2.
lock lever (2) to the LOCK (lower)
3. 4.
Run the engine
at low idling.
9JFOO398
Slide the armrest to the auxiliary position (the backmost position). * If the armrest is set to this position, the console switch is turned ON. Turn steering position. lock lever (2) to the FREE (upper)
5.
6.
About 1 second after, pips come out and adjustment is completed. * Do not operate the steering lever during the operations of 1) - 6). * If the sensors do not operate normally, check the installing direction of potentiometers (4) and (5) again, then calibrate again. . (4) Frame angle sensor (Potentiometer) . (5) Lever angle sensor (Potentiometer)
9JFOO437
1
9JFOO438
9JFOO439
20-l 48 0
WA1 200-3
PROCEDURE FOR CHECKING DIODE

.
Use the following procedure to check the diode as individual part and the wiring harness including the diode. Use a digital tester with a range for measuring diodes. Put the red (+) end of the test pin in contact with the anode (PI of the diode, and the black (-1 end in contact with the cathode (N). * There is a mark showing the direction of continuity on the surface of the diode.
1.
TLPO0663
If a normal tester is switched to the diode range, the voltage of the internal battery is displayed. The value indicates the following. . No change: No continuity l Changes: There is continuity (normal) (Note) l Value is 0 or near 0: Short circuit inside diode In the case of silicon diodes, a value between 450 and 600 is displayed.
l---z-Diode included in wiring harness TLP00664
Note:
J
BLPO1357
WA1 200-3
20-149 0
GREASING SYSTEM
METHOD OF ADJUSTING AUTO-GREASE INJECTOR DISCHARGE AMOUNT

1. The injector is actuated by pressure from the pump and sends the set amount of grease to the bearing.
2.
To check if the injector is working properly, observe the movement of indicator pin @ at the head. If the operation is normal, the pin will first be pulled in, and when the pump sto@s and the pressure is removed, the pin will return to its original position to complete the resetting for the next greasing. To adjust the injector discharge amount, turn adjustment screw @ at the head. 1) To reduce the discharge amount, loosen locknut @ and turn adjustment screw @ clockwise to gradually decrease the discharge amount. When the screw cannot be tightened any further (the position where it contacts the stopper), the discharge amount is the minimum. screw is turned counter2) If the adjustment clockwise 10 turns from the fully tightened position (minimum discharge amount), the setting will be maximum discharge amount. Maximum discharge amount: 1.3 cc/ST * After adjusting the injector discharge amount as shown above, be sure to tighten locknut
@ again.
K
0
3.
SJWOll33
4.
to overhaul or repair the injector, but if the injector fails, it is better to replace the injector with a new injector assembly. . Loosen locknut @ and turn adjustment screw @to adjust the amount of grease discharged each time.
It is possible
Discharge Screwed in clockwise contact stopper Loosened clockwise to
per time
0.3 cc (minimum)
10 turns counterfrom above position
1.30 cc (maximum
One turn between the maximum and minimum positions changes the discharge by 0.13 cc. After adjusting the screw, be sure to tighten the locknut.
LlJWO1134
20- 150
0
WA1 200-3
GREASING SYSTEM
METHOD OF SETTING AUTO-GREASE TIMER

.
. The timer is installed to control the greasing interval for the auto-greasing system. The timer is installed in box @ at the rear of the operators seat. The timer can be adjusted to the desired greasing interval according to the following table by turning the blue dial. Note that there is a tolerance of approx. +15%. (Both the operation and rest periods) Example: When timer is set to 11.25 minutes
11.25 minutes stop
11.25 minutes stop
11.25 minutes stop Operation
1.
Adjustment of greasing interval Timer box @ is in the position diagram on the right.
shown
in the
Power supply for timer Even after the starting switch is turned off, both the rest time and operating time are stored in this circuit board by the capacitor (Super Cap) for about five days, and the next operation starts under the condition when the power was turned off the previous time. However, if the power is kept turned off for more than five days, the data are deleted from memory.
Dial /
(red)
2.
Method of adjusting interval time (Blue dial) Open the door at the bottom rear of the cab, then open the lid of the timer box. Turn the dial shown in the diagram on the right to adjust the rest time and operating time. To adjust the rest time, turn blue rotary switch @ in the diagram on the right according to the following table.
AW43740B
WA1 200-3
GREASING SYSTEM
Position of switch Greasing interval (min) Position of switch Greasing interval (min) I)
1 3.75 A 37.5
2 7.5 B 41.25
3 11.25 C 45
4 15 D 48.75
5 18.75 E 52.5
6 22.5 F 56.25
7 28.25
8 30
9 33.75
Set the blue dial to position 3 after the autogreasing system is installed.
3.
Method of adjusting operating time (Red dial) To adjust the operating time, turn red rotary switch @ in the diagram on the right according to the following table. (Normally, fix this dial to position 2 (15 seconds).)
D i a I (b I ue)
AW437415
Position of switch Operating time of pump(set) Position of switch Operating time of pumpkiec) I) 2)
1 7.5 A 75
2 15 B 82.5
3 22.5 C 90
4 30 D 97.5
5 37.5 E 105
6 45 F 112.5
7 58.5
8 60
9 67.5
Set the red dial to position 2 (for normal operation). When greasing is finished and the greasing pump is balanced, the greasing pump stops even if within the specified operating time (15 set).
20-152 0
WA1 200-3
VHMS CONTROLLER
VHMS CONTROLLER
BASIC PRECAUTIONS
1. Handling machine, safety, inspection and maintenance For details of safety items, operation, inspection, and maintenance of the machine, see the Operation and Maintenance Manual for the machine. 2. Handling monitoring system Always obey the following precautions when handling the monitoring system. 1) When disassembling, repairing, or modifying the machine or system, follow the instructions in the manual. 2) Do not touch the system (equipment) when operating the machine. 3) Do not damage or get the wiring harnesses, connectors, or sensors of the system (equipment) caught or pulled by force. This may cause short circuits or disconnections that will lead to failure or fire on the machine or system (equipment). 4) Do not get water, dirt, or oil on the system (equipment) 3. Permanent power source for VHMS (battery direct power source) 1) Meaning and need of permanent power source The VHMS has the function of checking and collecting data on the condition of the machine from the moment the starting switch is turned ON to the moment the starting switch is turned OFF. Therefore, its power supply is different from many of the electronic equipment and electrical parts. For the system to provide the above functions, it is necessary to have a power supply that is connected directly to the battery and always supplies electricity (permanent power source) in addition to the power source (switch power source) that is cut when the starting switch is turned OFF or the engine is stopped. Because this switch power source and permanent power source are provided, the period needed for collecting data is clearly known and it becomes possible to store this data in the internal memory. In other words, the VHMS uses the permanent power source to save to memory the data accumulated from the moment the starting switch is turned ON to the moment the starting switch is turned OFF. Then the VHMS controller itself turns off the permanent power source. 2) Precautions when turning the permanent power source OFF When the starting switch is turned OFF, the power supply is maintained for at least 3 minutes (the VHMS system shutdown time: the time taken for the VHMS system to save the data to memory and switch off), and then the permanent power source is turned OFF. If the VHMS system shut-down time is shorter than 3 minutes, the accumulated data may be damaged. a. When removing VHMS from permanent power source When removing the VHMS from the permanent power source (for example, when carrying out repairs), check that the monitor display (7-segment LED in the diagram below) of the VHMS controller is out.
WA1200-3
20-153
(8)
VHMS CONTROLLER
b. When installing battery isolator or other battery shut-down device i) Basic connections It is a basic assumption that the engine stop switch is a type that will not shut off the permanent power source when the engine is stopped. ii) When safety regulations for user make it impossible to avoid shutting down all electric power Install a battery isolator so that the permanent power source is kept in the specified condition for at least 3 minutes after the starting switch is turned OFF before the permanent power source is shut down. If there is no timer, wait for at least 3 minutes before turning off the permanent power source. If the above shut-down time is shorter than 3 minutes, the accumulated data may be damaged. 4. Precautions when VHMS power source is ON For the first few seconds after the power is switched ON, the VHMS controller carries out the initial check (LEDs flash). Do not carry out any of the following operations until the initial check is completed. Operation of manual snapshot switch Downloading from PC (Check that the LEDs are displaying the aggregate numerals in turn before operating.)
20-154
(8)
WA1200-3
VHMS CONTROLLER
5. Precautions when replacing VHMS and transmission controller 1) Before starting replacement a. Download VHMS data When the VHMS controller is replaced, the data collected up to that point is lost, so be sure to download the accumulated data before starting the replacement operation. Next, send the accumulated data to web care. For details of the method of downloading, see the separate instruction manual for the technical analysis tool box. b. Specified method of shutting down VHMS power source i) Use the starting switch to turn the normal power source OFF ii) Maintain the permanent power source in the specified condition for at least 3 minutes. iii) Turn the permanent power source (battery direct) OFF. 2) Method of replacement, action after replacement When replacing the VHMS controller, be careful not to subject the VHMS controller or wiring harnesses to any excessive force or impact, and carry out the initial setup. For details, see the separate instruction manual for the technical analysis tool box.
6. Handling communications controller (ORB Orbcomm) 1) The ORB controller must be used. If the ORB controller is not used, it is impossible to carry out the request to open communications before starting to use. If the control power is turned on before completing the request, the transmission will be unauthorized and there will be problems with the communications system. If there are any problems or any part is unclear, please contact Komatsu or the person responsible for operation. 2) Finally, turn on the ORB power ON (connect the connector). After the VHMS controller confirmation is completed, connect the ORB controller connector (ORBA, ORB-B).
WA1200-3
20-155
(8)
VHMS CONTROLLER
SETTING UP VHMS CONTROLLER

1. Setting up VHMS controller In the following cases, always carry out the setup. 1) When making the initial installation of the VHMS system 2) When replacing or overhauling the following components VHMS controller Engine Transmission 3) When the ORBCOMM communication system (optional) is installed When carrying out the setup, the following are needed 1) PC (personal computer) 2) VHMS analysis tool (software) (799-608-3211) 3) Download cable (799-608-3220) For details of the setup method, see the instruction manual for the technical analysis tool box (for service)
The setup operation is carried out by trained personnel under the guidance of the person responsible at your company. Or contact Komatsu
2. Setting items VHMS: For details of the setup method, see the instruction manual for the technical analysis tool box (for service). 1) Calendar (date, time, time difference from GMT, summer time (daylight saving time)) 2) Machine model, Serial No., variation code 3) Engine model, Serial No. 4) Transmission serial No. 5) Setting of integration of load meter Starting ORBCOMM station 1) Communication method (Stop/Start, Interval, Transmission time) 2) Country code of communication controller (GCC)
3. Setup flow (outline)

Procedure Turn starting switch ON (starting switch ON) Check for generation of errors Start setup tool Method (specific content, points to remember, etc.) Check that no error is generated by the VHMS controller or other controller If there is any error, repair or correct to return condition to normal Calendar (date, time, time difference from GMT, summer time (daylight saving time)) Machine model, Serial No., variation code Engine model, Serial No. Transmission Serial No. Saving settings Checking VHMS functions Performing test (quick PM) Downloding Checking data (content of data) Time of start of data collection Data collection unit (day) Checking operation of Orbcomm Setting up communications (need for comminications file, comminications frequency, GCC code) Setup completion report, content of setup (data), sending checksheet Sending download data
Setting up VHMS
3 4 5
Starting switch OFF (starting switch OFF) Starting switch ON (starting switch ON) Start engine Test (quick PM) Start engine switch OFF Setting up load meter Starting switch ON (starting switch ON) Check for errors Start setup tool
Starting switch OFF (starting switch OFF)
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1. Checking operation, actuation Check the functions of the VHMS system as follows.
Start
Turn starting switch to [ON] position
Display Normal Engine, transmission controllers show past errors, then give [00] display (no error exists) No display
VHMS controller starts up, LEDs flash (see diagram below) and aggregate numerals are displayed in order (no error exists) No display
Display Normal
Turn starting switch [OFF], then check connection of wiring harnesses again
Turn starting switch again to [ON] position
Display Normal Engine, transmission controllers show past errors, then give [00] display (no error exists) No display Abnormality in machine system See machine shop manual
VHMS controller starts up, LEDs flash (see diagram below) and aggregate numerals are displayed in order (no error exists) No display Possible abnormality in VHMS controller
Display Normal
5. Collection of data 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.
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COLLECTING AND TRANSMITTING VHMS CONTROLLER DATA

1. Collecting data 1) Downloading to PC (personal computer) <Necessary tools> PC (Personal computer) VHMS analysis tool (Software) (799-608-3211) Download cable (799-608-3220) Download the collected data to a personal computer and transmit them to the file server in the computer center by e-mail (Internet). Only a part of the data which must be collected in real time is transmitted by satellite communication. For even a machine equipped with the ORBCOMM, the data must be downloaded to a personal computer periodically. For downloading and transmission of the data, see Instruction manual of analysis tool (for service). 2) Automatic transmission by communication satellite (Machine with ORBCOMM specification) Detected errors and specified data are automatically transmitted to the file server in the computer center via the communication satellite.
2. Setup flow (Outline)

Procedure Turn starting switch ON (starting switch ON) Check for generation of errors Start setup tool Setting up communication Method (specific content, points to remember, etc.) Check that no error is generated by the VHMS controller or other controller If there is any error, repair or correct to return condition to normal Checking data of satellite communication and setting of communication frequency Setting GCC code Saving settings Setup completion report
Starting switch OFF (Key switch OFF)
3. Executing quick PM See TESTING AND ADJUSTING, Executing PM Clinic with manual snap shot. Before downloading data to the PC, execute the quick PM (equivalent to PM clinic) to collect the data under the normal operating condition and those under the conditions of stall of the torque converter, high idling operation, etc.
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4. Method of downloading data to PC (personal computer) Stop the vehicle on level ground and lock the tires with chocks for safety. When turning the starting switch ON, check that the parking brake is turned ON and the gearshift lever is in the N position. When starting the engine, sound the horn and check that there is not a person around the vehicle. For the operating method of the personal computer, see Instruction manual of analysis tool (for service). <Preparation> Prepare the PC and wiring harness for downloading. <Downloading through connector in operators cab> 1) Install the download cable to the connector of the vehicle. 2) Connect either end of the download wiring harness to the PC. 3) Turn the starting switch of the vehicle ON. Check that the VHMS is in operation, and then start downloading to the PC. To check that the VHMS is in operation, check that the VHMS controller has started and the LED rotates and then displays the integrated numbers in order (See the following figure). 4) When downloading is completed, the download PC displays complete. 5) Turn the starting switch of the vehicle OFF, and then turn the PC OFF. Remove the download cable and return the connector cap.
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Items of trend data Table 1: Trend analysis data

No. 1 2 3 4 5 6 7 8 9 SMR Calendar Engine speed. Max. Blow-by press. Max. Boost press. Max. Eng. oil temp. Max. Coolant temp. Max. Coolant temp. Min. Eng. oil press. Max. Item Service meter Calendar Engine speed (Max.) Blow-by pressure (Max.) Boost pressure (Max.) Engine oil temperature (Max.) Engine coolant temperature (Max.) Engine coolant temperature (Min.) Engine oil pressure (Max.) Content h Unit Data source VHMS Remarks
y/m/d h:m:s VHMS rpm kPa kPa deg C deg C deg C MPa MPa Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS Engine controller
10 Eng. oil press. @Lo Idle Min Engine oil pressure at low idling (Min.) 11 Eng. oil press. @Hi Idle Min 12 Exh. temp. Max. (LF) 13 Exh. temp. Max. (LR) 14 Exh. temp. Max. (RF) 15 Exh. temp. Max. (RR) 16 Fuel rate Ave. 17 PPC press. Max. 18 Hyd. Oil press. Max. 19 Hyd. Oil press. Ave. 20 S/T pump press. Max. 21 S/T pump press. Ave. 22 Hyd. Oil temp. Max. 23 Hyd. Oil temp. Ave. 24 Hyd. Oil temp. Min. 25 Ambient temp. Max. 26 Ambient temp. Ave. 27 Ambient temp. Min. 28 T/C in press. Max. 29 T/C out press. Max. 30 T/M main press. Max. 31 T/M lube press. Max 32 TM M/C oil press. Max 33 T/C oil temp. Max 34 F. brake press. Max. 35 R. brake press. Max. 36 Atmos. Press. Ave.
Engine oil pressure at high idling (Min.) MPa Exhaust temperature at left front (Max.) deg C Exhaust temperature at left rear (Max.) deg C
Exhaust temperature at right front (Max.) deg C Exhaust temperature at right rear (Max.) Fuel consumption (Average) PPC pump pressure (Max.) Loader pump pressure (Max.) Loader pump pressure (Average) Steering pump pressure (Max.) Steering pump pressure (Average) Hydraulic oil temperature (Max.) Hydraulic oil temperature (Average) Hydraulic oil temperature (Min.) Atmospheric temperature (Max.) Atmospheric temperature (Average) Atmospheric temperature (Min.) Torque converter input pressure (Max.) Torque converter output pressure (Max.) Transmission main pressure (Max.) deg C Liter/h kg/cm2 kg/cm2 kg/cm2 kg/cm2 kg/cm2 deg C deg C deg C deg C deg C deg C kg/cm2 kg/cm2 kg/cm2
Transmission lubricating oil pressure (Max.) kg/cm2 Modulated clutch oil pressure (Max.) Torque converter oil temperature (Max.) Front brake charge pressure (Max.) Rear brake charge pressure (Max.) Atmospheric pressure (Average) kg/cm2 deg C kg/cm2 kg/cm2 hPa
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Table 2: Transmission trend data

No. 1 2 SMR Calendar Trig.Time F Ave. (fill time) Trig.Time R Ave. (fill time) 3 Trig.Time 1st (fill time) Trig.Time 2nd (fill time) Trig.Time 3rd (fill time) T/C oil temp. 120C 4 T/C oil temp. 130C T/C oil temp. 140C Torque converter using time at each oil temperature sec. VHMS Transmission fill-up time msec. Transmission controller (Every 200 h) Item Service meter Calendar Content h Unit Data source VHMS Remarks
y/m/d h:m:s VHMS
Table 3.1: Monitoring items of automatic snap shot (Trigger items)

No. 1 2 3 4 5 6 7 8 9 Content Lowering of engine oil pressure Rise of engine coolant temperature Error code C143 C151 No. Content Error code C647 C648 C651 C652 C653 C654 C655 C656 C657 C658
21 High exhaust temperature (L #7) 22 High exhaust temperature (L #8) 23 High exhaust temperature (R #1) 24 High exhaust temperature (R #2) 25 High exhaust temperature (R #3) 26 High exhaust temperature (R #4) 27 High exhaust temperature (R #5) 28 High exhaust temperature (R #6) 29 High exhaust temperature (R #7) 30 High exhaust temperature (R #8)
Rise of intake air temperature at left front C155 Rise of intake air temperature at left rear C158 Rise of intake air temperature at right front C162 Rise of intake air temperature at right rear C165 Rise of engine oil temperature Lowering of engine coolant pressure Engine overspeed C214 C233 C234 C235 C253 C261 C471 C555 C641 C642 C643 C644 C645 C646
10 Lowering of engine coolant level 11 Lowering of engine oil level 12 Abnormal rise of fuel temperature 13 Excessive lowering of engine oil level 14 High blow-by pressure 15 High exhaust temperature (L #1) 16 High exhaust temperature (L #2) 17 High exhaust temperature (L #3) 18 High exhaust temperature (L #4) 19 High exhaust temperature (L #5) 20 High exhaust temperature (L #6)
31 Sharp rise of left front inlet temperature C783 32 Sharp rise of left rear inlet temperature C2157
33 Sharp rise of right front inlet temperature C2158 34 Sharp rise of right rear inlet temperature C2159 35 High torque converter oil temperature 36 High hydraulic oil temperature 37 Malfunction of modulated clutch 38 Malfunction of transmission 39 Lowering of left brake charge pressure B@CENS B@HANS DBDOKT 1500LO 2G42ZG
40 Lowering of right brake charge pressurea 2G43ZG
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Table 3.2: Data items of manual snap shot

No. 1 2 3 4 5 6 7 8 9 Time Eng. speed Fuel inject Rail press. Cont. out-sig Blowby press. Boost press. Eng. oil temp. Eng. oil press. Item Date and time Engine speed Fuel injection rate Fuel rail pressure Controller output signal Blow-by pressure Engine boost pressure Engine oil temperature Engine oil pressure Engine coolant temperature Exhaust temperature (Cylinders 1, 2, 7, and 8L) Exhaust temperature (Cylinders 3, 4, 5, and 6L) Content Unit sec. rpm mm3/st kg/cm2 V mmAq kg/cm2 deg C kg/cm2 deg C deg C deg C Data source VHMS Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller Engine controller VHMS VHMS VHMS VHMS Work equipment controller Work equipment controller Work equipment controller Work equipment controller VHMS M/C controller VHMS Transmission controller VHMS VHMS VHMS Remarks
10 Eng. cool. temp. 11 Exh. temp. 1278L 12 Exh. temp. 3456L 13 Exh. temp. 1278R 14 Exh. temp. 3456R 15 PPC oil press. 16 Hyd. oil press. 17 S/T pump press. 18 Hyd. oil temp. 19 Boom raise sw. 20 Boom lower sw. 21 Bucket tilt sw. 22 Bucket dump sw. 23 Ambient temp. 24 M/C out speed 25 T/C oil temp 26 Short indicator 27 M/C slip rate 28 F. brake press. 29 R. brake press.
Exhaust temperature (Cylinders 1, 2, 7, and 8R) deg C Exhaust temperature (Cylinders 3, 4, 5, and 6R) deg C PPC pump oil pressure Loader pump oil pressure Steering pump oil pressure Hydraulic oil temperature Boom RAISE switch Boom LOWER switch Bucket TILT switch Bucket DUMP switch Atmospheric temperature Modulated clutch output speed Torque converter oil temperature Gear speed (position) Modulated clutch slip rate Front brake charge pressure Rear brake charge pressure kg/cm2 kg/cm2 kg/cm2 deg C D D D D deg C rpm deg C % kg/cm2 kg/cm2
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TESTING AND MAINTAINING VHMS CONTROLLER

1. Testing time: Testing and maintaining time of vehicle Test the system at the maintaining time of the vehicle. 2. Testing items Test and check each item. If it is abnormal, take a proper remedy. 1) At check before starting (Ask the customer to perform the following check) i) Check that the sensors are installed normally. (Check the fitting parts for looseness, damage, and dirt.) ii) Check the wiring harnesses, cables, and connectors for disconnection and damage. iii) Check the sensor fitting parts for oil leakage and gas leakage. 2) At 1000-hour maintenance i) Communication antenna (if installed) Check the antenna fitting parts for looseness and play. Check the antenna for flaw, looseness, and play. If the antenna is abnormal, replace it. 3) At irregular maintenance i) If a downloaded value is abnormal, check each sensor. 3. Remedy If any part is abnormal, repair, replace, or re-install (retighten) it.
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SETUP PROCEDURE FOR VHMS CONTROLLER

Setup tools for VHMS controller
Symbol 1 2 3 Part No. 799-608-3211 799-608-3220 Part name VHMS analysis tool Wiring harness
1. Check of machine information, engine information, and controller information This step is a work on the whole machine. Check and record the machine information, engine information, VHMS controller information, and ORBCOMM controller information.
Information to be checked No. Information Machine model Machine serial No. Current service meter reading Engine serial No. Transmission serial No. VHMS controller serial No. (*1) ORBCOMM terminal serial No. [For only ORBCOMM specification] (*2) By 0.1 h Remarks
Commercially Notebook personal computer available (OS: Windows98/2000) 21T-06-64590 Coupling assembly (Attached tool) Wiring harness (Attached tool) 1 2 3 4
4 21T-06-64392
Before starting operation after completion of local assembly or before resuming operation after storage for a long period, set up the VHMS controller according to the following procedure. Machine data collected with the VHMS controller are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, it is necessary to set the VHMS controller consistently. If it is not set correctly, data will not be taken into the WebCARE and data in the VHMS controller may not be utilized. Accordingly, be sure to carry out the setup procedure. For the method of installing the VHMS Setup Program to the personal computer, refer to the Operation Manual contained in the package of service kit Q1. When using the VHMS controller for the first time or after replacing it, set it up with a personal computer. Note that the contents of the VHMS controller cannot be changed with the service menu of the machine control monitor (CGC). The setup procedure covers both ORBCOMM Specification and ORBCOMMLESS Specification. In case of ORBCOMMLESS Specification, omit the procedures necessary for ORBCOMM Specification only. During the setup work, make necessary confirmations for each work according to the VHMS Setup Work Checklist.
5 6 7
(*1) (*2)
The VHMS controller is under the operators seat. The ORBCOMM controller is at the right rear of the operators seat.
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2. Check of operation of ORBCOMM controller (For only ORBCOMM specification) This step is a work performed in the operators cab. 1) Check that the starting switch is in the OFF position. 2) Check the green LED of the ORBCOMM controller and confirm that the controller is in operation. Power is constantly supplied to the ORBCOMM controller. Accordingly, if the green LED is lighting up while the starting switch is turned OFF, the controller is operating normally.
3. Connection of personal computer This step is a work performed in the operators cab. 1) Check that the starting switch is in the OFF position. Be sure to connect and disconnect the personal computer while starting switch is in the OFF position. 2) Connect personal computer Q3 and the download connector DL1 by wiring harness Q2. Connect the personal computer to the RS232C terminal.
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4. Check of operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is operating normally. Power is supplied to the VHMS controller. Accordingly, when the starting switch is turned ON, if the 7-segment LED rotates and flashes and then counts up, the controller is operating normally.
5. Startup of VHMS setting tool 1) Turn the personal computer ON and start the OS. 2) Click the icon of [VHMS Setting Tool] on the personal computer screen to start the VHMS setting tool.
3) Press the Next button. 4) Input the 10-digit service ID to [Service ID]. Service ID: Part No. of VHMS controller Input 0 to the position at the right end. The service ID is the same as the one used for the service menu of the machine control monitor (CGC). 5) Select [Data clear and Set up] in the [Select Function] box. 6) Press the [OK] button to go to the Set up screen.
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6. Setup of VHMS controller [Machine information] 1) The [Machine information] tab is displayed first in the [Data clear and Set up] menu, and the screen data are read automatically. 2) The default initial screen appears. (Initial screen set at the delivery time) 3) Check all the data.
iii) Check the current time. If it is wrong, correct it. Input the correct time directly in the corresponding box. iv) Correct the information and press the [OK] button.
4) If the information in the [Date/Time] box is not correct, change it according to the following procedure: i) Press the [Edit] button (1) in the [Date/Time] box to display the correction screen. ii) The pull-down menu appears in the [TimeZone] box. Press the [w] button to scroll the screen and select the correct information.
5) If the information in the [Machine information] box is not correct, change it according to the following procedure: i) Press the [Edit] button (2) in the [Machine information] box to display the correction screen. ii) When changing the variation code, press the [w] button in the pull-down menu to select the code to be changed. STD: Standard boom HL: High lift boom EHL: Extra high lift boom iii) When changing the Serial No., Engine Serial No. 1, or Engine Serial No. 2, input the correct No. directly in the corresponding box. Engine Serial No. 1: Engine serial No. Engine Serial No. 2: Transmission serial No. iv) Correct the information and press the [OK] button.
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6) If the information in the [SMR] box is not correct, change it according to the following procedure: i) Press the [Alt] and [S] buttons to display the correction screen. (Press both keys simultaneously.) ii) Input the correct information directly and press the [OK] button. (You can input the value to the 1st decimal place.) iii) The confirmation screen appears again. Press the [Y] button.
8) After checking and changing all the data of [Machine information], press [Exit] button (4) to finish [VHMS Setting Tool]. 7. Check of saving operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is turned OFF. When the starting switch is turned OFF, the VHMS controller records and updates the data. The power is still held for several seconds to save the data after the starting switch is turned OFF. Accordingly, check that the 7-segment LED of the controller is turned OFF. 8. Check of operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is operating normally. Power is supplied to the VHMS controller. Accordingly, when the starting switch is turned ON, if the 7-segment LED rotates and flashes and then counts up, the controller is operating normally.
7) After checking and changing all the data of [Machine information], press [Apply] button (3) to settle the setting. If [Apply] button (3) is pressed, the screen for checking the setting appears. Check the setting again and press the [OK] button when the setting is correct.
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9. Startup of VHMS setting tool 1) Click the icon of [VHMS Setting Tool] on the personal computer screen to start the VHMS setting tool. 2) Input the 10-digit service ID to [Service ID]. Service ID: Part No. of VHMS controller Input 0 to the position at the right end. The service ID is the same as the one used for the service menu of the machine control monitor (CGC). 3) Select [Set up] in the [Select Function] box. 4) Press the [OK] button to go to the Set up screen.
10. Setting of PLM data 1) Open the [PLM] tab and go to the setting screen. In the default mode (which was set when delivered), collection of the data is started at 0:00 AM to collect the data of 1 day. 2) Press the [Edit] button (5) to go to the screen for setting the collection start time and collection unit (day).
3) Select an item to be changed (Start time or Interval) and set it with (vw) buttons (6). You may input a value directly.
4) Press [OK] button (7).
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11. Setting of ORBCOMM communication [For ORBCOMM specification only] Open the [Communication Setting] tab. Check all the data.
2) To change setting of [SHORT TREND ANALYSIS], follow the procedures below. i) Select [SHORT TREND ANALYSIS] on the screen and press the [Edit] button (5) at the left lower part of the [File Transfer Setting] block to display the setting screen. ii) Change the setting and then press the [OK] button. When setting up, select [20h] in the [SMR] box, and set the function to [ON].
1) To change the setting of [SHORT FAULT HISTORY], follow the procedure below. i) Select [SHORT FAULT HISTORY] on the screen and press the [Edit] button (5) at the left lower part of the [File Transfer Setting] block to display the setting screen. ii) Change the setting and then press the [OK] button. When setting up, select [Occurrence] in the [Timing] box, and set the function to [ON].
iii) The confirmation screen appears again. If the setting is correct, press the [Y] button to finish setting. iv) After checking and changing all the data, press the [Exit] button at the right bottom of the screen to turn the software OFF.
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3) To change the setting of [Satellite Setting], follow the procedure below. i) Press the [Edit] button (6) in the [Satellite Setting] block to display the setting screen. ii) Bring GCC Code to the applicable area and then press the [OK] button.
i)
When the data are cleared, the system asks you if you will download the current data file. Since the file is not necessary for setting up, press the [No] button.
GCC codes and applicable areas Code 1 120 121 122 123 130 Applicable area USA Italy Malaysia Korea Brazil Japan ii) Check that OK is displayed at the left end and confirm that setting is finished normally, and then press the [Close] button.
4) After checking and changing all the data in [Communication Setting], press the [Apply] button (7) to settle the setting. If the [Apply] button is pressed, the screen for checking the setting appears. Check the setting again and press the [OK] button when the setting is correct.
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iii) Press the [Apply] button. Only the changed data are displayed. Check them and press [OK] button (9).
12. Check of saving operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is turned OFF. When the starting switch is turned OFF, the VHMS controller records and updates the data. The power is still held for several seconds to save the data after the starting switch is turned OFF. Accordingly, check that the 7-segment LED of the controller is turned OFF.
iv) The OK screen appears. Press [Close] button (10), and then press the [Exit] button to finish the VHMS Setting Tool and turn the starting switch OFF.
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13. Procedures for executing Quick Pm 1) Run the engine at low idling. 2) Set the safety lock lever in the FREE position. 3) Set the machine control monitor (CGC) to display the service menu selection screen. See Functions and operations of machine control monitor (CGC). 4) Select [Snap shot].
6) Operate the switches and levers at each execution time according to the Operating procedure for quick PM clinic shown on the following parts. The execution times are displayed on the machine control monitor (CGC). Since the work equipment and machine are operated actually during the quick PM clinic, take care of the safety around the vehicle extremely during the work.
5) Continue the operation on the screen to start the snap shot. While the following screen is displayed, press the [START] button, and the check message is displayed. Before starting the snap shot, fully understand the operating procedure for the snap shot. See STRUCTURE AND FUNCTION, CGC monitor.
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OPERATING PROCEDURE FOR QUICK PM CLINIC

1. 800 rpm Operating condition and order Engine 3. 2. Engine at Engine at low idling full throttle, bucket circuit relieved in tilt-back position N 0.5 5.0 3.5 2.0 N 4.0 1.5 4. Engine at full throttle, steering circuit relieved 5. Engine at high idling 6. 7. Engine at Engine at full throt- low idling tle, torque converter circuit relieved F3 5.0 0.5 5.5 0.0 N 6.0 0.5 8. Engine at high idling 9. 10. Engine at Engine at full throt- low idling tle and stalled fully
Transmission shift switch (minute) Operating time (minute) 0.0 5.5
N 4.5 1.0
N 6.5 1.0
F3 7.0 1.5
N 7.5 2.0
Snap shot trigger (Press START button) Only when personal computer is used 1-1 Engine speed 1/4 1/4 1/4 1/4 1/4 1/4
1-2 Engine oil pressure
1/4
1/4
1-3 Blow-by pressure
2/4
1-4 Boost pressure 2/4
2/4
1-5 Atmospheric temperature 2-1 Torque converter inlet pressure 2-2 Torque converter outlet pressure 3-1 Transmission main relief pressure 3-2 Transmission lubricating oil pressure 3-3 Transmission MOD oil pressure 4-1 Steering relief pressure 5-3 Brake charge cut-in (*1) 5-4 Brake charge cut-out (*1) 6-1 Work equipment relief pressure 6-2 PPC oil pressure
3/4
3/4
3/4
3/4
3/4
4/4
4/4
4/4
4/4
4/4
(*1)Before measuring the brake accumulator cut-in and cut-out oil pressures while the engine is running at low idling, press the brake pedal at least 10 times to lower the brake accumulator circuit pressure to below the cut-in pressure. The error of the operating condition changing time must be 5 seconds. 1/4 Value: Page No. of PM clinic on CGC : When a personal computer is not used, read each value.
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14. Downloading of set data 1) Set the starting switch to the ON position. 2) Click the icon of [VHMS Analysis Tool] on the personal computer to start the VHMS analysis tool. Input [User Name] and [Password]. For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool.
15. Check of Downloaded Data This step is a work performed in the operators cab (on the personal computer). 1) Check the set data with the [View] function. For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool. Make sure that the [MFA0] code at the time when the snapshot was executed is displayed in [Fault History]. Make sure that the snap shot data have been recorded.
3) Use the [Download] function to download the data recorded in the VHMS controller to the personal computer. For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool. Make sure that the downloading has completed before proceeding to the next step.
2) After checking the set data, turn the [VHMS Analysis Tool] OFF.
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16. Disconnection of personal computer 1) Make sure that the starting switch is in the OFF position. Be sure to turn the starting switch OFF before connecting or disconnecting the personal computer. 2) Turn the OS of the personal computer OFF and switch off the personal computer. 3) Disconnect wiring harness Q2 from download connectors DL1.
17. Communication to Komatsu After completing steps 1 to 16 successfully, please send the check sheet and the VHMS data to VHMS/WebCARE Support Center of Komatsu, Tokyo. Since Komatsu has to arrange the setting for satellite communication on the receiving side, be sure to inform Komatsu of the completion of the setting. There are 2 types of the check sheets, 1 for the VHMS and the other for the ORBCOMM (optional). Send them by fax. Send the VHMS data by Notes (LAN) or E-mail (WAN). Contact VHMS/WebCARE Support Center by Phone: 03-5561-2765 (Country No.: 81) Fax: 03-5561-4766 (Country No.: 81) E-mail: webcare@komatsu.co.jp
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To: VHMS/WebCARE Support Team (in KOMATSU, Tokyo)
VHMS Setup Work Check Sheet (For WA1200-3)

Setting step
Model name Serial No. 1 Check of machine information, engine information, and controller information
Date of setting: Date of fax: DB/Branch name: Filled by: Check item Result
Current service meter reading (by 0.1 h) Engine serial No. Transmission serial No. VHMS controller serial No. ORBCOMM controller serial No.
2 3 4 5
Check of operation of ORBCOMM controller (For only ORBCOMM specification) Connection of personal computer Check of operation of VHMS controller Starting of VHMS setting tool
Is green LED lighting? Is connection made securely? Is 7-segment LED operating normally? Is setting tool set in Data clear and set up? Is Date (mm/dd/yyyy) set? Date/Time [Local Time] Is Time set? Is time zone set? Is DST (Summer Time) set? SMR Machine information Is SMR (h) set? Is Variation code set? Is engine serial No. set? Is transmission serial No. set?
yes yes yes yes
no no no no
GMT+
Setting up of VHMS controller
Code Serial No. Serial No. yes yes yes yes no no no no
7 8 9 10
Check of saving operation of VHMS controller Check of operation of VHMS controller Starting of VHMS setting tool Setting of PLM data
Were Apply button and Exit button pressed in order? Turn starting switch OFF Wait for 3 min Turn starting switch ON Is 7-segment LED operating normally? Is setting tool set in [Set up]? Setting of PLM Short Fault History Is PLM Start Time set? Is Interval (day) set? Is Send set? Is Number (Default: 10) set? Is Send set? Is Interval (Default: 180) set? Is Send set? Is SMR set? Is GCC set?
ON ON ON
OFF OFF OFF
11
Setting of ORBCOMM communication [For only ORBCOMM specification]
Short Trend Analysis Short Load Meter GCC
12 13 14
Check of saving operation of VHMS controller Execution of quick Pm clinic Downloading of VHMS data
Were Apply button and Exit button pressed in order? Turn starting switch OFF Wait for 3 min Turn starting switch ON Was snap shot operated according to correct procedure? Is downloading completed? Are all files downloaded?
yes yes yes yes yes yes yes yes yes yes
no no no no no no no no no no
15
Check of downloaded data
When was download time (by wristwatch)? Is there [MFAO] error code in fault 0.csv? Is there snap shot file?
16 17
Disconnection of personal computer Communication to KOMATSU
Is personal computer disconnected normally? Was check sheet sent by fax? Was downloading sent by E-mail?
Where to make contact: VHMS/WebCARE Support Team (in KOMATSU, Tokyo) PHONE: 03-5561-2765 (Country No: 81) FAX: 03-5561-4766 (Country No: 81) E-mail: webcare@komatsu.co.jp
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SETTING PROCEDURE FOR REPLACED VHMS CONTROLLER

Setting tools for replaced VHMS controller
Symbol 1 2 Q 3 Commercially Notebook personal computer available (OS: Windows98/2000) Part No. 799-608-3211 799-608-3220 Part name VHMS analysis tool Wiring harness
Work before replacing VHMS controller Perform steps 1 - 4 on the currently installed VHMS controller. 1. Connection of personal computer This step is a work performed in the operators cab. 1) Check that the starting switch is in the OFF position. Be sure to connect and disconnect the personal computer while starting switch is in the OFF position. 2) Connect personal computer Q3 and the download connector DL1 by wiring harness Q2. Connect the personal computer to the RS232C terminal.
When the VHMS controller needs to be replaced, set it before removing it and set the newly installed VHMS controller according to the following procedure. Machine data collected with the VHMS controller are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, it is necessary to set the VHMS controller consistently. If it is not set correctly, data will not be taken into the WebCARE and data in the VHMS controller may not be utilized. Accordingly, be sure to carry out the setup procedure. For the method of installing the VHMS Setup Program to the personal computer, refer to the Operation Manual contained in the package of VHMS analysis tool Q1. When using the VHMS controller for the first time or after replacing it, set it up with a personal computer. The contents of the VHMS controller can be changed with the service menu of the machine control monitor (CGC), too. The setup procedure covers both ORBCOMM Specification and ORBCOMMLESS Specification. In case of ORBCOMMLESS Specification, omit the procedures necessary for ORBCOMM Specification only. During the setup work, make necessary confirmations for each work according to the Setting Work Checklist for replaced VHMS.
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2. Check of operation of VHMS controller This step is a work performed in the operators cab. 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is operating normally. The switch power is supplied to the VHMS controller. Accordingly, when the starting switch is turned ON, if the 7-segment LED rotates and flashes and then counts up, the controller is operating normally.
3. Downloading of set data This step is a work performed in the operators cab (on the personal computer). 1) Set the starting switch to the ON position. 2) Turn the personal computer ON and start the OS. 3) Click the icon of [VHMS Analysis Tool] on the personal computer to start the VHMS analysis tool. Input [User Name] and [Password]. For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool.
4) Use the [Download] function to download the data currently recorded in the VHMS controller to the personal computer. For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool. Make sure that the downloading has completed before proceeding to the next step.
5) Turn the VHMS analysis tool OFF.
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4. Check of set information This step is a work performed in the operators cab (on the personal computer). Check the setting of [Communication Setting] for only [ORBCOMM specification]. 1) Click the icon of [VHMS Setting Tool] on the personal computer screen to start the VHMS setting tool. 2) Input the 10-digit service ID to [Service ID]. Service ID: Part No. of VHMS controller Input 0 to the position at the right end. The service ID is the same as the one used for the service menu of the machine control monitor (CGC). 3) Select [Set up] in the [Select Function] box. 4) Press the [OK] button to go to the Set up screen.
5) Open the [Machine Information] tab and check and record all the information. The [Machine information] tab is displayed first in the [Set up] menu.
6) Open the [Communication Setting] tab and check and record all information.
7) After checking and recording all the information, press [Exit] button (1) at the right bottom of the screen to turn the [VHMS Setting Tool] OFF. 8) Turn the OS of the personal computer OFF and switch off the personal computer. 9) Set the starting switch in the OFF position. When the VHMS controller is replaced, the personal computer may be kept connected. Be sure to turn the personal computer and starting switch OFF, however.
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Work after replacing VHMS controller Perform steps 5 17 on the newly installed VHMS controller. 5. Check of operation of ORBCOMM controller [For only ORBCOMM specification] 1) Check that the starting switch is in the OFF position. 2) Check the green LED of the ORBCOMM controller and confirm that the controller is in operation. Power is constantly supplied to the ORBCOMM controller. Accordingly, if the green LED is lighting up while the starting switch is turned OFF, the controller is operating normally.
6. Check of connection of personal computer If the personal computer has been disconnected during the above work, connect it again, referring to 1. Connection of personal computer. 1) Check that the starting switch is in the OFF position. Be sure to check the connection of the personal computer while starting switch is in the OFF position. 2) Check that the personal computer and download connector DL1 are connected securely by wiring harness Q2.
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7. Check of operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is operating normally. The switch power is supplied to the VHMS controller. Accordingly, when the starting switch is turned ON, if the 7-segment LED rotates and flashes and then counts up, the controller is operating normally.
8. Startup of VHMS setting tool This step is a work performed in the operators cab (on the personal computer). 1) Turn the personal computer ON and start the OS. 2) Click the icon of [VHMS Setting Tool] on the personal computer screen to start the VHMS setting tool. 3) Input the 10-digit service ID to [Service ID]. Service ID: Part No. of VHMS controller Input 0 to the position at the right end. The service ID is the same as the one used for the service menu of the machine control monitor (CGC). 4) Select [Data clear and Set up] in the [Select Function] box. 5) Press the [OK] button to go to the setting screen.
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9. Re-setting of VHMS controller This step is a work performed in the operators cab (on the personal computer). [Machine Information] 1) Open the [Machine Information] tab. The [Machine Information] tab is displayed first in the [Data clear and Set up] menu. 2) Change all the data to the latest data or the data recorded before the replacement.
4) Collect the [SMR] information, if necessary, according to the following procedure. Press the [Alt] and [S] buttons to display the correction screen. (Press both keys simultaneously.) Be sure to set the service meter to the value recorded before the replacement + 0.1 h. If the service meter is set wrongly, the data on the WebCARE database cannot be controlled. Accordingly, set it accurately. Delete the value in the [SMR(h)] box and input a new value.
3) Collect the [Date/Time] information, if necessary, according to the following procedure. Set the [Date/Time] data, except the [Time Zone], to the accurate data at the time of correction. i) Press the [Edit] button at the right lower part of the [Date/Time] box to display the correction screen. ii) Correct the information and press the [OK] button.
5) Collect the [Machine Information] information, if necessary, according to the following procedure. i) Press the [Edit] button at the right lower part of the [Machine Information] box to display the correction screen. ii) Change the current information to the information recorded before the replacement and press the [OK] button.
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6) After checking and changing all the data in [Machine Information], press [Apply] button to settle the setting. If the [Apply] button is pressed, the screen for checking the setting appears. Check the setting again and press the [OK] button when the setting is correct.
10. Check of saving operation of VHMS controller Turn the starting switch OFF and wait for 3 minutes, and then turn the starting switch ON again. 11. Startup of VHMS setting tool 1) Click the icon of [Setting Tool] on the personal computer screen to start the VHMS setting tool. 2) Input the 10-digit service ID to [Service ID]. Service ID: Part No. of VHMS controller Input 0 to the position at the right end. 3) Select [Set up] in the [Select Function] box. 4) Press the [OK] button to go to the setting screen.
7) Press the [Exit] button to finish [VHMS Setting Tool].
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12. Setting of payload meter (PLM) 1) Open the [PLM] tab and go to the setting screen. Change all the data to the data recorded before the replacement. 2) Press [Edit] button (5) to go to the screen for setting the collection start time and collection unit (day).
13. Setting of ORBCOMM communication [For ORBCOMM specification only] 1) Open the [Communication Setting] tab. 2) Change all the data to the data recorded before the replacement.
3) Select an item to be changed (Start time or Interval) and set it with (vw) buttons (6). You may input a value directly.
3) To change the setting of [SHORT FAULT HISTORY], follow the procedure below. i) Select [SHORT FAULT HISTORY] on the screen and press [Edit] button (5) at the left lower part of the [File Transfer Setting] block to display the setting screen. ii) Change the current setting to the setting recorded before the replacement and then press the [OK] button.
4) Press [OK] button (7).
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4) To change setting of [SHORT TREND ANALYSIS], follow the procedures below. i) Select [SHORT TREND ANALYSIS] on the screen and press the [Edit] button at the left lower part of the [File Transfer Setting] block to display the setting screen. ii) Change the current setting to the setting recorded before the replacement and then press the [OK] button.
14. Check of saving operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is turned OFF. When the starting switch is turned OFF, the VHMS controller records and updates the data. The power is still held for several seconds to save the data after the starting switch is turned OFF. Accordingly, check that the 7-segment LED of the controller is turned OFF. 15. Check of operation of VHMS controller 1) Set the starting switch in the ON position. 2) Check the 7-segment LED of the VHMS controller and confirm that the controller is operating normally. The switch power is supplied to the VHMS controller. Accordingly, when the starting switch is turned ON, if the 7-segment LED rotates and flashes and then counts up, the controller is operating normally.
5) After checking and changing all the data in [Communication Setting], press [Apply] button (7) to settle the setting. If the [Apply] button is pressed, the screen for checking the setting appears. Check the setting again and press the [OK] button when the setting is correct.
6) Press the [Exit] button to finish [VHMS Setting Tool].
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VHMS CONTROLLER
16. Procedures for executing Quick PM-clinic 1) Run the engine at low idling. 2) Set the safety lock lever in the FREE position. 3) Set the machine control monitor (CGC) to display the service menu selection screen. See Functions and operations of machine control monitor (CGC). 4) Select [Snap shot].
6) Operate the switches and levers at each execution time according to the Operating procedure for quick PM clinic shown on the following parts. The execution times are displayed on the machine control monitor (CGC). Since the work equipment and machine are operated actually during the quick PM clinic, take care of the safety around the vehicle extremely during the work.
5) Continue the operation on the screen to start the snap shot. While the following screen is displayed, press the [START] button, and the check message is displayed. Before starting the snap shot, fully understand the operating procedure for the snap shot.
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N 4.5 1.0
N 6.5 1.0
F3 7.0 1.5
N 7.5 2.0
1/4
1/4
2/4
2/4
3/4
3/4
3/4
3/4
3/4
4/4
4/4
4/4
4/4
4/4
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17. Downloading of set data 1) Set the starting switch to the ON position. 2) Click the icon of [VHMS Analysis Tool] on the personal computer to start the VHMS analysis tool. Input [User Name] and [Password]. For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool.
18. Check of Downloaded Data This step is a work performed in the operators cab (on the personal computer). 1) Check the set data with the [View] function. For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool. Make sure that the [MFA0] code at the time when the snapshot was executed is displayed in [Fault History]. Make sure that the snap shot data have been recorded.
3) Use the [Download] function to download the data recorded in the VHMS controller to the personal computer. For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool. Make sure that the downloading has completed before proceeding to the next step.
2) After checking the set data, turn the [VHMS Analysis Tool] OFF.
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19. Disconnection of personal computer 1) Make sure that the starting switch is in the OFF position. Be sure to turn the starting switch OFF before connecting or disconnecting the personal computer. 2) Turn the OS of the personal computer OFF and switch off the personal computer. 3) Disconnect wiring harness Q2 from download connectors DL1.
20. Communication to Komatsu After completing steps 1 to 15 successfully, please send the check sheet and the VHMS data to VHMS/WebCARE Support Center of Komatsu, Tokyo. There are 2 types of the check sheets, 1 for the VHMS and the other for the ORBCOMM (optional). Send them by fax. Send the VHMS data (before and after the replacement) by Notes (LAN) or Email (WAN). Contact VHMS/WebCARE Support Center by Phone: 03-5561-2765 (Country No.: 81) Fax: 03-5561-4766 (Country No.: 81) E-mail: webcare@komatsu.co.jp
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To: VHMS/WebCARE Support Team (in KOMATSU, Tokyo)
Check Sheet for setting replaced VHMS (For WA1200-3)

Setting step
1. Connection of personal computer 2. Check of operation of VHMS controller 3. Downloading of VHMS data 4. Check of set information Date/Time [Local Time] SMR
Date of setting: Date of fax: DB/Branch name: Filled by: Check item Result
yes yes yes no no no
Is connection made securely? Is 7-segment LED operating normally? Is downloading completed? Date(mm/dd/yyyy) Time Time zone DST(Summer Time) Product Type Machine Model Type Variation code Serial No. Engine Model Serial No.1 Serial No.2 Send Number Send Interval Send SMR Start time Interval
GMT+
Machine
Engine Short Fault History Short Trend Analysis Short Load Meter PLM Repacemant of VHMS 5. Check of operation of ORBCOMM controller (For only ORBCOMM specification) 6. Check of connection of personal computer 7. Check of operation of VHMS controller 8. Start of VHMS setting tool 9. Re-setting of VHMS controller
ON ON ON
OFF OFF OFF
Is starting switch turned OFF? Is green LED lighting? Is connection made securely? Is 7-segment LED operating normally? Is setting tool set in [Set up]? Date/Time [Local Time] SMR Machine Engine Is setting matched to record before replacement? Is 0.1 h added to record before replacement for new setting? Is setting matched to record before replacement? Is setting matched to record before replacement?
yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes yes
no no no no no no no no no no no no no no no no no no no no no no no no no no no no no no
10. Writing of set data
Were Apply button and Exit button pressed in order? Turn starting switch OFF Wait for 3 min Turn starting switch ON Is setting tool set in [Set up]? Setting of PLM Short Fault History Short Trend Analysis Short Load Meter GCC Is setting matched to record before replacement? Is setting matched to record before replacement? Is setting matched to record before replacement? Is setting matched to record before replacement? Is setting matched to record before replacement?
11. Start of VHMS setting tool 12. Setting of PLM data 13. Setting of ORBCOMM communication [For only ORBCOMM specification]
14. Check of saving operation of VHMS controller
Were Apply button and Exit button pressed in order? Turn starting switch OFF Wait for 3 min Turn starting switch ON Is 7-segment LED operating normally? Was snap shot operated according to correct procedure? Is downloading completed? Are all files downloaded? When was download time (by wristwatch)? Is there [MFAO] error code in fault 0.csv? Is there snap shot file? Is personal computer disconnected normally? Was check sheet sent by fax? Was downloading sent by E-mail? Where to make contact: VHMS/WebCARE Support Team (in KOMATSU, Tokyo) PHONE: 03-5561-2765 (Country No: 81) FAX: 03-5561-4766 (Country No: 81) E-mail: webcare@komatsu.co.jp
15. Check of operation of VHMS controller 16. Execution of quick Pm clinic 17. Downloading of VHMS data 18. Check of downloaded data
19. Disconnection of personal computer 20. Communication to KOMATSU
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VHMS CONTROLLER
OUTLINE OF MEASUREMENT PROCEDURE FOR PM CLINIC

There are the following 3 types of measurement procedure for PM clinic of WA1200-3. Basically, apply measurement procedure 1 or 2. 1. Measurement procedure by machine control monitor (CGC) Read the data on the PM clinic screen with PM clinic function (1) of the machine control monitor (CGC).
2. Measurement procedure by stopwatch, scale, etc. Measure each data with a stopwatch, scale, etc.
3. Measurement procedure by downloading data in VHMS controller Connect a personal computer to the VHMS controller and execute the quick PM clinic with the machine control monitor (CGC), and then download the PM clinic data to the personal computer. The following tools are necessary to this measurement procedure.
Symbol 1 2 3 Part No. 799-608-3211 799-608-3220 Commercially available 21T-06-64590 4 21T-06-64392 Wiring harness (Attached tool) Part name VHMS analysis tool Wiring harness Notebook personal computer (OS: Windows98/2000) Coupling assembly (Attached tool)
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PREPARATION FOR MEASUREMENT FOR PM CLINIC

Stop
the vehicle on level ground and lock the tires with chocks for safety.
1. Check safety around the vehicle and start the engine. 2. Set the machine control monitor (CGC) to display the service menu selection screen, and then select the PM clinic menu and display PM clinic (1/4, 4/4) screen. For the operating method, see STRUCTURE AND FUNCTION, CGC monitor. 3. Warm up the engine to increase the engine coolant temperature and hydraulic oil temperature. Engine coolant temperature: Min. 40C Hydraulic oil temperature: Min. 40C 4. Lower the work equipment to the ground and stop the engine.
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VHMS CONTROLLER
MEASUREMENT PROCEDURE BY CGC MONITOR

1. Start of engine 1) Check that the CGC monitor is not displaying the abnormality screen. 2) Prepare the PM clinic sheet. Check safety around the vehicle, sound the horn, and start the engine. 3) Turn the steering lock switch in the OFF position. 4) Set the safety lock lever in the FREE position. 2. Check of indication of engine coolant temperature gauge and torque converter oil temperature gauge 1) Set the CGC monitor to display the monitor screen. 2) Check the indication of the engine coolant temperature gauge and torque converter oil temperature gauge.
3. Change of display of machine control monitor (CGC) Set the CGC monitor to display the service menu and select the PM clinic menu. For the operating method, see STRUCTURE AND FUNCTION, CGC monitor.
4. Measuring with PM clinic (1/4) 1) Display PM clinic (1/4). 2) Measure the engine speed, engine oil pressure, engine oil temperature, and engine coolant temperature. For the measurement conditions, see the check sheet.
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5. Measuring with PM clinic (2/4) 1) Display PM clinic (2/4). 2) Measure the engine speed, blow-by pressure, boost pressure, exhaust temperature, atmospheric temperature, and fuel rail pressure. For the measurement conditions, see the check sheet.
6. Measuring with PM clinic (3/4) 1) Display PM clinic (3/4). 2) Measure the torque converter oil temperature, torque converter inlet pressure, torque converter outlet pressure, transmission main pressure, transmission lubricating oil pressure, and transmission modulation pressure. For the measurement conditions, see the check sheet.
7. Measuring with PM clinic (4/4) 1) Display PM clinic (4/4). 2) Measure the hydraulic oil temperature, PPC oil pressure, hydraulic oil pressure, steering pump oil pressure, front brake oil pressure, and rear brake oil pressure. For the measurement conditions, see the check sheet.
8. Measuring work equipment speed and hydraulic drift Using a stopwatch, scale, etc., measure the work equipment speed and hydraulic drift.
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VHMS CONTROLLER
MEASUREMENT PROCEDURE BY DOWNLOADING DATA IN VHMS CONTROLLER

1. Connection of personal computer 1) Check that the starting switch is in the OFF position. Be sure to connect and disconnect the personal computer while starting switch is in the OFF position. 2) Connect personal computer Q3 and the download connector DL1 by wiring harness Q2. Connect the personal computer to the RS232C terminal. 2. Start of engine 1) Check that the CGC monitor is not displaying the abnormality screen. 2) Prepare the PM clinic sheet. Check safety around the vehicle, sound the horn, and start the engine. 3) Turn the steering lock switch in the OFF position. 4) Set the safety lock lever in the FREE position.
3. Change of display of machine control monitor (CGC) 1) Set the CGC monitor to display the service menu selection screen. See STRUCTURE AND FUNCTION, CGC monitor. 2) Select Snap shot.
4. Execution of snap shot 1) Continue the operation on the screen to start the snap shot. While the following screen is displayed, press the [START] button, and the check message is displayed. Before starting the snap shot, fully understand the operating procedure for the snap shot.
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2) Operate the switches and levers at each execution time according to the Operating procedure for quick PM clinic shown on the following parts. The execution times are displayed on the CGC monitor. Since the work equipment and machine are operated actually during the quick PM clinic, take care of the safety around the vehicle extremely during the work.
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VHMS CONTROLLER

N 4.5 1.0
N 6.5 1.0
F3 7.0 1.5
N 7.5 2.0
1/4
1/4
2/4
2/4
3/4
3/4
3/4
3/4
3/4
4/4
4/4
4/4
4/4
4/4
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5. Downloading of snap shot data 1) Turn the personal computer ON and start the OS. 2) Click the icon of [VHMS Analysis Tool] on the personal computer to start the VHMS analysis tool. Input [User Name] and [Password]. For the operation procedures, refer to the Operation Manual for VHMS Analysis Tool.
3) Use the [Download] function to download the data recorded in the VHMS controller to the personal computer. For the operation procedures and method of analyzing the data, refer to the Operation Manual for VHMS Analysis Tool.
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Pm clinic check sheet WA1200-3 Basic information

User name Address Date of delivery Year: Month: Day:
User No.
Chassis serial No.
Engine serial No.
Specifications Tire, front/rear 55.5/80-57-68PR(L5) 65 /65-57-62PR(L5) Bucket m3 (cu.yd) 20.9 (25.9)
Type of work Quarry, mining Coal Gold Limestone Others Construction Construction, civil engineering Road Others
Type of soil Specific gravity Rock Soft Ordinary Hard t/m3 Gravel Sand Clay Coal
Contents of work V-shape loading Cross drive loading Load and carry Remarks
Specified operating time Shifts/day Hours/shift hours Distributor/Dealer name
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Pm clinic service hour inspection

Work direction No. Date of execution
Interview with operator and walk-around inspection Is there any abnormality before starting inspection?
WA1200-3 (CUMMINS) QSK60

Service meter
Chassis serial No. Engine serial No.

Inspector
Accepted Rejected
Max. level of coolant temperature Blue Red
Max. torque converter oil temperature Blue Red
Ambient temperature Max. Min. Altitude C C m
1 2 3 4 5 6 7 8 9
(During work)
1 2 3 4 5 6 7 8 9
(During work)
Inspection item
Item 1 11 Engine speed Condition Engine: Low idling Engine: Full throttle Torque converter: Stalled Hydraulic equipment: Stalled Full stalled 12 Blow-by pressure Torque converter: Stalled
After starting engine

Unit Standard value of new machine 600 700 rpm Service limit value 575 725 Measurement result
Accepted Rejected
Engine
2000 2100 1950 2150 1850 2050 1750 2150 1890 2090 1790 2150 1545 1945 1445 2045 kPa {mmAq} Max. 1.25 {Max. 127} 0.34 0.48 {3.5 4.9} Min. 0.71 {Min. 1.76} Max. 3.29 {Max. 330} Min. 0.34 {Min. 3.5} Min. 0.137 {Min. 1.4} Min. 130 {Min. 1000} 0.95 1.15 {9.7 11.7} 0.78 0.98 {8.0 10.0}
13 Torque converter: Stalled Engine lubricating oil pressure Engine speed: 800 rpm (SAE15W-40) 14 Boost pressure 2 21 Torque converter inlet pressure 22 Torque converter outlet pressure 31 Main relief pressure 32 Lubricating oil pressure 33 Modulated clutch oil pressure Directional switch: 34 1st clutch Neutral modulating pressure Gear speed: 1st Directional switch: 35 2nd clutch Neutral modulating pressure Gear speed: 2nd Directional switch: 36 3rd clutch Neutral modulating pressure Gear speed: 3rd Directional switch: Neutral Torque converter: Stalled
MPa {kg/cm2}
150.5 180.5 kPa {mmHg} {1180 1406} 0.95 1.15 {9.7 11.7} 0.78 0.98 {8.0 10.0}
Engine: Full throttle Torque converter oil temperature: 60 80 C Transmission: Neutral
MPa {kg/cm2}
T/C
2.45 2.84 2.45 2.84 {25.0 29.0} {25.0 29.0} 0.05 0.15 {0.5 1.5} 0.05 0.15 {0.5 1.5}
Transmission
Engine: 2.30 2.60 2.30 2.60 Full throttle {23.5 26.5} {23.5 26.5} MPa Oil 2 temperature: {kg/cm } 2.10 2.40 2.10 2.40 {21.5 24.5} {21.5 24.5} 60 80C 2.30 2.60 2.30 2.60 {23.5 26.5} {23.5 26.5} 2.30 2.60 2.30 2.60 {23.5 26.5} {23.5 26.5}
1/2
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Pm clinic service
Item 4 4 Steering relief pressure
Steering Right lock (Left lock) wheel to operating Left lock (Right lock) time
Condition Engine: Full throttle Oil temperature: 45 55C Engine: Low idling Engine: Full throttle 45 55C
Oil temperature:
Unit
Standard value of new machine
Service limit value
Measurement result
Accepted Rejected
T/C
31.07 32.34 30.09 32.34 MPa {377 330} {kg/cm2} {317 330} Sec. Max. 6.5 Max. 5.6 Max. 7.5 Max. 6.5
5 51 Parking brake
Flat ground, F3, engine at full throttle Wear of brake disc Front right Front left Rear right Rear left mm
Vehicle is stopped 0.0 0.0 0.0 0.0 17.6 18.2 {180 186} 20.6 22.1 {210 225} 31.1 32.3 {317 330} 3.72 4.70 {38 40} 12.0 13.0 4.5 5.5 Max. 0.7 Max. 0.7 Max. 0.7 Max. 0.7 17.6 19.1 {180 195} 20.6 23.5 {210 240} 31.1 32.3 {317 330} 3.23 5.19 {33 53} Max. 14.0 Max. 7.0 Max. 5.0 2.7 3.3
Brake
52 Wheel brake
53 Accumulator charge pressure (Front)
Charge cut-in pressure Charge cut-out pressure
Engine: Low idling MPa Oil 2 temperature: {kg/cm } 45 55C C
6 Hydraulic oil temperature
Hydraulic equipment
61 Work equipment valve relief pressure 62 PPC oil pressure 63 Lift arm speed
Oil temperature: 45 55C Engine: Full throttle Bucket: Relieved in tilt position Oil temperature: 45 55C Engine: Full throttle Raise Lower Engine: Full throttle Full stroke Tilt back Full stroke Dump
MPa {kg/cm2}
64 Bucket speed
Sec.
3.4 4.0 2.7 3.3
Set lift arm and bucket in measuring positions and stop engine.
Hydraulic drift Lift arm and bucket: Horizontal Bucket hinge pin Bucket edge mm /15min Max. 250 Max. 100 Max. 250 Max. 100
Replace plug with spare.

Final drive
Front right final drive Visual check of final drive drain plug Engine: Stopped Front left final drive Rear right final drive Rear left final drive There must not be abnormally many metal chips.
Memo: Enter phenomena and information you noticed during todays check.
2/2
20-199-3
(8)
WA1200-3
METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES

1. Display on CGC monitor 1) Outline The VHMS controller sends various types of information via CAN (network) to the CGC monitor. The Failure history in that information can be displayed on the service menu selection screen. 2) Display of failure history Press failure history display button (1) in the service menu to display the Failure history screen. The codes, contents, failure occurrence times, and failure reset times are displayed in order from the oldest one. If a failure is not reset, its failure set time is not displayed. The total number of the failure histories is displayed in part (2), the failure history No. in (3), the 6digit error code in (4), the failure occurrence time in (5), failure reset time in (6), and number of times of failure occurrence in (7). 3) Function of each button i) Page selector buttons (8) and (9): These buttons are used to turn over the currently displayed page forward or in reverse ii) UP/DOWN buttons (10) and (11): These buttons are used to scroll the currently displayed part up or down. ii) Failure history No. button (3): If this button is pressed, the corresponding history is not displayed any more. Even if the history is not displayed any more, it is still saved in the controller. iv) Service menu display button (12): If this button is pressed, the Service menu screen appears.
WA1200-3
20-199-4
(8)
2. Display on main monitor 1) Outline Various control systems are checked and the results are displayed in the speedometer display section of the main monitor. The contents of each displayed troubleshooting result are the remedy code, error code, and elapsed time after failure are displayed. Communications between the main monitor and various controllers are made by means of serial signals through the network circuit. (Parallel signals are used specially for only the engine controller.) 2) Remedy code A remedy code notifies an abnormality directly to the operator and shows an action to take such as stopping the vehicle immediately. There are 3 types of the remedy code (displayed in part a), which are E00, E01 + CALL (E01 and CALL are displayed alternately), and CALL. If an emergency failure occurs, the corresponding remedy code is displayed in the speedometer display section. 3) Error code and elapsed time after failure Each failure detected by various controllers is displayed by a code. This code shows which system of which controller has a failure. Then, the operator troubleshoots the indicated controller. 4) Saving of error code Each error code is saved in the transmission controller. i) Up to 9 error codes can be saved. ii) The following items are saved. Error code (Part b) Elapsed time after failure (Up to 1,000 hours) (Part c) iii) The error codes are saved in the order of time of occurrence. The same code as one that was saved before is not saved. iv) After 7 error codes are saved, if a new failure occurs, the oldest error code is deleted and the error code of the new failure is saved. The saved error codes and the elapsed times can be displayed by operating the setting switch of the main monitor.
Example) When error code CALL is displayed
Example) When error code 41 occurred 27 hours before
20-199-5
(8)
WA1200-3
5) Switch operation procedures and operations main monitor Switch operation Operation of main monitor
Display of failure history mode i) Stop the engine. ii) Turn the starting switch ON. iii) Hold switch (1) (the 2nd switch from the top on the left side) and headlamp switch (2) for 5 seconds.
The error code and remedy code are displayed in the speedometer display section and the elapsed time after failure is displayed in the remedy code section. If there is not a failure, CC is displayed in the speedometer display section and 0000 is displayed in the remedy code display section.
Display of next error code iv) Press headlamp switch (2).
The error codes and elapsed times are displayed in order (from the newest one). The failures which have not been repaired flash and those which have been repaired light up. The displayed error code and elapsed time are cleared. The error code of a failure which has not been repaired is not cleared.
Clearing of error code v) Hold rear lamp switch (3) for 2 seconds.
Returning from failure history display mode vi) Hold switch (1) and headlamp switch (2) for 5 seconds or start the engine.
The main monitor starts the normal display.
WA1200-3
20-199-6
(8)
Monitoring items table

Signal name Real-time monitor Engine 1/2 Engine speed 1/2 Coolant temperature 1/2 Engine oil temperature 1/2 Fuel rail pressure 1/2 Engine oil level 2/2 Exhaust temperature table Transmission controller 1/4 Transmission direction signal F 1/4 Transmission direction signal N 1/4 Transmission direction signal R 1/4 Shift-up switch 1/4 Shift-down switch 2/4 Engine speed 2/4 Fill signal F 2/4 Fill signal R 2/4 Fill signal 1st 2/4 Fill signal 2nd 2/4 Fill signal 3rd 3/4 Engine speed 3/4 Solenoid F 3/4 Solenoid R 3/4 Solenoid 1st 3/4 Solenoid 2nd 3/4 Solenoid 3rd 4/4 Engine speed 4/4 Auto-shift signal Unit
Controller is omitted from each component name.

Component name Remarks
1rpm 1 C 1C 1kPa (ON/OFF) 1C (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1rpm (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1rpm 1mA 1mA 1mA 1mA 1mA 1rpm (ON/OFF)
VHMS CENSE CENSE CENSE CENSE CENSE T/M T/M T/M T/M T/M VHMS T/M T/M T/M T/M T/M VHMS T/M T/M T/M T/M T/M VHMS T/M
4/4
Manual shift signal
(ON/OFF)
T/M
4/4
Transmission cut-off signal
(ON/OFF) (ON/OFF) (ON/OFF) 0.1V 0.1V 0.1km/h 0.1km/h 1rpm 1rpm 0.1km/h 1% 1mA (ON/OFF) 1rpm (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1rpm 1rpm 0.1km/h 1mA 1ton
T/M T/M T/M MOD/C MOD/C MOD/C MOD/C VHMS MOD/C MOD/C MOD/C MOD/C MOD/C VHMS Work equipment Work equipment MOD/C MOD/C MOD/C VHMS MOD/C MOD/C MOD/C MOD/C
Each time momentary switch is turned ON, AUTO and MANUAL are selected alternately. Value recognized by controller is displayed. Each time momentary switch is turned ON, AUTO and MANUAL are selected alternately. Value recognized by controller is displayed. Condition for cutting off: Left brake pedal is pressed while cut-off switch (main monitor) is effective.
4/4 Kick-down switch signal Modulated clutch controller 1/6 Transmission cut-off signal 1/6 Drive force control dial signal 1/6 Travel speed control dial signal 1/6 Travel speed 1/6 Travel speed set 2/6 2/6 2/6 2/6 2/6 2/6 3/6 3/6 3/6 3/6 3/6 3/6 4/6 4/6 4/6 4/6 4/6 Engine speed Modulation output Travel speed Modulated clutch slip rate Modulated clutch solenoid Modulated clutch fill signal Engine speed Boom RAISE signal Boom LOWER signal Bucket TILT signal Bucket DUMP signal NC solenoid output signal Engine speed Wheel (Tire) speed Travel speed Modulated clutch solenoid Drive force
Travel speed control dial signal converted into value in km/h
MOD/C slip rate = (MOD/C output speed)/(Engine speed x 74/58) x 100(%)
20-199-7
(8)
WA1200-3
Signal name 4/6 Tire slip signal 5/6 Boom RAISE signal 5/6 Bucket TILT signal 5/6 Fill signal F 5/6 Fill signal 1st 5/6 Tire slip signal 6/6 Engine speed 6/6 Right brake proximity switch 6/6 Acceleration signal 6/6 Engine control signal 6/6 Set/Acceleration (Idle-up) 6/6 RESUME/Deceleration (Idle-down) Remote positioner controller 1/1 Boom angle signal 1/1 Boom RAISE signal 1/1 Boom LOWER signal 1/1 Detent signal 1/1 RAISE set signal 1/1 LOWER set signal Load meter 1/1 Boom bottom pressure 1/1 Measured pressure 1/1 Calibration pressure 1/1 No-load pressure 1/1 Measured weight Joystick steering 1/2 Joystick ON/OFF signal 1/2 Steering lever potentiometer 1/2 Articulation angle 1/2 Joystick solenoid output 1/2 Steering lock 2/2 Transmission direction signal F 2/2 Transmission direction signal N 2/2 Transmission direction signal R 2/2 Steering signal output PM clinic 1/4 Engine speed 1/4 Engine oil pressure 1/4 Engine oil temperature 1/4 Engine coolant temperature 2/4 Engine speed 2/4 Blow-by pressure 2/4 Boost pressure 2/4 Exhaust temperature 2/4 Atmospheric temperature 2/4 Fuel rail pressure 3/4 Torque converter oil temperature 3/4 Torque converter inlet pressure 3/4 Torque converter outlet pressure 3/4 Torque converter main pressure 3/4 Transmission lubricating oil pressure 3/4 Transmission modulation pressure 4/4 Hydraulic oil temperature 4/4 PPC oil pressure 4/4 Hydraulic oil pressure 4/4 Steering pump pressure 4/4 Front brake pressure 4/4 Rear brake pressure
Unit (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1rpm (ON/OFF) 0.1V 0.1V (ON/OFF) (ON/OFF) 0.1V (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1MPa 1MPa 1MPa 1MPa 1TON (ON/OFF) 0.1V 0.1V 1mA (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1rpm kPa C C rpm Pa kPa C C kPa C MPa MPa MPa MPa MPa C MPa MPa MPa MPa MPa
Component name Main monitor Work equipment MOD/C T/M T/M Main monitor VHMS MOD/C MOD/C MOD/C MOD/C MOD/C Work equipment Work equipment Work equipment Work equipment VHMS VHMS VHMS VHMS VHMS VHMS VHMS Work Work Work Work Work T/M T/M T/M Work equipment equipment equipment equipment equipment
Remarks
Positioner screen switch of CGC Positioner screen switch of CGC Differential pressure = Bottom pressure Head pressure Measured trigger pressure Calibration pressure Calibration pressure default value Measured trigger load
equipment
VHMS Quantum CENSE Quantum VHMS Quantum Quantum CENSE VHMS Quantum VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS VHMS
WA1200-3
20-199-8
(8)
Table of CGC display items related to alarm

1. The check lamp output is driven with the VHMS. 2. The flashing synchronization signal of the caution lamp output of the main monitor is driven with the ON/OFF output of the VHMS. Possibility of outputting of an alarm is sent from the VHMS to the main monitor by S-NET. 3. The check lamp and caution lamp are independent from each other. (If 2 abnormalities occur, both lamps flash.)
Detecting condition 1 No. 1 2 3 5 6 7 8 9 Item Engine oil level Engine oil pressure Engine coolant temperature Fuel level Indication range Below low level Below specified pressure Above 105C Detail of indication range H: Abnormal L: Abnormal See CUMMINS Maintenance Manual. Above 105C Condition for alarming Detecting Detecting condition 2 condition 3 While Abnormality Before engine is engine is detecting started running time
Resetting condition 1 Resetting condition When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied
2 2 10 10 10 2 2 10 5 5
Below specified level Below 1 segment of gauge (11%) Below specified level Below 1 segment of gauge (11%) Above 120C Above 130C Above 105C Temperature is above 120C but alarm for above 130C is not detected. Above 130C Above 105C Below 150 For 60 sec after engine is started. Below 150 kg/cm2 At 60 sec after engine is started. Below 150 kg/cm2 For 60 sec after engine is started. Below 150 kg/cm2 At 60 sec after engine is started. OPEN (When fluid level is insufficient) = 6-V cell is below 2 V OPEN (When fluid level is insufficient) = 6-V cell is below 2 V OPEN (When fluid level is insufficient) = 6-V cell is below 2 V kg/cm2
Torque converter oil temperature Hydraulic oil temperature
oil 10 Brake pressure (F) 11 (Cut-in/Cut-out pressure) oil 13 Brake pressure (R) 14 (Cut-in/Cut-out pressure)
Below 150 kg/cm2
Below 150
kg/cm2
16 Battery fluid level (1) Below low level 17 Battery fluid level (2) Below low level 18 Battery fluid level (3) Below low level 19 20 21 22 Brake oil level Coolant level
10
When condition at left is not satisfied
Below specified level OPEN = 24 V (When oil level is insufficient) Below specified level OPEN = 24 V (When oil level is insufficient) Below low level Below low level OPEN = 24 V (When coolant level is insufficient) OPEN = 24 V (When coolant level is insufficient) OPEN = 24 V (When clogged) and torque converter oil temperature is above 50C OPEN = 24 V (When clogged) OPEN = 24 V (When clogged) OPEN = 24 V (When clogged) OPEN = 24 V (When clogged) Below 9.3 V (while engine is running) (Condition for judging rotation of engine: Terminal R voltage is above 9.3 V or engine speed is above 600 rpm)
10 10 2 30 2 2 2 2 2
When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied When condition at left is not satisfied
23 Transmission filter Above specified differential pressure pressure 24 Clogging of air cleaner (1) 25 Clogging of air cleaner (2) 26 Clogging of air cleaner (3) 27 Clogging of air cleaner (4) Above specified negative pressure Above specified negative pressure Above specified negative pressure Above specified negative pressure
terminal When charging is 28 Alternator R voltage abnormal
When condition at left is not satisfied
20-199-9
(8)
WA1200-3
Alarm output Main monitor output Alarm display on CGC Abnormal Abnormal Abnormal Insufficient Insufficient Abnormal Abnormal Abnormal Pressure is being increased Abnormal Pressure is being increased Abnormal Screen color Yellow Red Red Yellow Yellow Red Red Red Yellow Red Yellow Red Cancel switch Installed Not installed Installed Installed Installed Installed Installed Installed Installed Not installed Installed Not installed Check lamp Flashing Flashing Caution lamp Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Buzzer ON ON ON ON ON Massage display (CGC) Sensor Constant Real-time monitor, Saving of Error detecting display PM clinic No. failure history component (Reference) (Reference) Saved: 901 902 904 905 906 907 908 911 912 913 912 915 916 Abnormal Yellow Installed Flashing 917 918 Abnormal Abnormal Abnormal Abnormal Abnormal Abnormal Abnormal Abnormal Abnormal Yellow Red Yellow Red Yellow Yellow Yellow Yellow Yellow Installed Not installed Installed Not installed Installed Installed Installed Installed Installed Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing ON ON 925 926 927 928 931 932 933 934 935 Remarks

x x
CENSE CENSE CENS VHMS
Gauge Gauge Gauge Gauge
VHMS Gauge VHMS VHMS VHMS

VHMS VHMS
VHSM VHSM VHMS

VHMS
Abnormal
Yellow
Installed
Flashing
937
WA1200-3
20-199-10
(8)
ERROR CODES TABLE
ERROR CODES TABLE

The main monitor displays a diagnosis code (excluding codes related to VHMS) and a remedy code. The CGC monitor displays a 6-digit error code. Obtain a diagnosis code from the displayed error code and this table, and then see the corresponding troubleshooting section.
Com- Diagponent nosis code 10 11 12 13 14 15 16 18 20 21 22 23 24 25 26 27 28 29 30 32 33 34 35 36 37 38 39 70 72 73 74 75 76 77 78 80 81 82 83 84 85 43 44 45 49 51 52 55 56 57 58 59 61 62 63 Remedy code Failed system Short circuit, disconnection, or short circuit with power source in backup lamp relay output signal system Disconnection in modulated clutch outlet speed signal sensor system Short circuit, disconnection, or short circuit with power source in F ECMV solenoid signal system Short circuit, disconnection, or short circuit with power source in R ECMV solenoid signal system Short circuit, disconnection, or short circuit with power source in 1st ECMV solenoid signal system Short circuit, disconnection, or short circuit with power source in 2nd ECMV solenoid signal system Short circuit, disconnection, or short circuit with power source in 3rd ECMV solenoid signal system Short circuit, disconnection, or short circuit with power source in R clutch drain valve solenoid signal system Short circuit or disconnection in joystick steering FNR switch system Short circuit or disconnection in joystick steering shift-up/shift-down switch system Disconnection in travel speed signal sensor system Short circuit or disconnection in engine rotation sensor system Abnormality in memory Short circuit in transmission oil temperature sensor system Grounding fault in F. fill switch system Grounding fault in R. fill switch system Grounding fault in 1st fill switch system Grounding fault in 2nd fill switch system Grounding fault in 3rd fill switch system Grounding fault in F/R fill switch system Disconnection in 1st, 2n, or 3rd fill switch system Disconnection or short circuit with power source in F bypass solenoid signal system Grounding fault in F bypass solenoid signal system Disconnection or short circuit with power source in R bypass solenoid signal system Grounding fault in R bypass solenoid signal system Disconnection or short circuit with power source in 1st bypass solenoid signal system Grounding fault in 1st bypass solenoid signal system Disconnection in boom RAISE/LOWER, bucket TILT/DUMP pressure switch system Short circuit, disconnection, or short circuit with power source in accelerator pedal sensor system Grounding fault in F/R ECMV fill switch system Disconnection in 1st, 2nd, or 3rd fill switch system Grounding fault in 1st, 2nd, or 3rd fill switch system Grounding fault in RPM-SET IDLE-UP/RESUME IDLE-DOWN system Grounding fault, disconnection, or short circuit in drive force control dial system Grounding fault, disconnection, or short circuit in travel speed control dial system Grounding fault, disconnection, or short circuit in wheel rotation sensor system Grounding fault, disconnection, or short circuit in modulated clutch outlet rotation signal sensor system Short circuit, disconnection, or grounding fault in engine rotation sensor system Short circuit, disconnection, or grounding fault in travel speed sensor system Short circuit, disconnection, or grounding fault in neutral-cut solenoid system Short circuit, disconnection, or grounding fault in modulated clutch ECMV solenoid system Disconnection, short circuit, or grounding fault in dumping solenoid system Short circuit with power source on hot side of dumping solenoid Short circuit with power source on return side of dumping solenoid Disconnection or grounding fault in boom lever kick-out solenoid system Disconnection in boom RAISE/LOWER pressure switch system Disconnection, grounding fault, or short circuit in boom angle sensor system Short circuit or disconnection in travel speed sensor system Disconnection, grounding fault, or short circuit in joystick caution buzzer relay system Disconnection, grounding fault, or short circuit in steering lever angle sensor system Deviation of potentiometer signal of steering lever angle sensor/frame angle sensor system Disconnection, grounding fault, or short circuit in frame angle sensor system Disconnection or grounding fault in steering lever lock switch system Disconnection, grounding fault, or short circuit in joystick neutral interlock relay system Disconnection, grounding fault, or short circuit in joystick basic pressure control EPC solenoid system Error code displayed on CGC D160KZ DLFAKA DXH8KZ DXH7KZ DXH4KZ DXH5KZ DXH6KZ DWJ2KZ DDF2KZ DDF3KZ DLT3KZ DLE2KZ DAQ0KT DGF1KB DDTQKB DDTNKB DDTKKB DDTLKB DDTMKB DDTDKA DDT8KA DW23KZ DW23KB DW24KZ DW24KB DW25KZ DW25KB DDNJL4 DK10L5 DDTDKB dDT8KA DDT8KB DDA7LD DDD8KX DDD7KX DLF6L8 DLT2KZ dLE2KZ dLT3KZ DWNAKZ DXHPKZ DXHNKZ DXHNKY DXHNKB DW72KZ DDNGL4 DKA0KX DLt3KZ D100KZ DK5FLX DKD0KZ DKD0KX DDQ2L6 D191KZ DXF0KZ Former error code E010 E011 E012 E013 E014 E015 E016 E018 E020 E021 E022 E023 E024 E025 E026 E027 E028 E029 E030 E032 E033 E034 E035 E036 E037 E038 E039 E070 E072 E073 E074 E075 E076 E077 E078 E080 E081 E082 E083 E084 E085 E043 E044 E045 E049 E051 E052 E055 E056 E057 E058 E059 E061 E062 E063
Transmission controller
E11 CALL CALL CALL CALL CALL CALL CALL CALL CALL E01 CALL CALL CALL CALL CALL E00 E00 CALL E01 CALL E01 CALL E01 E01 + CALL CALL E00 CALL E00 E00 E00 E00 E00 CALL CALL CALL E01 + CALL CALL
Work equipment controller
E00 E01 E01 E01 E01 + CALL + CALL + CALL + CALL E00 E01 + CALL
20-199-11
(8)
WA1200-3
ERROR CODES TABLE
Error codes related to engine controller (marked with *) are also displayed on the CGC.
Com- Diagponent nosis code V-1 V-2 V-4 V-5 V-6 V-7 V-8 V-9 V-10 V-11 V-12 V-13 V-14 V-15 V-16 V-17 V-18 V-19 V-20 V-21 V-22 V-23 V-24 V-25 V-101 V-102 V-103 V-104 V-105 V-107 Remedy code Error code displayed on CGC C253 (*) C143 (*) C151 (*) B@BFZK b@BFZK B@CENS b@CENS B@HANS 2G41MB 2G42ZG 2G43ZG B@GAZK B@GBZK B@GCZK B@G5ZK b@G5ZK B@BCZK b@BCZK 15BONX AA1ANX AA1BNX AA1CNX AA1DNX AB00MA DBB0KK DBB6KP DBB7KP DBB5KP DBB0KQ DBBRKR DAQSKR DBCSKR DB9SKR DAF0KR DVO0KB D5ZPKB D5ZQKB DHPCKX DHPDKX DHU3KX DH24KX DHU2KX DHT3KX DHT8KX DH20KX DHT9KX DHTAKX DGT1KX DGT2KX DGE5KX DHT4KX DHT5KX Former error code E901 E902 E904 E905 E906 E907 E908 E911 E912 E913 E915 E916 E917 E918 E925 E926 E927 E928 E931 E932 E933 E934 E935 E937 E811 E812 E813 E814 E818 E824 E825 E826 E827 E828 E841 E843 E844 E861 E862 E863 E864 E865 E866 E867 E868 E871 E872 E874 E875 E877 E878 E884
Failed system Engine oil level below LOW level Engine oil pressure below specified pressure Engine coolant temperature above 105C Fuel level below specified level (While engine is stopped) Fuel level below specified level (While engine is running) Torque converter oil temperature above 120C Torque converter oil temperature above 130C Hydraulic oil temperature above 105C Lowering of front or rear brake oil Lowering of front brake oil pressure Lowering of rear brake oil pressure Disconnection or grounding fault in battery fluid level sensor 1 system Disconnection or grounding fault in battery fluid level sensor 2 system Disconnection or grounding fault in battery fluid level sensor 3 system Brake oil level below specified level (Before engine is started) Brake oil level below specified level (while engine is running) Coolant level below LOW level (Before engine is started) Coolant level below LOW level (While engine is running) Clogging of transmission oil filter Clogging of air cleaner 1 Clogging of air cleaner 2 Clogging of air cleaner 3 Clogging of air cleaner 4 Charge trouble of alternator Disconnection or short circuit with power source in NSW power supply system Grounding fault of 24 V in sensor power supply Grounding fault of 12 V in sensor power supply Grounding fault of 5 V in sensor power supply Wrong connection of connector Failure in communication with CGC or controller Disconnection, grounding fault, or short circuit with power source in S-NET (line between S-NET and transmission controller) Disconnection, grounding fault, or short circuit with power source in S-NET (line between S-NET and modulated clutch controller) Disconnection, grounding fault, or short circuit with power source in S-NET (line between S-NET and work equipment controller) Disconnection, grounding fault, or short circuit with power source in S-NET (line between S-NET and main monitor) Short circuit with power source in buzzer output system Short circuit with power source in check lamp system Short circuit with power source in flashing synchronization signal system Disconnection or grounding fault in boom bottom pressure sensor Disconnection or grounding fault in boom head pressure sensor Disconnection or grounding fault in rear brake oil pressure sensor system Disconnection or grounding fault in work equipment relieve pressure sensor system Disconnection or grounding fault in front brake oil pressure sensor system Disconnection or grounding fault in transmission main relief pressure sensor system Disconnection or grounding fault in steering relief pressure sensor system Disconnection or grounding fault in torque converter outlet oil pressure sensor system Disconnection or grounding fault in transmission modulation oil pressure sensor system Disconnection, grounding fault, or short circuit with power source in transmission lubricating oil pressure sensor system Grounding fault in torque converter oil temperature sensor system Grounding fault or short circuit with power source in hydraulic oil temperature sensor system Disconnection, grounding fault, or short circuit with power source in atmospheric temperature sensor system Disconnection or grounding fault in PPC relief pressure sensor system Disconnection or grounding fault in torque converter inlet oil pressure sensor
VHMS controller
V-108 V-109 V-110 V-111 V-113 V-114 V-115 V-116 V-117 V-118 V-119 V-120 V-121 V-122 V-123 V-124 V-125 V-126 V-127 V-128 V-129 V-130
WA1200-3
20-199-12
(8)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

A A Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted. When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not allow any unauthorized person to come near. may spurt out and cause burns, so wait for
If the radiator cap is removed when the engine is hot, hot water A the engine to cool down before starting troubleshooting. A A
Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first. removing the plug or cap from a location which is under pressure from oil, water, or air, always release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
A When
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 function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms. 1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: . Parts that have no connection with the failure or other unnecessary parts will be disassembled. . It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask user or operator I) Have any other problems occurred apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 5) Had any repairs been carried out before the failure? When were these repairs carried out? 6) Has the same kind of failure occurred before? Check before troubleshooting 1) Check the oil level 2) Check for any external leakage of oil from the piping or hydraulic equipment. 3) Check the travel of the control levers. Check the stroke of the control valve spool. Other maintenance items can be checked externally, so check any item that is considered to be necessary. Confirming failure Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. + When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. Troubleshooting Use the results of the investigation and inspection in items 2 - 4 to narrow down the causes of failure, then use the troubleshooting flowchart to locate the position of the failure exactly. * The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. Measures to remove root cause of failure Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. To prevent this, always investigate why the problem occurred. Then, remove the root cause. 4) 5)
4.
5.
2.
6.
3.
20-202 0
WA1 200-3
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
ber of machine
1)
Look at the table of troubleshooting the shop manual toots. * . T-adapter Hydraulic pressure gauge and prepare
tools in * Pinpoint locations of failure (carry out
the necessary
kii, etc. the nec1) Before starting troubleshooting, locate and
2)
Look in the parts book and prepare essary replacement parts.
21
See the Troubleshooting manual, select
Section
of the shop flowchart
a troubleshooting
Drive
and operate
the
machine if there
to confirm is really a
the condition
and judge
Step 4
Was there
anything
strange
about
the ma-
chine before the failure Did the failure
occurred? out before the
occur suddenly?
Had any repairs been carried
WA1 200-3
20-203 0
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAlmNANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and Handling hydraulic equipment (particularly gear oil and hydraulic oil). 1. POINTS TO REMEMBER ELECTRIC EQUIPMENT
Handling wiring harnesses
WHEN
HANDLING
1)
and connectors
Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
Main failures
occurring
in wiring
harness
Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
Improper insertion
I
Defective crimping or soldering of connectors The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper correction or breakage.
TEwoo192
Crimped portion
TEwGm93
20-204 0
WA1 200-3
TROUBLESHOOTING
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 soldering may be damaged, or the wiring may be broken.
TEwOOl94
High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. As already said, the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry with compressed air and spray it with a contact restorer. f When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. * If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air.
TEWOO196
TEWW196
WA1 200-3
20-205 0
TROUBLESHOOTING
2)
Removing, installing, and drying connectors and wiring harnesses Disconnecting connectors Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. * Never pull with one hand. When removing from clips When removing a connector from a clip, pull the connector in a parallel direction to the clip. * If the connector is twisted up and down or to the left or right, the housing may break.
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. * If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
20-206 0
WA1 200-3
TROUBLESHOOTING
Connecting
connectors
Check the connector visually. 1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). 2) Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. 3) Check that there is no damage or breakage to the outside of the connector. If there is any oil, water, or dirt stuck to * the connector, wipe it off with a dry cloth. If any water has 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. If there is any damage or breakage, re* place the connector. Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper, push in the connector until the stopper clicks into position. Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion or the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. j, If the connector cannot be corrected easily, remove the clamp and adjust the position. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
WA1 200-3
20-207 0
TROUBLESHOOTING
Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 6) Disconnect the connector and wipe off the water with a dry cloth. Ir If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
TEWW196
Dry the inside of the connector with a dryer. lf water gets inside the connector, use a dryer to dry the connector. + Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. * After completely drying the connector, blow it with contact restorer and reassemble.
T-adapter
20-208 0
WA1 200-3
TROUBLESHOOTING
3)
Handling
control
box
The-control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. Do not open the cover of the control box unless necessary.
Do not place objects on top of the control box. Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. During rainy weather, do not leave the control box in a place where it is exposed to rain.
Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point. -
II
TEWC0206
2.
Points to remember
electric circuits when troubleshooting I) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
3) Disconnect and connect the related connectors several times to check. * Always connect any disconnected connectors before going on to the next step. If the power is turned ON with the connectors still disconnected, unnecessary abnormality * displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. + If there is any change, there is probably defective contact in that circuit.
WA1 200-3
20-209 0
TROUBLESHOOllNG
POINTS TO REMEMBER WHEN CARRYING OUT MAIMENANCE
3. POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful.
1) Be careful of the operating environment.

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

If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use unit exchange. Disassembly and main-tenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be confirmed with special test equipment.
I
31 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 entering. 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, collect it and ask the customer to dispose of it, or take it back with you for disposal.
TEWOO207
4)
Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
TEwOO209
20-210 0
WA1 200-3
TROUBLESHOOTING
51 Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6)
Flushing operations
After disassembling and assembling the equipment, or chanoing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.
oil
7)
Cleaning operations
After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3~11particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.
WA1 200-3
20-211 0
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

lItem 1. Check fuel level, type of fuel 2. Check for impurities in fuel 3. Check hydraulic oil level 4. Check hydraulic filter (Torque converte, Transmission hydraulic, hydraulic tank oil) 5. Check brake oil level 6. Check engine oil level 7. Check coolant level 8. Check dust indicator for clogging Judgement standard Remedy Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water Clean or replace
9. Check for looseness, corrosion of battery terminal, wiring 10. Check for looseness, corrosion of alternator terminal, wiring 11. Check for looseness, corrosion of starting motor terminal, wiring 12. Check operation of instruments
Tighten or replace Tighten or replace Tighten or replace Repair or replace
13. Check for abnormal noise, smell 14. Check for oil leakage 15. Carry out air bleeding 16. Check effect of parking brake, wheel brake
Repair Repair Bleed air Repair or replace
17. Check battery voltage (engine stopped) 18. Check battery electrolyte level 19. Check for discolored, burnt, exposed wiring 20. Check for missing wiring clamps, hanging wiring 21. Check for water leaking on wiring (be particularly careful attention to water leaking on connectors or terminals) 22. Check for blown, corroded fuses 23. Check alternator voltage (engine running at l/2 throttle or above) (If the battery charge is low, the voltage may be approx. 25V immediately after starting.) 24. Sound of actuation of battery relay (when starting switch is turned ON, OFF)
24 - 26 V -
Replace Add or replace Replace Repair Disconnect :onnector and dry Replace
28.5 - 29.5 V
Replace
20-212 0
WA1 200-3
TROUBLESHOOTING
CONNECTOR
TYPES AND MOUNTING
LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

* The Address column in the table below shows the address in the connector
(Bdimensional drawing). arrangement drawing
WA1 200-3
20-2 13 0
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING
LOCATIONS
Mounting location El0 El1 El2 E13 El4 El5 ER3 ER5 ER6 ER7 ER8 DTl DTl DTl Terminal DTl DTl 1 DTHD4l DTHD4 DT2 DT2 DT2 2 2 2 1 3 3 Compressor magnet clutch Diode Intermediate connector Engine ground PRE-LUB starter Safetv relav
Address H-9 l-3 K-5 K-5 l-2 H-2
ERI 1DTI
1 6 1Intermediate connector
1 I intermediate connector 1 1Intermediate connector 1 3 4 3 1 2 Intermediate connector Intermediate connector Intermediate connector Intermediate connector Ether injection solenoid Diode
1 L-2 1 1 GO2 1M 1 K-l 1 1 GO3 I M 1 K-1 1

K-1 L-2 L-2 L-2 l-9 l-9 GO4 GO4 GO5 GO6 GO6 GO7 I ~08 DTl Plug Plug DTl DTl M IM
1 2 1Riaht working lame 1 2 I Rioht workino lamp

3 1 1 3 2 2 I Stairway lamp switch Left backup buzzer Left backup buzzer Backup buzzer relay Coolant level sensor Left working lame
I Kl 1 J-9 I
K-4 K-7 K-7 K-7 l-9 K-7
ER4 I DTHD4l
ETHl ;t&r ETH2 DTl ETH3 F02 F04 F05
1 2 I Left working Iamp

6 I Left combination lamp 1 I Right backup buzzer
1
Imnnm,l -pi
DTl DT2 DT2
I K-6 I 1 K-7 I I K-8 I

K-8 J-8 l-9 K-8
1 I Ether iniection solenoid 6 3 3 Intermediate connector Boom angle sensor
I I-9 I I GO9 I M A-4 A-6

Gil
FOl 1DTl
1 6 I Intermediate connector
I A-5 l l GlO l-pi l mnntirir

l-pin conneuor
Right backup buzzer Left engine room lamp Right engine room lamp Left rear side working lame
G12 G13 G14
M M M I I
I
2 2 2
Proximity switch for load meter A-5
F06 I DT2 F06 l X F07 l X F07 FO9 F10 Fll F12 F13 F14
I
l
3 I Boom bottom Dresswe sensor I D-l I

3 1 Drive force control dial dial
I d-l I I G15 I M
2 1Rioht rear side working iamo I H-9 I 2 1Stairwav lame

1 I Right front combination Iamp
I 3 1Travel speed control I Terminal I 1 I Horn (350 Hz)

Terminal 1 Terminal 1 DT2 DT2 1 2 2 3 3 Horn (315 Hz) Horn (315 Hz)
1 d-l I I G16 1M
I B-l I I GND I M I B-l I I GND I M A-5 A-5 B-l A-2 A-4 HRl lDT2 I DT2 DT2 DTI DT2 DT2 DTI DT2
I K-8 I I B-7 I
F08 1Terminal I I I Horn (350 Hz)
1 I Left front combination lamp1 C-l I
Working lamp (Optional) Working lamp (Optional) Bucket positioner
~1
GRl HR4 HR6 HR8 HR9 HRlO HRll I HR12
DTlA
12
lntermedtate connector
Boom head oressure sensor A-3
1 2 I NC (Neutral) solenoid
I 2 I Diode 2 I Bucket TILT switch 2 2 2 2 2 2 I I I Bucket DUMP switch Rear brake level Boom dump solenoid Boom dump solenoid Front brake level Boom lever detent switch
t G-9 l
F15 I DT2
3 1 Wheel rotation sensor
I A-2 1 I HR2
I C-1 I C-l A-5 A-4 A-9 B-9 B-9
I G-l 1 I C-8 I
C-8 E-l B-7 B-7 D-l C-8
F20 I Terminal I 1 I Chassis ground F21 I Terminal1 1 I Horn (add) F22 F23 F24 FL1 FL2 FRl FSl Terminal 1 TeninaI 1 Terminal 1 HD-26086 14
HD-25085 14
I D-8 I I HR3 I DT2
Horn (add) Horn (add) Horn (add) Intermediate connector Intermediate connector Intermediate connector
HD-86J86 23 lL I
I DT2
2 I Boom RAISE switch 2 I Boom LOWER switch 2 I Parkina brake solenoid
1 B-7 I I C-8 I I F-l l
FR2 I HP4W82l21 I Intermediate connector 2 I Fuse box
I B-8 I I HR13 I DT2 I h-7 I I HR14 I DT2
20-214 0
TROUBLESHOOTING
LOCATIONS
Connectar Type No. JL9 JLlO ~ HR17 l DT2 l ~ HR18 1DT2 l HR19 1DT2 I 1 HSl HS2 ~ HS3 HS4 JBl JB2 JEI JE2 JE3 JE4 JFl JF2 DT2 DT2 DT2 DT2 DTl DTl 1DTl DTl DTIB DTl DTI DTl 2 l Ememencv brake switch 2 l Ememencv brake switch 1 E-I 1 JLII DT2 DT2B DTI
No. of pins 6 8 6 6 6 6 6 6 6 6
Mounting location Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector
Address a-2 a-2 a-l a-l I a-1 a-l a-l a-l a-l a-l a-l I a-l I a-l a-l a-l c-l C-l C-I Q-9 1W-6 I w-5 T-2 T-2 T-l u-2 Q-I R-I l Q-I l Q-9 Q-9 O-8 N-7 O-8 N-7 T-9 I i-7 I i-5 i-6 i-5 w-5 w-6 w-5
/ E-I 1 JL12 DT2 2 I Emergencvoarking brake reset solenoid1 F-l 1 1 JL13 1DTI I 2 3 3 3 8 6 6 8 6 6 6 6 Hydraulicoil temperaturesensor A-6 Work equipment oil pressure sensor A-7 Steering oil pressure switch PPC oil pressure sensor Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector C-I G-9 V-9 v-9 V-8 v-9 v-9 O-I N-l M-4 JL14 JL15 JL16 JL17 JL18 JLI9 DT2 DT2 DT2 DT2 DT2 DT2
6 I Joint connector
1 6 1Joint connector
I T-9 1 I JL20 l DT2 I 1 JL21 1DTIB I JL22 DT2B JL23 JL24 JL25 DTPB DT2 DTI
6 I Joint connector 8 l Joint connector 8 Joint connector 8 6 6 Joint connector Joint connector Joint connector
JF3 DT2 JF4 I DTZB I JF5 1DTlBl JF6 JGl JG2 JG3 JG4 JG7 DTI DTlB DTI DTlB DTI DTIB I I I
8 1Joint connector 8 / Joint connector 6 8 6 8 6 8 6 Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector
JL26 DT2 6 Joint connector 6 Joint connector 1M-4 I JM4 DTI I M-3 I I JRI i DTIB 1 8 1Joint connector M-4 w-7 w-7 w-7 W-8 W-8 I W-8 I I JR2 I DTI JR3 JR4 JR5 JR7 JR8 JR9 DTI DT2 DT2 DTl DTlB DT2 I 6 I Joint connector 6 6 6 6 8 6 Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector
JG8 l DTI JGN l DTl JGN I DTl
I Joint
connector
6 l Joint connector 6 1Joint connector
1M-2 I I JR10 I DT2 I I M-6 I I JRII I DT2 I JR12 DTI JR13 DTlB JR14 DT2 JR15 DTl JR16 DTl
6 I Joint connector 6 l Joint connector 6 8 6 6 6 6 Joint connector Joint connector Joint connector Joint connector Joint connector Joint connector
JLl1
DT2 1 6 1Joint connector 6 I Joint connector 8 \ Joint connector 6 Joint connector 8 8 6 6 Joint connector Joint connector Joint connector Joint connector
I z-2 I
JRA
DT2
JL2 I DT2 I JL3 1DT2Bl JL4 DTI JL5 JL6 JL7 JL8 DTlB DTZB DT2 DT2
1 Z-2 I I JSI
I SWP 1 12 I Jovstick lever switch 3 I Potentiometer 1 Console switch I 6 6 8 Console switch Joint connector Joint connector Joint connector
I z-2 I I JS2 I x I l-pin z-4 JS3 COllWCt0r l-pin z-4 JS4 connector z-4 z-2 z-2 JTI JT2 JT3 DT2 DT2 DT2B
WA1 200-3
20-Z
15
TROUBLESHOOTING
LOCATIONS
?O-216
0
WA1 200-3
TROUBLESHOOTING
LOCATIONS
Conlector No.
Type
No. of pins
Mounting
location relav
Address
L127 1Reiavl L128 1DT2 L129 I L130 &$&, L131 &$&), L132 L133 Relay Relav 1 I
5 1Steerina neutral 2 1 Diode 2 I Resistor 1 1 5 5
1 n-8 1 I r-9 I
I r-9 I MT5 OPl QP2 DT2
l-pin
Travel speed ON/OFF indicator u-2 Travel speed ON/OFF indicator Dust indicator Dust indicator 1 relay 2 relav 3 relav 4 relav t-2 m-9 n-9 I n-9 I n-8
Transmission modulating oilpressure sensor ab-6 Fuse box Fuse box Fuse box I Fuse box I Fuse box v-7 v-7 v-7
L134 1Relavl ~135 I Relay1 L136 &F&r L137 &$&, L138 L139 g&
COlXECtO~
5 I Dust indicator 5 I Dust indicator 1 1 1 1 1 1 1 1
OP3 0~4
I,2L,I
I,ZL,,I
1 COtNECtOf l-pin connector 1 z-tn. 1 I I
Iv-71
1 0~5
Remote positioner RAlSEindicator n-8 Remotepositioner RAlSEindicator o-8 Remote positionerLOWER indicator Remote positionerLOWER indicator PRE-LUBE indicator PRE-LUBE indicator Turn signal switch n-7 o-8 r-9 o-9 n-7 n-7
l-P
L140 &:&tor L141 &!$&,, L142 I&&orl L143
I,i.2~l
I Turn
sianal switch (24 V/12 VI (24 V/12 VI (24 VI12 V)

I
~144 I&$!&,/ L145 I&!$,,r/ ._. L146 mnnector -p l-147 L150

I
1 ( Turn signal switch 1 1DC converter 1 2

I
I n-7 ) v-5
v-6 v-5 s-9 I n-9
I 01 I ~2 I ROl
R03 R04 R05 R06 R07
IHD-~w I 21 I Enaine controller lH5~ I DT2 DT2 DT2 DTl ITerminal I I 31 I Engine controller I 1
I T-9 I T-9 I
2 l Torque converter oil fiiterdogging sensorI S-l I 2 1Torque converter oil filterclogging Sensor1 S-l 2 2 2 I Diode Diode Fuel level sensor Slow blow fuse I Slow blow fuse u-2 u-2 v-9 W-8 IW-81 IW-81
R02 ( DT2
DC converter DC converter Service meter ~~~
KES KES ~-
2 -,-1
L152 I Relavl L160 I;;{$;rl L161 l,Z~,,l LRI
5 I Alternator Alternator 1 I Alternator
sianal relav indicator indicator connector
I q-9
I o-9 I N-9
I I
Terminal 1
R08 \Terrninal I I I Slow blow fuse
1~~950861 31 I Intermediate
I
LR7 I DTI LR~ I DT2 LR9 I DT2 MO1 M02A M02B MC1 MC2 MC3 MT1 MIC 040 040 X I I I DT2 I I I 4 \ Intermediate 3 I Intermediate 4 I Intermediate 21 20 16 3 2 2 Modulated Modulated Modulated Resistor Diode connector connector connector clutch controller clutch controller clutch controller
R23 (DT2 R25 R26 R27 R30 R31 RAI RA2 RA3 DT2 KES DT2 DTI DTl
2 1Diode 2 I Rear windshield 2 2 2 3 3 3 6 Diode Side windshield Diode Left condenser Right condenser Intermediate Intermediate Intermediate connector connector connector connector connector washer washer
I a-9 I
1M-9 I M-9 I M-9

v-5 v-5 v-4 n-8 s-9 I v-4 z-9
1 R24 I KES I
\ O-8 I
Q-9 P-8 Q-9 P-9 P-8
I
Modulated clutch directcoupling switch u-8
DT2/DTl 4 _ M2/DTl DT2
u-9
1 R-9
I x-3 I x-2 I
MC4 I-
2 I Diode 3 I Tranunission lubricating oil preswre~nwj
RA4 I DTHDSI 1 I Intermediate
1 RA5 1DTI
1 4 I Intermediate
1x-2 1
WA1 200-3
20-217 0
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS
Connectar No. RA6 RA7 RA8
Type
I
No. of oins ,~ 1 2 2
Mounting location intermediate connector Battery fluid level sensor Battery fluid level sensor
Address u-9 W-3 R-9
Connectar No. T20 T21 T22 T23 T24
Type DT2 DT2 DT2 DT2
No. of pins 2 2 2 2
Mounting location 1st bypass solenoid
Add. ress
X-8
DTHD3 DTl DTl
R (Reverse) bypasssolenoid ab-4 F (Forward) bypasssolenoid aaR (Reverse) drain solenoid ab-4
RA9 1DTl RAll
1 2 1Batten, fluid level sensor
1 R-9 1 1 R-9 1
RAlO 1DTHD41 1 1Intermediate connector
1DT2 1 2 1Torqueconverter oil temperaturesensor 1 v-8
I Terminal 1 1 I Terminal
I S-9
V2B IAMPO7OI 12 RES3 IRES4 I-
I 2 I Resistor
I
(150 Q f 1 %I
I a-l
V3A
I AMP070 I 18
I VHMS
controller
r-l
I VHMS controller
2 I Resistor (120 Q)
I m-5 I
WORK21 M SMALLI M STL I DT2 SVl sv2 III I I 1 1 Left front combination lamp I P-l 2 I Steering lock switch 4 1Solenoid 1 4 I Solenoid 2 I WORK21 M WORK3 M WORK3 M
I I
2 2 2
I Riaht
headlamp
I M-6
2 1Left headlamp Right working lamp Left working lamp
I M-5
M-6 M-5
I t-1 I
I S-9 I
I s-9 I
T5 T6 Ti T8 T9 TlO 111 T12 T13 T14 T15 ~16 T17 T18 T19
I DT2
1 2 l2nd solenoid 1 2 I2nd fill switch

2 I3rd solenoid
I x-81
1DTl
1DT2 IDTl DT2 DTl DT2 DTl
1 x-8 I 1 v-8 I v-8

ab-5 aaab-3
2 I3rd fill switch

2 2 2 2 Modulated clutch solenoid R (Reverse) solenoid R (Reverse) fill switch
Modulated clutch fill switch ab-6
1DT2 I I DTl I
I DT2
2 1F (Forward) solenoid 2 I F (Forward) fill switch 2 I Speed sensor 2
I z-2
I I
I DT2 I DT2
DT2 DT2
I ModulatedclutchrotationsensorlabParking brake indicator switch y-l
1w-4 I
I z-9 I
2 I Engine rotation sensor
1 2 1 2
Torque converter oil temperature sensor a b-5
20-218 0
WA1 200-Z
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DIAGRAM
FL2 FL1 .
I
AR02 AR01
.
..._
Rl8 F22 HRi9
HR14 BwWOl5Ol +
20-220
0
WA1 200-3
TROUBLESHOOTING
CONNECTOR ARRANGEMENT
DIAGRAM
--ilS
c2
807
G16
G13
ETH2
.E03
GRl GR6
\
E07 Ell
E05
El3
GO4
\
I 16 AiOl AL02
El4
ERl ER6 ER7 ER8
BWWO1502
WA1 200-3
20-221 0
TROUBLESHOOTING
DIAGRAM
LRl LR2 I JR1 1 1119 -..-R30 R3! PHl \\\ JM4 11..
RAlO RA9 I_._ \ I._
R3-
WORK1 WORK2 WORK3 JHD
JGN
WORK3
WORK2 WORK1 JF6 JF3
Rll
JF2
JFl
TURN
SMAlLL
Ri2 BWW01503 +
20-222
0
WA1 200-3
TROUBLESHOOTING
+ PRE SV2
JGR3
REl
01
JE4 R07
JG4
/JG7 ,JG3 ,JGl bJG2
JR2
RA RA3
JGRP
RAS RA4 RA12
R01 R02 +
RA13 si2
WA1 200-3
20-223 0
TROUBLESHOOTING
DIAGRAM
c2 C3B I
+-
CO6
co4 \ \
JLb
JL6
20-224
0
WA1 ZOO-3
TROUBLESHOOTING
DIAGRAM
FS6 FS6 I I / FS4
JS2 33
YY\M\\\
'A10
1 A16 +
\ DLi
Al2 A\8B
A14
A14
1542 BWWO
WA1 200-3
20-225 0
TROUBLESHOOTING
DIAGRAM
L6iil:4L73L;L91 Ll14 L69 L69 L92 L61 L99 L68 L67 L63 L62 L4i Li6 W
17;;z3/::: Lf 19 L133 & -1134 I ~j;l?T L39 I
LiO6
RESP
RES4
LO6
L26
Li6 I L96 I L97 ,
20-226
0
WA1 XXI-3
TROUBLESHOOTING
DIAGRAM
+
Ll03 L160 LO1 L128 Ll50
t en I. OP2.OP3 OP6
WA1 200-3
20-227 0
TROUBLESHOOTING
DIAGRAM
Tl4
Ti2
T18 Tl
20-228 0
WA1 200-3
TROUBLESHOOTING
DIAGRAM
I8 I
c21 A17 Al6 Cl3 !ll Cl7 Cl4 Cl6 Cl8 C27 c12 \ \\\ 1
c29
c20
!!
C23
C24
.C26 .
cne
WA1 200-3
20-229 0
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

* The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing. No. of pins X type connector Male (female housing) Female (male housing)
EElI 2 4
TEwoozz5
20-230 0
WA1 200-3
TROUBLESHOOTING
No.
of pins
T
Male (female
housing)
SWP type connector
Female (male housing)
6
TFNc4l235
8
4 8
1 5 9
BLFWO34
4 8 12
BlPOKl35
11
11
14 3 i io ?14 TEwooz39
1
1
TEwoo240
5 16 9
8 2
WA1 200-3
20-231 0
TROUBLESHOOTING
No. of pins
T
Male (female housing)
M type connector Female (male housing)

2
2
e7 1
BLFOCO38
TEwoo244
ElS 4
TEwca245
2
lEwoo246
6 cl 3 6
TEWOO247
Qzl
8 5
BLFWXO BLPOOO41
20-232 0
WA1 200-3
TROUBLESHOOTING
NO.
of pins
T
S type connector Female (male housing)
Ezl
8 TEwKQ49 1 \ 6 /
10
(White
$3
5
10
Two0251
12 (White i 5
BEL00113
12
BEL00114
16 (White
is0
i6
BEL00115
16
BEL00116
WA1 200-3
20-233 0
TROUBLESHOOTING
CONNECTlON TABLE FOR CONNECTOR PIN NUMBERS
No. of pins
T
S type connector Female (male housing)
10 (Blue
10
1
BEL00117
BELO
12 (Blue
12 ElFwx3 8 8
1
16 (Blue
El
0
16
TEwoozs6
20-234 0
WA1 200-3
TROUBLESHOOTING
CONNECTION
TABLE FOR CONNECTOR PIN NUMBERS
No. of pins
MIC connector Male (female housing) Female (male housing)
13
13
BLFOOO4B
9
17 9
00 0
Bl.Pooo50
17
10
17
BLPmo52
21
WA1 200-3
20-235 0
TROUBLESHOOTING
No. of pins
T
AMP040 type connector Female (male housing)
12
8LFwos5
BLFUOOBB
16
16
20
ai
11
1 lEww234
20-236 0
WA1 200-3
TROUBLESHOOTING
No. of pins
lMale (female housing)
AMP070 type connector Female (male housing)
10
EWWOl601
BWWO1602
12
i 5
12
BWW01603
NW01604
14
aI
6 BWWO1605 EWWOl606
18
18
BWWO1607
18
8WWO1608
10
20
20
EWWOl609
Y
BWWOl6lO
WA1 ZOO-3
20-237 0
TROUBLESHOOTING
No. of pins
T
I
L type type connector Female (male housing)
ELI
a
m
20-238 0
WA1 200-3
TROUBLESHOOTING
No. of pins
Automobile (KESI 1 connector Male (female housing) Female (male housing)
WLOI
140
it3
BVLOI 141
BVLOl142
k
4 1
BLFQWW
8
Em
. f?3
5
BU%QQ?2
WA1 200-3
20-239 0
TROUBLESHOOTING
Type
Shell size code
T 1
HD30 series connector
Body (Plug)
Pin (male terminal)
Body (Receptacle) Pin (female terminal)
EWWO1612
18-8 (1)
Pin (female terminal)
Pin (male terminal)
NW01614
Pin (male terminal)
BWWO1616
18-14 (2)
Pin (male terminal)
BWWO1617
20-240 0
WA1 200-3
TROUBLESHOOTING
TYPE Shel size code
HD30 series connector Body (Plug) Pin (male terminal) Body (Receptacle) Pin (female terminal)
BWWO1820
18-2C (3)
Pin (male terminal)
BWWO1621
BWWO1622
Pin (male terminal)
BWWO1623
fn\ 0
'00 90 02'
200
IlO
o '2
03 o 060'6 0405 0'7 ::O ,' 0 O'6 15
,07
020
0'9
BWWO1624
18-21 (4)
Pin (male terminal)
BWWO1625
BWWOl626
WA1 200-3
20-24 1 0
TROUBLESHOOTING
Type
Shell size code
T
Body (Plug) Pin (male terminal)
HD30 series connector Body (Receptacle) Pin (female terminal)
f\
BWWO1627
0
0
ova oz oy
OS
oT
0
ox
ow
BWW01628
24-9 (5)
Pin (male terminal)
l-3 0
SOT
ox
ooopooV
oy
ow
/OR
X y
lT OS .Z lwl l
u
BWW01830
BWWOI 629
Pin (male terminal)
BWWO1631
BWWO1632
24-16 (6)
Pin (male terminal)
BWWOl633
BWW01634
20-242 0
WA1 200-3
TROUBLESHOOTlNG
Type
Shell size code i
EWWO1636
24-21 (7)
Pin (male terminal)
BWWO1637
BWWOI 636
Pin (male terminal)
BWWO1639
BWWOl640
24-23 (8)
Pin (male terminal)
BWWO1642
WA1 200-3
20-243 0
TROUBLESHOOTING
Type
Shell size code
T 1
BWWO1644
24-31 (9)
Pin (male terminal)
BWWO I646
20-244 0
WA1 200-3
TROUBLESHOOTING
CONNECTIONTABLE FOR CONNECTOR PIN NUMBERS
No. of pins
T
Body Plug)
[Number
is printed on each connector (Wire inserting end).]
DT series connector Body (Receptacle)
fiE3
lzzil
I
BWWO1647
EWWO1649
6WWO1650
BWW01652
WA1 200-3
20-245 0
TROUBLESHOOTING
No. Of pins
T
Body (Plug)
[Number is printed on each connector (Wire insetting end).] DT series connector Body (Receptacle)
BWWOl653
BWWO1654
@f!a!@
Em 08
I
4
BWWO1655
BWW01656
12
6
BWWO1657
BWWO1656
20-246 0
WA1 200-3
TROUBLESHOOTING
No. of pins
T
Body (Plug)
[Number is printed on each connector (Wire inserting end).] DTM series connector Body (Receptacle)
B
0 0
ihdi
1
BWWOl659
m c3
2
BWW01660
WA1 200-3
20-247 0
TROUBLESHOOTING
No. of pins
T
Body Fb)
DTHD series connector Body (Receptacle)
Q 0
0
EWWO1661
4%
BWWO1662
20-248 0
WA1 200-3
TROUBLESHOOTING
EXPLANATION
OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM

(For details, see section STRUCTURE AND FUNCTION) TRANSMISSION CONTROL SYSTEM
(Input sianals) (Dutwt sionalsl
_I
ECMV 3rd Shift-down c

0
ECHV R
Transmission cut-off switch
:....r:,...-
Auto/Manual
Backup
lamp relay
psolenoid
Fill wq?Fill *7Fill *7Fill *F---Fill -7-
switch
IstLE
I
switch R
switch
switch
switch
3
Work ewipsent
Transmission temPerature
oil
TXW02438
WA1 200-3
20-249 0
TROUBLESHOOTING
EXPLANATION
OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
MODULATED
CONTROL SYSTEM
(Input sionals) Klutuut sisnats)
I
Drive control force voltaoe $---_H
Travel control
speed voltaoe
Transmission
cut-off
selector
snitch
NC solenoid
valve
outout I
Sneed
settins
LE
VHMS controller
(+12VI
Modulated clutch (MOD/C) controller
Sneed
set a7
ON/OFF
sional
Modulated 1 Transmission -7 I Transmission q
clutch *7
ECMV fill
signal
F clutch
sisnal
Transmission O?
R clutch
signal
1st 2nd
clutch clutch
sinnal sisnal
Transmission q Transmission q
=7
3rd
clutch
signal TXW02439
20-250 0
WA1 200-3
TROUBLESHOOTING
WORK
EQUIPMENT CONTROL SYSTEM

lnout signals (1) Output Boon lever sianals kick-out solenoid
Boom anale r
ootentioaeter
@Boom
RAISE
witch
12) Boom PPC dumoino
solenoid
+?!!I
A: B: P: S: Analog signal Dioital sional Pulse signal S-NET sional Remote buzzer @Booa lever detent snitch (3) Positioner outout Main twitch raise Work eouionent controller (4) (5) (6) (7) R-IIxzI @ nettino Q) ~:y;;:,m:j;;ner @ @
snitch
inout
check
monitor
Diselar of lower settino of remote positioner Disolav of raise setting of remote positioner Disolav of raise stop of remote positioner Disolar of lower stop of remote Positioner TMS controller
Remote positioner raise eta0 selector witch Remote mritioner lower tten selector switch
@Remote Positioner function selector @Steerins potentiometer calibration relet switcl
:8) EPC solenoid of steering
for main
control Pressure Steerino lock velve To steerino
rrn? 5i1iy
@Steering
lever
anal1
@Frame angle Potentiometer
!y;;;
caution
buzzer
1 F
Steer ino lever lock switch
Startino
I
lever
Neutral
relay Nban
safetrl
.I
loratickknob
tch
is
la N
WA1 200-3
20-251 0
TROUBLESHOOTlNG
EXPLANATIONOF FUNCTIONS OF ELECTRICCONTROL MECHANISM
MAINMONITORSYSTEM
Network control sri tch Network tire slip ON/OFF I Auto grease
Modulated controller ,
clutch
_[
Parkino
brake
indicator
[ When jcrstick Gear Alarm weed
.Uodel shional .Abnormalitr signal .Neutcal sional
is used) signal
1
c
buzzer
sritcb tinnal
I
A
Transmitsion
cut-off
Rear relay
uorkino sional
lame
Transmission switch sidnal
cut-off
aressure
I-
..A
Ensine
weed
signal
Travel
speed
signal
;ygo;;f
coolant
temoerature
Main
monitor
Alarm
buzzer
signal I
Service
meter
Turn
signal
lame switch
signal
Joystick lever L switch Emersencv
FNR
INisht
Iishtinr
sisnaf
imi
steering
operation
I
Starting switch ON signal
VHYS controller
I
WA1 200-3
TROUBLESHOOTING
VHMS CONTROL SYSTEM

Monitoring items for maintenance
Engine
speed
I
Electromaonet ic
Fuel 1
level
Toraue converter oil temperature . Hydraulic tenperature . oil
Brake
fluid
level
g ~
Ataos~~
temperature Coolant level
Transmission differential
oil filter pressure
~;pa~;a
4;
air
cleaner %
Alternator
terminal
+24V
Brake differential wemutt
+24V
I
Transmission oil preswr.2 lubricatino
+24V
+24vfTj+q
+24V outlet Pressure +24Vrelief
I
Tranmission oi I Prefmre modulation
i24V
Steering
+24V
relief
nb
1
-+24V
Dressure
7h
I
TXW02442
WA1 200-3
20-253 0
TROUBLESHOOTING
Functional items of load meter
INPUT I
+24\
OUTPUl
+24\ +24V +*4m!i L
VHMS controller
Subtotal -7
switch
Cancel I
switch
Mele;ase
disDlav
1 TXW02443
20-254 0
WA1 200-3
TROUBLESHOOTING
METHOD OF DISPLAYING ACTION CODE AND FAILURE CODE

1. Display on CGC 1) Outline
The VHMS controller transmits information of various types through CAN (network) to the CGC monitor, and the Failure history information in that information is displayed on the SERVICE MENU SELECT SCREEN of the CGC monitor.
2) Display of failure history

If failure history button (1) on the service menu is pressed, the FAILURE HISTORY SCREEN appears. The Code, Contents, Starting time of failure detection start time, and Finishing time of failure detection of the failures are displayed in the order of time from the oldest one. If the failure still exists, the finishing time of failure detection is not displayed. The number of the all past failures is displayed in section (21, the failure No. in section (31, the failure code and its contents in section (41, and the time when the failure occurred in section 5. 31 Function of each button i) Service Menu button (6): . If this button is pressed, the SERVICE MENU SCREEN appears. ii) Page button (7): This button is used to turn over the page. iii) UP/DOWN button (8): This button is used to move the displayed part up and down. iv) Failure history No. button (3): . If this button is pressed, the history corresponding to it is not displayed. * Although the history is not displayed in this case, the data in the controller are saved.
l
SERVICE
Real Time PM-Clinic Serial Memory
MENU SELECT
Monitor aintenance Failure No. set Clear Snapshot Trigger Monitor History A ,1
BWWOl551
2 3 4
5
7 6
BWWO 1552
WA1 200-3
20-255 0
TROUBLESHOOTlNG
METHOD OF DISPLAYING ACTlON CODE AND FAILURE CODE
2. 1)
Display on main monitor

Outline The speedometer display on the main monitor is used to display the troubleshooting for each control system. The nature of the troubleshooting is displayed as the failure action code, failure code, and the time elapsed since failure. The signals between the main monitor and each controller are transmitted in serial through the network circuit. (Only the engine controller uses a special parallel signal.)
2)
Display of failure action code This code informs the operator directly of the abnormality, and takes action, such as stopping the machine immediately. There are three types of action code (a): EOO, E01 + CALL (EOI and CALL are displayed alternately), and CALL. If a failure occurs suddenly, one of these codes is shown on the speedometer display.
Examole: When action code CALL is displayed
SPEED
\ a
31 Failure code and time elapsed since failure The failures detected by each controller are changed to a code and displayed. It is possible to tell from this code which system in which controller has failed, so carry out troubleshooting for the applicable controller.
BWWO153
41 Saving failure code The transmission controller writes the failure codes to memory. i) A total of 9 failure codes can be saved in memory. ii) The data that is saved to memory is as follows: (1) Failure code (b) (2) Time elapsed since failure (c) (up to 1000 hours) iii) The failures are saved in the order that they occur. If a failure code already exists in the memory, the repeat failure code is not saved. iv) If there are already 9 items in memory, and a 10th failure occurs, the oldest item is deleted and the new item is saved. * It is possible to display the failure code and time elapsed since failure for items saved in memory by operating the main monitor set switch.
Example: When failure code 41 has occurred 27 hours before

b / SPEED /\ c
BWWOl532
20-256 0
WA1 200-3
TROUBLESHOOTING
METHOD OF DISPLAYING ACTlON CODE AND FAILURE CODE
5) Switch operation procedure and actuation Switch operation Trouble data memory mode display Stop engine. ii) Turn starting switch ON. iii) Switch (I) (Second switch from the left top) and head lamp switch (2) simultaneously ant keep pressed for at least 5 seconds. Actuation
i)
The failure code is displayed on the speedometer display and the time elapsed since failure is displayed on the action code display. If there is no failure, the speedometer display shows [CC] and the action code display shows 100001.
Going to nest failure code iv) Press head lamp switch (2). The failure code and time elapsed since failure are displayed in turn (when this is done, the failure code for the latest failure is displayed first). If the failure still exists, the display flashes; if the failure has been restored, the display lights up.
Clearing failure code Y) Keep rear lamp switch (3) pressed for at least 2 seconds. The failure code and elapsed time on the display are cleared. If the failure still exists, the failure code is not cleared.
Wtting 4
trouble data The display returns to the normal display.
memory display mode

Switch (I) and head lamp switch (2) simultaneously and keep pressed for at least 5 seconds. Or start the engine.
WA1 200-3
20-257 0
TROUBLESHOOTING
MONITORING
Screen No.
ITEMS
LIST (CGC)
Unit Component name Remarks
Name of signal
REAL TIME MONITOR
T/M UP SHIFT SW 114 114 274 2l4 2/4 2l4 I 2l4 ENGINE SPEED FILL SIGNAL F FILL SIGNAL R FILL SIGNAL 1st FILL SIGNAL 2nd FILL SIGNAL 3rd T/M DOWN SHIFT SWITCH (ON/OFF) (ON/OFF) 1 rpm (ON/OFF) (ON/OFF) (ON/OFF) VHMS T/M T/M TIM T/M
I I
(ON/OFF)
(ON/OFF)
) T/M I TIM
SOLENOID 2nd SOLENOID 3rd ENGINE SPEED AUTO SHIFT SIGNAL
I I
1 mA
1mA
1 rpm (ON/OFF)
1 T/M 1 TIM
VHMS T/M Each time momentary switch is turned ON, state (AUTO/MANUAL) is changed. Value recognized by controller is displayed. Each time momentary switch is turned ON, state (AUTO/MANUAL) is changed. Value recognized by controller is displayed.
20-258 0
WA1 200-3
TROUBLESHOOTING
(MOD/C OUTPUT SPEEDJAENGINE SPEED
WA1 200-3
20-259 0
TROUBLESHOOTING
Screen No.
Name of signal
Unit
Component name MOD/C
Remarks I
I 516 I
5/6 516 516
I 516 I BUCKET TILT SIGNAL

FILL SIGNAL F FILL SIGNAL 1st TIRE SLIP SIGNAL
(ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) 1 rpm (ON/OFF) 0.1 v 0.1 v --- - -
I T/M
T/M Main monitor
~~ ~~~
I 616 I ENGINE SPEED I 1 R.H. BRAKE PROXIMITY SWITCH 1 I 6/S I I 6/S I ACCELERATOR SIGNAL
616 6/S 616 REMOlE l/l
I VHMS
I MOD/C
I MOD/C
I MOD/C --- - -
I I
I
1 CONTROLLER OUTPUT SIGNAd

SET/ACCEL, DECEL (IDLE UP) RESUMEIACCEL, DECEL (IDLE DOWN) POSITIONER CONTROLLER BOOM ANGLE SIGNAL
0.1 v
Work equipment Work equipment Work equipment Work equipment VHMS VHMS Positioner screen switch of CGC Positioner screen switch of CGC
I l/l
l/7
l/l l/l 111
I BOOM
RAISE SIGNAL
(ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF) (ON/OFF)
BOOM LOWER SIGNAL DETENT SIGNAL UPPER SET SIGNAL LOWER SET SIGNAL
LOAD METER
I I
l/l
BOOM BOTTOM PRESSURE
O.OlMPa 10.1 kg/cm? 1 VHMS
1 Di$?~;~?~~fafr;;~~
I l/l
I I
l/l
MEASURED PRESSURE
O.OlMPa (0.1 kg/cm21 VHMS IO.OlMPa (0.1 kg/cm!I I VHMS O.OlMPa IO.1 kg/cm*] 1 TON VHMS VHMS
Measured trigger pressure
I CAL. PRESSURE
NO LOAD PRESSURE MEASURE LOAD
I Calibration
pressure
I I
l/l
lb
Default calibration pressure Measured trigger load
JOYSTICK STEERING
l/2
l/2
J/S ON/OFF SIGNAL S/T NEUTRAL SWITCH
_-(ON/OFF)
_-Work equipment I Work equipment Work equipment Work equipment Work equipment
I l/2
l/2
I 712 I S/T LEVER POTENT10

I ARTICULATE
ANGLE
0.1 v
0.1
II2
J/S SOLENOID OUTPUT STEERING LOCK
1 mA (ON/OFF)
20-260 0
WA1 200-3
TROUBLESHOOTING
Screen No. 2/2 1 2/2 1 Z/2
Name of signal T/M DIRECTION SIGNAL F 1 T/M DIRECTION SIGNAL N 1 T/M DIRECTION SIGNAL R S/l N SIGNAL OUTPUT
Unit (ON/OFF)
Component name T/M
Remarks
1 1
(ON/OFF) (ON/OFFIj (ON/OFF)
I T/M
Work equipment
I T/M
l/2
PM CLINIC 114 114 114 ENGINE SPEED COOLANT TEMP. T/C TEMP. 1 rpm 1C 1C TEMP. I 1C 1 mmAq VHMS CENSE VHMS j VHMS
I l/4
I AMBIENT
I 114 I BLOW-BY PRESSURE I l/4 I ENGINE OIL PRESSURE

1 2/4 2i4 2l4 2l4 1 2/4 1 Z/4 1 BOOST PRESSURE EXH. GAS TEMPERATURE T/C IN PRESSURE T/C OUT PRESSURE ( T/M MAIN PRESSURE 1 T/M LUB. PRESSURE
1 CENSE
I I
I
I
I
1O.OlMPa (0.1 kg/cm3 I CENSE

I O.OlMPa (0.1 kg/cm3 I CENSE 1% O.OlMPa IO.1 kg/cm3 O.OlMPa IO.1 kg/cm3 CENSE VHMS VHMS
1O.OlMPa (0.1 kg/cm3 1 VHMS I O.OlMPa 10.1 kg/cm3 I VHMS I O.OlMPa (0.1 kg/cm3 I VHMS
I o.lMPa 11 kg/cm3
I 314 I T/M MOD PRESSURE 314 -I- S/T PUMP PRESSURE

314 314 314 F BRAKE OIL PRESSURE R BRAKE OIL PRESSURE HYD. OIL TEMP.
I I I
I I I
1 VHMS
VHMS VHMS VHMS
O.lMPa 11 kg/cm3 O.lMPa 11 kg/cm3 1C
I 314 I HYD. OIL PRESSURE

414 PPC OIL PRESSURE
I O.lMPa 11 kg/cm3
O.lMPa (1 kg/cm3
I VHMS
VHMS
WA1 200-3
20-261 0
TROUBLESHOOTING
LIST OF ALARM ITEMS DISPLAYED ON CGC MONITOR

1. The check lamp output is driven with VHMS.
2.
3.
As the signal to synchronize flashing of the caution lamp output of the main monitor, the ON/OFF output of VHMS is used. Permission of the alarm output is given by S-NET and is sent from VHMS to main monitor. The check lamp and caution lamp are set independently (When two failures occur, both flash).
Al arming condiion
1
Letactinc
Detecting condiion 1
UO.
mdilkmi Resettingcondition 1
Failure engine engine etectinf starts is runnin mekec 0 -__ 2 Resettingcondition When left is not satisfied
Item Engine oil level
Display range Below LOW level
Detail of display range H: Normal lz Abnormal (Engine speed in rpm, oil pressure in kPa) Below followina linear interpolation graph (0.0) (800, 138) ;;;3 $4r71 12200:345)
t-l0
Engine oil pressure
Below specified pressure
Above 102oC
Above 105C
Above 102C but 1OEK alarm is not detected Above 105C
___ 1
2
When left is not satisfied
T-tx0
0
10
When left is not satisfied. When left is not satisfied When left is not satisfied When leit is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satistied. When left is not satisfied. When let?is not satisfied.
0
__-
10 10 10 10 10
10
Belowspecified level Below 1 segment of gauge (11%) Belowspecified level Below 1 segment of gauge (11%) Above 12OOC Above 130C Above 105oC Below 14.7 MPa (150 kglcmq Above 120C but 130C alarm is not detected Above 130C Above 10SC Below 14.7 MPa (150 kg/cm3 and within 60 set after engine starts Below 14.7 MPa (150 kg/cm? and atter 60 set after engine starts Below 14.7 MPa (150 kg/cm? Below 14.7 MPa I150 kg/cm9 and within 60 set after engine starts Below 14.7 MPa f150 kg/cm3 and after 60 set after engine starts Battery fluid level(1) Below LOW level 17 1Battery fluid level(21 Below LOW level Battery fluid level (3) Below LOW level OPEN (Fluid level is low) =6Vcellisbelow2V OPEN (Fluid level is low) = 6 V cell is below 2 V OPEN (Fluid level is low) = 6 V ceil is below 2 V
*_-O 0
0
0
--I0 0 0
-i-
__-
___
5
--___ -_-
0 0 0
___
5
Below speciiied level OPEN = 24 V (Fluid level is low) Belowsoecified level OPEN = 24 V (Fluid level is low)
4
1
Coolant level
Below LOW level Below LOW level Above specified pressure Above specified negative pressure Above specified negative pressure Above specified negative pressure above specified negative pressure
OPEN = 24 V (Coolant is insufficient) OPEN = 24 V (Coolant is insufficient) OPEN = 24 V (Clogging) and torque converter oil temoeratureis above 50C OPEN = 24 V (When clogged) OPEN = 24 V (When clogged) OPEN = 24 V (When clogged) OPEN = 24 V (When clogged) Above 9.3 V (While engine is running) [Criterionwhile engine is running: Voltage of terminal R is above 9.3 V or engine speed > 600 mm)
-I--__-_
0 0 ___ 0
10 10 2 2 2 2
10
When leti is not satisfied.
When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied.
When left is not satistied.
___ =I=
0 --_ 0 0 0
0
_______ _-_ ---
0
0
,8
Voitageat alternator when charging is terminal R sbnormal
When let?is not satisfied.
20-262 0
WA1 200-3
TROUBLESHOOTING
Alarm output w
T,
ompent &ference) Clinic (Reference) Flashing CENSE --0
Abnormal
Red
Not installed
- - -
I I 1 1
Abnormal
Yellow
Installed
- - -
Flashing CENSE
Gauge Gauge VHMS Gauge Gauge Gauge VHMS Gauge
0 0 ----0 0 0
-__
1 966
0
Abnormal Red Installed Installed - - --Flashing Flashing
VHMS
---
ressurizing Yellow Abnormal
--ON
0
0 0 0
1 Red 1Not installed1 - -Installed Not installed --- - -
1Flashing
Flashing Flashing
1913 1
VHMS
0 X
VHMS .
___ -__ ___
ressurizing Yellow Abnormal Red
___
ON
I 912 I
1915 1
Abnormal
Yellow
Installed
Flashing
- - -
---
Abnormal Abnormal Abnormal Abnormal
Yellow Red Yellow Red
Installed Not installed Installed Not installed
Flashina - - Flashing - - -
- - Flashing - - Fiashina
--VHSM ---
___
-__
Abnormal I Yellow Abnormal I Yellow Abnormal Abnormal Yellow Yellow
I installed ( Flashing 1 --I installed I Flashing 1 - -Installed Installed Flashing Flashing - ----
___
___
932 933 934 935
0
VHMS
___ -__
-__
0
0
Abnormal I Yellow
I Installed I Flashing 1 ---
Abnormal
1 Yellow 1 Installed 1Flashing / i:y
937
VHMS
+WA1 200-3
20-263 0
TROUBLESHOOTING
FAILURE CODES LIST
FAILURE CODES LIST

* * * Failure codes related to VHMS are not displayed on the main monitor (They are displayed on only CGC monitor). For display of cautions related to alarm, see the List of alarm items displayed on CGC monitor. In Display of history, EOOO + Contents of failure + Time when failure occurred + Time when failure is rest are displayed.
39 70 72
E01
1Short circuit with chassis ground in 1st bypass solenoid

Disconnection in boom RAISE/LOWER, bucket TILT/DUMP
signal
system switch system
1
EOl + CALL
pressure
Short circuit, disconnection, or short circuit with power source in accelerator pedal sensor system
1 E039 1 E070 / E072
a4 1 a5 ( CALL
Short circuit, disconnection, or short circuit with chassis ground in neutral cut solenoid system
I Short circuit. discunnsction,or short circuit with chassis gmund in modulated clutch ECMV solenoid system
( E084 1 E085
20-264
0
WA1 200-3
TROUBLESHOOTING
FAILURE CODES LIST
* * *
Failure codes related to VHMS are not displayed on the main monitor (They are displayed on only CGC monitor). For display of cautions related to alarm, see the List of alarm items displayed on CGC monitor. In Display of history, EOOO + Contents of failure + Time when failure occurred + Time when failure is rest are displayed.
CGC monitor Failed system Disconnection, short circuit, or short circuit with chassis ground in dumping solenoid EOl + CALL Short circuit of hot side of dumoina solenoid with Dower source CALL Short circuit of return side of dumping solenoid with power source Disconnection or short circuitwith chassisground in boom lever kick-outsolenoidsystem Disconnection in boom RAISE/LOWER pressure switch system Disconnection, short circuitwith chassis ground or short circuitin boom angle sensorsystem EOO Short circuit or disconnection in travel sDeed sensor svstem Disconnection, shortcircuit withchassis ground or short circuit in joystick caution buzzer relaysystem EOl t CALL Disconnection, shortcircuit withchassis ground or short circuit in steering lever angle sensor system EOlt CALL Deviationof potentiometer signal in steering lever angle sensor/frsmeangle sensor system EOl t CALL Disconnection, short circuitwith chassis groundor short circuitin frame angle sensorsystem EOl t CALL Disconnection or short circuit with chassis ground in steering lever lock switch system EOO Disconnection, short circeit withchassis around or short cinxitin iovstkk neutrel interfcck relevsystem Real-time Display of display history E043 E044 E045 E049 E051 E052 E055 E056 EO57 E058 E059 E061 E062 E063
)e,,ke Failure Action code code 43 44 45 g = 2 g U 2 : 3 B Y z 49 51 52 55 56 57 58 59 61 62 63 lE8ii
Disconnection, short circuit with chassis ground or short circuit in joystick main EOl t CALL pressure control EPC solenoid system
I 1
1 Disconnection or short circuit with Dower source in NSW Dower sutmlv svstem 1 Short circuit with chassis ground in 24-V system of sensor power supply
1 I I I !
E812 1 E813 E814)
1Short circuit with chassis around in 12-V svstem of sensor Dower SUDDIY
) Short circuit with chassis ground in 5-V system of sensor power supply
I I E821 l E824 1
E818 E825 E826 E827
I Wrong connection of connector I Failure in controller (Failure in securino of memorv) 1Failure in communication with CGC and engine controller
Disconnection, short circuit with chassis ground or short circuit with power source in S-NET (Between transmission controllers) Disconnection, short circuit with chassis ground or short circuit with power source in S-NET (Between modulated clutch controllers) Disconnection, short circuit with chassis ground or short circuit with power source in S-NET (Between work eauioment controllers1
I 1 1 1 I I 1
E811 E812 E813 E814 E818 E821 E824 E825 E826 E827
lE4
IE8311 E841 E843 E844 E861 E862
Disconnection, short circuit with chassis ground or short circuit with power source in S-NET (Between main monitors)
I Failure in controller (Handle error) 1 I

Short circuit of buzzer output with power source
I I
1Short circuit of check lamp with power source

Short circuit of flash synchronizing signal with power source Disconnection or short circuitwith chassis ground in boom bottompressuresensorsystem Disconnectionor short circuit with chassisaround in boom head oressure sensor svstem Disconnection or short circuitwith chassisground in rear brake oil pressuresensor system 1
I l 1 I
E828 I E831 I
E841 E843 E844 E861 E862
) E864 1
E863 E865 E866 E867 E8681 E871
1Disconnection or shortcircuitwith chassis ground in work equipment relief pressure sensor system 1
Disconnection or short circuitwith chassis ground in front brakeoil pressure sensorsystem Disconnection or shortcircuit withchassis gmundin transmission main relief pressure senscr system Disconnection or short circuitwith chassis around in steerinarelief oressuresensorsystem Disconnectionor short circuit with chassis ground in torque converter outlet oil pressure sensor system
) E863 1 E864
E865 E866 E867
1Disconnectionor short circuit with chassis around in transmission modulation oil pressure sensor system 1
Disconnection, short circuit with chassis ground or short circuit with power source in transmission lubricating oil pressure sensor system
1 E866 1 E871
lE8721 I
WA1 200-3
20-265 0
TROUBLESHOOTING
FAILURE CODES LIST
* * *
Failure codes related to VHMS are not displayed on the main monitor (They are displayed on only CGC monitor). For display of cautions related to alarm, see the List of alarm items displayed on CGC monitor. In Display of history, EOOO + Contents of failure + Time when failure occurred + Time when failure is rest are displayed.
1 Failed system E874 E875 ES77
1
CGC monitor 1 1 Real-time 1Displayof 1 1 display 1 history E874 E875 E877 ES78 E884 DkhvofcautbnE901
Short circuit with chassis ground in torque converter oil temperature sensor system Short circuit withchassis ground or short circuit withpower source in hydraulic oiltemperature senscr system Disconnection, short circuit with chassis ground or short circuit with power source in atmosoheric temoerature sensor svstem Disconnectionor short circuit with chassisground in PPC relief pressure sensor system Diicnnectionor shortcircuit withchassis ground in torqueconverter inletoil pressure secscrsystem Enaine oil level below LOW level
E878 5884 E901
E937
Charging trouble of alternator
~k$ayofratin( E937
For display of failure codes related to engine controller, see Troubleshooting system (G-mode).
for engine controller
20-266 0
WA1 200-3
TROUBLESHOOTING
METHOD OF USING JUDGEMENT
TABLE
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used to decide which troubleshooting table (E-00, H-OO, etc.) matches the symptoms. The judgement table is designed so that it is easy to determine from the self-diagnostic display which troubleshooting table to go to. * The abnormality display given by the monitor panel leads directly to troubleshooting of the monitor system (M-00). (See troubleshooting of the machine monitor system) [Method of using judgement table1 A 0 mark is put at the places where the failure mode and self-diagnostic display match, so check if an error code is displayed on the graphic display portion of the monitor panel. If an error code is displayed: Go to the troubleshooting code at the bottom of the judgement table (E-OO, etc.). If there is a problem but no error code is displayed: Go to the troubleshooting code on the right of the judgement table (H-001. For failure modes where no 0 mark is given, go directly to the troubleshooting code on the right of the judgement table.
l l l
WA1 200-3
20-267 0
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTINGCHARTS
METHOD OF USING TROUBLESHOOTING CHARTS 1. Category of troubleshooting code number

Troubleshooting
G-00
Code No.
1 Troubleshooting Troubleshooting Troubleshooting Troubleshooting 1 Troubleshooting 1 Troubleshooting Troubleshooting Troubleshooting
Component of engine controller system of transmission controller system
T-00 MC-00 J-00 w-00 M-00 v-00 H-00 2.
of modulated clutch controller system of joystick steering controller system of work equipment controller system of main monitor system of VHMS controller system of hydraulic, mechanical system
Method of using troubleshooting table Troubleshooting code number and problem The top left of the troubleshooting chart gives the troubleshooting code number and the problem with the machine. General precautions When using the troubleshooting chart, precautions that apply to all items are given at the top of the page and marked with f. The precautions marked * are not given in the I, but must always be followed when carrying out the check inside the I. Distinguishing conditions Even with the same problem, the method of troubleshooting may differ according to the model, component, or problem. In such cases, the troubleshooting chart is further divided into sections marked with small letters (for example, a), b)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item. Method of following troubleshooting chart * Check or measure the item inside In, and according to the answer follow either the YES line or the NO line to go to the next 0. (Note: The number written at the top right corner of the I is an index number; it does not indicate the order to follow.) . Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. . Below the I there are the methods for inspection or measurement, and the judgement values. If the judgement values below the I are correct or the answer to the question inside the I is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow ttie NO line. . Below the I is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from Item 1). Troubleshooting tools When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING. Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart. WA1 200-3
20-268
0
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING
CHARTS
<Example> @ M-5 Turn signal display does not light up Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not blown.
0* * *
0
@
a) L.H. turn signal display does not light up a) Divided into sections a) and bl I b) R.H. turn signal display does not light up Flow chart a1 L.H. turn signal display does not light up
1 YES IS voltage between Lo6 (14)
and chassis groundnormal? . Repeats0 V and NO M-30V. *Turn startingswitchON. . Turn LH. turn signalON.
DefBcdve cowact 0, d&connection in wirina
hamessbetweenLO6 (female)(14) and L144 (male)(1)
Repairor
b) R.H. turn signal display does not light up ,
Repair or replace
M-5
Related electrical circuit diagram

L.H. turn signal
I alllo - (25W)
WA1 200-3
20-269 0
TROUBLESHOOTING
METHOD OF USING MAiRlX TROUBLESHOOTINGTABLES
METHOD OF USING MATRIX TROUBLESHOOTING TABLES

The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the causes of failures in the machine. The troubleshooting tables are divided broadly into categories for the main components, such as the steering system and work equipment hydraulic system. Follow the procedure given below and carry out troubleshooting to locate the problems accurately and swiftly.
Step 1. Questioning the operator -The questions to ask the operator are given below the failure symptom. If the answers to the questions match the information given, follow the arrow to reach the probable cause of the failure. Consider the contents of the questions and consult the table while proceeding to Steps 2 and 3 to grasp the true cause. Step 2. Checks before troubleshooting Before starting the main troubleshooting and measuring the hydraulic pressure, first check the Checks before Starting items, and check for oil leakage and loose bolts. These checks may avoid time wasted on unnecessary troubleshooting. The items given under Checks before Starting are items which must be considered particularly for that symptom before starting troubleshooting. Step 3. Using cross-reference table 1) Operate the machine to carry out the checks in the troubleshooting item column. Mark the items where the results match the symptom. * It is not necessary to follow the troubleshooting checks in order; follow an order which is easiest to carry out troubleshooting. 2) Find the appropriate cause from the cause column. If the symptom appears, the 0 marks on that line indicate the possible causes. (For item No. 2 in the table on the right, the possible causes are c or e.) lf there is only one 0: Carry out the other troubleshooting items (where the same cause is marked with 0), check if the symptom appears, then repair. If there are two 0: Go on to Step 3) to narrow down the possible causes.
1.
Steering does not work t
Symptom [Example]
Ask the operator about the following points. Did the steering suddenly stop working + Had the steering gradually been becoming heavy? + Internal wear of steering equipment,
Checks before
l
starting
[Example]
Is the oil level in the hydraulic tank correct? Is the type of oil correct? Is there any leakage of oil from the steering valve or Orbit-roll? Has the safety bar been removed from the frame?
[Example
1I Remedy
No- Problems
1
I
Steering does not work to the left or right. Same as item 1, but abnormality in actuation of work equipment Steering can only be operated to one side. Steering wheel is heavy and cannot be turned.
3 3 4
[Example 21
-i--H
WA1 200-3
20-270 0
TROUBLESHOOTING
METHOD OF USING MATRIX TROUBLESHOOTING
TABLES
3)
Operate the machine and check the troubleshooting items other than those in 1). Operate the machine and check the items in the same way as in I), and if the symptom appears, mark that item. (In the chart on the right, the symptom appears again for item 5). Find the appropriate cause from the cause column. In the same way as in Step 21, if the symptom appears, the 0 marks on that line indicate the possible causes. (For item No. 5 in the table on the right, the possible causes are b or e-1 Narrow down the possible causes. There is one common cause amongthe causes located in Steps 2) and 41. (One cause marked 0 appears on the line for both items.) This cause is common to both the symptoms in troubleshooting Steps 1) and 3). Jr The causes which are not common to both troubleshooting items (items which are not marked 0 for both symptoms) are unlikely causes, so ignore them. (In the example given on the right, the causes for Troubleshooting Item 2 are c or e, and the cause for Troubleshooting Item 5 are b or e, so cause e is common to both.) Repeat the operations in Steps 31, 4) and 5) until one cause (one common cause) remains. J, If the causes cannot be narrowed down to one cause, narrow the causes down as far as possible.
4)
5)
LApplicable
troubleshooting item located in Step 3).
Applicable troubleshooting item located in Step 1).
///I1 Janore
these causes
causes
6)
n to take
71 Remedy If the causes are narrowed down to one common cause, take the aciton given in the remedy column.
The symbols given in the remedy column indicate the following: X: Replace, a: Repair, A; Adjust, C: Clean 4 101 5_--__I_+3c_I_
1 JOI i I
WA1 200-3
20-271 0
TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (G MODE)
Display method of CUMMINS
engine controller failure codes and contents of display .............. 20-302 20-303
Failure codes and actions table .... ........ .................. ..... ..... ...... ...... ..... ........-..........................................
WA1 200-3
20-301 0
TROUBLESHOOTING
DISPLAY METHOD OF CUMMINS ENGINE CONTROLLER FAILURE CODES AND CONTENTS OF DISPLAY
DISPLAY METHOD OF CUMMINS ENGINE CONTROLLER FAILURE CODES AND CONTENTS OF DISPLAY
1. The failure codes from the CUMMINS
engine controller are transmitted (CAN) line to the VHMS controller, where they are processed.
through communication
2. 3.
The failure codes and contents of the failures (displayed messages) are saved as failure history. The failure codes are displayed on the alarm screens corresponding to the operator codes (for the customer). Operator codes [Oil - I041 and other five screens are set for the alarm screens (for the customer). If a failure which is not shown in this list occurs, the alarm screen of occurrence of an unregistered error appears.
4. 5.
20-302 0
WA1 200-3
TROUBLESHOOTING
FAILURE CODES AND ACTIONS TABLE
Cl24
124
Abnormal
LB suction Dressure Hi
I SeeCummins Manual I
Short circuit in PTO circuit Lo Cl35 Cl36 Cl37 Cl41 Cl43 135 136 137 141 143 Abnormal Abnormal Abnormal oil pressure sensor Hi filter inlet pressure sensor Hi. filter inlet pressure sensor Lo 1 6 6 1
4
See CumminsManual See CumminsManual See CumminsManual 1See CumminsManual

1See Cummins Manual
1Abnormal oil pressure sensor Lo I Oil rxessure Lo
Cl51 Cl53
151
I 153
Coolant Hi LBF air boost temDerature 1Abnormal LBF air boost temoerature LBF air boost temperature Hi Abnormal LBR air boost temperature Abnormal LBR air boost temperature LBR air boost temperature Hi Abnormal RBF air boost temperature Abnormal RBF air boost temDerature RBF air boost temperature Hi Abnormal RBR air boost temperature Abnormal RBR air boost temperature RBR air boost temperature Hi Abnormal oil temperatuer sensor Hi Abnormal
1 Abnormal
Cl54
Cl55 Cl56 Cl57 Cl56 Cl59 Cl61 Cl62 Cl63 Cl64 Cl65 c212 C213 C214 c219 c221 c222 C223 C225
154 155 156 157 156 159 161 162 163 164 165 212 213 214 219 221 222 223 225
sensor Hi sensor Lo sensor Hi sensor Lo sensor Hi sensor Lo sensor Hi sensor Lo
3 1 1 4 6 6 4 6 6 4 6 6 4 6 6
1See CumminsManual 1See CumminsManual I See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual I See CumminsManual I See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual
I Oil temoerature
Abnormal
oil temDerature sensor Lo Hi Remote oil level Lo atmospheric temperature sensor Hi
1 6 6 1 1
Abnormal atmospheric temperature sensor Lo Short circuit in CORS BV solenoid Lo Short circuit in CORS M valve Lo
WA1 200-3
20-303 0
TROUBLESHOOTING
Contents
of failure
C452
452
Fuel rail pressure
Lo
1See Cummins Manual
C527 C528 c529 c55S c554 c555 C611
527 528 528 553 554 555 611
A-double
output
Hi
1 1 1 4 2 4 8
1Abnormal
B-double
aenerator output Hi Hi
1See Cummins Manual 1See Cummins Manual See Cummins Manual See Cummins Manual See Cummins Manual See Cummins Manual See Cummins Manual
Fuel rail pressure
Abnormal fuel rail pressure Blow-by pressure Hi Sudden stop of overheating
20-304 0
WA1 200-3
TROUBLESHOOTING
Komatsu failure code C612 C616 C621 C622

c
Cummins failure code 612 616 621 622 623 624 625 626 627 628 631
Contents of failure (System) Oil filter pressure Hi LBR turbocompressor #1 LB low pressure #2 LB low pressure #3 LB low oressure #4 #5 #6 #7 #8 #2 #3 #4 #5 #6 #7 #8 #l #2 #3 1#4 1#5 LB LB LB LB LB low low low low low pressure pressure pressure pressure pressure
Cummins operator code 2 Hi 6 1 1

1
Action (Diagnosis code) See CumminsManual See CumminsManual See CumminsManual Sea CummincManll:
. . .._.._.ij
suction temperature
C623 C624 C625 C626

C677
1 1 1 1 1 1 1 1 1 1 1 1 1 temperature temperature temperature temperature temperature temperature temoerature temperature temperature temperature temperature temperature temperature temoerature temperature temperature 4 4 4 4 4
t-
Manual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual
See --- Cflmminc __........._ Mant~al
,.,...
scva ___ fhnrnil _I........is
C631
#1 RB over-outout RB over-output RB over-output RB over-output RB over-output RB over-output RB over-output RB over-outout LB over-exhaust LB over-exhaust LB over-exhaust LB over-exhaust LB over-exhaust
i
636 $7 638 641 642 643 644 645 646 647
See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See CumminsManual See ..._..__. -__ Cummins _- .. ....._ Mniwal See CumminsManual See CumminsManual See CumminsManual 1See CumminsManual 1 / See CumminsManual 1 1See CumminsManual
I See Cummins Manual
I
C641 C642 C643 C644 C645 C646 C647
1#6 LB over-exhaust 1#7 LB over-exhaust

LB over-exhaust #l RB over-exhaust #2 RB over-exhaust / #3 RB over-exhaust -#4 #5 1#6 #7 RB over-exhaust RB over-exhaust RB over-exhaust RB over-exhaust
4
4
4 4 4 4 4 4
4
See CumminsManual See CumminsManual See CumminsManual 1See CumminsManual 1 1See CumminsManual 1 1See CumminsManual
I See Cummins Manual
C656 C657 C658 C661

i-x67 ___-
656 657 658 661 6f -_ i2 663 664 665 666 667
#8 RB over-exhaust #I LB over-output I #2 LB over-output
.4 4 2 2 2 2 2 2 2
See CumminsManual See CumminsManual See CumminsManual 1See CumminsManual1 ) See CumminsManual 1 1SeeCumminsManual 1 See CumminsManual Saa CumminsManual See CumminsManual
1 c
C663 C664 C665 C666 C667

C6fi8 ---_
I #3 LB over-output I #4 LB over-outout
#5 LB over-output #6 LB over-output #7 LB over-output
f% __
C6:
WA1 200-3
20-305 0
TROUBLESHOOTING
Contents of Cummins operator codes and display of CGC [message) * Operator codes [ll - [41 are displayed. Operator codes [51- I81 are not displayed, however, and they are only saved as history. (Ill - 141 are saved as history, too.)
l l
Check and maintain when the work is finished or the operator is changed. Stop the machine on a safe place, then check and maintain immediately. Operate the machine with the engine speed and travel speed low. Stop the machine immediately on a safe place and stop the engine, then check and maintain immediately. Operator codes 5 - 8: They are only saved as history (not displayed). Failures other than above: Contact your distributor.
Operator Operator Operator Operator
code code code code
1: 2: 3: 4:
20-306 0
WA1 200-3
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)
Judgement table for transmission
control system related parts ......................................................
20-404
Operations of controller against abnormality and conditions of machine caused by abnormality .......................................................................................................... Electrical circuit diagram for transmission controller system ........................................................... T- 1 Failure code [IO] (Short circuit, disconnection, short circuit with power source in backup lamp relay) is displayed ................................................................. T- 2 Error code [l II (Disconnection in modulated clutch outlet rotation signal sensor system) is displayed ..................................................................................................... T- 3 Error code 1121 (Short circuit, disconnection, or short circuit with power source in F solenoid system) is displayed ................................................................. T- 4 Error code 1131 (Short circuit, disconnection, or short circuit with power source in R solenoid system) is displayed ................................................................ T- 5 Error code 1141 (Short circuit, disconnection, or short circuit with power source in 1st solenoid system) is displayed .............................................................. T- 6 Error code II51 (Short circuit, disconnection, or short circuit with power source in 2nd solenoid system) is displayed ............................................................. T- 7 Error code [161 (Short circuit, disconnection, or short circuit with power source in 3rd solenoid system) is displayed.. ........................................................... T- 8 Error code 1181 (Short circuit, disconnection, or short circuit with power source in R clutch drain valve solenoid system) is displayed ................................ -20-425 T- 9 Error code 1201 (Short circuit or disconnection in joystick FNR switch system) is displayed.. ............................................................................. T-IO Error code 1211 (Short circuit or disconnection in joystick shift-up/shift-down T-II T-12 switch system) is displayed ...................................................... 20-427 Error code [221 (Disconnection in travel speed sensor system) is displayed.. .................. 20-428 Error code 1231 (Short circuit or disconnection in engine speed sensor system) is displayed.. ........................................................................... T-13 T-14 20-429 20-426 .20-424 20-423 20-422 .20-421 20-420 20-419 20-418 20-406 20-416
Failure code 1241 (Short circuit, disconnection in EEP ROM) is displayed ........................ 20-430 Error code 1251 (Short circuit in transmission oil temperature sensor system) 20-431
is displayed ................................................................................................................................ T-15 T-16 T-17 T-18 T-19 T-20
Error code 1261 (Short circuit in F ECMV fill switch system) is displayed ......................... 20-432 Error code 1271 (Short circuit in R ECMV fill switch system) is displayed.. ....................... 20-432 Error code I281 (Short circuit in 1st ECMV fill switch system) is displayed ...................... 20-433 Error code 1291 (Short circuit in 2nd ECMV fill switch system) is displayed.. ................... 20-433 Error code [301 (Short circuit in 3rd ECMV fill switch system) is displayed.. .................... 20-434 Error code [321 (Disconnection in F or R ECMV fill switch system) is displayed ............. 20-435
WA1 200-3
20-401 0
T-21
Error code [331 (Disconnection in lst, 2nd, or 3rd ECMV fill switch system) is displayed ................................................ ................................................................................ 20-436
T-22
Error code 1341 (Disconnection or 3rd short circuit with power source in F bypass solenoid system) is displayed ................................................................................. 20-437 Error code [351 (Short circuit in F bypass solenoid system) is displayed ......................... 20-438 Error code [361 (Disconnection or short circuit with power source in R bypass solenoid system) is displayed ................................................................................. 20-439 20-440 Error code [371 (Short circuit in R bypass solenoid system) is displayed ......................... Error code 1381 (Disconnection or short circuit with power source in 1st bypass solenoid system) is displayed .............................................................................. 20-441 Error code 1391 (Short circuit in 1st bypass solenoid system) is displayed ...................... 20-442 Auto/Manual selector switch system ...................................................................................... 20-443 20-443 20-444 20-445 20-446 20-447 20-448 20-449 20-450
T-23 T-24
T-25 T-26
T-27 T-28 T-29 T-30 T-31 T-32 T-33 T-34 T-35 T-36 T-37 T-38 T-39 T-40
Kickdown switch system .......................................................................................................... Transmission cut-off switch signal system ............................................................................
Steering lock switch signal system ......................................................................................... Neutralizer relay signal system ............................................................................................... Buzzer signal system ................................................................................................................ Network system ......................................................................................................................... Transmission controller power supply system ......................................................................
Short circuit in travel speed sensor system ...........................................................................
Short circuit in modulated clutch outlet rotation sensor system ........................................ 20-451 Disconnection in transmission oil temperature sensor system ........................................... 20-452 20-453 20-454
Fl (Forward 1st gear) signal system ....................................................................................... Abnormality in auto shift indicator lamp ...............................................................................
20-402 0
WA1 ZOO-3
JUDGEMENT TROUBLESHOOTING
TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS
JUDGEMENT TABLE FOR TRANSMISSION SYSTEM RELATED PARTS

i
CONTROL
Self-diaanosis disolav (Dis av of abnormality)
Location of failure
Failure mode controlle 1 1Machine cannot travel 2 1 Machine can travel even if steering lock lever is in LOCK position 3 1 Gear is not shiited automaticailv 4 FNR (Forward/Reverse) 5 Machine travels forward switch is not matched to travel direction even if FNR (Forward/Reverse) switch is not in F position
6 Machine travels in reverse even if FNR (ForwardlReverse) switch is not in R oosition 7 Gear is shifted down, regardless of travel speed 8 Gear is shifted up, regardless 10 11 12 13 14 15 16 17 of travel speed
9 Large shocks are made when gear is shifted Gear shift hunting occurs during travel Gear shift huntina occurs when aear is shifted Gear shift indicator does not follow up gear shift-up/down Gear speed cannot be controlled with gear shift-up/down Gear shifting operation and travel speed are abnormal cannot be changed. Travel mode (Manual/Auto) switch in auto mode switch in manual mode
in auto mode
Kickdown svstem does not work (Travel sot?4 must be below 13 km/h in auto mode)
1Scooping
power is lost when kickdown system operates. is not cut off when left brake is aonlied
18 I Transmission
19 1Machine can travel while oarkina brake is aoolied 20 21 22 23 24 25 26
1Backup lamp and 1F-R chanae alarm
alarm buzzer do not operate buzzer does not sound durina hiah-soeed travel
Alarm buzzer does not stop sounding Main motor does not display transmission controller information (Alarm buzzer, failure code, etc.) Modulated clutch controller does not function
Travel mode (and gear shift range)when key is turnedto OFF is not saveduntil engine is startedagain Auto aear shift indicator lamo does not liaht uo in auto mode Diagnosis code when failure code is displayed T-1 T-2 T-3 T-4 T-5 T6 T-7 T-8 T-9 T-10 T-11 T-12 T-13 T-14
20-404 0
WA1 200-3
JUDGEMENT TROUBLESHOOTING
TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS
Self-diagnosis
display (Dis
Transmission
controller error
WA1 200-3
20-405 0
OPERATIONS TROUBLESHOOTING
OF CONTROLLER
AGAINST
ABNORMALITY
AND
CONDITIONS
OF MACHINE CAUSED BY ABNORMALlTY
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY

(1) TRANSMISSION I
Failure code
CONTROLLER SYSTEM
Abnormal system Contents of abnormality
10
Short circuit, disconnection, or short circuit with power source in backup lamp relay system
1) Defective backup lamp relay 2) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller Cl (female) (11) - L54 (1) 3) Disconnection or defective contact in wiring harness between backup lamp relay L54 (female) (2) - chassis ground 4) Defective transmission controller 1) Defective modulated clutch outlet rotation sensor 2) Disconnection or defective contact in wiring harness between transmission controller C4 (female) (9) - T16 (female) (2) 3) Disconnection or defective contact in wiring harness between transmission controller C4 (female) (2) - T16 (female) (1) 4) Defective transmission controller 1) Defective F ECMV solenoid 2) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (2) - T13 (female) (1) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (13) - T13 (female) (2) 4) Defective transmission controller 1) Defective R ECMV solenoid 2) Disconnection, defectivecontact,short circuitwith chassis ground, or shortcircuitwith power sourcein wiring harness between transmission controllerC2 (female) (3) - Tll (female) (1) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (14) - Tll (female) (2) 4) Defective transmission controller 1) Defective 1st ECMV solenoid 2) Disconnection, defectivecontact,short circuitwith chassis ground, or short circuitwith power sourcein wiring harness between transmission controller C2 (female) (7) - T3 (female) (1) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (17) - T3 (female) (2) 4) Defective transmission controller 1) Defective 2nd ECMV solenoid 2) Disconnection, defectivecontact,short circuitwith chassis ground, or shortcircuitwith power sourcein wiring harness between transmission controller C2 (female) (8) - T5 (female) (1) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (18) - T5 (female) (2) 4) Defective transmission controller
11
Disconnection in modulated clutch outlet rotation signal sensor system
12
Short circuit, disconnection, or short circuit with power source in F ECMV solenoid system
13
Short circuit, disconnection, or short circuit with power source in R ECMV solenoid system
14
Short circuit, disconnection, or short circuit with power source in 1st ECMV solenoid system
15
Short circuit, disconnection, or short circuit with power source in 2nd ECMV solenoid system
20-406 0
WA1 200-3
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABNORMALlTY AND CONDlTlONS OF MACHINE CAUSED BY ABNORMALlTY
Normal condition (voltage, current, resistance) 1) Relay coil resistance: 200 - 400 R 2) Voltage between transmission controller Cl (11) - chassis ground in neutral: Below 1 V 3) Resistance of harness between transmission controller Cl (female) (11) - L54 (female) (1): Max. 1 Q 4) Resistance of harness between backup lamp relay L54 (female) (2) - chassis ground: Max. 1 R
Operation of controller against abnormality
Condition of machine caused by abnormality
Diagnos code
Neutral (All ECMV output: OFF)
Backup lamp does not light up when machine moves in reverse.
T-l
1) Modulated clutch outlet rotation sensor Resistance between T16 (male) (1) - (2): 500 Assumes MOD/C 1000 R outlet rotation to be Resistance between T16 (male) (11, (2) - chassis 2100 rpm. ground: Min. 1 MS2
Gear is not shifted automatically.
T-2
1) Resistance between transmission controller C2 (female) (2) - (13): 10 - 20 R 2) Voltage between transmission controller C2 (2) - chassis ground in neutral: Below 1 V 3) Resistance between transmission controller C2 (female) (21, (13) - chassis ground: Min. 1 MQ 4) Resistance of harness between transmission controller C2 (female) (21, (13) - 113 (female) (11, (2): Max. 1 R
Machine cannot travel.
T-3
1) Resistance between transmission controller C2 (female) (3) - (14): 10 - 20 Q !I Voltage between transmission controller C2 (3) - chassis ground in neutral: Below 1 V 3) Resistance between transmission controller C2 (female) (31, (14) - chassis ground: Min. 1 MR 4) Resistance of harness between transmission controller C2 (female) (3). (14) - Tll (female) (l), (2): Max. 1 Q I) Resistance between transmission controller C2 (female) (7) - (17): 10 - 20 R !I Voltage between transmission controller C2 (7) - chassis ground in neutral: Below 1 V 8) Resistance between transmission controller C2 (female) (71, (17) - chassis ground: Min. 1 MR 1) Resistance of harness between transmission controller C2 (female) (71, (17) - T13 (female) (1). (2): Max. 1 R I) Resistance between transmission controller C2 (female) (8) - (18): 10 - 20 R !I Voltage between transmission controller C2 (8) - chassis ground in neutral: Below 1 V r) Resistance between transmission controller C2 (female) (81, (18) - chassis ground: Min. 1 MR L) Resistance of harness between transmission controller C2 (female) (81, (18) - T5 (female) (1). (2): Max. 1 Q
T-4
T-5
T-6
WA1 200-3
20-407 0
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABNORMALITY AND CONDlllONS OF MACHINE CAUSED BY ABNORMALITY
-ailwe code
Abnormal system
Contents of abnormality
1) Defective 3rd ECMV solenoid 2) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (9) - 17 (female) (I) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller C2 (female) (19) - 17 (female) (2) 4) Defective transmission controller
I6
Short circuit, disconnection, or short circuit with power source in 3rd ECMV solenoid system
18
Short circuit, disconnection, or short circuit with power source in R clutch drain valve solenoid system
I) Defective R clutch drain valve solenoid 2) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between transmission controller Cl (female) (8) - T23 (female) (I) 3) Disconnection or defective contact in wiring harness between T23 (female) (2) - chassis ground 4) Defective transmission controller
20
Short circuit or disconnection in joystick FNR switch system
I) Defective joystick FNR switch system 2) Disconnection or defective contact in wiring harness between Cl (male) (71, (13) or C2 (male) (11, (12) - JSI (female) (1) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit in wiring harness between JSl (female) (21, (31, (4) - C3B (female) (71, (141. (15) 4) Defective transmission controller
21
Short circuit or disconnection in joystick shift-up/shiftdown switch system
I) Defective joystick shift-up/shift-down switch system 2) Disconnection or defective contact in wiring harness between Cl (male) (71, (13) or C2 (male) (I), (12) - JSl (female) (1) 3) Disconnection, defective contact, short circuit with chassis ground, or short circuit in wiring harness between JSl (female) (51, (61, (7). (8) - C3B (female) (81, (91, (161, (17) 4) Defective transmission controller
22
Disconnection in travel speed sensor system
I) Defective travel speed sensor 2) Improper installation and adjustment of travel speed sensor 3) Disconnection or defective contact in wiring harness between C5 (female) (2)- TO5 (female) (1) 4) Disconnection or defective contact in wiring harness between C5 (female) (I), (IO) - T15 (female) (2) 5) Defective transmission controller
20-408
0
WA1 200-3
TROUBLESHOOTING
(voltage,
Normal condition current, resistance)
Diagnosi code
1) Resistance between transmission controller C2 (female) (9) - (19): 10 - 20 R 2) Voltage between transmission controller C2 (9) - chassis ground in neutral: Below 1 V 3) Resistance between transmission controller C2 (female) (91, (19) - chassis ground: Min. 1 MD 4) Resistance of harness between transmission controller C2 (female) (91, (19) - 17 (female) (I), (2): Max. 1 R
T-7
I) R clutch drain valve solenoid Resistance between T23 (male) (1) - (2): 5-15R Resistance between T23 (male) (1). (2) - chassis ground: Min. 1 MD
R clutch drain valve solenoid output: OFF
Draining speed of oil in R clutch lowers. When R is selected next time, abnormally large gear shift shock may be made. If R clutch drain valve solenoid output is kept turned ON, hydraulic pressure is not applied to R clutch and machine cannot travel in reverse.
T-8
I) Voltage between C3B (14) - chassis ground When joystick FNR switch is in F: 17 - 30 V When joystick FNR switch is not in F: Max. 1 V !) Voltage between C9B (7) - chassis ground When joystick FNR switch is in N: 17 - 30 V When joystick FNR switch is not in N: Max. 1 V 1)Voltage between C3B (15) - chassis ground When joystick FNR switch is in N: 17 - 30 V When joystick FNR switch is not in N: Max. 1 V
I) In F: Machine stops. 2) In N or R: Ma1) When N signal is chine travels forinput: Sets in N ward suddenly. is 3) Ins;N~r;l~~ ~~tpllt is 2) $h:$i$$y;ignal input: Sets in N 4) In F or R: Gear is immediately. set in neutral 3) When no signals suddenly. are input: Holds for 5) In R: Machine 2 set, then sets in stops. N. 6) In N or F: Machine travels in reverse suddenly.
T-9
C5 (8) - chassis ground When joystick shift-up switch (N.0) is in ON: Max. 1 V When joystick shift-up switch (N.0) is in OFF: 17 - 30 V 1 Voltage between C5 (9) - chassis ground When joystick shift-down switch (N.0) is in ON: Max. 1 V When joystick shiidown switch (N.0) is in OA: 17- 30 V 1) Holds forward gear. 1 Voltage between C5 (16) - chassis ground When joystick shift-up switch (N.C) is in ON: 17 - 30 V When joystick shift-up switch (N.C) is in OFF: Max. 1 V 1 Voltage between C5 (17) - chassis ground When joystick shiftdown switch (N.C)is in ON: 17 - 30 V is in OFF:Max. 1 V When joystick shiftdown switch 1N.C)
1 Voltage between
1) Gear cannot be shifted up. 2) Gear cannOt be shifted down.
T-IO
1Travel speed sensor

Resistance between T15 (male) (1) - (2): 500 - 1,000 n Resistance between T15 (male) (1). (2) - chassis ground: Min. 1 MR I) Sets in manual mode. 1) Gear shift pattern is different. 2) Machine overruns. T-11
WA1 200-3
20-409 0
TROUBLESHOOTING
Iailure
code
Abnormal
system
Contents
of abnormality
23
Short circuit or disconnection in engine rotation sensor system
1) Defective engine rotation sensor 2) Improper installation and adjustment of engine rotation sensor 3) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between transmission controller C4 (female) (1) - T17 (female) (1) 4) Disconnection or defective contact in wiring harness between transmission controller C4 (female) (9) - T17 (female) (2) 5) Short circuit in wiring harness between transmission controller C4 (female) (1) - T17 (female) (1) and between C4 (female) (3) - T17 (female) (2) 6) Defective transmission controller
24
Short circuit or disconnection in memory (FEPROM)
I) Defective transmission controller
25
Short circuit in transmission oil temperature sensor system
1) Defective transmission oil temperature sensor 2) Short circuit with chassis ground in wiring harness between transmission controller C3A (female) (11) - T19 (female) (1) 3) Short circuit in wiring harness between FR2 (male) (12) - Tl9 (female) (1) and between FR2 (male) (20) - Tl9 (female) (2) 4) Defective transmission controller
26
Short circuit in F ECMV fill switch system
1) Defective F ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission controller C3B (female) (2) - T14 (female) (1) 3) Defective transmission controller
27
Short circuit in R ECMV fill switch system
1) Defective R ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission controller C3B (female) (10) - T12 (female) (I) 3) Defective transmission controller
28
Short circuit in 1st ECMV fill switch system
1) Defective 1st ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission controller C3B (female) (3) - 14 (female) (1) 3) Defective transmission controller
29
Short circuit in 2nd ECMV fill switch system
1) Defective 2nd ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission controller C3B (female) (11) - T6 (female) (1) 3) Defective transmission controller
20-410 0
WA1 200-3
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABN0RMALl-W AND CONDITIONS OF MACHINE CAUSED BY ABNORMALm
Normal condition (voltage, current, resistance)
Diagnosi! code
I) Resistance between engine rotation sensor T17 (male) (I) - (2): 100 - 500 R 2) Voltage between transmission controller C4 (female) (I) - (9): Min. 0.5 V
,) Can trave, with engine speed at 2,100 rpm. Gear shift shock is made. T-12
Gear shift shock is reduced by learning function.
1) Learning function is turned off and default data are
Gear shift shock is made. T-13
used.
1) Resistance between transmission oil temperature sensor T19 (female) (1) - (2): 38 - 48 kS2 (Approx. 25C) 2) Voltage between transmission controller C3A (female) (II) - (17): 1 - 5 V
When gear is shifted, data of low transmission oil temperature are used.
Gear shift shock is made.
T-14
1) Resistance between transmission controller C3B Neutral (All ECMV (female) (2) - chassis ground in neutral output: OFF) (F ECMV: OFF): Min. 1 MC?
T-15
I) Resistance between transmission controller C3B (female) (IO) - chassis ground in neutral (R ECMV: OFF): Min. 1 MR
Neutral (~11 ECMV output: OFF)
T-16
I) Resistance between transmission controller C3B Neutral (~11 ECMV (female) (3) - chassis ground in neutral output: OFF) (1st ECMV: OFF): Min. 1 MR
T-17
I) Resistance between transmission controller C3B (female) (1 I) - chassis ground in neutral (2nd ECMV: OFF): Min. 1 Mh
T-18
WA1 200-3
20-411 0
TROUBLESHOOTING
Failure code
Abnormal
system
Contents
of abnormality
30
Short circuit in 3rd ECMV fill switch system
I) Defective 3rd ECMV fill switch 2) Short circuit with chassis ground in wiring harness between transmission controller C5 (female) (I 1) - T8 (female) (I 1 3) Defective transmission controller
32
Disconnection in F or R ECMV fill switch system
I) Defective F or R ECMV fill switch 2) F ECMV fill switch: Disconnection or defective contact in wiring harness between transmission controller C3B (female) (2) - T14 (female) (I) 3) R ECMV fill switch: Disconnection or defective contact in wiring harness between transmission controller C3B (female) (IO) - T12 (female) (1) 41 Defective transmission controller 1) Defective 1st. 2nd, or 3rd ECMV fill switch Disconnection or defective contact in any of following wiring harnesses 2) 1st ECMV fill switch: Transmission controller C3B (female) (3) - T4 (female) (I) 3) 2nd ECMV fill switch: Transmission controller C3B (female) (I I) - T6 (female) (I) 4) 3rd ECMV fill switch: Transmission controller C5 (female) (11) - T8 (female) (1) 5) Defective transmission controller
33
Disconnection in Ist, 2nd. or 3rd ECMV fill switch system
34
Disconnection or short circuit with power source in F bypass solenoid system
I) Defective F bypass solenoid 2) Disconnection, defective contact, or short circuit with power source in wiring harness between transmission controller Cl (female) (3) - T22 (female) (1) 31 Disconnection or defective contact in wiring harness between T22 (female) (2) - chassis ground 4) Defective transmission controller
35
Short circuit in F bypass solenoid system
1) Defective F bypass solenoid 2) Short circuit with chassis ground in wiring harness between transmission controller Cl (female) (3) - T22 (female) (I) 3) Defective transmission controller
20-412 0
WA1 ZOO-3
TROUBLESHOOTING
OPERATIONS OF CON-IXOLLER AGAINST ABNORMALlTY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALlTY
Diagnosi: code
I) Resistance between transmission controller C5 (female) (1 I) - chassis ground in neutral lF ECMV: OFF): Min. 1 MQ
T-19
I) Resistance between transmission controller C3B (female) (2) - chassis ground in forward When gear is shifted, (F ECMV: ON): Below I Q 2) Resistance between transmission controller C3B data without fill swtch signals are used. (female) (IO) - chassis ground in reverse (R ECMV: ON): Below 1 R
Gear shift shock is made.
T-20
I) Resistance between transmission controller C3B (female) (3) - chassis ground during travel in 1st gear (1st ECMV: ON): Below 1 R 2) Resistance between transmission controller C3B When gear is shifted, data without fill switch (female) (11) - chassis ground during travel in signals are used. 2nd gear (2nd ECMV: ON): Below 1 R 3) Resistance between transmission controller C5 (female) (II) - chassis ground during travel in 3rd gear (3rd ECMV: ON): Below 1 Q I) When harness is disconnected: Cannot operate at all. (Since this failure cannot be distinguished from short circuit with power source, controller sets in neutral and cannot travel.) 2) When harness has short circuit with power source: Controller sets in neutral and can travel.
Gear shift shock is made_
T-21
1) F bypass solenoid Resistance between T22 (male) (I) - 12): 5-15R Resistance between T22 (male) (I), (2) - chassis ground: Min. 1 MR
1) F clutch makes gear shift shocks and it takes long time to engage (It engages at last). 2) F clutch cannot be disengaged.
T-22
1) F bypass solenoid Resistance between T22 (male) (I) - (2): 5-75n Resistance between 122 (male) (I), (2) - chassis ground: Min. 1 MS2
I) Stops outputting.
I) F clutch makes gear shift shocks and it takes long time to engage (It engages at last).
T-23
WA1 ZOO-3
20-413 0
TROUBLESHOOTING
:ailure code
Abnormal system
36
Disconnection or short circuit with power source in R bypass solenoid system
I) Defective R bypass solenoid 2) Disconnection, defective contact, or short circuit with power source in wiring harness between transmission controller Cl (female) (10) - T21 (female) (1) 3) Disconnection or defective contact in wiring harness between T21 (female) (2) - chassis ground 4) Defective transmission controller
37
Short circuit in R bypass solenoid system
I) Defective R bypass solenoid 2) Short circuit with chassis ground in wiring harness between transmission controller Cl (female) (IO) - T21 (female) (I) 3) Defective transmission controller
38
Disconnection or short circuit with power source in 1st bypass solenoid system
1) Defective 1st bypass solenoid 2) Disconnection, defective contact, or short circuit with power source in wiring harness between transmission controller Cl (female) (5) T20 (female) (1) 3) Disconnection or defective contact in wiring harness between T20 (female) (2) - chassis ground 4) Defective transmission controller
39
Short circuit in 1st bypass solenoid system
1) Defective 1st bypass solenoid 2) Short circuit with chassis ground in wiring harness between transmission controller Cl (female) (5) - T20 (female) (I) 3) Defective transmission controller
20-414 0
WA1 200-3
TROUBLESHOOTING
Operation of controller against abnormality 1) When harness is .disconnected: Cannot operate at all. (Since this failure cannot be distinguished from short circuit with power source, controller sets in neutral and cannot travel.) 2) When harness has short circuit with power source: Controller sets in neutral and can travel.
Diagnosis code
1) R bypass solenoid Resistance between T21 (male) (1) - (2): 5-15P Resistance between T21 (male) (I), (2) - chassis ground: Min. 1 ML?
1) R clutch makes gear shift shocks and it takes long time to engage (It engages at last). 2) R clutch cannot be disengaged.
T-24
1) R bypass solenoid Resistance between T21 (male) (1) - (2): 5-15R Resistance between T21 (male) (11, (2) - chassis ground: Min. 1 MR
1) Stops outputting.
1) R clutch makes gear shift shocks and it takes long time to engage (It engages at last).
T-25
1) 1st bypass solenoid Resistance between T20 (male) (I) - (21: 5-15R Resistance between T20 (male) (I), (2) - chassis ground: Min. 1 ML2
1) When harness is disconnected: Cannot operate at all. (Since this failure cannot be distinguished from short circuit with power source, controller sets in neutral and cannot travel.) 2) When harness has short circuit with power source: Controller sets in neutral and can travel.
1) 1st clutch makes gear shift shocks and it takes long time to engage (It engages at last). 2) 1st clutch cannot be disengaged.
T-26
1) 1st bypass solenoid Resistance between T20 (male) (I) - (2): 5-15R Resistance between T20 (male) (I), (2) - chassis ground: Min. 1 MR
1) Stops outputting.
1) 1st clutch makes gear shift shocks and it takes long time to engage (It engages at last).
T-27
WA1 200-3
20-415 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
20-416 0
TROUBLESHOOTING
Auto shift indicator

i'
TXWO2561
WA1 ZOO-3
20-417 0
TROUBLESHOOTING
T-l
T-l *
Failure code [lo] (Short circuit, disconnection, short circuit with power source in backup lamp relay) is displayed
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing connector and inserting the T-adapter, or when monitor display, the the on displayed longer no is code error to its original position, if the problem has been removed.
are properly inserted. Before carrying out troubleshooting, check that all the related connectors step. next the to Always connect any disconnected connectors before going on
Cause Remedy
f
4YES yes Is resistance YES between Cl - (female) (11) and chassis ground 2 - normal? Is resistance * Min. 1 MR YES between Cl (female) (17) and w (female) - *Turn starting switch OFF. (1) normal? 1 * Disconnect Cl ' locode Is failure Max. 1 R and L54. displayed when _ * Turn starting backup relay is NO switch OFF. replaced with other Disconnect Cl relay of same type? and L54. *Turn starting switch OFF. I NO * Replace backup relay with other relay of same type. -Turn startino switch ON. * Set directional lever to Ft. 5 YES
l l
Is resistance between L54 - (female) (2) and 3 chassis ground ~normal? . Max. 1 R - * Turn starting switch OFF. * Disconnect Cl and L54. NO
cGotoA Defective contact or disconnection in wiring harness between L54 (female) (2) and chassis ground Short circuit with chassis ground in harness between Cl (female) (11) and L54 (female1 (1) Defective contact or disconnection in wiring harness between Cl (female) (11) and L54 (female) (1)
NO
Repair or replace
Repair or replace
Repair or replace
Defective backup lamp relay
Repair
From A _
Is vottage between _ Cl (female) (11) and chassis ground normal?

l
Defective transmission controller Short circuit with power source in wiring harness
Repair
Turn starting switch ON. Disconnect Cl and L54. * Max. 1 V
?epair or .eplace
T-l
Related
electrical
circuit diagram
Cl (MICl3)
Backurr lamp relay
1 23 11 11 . 5fG
Backup relay lam
TXW02444
20-418 0
WA1 200-3
TROUBLESHOOTING
T-7
T-2 Error code [Ill (Disconnection in modulated signal sensor system) is displayed *
clutch outlet rotation
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.
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
3 YES
Is resistance YES between C4 (female) (9) and T16 2 (female) (2) normal? - Max. l R NO * Disconnect C4, T16, and M02B. -Turn starting switch OFF. NO
Defective transmission controller Disconnection or defective contact in wiring harness between C4 (female) (9) T16 (female) (2) Disconnection or defective contact in wiring harness between C4 (female) (2) 116 (female) (1) Defective modulated clutch outlet rotation sensor
Replace
n 1
T16 hale) 11) and (2)
Is resistance between C4 (female) (21and T16 (female) (1) normal? - Max. 1 R * Disconnect C4, T16, and M02B. -Turn starting switch OFF. 0
Repair or replace
andbetween (1).(21and chassis ground normal? Between (1) - (2): 500-lOOOR Between (l), (2) chassis ground: Min. 1 MR Disconnect T16. * Turn starting switch OFF.
l
qepair or splace
3epair or Pplace
T-2 Related
electrical
circuit diagram
RT2 (HD-85086)
TXWO2445
WA1 200-3
20-419 0
TROUBLESHOOTING
T-3
T-3 Error code [I21 (Short circuit, disconnection, or shot-t circuit with power source in F solenoid system) is displayed
*
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting the connector connector and inserting the T-adapter, or when removing the T-adapter and returning display, the monitor the on to its original position, if the error code is no longer displayed problem has been removed.
* *
carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Before
CaUSe
Remedy
4YES
GotoA
Disconnection or defective contact in wiring harness between C2 (female) (2) T13 (female) (1)
Repair or reolace
YES ween C2 (female)

(13) and T13
l-l
Is
resistance bet-
T13 (male) (1) and (2) and between (1). (2) and chassis ground
Between (1) (2): 5 - 15 n Between (1). (2) chassis ground: Min. 1 MD -Turn starting switch OFF. * Disconnect T13.
-
1R * Turn starting switch OFF. * Disconnect CZ and T13.
- Max.
* Min. 1 MD * Turn startina switch OFF.* Disconnect C2 and T13.
- Disconnect C2 and T13.

NO
--
Short circuit with chassis ground in wiring harness between C2 (female) 113) T13 (female1 (2) Disconnection or defective contact in wiring harness between C2 (female) (13) T13 (female) (2)
Repair or replace
Repair or replace
I
NO
Defective F solenoid
Replace
8YES
Defective transmission controller
Repair or replace
Ez ,Is resistance YES between C2 (female) (2) and 5 -From 1 6
C2 (female) (2) and _ -Turn starting awitch NC ON. chassis ground * DisconnectC2 and 113. normal? -Max. 1V - Turn starting sGtch ON. * Disconnect C2 and Tl3. NO
Shon circuitwith power source in wiring harness between C2 (female) (13) T13 (female) (21 Short circuit with power source in wiring harness between C2 (female) (2) -Tl: (female) (1) Short circuit in wiring harnessbetween C2 (female) (2) -T13 (female) (1) and between C2 (female) (13lT13 (female1(2) Short circuit with chassis ground in wiring harness between C2 (female) (2) - T13 (female) (1)
Repair or replace
Repair or replace
Repair or replace
* Turn starring switch OFF. * Disconnect C2 and T13.
I
NO
Repair or replace
T-3 Related
electrical
circuit diagram
Transmission
controller
F solenoid
TXW02446
20-420 0
WA1 200-3
TBOUBLESHOOTING
T-4
T-4 Error code [I31 (Short circuit, disconnection, or short circuit with power source in R solenoid system) is displayed
QYES
Is resistance betYES ween ~2 (female) 3 - (3) and TM1 (female) (1) normal? .Max.lR NO * Turn starting switch OFF. * DisconnectCt and Tll.
Cause
Remedy
Gotok
pIs resistance YES between C2 - (female) (14) and chassis ground 2 normal?
Disconnectionor defective contact in wiring harness between C2 (female1(3lTM1 (female) (7) with chassis ground in wiring harness between C2 (female) (14) Tl 1 (female) (2)
Short circuit
Repair or replace
YI
1 TM1(male1 (11and(2) andbetween (11, (21and chassis ground normal? * Between (1) - (2): 5-154-t Between (1). (2) chassis ground: Min. 1 MS-I - Turn starting switch OFF. * DisconnectTMl.
l
Is resistance bet* Min. 1 M R ween C2 (female) - -Turn staning switch NO (14) and 111 OFF. (female) (2) normal? . DisconnectC2 and p * Max. 1 R Tll. . Turn starting NO switch OFF. * Disconnect C2 and Tll. NO
Repair or replace
Disconnectionor defective contact in wiring harness batween C2 (female) (14lill (female) 12)
Repair or replace
Defective R solenoid
Short circuit with power source in wiring harness between C2 #amale) (141Tll (female) (2) Is resistance YES between C2 - (female) t3) and (14) normal7 5 From Is resistance betA _ ween C2 (female) (3) and chassis ground normal7 * Min. 1 MR -Turn starting switch OFF. * DisconnectC2 and Tll. 5-15Ct * Turn starting switch OFF. - Disconnect C2.
Repair or replace
* Turn startingswitch
ON. * DisconnectC2 and CN14. * Max. 1 V
Max.
1V
NO
Short circuit with power source in wiring harness between C2 (female) (3l- Tl (female) (1) Short circuit in wiring harness between C2 (female) (3) - Tl 1 (female) (1) and between C2 (female) (14) Tll (female) (2) Shon circuit with chassis ground in wiring harness between C2 (female) (31-Tll (female) Ill
Repair or reDlace
IO
Repair or replace
NO
Repair or replace
T-4 Related
electrical
circuit
diagram
R solenoid
TXW02447
WA1 200-3
20-42 1 0
TROUBLESHOOTING
T-5
T-5 Error code 1141 (Short circuit, disconnection, or short circuit with power source in 1st solenoid system) is displayed
*
the so when disconnecting is carried out when there is still an abnormality, This troubleshooting connector the returning and T-adapter the removing when or T-adapter, the connector and inserting to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed.
* *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Go to A.
Cause
Remedy
Disconnectionor defective contact in wiring harness between C2 (female) (7) - T3 (female) (1) Is resistance betYES ween C2 (female) - (17) and ~3 (female) - Turn starting switch NO OFF. (2) normal? 1 . DisconnectC2 and 1 between Is resistance T3. . Max. 1 R 11)and(21and T3 (male) - 0~;: starting switch NO (1).(21and between normal? ground chassis * Disconnect C2 and T3. . Between (1) - (2): 5-155-Z NO * Between (1). (2) chassis ground: Min. 1 MC? . Turn starting switch OFF. * DisconnectT3. Short circuit with chassis ground in wiring harness between C2 (female) I171- T 3 (female) (2) Disconnectionor defective contact in wiring harness between C2 (female) (17) - T:3 (female) (2)
IRepair or Ireplace
IRepair or replace
IRepair or Imeplace
Defective 1st solenoid
--c
between C2 ffemale)f7)and chassisground normal?
aYE S Defective transmission controller Is voltage between YES ~2 (female) (17) and chassis ground 7Short circuit with power normal? source in wiring harness L _I Isvoltage between between C2 (female) (17) -T 3 N( D YES ~2 {female) (7) and _ -Turn starting (female) (2) chassis ground wftch ON. 6 normal? * DisconnectC2 and T3. Short circuit with power *Max.lV Is resistance betsource in wiring harness * Turn starting switch ES_ wean C2 (female) _ Ibetween C2 (female) (7) - T3 ON. NO (71 and (17) Iifemale) (1) - Disconnect C2 and 5 normal? T3. Short circuit in wiring . Max. 1 V Iharnessbetween C2 (female) .5-15R I17)- T3 (female) 11)and - * 2;; stamng swtch NO 3 Ibetween C2 (female) (17) - TZ IIfemale) (2) * Diionnect C2. Short circuit with chassis ground in wiring harness between C2 (female) (7) - T3 (female) (1)
IReplace
f3epair or ,eplace 1
Iepair or F replaca
Xepair or F r,eplace
* Min. 1 MR * Turn starting switch OFF. - DisconnectC2 and T3.
Repair or reDlace
NO
T-5 Related
electrical
circuit diagram
id
TXWQ2448
20-422 0
WA1 200-3
TROUBLESHOOTING
T-6
T-6 Error code [I!51 (Short circuit, disconnection, or short circuit with power source in 2nd solenoid system) is displayed
4YES YES 3 P YES 2 _ yes 1 Is resistance between C2 (female1 (18) and T5 (female) (2)
1 normal7
Cause
Remedy
Go to A.
Is resistancebetween ~2 (female) (18) and chassis ground normal?
Is resistance between c2 (fernate) (8) and T5 (female) (1) normal? -Max. IR - Turn starting switch OFF. * Disconnect CZ and T5. NO
Disconnection or defective contact in wiring harness between C2 (female) (8) - T5 (female) (1) Short circuit with chassis ground in wiring harness between C2 (female) (18) -T? (female) (21 Disconnection or defective contact in wiring harness between CZ (female) (18) -I? (female) (2)
?epair or Feplace
IS resistsnce belwee
T5 (male)Ill and12) andbetween Ill, (2) andchassis ground n0tmai? ~

l
I * Max. 1 R . :I; starting switch NO

l
* Min. 1 MR * Turn startingswitch NO OFF. DisconnectC2 and Ts.
Repair or replace
Repair or replace
* DisconnectC2 and Defective 2nd solenoid Replace
T5. Between (l)-(2): 5-15R NO * Between 11). 12)chassis ground: Min. 1 MR * Turn starting switch OFF. * DisconnectT5. Is voltage between YES ~2 (female) (8) and chassisground 6 normal? Is resistance betYES_ ween cz (female) (8) and (18) 5 _ normal? From Is resistance betA ween C2 (female) (8) and chassis ground normal? * Min. 1 MR * 2;; aartlng swtch . Disconnect C2 and T5. _ *5-15R *~F;stanmgswnch * DisconnectCZ. NO _
BYE! YES 7 _ Is voltage between ~2 (female) (18) and chassis ground normal? * Turn starting switch NC ON. DisconnectC2 and T13. * Max. 1 V
?eplace
Short circuit with power source in wiring harness
between C2 (female) (18) - E (female) (2) Shoti circuit with power source in wiring harness between C2 (female) (8) -T5 (female) (1) Shon circuitin wiringharness behveenC2 (female)(81-T5 (female)(1) and betweenC2 (female)(13) -T5 (female) (2) Short circuit with chassis ground in wiring harness
between (female) C2 (female) (1) (8) -TS
3epair or Feplace
* Turn startingswitch ON. - DisconnectC2 and T5. Max. 1 V
NO
?epair or .eplace
NO
3epair or ,eplace
Repair or replace
T-6 Related
electrical
circuit diagram
Transmission controller id
TXW02449
WA 1200-3
20-423 0
TROUBLESHOOTING
T-7
T-7 Error code [IS] (Short circuit, disconnection, or short circuit with power source in 3rd solenoid system) is displayed
* 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.
check that Before carrying out troubleshooting, related connectors are properly inserted. connectors any disconnected Always connect going on to the next step. all the before
4YEL
* *
Cause
Remedy
I Is resistancebetlfrxnalel 1 normau IL NO -.. . -1 - -=2ing switch Is I bek,e.x,w d ~7 H *Turn staning switch NO (female) (19) ant __ I I W-F. (fema,e)(__--_, I * DisconnectC2 and 17. . Max. 1 R
Gotok
Disconnectionor defective contact in wiring harness between C2 (female) (9) -l7 (female) (1) Short circuit with chassis ground in wiring harness between C2 (female) (19) -T; (female) (2) Disconnectionor defective contact in wiring harness between C2 (female) (19) -T; (female) (2)
Repair or replace
st C2 and 17.
YE
1 l7 Imale) (1)and12) and betwean(1). (2) ground and chassis Between (1) - (2): 5-15R * Between (11, (2) chassis ground: Min. 1 MR . Turn STartin swirch OFF. * Disconnect17.
l
Repair or replace
z.LrzJ
Repair or replace
- Disconnect C2 and 17. Defective 3rd solenoid bolace
SYES -IIs voltage between YES cz (female) (19) and u chassis around 7
r-l
Short circuit with power source in wiring harness between C2 (female) (19) -Ti Ifemale) (2) Short circuit with power source in wiring harness between C2 (female) (9) - l7 (female) (1) Shon circuit in wiring harness between C2 (female) (9) - 17 (female) (1) and between C2 (female) (19) - T: (female) (2) Short circuit with chassis ground in wiring harness between C2 (female) (9) -T7 (female) (1)
Repair or replace
?epair or replace
Repair or replace
normal?* Min. 1 MQ -Turn starting switch OFF. * DisconnectC2 and 17.
. DisconnectC2.
NO
Repair or replace
T-7 Related electrical circuit diagram
Transiaission controller
id
TXW02450
20-424 0
WA1 ZOO-3
TROUBLESHOOTING
T-8
T-8 Error code [I81 (Short circuit, disconnection, or short circuit with power source in R clutch drain valve solenoid system) is displayed
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. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
Go to A.
YE
(8) and chassis
*Turn starting switch OFF. * Disconnect T23.
-Max.
1R
NC
Disconnection or defective contact in wiring harness between T23 (female) (2) chassis ground Short circuit with chassis ground in wiring harness between Cl (female) (8) T23 (female) (1) Disconnection or defective contact in wiring harness between Cl (female) (8) T23 (female) (1) Defective R clutch drain valve solenoid
Repair or replace
NO
IS reslstawe between - Max. 1 R * Turn starting switch OFF. . Disconnect Cl and T23.
Repair or replace
l23 bnale)(11and2 and _ between (11,(2)and chassisground normal? * Between (1) - (2): 5-15R * Between (1). (2) chassis ground: Min. 7 MR * Disconnect T23. + Turn starting switch OFF.
and T23. NO
Repair or replace
No
5
between Cl (female1(61 and chassis ground normal?
Is voltage
l
YES
_
Defective transmission controller Short circuit with power source in wiring harness between Cl (female) (8) T23 (female) (I)
From A -D
Turn srening switch ON. * DisconnectCl and T23. Max. 1 V
NO
Repair or replace
Transmission controller FRI (HO-660661 RTI (HD-860661
R clutch drain valve solenoid
11
TXW02451
WA1 200-3
20-425 0
TROUBLESHOOTING
T-9
T-9
Error code [201 (Short circuit or disconnection switch system) is displayed
in joystick FNR
1:
* * *
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. Check that fuse ii (6) is normal. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Remedy
Replace
I:;showninTable
11
NO
- Turn
Is voltage between JSl (2). (3). (4) and chassis ground as shown in Table 17
l
starting switch ON.
Disconnection, defective contact, short circuit with chassis ground, or short circuit in wiring harness between JSl (female) (2). (3). [;;;C3B (female) (71, (14). Disconnection or defective contact in wiring harness between Cl (male) l7). (13) or C2 (male) (1). (12)- JSl (female) (1) Defective joystick FNR switch
Repair or replace
uo
Repair or replace
Turn starting switch ON.
NO
Replace
Table 1 Voltage measured with joystick FNR switch at each position Position of FNR switch Terminals JSI (male) (1) - (2) JSl (male) (I) - (3) JSI (male) (1) - (4) C3B (14) - Chassis ground C3B (7) - Chassis ground C3B (15) - Chassis ground 20 - 30 V Max. 1 V Max. 1 V Max. 1 V 20 - 30 V Max. 1 V Max. 1 V Max. 1 V 20 - 30 V F N R

Transmission control Joust ick lever switch
TXW02452
20-426 0
WA1 200-3
TROUBLESHOOTING
T-IO
T-10
*
Error code [211 (Short circuit or disconnection switch system) is displayed up/shift-down
in joystick shift_
the so when disconnecting is carried out when there is still an abnormality, This troubleshooting connector the returning and T-adapter the removing when or T-adapter, connector and inserting the display, the to its original position, if the error code is no longer displayed on the monitor problem has been removed.
* * *
Check that fuse II (6) is normal. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Remedy
Is yes
L5 (ternale) v3). (9).
__ ._
v&agebetween .-.
contdct, short circuit with
Replace Disconnection,defective
2 _ Is voltage YES_ between JSl (I) and chassis 1 ground normal? -2O-30V -Turn starting switch ON.
(16). (17) and chassisground as shown in Table 17 NO
_ - Turn starting switch ON.
chassisground. or short circuit in wiring harness between JSl (female) (5). (6). (7). (8) - C5 (female) (8), (9). 116).(17) Disconnectionor defective cOntactin wiring harness between Cl (male) VI, (131 or C2 (male) (lb, 112)- JSl (female) (1)
Repair or replace
p ISvoitage between JSl (5). (6). (7). (8) and chassisground as shown in Table 17 -Turn starting switch ON.
NO
Repair or replace
Replace
Table 1 Voltage measured with joystick shift-up/shift-down
switch at each position Shift-down switch ON Max. 1 V 20 - 30 v 20 - 30 v Max. 1 V
Terminals JSI (5) - Chassis ground JSl (6) - Chassis ground JSl (7) - Chassis ground JSI (8) - Chassis ground
T-IO Related
Shift-up switch ON C5 (17) - Chassis ground C5 (91- Chassis ground C5 (16) - Chassis ground C5 (8) - Chassis ground 20 - 30 v Max. 1 V Max. 1 V 20 - 30 v
electrical
circuit diagram
Joust ick lever switch
TXW02452
WA1 200-3
20-427 0
TROUBLESHOOTlNG
T-11
T-11
Error code [22] (Disconnection displayed
in travel speed sensor system) is
Cause
Remedy
YES
Replace
Es
1 Is resistance between T15 lmalet (1) and (2) and-n (V. (2) and chassis ground
normal?
Ii
. Between (1) - (2): wo- lOM)R * Between (l), (2) chassis ground: Min. 1 MR * Disconnect T15. * Turn starting switch OFF.
1normal? II Isresistance between C5 NO _ *Max. 1 Q (female) (2) and T15 Disconnect T75, C5, (female) (1) normal? M02A, U8, and L07. P . Max. 1 R NO * Disconnect T1.5, C5, M02A. L28, and L07. * Turn starting switch OFF.
l
contact in wiring harness batwaen C5 (female) Ht. (10) -T15 (female) (2) Disconnaction or defective contact in wiring harness beween C5 (female) 12) T15 (female) (1) Defective travel speed sensor
Repair or replace
Repair or replace
NO
Replace
T-l 1 Related
Work
electrical
circuit
diagram
RT2 m-85086)
1I 5 IDTZ)
equipment controller
TXW02453
20-428 0
WA1 200-3
TROUBLESHOOTING
T-12
T-12
Error code [23] (Short circuit or disconnection sensor system) is displayed
in engine speed I
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting 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.
QYE! YES 3 - Is resistance YES between C4 - (female) 11)and chassis ground 2 Is resistance between c4 (female) (9) and T17 (female) (2) normal? .Max.lR NC - DisconnectC4,T1J. LOJ, and MO2B *Turn starting switch OFF. Go to A.
Cause
Disconnection or defeotive contact in wiring harness between C4 (female) (9) - T17 (female) (2)
Short
Repair or replace
NO nect C4, )7, and M02B , switch
with chassis circuit ground in wiring harness between C4 (female) (1) -T17 (female) (1)
Repair or replace
Disconnection or defective contact in wiring harness between C4 (female) (1) - T17 (female) (1)
Repair or replace
~100-500R - Disconnect T17. * Turn starting switch OFF.
* Turn starting switch OFF. NO
Defective engine speed sensor
qeplace
YES
From A
-I
Is resistance between C4 (female) (1) and (9)

normal?
I I I
Y
Defective transmission controller Short circuit in wiring harness between C4 (female) (1) -T17 (female) (1) and between C4 (female) (3) - T17 (female) (2)
1 MR * Disconnect C4, T17, L07, and M02B * Turn starting switch OFF.
* Min.
NO
Repair or replace
T-12 Related
electrical
circuit diagram
LO7 I040 121 3 I24ElTachometer I I3FI Main monitor
c4 (MICl.2)
TXW02454
WA1 200-3
20-429 0
TROUBLESHOOTING
T-13
T-13
Failure code [24] (Short circuit, disconnection displayed
in EEP ROM) is
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. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Remedy
Replace
20-430 0
WA1 200-3
TROUBLESHOOTING
T-14
T-14
Error code 1251 (Short circuit in transmission sensor system) is displayed
oil temperature
J,
Cause
Remedy
3 YES
Is resistance
YES betweenFlU _ (male) (12) and 2 (20) normal? * Min. 1 MR . Turn -Ring switch OFF. * Disconnect FR2 and T19. NO NO
Defective transmission controller Short circuit in wiring harness between FR2 (male) (12) -119 (female) (1) and between FR2 (male) (20) -T19 (female) (2) Short circuit with chassis ground in wiring harness between C3A (female) (ll)-T19 (female) (1) Defective transmission oil temperature sensor
Replace
Is resistance yES betweenc3A r- (female) (111 and chassis ground 1 Is resinance betwe& norrna7 * Min. 1 MC! T19 (male)(1) and (2) andbetween( andchassisground IlOnlUl?
Repair or replace
- Between (1) - (2): 39 - 49 Id2 fat 25C) * Between (l), (2) chassis ground: Min. 1 MR *Turn starting switch OFF. - Disconnect T19.
*Turn startin9 switch OFF. * Disconnect C3A and T19.
Repair or replace
Replace
NO
T-14 Related
electrical
circuit diagram
C3A(040201 T/M oil temerature 328 11 . 5u J T3 (DTZB)
WA1 200-3
20-43 1 0
TROUBLESHOOTING
T-15, T-16
T-15 +
Error code [26] (Short circuit in F ECMV fill switch system) is displayed
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 problem has been removed. * Before carrying out troubleshooting, check that all the Cause related connectors are properly inserted. Jr Always connect any disconnected connectors before going on to the next step.
2 Is resistance batYES Defective transmission controller Short circuit with chassis ground in wiring harness between C3B (female) (2) -T14 (female) (1) Defective F ECMV fill switch
display, the
Remedy
Replace
Is resistance between T14 hale) (1) and chassis ground normal? * Min. 1 MR * Disconnect T14. * Turn starting switch OFF.
NO Min. 1 MR s Disconnect C3B. T14, and M02A. . Turn starting switch OFF.
*
Repair or replace
Replace
NO
T-16
*
Error code [271 (Short circuit in R ECMV fill switch system) is displayed
* *
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. Before carrying out troubleshooting, check that all the Remedy Cause related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
This troubleshooting
2 __/lsresistancebetYES
1 Ii
Defective transmission controller Short circuit with chassis ground in wiring harness between C3B (female) (10) -T12 (female) (1)
Replace
Repair or replace
- Disconnect T12. * Turn starting switch OFF.
NO
Defective R ECMV fill switch
Replace
T-15, 16 Related electrical circuit diagram
TXW02456
20-432 0
WA1 200-3
TROUBLESHOOTING
T-17, T-18
T-17
Error code E281 (Short circuit in 1st ECMV fill switch svstem) is I displayed
Before carrying out troubleshooting, check that all the related connectors are orooerly inserted. Always connect any disconnected connectors before going on to the next step.
ChUSe
Remedy
2 Is resistance bet-
YES
Defective transmission controller Short circuit with chassis ground in wiring harness between C36 (female) (3) -T4 (female) (1)
Replace
Repair or replace
(1) and chassis Min. 1 MR * Disconnect T4. * Turn starting switch OFF.
-
* Disconnect C3B. T4, and

MOZA
l
Turn
starting switch OFF.
NO
Defective 1st ECMV fill switch
T-18
Error code 1291 (Short circuit in 2nd ECMV fill switch system) is displayed
Cause
Remedy
YES
Defective transmission controller Short circuit with chassis ground in wiring harness between C3B (female) (ll)-T6 (female) (1) Defective 2nd ECMV fill switch
Replace
Repair or replace
Replace
. Disconnect T6. -Turn starting switch OFF.
NO
WA1 200-3
20-433 0
TROUBLESHOOTING
T-1Q
T-19
Error code [30] (Short circuit in 3rd ECMV fill switch svstem) is . displayed
* *
2 YES
yes
0etweenC5
Is resistance __
II -
Defective transmission controller Short circuit with chassis ground in wiring harness between CS (female) (11) -T8 (female) (1) Defective 3rd ECMV fill switch
Replace
- (female) (11) and between T8 (female) (1) and chassis ground * Min. 1 MR . Disconnect T8. * Turn starting switch OFF.
NO * Min* MR * Disconnect C5. T8, and * Turn starting switch OFF. NO
Repair or replace
Replace
T-19 Related
electrical
circuit diagram
Transmission
TXW02457
20-434 0
WA1 200-3
TROUBLESHOOTING
T-20
T-20 *
Error code 1321 (Disconnection system) is displayed
in F or R ECMV fill switch
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and connector and inserting the T-adapter, or when removing the T-adapter monitor display, the the on displayed longer to its original position, if the error code is no problem has been removed.
Cause
Remedy
s
M
3
Defective transmission
Replace
YES 2 Is resistance between C3B . (female) (10) and T12 (female) (1)
n0ITlall
0;;. starting switch N( I
Defective R ECMV fill switch
(female) (2) and T14 (female) (11 normal? * Max. 1 R * Turn starting switch OFF. Disconnect C3B. T14, and M02A.
l
Max. 1 R Turn starting switch OFF. . Disconnect C3B, T12, and M02k
l l
*Turn startingswitch OFF. - Disconnect Tl4. engine. -Start cut-offswitchOFF(Putout lamp). *Turn transmission *Turn parkingbrakeswitchOFF. * Pressbrake. switchto F. * Set directional NO
tf T14 (female) (1) is grounded to chassis, is 32 displayed?
* DisconnectT12. - Start engine. R * Turn transmissioncut-oi switch OFF (Put out lame). . Turi parking brake switch OFF. * Press brake. switchin F . Set directional I. I3efective F ECMV fill switch IUO
Replace
I Disconnection or defective ,:ontact in wiring harness Ibetween C3B (female) (10) -T12 (female) (1) I Disconnection or defective ,Contact in wiring harness I between C3B (female) (2) T14 (female) (1)
qepair or eplace
NO
3epair or pplace
T-20 Related
electrical
circuit diagram
Transmission
Mod
CC
TXW02456
WA1 200-3
20-435 0
TROUBLESHOOTING
T-21
T-21
*
Error code 1333 (Disconnection switch system) is displayed
in lst, 2nd, or 3rd ECMV fill
* *
This troubleshooting is carried out when there is still an abnormalii, 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. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Cause Remedy
,
YES
_rl
H
I
NO
Is resistance betweenC5 Ifemale) (11) and T6
Replace
_m _^^^ _- T,.
Disconnection or defective contact in wiring harness between C5 (female) I1 1)T8 (female) (1) Disconnection or defective contact in wiring harness between C3B (female) (11) - T6 (female) (1) Disconnection or defective contact in wiring harness between C3B (female) (3) 14 (female) (1) Repair or replace
(female)
(lil
and T6
(female) 11)normal?
1R * Turn starting switch OFF. . Disconnect C3B. 14. and M02A.
- Max.
I I
* Turn starting switch OFF. . Disconnect C3B. T6, and M02A.
*Turn starting switch OFF. * Disconnect CS, T8. and M02A
Repair or replace
NO
Repair or replace
YES
From A -
If TS (female) (1) is YES grounded to chassis, is 33 5 displayed? ifT6 (female) (1) is NO . Td;F: startingswitch grounded to chassis, is 33 * Disconnect T6. . Start engine. displayed? - Set directionalswitchin N. - Set gear shift cnsition in %-I - Turn starting switch OFF. NO - Disconnect T6. * Start engine. * Set directional switch in N. * Set gear shift position in 2nd.
Defective 3rd ECMV fill switch
Replace
Defective 2nd ECMV fill switch
3eplace

Transmission
TXWO2457
20-436 0
WA1 200-3
TROUBLESHOOTING
T-22
T-22 *
Error code [341 (Disconnection or short circuit with power source in F bypass solenoid system) is displayed
Cause
Remedy
I
YES
Is voltage between Cl (female) (3) and

chassis ground normal?
4YEs ,A
Defective transmission controller Short circuit with power source in wiring harness between Cl (female) (3) TZ2 (female) (11 Short circuit with chassis ground in wiring harness between T22 (female) (2) chassis ground Disconnection or defective contact in wiring harness between Cl (female) (3) T22 (female) (1)
Replace
3
Is resistance bet-
YES weenT22 (female) 2

(21and chassis ground normal?
- Max. 1 V
N(
switch
Repair or replace
- Turn starting
OFF.
Is resistance * Max. 1 Q YES between CI (female) (3) and T22 - -Turn starting switch OFF. 1 (female) (1) normal? p * Disconnect T22. * Max. 1 R between T22 (male) (1) and (2) and between (11, (2) and - * Turn starting NO switch OFF. chassis ground normal? - Disconnect Cl and T22. * Between (1) - (2): 5-15R - Between (l), (2)chassis ground: Min. 1 MR * Turn starting switch OFF. . Disconnect T22. NO
. DisconnectCl and T22. NO
Repair or replace
Repair or replace
Defective F bypass solenoid
Replace
T-22 Related
electrical
circuit diagram
Transmission
controller
F brrass
k
WA1 200-3
TXW02458
20-437 0
TROUBLESHOOTING
T-23
T-23
Error code [35] (Short circuit in F bypass solenoid system) is displayed
This troubleshooting is carried out when there is still an abnormalii, 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. Before carrying out troubleshooting, check that all the related connectors are properly inSerted_ Always connect any disconnected connectors before going on to the next step.
GWX!
Remedy
2 Is resistance between Cl (female) (3) and chassis ground normal? * Min. 1 MR * Turn starting switch OFF. * Disconnect Cl and T22.
Defective transmission controller Short circuit with chassis ground in wiring harness between Cl (female) (3) T22 (female) (1)
Replace
Repair or replace
. Between (1) - (2): 5-15R * Between (1 L (2) chassis ground: Min. 1 MR . Turn starting switch OFF. * Disconnect T22.
Defective F bypass solenoid
Replace
F bylass
TXW02458
20-438 0
WA1 200-3
TROUBLESHOOTING
T-24
T-24
Error code [361 ( Disconnection or short circuit with power source in R bypi ISS solenoid system) is displayed
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting connector and inserting the T-adapter, or when removing the T-adapter and returning the connector if the error code is no longer displayed on the monitor display, the to its original position, problem has been removed.
Before carrying out troubleshooting, check that all the related connectors are properly inserted. -k Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
Defective transmission controller Short circuit with power source in wiring harness between Cl (female) (10) T21 (female) (1)
I
Replace
n
I
Is resistance YES between cl
Repair or replace
- Disconnect
Cl and T21.
1 between T21 (male) 11)and (2) and between (1). (2) and &s;,ground * Between (1) - (2): 5-15R - Between (1). (2) chassis ground: Min. 1 MD * Turn starting switch OFF. - Disconnect T27.
(female) (3) and T21 (female) (1) normal? - Max. 1 R . Turn starting switch OFF. * Disconnect Cl and T21.
Max. 1 R * Turn starting switch OFF. * Disconnect T21.

-
NO
Short circuit with chassis ground in wiring harness between T21 (female) (2) chassis ground Disconnection or defective contact in wiring harness between Cl (female) (10) T21 (female) (1)
Repair or replace
NO
Repair or replace
I
NO
Defective R bypass solenoid
Replace
T-24 Related
electrical
circuit diagram
Tl
TXW0.2459
WA1 200-3
20-439 0
TROUBLESHOOTING
T-25
T-25
*
Error code [37] (Short circuit in R bypass solenoid system) is displayed
* +
Cause
Remedy
YES 1 Is resistance between l-21 tmale) (11and (21and _ between (1). (2) and
chassis ground
Is resistance between Cl (female) (10) and chassis ground normal?
Replace
lMin.lMQ
l l
n0nllall . Between (1) - (2): 5-15n * Between (1). (2) chassis ground: Min. 1 MD . Turn starting switch OFF. * Disconnect T21.
NO Turn starting switch OFF. Disconnect Cl and T21.
Short circuit with chassis ground in wiring harness between Cl (female) (10) - T21 (female) (1) Defective R bypass solenoid
Repair or replace
Replace
NO
I74
11
TXW02459
20-440 0
WA1 200-3
TROUBLESHOOTING
T-26
T-26
Error code 1381 (Disconnection or short circuit with power source in 1st bypass solenoid system) is displayed
Sr
I
4YES 7 Is resistance YES between T20 - (female) (21and chassisground 2 normal?
Is
Cause
1 Remedy
1 -
Is voltage between Cl (female) 6) and _ chassis ground normal? . MaxV * Turn starting switch
OFF.
Replace
NO
Short circuit with power source in wiring harness 1 Repair or replace between Cl (female) (5) T20 (female) (1) Short circuit with chassis ground in wiring harness between T20 (female) (2) -chassis ground Disconnection or defective contact in wiring harness between Cl (female) (5) - T20 (female) (1) Defective 1st bypass solenoid Repair or replace
resistance * Max. 1 R YES between Cl (female) (5) and TZO - -Turn starting switch OFF. (female) (1) normal? 1 . Disconnect T20. * Max. 1 R between T20 (male) (1) and (2) and * Turn starting between (1). (21 and NO switch OFF. ;;z;7ground . Disconnect Cl and T20. - Between (1) - (2): 5-15R * Between (1). (2) chassis ground: Min. 1 MD * Turn starting switch OFF. . Disconnect T20. NO
* DisconnectCl and T20. NO
Repair or replace
Replace
T-26 Related
electrical
circuit diagram
11
TXW0.2460
WA1 200-3
20-441
0
TROUBLESHOOTING
T-27
T-27
*
Error code [391 (Short circuit in 1st bypass solenoid system) is __ _ displayed
* *
Cause
Remedy
YES
Defective transmission controller Short circuit with chassis ground in wiring harness between Cl (female) (5) T20 (female) (1) Defective 1st bypass solenoid
Replace
~~
Repair or replace
* Between (1) - (2): 5-15n * Between (l), (2) chassis ground: Min. 1 MR * Turn starting switch OFF. - Disconnect T20.
Replace
T-27 Related
electrical
circuit
diagram
TI
TXWO2460
20-442 0
WA1 200-3
TROUBLESHOOTING
T-28, T-29
T-28
* f +
Auto/Manual
selector switch system
check that all the related connectors are properly inserted. Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. the connector or connecting the TAlways turn the starting switch OFF before disconnecting adapter (or socket). Cause Remedy
3 YES
Defective transmission controller Disconnection in wiring harness between L15 (female) (4) -chassis ground Short circuit with chassis ground, disconnection, or defective contact in wiring harness between C38 (female) (1) - L15 (female) (3) Defective Auto/Manual selector switch
Replace
$S/II - Max. 1 R * Disconnect Ll5. Repair or replace
(1) and L15 lfemalel

I
(male) (3) and (4)
* Disconnect C3B. * Auto/Manual selector switch ON: Max. 1 R OFF: Min. 1 MR
I
NO
NO
Repair or replace
- Auto/Manual selector switch ON: Max. 1 R OFF: Min. 1 MD
I
No
Replace
T-29
Kickdown switch system

Cause Remedy
3 YES Is resistance betYES Wee L15 (female) (2) and chassis ground normal? _ 2 Is resistance YES between c3A (female) 20 and ~15 (female) 11) normal? 1 * Disconnect C3A (male) (1) and (2) * Disconnect L15. * Kickdown switch ON: Max. 1 R OFF: Min. 1 MR * Kickdown switch ON: Max. 1 R OFF: Min. 1 MD NO * Max. 142 - Disconnect L15. NO
Defective transmission controller Disconnection in wiring harness between L15 (female) (2) -chassis ground Short circuit with chassis ground, disconnection, or defective contact in wiring harness between C3A (female) (20) - L15 (female) (1) Defective kickdown switch
Replace
Repair or replace
Repair or replace
qeplace
T-28, T-29 Related electrical circuit diagram

Transmission Kick-doun k manual swrtch
TXW0246 1
WA1 200-3
20-443 0
TROUBLESHOOTING
T-30
T-30 f
f f
Transmission
cut-off switch signal system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket).
Remedy
I
YES Is resistance betveen CSA (female) (10) and
YES
Defective transmission controller Short circuit with chassis ground, disconnection, or defective contact in wiring harness between C3A (female) (10) - L12 (female) (1) Defective transmission cut-off switch
Is resistance between L12 (male) (1) and (2) normal? Disconnect L12. . Transmission cut-off switch ON: Max. 1 R OFF: Min. 1 MR
l
1 -
*Transmission cut-off ND switch ON: Max. 1 Q OFF: Min. 1 h4Q * Disconnect C3A L06. and M02A.
Repair or replace
NO
T-30 Related
electrical
circuit diagram
Transmission
ed when stwoino Pedal. left brake
on
1
TXW02462
20-444 0
WA1 200-3
TROUBLESHOOTING
T-31
T-31
* * *
Steering
lock switch signal system
Cause
Remedy
YES 1 Is voltage between C3B (female) (9) and chassis ground normal?
Replace
2 YES Is voltage between _ STL (male) (1) and _ NO chassis ground normal? - Start engine. * Steering lock lever LOCK: 17 - 30 v FREE: Max. 1 V NO
- Stat-t engine. Steering lock lever LOCK: 17 - 30 v FREE: Max. 1 V

l
Defective steering lock switch Short circuit with chassis ground, disconnection, or defective contact in wiring harness between C3B (female) (9) - STL (female) (1)
Replace
Repair or replace
T-31 Related
electrical
circuit diagram
Transmission
Sleeri
ng lock
co
controller
WA 1200-3
20-445 0
TROUBLESHOOTING
T-32
T-32
* * * *
Neutralizer relay signal system
Check that the main monitor and alarm buzzer work normally. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket).
Cause
Remedy
YES
Defective :ontroller
transmission
Replace
1 Is voltage between C3A (19) _ and chassis ground normal? - Turn starting switch ON. . Parking brake switch ON --f OFF l20-30V j 2 Is resistance between L58 - (female) (2) and NO chassisground normal? * Disconnect L5B. Max. 1 R
l
4YE!
Iefective alay
neutralizer
Replace
(female) (6) and Is voltage between L56 (female) (1) Disconnect C3A, Nc C3B. and L5B. . Short L58 (3) to (5). - Max. 1 R
l
:ontact in wiring harness between C3A (female) (6) (19) Short circuit with chassis ground, disconnection, or defective contact in wiring harness between L58 (female) 11) - LO1 (female) (3) Disconnection or defective contact in wiring harness between L58 (female) (2) chassis ground
Replace
* Disconnect LB5 . Turn starting uo switch ON. . Parking brake switch ON --f OFF *20-30V
L
Repair or replace
N0
Repair or replace
T-32 Related
electrical
circuit
diagram
Parkino switch ^ brake
__.
Neutralizer relay Fuse FS2 (S12)(t?luel L59 Parkino safety brake relay
lpn 88E 0.5fY 0.75fU 0 5fB 0:5tIf 4 t,
(I 1
LR~ (HD-760861
I-
li3A;i
--
20-446
0
WA1 ZOO-3
TROUBLESHOOTING
T-33
T-33
* * * +
Buzzer signal system
Check that the main monitor and alarm buzzer work normally. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket).
2 YES 1 Is resstance between Cl (female) (2) and chassis ground normal? - Disconnect Cl, L08, and L28. * Min. 1 MR _ Is resistance between Cl ffemale) (2) and chassis ground normal? *DisconnectCl, L08, and U8. * Max. 1 R NO
YES
Defective transmission controller Disconnection or defective contact in wiring harness between Cl (female) (2) Lo8 (female) (6) or L26 (female) (16) Short circuit with chassis ground in wiring harness between Cl (female) (2) LO8(female) (6) or L28 (female) (16)
Replace
NO
Repair or replace
Repair or replace
T-33 Related
electrical
circuit diagram
JLIE (DT2)
or
TXW02465
WA1 200-3
20-447 0
TROUBLESHOOTING
T-34
T-34
f * *
Network
system
Call93
Remedy
YES
Defective transmission controller Disconnectionor defective contact in wiring harness between c3B (female) (4). (121-LOS (female) (1 t, (31. MO1 (female) (1). (12) or L26 (female) (11, (12). or V3A (female) (8). (18)
Replace
Repair or replace
- Min. 1 MR -Turn starting switch OFF. - Disconnect C3B. L08, MOl, L26, and V3A
Disconnect c3B. LO8, MOl, L26, and V3A Short LO8 (female) (1). (3) to chassis.
Shon circuit with chassis ground in wiring harness between C3S (female) (41, (12) -LOS (female) (1). (3). MO1 (female) (1). (121or L26 (female) (1). (12). or V3A (female) (8). (18)
Repair or replace
VHMS controller
Transmission
controller
TXW02466
20-448
0
WA1 ZOO-3
TROUBLESHOOTING
T-35
T-35
* * * *
Transmission
controller power supply system
Check that fuse II (6) is normal. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket).
2 YES Is r&Stance betYES ween Cl (female) (6). - W2). CZ (female) Ill), 1 (21) and chassis _, Is voltage between ground normal? Cl (71, (13). c2 (1). NO (12) and Cl (6). (12). - * Max* n * Turn starting switch OFF. c2 (11). (21) * Disconnect Cl and C2. normal?
*20-30V *Turn starting switch ON.
I
Defective transmission controller Short circuit with chassis ground, disconnection,or defective contact in wiring harness between Cl (female) 171, (13). C2 (female) (1). (12) - FS5 (female) (6) Disconnectionor defective contact in wiring harness between Cl (female) (6). (12). C2 (female) (1). (121-chassis ground
Replace
Repair or replace
NO
Repair or replace
T-35 Related
electrical
circuit
diagram
Fuse (II) Transmission controller FS5 (M6) Cl f

I 6
90A
RAI 0 (DTHD4)
Battery
=Yz= TXW02467
WA1 200-3
20-449 0
TROUBLESHOOTING
T-36
T-36 Ir
*
Short circuit in travel speed sensor system
Cause
Remedy
2 Is resistance YES between CS I r (female) (2) and ween C5 (female) (2) and chassis ground normal?
.I
YES

Short circuit in wiring
Replace
harness between CS (female) (2) -TlS (female) (11and between Cl5 (female) (10) T15 (female) (21 Short circuit with chassis ground in wiring harness
Repair or replace
. Min. 1 MR -Turn starting switch OFF. . Disconnect C5, L07, M028, L28, and T15.
1
between (female)
C5 (female) (1)
(2) - TlE
Repair or replace
York esuiumcot controller
FR2 (HD-46082)
TXW02453
20-450 0
WA1 200-3
TROUBLESHOOTING
T-37
T-37 f
*
Short circuit in modulated
clutch outlet rotation
sensor system
2 Is resistance betYES ween C4 (female) 1 (2) and (9) normal? _
YES
Defective transmission controller Short circuit in wiring harness between C4 (female) (21-T16 (female) (1) and between C4 (female) (9) -TIE (female) (21 Short circuit with chassis ground in wiring harness between C4 (female) (2) T16 (female) (1)
Replace
Is resistance between C4 (female) (2) and chassis ground normal? Min. 1 MR * Turn starting switch OFF. * Disconnect C4, M02B. and T16.
NO *Min.lMR - Turn starting switch OFF. * Disconnect C4, M026, and T16. NO
Repair or replace
Repair or replace
T-37 Related
electrical
circuit diagram
J L26 (LIT21 Tra con
Mod con
TXW02445
WA1 200-3
20-45 1 0
TROUBLESHOOTING
T-38
T-38
* Ir
Disconnection
in transmission
oil temperature
sensor system
Cause
Remedy
3 YES Is resistance betYE? ween T19 (female) (2) and chassis 2 ground normal? Max. 1 R * Turn starting switch OFF. - Disconnect C3A.
l
Defective transmission controller Disconnection or defective contact in wiring harness between T19 (female) (2) -chassis ground Disconnection or defective contact in wiring harness between C3A (female) (11) -T19 (female) (1) Defective transmission oil temperature sensor
Reolace
Is resistance betYES ween C3A (female) (11)and T19 (female) (1) normal? 1 Is resiStancehetween T19 (male) (1) and (2) and between (1). (2) and chassis ground normal? * Between (1) - (2): 3.8 - 4.8 R (at 25W . Between (1). (2) chassis ground: 3.6 - 3.9 R * Turn starting switch OFF. . Disconnect T19. * Max. 1 R . Turn starting switch OFF. * Disconnect C3A and 119. NO
NO
Repair or reolace
NO
Repair or replace
?eplace
T-38 Related
electrical
circuit
diagram
Transmission contr JT3 (LIT261
temperature
sensor
20-452 0
WA1 200-3
TROUBLESHOOTING
T-39
T-39 *
*
Fl (Forward
1st gear) signal system
r
_ L normal?
Replace
* Max. 1 Q * Turn starting switch OFF. - Disconnect C2 and M02A.
between C2 (female) 16) and chassis ground normal? L Min. 1 MQ * Turn starting switch OFF. * Disconnect C2 and M02.A.
IS reStStSnCe
II
NO - Stan engine. . Set FNR switch in F and shift-down switch to Fl: Max. 1 V Other setting than above: 17 - 30 V NO
Repair or replace
circuit Short
with chassis ground in wiring harness between M02A (female) (13) - C2 (female) (6)
Repair or replace
NO
Disconnection or defective contact in wiring harness between M02A (female) (13) - C2 (female) (6)
T-39 Related
electrical
circuit diagram
h Transmission steering joystick controller FI signal
c2 ~YIC21) 518 6 p. 5fW
Modulated control I
clutch
TXW02466
WA1 ZOO-3
20-453 0
TROUBLESHOOTING
T-140
T-40
* * *
Abnormality
in auto shift indicator
lamp
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Perform diagnosis steps 2 - 6 when all of the lst, 2nd, and 3rd auto shift indicator lamps are defective.
CaUSe
Remedy
1YES
YES
3 Is resistance beYES tween L69 (male) (6) and chassis 2 ground normal? If L69 is replaced with another relay, is operation normal? *Max.lD * Turn starting switch OFF. Disconnect L69. r
Is resistance between ~92 (male) (1) and (2) normal?
Go to
A.
* 5 - 6.2 Id2 NO . Turn starting switch OFF. . DisconnectW2. NO
Defective resistor V-92) Disconnection or defective contact in wiring harness between L69 (female) (6) -chassis ground Defective illumination relay (L69)
Replace
Repair or replace
* Turn starting switch ON. . _ IJO - Turn auto/manual selector switch OFF (Auto shift mode). * Turn starting switch
*Turn starting switch ON. * Turn auto/manual NO selector switch OFF (Auto shift mode). * Turn startina switch ON.
Replace
Defective auto shift indicator lamp (1st. 2nd, or 3rd)
Replace
ON.
YES haleImadI.87 h!& Ill. temen L96 Ifemak) (21 _

yEs _ Is resistance between L69 (female) (5) and chassis ground normal7 -5-6.2 kcz * Turn starting switch OFF. . Disconnect L69. 5 6Is voltage batwean L55 tfemafe) (1).I.% (female) 11).I.97 (female) (1) andL66 lfemalell2)normal?
lyE! kmktawbrtweaaL95
GotoB Disconnection or defect% contactintiring haineaa betweanLWfemale) (2) - L67 Imale)(1). betweenL96(female) (2) - L66lmale)(1). or between U7 ffemale)I21- L65(male)(1) Disconnectionor defective contact in wiring harness between W5 (female) (1). L96 (female) (1 L LS7 (female) (1) - L69 (female) 121 Disconnection or defective contact in wiring harness between L&9 (female) (5) chassis ground
From A -
-Max.lD Turn starting NO switch OFF. . Disconnect L95, L96, L97. and L69.
l
and L86 ImaW (11. and klwemL97WrcidOland LBS ImaIell11 lbxrf?al? *Max.lQ N( *Turn starting awitch OFF. . Disconnect lJ5, LS6,L67, l.57.L56,andI.%
Repair or replace
qepair or Pplace
NO
Repair or replace
10 YE!
Is voltage between YES C2 (female) (5). (4). (10) and chassis 9 ground normal? b resaance be 1 j tween C2 (female) - Max. 1 V N( - *Turn starting switch OFF - (5). (4). (10) and chassis ground * DisconnectCZ. L62, L63. nounal) and L64 . Turn starting switch ON. . Min. 1 MD -Turn starting NO switch OFF. = Disconnect C2, L82, L83, and L84.
Defective transmission controller Shortcircukwithcower s.wce in tiring harness betweenQ 6emale)(5)- L62(male)(1). batweenCL(female)(4)- L63 (male)(1t, or Mwaen Q (female)DO)- L64Imale)(1)
Replace
3epair or Fplace
a
From 8,~~
I Shortdrcuk with chassis ground in wiringharness betweenQ Repair or (female)f5)- L62(male)(11. replace baween Cz Ifemale)14)- L63 (male)(1). or bahwaen C2 Hamale)110) - L64hnale)11)
*MaxlD *Turn starting switch VO OFF. * Disconnect C2, L92, L83, and L84.
Disconnectionor defective contact in wiring hamesa batwaen C2 (female) f5)- L62 (male) (1). between C2 (female1(41 - L63 (male) (1). or between C2 (female) (10) L64 (male1 (1)
Repair or .eplace
20-454 0
WA1 200-3
TROUBLESHOOTING
T-40

Auto shift indicator 51
FS2 (St2 Blue)
illumination
TXW02563
WA1 200-3
20-455 0
TROUBLESHOOTING OF MODULATED CLUTCH CONTROLLER SYSTEM (MC MODE)
Judgement table for modulated clutch control system related parts .............................................. 20-502 Operations of controller against abnormality and conditions of machine caused by abnormality ................................................................................................................................. 20-504 Electric circuit diagram of modulated clutch control system .......................... .................................. 20-510 MC- 1 Error code [701 (Disconnection in boom RAISE/LOWER or bucket TILT/DUMP pressure switch system) is displayed ............................................................................... 20-512 MC- 2 Error code 1721 (Abnormality in accelerator pedal sensor system) is displayed ............ 20-514 MC- 3 Error code 1731 (Short circuit in F/R ECMV fill switch system) is displayed.. .................. 20-515 MC- 4 Error code 1741 (Disconnection in Ist, 2nd, or 3rd ECMV fill switch system) is displayed .......................................................................................................................... 20-516 MC- 5 Error code 1751 (Short circuit with chassis ground in lst, 2nd, or 3rd ECMV fill switch system) is displayed ......................................................................................... 20-517 MC- 6 Error code 1761 (Short circuit in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system) is displayed ............................................................................................... 20-518 MC- 7 Error code 1771 (Short circuit or disconnection in drive force control dial system) is displayed ........................................................................................................... 20-519 MC- 8 Error code [781 (Short circuit or disconnection in travel speed control dial system) is displayed ........................................................................................................... 20-520 MC- 9 Error code 1801 (Short circuit or disconnection in wheel rotation sensor system) is displayed ........................................................................................................... 20-521 MC-10 Error code 1811 (Short circuit, disconnection, or short circuit with power source in modulated clutch outlet rotation sensor system) is displayed ................................ .20-522 MC-11 Error code 1821 (Short circuit, disconnection, or short circuit with power source in engine speed sensor system) is displayed .................................................................. 20-523 MC-12 Error code 1831(Short circuit or disconnection in travel speed sensor system) is displayed .......................................................................................................................... 20-524 MC-13 Error code [841 (Short circuit, disconnection, or short circuit with power source in neutral cut solenoid system) is displayed ................................................................... 20-526 MC-14 Error code 1851 (Short circuit, disconnection, or short circuit with power source in modulated clutch ECMV solenoid system) is displayed ............................................ 20-527 MC-15 Short circuit in boom RAISE/LOWER or bucket TILT/DUMP pressure switch system ................................................................................................................................ 20-528 -20-529 MC-16 Disconnection in F ECMV fill switch system ....................................................................... 20-529 MC-17 Disconnection in R ECMV fill switch system ....................................................................... MC-18 Disconnection in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system. .................... 20-530 MC-19 Abnormality in electronic governor voltage command system ........................................ -20-531 MC-20 Abnormality in transmission cut-off signal system ............................................................. 20-532 MC-21 Abnormality in modulated clutch ECMV fill switch system .............................................. .20-533 20-534 MC-22 Abnormality in right brake pedal switch system ................................................................. MC-23 Abnormality in travel speed control ON/OFF switch system ............................................. 20-535 MC-24 Abnormality in RPM-SET ON/OFF switch system ............................................................... 20-536 MC-25 Abnormality in engine rotation output signal system ........................................................ 20-537 MC-26 Abnormality in power supply system of modulated clutch control system ................... 20-538 20-539 MC-27 Abnormality in network system ............................................................................................ MC-28 Abnormality in Fl (Forward 1st gear) input signal system ............................................... -20-539
WA1 200-3
20-501 0
TROUBLESHOOTING
JUDGEMENT TAB .E FOR MODULATED CLUTCH corn OL SYSTEM RELATED PARTS
JUDGEMENT TABLE FOR MODULATED CLUTCH CONTROL SYSTEM RELATED PARTS

Self-diagnosis
display
Location of failure
2 3
m
E ;;
P
E 8
ii -0
,P
T
2 z
.E
5 ._ z
I
2 :: s 8 .%
.k
Failure mode
I% Bte
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
78 Machine cannot travel Travel speed cannot be controlled Travel speed control system operates while travel speed control ON/OFF switch is OFF
Travel speed control system operates while gear speed is F3 or R3 Travel speed control system operates while travel speed is below 1.5 km/h Travel speed control system does not follow up travel speed control dial Drive force does not change even if drive force control dial is turned Drive force control system operates while gear speed is not Fl Drive force control system does not follow up drive force control dial Tire slip control system does not work Tire slip control system works while tire slip control switch is OFF
0 -
0 0 E 8
( 1
Tire slip control system works while gear speed is not Fl Tire slip control system works while work equipment Engine speed does not rise even if accelerator Shock timelag is not operated
pedal is pressed
is made when F & R gear is shifted
Engine speed does not change even if RPM SST ON/OFF switch is operated Engine speed can be set while RPM SET ON/OFF switch is OFF RPM-SET IDLE-UP/RESUME IDLE-DOWN switch does not work
Travel speed, drive force, and tire slip control system operates while cut-off switch is OFF Multi-hydraulic control system does not work is low
Rising speed of work equipment
1 1
Display of engine speed is abnormal Main monitor does not display modulated clutch control system information Diagnosis code when failure coda is displayed
20-502 0
WA1 200-3
TROUBLESHOOTING
JUDGEMENT TABLE FOR MODULATED CLUTCH CONTROL SYSTEM RELATED PAFiTS
WA1 200-3
20-503 0
TROUBLESHOOTING

/ M~nlII ._.___ATFD .._- CLLITCH ___. _.. CONTROL ----. .--SYSTEM - - - _-__.
-ailure code
Abnormal system
1) 2) 3) 4) 5) 6) Disconnection in boom RAISE/LOWER or bucket TILT/DUMP pressure switch system
Defective bucket DUMP pressure switch Defective bucket TILT pressure switch Defective boom RAISE pressure switch Defective boom LOWER pressure switch Disconnection or defective contact in wiring harness between HR3, HR4, HRIZ, HR13 (female) (2) - chassis ground Disconnectionor defective contact in wiring harness between modulated clutch controller M02A (female) (5) - HR4 (female) (1) Disconnection or defective contact in wiring harness between modulated clutch controller M02A (female) (6) HR3 (female) (1) Disconnection or defective contact in wiring harness between modulated clutch controller M02A (female) (7) HR12 (female) (1) Disconnection or defective contact in wiring harness between modulated clutch controller M02A (female) (8) HR13 (female) (1) Defective modulated clutch controller
70
7) 8) 9) 10)
72
Abnormality in accelerator pedal sensor system
1) Defective accelerator pedal potentiometer 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (19) - L25 (female) (1) 3) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (10) - L25 (female) (3) 4) Short circuit of wiring harness between modulated clutch controller M02A (female) (19) - L25 (female) (1) with wiring harness between modulated clutch controtler M02A (female) (10) - L25 (female) (3) 5) Defective modulated clutch controller
1) Defective F ECMV fill switch 2) Defective R ECMV fill switch 3) Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (4) T14 (female) (1) 4) Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (3) T12 (female) (1) 5) Defective modulated clutch controller 1) 2) 3) 4) Defective 1st ECMV fill switch Defective 2nd ECMV fill switch Defective 3rd ECMV fill switch Disconnection or defective contact in wiring harness between modulated clutch controller M02A (female) (2) T4 (female) (1) 5) Disconnection or defective contact in wiring harness between modulated clutch controller M02A (female) (1) T6 (female) (1) 6) Disconnection or defective contact in wiring harness between modulated clutch controller M02A (female) (14) - T8 (female) (1) 7) Defective modulated clutch controller I) 2) 3) 4) Defective 1st ECMV fill switch Defective 2nd ECMV fill switch Defective 3rd ECMV fill switch Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (2) - T4 (female) (1) 5) Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (I) - T6 (female) (I) 6) Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (14) - T8 (female) (I) 7) Defective modulated clutch controller
73
Short circuit in F/R ECMV fill switch system
74
Disconnection in lst, 2nd, or 3rd ECMV fill switch system
75
Short circuit with chassis ground in 1st. 2nd, or 3rd ECMV fill switch system
20-504
0
WA1 200-3
OPERATIONS OF CONTROLLER AGAINST TROUBLESHOOTING

CONDITIONS OF MACHINE CAUSED
ABNORMALITY
AND
BY ABNORMALITY
Normal
condition
Operation
of controller
Condition
of machine
Diagnosi!
(Voltage,
current,
resistance)
against abnormality
1) NC solenoid = OFF
caused by abnormality
1) Machine condition does not change particularly. 2) Hydraulic loss is increased if machine travels at speed of 10 km/h or below in F3 gear.
code
1) Voltage between M02A (8) - chassis ground
When work equipment control lever is in neutral: Max. 1 V When work equipment control lever is in boom RAISE position: 15 - 30 V 2) Voltage between M02A (7) - chassis ground When work equipment control lever is in neutral: Max. 1 V When work equipment control lever is in boom LOWER position: 15 - 30 V 3) Voltage between M02A (6) - chassis ground When work equipment control lever is in neutral: Max. 1 V When work equipment control lever is in bucket TILT position: 15 - 30 V 4) Voltage between M02A (5) - chassis ground When work equipment control lever is in neutral: Max. 1 V When work equipment control lever is in bucket DUMP position: 15 - 30 V Note: Move each lever a little (to degree that work equipment does not move actually) (for detection of PPC pressure signal).
C-l
1) Voltage between M02A (10) - M02A (9): 4.75 - 5.25 V 2) Voltage between M02A (19) - M02A (9): 0.5 - 4.75 V 3) Voltage between M02A (19) - M02A (9) fat low idling): 0.5 - 1.6 V 4) Voltage between M02A (19) - M02A (9) (at high idling): [Voltage at low idling + 2.1) - 4.75 V Note: Above table shows standard potentiometer voltage by which controller can recognize dial area normally. When adjusting potentiometer again, leave margin to error judgment area. Adjust voltage in range from 1.3 to 1.6 V at low idling. (Error judgment area is as follows; Potentiometer voltage < 0.5 V or Potentiometer voltage x- 4.5 V) 1) Resistance between F ECMV fill switch T14 (male) (1) chassis ground: When forward switch is set to measuring point: Max. 1 R When forward switch is set out of measuring point Min. 1 MC 2) Resistance between I? ECMV fill switch T12 (male) (1) - chassis ground: When reverse switch is set to measuring point: Max. 1 R When reverseswitch is set out of measuring point Min. 1 MR t Start engine, turn transmission cut-off switch OFF, turn parking brake OFF, and press brake pedal. 1) Resistance between lstJ2nd/3rd ECMV fill switch T4, T6, T6 (male) (I) - chassis ground: . $r;_n,se; to measunng point with shrft-up/down switch: When set out of measuring point with shift-up/down switch: Min. 1 MR It Starl engine, set forward/reverse lever in N, and turn manual switch ON. Note: Default when engine is started is 2nd. If shift-down switch is pressed and held, gear is shifted down to 1st. If shift-up switch is pressed and held, gear is shifted up to 3rd.
1) Controls idling.
for
low
Engine speed does not rise even if accelerator pedal is pressed.
c-2
1) Engages modulated clutch directly. 2) NC so)enojd = OFF
1) Drive force doesnot changeeven if driveforce controldial is operated. 2) Tire slip control system does not work. 3) Shock time lag is made when travel direction is changed. 1) Drive force does not change even if drive force control dial is operated. 2) Shock time lag is made when travel direction is changed.
C-3
1) Engages modulated clutch directly. 2) NC solenoid = OFF
c-4
1) Resistance between lstf2nd/3rd ECMV fill switch T4, T6, T8 (male) (1) - chassis ground:. KzF;;t to measurmg pomt wrth shrft-up/down switch: When set out of measuring point with shift-up/down switch: Min. 1 MR Start engine, set forward/reverse lever in N, and turn manual switch ON. Note: Default when engine is started is 2nd. If shift-down switch is pressed and held, gear is shifted down to 1st. If shift-up switch is pressed and held, gear is shifted up to 3rd.
1) Engages modulated clutch directly. 2) NC solenoid = OFF
1) Drive force does

not change even if drive force control dial is operated. 2) Shock time lag is made when travel direction is changed.
c-5
WA1 200-3
20-505
0
TROUBLESHOOTING
Failure code
Abnormal
system
Contents
of abnormality
76
Short circuit in RPM-SET IDLE-UP/RESUME IDLEDOWN switch system
1) Defective RPM-SET/IDLE-UP switch, RESUME/IDLE-DOWN switch 2) Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (15) - LllO (female) (1) 3) Short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (16) - LIIO (female) (3) 4) Defective modulated clutch controller
77
Short circuit or disconnection in drive force control dial system
I) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02B (female) (I) - F06 (female) (2) 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (10) - F06 (female) (1) 3) Short circuit of wiring harness between modulated clutch controller M02B (female) (1) - F06 (female) (2) with wiring harness between modulated clutch controller M02A (female) (IO) - F06 (female) (1) 4) Defective drive force control dial 5) Defective modulated clutch controller
78
Short circuit or disconnection in travel speed control dial system
I) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02B (female) (10) - F07 (female) (2) 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02A (female) (10) - F07 (female) (1) 3) Short circuit of wiring harness between modulated clutch controller M02B (female) (10) - F07 (female) (2) with wiring harness between modulated clutch controller M02A (female) (10) - F07 (female) (1) 4) Defective travel speed control dial 5) Defective modulated clutch controller
80
Short circuit or disconnection in wheel rotation sensor system
1) Defective wheel rotation sensor 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02B (female) (I I) - F15 (female) (2) 3) Disconnection or defective contact in wiring harness between F15 (female) (3) - chassis ground 4) Short circuit of wiring harness between modulated clutch controller M02B (female) (1 I) - F15 (female) (2) with wiring harness between VHMS controller Vl (female) (3) - F15 (female) (1) 5) Defective modulated clutch controller I) Defective modulated clutch outlet rotation sensor 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02B (female) (4) - T16 (female) (I) 3) Disconnection or defective contact in wiring harness between modulated clutch controller M02B (female) (12) - T16 (female) (2) 4) Short circuit with power source in wiring harness between modulated clutch controller MOZB (female) (4) -chassis ground 5) Defective modulated clutch controller
81
Short circuit, disconnection, or short circuit with power source in modulated clutch outlet rotation sensor system
20-506 0
WA1 200-3
TROUBLESHOOTING
Normal
condition
(Voltage, current, resistance)
Condition of machine caused by abnormality Engine speed does not change even if RPMSET switch is operated.
Diagnosb code
I) Turns off RPM-SET I) Voltage between M02A (15) - chassis ground: IDLE-UP/RESUME When RPM-SET IDLE-UP/RESUMEIDLE-DOWNswitch IDLE-DOWN is set to RESUME IDLE-DOWN position: Max. 1 V function. When RPM-SET IDLE-UP/RESUME IDLE-DOWN switch is set to SET IDLE-UP position: 15 - 30 V !I Voltage between M02A (16) - chassis ground: When RPM-SET IDLE-UP/RESUMEIDLE-DOWN switch is set to RESUME IDLE-DOWN position: 15 - 30 V When RPM-SET IDLE-UP/RESUMEIDLE-DOWN switch is set to RPM SET IDLE-UP position: Max. 1 V I) Voltage between M02A (IO) - M02A (9): 4.75 - 5.25 V !) Voltage between M02A (I) - M02A (9kO.5 - 4.75 V 3) Voltage between M02A (I) - M02A 19) (Min.): 0.5 - 1.6V 1) Voltage between M02A (19) - M02A (9) (Max.): [Min. voltage + 2.11 - 4.75 V Jote: Above table shows standard potentiometer voltage by which controller can recognize dial area normally. When adjusting potentiometer again, leave margin to error judgment area. Adjust voltage in range from 1.3 to 1.6 V at low idling. (Error judgment area is as follows; Potentiometer voltage c 0.5 V or Potentiometer voltage > 4.5 VI I) Voltage between M02A (10) - M02A (9): 4.75 - 5.25 V !) Voltage between M02A (10) - M02A (9): 0.5 - 4.75 V $1Voltage between M02A (10) - M02A (9) (Min.): 0.5 - 1.6 V 1) Voltage between M02A (IO) - M02A (9) (Max.): [Min. voltage + 2.71 - 4.75 V rlote: Above table shows standard potentiometer voltage by which controller can recognize dial area normally. When adjusting potentiometer again, leave margin to error judgment area. Adjust voltage in range from 1.3 to 1.6 V at low idling. (Error judgment area is as follows; Potentiometer voltage e 0.5 V or Potentiometer voltage > 4.5 VI I) Resistance between wheel rotation (male) (2) - (3): 100 - 500 R sensor PI5 I) Slip ratio by drive force control dial = 100%
C-6
1) Drive force does
not change even if drive force control dial is operated. 2) Tire slip control system does not
work.
3) Travel speed cannot be controlled.
c-7
I) Slip ratio by travel speed control dial = 100% 2) Max. travel speed = 12 km/h
I) Drive force does not change even if drive force control dial is operated. 2) Tire slip control system does not work. 3) Travel speed cannot be controlled.
C-8
1) Turns off tire slip control.
c-9
I) Modulated clutch outlet rotation sensor Resistance between T16 (male) (I) - (2): 500 - 1000 R Resistance between T16 (male) (I), (2) - chassis ground: Min. 1 MS2
I) Turns off modulated clutch control (Engages clutch directly).
C-IO
WA1 200-3
20-507 0
TROUBLESHOOTING
Failure code
Abnormal system
1) Defective engine speed sensor 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller C4 (female) (1) - T17 (female) (1) 3) Disconnection or defective contact in wiring harness between modulated clutch controller C4 (female) (9) - T17 (female) (2) 4) Short circuit of wiring harness between modulated clutch controller MO28 (female) (51- T17 (female) (1) with wiring harness between modulated clutch controller M02B (female) (12) - T17 (female) (2) 5) Short circuit with power source in wiring harness between modulated clutch controller M02B (female) (5) - T17 (female) (1) 6) Defective modulated clutch controller
82
Short circuit, disconnection, or short circuit with power source in engine speed sensor system
83
Short circuit or disconnection in travel speed sensor system
1) Defective travel speed sensor 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller M02B (female) (13) - T15 (female) (1) 3) Disconnection or defective contact in wiring harness between modulated clutch controller M02B (female) (12) - T15 (female) (2) 4) Short circuit of wiring harness between modulated clutch controller M02B (female) (13) - T15 (female) (1) with wiring harness between modulated clutch controller MOZB (female) (12) - T15 (female) (2) 5) Defective modulated clutch controller
84
Short circuit, disconnection, or short circuit with power source in neutral cut solenoid system
1) Defective neutral cut solenoid 2) Disconnection, defective contact, short circuit with chassis ground, or short circuit with power source in wiring harness between modulated clutch controller MO1 (female) (21) - HRl (female) (1) 3) Disconnection or defective contact in wiring harness between HRl (female) (2) - chassis ground 4) Defective modulated clutch controller
85
Short circuit, disconnection, or short circuit with power source in modulated clutch ECMV solenoid system
1) Defective modulated clutch ECMV solenoid 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller MO1 (female) (16) - T9 (female) (2) 3) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between modulated clutch controller MO1 (female) (7) - T9 (female) (1) 4) Short circuit of wiring harness between modulated clutch controller MO1 (female) (16) - T9 (female) (2) with wiring harness between modulated clutch controller MO1 (female) (7) - T9 (female) (1) 5) Defective modulated clutch controller
20-508
0
WA1 200-3
TROUBLESHOOTING
Normal
condition
OPeratbn
of COntrOller
(Voltage, current, resistance)
against abnormality 1) Turns off modulated clutch control (Engages clutch directly).
Condition of machine caused by abnormality 1) Drive force does not change even if drive force control dial is operated. 2) Tire slip control system does not work. 3) Travel speed cannot be controlled. 4) Engine speed is not displayed normally.
Diagnosi
code
1Engine speed sensor 1)
Resistance between T17 (male) (1) - (2): 500 - 1000 R Resistance between T17 (male) (I), (2) - chassis ground: Min. 1 MD 2) Voltage between M02B 6) - (12): Min. 0.5 V Note) Measure in AC range.
c-11
I
WA 1200-3
1) Travel speed sensor
Resistance between T15 (male) (1) - (2): 500 - 1000 R Resistance between T15 (male) (11, (2) - chassis ground: Min. 1 MR
I) Turns off tire slip control. 2) Turns off modulated clutch control (Engages clutch directly). 3) NC solenoid = OFF
1) Drive force does not change even if drive force control dial is operated. 2) Tire slip control system does not work. 3) Travel speed cannot be controlled.
c-12
Voltage between MO1 (female) (21) - chassis ground When work equipment control lever is operated: 17-3ov When work equipment control lever is in neutral: Max. 1 V lte) Move the lever a little (to degree that work equipment does not move actually) (for detection of PPC pressure signal).
1) NC solenoid output OFF (When short circuit with power source is made, NC solenoid output cannot be turned off.)
Work equipment does not rise quickly. (When short CkCUit with power source is made) Neutral cut control system does not work (Machine condition does not change particularly). (When disconnection or short circuit with chassis ground is made) 1) Drive force does not change even if drive force control dial is operated. 2) Tire slip control system does not work. 3) Travel speed cannot be controlled. 4) Machine cannot travel in any gear speed.
c-13
Modulated clutch ECMV solenoid Resistance between TS (male) (I) - (2): 5 - 15 R Resistance between TS (male) (11, (2) - chassis ground: Min. 1 MR
1) Operates
emergency spool. 2) Turns ON emergency operation switch. 3) Cannot work (when short circuit with power source is made on CNI (7) side).
c-14
20-509 0
TROUBLESHOOTING
ELECTRIC CIRCUIT DIAGRAM OF MODULATED CLUTCH CONTROL SYSTEM
20-510 0
WA1 200-3
TROUBLESHOOTING
IMP-SET IDLE-UP/ RESUME
Boom LOWER switch
1st Ii
I-
I rmitcb
0uMTuY
TXW02470
WA1 200-3
20-511
0
TFtOUBLESHOOTlNG
MC1
MC-l
Error code [70] (Disconnection in boom RAISE/LOWER TILT/DUMP pressure switch system) is displayed
or bucket
* *
CaUSe
Remedy
4M!
Is resistance
YES 3 Is resistance YES between HR13 - (female) (1) and 2 (2) normal? IsYES between HR3 - (female) (1) and 1 (2) normal? Is resistance between HRb (female) (1) and (2) normal? * Start engine. operation When lever is operated a little: Max. 1 R When lever is in neutral: Min. 1 MR
l
GotoA
between HR12 (female) (1) and (2) normal? -Start engine. *bornLOWER operation NC Whenleveris operated aliie:Max.lQ Whenleverisin neutral: Min. 1 MQ
Defective boom LOWER pressure switch
Replace
Start engine.
_ * Start engine. . Bucket TILT NO operation When lever is operated a little: Max. 1 R When lever is in neutral: Min. 1 MR
NO * Oorn RASE operation When lever is operated a little: Max. 1 R When lever is in neutral: Min. 1 MR
Defective boom RAISE pressure switch
Replace
Defective bucket TILT pressure switch
Replace
NO
Defective bucket DUMP pressure switch
Replace
7YEs
YES 6 resistance between M02A (female)6) and HR3 (female1 (1) normal?
Is
Go to
B.
From A
Is resistance - Max. 1 Q YES between MO24 NO * Turn starting switch (female) (5) and HR4 5 OFF. _ (female) (11normal? - Disconnect MO2and - Max. 1 R _ HR3. Turn starting HR13 (female) (2) and 7 NO switch OFF.. ._* Disconnect MO2 - Max. 1 R and HRb. Turn starting NO switch OFF. * Disconnect HR3, HRb, HR12, and 9 YES HR13. Is resistance II
l l
Disconnection or defective contact in wiring harness between M02A (female) (6) - HR3 (female) (1)
Repair or replace
contact in wiring harness between M02A (female) (5) - HR4 (female) (1) Disconnection or defective contact in wiring harness between HR3, HR4, HR12, HR13 (female) (2) -chassis ground Defective modulated clutch controller Disconnection or defective contact in wiring harness between MO% (female) (8) - HR13 (female) (1) Disconnection or defective contact in wiring harness between M02A (female) (7) - HR12 (female) (1)
Repair or replace
Repair or replace
Replace
From
Repair or replace
*Turn starting switch OFF. . Disconnect MO2 and HR12.
NO
Sepair or replace
20-512 0
WA1 200-3
TROUBLESHOOTING
MCI
MC-1 Related electrical circuit diagram

RA5 Modulated controller clutch 2L (DTI) ( RAIO (DTHD4) 11000
3 boocf
Wor con
switch
WA1 200-3
20-513 0
TROUBLESHOOTING
MC-2
MC-2 Error code [721 (Abnormality in accelerator pedal sensor system) is displayed
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. Jr Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Always connect any disconnected connectors before going on to the next step.
ChUSe
This troubleshooting is carried out when there is still an abnormality,
Remedy
- Is resistance between MOZA (female) (19) and LZ5 (female) (1) normal?
- Max.
1Q *Turn starting switch OFF. and l-25.
3 YES Is resistance yEs between M02A - Ifemale) (10) and 2 _ L25 (female) (3) Is resistance normal? YES between MWA Max. 1 R NO - (female) (19) and * Turn starting chassis ground 1 switch OFF. normal? * Disconnect MO2 and l.25. * Min. 1 MR Turn starting NO switch OFF. Disconnect MO2 and l.25.
l l l
GotoA
Disconnection or defective contact in wiring harness between MOZA (female) (10) - L25 (female) (1) Short circuit with chassis ground in wiring harness between M02A (female) (19) -L25 (female) (1) Disconnection or defective contect in wiring harness between M02A (female) (19) - L25 (female) 41) Defective modulated clutch controller
Repair or replace
Repair or replace
NO
Repair or replace
6 YES
YES
Is voltage
Replace
n
4
I Is resistance
Fro~~j;~d
1
]
* Min. 1 MR * Turn starting switch OFF. Disconnect MO2 and L25.
- between I_25 (1) 5 _ and (2) normal? Isrssistsncebetween ~ ._ *At low idling: ; M02A (female)110). NO 0.5-1.6V (19) and chassis At high idling: groundnormal? ~ (Low idling voltage + 2.1 VI - 4.75 V -Turn staning switch ON. - Min. 1 MQ * Turn starting NO switch OFF. * Disconnect MO2 and L25.
Defective accelerator pedal potentiometer Short circuit of wiring harness between MO2A (female) (10) - L25 (female) (3) with wiring harness between M02A (19) - L25 (female) 11) Short circuit with chassis ground in wiring harness between M02A (female) (10) - L25 (female) (3)
Replace
Repair or replace
uo
Repair or replace
Accelerator Pedal Madulated con clutch
ri+r TXW02472
20-514 0
WA1 ZOO-3
TROUBLESHOOTING
MC-3
MC-3 Error code [73] (Short circuit in F/R ECMV fill switch system) is displayed
Call!%
Remedy
Defective modulated clutch controller
Replace
Is resistance YES *Turn starting switch chassisground OFF. noma~~~ - DisconnectMOZA.C3B. Min. 1 MD _ andT14. * Turn starting NO switch OFF. * Disconnect M02A. C3B. and T14.
l
between MO2A (female) (4) and
- Min.
1 MQ
NC
2 YES _jzy between T12 (male) normal? 1 M!3 .__

etrrrti
Short circuit with chassis ground in wiring harness between M02A (female) (3) -Tl2 (female) (1) Short circuit with chassis ground in wiring harness between M02A (female) (4) -T14 (female) (1) Defective R ECMV fill switch
Repair or replace
Repair or replace
1
between T14 (male) (1) and chassis
11ground
L
.-. ..na switch OFF* Disconnect T12.

NO
- Min. . fur
NO
Replace
*Min. 1 MR *Turn starting switch OFF. Disconnect T14.

l
Defective F ECMV fill switch
Replace
Transnission
TXWO2456
WA1 200-3
20-5 15 0
TROUBLESHOOTlNG
MC-4
MC-4 Error code [741 (Disconnection switch system) is displayed +
in lst, 2nd, or 3rd ECMV fill
* It
Cause
Remedy
4YE
YES 3Is resistance YES between MOZA (female1 (14) and T8 2 (female) (1) normal?
Is resistance fis between MOZA -
Go to A.
If T4 (female) (1) is grounded to chassis, is 74 displayed?

-TUT starting Switch
* Discomen 14. -Start engine. *Setf0WwdlmmrselsvsrinN

*SOt~~~ShiilOV~illlSt.
OFF.
N(
Replace
1 Is resistance between M02A (female) (2) and T4 (female) (1) normal? *MaxlR * Turn starting switch OFF. * Disconnect UB, T4, M02k
(female) (1) and T6 (female) (1) normal?
Max. 1 R * Turn starting switch OFF. Disconnect C3B. TS, M02A.
*Max.lR * Turn starting switch OFF. * Disconnect C5, TB, M02A.
NO
Disconnection or defective contact in wiring harness between M02A (female) (14) - T8 (female) (1) Disconnection or defective contact in wiring harness between MO24 (female) (1) -T6 (female) (1) Disconnection or defective contact in wiring harness between M02.A (female) (2) - T4 (female) (1)
Repair or replace
NO
Repair or replace
NO
Repair or replace
6 If T8 (female) (1) YES is grounded to 5 chassis, is 74 If T6 (female) (1) , displayed? *T$;; starting switch is grounded to chassis, is 74 * Disckct T8. * Stan engine. displayed?
* * Set forward/reverse
YES
From A -
NO
lever in N.
. Set gear shift lever in 3rd. Turn starting switch OFF. NO * Disconnect T6. Start engine. * Set forward/reverse lever in N. Set gear shift lever in 2nd.
l l

Transniarion
TXW0.2457
20-5
0
16
WA1 200-3
TROUBLESHOOTING
MC-5
MC-5 Error code 1751 (Short circuit with chassis ground in Ist, 2nd, or 3rd ECMV fill switch system) is displayed *
* *
Before carrying out troubleshooting, check that all the related connectors are Drooerly inserted. Always connect any disconnected connectors before going on to the next step.
CaUSe
Remedy
4YE! YES_
(female) (21 and
GotoA
[ Short circuit with chassis ground in wiring harness between M02A (female) (2) -T4 (female) (1)
Is resistance YES between ~8 (mate) (1) and chassis 2 _ ground normal? Is resistance Min. 1 MD YES between T6 (male) Turn starting (1) and chassis switch OFF. 1 ground normal? * Disconnect T8. Is resistance Min. 1 MR between T4 (male) * Turn starting (1) and chassis NO switch OFF. ground normal? * Disconnect T6.
l l l
-Min.1 MQ
*Turn starting switCh OFF. * DisconnactM&U, 635, and TO. NO
NC
Repair or replace
Replace
Replace
* Min. 1 MD *Turn starting switch OFF. Disconnect T4.

l
I
NO
6 yes 5 Is resistance between M02A (female1(1) and I&a~.sground Is resistance between MOZA (female) (14) and chassis ground normal?
YES
Replace
Short circuit with chassis ground in wiring harness between M02A (female) (14) - T8 (female) (1) Short circuit with chassis ground in wiring harness between MOZA (female) (1) -T6 (female) (1) Bepair or replace
From A
* Min.
l
1 MR Turn starting switch OFF. * Disconnect M02A. C3B, and T6.
* Min. 1 MD NO * Turn starting switch OFF. * Disconnect M02A. C5, and T8.
NO
?epair or *eplace
MC-5 Related
electrical
circuit diagram
WA1 200-3
20-517 0
TROUBLESHOOTING
Mt?A
MC-6 Error code [76] (Shot-t circuit in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system) is displayed
* 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. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
CaUSt?
* *
Remedy
3 YES Isresistance
between MOZA resistance between MO2A (female) (15) and chassisground
Is
Defective modulated clutch controller Short circuit with chassis ground in wiring harness between M02A (female) (16) - LllO (female) (3) Short circuit with chassis ground in wiring harness between M02A (female) (15) - LllO (female) (1) Defective SET IDLE-UP /RESUME IDLE-DOWN switch
Replace
rhazground
11
yES 1 _IS resistance between LllO (male) (1). (2) and (3) as shown in -Table 17 * Disconnect LllO. *Turn starting switch OFF.
* Min. 1 MR *Turn starting switch OFF. - Disconnect M02A and LllO. NO
* Min. 1 MQ NO *Turn starting switch OFF. Disconnect MOZA and LllO.
Repair or replace
NO
Repair or replace
Replace
Table 1
RPM-SET IDLERESUMEJDLE-
UP Between LllO (female) (1) - (2) Between LllO (female) (3) - (2)
switch
ON
DOWN
switch
ON
Min. 1 MR Max. 1 R
Max. 1 R Min. 1 MC?
RPM-SET
I OLE-UP/RESUME IDLE-DOWN switch
Modulated con
clutch
LR7
(DTI)
RAlO
(DTHD4)
Battery
TXW02473
20-518 0
WA1 200-3
TROUBLESHOOTING
MC-7
MC-7 Error code 1771 (Short circuit or disconnection control dial system) is displayed
*
in drive force
* *
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. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. . Remedy
GotoA
Is
yEs
resistance
Ihaha;round
2 pIs resistance *Max.lQ YES between MOZB - (female) (1) and - *Turn starting chassis ground switch OFF. 1 * Disconnect M02A normal? Isresistance * Min. 1 MO and F06. between MOZB *Turn starting (female) (1) and F06 NO switch OFF. (female) (2) normal? * Disconnect M02B and F06. *Max.10 *Turn starting switch OFF. * Disconnect M02B and F06. NO
belweenM02A (female) (10) and FO6 (female) (1) - normal?
*Min. 1 MR NO *Turn starting awitch OFF. * C&connect MOZA and

FO6. i
Short circuit with chassis ground in wiring hamesa between M02A (female) (10) - F06 (female) (1) Disconnection or defective contact in wiring harness between M02A (female) (10) -H)6 (female) (1) Shon circuit with chassis ground in wiring harness between M02B (female) (1) - FO6 (female) (2) Disconnection or defective contact in wiring harness between MOZB (female) (1) - F06 (female) (2)
Repair or replace
NO
Repair or replace
Repair or replace
Repair or replace
6 YEs Is voltage - between F06 (2) 5 and (3) normal?

Drive force
YES
Replace
Defective drive force control dial Short circuit of wiring harness between M02A Ifemale) (10) - FO6 liemale) 11) with wiring harness between MO28 (female) (11 - FO6 (female) (2) Replace
Is resisance
between MOZA
From A (female) (10) and MOZB (female) (1)
NO
normal? Min. 1 MR + Turn starting switch OFF. * Disconnect M02A. M02B. and F06.
l
control dial At2044V AtlOO%:lV *Turn starting switch ON. NO
Repair or replace
I I

Modulated con clutch Dial controlline the driving force
fi
TXW02474
WA1 200-3
20-519 0
TROUBLESHOOTING
MC-8
MC-8 Error code 1781 (Short circuit or disconnection control dial system) is displayed
*
in travel weed .
* *
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. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Remedy
GotoA
IS
resistance
[;;z;ground
11
yes
- IS resistance YES between MO26 - (female) (10) end chassis ground 1 normal? * Min. 1 MR
between MOZA (female) (10) and Fo7 (female) (1) normal? .Max.lR Turn starting switch OFF. * Disconnect M02A and F07.
l
*Min. 1 MD NC *Turn starting switch OFF. * Disconnect MOZAand F07. NO
Disconnection or defective contact in wiring harness between M02A (female) I101 - F07 (female) (1) Disconnection or defective contact in wiring hamess between M02A (female) (10) - F07 (female) (1) Short circuit with chassis ground in wiring harness between MOZB (female) (10) - F07 (female) (2) Disconnection or defective contact in wiring harness between MOZB (female) (10) - F07 (female) (2)
Repair or replace
Repair or replace
Is resistance between MO26 - *Turn starting (female) (10) and switch OFF. F07 (female) (2) * Disconnect M02B normal? and F07. lMax.lf2 * Turn starting I NO switch OFF. * Disconnect M02B and F07.
NO
Repair or replace
Repair or replace
YES II
I Isvoltaae
Replace
From A normal? Min. 1 MR * Turn starting switch OFF. * Disconnect M02A, M02B. and F07.
l
Defective travel speed control dial
Replace
At12km/h:lV At3km/h:4V *Turn starting switch ON. NO
Short circuit of wiring harness between M02A (female) (10) - F07 (female) (1) with wiring harness between M02B (female) (10) - F07 (female) (2)
Repair or peplace

Modulated controller clutch
MOZA (04020)
Vehicle
speed
rffr
TXW02475
20-520
0
WA1 200-3
TROUBLESHOOTING
MC-9
MC-9 Error code [801 (Short circuit or disconnection sensor system) is displayed
in wheel rotation
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting connector and inserting the T-adapter, or when removing the T-adapter and returning the connector if the error code is no longer displayed on the monitor display, the to its original position, problem has been removed.
CaUSe
Remedy
GotoA
I&ss;ground
Max*
l
11
NO
yes 2
Is raaktance between MOZB (female) (11) and
*loo-500R * Disconnect F15. *Turn starting switch OFF.
- Is resistance ES between M02B - (female) (11) and FlS (female) (2) normal? -Max.1 R _ *Disconnect M02B , NO and F15. *Turn starting switch OFF.
l
chassis ground ,normal? Min. 1 MR Disconnect M02B and F15. * Turn starting switch OFF.
Disconnect F15. *Turn starting switch OFF.
Disconnection or defective contact in wiring harness between F15 (female) (3) chassis ground Short circuit with chassis ground in wiring harness between M02B (female) (11) - F15 (female) (2)
Repair or replace
NO
Repair or replace
/ contact in wiring harness

between M02B (female) (11) - F15 (female) (2)
Repair or replace
N10
Defective wheel rotation sensor
Replace
Replace From A -I between MOZB (female) (11) and Vl (female) (3) normal? MS2 - Min. 1..- Disconnect M02B Vl, and F15. *Turn starting switch OFF.
Short circuit of wiring harness between M02B Repair or replace
MC-9 Related
electrical
circuit diagram
WA1 200-3
TROUBLESHOOTING
MC-IO
MC-10
Error code [81] (Short circuit, disconnection, or short circuit with power source in modulated clutch outlet rotation sensor system) is displayed
* *
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. Before carrying out troubleshooting, check that all the CaUSe Remedy related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
GotoA
Is resistance Min. 1 MR between M02B (female) (4) and T16 - .DisconnectT16, M02B, and C4. 1 (female) ~llnorrnal? P Turn starting Is resistance *Max. 1 R switch OFF. between T16 _ * Disconnect T16, (male) (1) and (2) M02B, and C4. ND normal? * Turn starting switch OFF. l 600-1,OOOR * Disconnect T16. *Turn starting NO switch OFF. Eg
l l
resistence yRS between MO26 - (female) (4) and chassisgmund 2 normal?

Is
'MaX.lQ NC * DisconnectTX, M02B. and C4. *Turn starting switch OFf NO
Disconnection or defective contact in wiring harness between M02B (female) (12) -T16 (female) (2) Short circuit with chassis ground in wiring harness betwean MOZB (female) (41 -T16 (female) (1) Disconnection or defective contact in wiring harness between MO26 (female) (4) -TN (female) (1) Defective modulated clutch outlet rotation sensor
Repair or replace
Repair or replace
Repair or replace
Replace
From*Jijg%jf
1normal?
*Max. 1 V * Disconnect T16, MOZB. and C4. *Turn starting switch ON.
Defective modulated clutch controller Short circuit with power source in wiring harness between M02B (female) (4) -chassis ground
Replace
Repair or replace

JL26 (OT2)
TXW02445
20-522
0
WA1 200-3
TROUBLESHOOTING
MC-11
MC-11
Error code 1821 (Short circuit, disconnection, or short circuit with power source in engine speed sensor system) is displayed
* *
GotoA
yES between MOZB
Cause
Remedy
Is resistance
yes ! between MOZB (female) (5) and chassis ground normal? -
3 -
(female) (12) and T17 (female) (2)

normal? *MaX.1R * Disconnecr C4, T17, L07, and MOZB.
Disconnection or defective contact in wiring harness between C4 (female) (9) T17 (female) (2) Short circuit with chassis ground in wiring harness between C4 (female) (1) T17 (female) (1) Disconnection or defective contact in wiring harness between C4 (female) (1) T17 (female) (1) Defective engine speed jensor Repair or replace
N(
1 (female) (1) normal?
lMax.lR
(male) (1) and (2) *Disconnect C4, T17, L07, and MOZB. * Turn starting 1 switch OFF.
-Turn starting switch Min. 1 MR OFF. NO *Disconnect C4, T17, L07, and M02B. *Turn starting switch OFF.
l
Repair or replace
NO
Repair or replace
*500-1,ooon
* Disconnect T17. Turn starting switch OFF.l
NO
6 YES
YES 5 From A _ Is resistance between M02B (female) (5) and (12) normal? * Min. 1 MR * Disconnect C4, T17, L07, and M02B. * Turn starting switch OFF. _ Is voltage between M02B (female) (5) and chassis ground normal? *Max.lV NO * Disconnect C4, T17, L07, and M02B. *Turn starting switch ON. NO
Iefective modulated :lutch controller

Short circuit xtween with power harness
source in wiring
M02B (female) (5) - T17 (female) (1) short circuit of wiring larness between M02B female) (5) -T17 (female) 1) with wiring harness xlween M02B (female) 12) - T17 (female) (2)
Repair or replace
qepair or eplace
MC-11
Related
electrical
circuit diagram
Main monitor
Modulated controller
clutch MOZB (040 16)
TXW02454
WA1 200-3
20-523 0
TROUBLESHOOTING
MC-12
MC-12
Error code 1831 (Short circuit or disconnection sensor system) is displayed
in travel speed
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. Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted. * Always connect any disconnected connectors before going on to the next step.
C.WSB
Remedy
4YE! Is resistance
yRG
Is resistance yes between M02E -
GotoA
between MO25
Ifemale) (12) and T15 (female) (2) normal? *Max.lQ -
?
-
(female) (13) and chassisgmund Pnormal?

l
I
normal?
Min. 1 MR lDisconnectC5, T15, L07, and M02B. Turn starting switch OFF.
l
*Disconnect Cf. T15, L07, and M02B. *Turn starting switch OFF. NO
NC
Disconnection or defective contact in wiring harness between M02B (female) (12) - T15 (female) (2) Short circuit with chassis ground in wiring harness betwesn M02B (female) (13) -T15 (female) (1) Disconnection or defective contact in wiring harness between MOZB (female) (13)-T15 (female) (1) Defective travel speed sensor
Repair or replace
Repair or replace
NO
Repair or replace
*5oo-wo0R * Disconnect T15.

l
M02B. *Turn starting switch OFF. NO
Replace
Turn starting switch OFF.
6 YES
n ES
5
I
From A -I
Is resistence between MOZB (female) (13) and 1112) normal? *Min. 1 MR * Disconnect C5, T15, L07, and M02B. *Turn starting switch OFF.
I
l
figi%Jj-
Defective modulated clutch controller Short circuit with power source in wiring harness between M02B (female) (13) - T15 (female) (11 Short circuit of wiring harness between M02B (female) (13) - T15 (female) 11) with wiring harness between MO25 (female) (141- T15 (female) (2)
Replace
Max. 1 V NO Disconnect C5, T15, L07, and M02B. *Turn starting switch ON.
Repair or replace
nIO
Repair or replace
20-524 0
WA1 200-3
TROUBLESHOOTING
MC-12
MC-12 Related
electrical
circuit diagram
RT2(HD-850861
T15 IDTZ)
SDeed S~"SO~
Transmission
II
TXW02453
WA1 200-3
20-525 0
TROUBLESHOOTING
MC-13
MC-13 *
Error code [841 (Short circuit, disconnection, or short circuit with power source in neutral cut solenoid system) is displayed
Ir
Cause
Remedy
[Is resistance
OYE! lr-
GotoA
Yf
2 Is rssistance YES between MO1 - (female) (21) and HRl (female) (11 1 normal? Is resistancebetween *Max.lR HRl (male) (1) and (2) and between (1). - Turn atarting switch OFF. (2) and chassis * Disconnect MO1 mound normal? and HRl. + Between (1) - (2):
Disconnection or defective contact in wiring harness between HRl (female) (2) chassis ground Short circuit with chassis ground in wiring harness between MO1 (female) (21) - HRl (female) (1) Disconnection or defective contact in wiring harness between MO1 (female) (21) - HRl (female) (1) Defective neutral cut solenoid
Repair or replace
*Turn starting mitch OFF. * Disconnect Mol. HRI, and HR2.
NO
Repair or replace
10
Repair or replace
5-15Q I NO (1). (2) chassis ground: Min. 1 MR *Turn starring switch OFF. 5 YES * Disconnect HRl. Is v&age between MO1 (female) (21) From A and chassis ground l-l -I normal?
* Between
Replace
Defective modulated clutch controller Short circuit with power source in wiring harness between MO1 (female) (21) - HRl (female) (1)
Replace
1V NO * Turn starting switch OFF. * Disconnect Mol. HRl, and HR2. *Turn starting switch ON.
- Max.
Repair or replace
MC-13
Related
electrical
circuit diagram
JR3 (DTl)
Modulated controller
clutch
Nuetral solenoid HRZ (DTZ) R2D
cut
TXW02477
20-526 0
WAIZOQ-3
TROUBLESHOOTING
MC-14
MC-14
Error code 1851 (Short circuit, disconnection, or short circuit with power source in modulated clutch ECMV solenoid system) is displayed
* *
the so when disconnecting is carried out when there is still an abnormality, This troubleshooting 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. check that all the related Before carrying out troubleshooting, CaUSe inserted. connectors are properly Always connect any disconnected connectors before going on to the next step. IIIs
4YEI
GotoA
P Is resistance between MO1 yes - (female) (16) and chassis ground 2 _ normal) + Min. 1 MD Turn starting switch OFF. Disconnect MO1 and T9.
l l
resistance YES_ between MO1 (female) (7) and T9 3 (female1(1) normal? *Max.lR Starting *Turn switch OFF. N(
Disconnection or defective contact in wiring harness between MO1 (female) (7) T9 (female) (1) Short circuit with chassis ground in wiring harness between MO1 (female) (16) -T9 (female) (2) contact in wiring harness between MO1 (female) (16) - T9 (female) (2) Defective modulated clutch ECMV solenoid
Repair or replace
*Disconnect
NO
MO1 and T9.
T9 (male)(1) and (2) and between (1). (2)
. Between (1) - (2): I 5-15s2 NO * Between (1). (2) chassis ground: Min. 1 MR *Turn ataning switch OFF. * Disconnect T9.
Ifemale) (16) and T9 (female) (2) normal? *Max. 1 R * Turn starting NO switch OFF. * Disconnect MO1 1 and T9.
Repair or replace
Repair or replace
Replace
1 YEZ Is voltage YES between
Defective modulated clutch controller Short circuit with power source in wiring harness between MO1 (female) (7) - T9 (female) (1) Short circuit of wiring harness between MO1 (female) (7) - T9 (female) (1) with wiring harness between MO1 (female) (16) - T9 (female) (2) Short circuit with chassis ground in wiring harness between MO1 (female) (7) - T9 (female) (1)
Replace
6 Is resistance YES batween MOT (female) I71and (16) 5 normal? _ l5-15n * Turn starting switch OFF. * Disconnect MOZ. -
MO1 (female) (7) and chassisground normal?
From A
batween MO1 (female) (7) and
*Max.lV NC *Turn starting switch OFF. *DiaconnactMO1 and T9. *Turn starting switch ON.
NO
Repair or replace
Repair or peplace
* Min. 1 MD *Turn starting switch OFF. * Disconnect MO1 and T9.
NO
Repair or .eplace
MC-14
Related
electrical
circuit diagram
Hodulated clutch CO
solenoid
TXW02478
WA1 200-3
20-527 0
TROUBLESHOOTING
MC-15
MC-15
Shot-t circuit in boom RAISE/LOWER or bucket TILT/DUMP pressure switch system

inserted.
* *
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
4YE Is resistance YES between M02A - (female) (81 and 3 chassis ground OTlel? 1 MR -
GotoA
YES , between M02A (female) (5) and
PIs resistance between MOZA (female) (6) and chassis ground

normal?
l
* Min. 1 MD *Turn starting awitch OFF. * Disconnect MOZA and HR4.
Min. 1 MD *Turn starting NO switch OFF. * Disconnect MOZA and HR3.
Is resistence YES between MO2A - (femele) (7) end chassis ground 2 - normal? *Disconnect MO24 HR13, and i27. * Min. 1 MD Turn starting NO switch OFF. I Disconnect MOZA, HR12. and L27.
l
*Min. .T;;;.mning &t,.h N
Short circuit with chassis ground in wiring harness between M02A (female) (8) - HA13 (female) (1) Short circuit with chassis ground in wiring harness between M02A (female) (7) - HR12 (female) (1) Short circuit with chassis ground in wiring harness beween M02A (female) (6) - HR3 (female) (1) Short circuit with chassis ground in wiring harness between M02A (female) (5) - HR4 (female) (1)
Repair or replace
Repair or replace
Repair or replace
I
NO
Repair or replace
5 YES Is resistance II between M02A (female) (5). 16).(71, and (8) normal? * Min. 1 MR NO *Turn atatting switch OFF. * Disconnect M02A. U7, HR3, HR4, HR12, and HR13
Defective modulated clutch controller Short circuit of wiring harness between M02A (female) (5) - HR4 (female) (1). between MOZA(female) (6) - HR3 (female) (1). between MONA(female) (7) HR12 (female) (1). and bsrween MONA(female) (8) HR13 (female) (1) with each other
Replace
From A -
Repair or replace

RAS (DTI) Modulated controller clutch 2L 31000 ( RAtO (DTHD4)
Bucket switch Wor con Bucket switch
37 dump tilt
Boom raise switch
TXW0247 1
20-528 0
WA1 ZOO-3
TROUBLESHOOTING
MC16,
MC-17
MC-16 *
*
Disconnection
in F ECMV fill switch system
Cause
2 YES Is resistance between M02A 13) and Tl4 (female) (1) normal? NO . Max. 1 R - Disconnect C3B. M02A. and T14. * Turn starting switch OFF. Defective modulated clutch controller Disconnection or defective contact in wiring harness between M02A (female) (3) - T14 (female) (1) Defective F ECMV fill switch
Remedy
Replace
Is voltage between T14 (1) and chassis ground normal?
YES 1 -
Repair or replace
* *20-30V Turn starting NO switch OFF. * Disconnect T14. . Start engine. * Turn transmission cut-off switch OFF (Put out lamp) * Turn parking brake switch OFF. * Press brake.
l
MC-17
* *
Disconnection
in R ECMV fill switch system
Remedy
2 YES Is resistance between M02A (4) and T12 (female) (I) normal? NO *Max. 1 R * Disconnect C3B, M02A. and T12. . Turn starting switch OFF. Defective modulated clutch controller Disconnection or defective contact in wiring harness between M02A (female) (4) - T14 (female) (1) Defective R ECMV fill switch Replace
Is voltage between T12 (1) and chassis ground normal?
YES 1 -
Repair or replace
p *20-30V * Turn starting NO switch OFF. * Disconnect T12. * Start engine. Turn transmission cut-off switch OFF (Put out lamp) * Turn parking brake switch OFF. Press brake.
l l
MC16,

Transmission
_ R fill switch
TXW02456
WA1 200-3
20-529 0
TROUBLESHOOTING
MC18
MC-18 f
t
Disconnection in RPM-SET IDLE-UP/RESUME switch system
IDLE-DOWN
Remedy
4YE! Is resistance YES between LllO - (female) (21 and 3 chassis ground IlOrlllsl? * Max. R Turn starting switch OFF. Disconnect LllO.
l
Replace
Disconnection in wiring harness between LllO (female) (2) -chassis ground Disconnection in wiring harness between MOZA (female) (16) - LllO (female) (3) Disconnection in wiring harness between MOZA (female) (15) - LllO (female) (1) Defective RPM-SET IDLE -UP/RESUME IDLEDOWN switch Repair or replace
Is resistsnce YES between M02A - (female) (16) and LllO (female) (3) 2 mrma,,
NC
n
1
(male) (11,(2) and (3) as shown in - Disconnect Lll 0. * Turn starting switch OFF.
Max. 1 R ; between M02A - (female) (15) and - *Turn starting LllO (female) 11) switch OFF. n0rHlal? * Disconnect MOZA - Max. 1 R and L110. Turn starting NO switch OFF. Disconnect MOZA and LllO.
l l l
NO
Repair or replace
Repair or replace
IReplace
Table 1
RPM-SET IDLEUP switch ON Between LllO (female) (1) - (2) Between LllO (female) (3) - (2) Min. 1 MR Max. 1 R RESUMEJDLEDOWN switch ON Max. 1 R Min. 1 MR
MC-18 Related
electrical
circuit diagram
RPM-SET IDLE-UP/RESUME IDLE-DOWN switch
Modulated
clutch
LR7 (DT~) 4-j
RA5 (DTI) 2 000
RAI 0 (DTHD4)
Battery
TXW02473
20-530 0
WA1 200-3
TROUBLESHOOTING
MC-19
MC-19
+ +
Abnormality
in electronic governor voltage command
system
3 YES Is voltage between YES MO1 (female) (14) _ and chassis 2 ground nOrmal? * At low idling: NO Max. 0.5 V * At high idling: 3.8 - 5 V * Turn starting switch ON. NO
Short circuit with power source in wiring harness between MO1 (female) (14) - 02 (female) (5) Defective modulated clutch controller Short circuit with chassis ground in wiring harness between MO1 (female) (14) - Cl2 (female) (5) Disconnection or defective contact in wiring harness between MO1 (female) (14) - 02 (female) (5)
Repair or replace
yes
Is resistance b&wean MO1 (female) (14) and (12 (female) (5) normal?
1
Is resistan between MO1 - (female) (14) and chassis ground 1 normal? * Min. 1 MR
Trn
l
Replace
Max. 1 R * Turn starting switch OFF. * Disconnect MO1 and Q2.

*
switch OFF. Disconnect MO1 and Q2.
aaning
Repair or replace
NO
Repair or replace
MC-19
Related
electrical
circuit diagram
NO1 (NIC21)
LRI (HD-95066)
OUANTUM
)ELc.0.*01 W1..1 1 355 (I TXW02479
WA1 200-3
20-531 0
TROUBLESHOOTING
MC-21
MC-21 *
*
Abnormality
in modulated clutch ECMV fill switch system
*
;I resistance yes between M02A - (female) (12) and 2 T10 (female) (11 Is resistance normal? YES between MOZA Min. 1 MR NO - (female) (12) and *Turn starting T10 tfemale) (1) 1 switch OFF. _ normal? Is resistance * Disconnect M02A and TlO. *Max. 1 R between TlO (male) - * Turn starting NO (1) and chassis switch OFF. ground normal? Disconnect MO24 * Turn starting and TlO. I switch OFF.No Disconnect TlO. -Turn starting switch ON (Do not start engine): Min. 1 MR When engine speed is above 500 rpm: Max. 1 Q
Is
l l l
Defective modulated clutch controller Short circuit with chassis ground in wiring harness between M02A (female) (12) -TlO (female) (1) Disconnection in wiring harness between M02A (female) (12) -TlO (female) (1) Defective modulated clutch ECMV fill switch
Replace
Repair or replace
Repair or replace
Replace
Modulated rnntrnlIPr __ . _
clutch RT2 (HD-85086) T10 (011) 111711 - __-
MOO/C f i switch =FE
II
lLLl
TXWO2480
WA1 200-3
20-533 0
TROUBLESHOOTING
MC22
MC-22 Abnormality
in right brake pedal switch system
f Check that fuse l(9) is normal. f Before carrying out troubleshooting, check that all the related connectors are properly inserted. or Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
4YE! ISvoltage between YES_ MOZA (female) (18) _ and chassisground 3 normal? NC
Replace
ES 2 Is resistance YES b-en M02A - (female) (18) and chassis ground 1 pnormal? * Min. 1 MS1 *Turn star%J switch OFF. * Disconnect M02A and Llll.
Is r&Stance between M02A (female) (18) and Ll 11 (female) (2) normal? * Max. 1 R * Turn starting switch OFF. * Disconnect M02A and Llll.
Is resistance * Press right brake between Llll pedal: Max. 1 V (female) (1) and FS2 Release right brake (female) (8) normal? _ pedal:17-30V. * Max. 1 R * Turn starting NO switch OFF. * Disconnect Ll 11 and FSZ. NO
Defective right brake pedal switch
Replace
Disconnection or defactive contact in wiring harness between Ll 11 (female) (1) FS2 (female) (8) Short circuit with chassis ground in wiring harness between MOZA (female) (18) - Llll (female) (2) Disconnection or dafactive contact in wiring harness batwaen M02A (female) 118) - Llll (female) (2)
Repair or replace
Repair or replace
Repair or replace
MC-22
Related
electrical
circuit diagram
Modu lated cant
clutch
Fuse (I 1
TXW0248 I
20-534 0
WA1 200-3
TROUBLESHOOTING
MC-23
MC-23
* *
Abnormality
in travel speed control ON/OFF
switch system
Before carrying out troubleshooting, check that all the related connectors are properly inset-ted. Always connect any disconnected connectors before going on to the next step.
4YE!
I Isresistance
YES 3 ~Is resistance YES between M02A Ifemale) (201 and chassis ground between (female) L24 (4) and chassis ground normal? Maxe * Turn *
lr-
Defective modulated clutch controller Disconnection in wiring harness between I24 (female) (4) -chassis ground Short circuit with chassis ground in wiring harness between M02A (female) (20) - L24 (female) (3) Disconnection in wiring harness between M02A (female) (20) - I24 (female) (3) Defective travel speed control ON/OFF switch
Replace
NC
Repair or replace
YE 1
I Is resistance
Isresiaance between M02A (femaleI (20) and

L24 (female) (3)
* Travel speed control ON/OFF 0 switch ON: Max. 1 R OFF: Min. 1 MR * Disconnect f-24. Turn starting switch OFF.
normal? *Max.lR *Turn starting switch OFF. . Disconnect M02A and L24.
crme7 ~*Min. 1 MR *Turn starting switch OFF. * Disconnect M02A and l.24. NO
starting switch OFF. * Disconnect K4. NO
Repair or replace
Repair or replace
Replace
MC-23 Related
electrical
circuit diagram
Modulated
clutch M02A (04020)
Speed set switch
LR7 IDTI)
RA5 (DTI
RAlO (DTHD4)
Battery
WA1 200-3
20-535 0
TROUBLESHOOTING
MC-24
MC-24 *
+ *
Abnormality
in RPM-SET ON/OFF
switch system
inserted.
Check that fuse I(101 is normal. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
YES Is voltage YES M02B between

Short circuit with chassis ground, disconnection, defective contact, or short circuit with powersource in
Replace
2 Is resistance
(female) (3) and chassis ground normal?

* RPM-SET switch ON/OFF NO OFF: Max. 1 V ON:l?-3av . Turn starting switch OFF.
yf
1
between
L108 -
(female) (2) and chassis ground normal? *Max. 1 R *Turn starting switch OFF. Disconnect L108.
l
wiring harness between M02B (female) (3) - L108 (female) (1)
Repair or replace
(female1
(1) and (2)
NO
Disconnection or defective contact in wiring harness between L108 (female) (2) chassis ground
Repair or replace
RPM-SET ON/OFF switch b ON: Max. 1 R OFF: Min. 1 MS2 * Turn starting switch OFF. * Disconnect L108.
Defective RPM-SET ON/OFF switch
Replace
MC-24
Related
electrical
circuit diagram
Nodu cant
RPM-SET
20-536 0
WA1 200-3
TROUBLESHOOTING
MC-25
MC-25
* *
Abnormality
in engine rotation output
signal system
inserted.
Before carrying Always connect
out troubleshooting, check that all the related connectors are properly any disconnected connectors before going on to the next step.
1 and
YES
Defective modulated clutch controller Shon circuit with chassis ground, disconnection, defective contact, or short circuit with power source in wiring harness between MO25 (female) (14) - L28 (female) (4) or V3A (female) (7)
Replace
r
NO
Repair or
* Start engine. : Min. 0.5 V
Modulated con
clutch
VHMS controller
Work eauiDment controller
L28 1040 16) TXW02484
WA1 200-3
20-537 0
TROUBLESHOOTING
MC-26
MC-26
Abnormality in power supply system of modulated control system
clutch
* * * *
Check that fuse I (9) is normal. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket).
I
YES 1 I
Cause
Remedy
Defective modulated clutch controller Disconnection or defective contact in wiring harness between MO1 (female)(8), (17). (18)-MO1 W,M02A(9) Disconnection or defective contact in wiring harness between MO1 (female) (91, M02A (female) (9) - chassis ground
Replace
Repair or replace
1R . Turn starting switch OFF. - Disconnect MO1 and M02A.
- Max.
NO
Repair or replace
MC-26
Related
electrical
circuit diagram
Modulated con
clutch
TXW02485
20-538 0
WA1 200-3
TROUBLESHOOTING
MC-27, MC-28
MC-27 *
Abnormality
in network
system
for transmission controller system.
See T-34 Network system in troubleshooting
MC-28 *
Abnormality
in Fl (Forward
1st gear) input signal system

for transmission controller
See T-39 Fl (Forward 1st gear) signal system in troubleshooting system.
WA1 200-3
20-539 0
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER (JOYSTICK STEERING CONTROL) SYSTEM (J MODE)
Judgement table for work equipment control system related parts ............................................... Operations of controller against abnormality and conditions of machine caused by abnormality ................................................................................................................................. Electrical circuit diagram for joystick steering system ..................................................................... J- 1 J- 2 Error code I551 (Abnormality
.20-602
20-604 .20-608
in travel speed sensor system) is displayed.. ....................... 20-609
Error code 1561 (Disconnection or short circuit with chassis ground in caution buzzer relay system) is displayed ....................................................................... 20-610
J- 3
Error code 1571 (Disconnection or short circuit with chassis ground in steering lever angle sensor system) is displayed ........................................................... 20-611
J- 4
Error code [581 (Deviation of steering lever angle sensor and frame angle sensor potentiometer signals ................................................................................. 20-612
J- 5
Error code I591 (Disconnection or short circuit with chassis ground in frame angle sensor system) is displayed. ........................................................................ 20-613
J- 6
Error code 1611 (Disconnection or short circuit with chassis ground in steering lever lock pressure switch system) is displayed .............................................. 20-614
J- 7
Error code [621 (Disconnection or short circuit with chassis ground in steering neutral interlock relay system) is displayed ..................................................... 20-615
J- 8
Error code [631 (Disconnection, short circuit with chassis ground, or short circuit with power source in steering main pressure control EPC solenoid system) is displayed ........................................................................................... 20-616
J- 9 J-10 J-l 1
Short circuit with chassis ground in travel speed sensor system ......................................... 20-617 Steering speeds in both directions are different ..... ................................................................ Abnormality in console switch (adjustment of steering lever angle sensor 20-619 20-620 20-618
and frame angle sensor is impossible) ............................................................................ J-12 Abnormality in power source and voltage ...............................................................................
WA1 200-3
20-60 1 0
TROUBLESHOOTING
JUDGEMENT TABLE FOR WORK EQUIPMENT CONTROL SYSTEM (JOYSTICK CONTROL SYSTEM) RELATED PARTS
JUDGEMENT TABLE FOR WORK EQUIPMENT CONTROL SYSTEM (JOYSTICK CONTROL SYSTEM) RELATED PARTS
ielf-di, nosis disp
Ial y (Display of abnormal-m
Location of failure
Failure mode
63
1 1 Engine cannot be started 2 1 Steering speed is heightened 3 1 Steering speed ir_lowered 4 5 6 7
Refer to G mode -
H-6
Response of steering system is heightened Response of steermg system IS lowered Steering speeds in both directions are different Steering speed is heightened even at high travel speed
8 ( Machine is steered suddenly after engine is started 9 1 Engine can be started while machine is steered IO ) Caution buzzer does not sound or keeps sounding Diagnosis code when failure code is displayed
M-16
20-602 0
WA1 200-3
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABNORMALllY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY

-ailure code Abnormal system Contents of abnormality
55
Abnormality in travel speed sensor system
I) Defective travel speed sensor 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between work equipment controller L28 (female) (5) - T15 (female) (1) 3) Disconnection or defective contact in wiring harness between work equipment controller L28 (female) (12) T15 (female) (2) 4) Defective joint connector (JLI9, JL6, JL12, JM4) 5) Defective work equipment controller
56
Disconnection or short circuit with chassis ground in caution buzzer relay system
I) Defective caution buzzer relay 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between work equipment controller L28 (female) (13) - L65 (female) (I) 3) Disconnection or defective contact in wiring harness between caution buzzer relay L65 (female) (2) - chassis ground 4) Defective work equipment controller
57
Disconnection or short circuit with chassis ground in steering lever angle sensor (potentiometer) system
I) Improper installation (Misalignment) of steering lever angle sensor 2) Defective steering lever angle sensor 3) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between work equipment controller L27 (female) (20) - JS2 (female) (1) 4) Defective work equipment controller
58
Deviation of steering lever angle sensor and frame angle sensor potentiometer signals
I) Improper installation (Misalignment) of steering lever angle sensor 2) Defective steering lever angle sensor 3) Improper installation (Misalignment) of frame angle sensor 4) Defective frame angle sensor 5) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between L27 (female) (20) - JS2 (female) (1) 6) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between L28 (female) (I) - L30 (female) (1) 7) Defective work equipment controller
59
Disconnection or short circuit with chassis ground in frame angle sensor (potentiometer) system
I) Improper installation (Misalignment) of frame angle sensor 2) Defective frame angle sensor 3) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between L28 (female) (I) - L30 (female) (I) 4) Defective work equipment controller
20-604
0
WA1 200-3
TROUBLESHOOTING
Normal condition (Voltage, current, resistance) 1) Resistance between travel speed sensor T15 (male) (1) - (2): 500 - 1,OOOQ
Operation of controller against abnormality Turns off steering main pressure control EPC solenoid.
Condition of machine caused by abnormality Steering speed is heightened even at high travel speed.
Diagnosi code
J-l
11 Voltage between relay L65 (1) - chassis ground when caution buzzer is turned on: 20 - 30 V 2) Resistance between work equipment controller L28 (15) - chassis ground, caution buzzer relay: 200 - 4OOQ 3) Resistance between work equipment controller L28 (female) (15) - L65 (female) (1): Max. 1 R 4) Resistance between caution buzzer relay L65 (female) (2) - chassis ground: Max. 1 R
Does not operate at all.
Caution buzzer does not sound or keeps sounding.
J-2
I) Voltage between work equipment controller L27 (20) - (9): 0.5 - 4.5 v !I Resistance between steering lever angle sensor JS2 (male) (1) - (2): 0 - 5 kS2
1) Turns off steering main pressure control EPC solenoid output. 2) Controls steering lever angle sensor signal voltage as input voltage.
Steering speeds in both directions are different. J-3
I) Voltage between work equipment controller L27 (20) - (9): 0.5 - 4.5 v 2) Voltage between work equipment controller L28 (1) - L27 (9): 0.5 - 4.5 V 3) Resistance between steering lever angle sensor JS2 (male) (1) - (2): 0 - 5 kQ 4) Resistance between frame angle sensor L30 (male) (1) - (2): 0 - 5 kD
Turns off steering main pressure control EPC solenoid output.
Steering speeds in both directions are different.
J-4
1) Voltage between work equipment controller L28 (1) - L27 (9): 0.5 - 4.5 V 2) Resistance between frame angle sensor L30 (male) (1) - (2): 0 - 5 kQ
1) Turns off steering main pressure control EPC solenoid output. 2) Controls frame angle sensor signal voltage as input voltage.
Steering speeds in both directions are different. J-5
WA1 200-3
20-605 0
TROUBLESHOOTING
ailure
code
Abnormal
system
Contents
of abnormality
61
Disconnection or short circuit with chassis ground in steering lever lock pressure switch system
1) Defective steering lock pressure switch 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between work equipment controller L27 (female) (1) - STL (female) (1) 3) Disconnection or defective contact in wiring harness between work equipment controller L27 (female) (2) chassis ground 4) Defective work equipment controller
62
Disconnection or short circuit with chassis ground in steering neutral interlock relay system
1) Defective steering neutral interlock relay 2) Disconnection, defective contact, or short circuit with chassis ground in wiring harness between work equipment controller L26 (female) (21) - L127 (female) (1) 3) Disconnection or defective contact in wiring harness between L127 (female) (2) - chassis ground 4) Defective work equipment controller
63
Disconnection, short circuit with chassis ground, or short circuit with power source in steering main pressure control EPC solenoid system
1) Defective steering main pressure control EPC solenoid system 2) Disconnection, defective contact, short circuit with chassis ground, short circuit, or short circuit with power source in wiring harness between work equipment controller L26 (female) (2) - L29 (female) (2) 3) Short circuit with chassis ground in wiring harness between work equipment controller L26 (female) (16) L29 (female) (1) 4) Defective work equipment controller
20-606 0
WA1 200-3
TROUBLESHOOTING
OPERATIONS OF CONTROLLER AGAINST ABNORMALlTY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALlTY
Normal condition (Voltage, current, resistance)
Condition of machine caused by abnormality (In case of disconnection} I) Transmission is kept in N. 2) Steering system is operable normally. (In case of short circuit with chassis ground) 1) Machine can travel although steering system is locked. 2) Gear is shifted in F or R. 3) Gear is shifted in F or R.
Diagnosis code
Voltage between work equipment controller L27 Turns on caution buzzer. (female) (1) - chassis ground: When steering lock lever is in LOCK: 20 - 30 V . When steering lock lever is in FREE: Max. 1 V
l
J-6
Voltage between work equipment controller L26 (female) (21) - chassis ground: When steering lock lever is in NEUTRAL: Max. 1 V
l
Does not operate at all.
1) Engine can be started while machine is steered. 2) Machine is steered suddenly after engine is started 3) Engine cannot be started.
J-7
Current flowing between work equipment controller L26 (2) - (16): 600 & 80 mA (Check on CGC monitor.)
Turns off steering main pressure control EPC solenoid output.
I) Response of steering system is lowered. 2) Steering speed is lowered. 3) Response of steering system is heightened 4) Steering speed is heightened
J-8
WA1 200-3
20-607 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM
FOR JOYSTICK STEERING SYSTEM
ELECTRICAL CIRCUIT DIAGRAM SYSTEM
FOR JOYSTICK
STEERING
ram anell mtentioaetsr
Stssrino switch lock
TXW02486
WA1 200-3
TROUBLESHOOTING
J-l
J-1
Error code 1551 (Abnormality displayed
in travel speed sensor system) is
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing when or T-adapter, the inserting and connector on the monitor display, the to its original position, if the error code is no longer displayed problem has been removed.
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Cause Remedy
4YE
Defective work equipment controller Short circuit with power source in wiring harness between L26 (female) (5) JL19 (3), (5) - JL6 (3). (6) FR2 (7) - T15 (female) (1)
Repair or replace
1 ye I
Is resistance between T15 * Disconnect L28
1 *Turn starting switch ON.
NO
Disconnection or defective contact in wiring harness between L26 (female) (5) JL19 (3). (5) - JL6 (3). (61FR2 (7) - T15 (female) (1) Defective travel speed sensor
Repair or replace
NO
Replace
* Max. * Turn
l
1R starting switch OFF. Disconnect JL19, JL6, JL12, and JM4.
I
NO
Defective joint connector (JL19, JL6, JL12, JM4)
Replace
J-l
Related
electrical
circuit diagram
TXW02453
WA1 200-3
TROUBLESHOOTING
J-2
J-2
*
Error code [56] (Disconnection or short circuit with chassis ground in caution buzzer relay system) is displayed
* * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. When the joystick steering lever is not being used, leave it at the neutral position. Always connect any disconnected connectors before going on to the next step.
Replace
yes 2 Is resistance YES between L65 - (female) (2) and chassis ground 1 - normal?
Is rssistance between I.28 (female) (15) and L65 Ifemale) (1) normat?
l;;ha;ground
11 withc&as$sis;md& NO
L28 (female) (15) - L66 (female) (1) Disconnection or defective contact in wiring harness between L28 (female) (15) L65 (female) (1) Disconnection or defective contact in wiring harness between L65 &male) f21chassis ground
* Turn starting . D~~~~nor.U8 and L65. NO
* Mi- MC2
Repair or replace
Is resistance * Max. 1 R between L65 _ * Turn starting (male) (1) and (2) switch OFF. normal? * Disconnect LG. 1 .200-400R Lo Turn starting switch OFF. * Disconnect L65.
- Max. 1 R -Turn starting switch OFF. - Disconnect L28 and L65. NO
Repair or replace
Repair or replace
1r
caution buzzer
Rep,ace
J-2 Related
electrical
circuit diagram
Fuse
Power source
(II
Caution FS2 (S 12)(B1ue)

>
I 91A
0.75fY
I Work eauipment~ controller

J/S caution OlOAV 0.5fB 0.5fL 0.5fB 0.5fY
L65
6 : :
L28 (04016)
relay 252 15 5fY m m
124AB OIOAU 252
Jovst ick taut ion buzzer relay
TXW024137
20-610 0
WA1 200-3
TROUBLESHOOTING
J-3
J-3 +
Error code [57] (Disconnection or short circuit with chassis ground in steering lever angle sensor system) is displayed
* *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. When the joystick steering lever is not being used, leave it at the neutral position. Always connect any disconnected connectors before going on to the next step.
Remedy
neutral position)
Disconnection, defective
Replace or adjust neutral position
(female) (20) and
contact,short circuitwith
chassis ground, or short circuti with power source in wiring
Repair or replace
harnessbetween L27 ffemale) (20) - JS2 (female)(1) (female) (10) and left (0.5 - 4.5 V) * Lean steering lever to right or left (0.2 - 5 kc11 Defective steerintg lever angle sensor Replace
Replace
J-3 Related
Work
electrical
circuit diagram
eauiwnent
Pontentionetcl
TXWO.2488
WA1 200-3
20-611
TROUBLESHOOTING
J-5
J-5
Error code 1591 (Disconnection or short circuit with chassis around in frame angle sensor system) is displayed
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing when or T-adapter, the connector and inserting if the error code is no longer displayed on the monitor display, the to its original position, problem has been removed. check that all the related connectors are properly inserted. Before carrying out troubleshooting, When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step.
CaUSe
Remedy
Improper installation of frame angle sensor (Deviation of neutral position) Disconnection, defective contact short circuit with chassis ground, or short circuit with power source in wiring harness between LZ8 (female) (1) - WO (female) 11) Defective frame angle sensor
Replace or adjust neutral position
Repair or replace
-4.9-5.1 v *Turn starting switch ON.
Change frame angle (0.2 - 5 kQ)
NO
Replace
IO
Defective work equipment controller
Replace
J-5 Related
Work
electrical
circuit diagram
eauiDment
Pontentioncter
rotentiometer
Txw024aa
WA1 200-3
20-613 0
TROUBLESHOOTING
J-6
J-6 f
Error code [611 (Disconnection or short circuit with chassis ground in steering lever lock pressure switch system) is displayed
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing when or connector and inserting the T-adapter, to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed.
Ir
Before carrying out troubleshooting, check that ail the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
cause
Remedy
4YE:
Defective work equipment controller Disconnection or defective contact in wiring harness between L27 (female) (2) chassis ground Disconnection or defective contact in wiring harness between L27 (female) (1) STL (female) (1) Short circuit with chassis ground in wiring harness between L27 (female) (1) - STL (female) (1) Defective steering lock pressure switch
Replace
fZ!Z&-H
YES between STL (1) .dlh L ground normal? YES 1 _ _ (male) (1) and (2) Is voltage between L27 (1) and chassis ground normal?
Repair or replace
lo-2v
. Turn starting switch OFF. . Disconnect L27 and STL
Repair or replace
* Max. 1 R * Disconnect STL NO Start engine. When steering lock lever is in FREE: Max. 1 R When steering lock lever is in LOCK: Min. 1 MR
l
~20-3ov Turn starting NO switch ON. Turn steering lock pressure switch ON.
l
Repair or replace
Replace
J-6 Related
electrical
circuit diagram
Steering switch # lock
Work eou iDment ler control
STL
CDT21
ry
WA1 200-3
TROUBLESHOOTING
J-7
J-7 j,
Error code 1621 (Disconnection or short circuit with chassis ground in steering neutral interlock relay system) is displayed
YES
F
I
4YEs yes 3
Is volt& between
Cause
Remedy
Defective steering neutral relay
Replace
1 If L127 relay is replaced, is

system * normal? -
Is resistance between L127

(female) (2) and i chassis ground Il0rHIel7
Defective work equipment controller Disconnection or defective contact in wiring harness between L127 (female) 12) chassis ground Short circuit with chassis ground in wiring harness between l26 (female) (21) - L127 (female) (1) Disconnection or defective contact in wiring harness between L26 (female) (21) - L127 (female) (1)
Replace
Replace L127 with normal relay.
YES 2 Is resistance between l.26 (21) NO and L127 (female) (1) normal? Max. 1 R . Turn starting switch OFF. * Disconnect U6 and L127.
l
~261female) ~1)
and chassis ground
normal? 1V * Turn starting switch OFF. * Disconnect l26 and L127. NO
- Max.
NO _ - Max. 1 R * Turn starting I switch OFF. * Disconnect L127. NO
Repair or replace
Repair or replace
Repair or replace
J-7 Related
electrical
circuit diagram

J/S neutral lock
L26
relay
(MIC21)
573
21 . 5fY 573 OlOBT 0.5fY 0.5fB
L127
; 3
m nr) < 0
5 6
Steer ins neutral relay
TXW02490
WA 1200-3
20-615 0
TROUBLESHOOTING
J-8
J-8
Error code [631 (Disconnection, short circuit with chassis ground, or short circuit with power source in steering main pressure control EPC solenoid system) is displayed
+ f *
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. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When the joystick steering lever is not being used, leave it at the neutral position.
This troubleshooting is carried out when there is still an abnormality,
CalIS
Remedy
4YE! 5 YES 3 y~5 i! pIs resistance betweenl.26 (female) (16) and chassis gmund normal? * Min. 1 MD * Turn starting switch OFF* Disconnect I_26 and l29. Is resistance between L26 (female) (6) and (16) normal? * Min* MR * Turn starting switch OFF. * Disconnect L26. NO
GotoA.
Short circuit of wiring harness betwean I_26 (female) (6) - L2S (female) (2) with wiring harness NC1 between U6 (female) (16) and L29 (female) (1) Short circuit with chassis ground in wiring harness between L26 (female) (16) US (female) (1) Short circuit with chassis ground in wiring harness between L26 (female) (6) US (female) (2) Defective steering main pressure control EPC solenoid
Repair or replace
1Is resistance
lfamalelf6l and
Repair or replace
*Turn starting switch OFF. * Replace with other same EPC solenoid. *Turn starting switch ON. From A -
* Min. 1 MQ *Turn starting switch OFF. . Disconnect l-26 and US.
I
5
NO
Repair or replace
Replace
YES
-
is resistance between L26 (female) (6) and chassisground normal? * Max. 1 V . Disconnect L26 and l-29. *Turn starting switch ON.
Defective work equipment controller Short circuit with power source in wiring harness between l.26 (female) (6) - L29 (female) (2)
Replace
NO
rlepair or aplace
J-8 Related electrical circuit diagram
Work equiDment controller
Joust
ick
EPC L29 (DT2)

111901 2 I191 I
solenoid
TJW02491
20-6 16
0
WA1 200-3
TROUBLESHOOTING
J-9
J-9 *
Ir
Short circuit with chassis ground in travel speed sensor system

Cause
2 YES YES 1 Is resistancebetween L28 (female) (51 and chassisground normal? . Min 1 R * Turn starting switch OFF. * Disconnect L28 and 115. Is resistance between U8 (female) (12) and (5) normal? Defective travel speed sensor Shon circuitof wiring harness between L28 ifemale) (5) JL19 13).(5) - JL6 (3) , (6) FR2 (7)-T15 (female) (1) with wimg harnessbetween L28 (female) (12) - L19 (11,(6) JL6 (1). (81- JL12 (3). (1) - FR2 (8) -T15 (female) (2) Short circuit with chassis ground in wiring harness between L28 (female) (5) L19 (3). (5) - JL6 (31, (6) - FR2 (7) - T15 (female) (11
Remedy
Replace
j NO * Max. 1 R * Turn starting switch OFF. . Disconnect L28 and T15.
Repair or replace
NO
Repair or reolace
J-9 Related
electrical
circuit diagram
Transmission
TXW02453
WA1 200-3
20-617
TROUBLESHOOTING
J-IO
J-IO *
Steering
speeds in both directions
are different
to it. Cause
If an error code is displayed, check the parts corresponding
Deviation of steering lever angle sensor or frame angle sensor potentiometer
Repair or replace
20-618 0
WA1 200-3
TROUBLESHOOTING
J-l 1
J-II
Abnormality in console switch (adjustment of steering angle sensor and frame angle sensor is impossible)
lever
* *
Remedy
4y~S Is voltage between YES L27 (female) (14) and chassis ground I normal? ND . Max. 1 V -Turn starting switch OFF. - DisconnectL27 and JS4. -Turn starting switch ON NO
Replace
Is resistance YES batweenC3A (female) 16) and JS3 2 (female) (1) normal? Is resistance YES betwaen L27 - (female) 114)and JS4 (male) (1) 1 - normal? *Max. 1 R * Turn starting switch OFF. * Disconnect I_27 and JS4. * Max. 1 R * Turn starting switch OFF. * Disconnect C3A and JS3. NO
Short circuit with power source in wiring harness between L27 (female) (14) JS4 (male) (1) Disconnection or defective contact in wiring harness between C3A (female) (6) JS3 (female) (1) 1 Disconnection or defective contact in wiring harness between L27 (female) (14) JS4 (male) (1)
Repair or replace
Repair or replace
Is resistance between console switchJS3 (male) (1) and JS4 (female) _(l) normal? .
Replace
* When left armrest is at rearmost position , kwitch is ON): NO Max. 1 R . When left armrest is not at rearmost position kwitch is OFF): Min. 1 MR * Turn starting switch OFF. . DisconnectJLlS, JL6, JL12, and JM4.
Defective console switch
J-l 1 Related
electrical
circuit diagram
L27 (04020)
Cons0 I Transmission h joystick steering controller
WA1 200-3
20-619 0
TROUBLESHOOTING
J-12
J-12
* * J, j:
Abnormality
in power source and voltage

inserted.
Before carrying out troubleshooting, check that all the related connectors are properly Check that fuse I (10) is normal. When the joystick steering lever is not being used, leave it at the neutral position. Always connect any disconnected connectors before going on to the next step.
I
1 YES
Is voltage between L26 (female) (81, (18) and chassis ground normal?
Cause
Remedy
Defective work equipment controller Disconnection or defective contact in wiring harness between L26 (female) (8). (181, (17) -FS2(10)-fuseI
Replace
Repair or repiace
l20-3ov
l
NO
J-12 Related
electrical
circuit diagram
Work eau i Pment controller

\
Fuse ( I )
LLO \MILZII
Power INPUTt Power INPUTS t 2.1
1.25fW
FS2 (Sl 2 Blue 1 11. 25fW
1.25fW
101 58AI
TJW02493
20-620 0
WA1 200-3
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER (REMOTE BOOM POSITIONER CONTROL) SYSTEM (W MODE)
Judgement table for work equipment controller related parts .........................................................
20-652
Action taken by controller when abnormality occurs and problems on machine.. ....................... 20-654 Electrical circuit diagram for work equipment controller system ..................................................... 20-656
w-
Failure code [431 (Shot-t circuit, disconnection in damping solenoid) is displayed.. ........ 20-658 Failure code 1441 (Short circuit in power source at hot end of damping solenoid) is displayed ......................................................................................................... 20-659
w- 2
w- 3
Failure code [451 (Short circuit in power source at return end of damping solenoid) is displayed ......................................................................................................... 20-659
w- 4
Failure code [491 (Short circuit, disconnection in boom lever kick-out relay system) is displayed ........................................................................................................... 20-660
w- 5
Failure code 1511 (Disconnection in boom RAISE, LOWER detection pressure switch) is displayed ............................................................................................................ 20-661
W- 6
Failure code 1521 (Short circuit, disconneciton in boom angle potentiometer system) is displayed ........................................................................................................... 20-662 20-663 20-663 20-664
w- 7 W- 8 w- 9 W-IO
Sensor cannot be adjusted ...................................................................................................... Abnormality in engine speed signal system ..........................................................................
Remote positioner RAISE, LOWER LEDs do not light up ..................................................... Remote positioner RAISE stop lamp (CGC monitor) does not flash (for 2.5 seconds) .................................................................................................................
20-665
w-11
Remote positioner LOWER stop lamp KGC monitor) does not flash (for 2.5 seconds) ................................................................................................................. 20-665 20-666
w-12 w-13 w-14
Buzzer for switch operation does not sound ......................................................................... Short circuit in boom RAISE, LOWER pressure detection switch.. ......................................
Shock when stopping boom (abnormality in boom lever detent switch) ......................... 20-667 20-668
WA1 200-3
20-65 1
0
TROUBLESHOOTING
JUDGEMENT ABLE FOR WORK EQUIPMENT CONTROLLER (REMOTE BOOM POSITIONER CONTROLLER SYSTEM) RELATED PARTS
JUDGEMENT TABLE FOR WORK EQUIPMENT CONTROLLER (REMOTE BOOM POSITIONER CONTROLLER SYSTEM) RELATED PARTS
Location of failure
Failure mode
20-652 0
WA1 200-3
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

IEMOTE B( DM POSITIONER CONTROL ER SYSTEM Nature of abnormality
Defective damping solenoid
-ailure code
Abnormal system
:; Short circuit in wiring harness between work equipment

controller L26 (female) (51, (15) and HRS (female) (11, (2) defective contact, or 3) Short circuit with ground, disconnection in wiring harness between work equipment controller L26 (female) (5) - HRS (1) defective contact, or 4) Short circuit with ground, disconnection in wiring harness between work equipment controller L26 (female) (15) - HRS (2) 5) Defective work equipment controller I) Defective damping solenoid 2) Short circuit with power source in wiring harness between work equipment controller L26 (female) (5) - HRS (1) 3) Defective work equipment controller
43
Damping solenoid system
44
Short circuit with power source in damping solenoid system
45
Short circuit with power source at return end of damping solenoid system
1) Defective damping solenoid 2) Short circuit with power source in wiring harness between work equipment controller L26 (female) (15) - HRS (2) 3) Defective work equipment controller
49
Boom kickout relay system
1) Defective boom relay 2) Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between work equipment controller L26 (female) (20) boom relay L45 (1) 3) Defective contact or disconnection in wiring harness between boom relay L45 (female) (2) - chassis ground 4) Defective work equipment controller Defective boom RAISE/LOWER switch contact or disconnection in wiring harness between work equipment controller L27 (female) (5) - HR13 (female) (1) Defective contact or disconnection in wiring harness between HR13 (female) (2) - chassis ground Defective contact or disconnection in wiring harness between work equipment controller L27 (female) (6) - HR12 (female) (1) Defective contact or disconnection in wiring harness between HR12 (female) (2) and chassis ground Defective work equipment controller Defective boom angle potentiometer
:; Defective
3) 51 Boom RAISE/LOWER switch system 4)
5) 6)
:; Short circuit with power source, short circuit with ground,

defective contact, or disconnection in wiring harness between work equipment controller L27 (female) (19) F04 (female) (1) 31 Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between work equipment controller L27 (female) (9) - F04 (female) (2) 4) Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between work equipment controller L27 (female) (10) F04 (female) (3) 5) Defective work equipment controller
52
Boom angle potentiometer system
20-654 0
WA1 ZOO-3
TROUBLESHOOTING
Condition when normal (voltage, current, resistance) 1) Resistance between work equipment controller L26 (female) (5) and (15): 10 - 20 12 2) Voltage between work equipment controller L26 (female) (5). (15) and chassis ground: Less than 1 V 3) Resistance of wiring harness between work equipment controller L26 (female) (51, (15) - HR9 (11, (2): Less than 1 Q
Action by controller when abnormality is detected Damping solenoid output: OFF
Rr$l&;$n,a$~;;rs there is abnormality There is shock when stopping boom in remote positioner mode
,,r;EgF code
W-l
Voltage between work equipment controller L26 (female) (5) and chassis ground: Less than 1 V
Damping solenoid output: OFF
There is shock when stopping boom in remote positioner mode
w-2
Voltage between work equipment controller L26 (female) (15) and chassis ground: Less than 1 V
There is shock when stopping boom in remote positioner mode
w-3
1) Resistance of relay coil: 200 - 400 R 2) Resistance of wiring harness between work equipment controller L26 (female) (20) - boom relay L45 (1): Less than 1 R 3) Resistance of wiring harness between boom relay L45 (female) (2) and chassis ground: Less than 1 R
Boom lever kickout output: OFF
Boom does not stop at desired position in remote positioner mode (boom lever detent is not canceled)
w-4
1) When boom lever is at neutral, resistance becomes as follows. 2) Resistance between work equipment controller L26 (female) (5) and chassis ground: Less than 1 R and resistance between work equipment controller L26 (female) (3) and chassis ground: Less than 1 R
There is shock when stopping boom in remote positioner mode w-5
Voltage between work equipment controller L26 (female) (19) and L27 (9): 0.3 - 4.8 V
Remote positioner function: OFF
Remote positioner function does not work
W-6
WA1 200-3
20-655 0
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT CONTROLLER SYSTEM

Fuse (I)
FS2 (S12Xeluel
Fuse
20-656 0
WA1 200-3
TROUBLESHOOTING
Positioner raise indicator (Green1
Boom kick solenoid Bucket positioner solenoid
out
FLI
(HD-26086)
Bucket sositioner
sensor FR2 (HD-46082) RT2 (HD-85086) T15 (DT2)
Boom
angle
I
R20
Boom lever detent switch Boom lower switch
I//
Boom dump solenoid Boom dumv solenoid TXW02495
WA1 200-3
20-657 0
TROUBLESHOOTING
W-l
W-l
Failure code M31 (Short circuit, disconnection solenoid) is displayed
in damping
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing when or T-adapter, the connector and inserting if the error code is no longer displayed on the monitor display, the to its original position, problem has been removed.
f f
Before Always Always socket
carrying out troubleshooting, check that all the related connectors are properly inserted. connect any disconnected connectors before going on to the next step. turn the starting OFF before disconnecting any connector to connect the T-adapter (or adapter).
Cause
Remedy
YES 2
Defective work equipment controller Short circuit with chassis ground in wiring harness between I26 (female) (5), (15) - HR9 (female) (l), (2) Defective damping solenoid wiring harness Short circuit, defective contact. or disconnection in wiring harness between L26 (female) (5). (15) - HR9 (female) (1). (2) Defective damping solenoid
Replace
YE
Is resistance between L26 (female) (5) and chassis normal?

l
3 YES _ Is resistance between HR9 NE (male) (1) and chassis normal? * Disconnect HR9. Min. 1 MR
l
Repair or replace
I Is resistance between L26 (female) (5) and (15) normal? * Disconnect L26. l15-2552
I
t
Disconnect L26. * Min. 1 MS2
NO
4 YES
Is resistance between HR9 (female) (1) and (2) normal? * Disconnect HR9. .15-25R
Repair or replace
W-l
Related
electrical
circuit
diagram
Work equipment cant rol ler DUMP ins solenoid

TJW02496
20-658 0
WA1 200-3
TROUBLESHOOTING
w-2,
w-3
W-2
Failure code [441 (Short circuit in power source at hot end of damping solenoid) is displayed
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or socket adapter).
Cause Remedy
Is voltage between L26 (female) (5)
Defective work equipment controller Short circuit with power source in wiring harness between L26 (female) (5) and HR9 (female) (1)
Replace
* Disconnect L26. Turn starting switch ON. - Max. 1 V

l
NO
Repair or replace
w-3
Failure code 1451(Short circuit in power source at return end of damping solenoid) is displayed
CaUSe
Remedy
Defective work equipment controller L26 (female) (15)
Replace
Disconnect U6. * Turn starting switch ON. - Max. 7 V

l
NO
Short circuit with power source in wiring harness between L26 (female) (15) and HRg (female) (2)
Repair or replace
W-2, 3 Related
electrical
circuit diagram
Work cant
equipment Dumping solenoid

TJW02496
WA1 200-3
20-659 0
TROUBLESHOOTING
w-4
W-4
Failure code [491 (Short circuit, disconnection out relay system) is displayed
in boom lever kick-
the so when disconnecting is carried out when there is still an abnormality, This troubleshooting 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.
* *
Before Always Always socket
carrying out troubleshooting, check that all the related connectors are properly inserted. connect any disconnected connectors before going on to the next step. turn the starting OFF before disconnecting any connector to connect the T-adapter (or adapter).
Cause
Remedy
Defective work equipment controller Disconnection in wiring harness between U6 (female) (20) - L45 (female) (1) Short circuit with chassis ground in wiring harness between L26 (female) (20) - L45 (female) (1)
Replace
Repair or
* Disconnea L46. - Min. 1 Mf2
NO
Repair or replace
W-4 Related Work coni
electrical
circuit diagram
equipment
Booim kit k-out SOI enoid
FS2
(Sl2
Blue (
10 58A
R20
TJW02497
20-660 0
WA 1200-3
TROUBLESHOOTlNG
w-5
W-5
*
Failure code [511 (Disconnection in boom RAISE, LOWER detection pressure switch) is displayed
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting 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.
* * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. (Or Always turn the starting OFF before disconnecting any connector to connect the T-adapter socket adapter).
Cause Remedy
YES 3 Is resistance between L27 (female) (6) and (9) normal? - Max. 1 R - Turn starting switch OFF. * Disconnect U7. * Boom lever: Neutral. 5
Defective work equipment controller Defective contact disconnection in harness between (female) (6). (9) (female) (1). (2) or wiring L27 HR12
Replace
YI
4YE
2 Is resistance
YI
is resistance between HR12 NO (male) (1) and (2) nomtal? .Max.lR * Turn startingswitch0% * DisconnectHR12.
* Boom lever: Neutral.
Repair or replace
Defective boom LOWER switch Defective contact disconnection in harness between (female) (5). (9) (female) (lb, (2) or wiring I27 HR13
Replace
1R * Turn starting switch OFF. * Disconnect L27. n - Boom lever: Neutral. 1D -Turn starting switch OFF. - Disconnect HR12, HR13.
- Max.
YES
Repair or replace
PIP - Max. 152 NO * Turn starting switch OFF. Disconnect HR13. Boom lever: Neutral.
l
- Max.
Defective boom RAISE switch Xsconnection or fefective contact in wiring harness between iR12 (female) (2). HR13 female) (2) - JR15 (5). 3). 16) -chassis grqund, x defective joint connector JR15
Replace
Repair or replace
W-5 Related Work
electrical
circuit diagram
eauipment
pressure Pressure
switch switch
WA1 ZOO-3
20-66 1 0
TROUBLESHOOTING
W-6
W-6
*
Failure code 1521(Short circuit, disconneciton system) is displayed potentiometer
in boom angle
* * *
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. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or socket adapter).
YES
1
F
3 YES 2 _ Is resistance between F04 (female) (19). (9). (10) -chassis nl%Tnal? YES -
Remedy
Replace
Is voltage
between L27 (female) (9) and (19) normal? - 0.3 - 4.8 V * Turn starting switch ON.
Short circuitwith power source in wiring harness between L27 (female)(9) FO4(female) (2). L27 (female) (10) - F04 (female) (3). L27 (female) (19) - FO4(female) (1 Shcrf circuit in wiring hames! between L27 (female) (9) F04 (female) (2) and between L27 (female) (10) - FO4 (female) (3). between L27 (female) (19) - F04 (female) I1 Defective boom angle potentiometer
Repair or replace
~6
Is resistance between F04 (female) (1) and (2). (2) and (3) normal?
- Between (1) and NO (2): 0.2 - 5 kR Between (2) and (3):4-5M . Turn starting switch OFF. * Disconnect F04.
l
NO * Min. 1 MR -Turn starting switch OFF. * Disconnect L27 and F04.
Replace
Repair or
W-6 Related electrical circuit diagram

Work cant eauipment
JL24
(DT2)
Boom angle Potentiometer
LR~ (DTI)
RA5 (DTI)
RAtO
(DTHD4)
Battery
TJWO2499
20-662
0
WA1 200-3
TROUBLESHOOTING
w-7,
W-8
W-7
* f * * *
Sensor cannot be adjusted
For details of the method of operation, see STRUCTURE AND FUNCTION. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or socket adapter). If the set switch display flashes in the set mode, check the installation of the boom angle potentiometer.
1
Remote positioner Is remote RAISE, LOWER _ positioner set LEDS does not signal system light up of flash normal? * Turn remote positioner RAISEAOWER set switch ON.
l
ZYES _
Replace
See troubleshooting W-10.
NO
Defective remote positioner RAISEROWER set switch or LED s&em
RezaFeor
W-8
* * *
Abnormality
in engine speed signal system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or socket adapter).
Cause Remedy
_ Is resistance between L28 (female) (4) and chassis normal? - Disconnect L28 and MOZB. * Min. 1 MD
2 YES Is resistance berween MS I28 (female) (41and - chassisnormal when 1 MO28Wemale) (141is grounded to chassis? , _
l
Defective work euqipment controller Defective contact or disconnection in wiring harness between US (female) (4) and M02B (female) (14) Short circuit with chassis ground in wiring harness between L28 (female) (4) and MOZB (female) (14)
Replace
DisconnectL28. * Max. 1 R
NO
Repair or replace
NO
Repair or replace
W-8 Related
Work con
electrical
circuit diagram
Modulated . . .
equipment
WA1 200-3
20-663 0
TROUBLESHOOTING
w-9
W-9 Remote positioner RAISE, LOWER LEDs do not light up

* * Jc * * Check that CGC works properly. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or socket). If fuse I-(11) is broken, check the wiring harness between the fuse and L136 (female) (1) and L136 (female) (I) for short circuit with chassis ground.
Defective work euqipment controller
Replace
D&connection or defective contactin wiring harness Repair or betweenI26 (female)(61Ll37 (male) (1). or betweenL28 recdace (female)(14) - L13S(male)(1)
,____.___.. male) (1).

nale) (1) 1and chassis ground normal7 -2O-30V * ~isxnn L136
II
- Disconnect L28, L137, and L139. * Min. 1 MR
NO
with chassis groundin wiring harness betweenU8 (female)(8) Ll37 (male) (1). or betweenI26 (female)(141-LES (male)(1)
Short circuit
Repair or
NO
- Turn starting switch ON.
Diinnection, defective contact.or short circuitwith chassis ground in wiring harnessbeween fuse I (11) L136(female) (1). L136 (female)(1)
Repair or
Work esuiDment controller
Positioner RAISE indicator (a reen) Positioner LOWER indicator (green)

TJW02501
20-664 0
WA1 200-3
TROUBLESHOOTING
w-10, w-11
W-IO
Remote positioner RAISE stop lamp (CGC monitor) flash (for 2.5 seconds)
Cause
does not
Remedy
Defective CGC
Repair or replace
W-II
Remote positioner LOWER stop lamp (CGC monitor) does not flash (for 2.5 seconds)
Cause Remedy
Defective CGC
Repair or replace
WA1 200-3
20-665 0
TROUBLESHOOTING
w-12
W-12
* * * *
Buzzer for switch operation does not sound
Check that the main monitor and alarm buzzer work properly. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or socket adapter).
Cause
Remedy
Is
resiincebetween
Defective work euqipment controller Defective contact or disconnectionin wiring harness between L28 (female) MI- JL16 (1). (6) LO8(female) (6) . Defective contact or disconnacitonin wiring harness between L28 (female) (16!- RES2 (1). (2) - JL6 (5). (6) -chassis - Short circuit with chassis ground in tiring harness between L28 (female) WIJL16 (1). (6) - LO8(female) (6)
Replace
chassis normal when
Repair or replace
chassis normal? and LO8. .5-6kQ
NO
Repair or replace
Work epu i Pment controller
R20
TJW02502
20-666 0
WA1 200-3
TROUBLESHOOTING
w-13
W-13 *
* * *
Shock when stopping boom (abnormality switch)
in boom lever detent
Check that the failure mode [491 is not displayed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When the boom lever is at neutral, [GNDI is input to the controller when the boom detent switch is closed.
cause
Remedy
4YE: *S 3 Is resistance ;zEl%E9,MS HRll (fern&) (1). 2 (2) normal? pIs resistancebetween I.27 (female)(8). (9) * Min. 1 MD YES _ _ and chassis normal Turn starting when HI31 1 (female) switch OFF. (IokA$$ grounded 1 s c Disconnect L27 Is resistance * Max. 1 R and HRll. between HRll - * Turn starting NO (male) (1) and (2) switch OFF. normal? * Disconnect l27
l l
Is resistance between I_27 (female) (8) and (9) nom-rat? * Min. 1 MQ NC * Turn starting switch OFF. * Disconnect L27 and HRll. NO

Short circuit in wiring harness between L27 (female) (8) - HRll (female)
Replace
(1) and between L27 (female) (9) - HRl 1 (female1(2) Short circuit with chassis
ground in wiring harness between L27 (female) (8) -
Repair or replace
and HRll. * At boom lever neutral: Max. 1 52 NO . Other than neutral: Min. 1 MR Turn starting switch OFF. . Disconnect HRll
l
HRll (female) (11, or between L27 (female) f91HRl 1 (female) (2) Defectivecontact or disconnectionin wiring harnessbetween LZ7 (female) (8) - HRll (female) (1). or between L27 (female) (91HRl 1 (female) (2) Defective boom lever detent switch
Repair or replace
Repair or replace
Replace
Work uipment Intro1 ler
L27 (04020)
3 (HD-76086)
JL21 (DTIE)
(DTt)
Boom I ever detent switch
JR13 (DTlB)
JLll
(DTl)
,,
LR~ (~~11
RAlO
(DTHD4)
Battery
A7
TJW02503
WA1 200-3
20-667 0
TROUBLESHOOTING
w-14
W-14 *
*
Short circuit in boom RAISE, LOWER pressure detection
switch
Before carving out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
cause
Remedy
4YE
c
n j between
Yl 1
between HFi12 (male) 11) and HR73 (male) (1) -chassis Min. 1 M~z *Turn starting switch OFF. * Disconnect HR12 and HR13.
l
i/OE,,i
l l
Min. 1 MR Turn starting switch OFF. * Disconnect U7, HR12, and HR13.
l l
* Min. 1 MR Turn starting switch OFF. Disconnect K7, HR12, and HR13.
is resistance L27 (female) (5). (61, and (9) normal?
Is resistance YES_ between ~27 3 (female) (6) and (9) normal? * Min. 1 MQ NC * Turn starting switch OFF. - Disconnect L27 and HRl NO
Defective work equipment controller Short circuit in wiring harness between L27 (female) (6) - LRl 1 (2) - F22 (female) (1) and between L2i (female) (9) - LRll (6) - F22 (female) (2) Short circuitin wiring harness betweenL27 (female)(6) HR13(female)(1) and betweer l27 (female)(6) - HR12 (female)(l), or between l27 (female)(5) and HR13(female) (11,HR12 (female)(1) grow, Shortdr& withchassis betweenL27 in wiringharness (1) (female) HRl3 (5) (female) (6)or betwell L27wemale) between or (1). HRl2 (female) I27 Ifemale (9)- HR13(female) 12) (2). HR12(female) Defective boom RAISE switch or boom LOWER switch
Replace
Repair or replace
Repair or replace
;0
Repair or replace
NO
Replace
W-14 Work cant
Related
electrical
circuit diagram
esuipment
Dressure Dressure
switch switch
TJW02498
20-668
WA1 200-3
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)

Trouble data display ,.................................,................ ,.................. ........ .... ... ............i .................. ......... . 20-703
Electrical circuit diagram of main monitor system .......... .......... ................... ....... ...... .......... .............. 20-704 20-706 M- 1 Main monitor does not work ..................................................................................................... M- 2 When starting switch is turned ON (within 3 seconds) and engine is started (PRE-LUBE) immediately, M- 3 Speedometer all lamps stay lighted up ................................................................ 20-707 20-708 20-709 20-709 20-709 20-710 display does not work properly ......................................................................... in shift indicator ....................................................................................................
M- 4 Abnormality a) Displays N even when directional lever is at F ................................................................. b) Displays N even when directional lever is at R. ................................................................ c) Does not display N even when FNR (Forward-reverse) switch is set in N ...................
d) Does not display F even when FNR (Forward-reverse) switch is set in F.. ................... 20-710 e) Does not display R even when FNR (Forward-reverse) switch is set in R .................... 20-710 20-712 M- 5 Turn signal display does not light up ....................................................................................... .20-7X? a) L.H. turn signal display does not light up.. ....................................................................... b) R.H. turn signal display doesnot light up ......................................................................... M- 6 Abnormality in parking display .................................................................................................. a) Parking lamp display does not light up ............................................................................ b) 20-712 20-713 .20-713
-20-713 Parking lamp display stays lighted up .............................................................................. 20-714 M- 7 Night lighting does not light up ................................................................................................ 20-715 M- 8 Abnormality in front working lamp. .......................................................................................... a) Neither monitor display nor front working lamp light up.. ............................................. .20-715 b) Working lamp lights up but monitor display does not light up.. ................................... .20-715 c) Monitor display lights up but front working lamp does not light up ............................ M- 9 Abnormality in rear working lamp ............................................................................................ a) Neither monitor display nor rear working lamp light up.. .............................................. b) Rear working lamp lights up but monitor display does not light up ............................ c) 20-715 20-717 .20-717
20-717 Monitor display lights up but working lamp does not light up ..................................... .20-717 20-719 M-10 Abnormality in transmission cut-off.. ........................................................................................
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is

not switched and display does not change . ... ................ .. .. .......... ...... .. .............. .............. . 20-719 b) c) d) e) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out but cut-off function is actuated when pedal is depressed .. .. ............ ....._...... 20-719 When monitor display is turned off (transmission cut-off switch turned OFF), cut-off function is always actuated ... ....... ...... .. ................ ... ..................... ........................... 20-719 Cut-off function is always actuated regardless of monitor display (transmission cut-off switch ON or OFF) .... .. ... .. ................. ............ ...... .............................. 20-719
Monitor display lights up (transmission cut-off switch turned ON), but cut-off function is not actuated .... ............. ...........**..*.................***............................... 20-720 M-l 1 Abnormality in emergency steering normal display ............................................................... 20-721 Emergency steering normal display does not light up ........................................................... 20-721 M-12 Abnormality a) b) in emergency steering actuation display ........................................................... Emergency steering actuation display does not light up ................................................. 20-722 20-722 .20-722
Emergency steering actuation display stays lighted up ..................................................
WA1 200-3
20-701 0
M-13 Abnormality a)
in parking brake dragging warning .....................................................................
20-723 20-723
When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even when directional lever is at 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 .................. 20-723 M-14 Abnormality in parking brake dragging warning (When joystick steering mode). ............. 20-725 a) When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even when directional lever is at N ........................................... 20-725 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 .................. 20-725 M-15 When parking brake dragging warning is given, buzzer and CAUTION lamp are actuated continuously, or they are not actuated .............................................................. a) Actuated continuously .......................................................................................................... Not actuated .......................................................................................................................... M-16 Abnormality in buzzer.. ............................................................................................................... b) a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check) ................................................................................................................. 20-727 20-727 20-727 20-728 20-728
20-728 b) Buzzer always sounds .......................................................................................................... Condition of monitor switches is not stored in memory.. ..................................................... -20-730 M-18 Service meter does not advance or advances while engine is stopped .............................. 20-731 20-731 a) Service meter does not advance.. ....................................................................................... .20-731 b) Service meter advances while engine is stopped ............................................................ 20-732 M-19 Buzzer is not made to sound by transmission controller ....................................................... M-17 M-20 Abnormality a) b) M-21 in auto-greasing system ....................................................................................... Forced greasing cannot be carried out .............................................................................. Monitor display flashes rapidly (2 times/set) .................................................................... Monitor display flashes slowly (1 time/r&. ...................................................................... 20-733 20-733 20-733 20-733 20-735
c) Failure code is not sent to main monitor (abnormality in network) .....................................
20-702 0
WA1 200-3
TROUBLESHOOTING
TROUBLE
DATA DISPLAY
TROUBLE DATA DISPLAY

1. Outline
The speedometer display on the main monitor is used to display the troubleshooting for each control system. The nature of the troubleshooting is displayed as the failure action code, failure code, and the time elapsed since failure. The signals between the main monitor and each controller are transmitted in serial through the network circuit. (Only the engine controller uses a special parallel signal.)
2.
Display
of failure
action code
This code informs the operator directly of the abnormality, and takes action, such as stopping the machine immediately. There are three types of action code: EOO,EOI + CALL (EOI and CALL are displayed alternately), and CALL. If a failure occurs suddenly, one of these codes is shown on the speedometer displaysince failure
ExamPle:When
action
code
CALL
is
I f
SPEED
3.
Failure code and time
elapsed
The failures detected by each controller are changed to a code and displayed. It is possible to tell from this code which system in which controller has failed, so carry out troubleshooting for the applicable controller. For failure that have occurred and been reset, the failure code and the time elapsed since failure are displayed to make it easy to check failures that are not occurring at present. The failure codes for failures that are now occurring flash, and the codes for failures that are not occurring light up. For details of the method of operating and transferring data to the trouble data display mode, see STRUCTURE AND FUNCTION for the main monitor. Note: If the engine is not stopped, it is impossible to switch to the trouble data display mode, so the codes for failures which can only be detected when the engine is operating light up.
4. Failure codes list See Introduction
TDW01377
code failure ExamDle:When before 27 hours occurred Failure
41has code
I /
/
SPEED /\
TOW01378
of Troubleshooting.
WA1 200-3
20-703 0
TROUBLESHOOTING
FOR MAIN MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM SYSTEM
FOR MAIN
MONITOR
20-704 0
WA1 200-3
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR MAIN MONITOR SYSTEM
l-l-%
-~~-~~-~~-_~-~~-_________=
z z
z
0
WA1 200-3
TROUBLESHOOTING
M-l
M-l Ir
*
Main monitor
does not work
YES
1 Is voltage between LO5 ll), (2) - (3) normal? *20-30V * Turn starting switch ON. -
Defective main monitor Defective contact or disconnection in wiring harness between LO5 (female) (1). (2) and FS2 (female) (9) Defective contact or disconnection in wiring harness between LO5 (female) (3) - JL5 (2). (8) and LR7 (male) (4)
Replace
.
NO
2
Is resisance between LO5
(female) (31 and chassis ground -
YES
Repair or replace
normal7 -Turn starting switch OFF. * Disconnect L05. * Max. 1 R NO
Repair or replace
M-l
Related
electrical
circuit diagram
Bat tery~Battery/A~
Bat terv relay
/I
TJW02506
20-706 0
WA1 200-3
TROUBLESHOOTING
M-2
M-2
When starting switch is turned ON (within 3 seconds) and engine is started (PRE-LUBE) immediately, all lamps stay lighted up
* *
check that all the reBefore carrying out troubleshooting, inserted. ,lated connectors are properly connectors before going Always connect any disconnected on to the next step.
1
1
I
Defective PRE-LUBE HOLD relay (L114) Replace
YES I
If L114 is replaced, do lamps operate normally? * Turn starting L switch OFF. NO * Replace Ll14 with normal relay of same type. * Turn starting switch ON.
When
2YEs engine is tined, is voltage between LO5 14) and chassisground normal? NO
Defective main monitor Disconnection or defective contact in wiring harness between LO5 (female) (4) - JL15 (4). (3) - SJ2 (female) (3) - L57 (female) (1)
Replace
.20-30V Start engine.

l
Repair or replace
M-2
Related
electrical
circuit diagram
fl
ml
Starting
switch
PRE-LUBE indicator (orange)
-1 1
swIt,ch
;;;;;;;g
PRE-LUBE
re I ay WA1 200-3
hold
relay
Neutral relay
a
Rear
ENG
frame
TJW02507
20-707 0
TROUBLESHOOTING
M-3
M-3 *
* * *
Speedometer
display does not work properly
When error code is not displayed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that the gap between the speed sensor and gear is normal.
Cause
Remedy
1 YES Is resistance between LO7 (female) (1) - (2) normal? .500-lktl -Turn starting switch OFF. * Disconnect L07.
Defective main monitor Defective contact or disconnection in wiring harness between LO7 (female) (1). (2) -115 (11, (2) (female)
Replace
NO
Repair or replace
M-3
Work controller
ewiment
128 hl4016)
Modulated
clutch
Transmission
Main
monitor
TXW02453
20-708 0
WA1 200-3
TROUBLESHOOTING
M-4
M-4
+ Ir * Ir + a)
Abnormality
in shift indicator
inserted.
Check that error code is not displayed. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step. Check that the transmission shifts. The steering system must be in the steering wheel mode. Displays N even when directional lever is at F Cause
1 YES Is voltage between LO8 (7) and chassis ground normal? NO -2O-30V * Turn starting switch ON. * Directional lever: F
Defective main monitor Defective contact or disconnection in wiring harness between LO8 (female) (7) and JSl (female) (2)
Repair or replace
bl
Displays
N even when
directional
lever is at R Cause Remedy
1 YES Is voltage between LO8 63) and chassis ground normal? NO *20-30V Turn starting switch ON. * Directional lever: R
l
Defective main monitor Defective contact or disconnection in wiring harness between LO8 (female) (8) and JSl (female) (4)
Replace
Repair or replace
WA1 200-3
20-709 0
TROUBLESHOOTING
M-4
c)
Does not display
N even when
FNR (Forward-Reverse)
switch
is set in N.
1 YES Is voltage between LO8 (7) or (8) and chassis ground normal? NO - Max. 1 V * Turn starting switch ON. * Set FNR (ForwardReverse) switch in N.
Defective main monitor Short circuit with power source in wiring harness between LO8 (female) (7) and JSl (female) (2) or harness between LO8 [female) (8) and JSl (female) (4)
Repair or replace
d)
Does not display
F even when
switch
is set in F.
Cause
Remedy
YES
Defective main monitor
Is voltage betvveen LO8 (female) (7) and chassis ground normal?
Replace
I
Defective contact or disconnection in wiring harness between LO8 (female) (7) - JL16 (4). (3) and JSl (female) (2) Repair or replace
NO *20-30V * Turn starting switch ON. . Set FNR (FotwardReverse) switch in F.
e)
Does not display
R even when
switch
is set in R.
1
Is voltagebetween LO8 (female) (8) and chassis ground normal? *20-30V Turn starting switch ON. * Set FNR (ForwarcfReverse) switch in R.
l
Replace
Repair or
20-710 0
WA1 200-3
TROUBLESHOOTING
M-4
M-4

JLl8 (DT2l
Transmissi controller D n d-l
on
JL16 (DT2)
TJWO2508
WA1 200-3
20-711 0
TROUBLESHOOTING
M-5
M-5
* * *
Turn signal display does not light up
check that all the related connectors are properly inserted. Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. check that the lamp bulb of the turn signal indicator on the Before starting troubleshooting, blown. monitor is not T L.H. turn signal display does not light up Cause Remedy
al
1 YES Is voltage between LO6 (14) and chassis 1ground normal? NO * Repeats 0 V and 20-30V. * Turn starting switch ON. -Turn L.H. turn signal ON.
Defective main monitor Defective contact or disconnection in wiring harness between LO6 (female) (14) and L144 (male) (1)
Replace
Repair or replace
Cause b1 R.H. turn signal display does not light up
Remedy
1 YES
Is voltage between LO6 (15) and chassis ground normal? NO -RepeatsOVand 20-30v. *Turn starting switch ON. * Turn R.H. turn signal ON.
Defective main monitor Defective contact or disconnection in wiring harness between LO6 (female) (15) and L142 (male) (1)
Replace
Repair or replace
M-5
Related
electrical
circuit
diagram R. H. turn signal I amp(25W) L. H. turn

signal
I amp (25W)
F20
TJW02509
20-712 0
WA1 ZOO-3
TROUBLESHOOTING
M-6
M-6
* * al
Abnormality
in parking display
Before carwing out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Parking lamp display does not light up Cause
3 YES Is resistance
YES .B r between T18 (female) (2) and -
Defective main monitor Defective contact or disconnection in wiring harness between T18 (female) (2) - JMl (21, (7) and chassis ground Defectivecontact or disconnectionin wiring
harness between LO6 (fernale)(FR2ill)-RT2 (N) and T18 (female) (1)
Replace
L.
1gyfrl9rchc 1R * Turn starting switch OFF. - Disconnect Tl8. NO
11 NO
Is voltage between LO6 (11) and chassis 1 ground normal? _ P Is resistance -2O-30V between T18 - * Turn starting (male) (1) and (2) switch ON. normal? * Turn parking switch ON. * Max. 1 R NO * Disconnect T18. *Turn starting switch ON. * Turn parking switch ON.
YES
- Max.
Repair or replace
Repair or replace
Defective parking brake indicator switch
Replace
b)
Parking
lamp display stays lighted
up
Cause
Remedy
2
Is voltage YE ; between T18 (1) and chassis 1 1ground normal?
I-
YES
Defective main monitor Short circuit with power source in harness between LO6 (female) Ill)-FR2(11)-RT2(N) T18 (female) (1) Defective parking brake indicator switch
Replace
11
I ,
(male) (1) and (2) - Min. 1 MD * Disconnect T18. * Turn starting switch ON. * Turn parking switch OFF.
NO *o-2v -Turn starting switch ON. * Turn parking switch OFF.
Repair or replace
Replace
M-6
Related Ma i n
electrical
circuit diagram
RT2 (HO-85086)
Parking brake indicator
Tl
TJW02510
WA1 200-3
20-713 0
TROUBLESHOOTING
M-7
M-7
* * * *
Night lighting
does not light up
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Before starting troubleshooting, check that the lamp bulbs are not blown. 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 LO5 (female) (16).
1 YES I Is valtaae between LO5 (16) and chassis ground normal? *20-3ov * Turn starting switch ON. * Turn small lamp switch ON.
Defective main monitor Defective contact or disconnection in wiring harness between LO5 (female) (16) and FSZ (female) (5)
NO
Repair or replace
M-7
Related
Main
electrical
circuit diagram
monitor
LO5 (04020)
0.5fY
Small lamp relay
1 25fP :___
LR1 (HD-QKnRfi,
k /, 1
IIIIIII
n i
I0
asp
R.H. clearance
04 I 25fP .,A.', lL,D
nCIs,
JHDIDTI)
rance
(5W)
G14
TJW02511
20-714 0
WA1 ZOO-3
TROUBLESHOOTING
M-8
M-8
* * * al
Abnormality
in front working
lamp
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Before starting troubleshooting, check that the monitor lighting is lighted up.
Neither monitor display nor front working lamp light up Cause
Defective contact or disconnsction in wiring harness between L60 (female) (1) - LO5 (female) 117). L75 (female) (5). CL6 (female) (1) YES Defective front working lamp relay
Remedy
YES
Repair or replace
Replace
between L60 (1)
1
NO 4 .20-30V * Turn starting switch ON.
YE S
between L66 (6) Defective main monitor between LO6 (1) Defective contact or disconnection in wiring harness between LO6 (female) (1) and L60 (female) (6) Defective contact or disconnection in wiring harness between L60 (female) (21, (4), (5) and FS5 (female) (1) Replace
Max. 1 V -Turn starting switch ON.

l
2 Is voltage between L60 f2), (4), (5) and chassis ground normal?
1
l
Max. 1 V
switch ON.
l20-30V
* Turn starting switch ON.
Repair or replace
Repair or replace
b)
Working lamp lights up but monitor display does not light up
3
Is voltage
between LO5 (17) and chassis ground normal? *20-30V + Turn starting switch ON. NO
Replace
Defective contact or disconnection in wiring harness between LO5 (female) (17) and L60 (female) (1)
Repair or replace
c)
Monitor display lights up but front working lamp does not light up
WA1 200-3
20-715 0
TROUBLESHOOTING
M-8
M-8
Related Ma i n In onito
electrical
circuit
diagram
Fuse (II,
eht I amp eft amp
j
FL1 (HD-26066)
I.25fBr
I. 25fY I I
a
FZO
!34
L60
L61
Front working lam0 relay
Rear working I amp relay
Front working lamp relay
D
5
lamp (R. H. 1
I amp
ine
--
(L. H. )
Working I amp
TJW02512
20-716 0
WA1 200-3
TROUBLESHOOTING
M-9
M-9
* * * a)
Abnormality
in rear working lamp

inserted.
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step. Before starting troubleshooting, check that the monitor lighting is lighted up. Neither monitor display nor rear working lamp light up
CaUSe
Defective contact or disconnection in wiring harness between L61 (female) (1) - LO5 (female) (18). LRI (female) (13)
Remedy
Repair or replace
YES 3 between L61 (I
I Defective rear working lamp relay
Replace
)
YES
*20-30V *Turn starting switch ON.
2
l
Is voltage between L61 (6) and chassis ground normal? * Max. 1 V Turn starting switch ON.
- Is voltage between LO6 (2) NO and chassis ground normal? *Max.lV -Turn starting switch ON.
4YES -
Defective main monitor Defective contact or disconnection in wiring harness between LO6 (female) (2) and L61 (female) (6) Defective contact or disconnection in wiring harness between L61 (female) (2). (41, (5) and FS5 (female) (2)
Replace
NO
Repair or replace
l20-30V
* Turn starting switch ON. NO
Repair or replace
b)
Rear working
lamp lights up but monitor display does not light up

CaUSe
Remedy
I YES Is voltage between LO5 (18) and chassis ground normal? .20-30v - Turn starting switch ON. NO
Defective main monitor Defective contact or disconnection in wiring harness between LO5 (female) (18) and L61 (female) (1)
Replace
Repair or replace
cl
Monitor display lights up but rear working lamp does not light up
I
.
Glse
Defective contact or disconnection in wiring harness between L61 (female) (1) - GO3 (female) (1). GO7 (female) ULor L61 (female) (3) - GO2 (female) (1). GO8 (female) Cl), or blown working lamp bulb
Remedy
Repair or
WA1 200-3
20-717 0
TROUBLESHOOTING
M-9
M-9

Main
monito r
Fuse (II) I-88-b
7
L
aht iamp eft lamp
LRI MD-95086)
FLItHO-26066)
Im
lr
Y 0
i 34
i
L60 worixlna lamp relay L61 worklna lamp relay
L75
a
lamp (R. H. ) lamp
c
0
Front *
Rear
worklna IamP relay
Front
Worki ne It
k
(L. H. )
lamp
TJWO2512
20-718 0
WA1 200-3
TROUBLESHOOTING
M-10
M-l 0 Abnormality
* * a)
in transmission
cut-off
inserted.
check that all the related connectors are properly Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. When monitor switch (transmission cut-off switch) is pressed, cut-off function is not switched and display does not change Cause
Remedy
Replace
bl
cut-off switch) is OFF, When monitor switch (transmission monitor display goes out but cut-off function is actuated when pedal is depressed
disconnection in wiring harness between L66 (female) (3) - C3A (female) (10) and M02A (female) (11) Defective main monitor NO Repair or replace
between LO6 (3) and chassis ground normal? *MaxlV * Turn starting switch ON. * Disconnect L12.
Replace
cl
When monitor display is turned off (transmission cut-off switch turned OFF), cut-off function is always actuated
CaUSt2
2
(female) (2)and
YES
Defective contact or disconnection in wiring harness between L12 (female) (1) and C3A (female) (10) Defective contact or disconnection in wiring harness between L12 (female) (2) and chassis ground Defective transmission cut-off switch
Repair or replace
Repair or replace
*Max.152 * Turn starting switch OFF. + Disconnect L12.
switch OFF.* Disconnect L12. NO
Replace
dl
Cut-off function is always actuated regardless of monitor cut-off switch ON or OFF) display (transmission
1 YES
Is voltage between C3A (10) and chassis ground normal? WMaxlV NO
Defective transmission controller Defective contact or disconnection in wiring harness between C3A (female) (10) and LO6 (female) (3). L12 (female) (1)
Replace
Repair or replace
WA1 200-3
20-719 0
TROUBLESHOOTING
M-10
e)
Monitor display ON), but cut-off
lights up (transmission cut-off switch function is not actuated
turned
Cause
Remedy
Defective transmission cut-off switch
Replace
function work r) disconnected? * Disconnect L12. -Turn starting switch ON. N
YES
1Does
cut-off
II
Defective transmission controller Short circuit with chassis ground in harness

- Disconnect L12. . Turn starting switch ON. *20-30V
Replace
NO
between LO6 (female) (3) - M02A (female) (1 l), C3A (female) (10) and L12 (female) (1)
Repair or
M-10
Related
Madulated controloer
electrical
clutch
circuit diagram
Main monitor
H02A (040201
LO6 (040
16)
Transmission
controller
Transmission cut-off switch (OPEN at left

brake dePressed)
TJW02513
20-720 0
WA1 200-3
TROUBLESHOOTING
M-l 1
M-II *
*
Abnormality
in emergency steering
normal display
inserted.
check that all the related connectors are properly Before carrying out troubleshooting, before going on to the next step. connectors Always connect any disconnected steering normal display does not light up
Emergency
*
1 YES Is voltage between LO5 (10) and chassis ground normal? *20-30V - Turn starting switch ON. NO Defective main monitor Replace
Defective contact or disconnection in wiring harness between LO5 (female) (10) -chassis
Repair or replace
M-l 1 Related
electrical
circuit
diagram
Main LR2 (HD-85086)
TJW02514
WA1 200-3
20-721 0
TROUBLESHOOTING
M-12
M-12
* *
Abnormality
in emergency
steering
actuation
display
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always co&e6t any disconnected connectors before going on to the next step. Emergency steering actuation display does not light up ICause
al
Remedy
2
Is resistance YES between LO5 , r Wemale)(11) and
YES
(male) (1) and Rll
* Min. 1 MS2 NO -Turn starting switch OFF. * Disconnect LO5 and R12.
Short circuit with chassis ground in harness between Lo5 (female) (11) and Rll (female) (1) Defective emergency steering indicator switch
Repair or replace
* Turn
l
* Min. 1 MD starting switch ON. Disconnect Rll, R12.
I
NO
b1 Emergency steering actuation display stays lighted up
2 YES
Is voltage YES between LO5 (11) _ 1 r and chassis
(male) (2) normal?

I.
-Max.lR - Start engine. - Disconnect Rll, R12.
I
l
Defective contact or disconnection in wiring harness between LO5 (female) (11) and chassis ground Defective emergency steering indicator switch
Repair or replace
Replace
NO
M-12
Main
l-h?
R20
TJW02514
20-722 0
WA1 200-3
TROUBLESHOOTING
M-13
M-13
* *
Abnormality
in parking brake dragging
warning
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. and CAUTION lamp flashes even
al When parking brake is applied, buzzer sounds (intermittently)

when directional lever is at N
F
Is voltage between LO5 (female) (8) and chassis ground normal? NO *20-30V * Turn starting switch ON. * Directional lever: N
Cause
Remedy
Defective main monitor Defective contact or disconnection in wiring harness between LO5 (female) (8) - JSl (female) (3)
Replace
Repair or replace
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 Ir Check that the synchronous flash is normal.
CaUSe
Remedy
YES
Is voltage between LO5 (female) (8)
Defective main monitor Short circuit with power supply in wiring harness between LO5 (female) (8) - JSl (female) (3). or defective directional lever Defective main monitor NO
Replace
2
II
YES
Repair or replace
switch ON. * Directional lever: Other than N
I
*3kQ-4k,s2 . Turn starting switch OFF. * Disconnect LO5
Replace
WA1 200-3
20-723 0
TROUBLESHOOTING
M-13
M-13
JSl LsWP12)
Joust ick lever switch
TJW02515
20-724 0
WA1 200-3
TROUBLESHOOTING
M-14
M-14
Abnormality in parking brake dragging warning steering mode)
(When joystick
* *
a1
When parking brake is applied, when directional lever is at N buzzer sounds (intermittently) and CAUTION lamp flashes even
:
1 YES Is S-NET has any trouble? Defective main monitor *20-30V *Turn starting switch ON. *Joystick lever switch: N NO Repair or replace See troubleshooting of transmission controller system CTmode)
bl
When parking brake is applied, buzzer does not sound and CAUTION when directional lever is at position other than N *
lamp does not light up even
Check that the synchronous flash is normal.
Remedy
1 YES Is S-NET has any trouble?
See troubleshooting of transmission controller system CT mode)
Repair or replace
Defective main monitor * Max. 1 V *Turn starting switch ON. * Joystick lever switch: F or R NO
Replace
WA1 200-3
20-725 0
TROUBLESHOOTING
M-14
M-14 Related electrical circuit diagram
VHMS controller
a a
Work esuipment controller
Transm ission contra I ler I
Main monitor
Jovst lever
ck switch
_I
JLI
5 (IIT
I 1:
TJW02516
20-726 0
WA1 200-3
TROUBLESHOOTING
M-15
M-15 f
-k
a)
When parking brake dragging warning is given, buzzer and CAUTION lamp are actuated continuously, or they are not actuated
Actuated continuously Cause Remedy
YES 1 Does buzzer stop and lamp go out? *Turn starting switch ON. * Connect LO7 (male) (6) to chassis ground. Does buzzer stop and lamp go out? *Turn starting switch ON. - Connect Vl (female) (13) to chassis ground. NO
Replace
Defective VHMS controller NO Defective contact or disconnection in wiring harness between LO7 (female) (6) and Vl (female) (13)
Replace
Repair or replace
b)
Not actuated
Cause
Remedy
- IIefective
main monitor
Replace
Defective VHMS controller Short circuit with power source in harness between LO7 (female) (6) and Vl (female) (13)
Replace
-Turn starting switch ON. * Disconnect Vl
NO
Repair or replace
M-15
Related
electrical
circuit diagram
VHMS
Main
TJW02517
WA1 200-3
20-727 0
TROUBLESHOOTING
M-16
M-16
* +
a)
Abnormalrty
in buzzer
Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)
cause
Defective contact or disconnection in wiring harness between LO6 (female) (8) and L43 (male) (1) Does buzzer sound? * Turn starting switch ON. * Contact L43 (female) to chassis ground. 2 YES Is voltage between L42 (female) (1) and chassis ground nonnat? *20-30V Turn starting switch ON. NO Defective buzzer Defective contact or disconnection in wiring harness between L42 (female) (1) and FS2 (female) (9)
Remedy
Repair or replace
Replace
NO
Repair or replace
b1 Buzzer always sounds

CaUSe
Remedy
YES 1 If LO6 is II
Defective caution buzzer relay
Replace
3 * Turn starting switch OFF. * Disconnect L99. If L89 is
Defective emergency parking brake reset switch
Replace
I
Defective buzzer Short circuit with chassis ground in wiring harness between L43 (male) (1) LO6 (female) (8) - I_89 (female) (3) - L99 (female) (female) (3)
. Min. 1 MR. * Turn starting switch OFF. * Disconnect L06, L89, L99, and . L43.
NI
Repair or replace
20-728 0
WA1 200-3
TROUBLESHOOTING
M-16
M-16
Related
electrical
circuit diagram
Emergency Darkins brake cancel switch
Main
monitor
LO6
(04016) 8 0.5fL
Buzzer OUTPUT 124A VHMS
I-#7
TJW02518
WA1 200-3
20-729 0
TROUBLESHOOTING
M-17
M-17 Condition *
* Before carrying Always connect
of monitor
switches is not stored in memory

inserted.
check that all the related connectors are properly out troubleshooting, connectors before going on to the next step. any.disconnected
cause
Remedy
1 YES Is voltage
between LO7 (10) and chassis ground normal? *20-30V * T&n starting switch ON. NO
Defective main monitor Defective contact or disconnection in wiring harnessbetweenL07 (female) (10) and LO9 (female) (2)
Replace
Repair or replace
M-17
Related electrical circuit diagram Battery relay monitor

Starting
Main
LO7 (04012) switch 66AC 10 0.5fY -
R03 (DT2)
JR3 (DTl)
Start
ina
switch
R20
TJW02519
20-730 0
WA1 200-3
TROUBLESHOOTING
M-18
M-18 *
* a)
Service meter does not advance or advances while engine is stopped

inserted.
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step. Service meter does not advance
1 YES Is voltage between LO5 (5) and chassis ground normal? *20-30V * Start engine. NO
Defective main monitor Defective contact or disconnection in wiring harness between LO5 (female) (5) -alternator terminal L, or defective alternator
Replace
Repair or replace
b1
Service
meter
advances
while
engine
is stopped
I
1 YES Is voltage between LO5 (5) and chassis ground normal? *o-5v * Turn starting switch ON. NO
Cause
Remedy
Defective main monitor Short circuit with power source in wiring harness between LO5 (female) (5) -alternator terminal L, or defective alternator
Replace
Repair or replace
M-18
Related
electrical
circuit diagram
Alternator
psg~
TJW02520
WA1 200-3
20-73 1
TROUBLESHOOTING
M-20
M-20
* *
a)
Abnormality
in auto-greasing
system
inserted.
check that all the related connectors are properly Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. Forced greasing cannot be carried out Cause
Remedy
2
YES
YES
1
Is voltage between LO6 (5) and chassis ground normal? *Max.3V Turn starting switch ON. * Turn auto-greasing switch ON.
l
mvoitage_ between GREl (1) and chassis ground normal? NO * Turn starting switch ON. *Turn auto-greasing switch ON. . Max. 3 V
See Handling autcgreasing system in Operation and Maintenance Manual Defective contact or disconnection in wiring harness between LO6 (female) (5) and GREl (female) (1) Defective main monitor
Repair or replace
Replace
NO
b1 Monitor
display flashes rapidly (2 times/set)
A
YES
1 Is voltage between LO8 (5) and chassis ground normal? Defective main monitor Defective contact or disconnection in wiring harness between LO8 (female) (5) and GREl (female) (2) See Handling autogreasing system in Operation and Maintenance Manual Replace
2 YES _ NO Is voltage
Repair or replace
l20-3ov -Turn starting switch ON.
between GREl
(2)and chassis ground normal? .20-3ov * Turn starting switch ON. -
NO
c1
Monitor Confirm
display flashes slowly (1 time/set) that grease is not empty.
Cause
Remedy
See Handling autogreasing system in Operation and Maintenance Manual
Table
1 (Relationship
between
input signal and display)
WA1 200-3
20-733 0
TROUBLESHOOTING
M-20
M-20
Related
electrical
circuit diagram
Main m
TJW025.22
20-734 0
WA1 200-3
TROUBLESHOOTING
M-21
M-21 *
Ir *
Failure code is not sent to main monitor network)
(abnormality
in
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Set dipswitch 3 at the rear of the main monitor to F.
Cause
Remedy
M-21
Related
electrical
circuit diagram
1 VHMS
coatrillle /
lort
wi PIE
Transmission
ontrol ler
TWW02601
WA1 200-3
20-735 0
TROUBLESHOOTING OF VHMS CONTROLLER SYSTEM (V MODE)
Operations of VHMS controller against abnormality and conditions of machine caused by abnormality .................................................................................................... 20-804 List of alarm items displayed on CGC monitor .................................................................................. 20-820 Electrical circuit diagram for VHMS system ....................................................................................... 20-822 V- 1 V- 2 V- 4 V- 5 V- 6 V- 7 V- 8 V- 9 V-10 V-11 V-12 V-13 V-14 V-15 V-16 V-17 V-18 V-19 V-20 V-21 V-22 V-23 V-24 V-25 [E901] (Engine oil level below LOW level) is displayed ........................................................ 20-824 [E902] (Engine oil pressure below specified pressure) is displayed ...................................20-824 [E904] (Engine coolant temperature above specified temperature) is displayed .............. 20-824 [E905] [Fuel level below specified level (before engine starts)] is displayed .................... 20-825 [E906] [Fuel level below specified level (While engine is running)] is displayed ............. 20-827 [E907] (Torque converter oil temperature above 120C) is displayed .................................20-829 [E908] (Torque converter oil temperature above 130C) is displayed .................................20-830 [E911] (Hydraulic oil temperature above 105C) is displayed .............................................. 20-831 [E912] (Low front or rear brake oil pressure) is displayed ................................................... 20-832 [E913] (Low front brake oil pressure) is displayed ................................................................ 20-834 [E915] (Low rear brake oil pressure) is displayed ................................................................. 20-836 [916] (Disconnection or short circuit with chassis ground in battery fluid level sensor 1) is displayed ............................................................................ 20-838 [917] (Disconnection or short circuit with chassis ground in battery fluid level sensor 2) is displayed ............................................................................ 20-839 [918] (Disconnection or short circuit with chassis ground in battery fluid level sensor 3) is displayed ............................................................................ 20-840 [E925] [Brake fluid level below specified level (before engine starts)] is displayed ......... 20-841 [E926] [Brake fluid level below specified level (While engine is running)] is displayed .. 20-842 [E927] [Coolant level below LOW level (before engine starts] is displayed ...................... 20-843 [E928] [Coolant level below LOW level (While engine is running)] is displayed .............. 20-844 [E931] (Clogging of transmission oil filter) is displayed ....................................................... 20-845 [E932] [Clogging of air cleaner (1)] is displayed .................................................................... 20-847 [E933] [Clogging of air cleaner (2)] is displayed .................................................................... 20-849 [E934] [Clogging of air cleaner (3)] is displayed .................................................................... 20-850 [E935] [Clogging of air cleaner (4)] is displayed .................................................................... 20-851 [E937] (Abnormal charge by alternator) is displayed ............................................................ 20-852
V-101 [E811] (Abnormality in NSW power source system) is displayed in history..................... 20-853 V-102 [E812] (Short circuit with chassis ground in 24-V circuit of sensor power supply) .......... 20-854 V-103 [E813] (Short circuit with chassis ground in 12-V circuit of sensor power supply) .......... 20-856 V-104 [E814] (Short circuit with chassis ground in 5-V circuit of sensor power supply) ............ 20-857 V-105 [E818] (Wrong connection of connector) is displayed in history ......................................... 20-858
WA1200-3
20-801
(8) 2
V-107 [E824] (Communication with CGC and engine controller is impossible) is displayed in history .............................................................................................................. 20-859 V-108 [E825] (Abnormality in S-NET communication between VHMS transmission controller) is displayed in history ............................................................................................ 20-860 V-109 [E826] (Abnormality in S-NET communication between VHMS modulated clutch controller) is displayed in history ................................................................................ 20-862 V-110 [E827] (Abnormality in S-NET communication between VHMS work equipment controller) is displayed in history ........................................................................ 20-864 V-111 [E828] (Abnormality in S-NET communication between VHMS main monitor) is displayed in history .............................................................................................................. 20-866 V-113 [E841] (Short circuit with power source in buzzer output system) is displayed in history .............................................................................................................. 20-869 V-114 [E843] (Short circuit with power source in check lamp system) is displayed in history .............................................................................................................. 20-870 V-115 [E844] (Short circuit with power source in flash synchronizing signal system) is displayed in history .............................................................................................................. 20-871 V-116 [E861] (Disconnection or short circuit with chassis ground in boom bottom pressure sensor system) is displayed in history ........................................... 20-872 V-117 [E862] (Disconnection or short circuit with chassis ground in boom head pressure sensor system) is displayed in history............................................... 20-874 V-118 [E863] (Disconnection or short circuit with chassis ground in rear brake oil pressure sensor system) is displayed in history ........................................... 20-876 V-119 [E864] (Disconnection or short circuit with chassis ground in work equipment relief pressure sensor system) is displayed in history ........................... 20-878 V-120 [E865] (Disconnection or short circuit with chassis ground in front brake oil pressure sensor system) is displayed in history .......................................... 20-880 V-121 [E866] (Disconnection or short circuit with chassis ground in transmission main relief pressure sensor system) is displayed in history ........................ 20-882 V-122 [E867] (Disconnection or short circuit with chassis ground in steering relief pressure sensor system) is displayed in history ........................................... 20-884 V-123 [E868] (Disconnection or short circuit with chassis ground in torque converter outlet oil pressure sensor system) is displayed in history .................... 20-886 V-124 [E871] (Disconnection or short circuit with chassis ground in transmission modulation pressure sensor system) is displayed in history....................... 20-888 V-125 [E872] (Disconnection or short circuit with chassis ground in transmission lubricating oil pressure sensor system) is displayed in history .................. 20-890 V-126 [E874] (Short circuit with chassis ground in torque converter oil temperature sensor system) is displayed in history ................................................................................... 20-892 V-127 [E875] (Short circuit with chassis ground and with power source in hydraulic oil temperature sensor system) is displayed in history ........................................................ 20-893 V-128 [E875] (Short circuit with chassis ground in ambient temperature sensor system) is displayed in history ................................................................................... 20-894
20-802
(8) 2
WA1200-3
v-129
IE8781 (Disconnection
or short circuit with chassis ground in .20-896
PPC relief pressure sensor system) is displayed in history ................................................ v-130 IE8841 (Disconnection or short circuit with chassis ground
in torque converter inlet oil pressure sensor system) is displayed in history.. ................ 20-898 v-201 Disconnection or short circuit with power source in 24-V system 20-900 20-902
of sensor power supply ............................................................................................................ v-202 Disconnection or short circuit with power source in 12-V system
of sensor power supply ............................................................................................................ V-203 Disconnection or short circuit with power source in 5-V system of sensor power supply ............................................................................................................ V-204 V-205 V-206 Disconnection Disconnection Disconnection
20-903
or short circuit with chassis ground in buzzer output system.. ................. 20-904 or short circuit with chassis ground in check lamp system.. ..................... 20-905 or short circuit with chassis ground in signal system .......................................................................................... 20-906
flash synchronizing V-207 V-208 v-209 v-210
Short circuit with power source in boom bottom pressure sensor system ...................... 20-907 Short circuit with power source in boom head pressure sensor system .......................... 20-908 Short circuit with power source in rear brake oil pressure sensor system.. ..................... 20-909 Short circuit with power source in front brake oil pressure sensor system ..................... 20-910 relief pressure sensor system.. ............ 20-912
v-21 1 Short circuit with power source in work equipment relief pressure sensor system.. ...... 20-911 v-212 V-213 V-214 V-215 V-216 Short circuit with power source in transmission
Short circuit with power source in steering relief pressure sensor system ...................... 20-913 Short circuit with power source in torque converter outlet oil pressure sensor system 20-914 Short circuit with power source in transmission Disconnection modulation pressure sensor system.. . 20-915
or short circuit with power source in 20-916 20-917 20-918
torque converter oil temperature sensor.. .............................................................................. V-217 V-218 v-219 v-220 v-221 v-222 V-223 V-224 V-225 V-226 Disconnection Disconnection in hydraulic oil temperature sensor system .................................................
in ambient temperature sensor system .........................................................
Short circuit with power source in PPC relief sensor system ............................................. .20-919 Short circuit with chassis ground in fuel level sensor system ............................................ 20-920
Short circuit with power source in battery fluid level sensor 1 ....................................... 20-921 Short circuit with power source in battery fluid level sensor 2 ....................................... 20-922 Short circuit with power source in battery fluid level sensor 3. ..................................... .20-923 Short circuit with chassis ground or power source in brake fluid level sensor.. ............. 20-924 Short circuit with power source in coolant level sensor ...................................................... Short circuit with chassis ground or power source in transmission oil filter clogging sensor ................................................................................... 20-926 20-925
V-227 V-228 v-229 V-230 V-231
Short circuit with power source in air cleaner clogging (I) relay system ......................... 20-927 Short circuit with power source in air cleaner clogging (2) relay system ......................... 20-928 Short circuit with power source in air cleaner clogging (3) relay system ......................... 20-928 Short circuit with power source in air cleaner clogging (4) relay system.. ....................... 20-929 Abnormal charge by alternator ............................................................................................... 20-930
WA1 200-3
20-803 0
TROUBLESHOOTING
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDlTlONS OF MACHINE CAUSED BY ABNORMALrrY
OPERATIOF IS OF VHMS CONTROLLER AGAINST ABNORMALITY AND COND TIONS OF MACHINE CAUSED BY ABNORMALITY
40. -
*
Abnormal system pv$ne oil Failure mode
List of alarm items displayed on CGC monitor: See page 20-820. I

Contents of abnormality 1) Low engine oil level 2) Abnormality related to engine controller (CENSE) * See alarm items displayed on CGC monitor 1) Low engine oil pressure 2) Abnormality related to engine controller (CENSE) + See alarm items displayed on CGC monitor 1) Engine coolant temperature above 102OC (E903) 2) Engine coolant temperature above 105X (E904) 3) Abnormality related to engine controller (CENSE) It See alarm items displayed on CGC monitor
-ailur e Action code code E901 ---
1 2 3 -
Engine oil pressure Engine coolant temperature
E902
---
--_ ___
E903 E904
Disconnection Short circuit with chassis ground Short circuit with power source Disconnection Short circuit with chassis ground Short circuit with power source Disconnection
E905 E906
---
1) Low fuel level or defective fuel level sensor 2) Disconnection or defective contact in wiring harness between V2A (female) (2) - R05 (female) (1) 3) Defective VHMS controller f See alarm items displayed on CGC monitor 1) Defective fuel level sensor 2) Short circuit with chassis ground in wiring harness between V2A (female) (2) - R05-(female) (1) 3) Defective VHMS controller 1) Low fuel level or defective fuel level sensor 2) Short circuit with power source in wiring harness between V2A (female) (2) - R05 (female) (1) 3) Defective VHMS controller + See alarm items displayed on CGC monitor 1) Defective torque converter oil temperature sensor 2) Disconnection or defective contact in wiring harness between V2A (female) (3) - T24 (female) (1) 3) Defective VHMS controller 1) Torque converter oil temperature above 120C (E907) 2) Torque converter oil temperature above 130C fE908) 3) Defective torque converter oil temoerature sensor 4) Defective VHMS controller * For E907 and E908, see alarm items displayedon CGC monitor Sensing is impossible. Sensing is impossible.
Fuel level
---
--_
E905 E906
---
___
---
Torque :onverter oil :emperature
z E874
__-
Input voltage < 0.3 v
_--
___
1) Defective torque converter oil temperature sensor 2) Short circuit with power source in wiring harness between V2A (female) (3) - T24 (female) (1) 3) Defective VHMS controller
1) Defective hydraulic oil temperature sensor 2) Disconnection or defective contact in wiring harness between V2A (female) (11) - HS (female) (1) 3) Defective VHMS controller 1) Hydraulic oil temperature above 105C (E911) 2) Defective hydraulic oil temperature sensor 3) Short circuit with chassis ground or with pcwer scurce in wiring harness between V2A (female) (11)- HSl (female) (1) 4) Defective VHMS controller * For E911, see alarm items displayed on CGC monitor 1) Defective hydraulic oil temperature sensor 2) Short circuit with power source in wiring harness between V2A (female) (11) - HSl (female) (1) 3) Defective VHMS controller 1) 2) 3) 4) Low front brake oil pressure (E912, E913) Defective front brake oil pressure sensor Defective joint connector JR14, JL2: or JR13 Disconnection or defective contact m wiring harness between Vl (female) (2) - HR15 (female) (2) 5) Disconnection or defective contact in wiring harness between V2A (female) (7) - HR 15 (female) (3) 6) Defective VHMS controller t For E912 and E913, see alarm items displayedon CGC monitor
Sensing is impossible.
_--
-__
iydraulic oil emperature
Short circuit with chassis ground Short circuit with power source
5911 f875
_--
Fg<
Tltage
E875
___
Disconnection
E912 ::z
Input voltage c 0.5 v
Brake oil pressure (F) Short circuit with chassis ground
E3 E865
__-
1) Low front brake oil pressure (E912, E913) 2) Defective front brake oil pressure sensor 3) Short circuit with chassis ground in wiring harness between Vl (female) (2) - HR15 (female) (2) 4) Short circuit with chassis ground in wiring harness between V2A (female) (7) - HR15 (female) (3) 5) Defective VHMS controller f For E912 and E913, see alarm items displayed on CGC monitor
20-804 0
WA1 200-3
TROUBLESHOOTING
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Normal condition
Alarm buzzer
Failure history Saved: Other: x
Phenomena under abnormal condition Insufficient engine oil level Cummins engine controller (CENSE) defective Low engine oil pressure or Cummins engine controller (CENSE) defective Engine coolant temp. above 105C, or Cummins engine controller (CENSE) defective Gauge keeps indicating EMPTY. Low fuel level alarm is output wrongly. Gauge keeps indicating FULL. Low fuel level alarm cannot be output. Gauge keeps indicating EMPTY. Low fuel level alarm is output wrongly. Gauge keeps indicating 25C. Alarm screen cannot be output. Gauge keeps indicating 130C. Alarm screen is output wrongly. Gauge keeps indicating 25C. Alarm screen cannot be output. Gauge keeps indicating 25C. Alarm cannot be output.
Resetting method Refill engine oil or see Cummins Service Manual. Check or see Cummins Service Manual. Check or see Cummins Service Manual.
Diagnosis code V-1
V-2
V-4
Resistance (between R05 (1) (2)) FULL (100%): 10 1/2 (50%): 32 1/4 (25%): 49.5 EMPTY (0%): 85 (Max. power consumption: 0.5 W)
V-5 V-6
V-220
V-5 V-6
Resistance (between T24 (1) (2)) Normal temperature (25C): Approx. 40 k 130C: Approx. 1.7 k
V-216
When left is not satisfied.
V-7 V-8 V-126
V-216
Resistance (between HS (1) (2)) 100C: Approx. 3.5 4.0 k 25C: Approx. 37 50 k
V-217
Gauge keeps indicating 130C. Alarm is output wrongly.
V-9 V-127
Gauge keeps indicating 25C. Alarm cannot be output.
V-127
Real-time monitor is displayed. Min. pressure is always sensed. Alarm is sensed wrongly. (Max. 0 MPa {0 kg/cm2})
V-10 V-11 V-120
Voltage (between V2A (7) (3)): 0.7 5.3 V
Real-time monitor is displayed. Min. pressure is always sensed. Alarm is sensed wrongly. (Max. 0 kg/cm2)
V-120
WA1200-3
20-805
(8) 2
TROUBLESHOOTING
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALJTY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Abnormal VO. 7 system Brake oil pressure (F)
Failure mode Short circuit with power source
Failure code ---
Action code ---
Contents
of abnormality
Abnormal condition __-
1)Shon circuit with power source in wiring harness between V2A (female) (7) - HR15 (female) (3) 2) Defective VHMS controller 1) Low rear brake oil pressure (E912, E915) 2) Defective rear brake oil pressure sensor 3) Defective joint connector JR14, JL?, or JR13 41 Disconnection or defective contact In wiring harness between Vl (female) (2) - HR16 (female) (2) 5) Disconnection or defective contact in wiring harness between V2A (female) (8) - HR 16 (female) (3) 6) Defective VHMS controller + For E912 and E915, see alarm items displayed on CGC monitor 1) Low rear brake oil pressure (E912, E915) 2) Defective rear brake oil pressure sensor 3) Short circuit with chassis ground in wiring harness between Vl (female) (2) - HR16 (female) (2) 4) Short circuit with chassis ground in wiring harness between V2A (female) (8) - HR16 (female) (3) 5) Defective VHMS controller * For E912 and E915, see alarm items displayed on CGC monitor 1) Short circuit with power source in wiring harness between WA (female) (8) - HR16 (female) (3) 2) Defective VHMS controller
Disconnection
E912 E915 E863
---
Input voltage < 0*5V
Brake oil pressure (R)
Short circuit with chassis ground
E912 Eg15 E863
- _ _
Input < o 5v voltage
Short circuit with power source Disconnection
---
---
-_-
E916
---
1)Defective battery fluid level sensor (1) or inscfricientcharge of battery 2) Disconnection or defective contact in wiring harness between WA (female) (1) - RA7 (female) (1) 3) Defective VHMS controller f See alarm items displayed on CGC monitor
1) Defective battery fluid level sensor (1) or insufficientcharge of battery 2) Short circuit with chassis ground in wiring harness between WA (female) (1) - RA7 (female) (1) 31 Defective VHMS controller + See alarm items displayed on CGC monitor 1) Short circuit with power source in wiring harness between V2B (female) (1) - RA7 (female) (1) 2) Defective VHMS controller 1) Defective battery fluid level sensor (2) or insufficientcharge of battery 2) Disconnection or defective contact in wiring harness between V2B (female) (2) - RA6 (female) (1) 3) Defective VHMS controller t See alarm items displayed on CGC monitor
6-v cel, voltage c 2 V
Battery fluid level (1)
Short circuit with chassis ground Short circuit
6-v cell voltage < 2 V
E916
- - -
with power
source Disconnection
---
---
Sensing is impossible. 6V cell < 2 V
E917
---
voltage
lo
Battery fluid level (21
Short circuit with chassis ground Short circuit
E917
- - -
1) Defective battery fluidlevelsensor(2) or insufficientcharge of battery 2) Short circuit with chassis ground in wiring harness between V2B (female) (2) - RA6 (female) (1) 3) Defective VHMS controller f See alarm items displayed on CGC monitor
1) Short circuit with power source in wiring harness between V2B (female) (2) - RA9 (female) (1) 2) Defective VHMS controller 1) Defective battery fluid level sensor (3) or insufficientcharge of bsttery 2) Disconnection or defective contact in wiring harness between V2B (female) (3) - RA9 (female) (1) 3) Defective VHMS controller * See alarm items displayed on CCC monitor
6-V cell voltage < 2 V
with power
source Disconnection
---
---
Sensing is impossible. 6-V cell voltage < 2 V
E918
---
11 Banery fluid
level (3)
Short circuit
with chassis ground Short circuit with power E918 - - -
1) Defective battery fluid level sensor (3) or insufficientcharge of battery 2) Short circuit with chassis ground in wiring harness between V2B (female) (3) - RA9 (female) (1) 3) Defective VHMS controller rt See alarm items displayed on CGC monitor
1) Short circuit with power source in wiring harness between V2B (female) (3) - RA9 (female) (1) 2) Defective VHMS controller 1) Low front brake fluid level or defsctive front brake fluid level sensor 2) Low rear brake fluid level or defective rear brake fluid level sensor 3) Disconnection or defective contact in wiring harness between V3A (female) (5) - HR6 (female) (1) 4) Disconnection or defective contact in wiring hamess between V3B (female) (5) - HRlO (female) (1) 5) Defective VHMS controller t See alarm items displayed on CGC monitor 1) Short circuit with chassis ground in wiring harness between V3A (female) (5) - HR6 (female) (1) 2) Short circuit with chassis ground in wiring harness between V3B (female) (5) - HRlO (female) (1) 3) Defective VHMS controller 1) Short circuit with power source in wiring harness between V3A (female) (5) - HR6 (female) (1) 2) Short circuit with power source in wiring harness between V3B (female) (5) - HI?10 (female) (1) 3) Defective VHMS controller
6-V cell voltage < 2 V
source
---
---
Disconnection
E925 E926
- - -
l2
Brake fluid level
- - -
- - -
Short circuit with power source
- - -
- - -
20-806 0
WA1 200-3
TROUBLESHOOTING
Condition of machine caused by abnormality --Alarm buzzer -_F$lUeist$y Other: x ---
Normal condition Joltage (between V2A :7) - (3)): 0.7 - 5.3 v
Phenomena under abnormal condition Real-time monitor is displayed. Max. pressure is always sensed. Alarm cannot be output. Real-time monitor is displayed. Min. pressure is always sensed. Alarm is sensed wrongly. (Max. 0 MPa {O kg/cm211
Resetting method - - -
Diagnosis code v-210
___
--_
v-10 v-12 V-118
Voltage (between ;;A (;)3-J3)):
. - .
--_
--_
Real-time monitor is displayed. Min. pressure is always sensed. Alarm is sensed wrongly. (Max. 0 MPa {O kg/cm% Real-time monitor is displayed. Max. pressure is always sensed. Alarm cannot be output.
V-118
v-10 v-12
--_
-_-
---
- - -
v-209
___
---
Alarm is output wrongly.
v-13
Voltage (between RA7 (1) - chassis): 5.5 - 6.5 V
-__
__-
v-13
___
__-
_-_
Alarm cannot be output.
___
v-221
_--
_-_
v-14
Voltage (between RA8 ( 1) - chassis): 5.5 - 6.5 V
---
v-14
__-
--_
---
-__
v-222
-_-
v-15
Voltage (between E (;)5-;hassrs):
. - .
_--
_-_
v-15
__-
___
---
---
V-223
_-a Voltage (between HR6 (1) - chassis, HRlO (1) - chassis) --_ ---
---
Alarm is always output (Wrong sensing). E925: Before engine is started. E926: After engine is started.
---
V-16 v-17
-__
__-
V-224
---
--_
---
---
---
V-224
WA1 200-3
20-807 0
TROUBLESHOOTING
JO.
Abnormal system
Failure mode
Failure code
Action code
Contents
of abnormality
Abnormal condition
Disconnection
ES27 E928
---
1) Coolant level below LOW or defective coolant level sensor 2) Defective joint connector JR2 or JR7 3) Disconnection or defective contact in wiring harness between V3A (female) (10) - GO6 (female) (1) 4) Defective VHMS controller * See alarm items displayed on CGC monitor 1) Defective coolant level sensor 2) Short circuit with chassis ground in wiring harness between V3A (female) (10) - GO1 (female) (1) 3) Defective VHMS controller circuit with power source in wiring harness between V3B (female) (10) - GO6 (female) (1) 2) Defective VHMS controller
13
Coolant
level
Short circuit withchassis ground Short circuit with power source -----
Sensing is impossible. Sensing is impossible.
1)Short
---
---
Disconnection 14 Differential pressure on transmission oil filter (clogging)
E931
---
1)Clogging of transmission oil filter or defective transmission oil filter sensor (ROl) 2) Cl ging of transmission oil filter or defective transmission oil filter sensor (ROZ) Sensing is 31 Dzective joint connector JR7 impossible. 4) Disconnection or defective contact in wiring harness between V3A (female) (11) - V2A (female) (1) 5) Defective VHMS controller 1)Short circuit with chassis ground in wiring harness between V3A (female) (11) - R02 (female) (1) 2) Defective VHMS controller 1) Short circuit with power source in wiring harness between V3A (female) (11) - R02 (female) (1) 2) Defective VHMS controller 1)Ciogging of air cleaner (1) or defective dust indicator (1) 2) Defective dust indicator relay (1) 3) Disconnection or defective contact in wiring harness between V3B (female) (1) - L132 (female) (6) 4) Defective VHMS controller * See alarm items displayed on CGC monitor 1) Short circuit with chassis ground in wiring harness between V36 (female) (1) - L132 (female) (6) 2) Defective VHMS controller 1) Short circuit with power source in wiring harness between V3B (female) (1) - L132 (female) (6) 2) Defective VHMS controller 1) Clogging of air cleaner (2) or defective dust indicator (2) 2) Defective dust indicator relay (2) 3) Disconnection or defective contact in wiring harness between V36 (female) (2) - L133 (female) (6) 4) Defective VHMS controller *See alam items displayed on CGC monitor 1)Short circuit with chassis ground in wiring harness between V3B (female) (2) - L133 (female) (6) 21 Defective VHMS controller 1) Short circuit with power source in wiring harness between V3B (female) (2) - L133 (female) (6) 2) Defective VHMS controller 1) Clo ging of air cleaner (3) or defective dust indicator (3) . dust indicator relay (3) 2) De 3ectlve 3) Disconnection or defective contact in wiring harness between V3B (female) (3) - L134 (female) (6) 4) Defective VHMS controller f See alarm items displayed on CGC monitor 1) Short circuit with chassis ground in wiring harness between V3B (female) (3) - L134 (female) (6) 2) Defective VHMS controller 1) Short circuit with power source in wiring harness between V3B (female) (3) - L134 (female) (6) 2) Defective VHMS controller 1) Clogging of air cleaner (4) or defective dust indicator (4) 2) Defective dust indicator relay (4) 3) Disconnection or defective contact in wiring harness between V3B (female) (4) - 1135 (female) (6) 4) Defective VHMS controller f See alarm items displayed on CGC monitor 1) Short circuit with chassis ground in wiring harness between V3B (female) (4) - L135 (female) (6) 2) Defective VHMS controller 1) Short circuit with power source in wiring harness between V3B (female) (4) - L135 (female) (6) 2) Defective VHMS controller 1) Defective alternator signal relay L152 2) Defective alternator 3) Disconnection or defective contact in wiring harness between V2A (female) (4) - L152 (female) (6) 4) Defective VHMS controller * See alarm items displayed on CGC monitor 1) Short circuit with chassis ground in wiring harness between V2A (female) (4) - L152 (female) (6) 2) Defective VHMS controller 1)Short circuit with power source in wiring harness between V2A (female) (4) - L152 (female) (61 - El4 (female) (2). El5 (female) (2) 2) Defective VHMS controller Sensing is impossible. Sensing is impossible.
- --
---
---
---
Disconnection !5 Clogging of air cleaner (1)
E932
---
Short circuit withchassis ground
Sensing
is
---
---
impossible. Sensing is impossible.
with power
source
Short circuit -----
Disconnection 6 C!ogging of air cleaner (2)
E933
---
Short circuit withchassis ground Short circuit with power source
---
---
Sensing is impossible. Sensing is impossible.
---
---
Disconnection ,, Clogging of air cleaner (3)
ES34
---
Sensing
is
---
---
---
---
Disconnection ,8 Clogging of air cleaner (4)
E935
---
Sensing
is
---
- --
---
---
Disconnection 9 Alternator terminal R voltage
E937
---
_ _ _
---
---
___
---
---
- - -
20-808 0
WA1 200-3
TROUBLESHOOTING
Alarm buzzer F$keekt$y Other: x Phenomena under abnormal condition Low coolant level alarm is output (E928 is sensed wrongly). Resetting method Diagnos, code
Normal condition
_-Voltage (between V3A (IO) - (9)) Coolant level normal: Max. 1 V Coolant level insufficient: 17 - 30 V
---
-__
---
V-18 v-19
-_-
___
---
Low coolant level alarm is not output. ---
-_-
---
-_-
--_
---
_--
v-225
--Voltage (between V3A (11) - (9)) Filter normal: Max. 1 V Filter clogged: 17 - 30 V
_--
--_
Clogging alarm is output (E931 is sensed wrongly).
---
v-20
-----
-----
---_-
Low coolant level alarm is not output. -__
__ _
V-226 V-226
-__
_-_
---
_--
$I;;:)
is output wrongly
---
v-21
Voltage (between
V3B (1) - chassis) Filter normal: Max. 1 V Filter clogged: 17 - 30 V ----- ---_ --Alarm cannot be sensed. ___ -__ --_
---
-__
V-227
--Joltage (between J3B (2) - chassis) :ilter normal: Max. 1 V ilter clogged: 17 - 30 V
___
---
;:;;Tj is output wrongly
-_-
v-22
-----
----_
--_--
Alarm cannot be sensed. ___
--_ _-_
-__
V-228
--Voltage (between V3B (3) - chassis) Filter normal: Max. 1 V Filter clogged: 17 - 30 V
---
---
t;;yj
is output wrongly
-_-
V-23
---_-
----_
---__
Alarm cannot be sensed. ---
_----
_--
v-229
_-Voltage (between V3B (4) - chassis) Filter normal: Max. 1 V Filterclogged: 17-30V
---
__-
g;;;j
is output wrongly
-_-
V-24
--_--
----_
--___
Alarm cannot be sensed. _--
-__ -_-
___
V-230
rVhen generating: 24 V Criterion Min. 9.3 V (While Pngine is running and generating) Vlax. 9.3 V (While sngine is stopped)
---
---
---
Abnormal charge level alarm is output wrongly. (E937)
___
v-25
--_
___
--___
_-_--
Abnormal charge level alarm is output wrongly. (E937) Misjudgment ismade while engine is running. Engine stop alarm may te sensed wrongly while engine is running.
___
V-231 ___
-__
--
WA1 200-3
20-809 0
--_
TROUBLESHOOTING
No.
Abnormal system
Failure mode Disconnection
Failure Action code code E811 E811
1) Disconnection or defective contact in wiring harness between V1 (female) (6) FS3 (5) Fuse FS3 (6) battery relay terminal B battery (+) 2) Defective VHMS controller 1) Short circuit with chassis ground in wiring harness between V1 (female) (6), (7) Fuse I (13) 2) Defective VHMS controller 1) Short circuit with power source in wiring harness between V1 (female) (6) FS3 (5) Fuse FS3 (6) battery relay terminal B battery (+) 2) Defective VHMS controller 1) Disconnection or defective contact in wiring harness between V1 (female) (2) MT1, 2, 3, 4, 5 (female) (2) or between V1 (female) (2) HR15, 16 (female) (2), HS2, 3, 4 (female) (2) 2) Defective VHMS controller
Abnormal condition Below 12 V Sensing is impossible. Above 40 V Sensing is impossible.
NSW power 20 source (+24 V) (Battery)
Short circuit with chassis ground Short circuit with power source Disconnection
21
24-V output of sensor power source
E812
1) Defective transmission main relief pressure sensor, torque converter outlet oil pressure sensor, torque converter inlet pressure sensor, transmission modulation pressure sensor, front brake pressure sensor, rear brake pressure sensor, work equipment relief pressure sensor, steering relief pressure sensor, or PPC pressure sensor 2) Defective joint connector JT2, JR14, or JL2 3) Short circuit with chassis ground in wiring harness between JT2 (female) (2), (3), (4), (5) MT5 (female) (2), MT4 (female) (2), MT3 (female) (2), MT2 (female) (2) 4) Short circuit with chassis ground in wiring harness between JR14 Voltage is below 14 V (female) (2), (3), (4), (5), (6) HS4 (female) (2), HS2 (female) (2), HS3 (female) (2), HR16 (female) (2), HR15 (female) (2) 5) Short circuit with chassis ground in wiring harness between JL2 (female) (4) JT2 (female) (1) or between JL2 (female) (5) JR14 (female) (1) 6) Short circuit with chassis ground in wiring harness between V1 (female) (2) JL2 (female) (3) 7) Defective VHMS controller 1) Short circuit with power source in wiring harness between V1 (female) (2) MT1, 2, 3, 4, 5 (female) (2) or between V1 (female) (2) HR15, 16 (female) (2), HS2, 3, 4 (female) (2) 2) Defective VHMS controller 1) Disconnection or defective contact in wiring harness between V1 (female) (3) F15 (female) (1) 2) Defective VHMS controller 1) Defective wheel rotation sensor 2) Short circuit with chassis ground in wiring harness between V1 (female) (3) F15 (female) (1) 3) Defective VHMS controller 1) Short circuit with power source in wiring harness between V1 (female) (3) F15 (female) (1) 2) Defective VHMS controller
Short circuit with power source Disconnection 22 12-V output of sensor power source Short circuit with chassis ground Short circuit with power source Disconnection
Sensing is impossible. Sensing is impossible. Voltage is below 7 V Sensing is impossible.
E813
1) Disconnection or defective contact in wiring harness between V1 (female) (4) RES3 (female) (1) Sensing is 2) Disconnection or defective contact in wiring harness impossible. between V1 (female) (5) MT1 (female) (2) 3) Defective VHMS controller 1) Defective transmission lubricating oil pressure sensor 2) Defective fuel level sensor 3) Short circuit with chassis ground in wiring harness between V1 (female) (5) MT1 (female) (2) 4) Short circuit with chassis ground in wiring harness between V1 (female) (4) RES3 (female) (1) 5) Defective VHMS controller 1) Short circuit with power source in wiring harness between V1 (female) (4) RES3 (female) (1) 2) Short circuit with power source in wiring harness between V1 (female) (5) MT1 (female) (2) 3) Defective VHMS controller 1) Disconnection or defective contact in wiring harness between V2A (female) (12), V3A (female) (9) chassis ground 2) Defective VHMS controller 1) Short circuit with chassis ground in wiring harness between V2A (female) (9) V3B (female) (12) 2) Defective VHMS controller 1) Short circuit with power source in wiring harness between V2A (female) (12), V3A (female) (9) chassis ground 2) Defective VHMS controller 1) Disconnection, short circuit with chassis ground, or short circuit in wiring harness between V2A (female) (9), (12), V3A (female) (9), V3B (female) (12) chassis ground 2) Defective VHMS controller 1) Defective joint connector JL1 2) Disconnection or defective contact in wiring harness between V4A (female) (6) D1 (female) (G), C2 (female) (A) 3) Disconnection or defective contact in wiring harness between V4A (female) (14) D1 (female) (H), C2 (female) (B) 4) Defective CGC, engine controller, or VHMS controller
23
5-V output of Short circuit sensor power with chassis ground source
E814
Voltage is below 3.4 V
Short circuit with power source Disconnection Short circuit with chassis ground Short circuit with power source Wrong connection of connector
24
Wrong connection of connector
E818
GND is input
26
Defective communication with CGC, engine controller (CUMMINS CENSE)
Disconnection
E824
Data are not updated
20-810
(8) 2
WA1200-3
TROUBLESHOOTING
Condition of machine caused by abnormality Voltage (between V1 (6), (7) chassis): 20 30 V
Failure history Saved: Other: x
Normal condition
Alarm buzzer
Phenomena under abnormal condition Data cannot be saved. (2 wires are set. Failure occurs only when both wires are disconnected.) Fuse may be broken. Failure does not occur. Abnormal value of power source sensor
Resetting method When left is not satisfied. When left is not satisfied.
Diagnosis code V-101 V-101
V-201
Voltage (between V1 (2) chassis): 22 25 V
Stops outputting.
Abnormal value of power source sensor
Hold until turning starting switch OFF.
V-102
Abnormal value of power source sensor Abnormal value of power source sensor Abnormal value of power source sensor Abnormal value of power source sensor Abnormal value of power source sensor
V-201
Voltage (between V1 (3) chassis): 11 13 V
V-202
Stops outputting.
V-103
V-202
V-203
Voltage (between V1 (4), (5) chassis): 46V
Stops outputting.
V-104
V-203
Connected to connector CN3A wrongly.
Voltage V2A (9): 20 30 V V2A (12): 0 5 V V3A (9): 0 5 V V3B (12): 20 30 V
V-105
Communication with CGC and engine controller (CENSE) is impossible.
V-107
WA1200-3
20-811
(8) 2
TROUBLESHOOTING
Abnormal system Failure mode
Failure Action code code Abnormal condition Data are not updated
No.
1) Defective joint connector JL1 2) Short circuit with chassis ground in wiring harness between V4A (female) (6) D1 (female) (G), C2 (female) (A) 3) Short circuit with chassis ground in wiring harness between V4A (female) (14) D1 (female) (H), C2 (female) (B) 4) Defective CGC, engine controller, or VHMS controller 1) Defective joint connector JL1 2) Short circuit with power source in wiring harness between V4A (female) (6) D1 (female) (G), C2 (female) (A) 3) Short circuit with power source in wiring harness between V4A (female) (14) D1 (female) (H), C2 (female) (B) 4) Defective CGC, engine controller, or VHMS controller
Short circuit with chassis Defective communication ground 26

with CGC, engine controller (CUMMINS CENSE)
E824
E824
Data are not updated
Disconnection Defective communication with transmission controller (SNET)
E825
1) Defective joint connector JL17, JL18. JL22, or JL23 2) Disconnection or defective contact in wiring harness between Received data V3A (female) (8) C3B (female) (4) 3) Disconnection or defective contact in wiring harness between are not updated V3A (female) (18) C3B (female) (12) 4) Defective transmission controller 1) Defective joint connector JL17, JL18. JL22, or JL23 2) Short circuit with chassis ground in wiring harness between V3A (female) (8) C3B (female) (4) 3) Short circuit with chassis ground in wiring harness between V3A (female) (18) C3B (female) (12) 4) Defective transmission controller 1) Defective joint connector JL17, JL18. JL22, or JL23 2) Short circuit with power source in wiring harness between V3A (female) (8) C3B (female) (4) 3) Short circuit with power source in wiring harness between V3A (female) (18) C3B (female) (12) 4) Defective transmission controller
27
E825
Received data are not updated
E825
Disconnection Defective communication with 28 modulated clutch controller (SNET)
E826
1) Defective joint connector JL22 or JL23 2) Disconnection or defective contact in wiring harness between Received data V3A (female) (8) M01 (female) (1) 3) Disconnection or defective contact in wiring harness between are not updated V4A (female) (18) M01 (female) (12) 4) Defective modulated clutch controller 1) Defective joint connector JL22 or JL23 2) Short circuit with chassis ground in wiring harness between V3A (female) (8) M01 (female) (1) 3) Short circuit with chassis ground in wiring harness between V4A (female) (18) M01 (female) (12) 4) Defective modulated clutch controller 1) Defective joint connector JL22 or JL23 2) Short circuit with power source in wiring harness between V3A (female) (8) M01 (female) (1) 3) Short circuit with power source in wiring harness between V4A (female) (18) M01 (female) (12) 4) Defective modulated clutch controller 1) Defective joint connector JL22 or JL23 2) Disconnection or defective contact in wiring harness between V3A (female) (8) L26 (female) (1) 3) Disconnection or defective contact in wiring harness between V4A (female) (18) L26 (female) (12) 4) Defective work equipment controller 1) Defective joint connector JL22 or JL23 2) Short circuit with chassis ground in wiring harness between V3A (female) (8) L26 (female) (1) 3) Short circuit with chassis ground in wiring harness between V4A (female) (18) L26 (female) (12) 4) Defective work equipment controller 1) Defective joint connector JL22 or JL23 2) Short circuit with power source in wiring harness between V3A (female) (8) L26 (female) (4) 3) Short circuit with power source in wiring harness between V4A (female) (18) L26 (female) (12) 4) Defective work equipment controller
E826
E826
Disconnection Defective communica29 tion with work equipment controller (S-NET)
E827
E827
E827
Disconnection
E828
1) Defective joint connector JL17, JL18, JL22, or JL23 2) Disconnection or defective contact in wiring harness between Received data V3A (female) (8) L08 (female) (1) 3) Disconnection or defective contact in wiring harness between are not updated V3A (female) (18) L08 (female) (3) 4) Defective main monitor 1) Defective joint connector JL17, JL18, JL22, or JL23 2) Short circuit with chassis ground in wiring harness between V3A (female) (8) L08 (female) (1) 3) Short circuit with chassis ground in wiring harness between V3A (female) (18) L08 (female) (3) 4) Defective main monitor 1) Defective joint connector JL17, JL18, JL22, or JL23 2) Short circuit with power source in wiring harness between V3A (female) (8) L08 (female) (1) 3) Short circuit with power source in wiring harness between V3A (female) (18) L08 (female) (3) 4) Defective main monitor
Defective communica30 tion with main monitor (S-NET)
E828
E828
20-812
(8) 2
WA1200-3
TROUBLESHOOTING
Alarm buzzer Failure history Saved: Other: x Phenomena under abnormal condition Resetting method Diagnosis code
Normal condition
Communication with CGC and engine controller is impossible. When left is When () wire is shorted, not satisfied. failure does not occur (Communication is possible).
V-107
Communication with CGC and When left is engine controller is impossible. not satisfied.
V-107
Display of real-time monitor does not change.
V-108
Voltage (between V3A (8), (18) chassis): 48V
V-108
V-108
V-109
V-109
V-109
V-110
V-110
V-110
V-111
V-111
V-111
WA1200-3
20-813
(8) 2
TROUBLESHOOTING
-7
Nt -
Abnormal system
Failure mode Disconnection
Izailur
code --_
Actior code ___
Contents
of abnormality
Abnormal condition
1) Disconnection or defective contact in wiring harness between Vl (female) (16) - I99 (female) (2) 2) Defective VHMS controller 1) Short circuit with chassis ground in wiring harness between Vl (female) (16) - L99 (female) (2) 2) Defective VHMS controller 1) Short circuit with power source in wiring harness between Vl (female) (16) - L99 (female) (2) 2) Defective VHMS controller 1) Disconnection or defective contact in wiring harness be&veer Vl (female) (14) - LO6 (female) (10) 2) Defective VHMS controller 1) Short circuit with chassis ground in wiring harness between Vl (female) (14) - LO6 (female) (10) 2) Defective VHMS controller 1) Short circuit with power source in wiring harness between Vl (female) (14) - LO6 (female) (10) 2) Defective VHMS controller 1) Disconnection or defective contact in wiring harness between Vl (female) (13) - LO7 (female) (6) 2) Defective VHMS controller 1)Short circuit with chassis ground in wiring harness between Vl (female) (13) - LO7 (female) (6) 2) Defective VHMS controller 1) Short circuit with power source in wiring harness between Vl (female) (13) - LO7 (female) (6) 2) Defective VHMS controller
_-_-Overcurrent
3i
Buzzer output
Short circuil with chassis ground Short circuii with power
---
_--__ --_ --_ _---_ ___
E841
Disconnection 33 Check lamp (For main monitor) Short circuit with chassis ground Short circuit with power source Disconnection Short circuit with chassis ground Short circuit with power source Disconnection E644 --_
--_ ___
Overcurrent
--_
E843
---
-__ _-_
Overcurrent
34
Flash synchronizing signal (For main monitor)
--_
E861
_--
1)Defective boom bottom oressure sensor 2) Defective joint connector JF3 3) Disconnection or defective contact in wiring harness between Vl (female) (1) - F06 (female) (3) 4) Defective VHMS controller
1) Defective boom bottom pressure sensor 2) Short circuit with chassis ground in wiring harness between Vl (female) (1) - F06 (female) (3) 3) Defective VHMS controller 1) Short circuit with power source in wiring harness between Vl (female) (1) - F06 (female) (3) 2) Defective VHMS controller I) Defective boom head oressure sensor 2) Defective joint connector JF3 3) Disconnection or defective contact in wiring harness between Vl (female) (10) - F14 (female) (3) 1) Defective VHMS controller II Defective boom head pressure sensor 2) Short circuit with chassis ground in wiring harness between Vl (female) (10) - F14 (female) (3) 3) Defective VHMS controller I) Short circuit with power source in wiring harness between Vl (female) (10) - F14 (female) (3) !) Defective VHMS controller
Sensed voltage is below 0.5 V Sensed voltage is below 0.5 V
35
Boom bonom pressure sensor
_____
E862
-__
Sensed voltage is below 0.5 V Sensed voltage
36
Boom head Dressure sensor
Short circuit with chassis ground Short circuit with crower
E862
--_
is
below 0.5 V
-__
e-m
-__
hzonnec-
E864
--_
I) Defective work equipment relief pressure sensor !I Defective joint connector JR14, JL2, JR16, or JR13 3) Disconnection or defective contact in wiring harness between Vl (female) (2) - HS2 (female) (2) 1) Disconnection or defective contact in wiring harness between V2A (female) (18) - HS2 (female) (3) j) Defective VHMS controller
I) Defective work equipment relief pressure sensor !) Short circuit with chassis ground in wiring harness between Vl (female) (2) - HS2 (female) (2) $1 Short circuit with chassis ground in wiring harness between WA (female) (18) - HS2 (female) (3) 1)Defective VHMS controller I) Short circuit with power source in wiring harness between WA (female) (18) - HS2 (female) (3) !I Defective VHMS controller 1) Defective transmission main relief pressure sensor 2) Defective joint connector JT2, JU, JT3, or JLll 3) Disconnection or defective contact in wiring harness between Vl (female) (2) - MT2 (female) (2) 4) Disconnection or defective contact in wiring harness between V2A (female) (6) - MT2 (female) (3) 5) Defective VHMS controller 1) Defective transmission main relief pressure sensor 2) Short circuit with chassis ground in wiring harness between Vt (female) (2) - MT2 (female) (2) 3) Short circuit with chassis ground in wiring harness between V2A (female) (6) - MT2 (female) (3) 4) Defective VHMS controller 1)Short circuit with power source in wiring harness between WA (female) (6) - MT2 (female) (3) 2) Defective VHMS controller
nput voltage : 0.5 v
37
Nork equipnent relief xessure sensor
IE864
-em
nput voltage : 0.5 v
---
_--
Sensing is mpossible
Disconnection Transmission main relief pressure sensor
E866
-__
38
E866
m-m
--_
__-
20-814 0
WA1 200-3
TROUBLESHOOTING
Condition of machine caused by abnormality ___ --stops outputting. --_ $eb;zk$mp is --Wh& check lamp is OFF: 20 - 30 V stops outputting.
---
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDITIONS OF MACHINE CAUSED BY ABNORMALllY
Alarm buzzer --_-F~~~e~~~ Other: x ___-Phenomena under abnormal condition Buzzer does not sound. Resetting method --_ --When left is not satisfied_ - - -__ When left is not satisfied.
- - -
Normal condition
Diagnosi code V-204 V-204
Buzzer is output when alarm is made, when load meter finishes measurement, etc. When output: Max. 1 V Normally: 20 - 30 V
Buzzer does not sound.
-__
__-
Buzzer does not sound.
v-113
_-_--
_--_-
Check lamp does not light up. Check lamp keeps lighting up. itcFv;rscreen appears,
kgzzerscreen
v-205 V-205
v-114
_--
_--
Check lamp keeps lighting up.

appears,
---
-_-
$ck;;i;i;g
OFF: 20 : 30 V
signal
.
-----__
When alarm is made, caution lamp keeps lighting up or does not light up. Alarm is displayed on CGC, however. When alarm is made, caution lamp keeps lighting up or does not light up. Alarm is
V-206
- - -
V-206
;08N;K)zIF at interval of stops outputting. ---__
displayed onCGC. however. When alarm is made, caution lamp keeps lighting upor does notlight up. Alarm is displayed onCGC. however. Load measured by load meter is always 0 ton.
When left is not satisfied. When left is not satisfied.
v-115
_-doltage (between ;~j:;::
_--
V-l 16
---
-_-
Load measured by load meter is always 0 ton.
V-116
---
-__ Accuracy dispersion depends on operation of lever. (Back pressure cannot be corrected with boom head pressure.) Accuracydispersion dependson be corrected with boom head pressure.) Load measured by load meter is extremely low. Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa {O kg/cm?)
$%$~s%~bot
V-207
__doltage (between f174 : $1,:

. .
-a-
v-117
---
---
When left is not satisfied. ---
v-117
-__
-__
-__
V-208
_--
-_-
v-119
Joltage (between ;;2 $-$1)): . - .
---
Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa (0 kg/cm% Real-time monitor is displayed. Max. pressure is always sensed. Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa (0 kg/cm%
v-119
---
__-
-__
v-21 1
__-
__-
v-121
Voltage (between ;;A (;13-;3)): . - .
_-_
---
Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa f0 kg/cm% Real-time monitor is displayed. Max. pressure is always sensed.
v-121
-_-
---
__-
-__
v-212
WA I 200-3
20-8 15 0
TROUBLESHOOTING
Abnormal system Failure mode
Failure Action code code Abnormal condition
No.
1) Defective steering relief pressure sensor 2) Defective joint connector JR14, JL2, JR16, or JR13 3) Disconnection or defective contact in wiring harness between V1 (female) (2) HS3 (female) (2) 4) Disconnection or defective contact in wiring harness between V2A (female) (16) HS3 (female) (3) 5) Defective VHMS controller 1) Defective steering relief pressure sensor 2) Short circuit with chassis ground in wiring harness between V1 (female) (2) HS3 (female) (2) 3) Short circuit with chassis ground in wiring harness between V2A (female) (16) HS3 (female) (3) 4) Defective VHMS controller 1) Short circuit with power source in wiring harness between V2A (female) (16) HS3 (female) (3) 2) Defective VHMS controller
Disconnection Steering 39 relief pressure
E867
Input voltage < 0.5 V
E867
Sensing is impossible
Disconnection Torque converter 40 outlet pressure
E868
1) Defective torque converter outlet pressure sensor 2) Defective joint connector JT2, JL2, JT3, or JL11 3) Disconnection or defective contact in wiring harness between Input voltage V1 (female) (2) MT3 (female) (2) 4) Disconnection or defective contact in wiring harness between < 0.5 V V2A (female) (5) MT3 (female) (3) 5) Defective VHMS controller 1) Defective torque converter outlet pressure sensor 2) Short circuit with chassis ground in wiring harness between V1 (female) (2) MT3 (female) (2) 3) Short circuit with chassis ground in wiring harness between V2A (female) (5) MT3 (female) (3) 4) Defective VHMS controller 1) Short circuit with power source in wiring harness between V2A (female) (5) MT3 (female) (3) 2) Defective VHMS controller 1) Defective transmission modulating pressure sensor 2) Defective joint connector JT2, JL2, JT3, or JL11 3) Disconnection or defective contact in wiring harness between V1 (female) (2) MT5 (female) (2) 4) Disconnection or defective contact in wiring harness between V2A (female) (15) MT5 (female) (3) 5) Defective VHMS controller 1) Defective transmission modulating pressure sensor 2) Short circuit with chassis ground in wiring harness between V1 (female) (2) MT5 (female) (2) 3) Short circuit with chassis ground in wiring harness between V2A (female) (15) MT5 (female) (3) 4) Defective VHMS controller 1) Short circuit with power source in wiring harness between V2A (female) (15) MT5 (female) (3) 2) Defective VHMS controller 1) Defective transmission lubricating oil pressure sensor 2) Defective joint connector JT3 or JR11 3) Disconnection or defective contact in wiring harness between V1 (female) (5) MT1 (female) (2) 4) Disconnection or defective contact in wiring harness between V2A (female) (14) MT1 (female) (3) 5) Defective VHMS controller 1) Defective transmission lubricating oil pressure sensor 2) Short circuit with chassis ground in wiring harness between V1 (female) (5) MT1 (female) (2) 3) Short circuit with chassis ground in wiring harness between V2A (female) (14) MT1 (female) (3) 4) Defective VHMS controller 1) Defective transmission lubricating oil pressure sensor 2) Defective joint connector JT3 or JR11 3) Short circuit with power source in wiring harness between V2A (female) (14) MT1 (female) (3) 4) Defective VHMS controller 1) Defective ambient temperature sensor 2) Disconnection or defective contact in wiring harness between V2A (female) (10) PH1 (female) (1) 3) Defective VHMS controller 1) Defective ambient temperature sensor 2) Short circuit with chassis ground or with power source in wiring harness between V2A (female) (10) PH1 (female) (1) 3) Defective VHMS controller 1) Defective ambient temperature sensor 2) Short circuit with power source in wiring harness between V2A (female) (10) PH1 (female) (1) 3) Defective VHMS controller
E868
Disconnection Transmission 41 modulating pressure
E871
E871
Disconnection
E872
Transmission 42 lubricating oil Short circuit with chassis pressure ground
E872
Short circuit with power source Disconnection Ambient 43 temperature Short circuit with chassis ground Short circuit with power source
E872
Input voltage > 4.7 V Input voltage < 0.3 V Input voltage > 4.7 V
E877
E877
44 PPC relief pressure
Disconnection
E878
1) Defective PPC relief pressure sensor 2) Defective joint connector JR14, JL2, or JR7 3) Disconnection or defective contact in wiring harness Input voltage between V1 (female) (2) HS4 (female) (2) 4) Disconnection or defective contact in wiring harness between < 0.5 V V2A (female) (1) HS4 (female) (3) 5) Defective VHMS controller
20-816
(8) 2
WA1200-3
TROUBLESHOOTING
Condition of machine cause d by abnormal@ I
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY AND CONDlTlONS OF MACHINE CAUSED BY ABNORMALlTY
I:ailurehistol Saved: C Other: x
Normal condition
Alarm buzzer
Phenomena under abnormal condition Real-time monitor is displayeo Min. pressure is always sensed. (0 MPa 10 kg/cm%
Resetting method
Xagnosis code
-_Voltage (between ;-;A 263; (12)): - .
---
___
--_
Real-time monitor is displayed Min. pressure is always sensed. (0 MPa {O kg/cm31 Real-time monitor is displayed Max. pressure is always sensed. Real-time monitor is displayed Min. pressure is always sensed. (0 MPa {O kg/cm%
v-122
___
---
___
_--
V-213
---
---
When letI is not satisfied.
V-123
Voltage (between V2A (5) - (3)): 0.7 - 5.3 v
-__
---
Real-time monitor is displayed Min. pressure is always sensed. (0 MPa f0 kg/cm% Real-time monitor is displayed Max. pressure is always sensed. Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa 10 kg/cm3)
V-123
_--
-__
___
--_
V-214
V-124
Voltage (between ;A_;_53 ; (12)):
Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa IO kg/cm%
V-124
_-_
___
__-
Real-time monitor is displayed. Max. pressure is always sensed. Real-time monitor is displayed. IS always t$rseyure (0 MPa{O kg/cm%
___
v-215
---
v-125
Voltage (between ;;A U43); (12)):
. - .
---
---
Real-time monitor is displayed. Min. pressure is alwavs sensed. (0 MPa (0 kg/cm?) Real-time monitor is displayed Min. pressure is always sensed. (0 MPa {O kg/cm% PM Clinic display is abnormal (held at -30C).
V-125
-__
V-125
--Resistance (between V2A (10) - (12)): Ambient temperature 20% Approx. 12 kQ 0C: Approx. 4 kQ
_-_
V-128
___
___
PM Clinic display is abnormal (held at 100C). PM Clinic display is abnormal (held at -30C).
When left is not satisfied. When left is not satisfied.
V-128
___
_--
V-128
Voltage (between J2p_;3-Vf12:
---
PM Clinic is displayed. Min. oressure is alwavs sensed. (0 MPa IO kg/cm?)
v-129
WA1 200-3
20-817 0
TROUBLESHOOTING
Abnormal system Failure mode Short circuit with chassis ground Short circuit with power source Failure code
Action code Contents of abnormality Abnormal condition
No.
E878
- - -
44
PPC relief pressure
1) Defective PPC relief pressure sensor 2)Short circuit with chassis round in wirin harness between Vl (female) (2) - Y-l S4 (female) (2 3) Short circuit with chassis ground in wirin harness between V2A (female) (1) - HS4 (female) % 3) 4) Defective VHMS controller 1)Shor-t circuit with power source in wirin harness between V2A (female) (1) - HS4 (female 3 (3) 2) Defective VHMS controller 1) Defective torque converter inlet pressure sensor 2) Defective joint connector JT2, JU, JT3, or JLll 3) Disconnection or defective contact in wiring harness between Vl (female) (2) - MT4 (female) (2) 4) Disconnection or defective contact in wirin harness between V2B (female) (10) - MT4 (female) & 5) Defective VHMS controller 1) Defective torque converter inlet pressure sensor 2) Short circuit with chassis round in wirin harness between Vl (female) (2) - xl T4 (female) ( ) 3) Short circuit with chassis ground in wirin harness between V2B (female) (10) - MT4 (female ; (3) 4) Defective VHMS controller 1)Short circuit with power source in wirin harness between V2B (female) (10) - MT4 (fema P e) (3) 2) Defective VHMS controller 1) Disconnection or defective contact in wiring harness of Vl (female) (8). (9) 2) Defective VHMS controller 1) Short circuit with chassis ground in wiring harness of Vl (female) (8). (9) 2) Defective VHMS controller circuit with power source in wiring harness of Vl (female) (8), (9) 2) Defective VHMS controller or defective contact in wiring harness of V2B (female) (8) 2) Defective VHMS controller 1)Short circuit with chassis ground in wiring harness of V2B (female) (8) 2) Defective VHMS controller 1)Short circuit with power source in wiring harness of V2B (female) (8) 2) Defective VHMS controller 1) Disconnection or defective contact in wiring harness of V3A (female) (7) 2) Defective VHMS controller 1) Short circuit with chassis ground in wiring harness of V3A (female) (7) 2) Defective VHMS controller 1) Short circuit with power source in wiring harness of V3A (female) f7) 2) Defective VHMS controller
---
---
_--
Disconnection
E884
---
45
Torque converter inlet pressure
E884
- - -
--___
----_
Sensing is impossible Sensing is impossible Sensing is impossible Sensing is
46
SW power source (+24 VI
Short circuit withchassis ground Short circuit
---
---
1)Short
with power
source Disconnection 47 Small lamp ON voltage Short circuit withchassis ground Short circuit
--___
-----
impossible Sensing is impossible Sensing is impossible Sensing is impossible Sensing is impossible (Becauseof output of mcdulated clutch) Sensing is impcs-sible (Becauseof output of modulated clutch) Sensing is impossible (Becauseof output of modulatedclutch) Sensing is impossible
1)Disconnection
---
---
with power
source Disconnection Engine speed (+) Short circuit withchassis ground Short circuit
---
---
__-
--_
48
---
---
with power
source Disconnection 49 Cancel switch (Load meter) Short circuit ;;$ceKWS Short circuit with power source Disconnection Subtotal swsw;; (Load Short circuit withchassis ground Short circuit with power source Disconnection Boom proximity sensor Short circuit withchassis ground Short circuit
---
---
___
___
1)Defective cancel switch 2) Diinnection or defective contact in wiring harness of V3A (female) (14) 3) Defective VHMS controller
1) Defective cancel switch 2) Short circuit with chassis ground in wiring harness of V3A (female) (14) 3) Defective VHMS controller 1)Short circuit with power source in wiring harness of V3A (female) (14) 2) Defective VHMS controller 1) Defective subtotal switch 2) Disconnection or defective contact in wiring harness of V3A (female) (15) 31 Defective VHMS controller 1) Defective subtotal switch 2) Short circuit with chassis ground in wiring harness of V3A (female) (15) 3) Defective VHMS controller 1) Short circuit with power source in wiring harness of V3A (female) (15) 2) Defective VHMS controller 1) Defective boom proximity sensor 2) Disconnection or defective contact in wiring harness of V3A (female) (16) 3) Defective VHMS controller 1) Defective boom proximity sensor 2) Short circuit with chassis ground in wiring harness of V3A (female) (16) 3) Defective VHMS controller 1) Short circuit with power source in wiring harness of V3A (female) (16) 2) Defective VHMS controller
- - -
- - -
Sensing is impossible Sensing is impossible Sensing is impossible
---
---
-_-
_-_
50
---
---
Sensing is impossible Sensing is impossible Sensing is impossible
---
---
_ _ _
_ _ _
51
---
---
Sensing is impossible Sensing is impossible _--
with power
source 52 ky;;;ading %Z$$$j$&$ mm pckr lcurca
--_ __
--_ __
20-8 18
0
WA1 200-3
TROUBLESHOOTING
Normal condition Condition of machine caused by abnormality
Alarm buzzer F$Tebt&n Others x Phenomena under abnormal condition PM Clinic Min. pressure is always sensed. (0 MPa {O kg/cm% PM Clinic Max. pressure is always sensed. Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa {O kg/cm?) Real-time monitor is displayed. Min. pressure is always sensed. (0 MPa {O kg/cm?) Real-time monitor is displayed. Max. pressure is always sensed. (4.9 MPa {50 kg/cm? VHMS doesnet operate. (2 wiresare sat. Failure occurs only whenbothwiresare disconnected.) Fuse may be broken. Failure does not occur. Resetting method Diagnosi: code
_-Voltage (between ;p (;)3-$12)):
__-
v-129
. - .
_--
--_
___
--_
v-219
_--
---
v-130
Voltage (between JJB ;Oj v (12)): . - .
_--
__-
v-130
--_-Voltage (between Vl (81, (9) - chassis): 20 - 30 v --_
_---_ --___
-_-_-____
- - - - ----_
- - - - -__ -_-
Voltage (between V2B (8) - chassis): Small lamp ON:
ON: GND (When canceled) 3FF: OPEN Fuse is broken.
Switch is kept turned off. ON: GND (When subtotaled) OFF: OPEN ___ ___
Switch is kept turned off.
Fuse is broken. Trigger is not applied and load meter does not calculate load. Trigger is not applied and load meter does not calculate load. Trigger is not applied and load meter does not calculate load. Data cannot be downloaded with service tool.
--_
-__
___ Load measurement !!?l!g: OPEN -__ _--
___
--___
--
-__
__ _
__-__
___ _--
-__-_
___ ___
___ _-_
WA1 200-3
20-819 0
TROUBLESHOOTING

1. The check lamp output is driven with VHMS. 2. As the signal to synchronize flashing of the caution lamp output of the main monitor, the ON/OFF output of VHMS is used. Permission of the alarm output is given by S-NET and is sent from VHMS to main monitor. 3. The check lamp and caution lamp are set independently (When two failures occur, both flash).
Detecting condition 1 No. 1 Item Engine oil level Display range Below LOW level Detail of display range H: Normal L: Abnormal Alarming condition Detecting condition 2 Before While engine engine starts is running Detecting condition 3 Failure detecting time (sec) 2 Resetting condition 1 Resetting condition When left is not satisfied.
Engine oil pressure Below specified pressure
Refer to Engine Shop Manual
3 5 6 7 8 9
Engine coolant temperature Fuel level Torque converter oil temperature Hydraulic oil temperature
Above 105C
Above 105C
Below specified level Below 1 segment of gauge (11%) Below specified level Below 1 segment of gauge (11%) Above 120C Above 130C Above 105C Below 14.7 MPa {150 kg/cm2} Above 120C but 130C alarm is not detected Above 130C Above 105C Below 14.7 MPa {150 kg/cm } and within 60 sec after engine starts Below 14.7 MPa {150 kg/cm } and after 60 sec after engine starts Below 14.7 MPa {150 kg/cm2} Below 14.7 MPa {150 kg/cm2} and within 60 sec after engine starts Below 14.7 MPa {150 kg/cm2} and after 60 sec after engine starts OPEN (Fluid level is low) = 6 V cell is below 2 V OPEN (Fluid level is low) = 6 V cell is below 2 V OPEN (Fluid level is low) = 6 V cell is below 2 V
2 2
10 10 10 2 2 10 5 5
When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied.
Brake oil 10 pressure (F) (Cut-in/Cut-out 11 pressure) Brake oil 13 pressure (F) (Cut-in/Cut-out 14 pressure)
16 Battery fluid level (1) Below LOW level 17 Battery fluid level (2) Below LOW level 18 Battery fluid level (3) Below LOW level 19 Brake fluid level 20 21 Coolant level 22
10
Below specified level OPEN = 24 V (Fluid level is low) Below specified level OPEN = 24 V (Fluid level is low) Below LOW level Below LOW level OPEN = 24 V (Coolant is insufficient) OPEN = 24 V (Coolant is insufficient) OPEN = 24 V (Clogging) and torque converter oil temperature is above 50C OPEN = 24 V (When clogged) OPEN = 24 V (When clogged) OPEN = 24 V (When clogged) OPEN = 24 V (When clogged) Above 9.3 V (While engine is running) (Criterion while engine is running: Voltage of terminal R is above 9.3 V or engine speed > 600 rpm)
10 10 2 30 2 2 2 2 2
When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied. When left is not satisfied.
Transmission filter Above specified 23 differential pressure pressure Clogging of air 24 cleaner (1) of air 25 Clogging cleaner (2) of air 26 Clogging cleaner (3) of air 27 Clogging cleaner (4) Voltage at alternator 28 terminal R Above specified negative pressure Above specified negative pressure Above specified negative pressure Above specified negative pressure When charging is abnormal
20-820
(8) 2
WA1200-3
TROUBLESHOOTING
Alarm output Main monitor output Alarm display on CGC Abnormal Screen color Yellow Cancel switch Installed Check lamp Flashing Caution lamp Buzzer Display of message (CGC) Sensor Normal Real-time Saving of Error detecting display monitor, PM No. failure history component (Reference) Clinic (Reference) Saved: 901
Remarks
CENSE
Abnormal
Red
Not installed
Flashing
ON
902
CENSE
Abnormal Insufficient Insufficient Abnormal Abnormal Abnormal Pressurizing Abnormal Pressurizing Abnormal
Red Yellow Yellow Yellow Red Red Yellow Red Yellow Red
Installed Installed Installed Installed Installed Installed Installed Not installed Installed Not installed
Flashing
Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing Flashing
ON ON ON ON
904 905 906 907 908 911 912 913 912 915 916
x x
CENSE VHMS
Gauge Gauge Gauge Gauge
VHMS Gauge VHMS VHMS VHMS

VHMS VHMS
Abnormal
Yellow
Installed
Flashing
917 918
Abnormal Abnormal Abnormal Abnormal Abnormal Abnormal Abnormal Abnormal Abnormal
Yellow Red Yellow Red Yellow Yellow Yellow Yellow Yellow
Installed Not installed Installed Not installed Installed Installed Installed Installed Installed
Flashing Flashing Flashing Flashing Flashing Flashing Flashing
Flashing Flashing
ON ON
925 926 927 928 931 932 933 934 935
VHSM VHSM VHMS

VHMS
Abnormal
Yellow
Installed
Flashing
937
WA1200-3
20-821
(8) 2
TR(3UBLESHOOTlNG -
FOR VHMS SYSTEM
.ECTRICAL CIRCUIT DIAGRAM FOR VHMS SYSTEM
20-822 0
WA1 200-3
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR VHMS SYSTEM
WA1 200-3
20-823 0
TROUBLESHOOTING
V-1, V-2, V-4
V-1 [E901] (Engine oil level below LOW level) is displayed

Cause Remedy
Insufficient engine oil or defect related to CUMMINS engine controller (CENSE)
Supply oil or see Service Manual of CUMMINS
V-2 [E902] (Engine oil pressure below specified pressure) is displayed

Cause Remedy
Low engine oil pressure or defect related to CUMMINS engine controller (CENSE)
Check or see Service Manual of CUMMINS
V-4 [E904] (Engine coolant temperature above specified temperature) is displayed

This failure code is displayed when the engine coolant temperature is above 105C (The caution lamp flashes and the buzzer sounds).
Cause
Engine coolant temperature above 105C or defect related to CUMMINS engine controller (CENSE)
Remedy
Check or see Service Manual of CUMMINS
20-824
(8) 2
WA1200-3
TROUBLESHOOTING
V-5
V-5 EE9051 [Fuel level below specified level (before engine starts)] is displayed
* so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing connector and inserting the T-adapter, or when monitor display, the CGC the on displayed longer no is code error the if position, original its to problem has been removed.
* * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. This failure code is displayed before the engine starts.
Cause
Remedy
4YE I ISvoltage between R05 (female) 11)and

J
Ir
Defective VHMS controller Short circuit with power source in wiring harness between V2A (female) (2) - R05 (female) (1) Disconnection or defective contact in wiring harness between R05 (female) (2) chassis ground Disconnection or defective contact in wiring harness between V2A (female) (2) R05 (female) (1) insufficient fuel or defective fuel level sensor
Replace
Yl
1 Is
ween I305 hale)
betresistance
. See Table 1. - Disconnect R05.
resistance yEs between ROS - (female) (2) and chassisground 2 normal7 If VZA (female)(21is groundedtochassis, - Max. 1 R is resistancebatwaen R05 (female)(1) and - . Turn starting ;z;$ground switch OFF. * Disconnect R05. *Max. 1 R ,, *Turn starting switch OFF. . Disconnect V2A and R05.
Is
Repair or replace
* DisconnectWA and R05. *Turn starting switch ON
NO
Repair or replace
Repair or replace
NO
Suppiy fuel or replace fuel level sensor
Table 1 Fuel level 1 Resistance Approx. 10 R Appror1 Approx. 48.5 Q Aoorox. 85 R I 1 1
1 FULL (100%) 1 1 I l/Z (50%) 11 (25%) 1 /
1 EMPTY (0%) 1
WA1 200-3
20-825 0
TROUBLESHOOTING
V-5
V-5 Related electrical circuit diagram
VHM JR2 (DTI)
RAlO
(DTHD4)
TJW02526
20-826 0
WA1 200-3
TROUBLESHOOTING
V-6
V-6 [E906] [Fuel level below specified level (While engine is running)] is displayed
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 CGC monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. This failure code is displayed before the engine starts.
Cause
Remedy
Defective VHMS controller
Replace
11 Ick&sground Is resistance between R05 -Max.lV NC - (female) (2) and - DisconnectWA chassis ground 2 and R05. - If VZA (female)is normal? * Turn starting switch ON. P YES grounded10chassis, * Max. 1 R ISresmance between _ Turn starting NO - RO5(female)(1) and chassisground switch OFF. 1 normal? * Disconnect R0.5. Is resistance bet. Max. 1 Q ween RO5 (male) NO - -Turn starting (1) and (2) as switch OFF. shown in Table l? * Disconnect VZA I I and R05. * See Table 1. Disconnect R05.
yfrS
l l
Short circuit with power source in wiring harness between VZA (female) (2) - R05 (female) (1) Disconnection or defective contact in wiring harness between R05 (female) (2) chassis ground Disconnection or defective contact in wiring harness between V&I (female) (2) R05 (female) (1) Insufficient fuel or defective fuel level sensor
Repair or replace
Repair or replace
Repair or replace
NO
Supply fuel or replace fuel level sensor
Table 1 Fuel level 1 FULL (100%) 1 l/2 (50%) 1 l/4 (25%) Resistance Approx. 10 R Approx. 32 R 1 Approx. 49.5 R Approx. 85 R I 1
EMPTY (0%) )
WA1 200-3
20-827 0
TROUBLESHOOTING
V-6
V-6 Related
electrical
circuit
diagram
II
level Fuel sensor
TJW02526
20-828 0
WA1 200-3
TROUBLESHOOTING
V-7
V-7 [ES071 (Torque converter oil temperature
above 120C) is displayed
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 CGC monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
1
2 1Is resistance betwen YES WA Ifemale)(3). T24 , r (female)11)and _ chassis ground normal? YES
II
Defective VHMS controller Short circuit with chassis ground in wiring harness between V2A (female) (3) -T24 (female) (1) Torque converter oil temperature is above 120C or defective torque converter oil temperature sensor
Replace
Is resistance between T24 Imale) _ (1) and (2) as shown in Table 17 - See Table 1. * Turn starting switch OFF. * Disconnect T24.
NO - Min. 1 MR . Turn starting switch OFF. * Disconnect VZA and T24. NO
Repair or replace
Repair or replace
Table 1
*j
v-7 Related electrical circuit diagram

VHMS
Totsue converter oil temDerature sensor bon i tar)
LR7fDTI)
_.
RA5 (DTI)
_,
l!
TJW02527
WA1 200-3
20-829 0
TROUBLESHOOTING
V-8
V-8 [E908] (Torque converter A-
oil temperature
* *
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the connector and inserting the T-adapter, or when removing monitor display, the CGC the on displayed longer no is code to its original position, if the error removed. problem has been check that all the related connectors are properly inserted. Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. Cause Remedy
YES
_
1
Is
2 between Is rasisIanca T24 (3). 'kW(female) (1) and (female)

chassis ground
YES
Replace
resistance between T24 knale) (1) and 12)as shown , in Table 17 * See Table 1. Turn starting switch OFF. * Disconnect T24.
l
lwmal? NO * Min. 1 MQ * Turn starting switch OFF. * Disconnact V2A and T24. NO
Short circuit with chassis ground in wiring harness between V2A (female) (3) T24 (female) (1) Torque converter oil temperature is above 130C or defective torque converter oil temperature sensor
Repair or replace
Repair or replace
V-B Related
electrical
circuit diagram
lverter Tome car ni L*,llr*l I tmmmr ,ature YI I sensor bon i tar)
VHMS
LR7 (0
.*
RAlO [DTHD4)
TJW02527
20-830 0
WA1 200-3
TROUBLESHOOTING
v-9
V-9 [E911] (Hydraulic
oil temperature
so when disconnecting the is carried out when there is still an abnormality, This troubleshooting returning the connector and T-adapter the removing when or connector and inserting the T-adapter, monitor display, the CGC the on displayed longer no is code error the if position, to its original problem has been removed.
Cause
Remedy
2
Is resistance baty,zs , r wean V2A (female) (11). HSl ~famalel ._.
YES
Defective VHMS controller Short circuit with chassis ground in wiring harness between V2A (female) (11) - HSl (female) (1) Hydraulic oil temperature is above 105% or defective hydraulic oil temperature sensor
Replace
batwaan
HSl
(male)
Repair or replace
(11 and (2) as shown I I
Table 1. Turn starting switch OFF. * Disconnect HSl.

- See
l
-Turn starting switch OFF. - Disconnect V2A and HSl.
Replace
Table 1 Temperature 25C 105C Resistance Approx. 37 - 50 kI2 Approx. 3.0 - 3.6 kQ
V-9 Related VHMS
electrical
circuit diagram
controller
V2A(07018)
0. 5Y
JR16 (DTl)
Hydraulic
LR2 (HD-85086)
oi
I
sensor
TJW02528
WA1 200-3
20-831 0
TROUBLESHOOTING
v-10
V-IO
*
[E912] (Low front or rear brake oil pressure) is displayed
* * * *
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 CGC monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. This failure code is displayed when the brake cut-out oressure is below 14.71 MPa (150 kg/cm? (for 60 seconds after the engine starts). Perform the following troubleshooting when the cut-out presRemedy Cause sure is normal. Always connect any disconnected connectors before going on to the next step. Low front brake oil
YES
I
1 If HR15 is II
pressure or defective front brake oil pressure sensor Low rear brake oil pressure or defective rear brake oil pressure sensor
L
Check or replace
Check or replace
. Turn starting If HRlr switch OFF. discon Disconnect HRlS. raiiure code = SC+ NO dr-Start engine.
J-di
GotoA
* Turn starting switch OFF. . Disconnect HR16. h * Start engine.
round normal? * Min. 1 MD - Turn starting switch OFF. Disconnect V2A and HR15. YF 6
_.
* DisconnectVZA and HR16. VO
Contact of wiring harness between V2A (female) (8) - HR16 (female) (3) with chassis ground Contact of wiring harness between V2A (female) (7) - HR15 (female) (3) with chassis ground
Repair or replace
Repair or replace
7 YES
Go to 8.
HR16 ffamale) 13)and

I if WA (female) 17) is
1Q Max.
*Turn starring switch OFF. * DisconnectJR14
. __
Disconnection or defective contact in wiring harness between JR14 (female) (6) - HR15 (female) (2) Disconnection or defective contact in wiring harness between WA Ifemaie) (8) HR16 (female) (3) Disconnection or defective contact in wiring harness between WA (female) (7) HR15 (female) (3) Defective VHMS controller Contact of wiring harness between JR14 (female) (5) - HR16 (female) (2) with chassis ground Contact of wiring harness between JR14 (female) (6) - HR15 (female) (2) with chassis ground Disconnection or defective contact in wiring harness between JR14 (female) (5) - HR16 [female) (2)
Repair or replace
From A
Repair or replace
Max. 1 R -Turn starting switch OFF. Disconnect V2A and HR15.

l l
and HR16. NO
Repair or replace
From S _
Is resistance betYES ween JR14 (female) - (5). HR16(female)(2) 9 and chassisground Is resistance batnormal? _ yfcS ween JR14 (female) * Min. 1 MQ NC - (6), HR15 (female) - -Turn starting switch OFF. a (2) and chassis ground IfJR14 - DisconnectJR14 - normal? and HR16. gmundedto chz Min. 1 MD between is resistance NO HR16 (female)(2) and - * Turn start@ chassisground switch OFF. normal? * Disconnect JR14 - Max. 1 R and HR15 -Turn starting NO switch OFF. . Disconnect JR14 and HR16.
l
Replace
Repair or replace
Repair or replace
Repair or replace
20-832 0
WA1 200-3
TROUBLESHOOTING
v-10
V-10 Related
VHMS
electrical
circuit
diagram
JR13 (DTIB)
brake Front oi I Pressure
Rear brake oil Pressure
RAlO(DTHD4)
TJW02529
WA1 ZOO-3
20-833 0
TROUBLESHOOTING
v-11
V-II
*
[E913] (Low front brake oil pressure) is displayed
* * * *
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 CGC monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. This failure code is displayed when the cut-in/cut-out pressure of the front brake is below 14.71 MPa (150 kg/cm21 (60 seconds after the engine starts). Perform the following troubleshooting when the front brake cut-in/cut-out pressure is normal. Always connect any disconnected connectors before going on to the next step.
Remedy
IYF! . .-
GotoA
d
Yl
replaced with rear
-Max.10
NC
and
*Turn startino switch
Disconnection or defective contact in wiring harness between JR14 (female) (6) - HR15 (female) (2) Contact of wiring harness between V2A (female) (7) HRt5 (female) (31 with chassis ground
Repair or replace
).~$m?ct ii14
NO
- Turn starting switch OFF. * Replace with (normal) rear brake oil pressure sensor. *Start engine. From A
* Max. 1 D . Turn starting switch OFF. - Disconnect V2A and HR15.

IO
- Min. 1 MR *Turn starting switch OFF. - Disconnect V2A and HR15. NO
Repair or replace
contact in wiring harness between WA (female) (7) HR15 (female) (3) Low front brake oil pressure or defective front brake oil pressure sensor Defective VHMS controller
Repair or replace
Check or replace
Replace
(61. HRl5 (female) (2) and chassis ground normal? * Min. 1 MQ Turn starting switch OFF. * Disconnect JR14 and HR15.
l
NO
Contact of wiring harness between JR14 (female) (6) - HR15 (female) (2) with chassis ground
Check or replace
20-834 0
WA1 ZOO-3
TROUBLESHOOTING
v-11
V-II
VHMS
controller
%,, Im-,A.,,,l
JL21fDTlBl
Front brake oi I Pressure
RA5 (LITI)
RAlU(DTHD4) qmp
TJW02530
WA1 200-3
20-835 0
TROUBLESHOOTING
v-12
V-12
*
[ES151 (Low rear brake oil pressure) is displayed
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 CGC monitor display, the problem has been removed.
* * * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. This failure code is displayed when the cut-in/cut-out pressure of the rear brake is below 14.71 MPa (150 kg/cm21 (60 seconds after the engine starts). Perform the following troubleshooting when the rear brake cut-in/cut-out pressure is normal. Always connect any disconnected connectors before going on to the next step.
cause
Remedy
Gotok
HR16 (female)(2) and
*Turn startingswitch
Disconnectionor defective contact in wiring harness between JR14 (female) (5) HR16 (female) 12) Contact of wiring harness between WA (female) (8) HR16 (female) (3) with chassis ground
Repair or replace
Yl
Hi%6 (female1 (31and 1
Repair or replace
1If rear brake oil
- Max.
l
-Turn starting switch OFF. . Replace with (normal) front brake oil pressure sensor. . Start engine. From A M
1Q -Turn starting switch OFF. Disconnect V2A and HR16.
* Disconnect WA and HR16. NO
Disconnectionor defective contact in wiring harness between V2A (female) (8) HR16 (female) 13) Low rear brake oil pressure or defective rear brake oil pressure sensor
Repair or replace
IO
Check or replace
5 YES
Is resistance between JR14 (female) (5). HR16 (female) (2) and chassis ground normal? . Min. 1 MD Turn starting switch OFF. - Disconnect JR14 and HR16.
l
Defective VHMS controller Contact of wiring harness between JR14 (female) (5) - HR16 (female) (2) with chassis ground
Replace
NO
Check or replace
20-836 0
WA1 200-3
TROUBLESHOOTING
v-12
V-12 Related
electrical
circuit diagram
VH
e ure
TJW02531
WA1 200-3
20-837 0
TROUBLESHOOTING
v-13
V-13
[916] (Disconnection or short circuit with chassis ground in battery fluid level sensor 1 I is displayed
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 CGC monitor display, the problem has been removed. -)r Before carrying out troubleshooting, check that all the related connectors are properly inserted. f Always connect any disconnected connectors before going on to the next step. * Perform the following troubleshooting when the battery fluid level is normal.
F=Is resistance betYES _ 2 ifV28 (female) (1) [s grounded to chassis. 1s resistance batwean _ RA7 (female) (1) and wean V2B (female)
Remedy
YES
Defective VHMS controller Short circuit with chassis ground in wiring harness between V2B (female) (1) - RA7 (female) (1) Disconnection or defective contact in wiring harness between VZB (female) (1) RA7 (female) (1) Defective battery fluid level sensor 1 or insufficient battery charge
Replace
YES _
(11, RA7 (female) (1) and chassisground normal?

l
1 Is voltage between RA7 (male) (1) and chassis ground normal? -5.5-6.5V . Disconnect RA7.
$aEa;?ground *Max.1 Q *Turn starting switch OFF. Disconnect V2B and RA7.
NO Min. 1 MR *Turn starting switch OFF. * Disconnect V2B and RA7. NO
Repair or replace
Repair or replace
i.
Charge or replace
VHMS
RA2 (DTP/DT
1)
TJW02532
20-838 0
WA1 200-3
TROUBLESHOOTING
v-14
V-14
[917] (Disconnection or short circuit with chassis ground in battery fluid level sensor 2) is displayed
Ir *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Perform the following troubleshooting when the battery fluid level is normal.
*
3 YES
YES 2 If V26 (fern YES gs$:: EC;:;, _ RA6 (female) (1) and 1 chassisground normal? Is resistancebetween VZB (female) (2). RA8 (female) (1) and chassisground normaI? *Min.lMR Turn starting switch OFF. - Disconnect V2B and RAB.
l
Defective VHMS controller Short circuit with chassis ground in wiring harness between V2B (female) (2) - RAB (female) (1) Disconnection or defective contact in wiring harness between VZB (female) (2) RA6 (female) (1) Defective battery fluid level sensor 2 or insufficient battery charge
Replace
NO
Repair or replace
- Max. 1 Q - - Turn starting switch OFF. Disconnect VZB - 5.5 - 6.5 V and RAB. - Disconnect RAB. NO
l
Is voltage between RAB (male) (1) and chassis ground normal?
NO
Repair or replace
Charge or replace
I
V-l 4 Related electrical circuit diagram
VHMS
Battery
TJW02532
WA1 200-3
20-839 0
TROUBLESHOOTING
v-15
V-15
[918] (Disconnection or short circuit with chassis ground battery fluid level sensor 3) is displayed
in
* * *
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 CGC monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Perform the following troubleshooting when the battery fluid level is normal.
ChJSe
Remedy
3 _ MS ._reskance betYES wee V2B (female) - 131.RA9 (female) (1) 2 and chassisground _ If V2B (female)(3) is normal? ES grourjded tochassis, NO _ Is re%tance between _ . Min. f MD RA3 (female)11)and * Turn starting switch OFF. 1 chassisground normal? * Disconnect VZS and FiA9. Is voltage bet* Max. 1 R ween RA9 (male) - * Turn starting NO (1) and chassis switch OFF. ground normal? * Disconnect VZB .5.5-6.5V and RA9. - Disconnect RA9. Is
Defective VHMS controller Short circuit with chassis ground in wiring harness between VZB (female) (3) - RA9 (female) (1) Disconnection or defective contact in wiring harness between V26 (female) (3) RA9 (female) (1) Defective battery fluid level sensor 3 or insufficient battery charge
Replace
Repair or replace
Repair or replace
NO
Charge or replace

VHMS
TJW02532
20-840 0
WA1 200-3
TROUBLESHOOTING
V-16
V-16
*
[E9251 [Brake fluid level below specified level (before engine starts)] is displayed
* *
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 CGC monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
This failure code is displayed before the engine starts.
CaUSe
Remedy
YES I 1 If HRlO (female) (11 is grounded to chassis,does failure code disappear? 2 * Turn starting switch OFF. - Ground HRlO (female) (1) to chassis. * Turn starting switch ON. If HR6 (Lemale) (1) is _ grounde dto dwsfailure No :~~~~s appear? *Turn starting switch OFF.
I
YES
Low front brake fluid level or defective front brake fluid level sensor Low rear brake fluid level or defective rear brake fluid level sensor
Supply or replace brake fluid
Supply or replace brake fluid
Replace
llC - ___..__I urouno no
(female) (1) to chassis. * Turn starting switch ON.
NO between _ -Max.lQ . Turn aarting switch OFF. * DisconnectV3A and HR6. Disconnection or defective - Max. 1 Q contact in wiring harness between V3B (female) (5) * Turn starting NO HRlO (female) (1) switch OFF. * Disconnect V3B and HRlO.
Ie
-.-.ce
Disconnection or defective contact in wiring harness between V3A (female) (5) HR6 (female) (1)
Repair or replace
Repair or replace
V-16 Related
electrical
circuit diagram Front brake oil level
VHMS controller ake el
TJW02533
WA1 200-3
20-841 0
TROUBLESHOOTING
v-17
V-17
[E926] [Brake fluid level below specified level (While engine is running)] is displayed
+I * *
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 CGC monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. This failure code is displayed while the engine is running.
Cause
Remedy
YES
Low front brake fluid level or defective front brake fluid level sensor Low rear brake fluid level or defective rear brake fluid level sensor
Supply or replace brake fluid Supply or replace brake fluid
code disappear? II *Turn starting switch OFF. * Ground HRlO (female) (1) to chassis. * Turn starting switch ON. 2
4 YES Defective VHMS

controller code disappear? * Turn starting switch OFF. . Ground HR6 (female) (1) to chassis. *Turn starting switch ON. Disconnection or defective contact in wiring harness between V3A (female) (5) HR6 (female) (1)
Replace
Repair or replace
h Jj &&$gmund * Max. 1 R * Turn starting switch OFF. * Disconnect V3B and HRlO.
switch OFF* DisconnectV3A and HR6. contact in wiring harness between V3B (female) 15) HRlO (female) (1) Repair or replace
NO

Front brake oil level VHM ake el
,,,I
TJW02533
20-842 0
WA1 200-3
TROUBLESHOOTING
V-18
V-18
*
[ES271 [Coolant displayed
level below LOW level (before engine starts] is
* * *
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 CGC monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step, This failure code is displayed before the engine starts. Remedy
CaUSe
Coolant level below LOW level or defective coolant level sensor
Supply or replace coolarr
4 YE!
I.,
If GO6 (female)
* -
(1)
Defective VHMS controller Disconnection or defective contact in wiring harness between GO6 (female) (2) -chassis ground Defective JR2 or JR7 Disconnection or defective contact in wiring harness between V3A (female) (10) - GO6
Replace
and 12) are shorted to each other, does failure code disa ear?
$j%j$jz~ - IS resistance MS between JR2 Imale) and (1) and
Turn starting switch OFF. * Short GO6 (female) (1) and Turn starting switch ON.
I i
-
- 0)
l
IL
NO
ground normal?
between
JR7 (male)
(2) and (1) normal? * Max. 1 R Turn starting switch OFF. * Disconnect JR2 and JR7. NO
. Max. 1 R N( * Turn starting switch OFF. * Disconnect G06.
Repair or replace
Replace
- Max.
1R . Turn starring switch OFF. * Disconnect V3A and G06.
Repair or replace

VHMS
RAlO
(DTHD4) 000
--I
GO6CDT11
Coolant sensor
level
TJW02534
WA1 200-3
20-843 0
TROUBLESHOOTING
v-19
V-19 *
[E9281 [Coolant level below LOW level (While engine is running)] is displayed
* *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. . This failure code is displayed while the engine is running.
Cause
Remedy
Y ES
Coolant level below LOW level or defective coolant level sensor
Supply or replace coolar
4Ylz
1If GO6
(female)
(1)
Defective VHMS controller Disconnection or defective contact in wiring harness between GO6 (female) (2) -chassis ground Defective JR2 or JR7
Replace
* Turn starting switch OFF. * Short GO6 (female) (1) and (2) to each other. m Turn starting switch ON.
N? * Turn starting switch . Disconnect G06.
Repair or replace
NO
Replace
- Max.
l
1R s Turn starting switch OFF. Disconnect V3A and G06.
I
NO
Disconnection or defective contact in wiring harness between V3A (female) (10) - GO6 (female) (1)
Repair or replace
V-19 Related
VHMS
electrical
circuit diagram
Coolant level
TJW02534
20-844 0
WA1 ZOO-3
TROUBLESHOOTING
v-20
v-20
*
[E931] (Clogging of transmission
oil filter) is displayed
-k Before carrying out troubleshooting, check that all the related connectors are properly inserted. Sr Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
Clogging of transmission oil filter or defective transmission oil filter sensor (ROl ) and (2) are shorted to each other, does
Check or replace
YES
Clogging of transmission oil filter or defective transmission oil filter sensor (R02) 4YE
Check or replace
- Turn starting
switch OFF.
If ROZ(female) and (2) are shorted
Gotok
(female) (1) and (2) to each other.
disappear? * Turn starting switch OFF. . Disconnect ~02.

-
Short R02 (female) (1) and (2) to each other.
Is resistance YES between R02 (female) (2) and ROl 3 PIf v3A (female)I11 I is (female) (1) normal? groundedto chassis, p _ is resistance between _ -Max.lQ NI ND RO2Uynale) (1) and . Turn starting chassrs ground switch OFF. normal?
-
Disconnection or defective contact in wiring harness between R02 (female) (2) ROl (female) (1) Disconnection or defective contact in wiring harness between V3A (female) Ill) - RO2 (female) (1)
Repair or replace
Max. 1 R * Turn starting switch OFF. * Disconnect V3A and R02. 6
*Disconnect ROl
and AOi
NO
Repair or replace
YES
From A _
Is resistance between JR7 (male) (3) and (1) normal?

l
Is resistancebetYES ween ~101(female) (2) and chassis 5 ground normal? * Max. 1 R * Turn starting switch OFF. * Disconnect ROl. NO NO
Defective VHMS controller Disconnection or defective contact in wiring harness between ROl (female) (I) - chassis ground Defective joint connector (JR71
Replace
Repair or replace
Max. 1 R * Turn starting switch OFF. Disconnect JR7.

l
Replace
WA1 200-3
20-845 0
TROUBLESHOOTING
w-20
V-20 Related
electrical
circuit diagram
VHMS
TJW02535
20-846 0
WA1 ZOO-3
TROUBLESHOOTING
v-21
V-21
+
[E9321 [Clogging
of air cleaner (I)] is displayed
ChUSe
Remedy
Replace
If connector B06
Y ES
does failure code * Turn starting switch OFF. * Disconnect B06. n * Turn starting switch ON. . Turn starting switch OFF. Replace with another relay. Turn starting switch ON.
Defective dust indicator relay 1
Replace
- Is resistance between B06 (female) -Max.lQ NC N- (1). 1132 (female) (2) *Turn starting 0 and chassis ground switch OFF. normal? * DisconnectV3B and L132 p . Max. 1 R NO * Turn starting switch OFF. * Disconnect B06 and L132.
4 YE: -IIs resistance betMS ween V3B (female) _ 3 (1) and L132 (female) (61 normal?
Gotok
Disconnection or defactivc contact in wiring harness behnreen V3B (female) (1) L132 (female) (6) Contact of wiring harness between 606 (female) (1). L132 (female) (2) with chassis ground Defective VHMS controller
Repair or replace
Repair or replace
Replace
From A _
Is resistance between L132 (female) _ (3) and chassis ground normal? * Max. 1 $2 * Turn starting switch OFF. - Disconnect L132. NO
Disconnection or defective contact in wiring harness between L132 (female) (3) chassis ground
Repair or replace
WA1 200-3
20-847 0
TROUBLESHOOTING
v-21
VHMS
C
Dust indicator I relay
indicator 2 relay Dust indicator 3 relay Dust indicator 4 relay
Dust
TJW02536
20-848 0
WA1 200-3
TROUBLESHOOTING
V-22
V-22
*
[E933] [Clogging of air cleaner (211 is displayed
ChJSe
Remedy
Defective dust indicator 2 1 If connector 807 is disconnected, does failure code I disappear? I -Turn starting switch OFF. . Disconnect 807. P . Turn starting switch ON.
Replace
Y ES
2 relay 2 is replaced with another relay,
Replace
* Turn starting switch OFF. Replace with another relay. Turn starting switch ON.
Is resistancebetween 807 (female)
resistamce betYES ween ~38 (femaw (2) and L133 3 (female) 16) normal?
Is
-r
4 YE5
Gotok
NC
Disconnection or defective contact in wiring harness between V3B (female) (2) L133 (female) (6) Contact of wiring harness between 807 (female) (1) L133 (female) (2) with GND harness or chassis ground Defective VHMS controller Disconnection or defective contact in wiring harness between L133 (female) (3) chassis ground
Repair or replace
and chassisground switch OFF. normal? * DisconnectV3E and L136 - Max. 1 R -Turn starting NO switch OFF. Disconnect 807 and L133.
l
Repair or replace
5 YES
From A _ Is resistance between L166 (female) _ (3) and chassis ground normal? Max. 1 R -Turn starting switch OFF. . Disconnect L133.
l
Replace
NO
Repair or replace
The related electrical circuit diagram is the same as that for V-21.
See V-21.
WA1 200-3
20-849 0
TROUBLESHOOTING
V-23
V-23
J,
[E934] [Clogging of air cleaner (3)] is displayed
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
J, *
to its original position, if the error code is no longer displayed on the CGC monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
ES
Defective dust indicator 3
If connector B08 is disconnected, does failure code disappear?
Y FS
Replace
I
relay 3 is replaced h *Turn starting switch OFF. Replace with another relay. * Turn statting switch ON.
*Turn starting switch OFF. - Disconnect 808. * Turn starting switch ON.
4 YE! Ir Is resistance betYES ween ~36 (female) _ 3 (3) and L134 - bat(female) (6) normal? Is resistance ween Bo8 (female) P _ -Max.lQ N( - (1). L134 (female) (2) *Turn starting h10 and chassisground switch OFF. normal? . Okconnect V3B and L136 * Max. 1 D -Turn starting NO switch OFF. . Disconnect BOB and L134.
GotoA.
Disconnection or defective contact in wiring harness between V3B (female) (3) L134 (female) (6) Contact of wiring harness between 808 (female) (1) L134 (female) (2) with GNC harness or chassis ground
Repair or replace
Repair or replace
Defective VHMS controller From A

[groundnormal? c
-
Replace
1i
I
Max. 10 * Turn starting switch OFF. - Disconnect L134.
NO
Disconnection or defective contact in wiring harness between
qepair or
1134 (female) (3) chassis ground
See V-21.
20-850 0
WA1 200-3
TROUBLESHOOTING
V-24
V-24
j,
[E935] [Clogging
of air cleaner (411 is displayed
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 positio& if the error code is no longer displayed on the CGC monitor display, the problem has been removed.
* *
cause
Remedy
Defective dust indicator 4
Replace
is disconnected, does failure code - Turn starting
Replace
If dust indicator
GotoA.
Is resistance betdisaopear? yEs wee (4)
switch ON.
3
- Is resistance bet-
- Turn starting mritch OFF. . Replace with another relay. . Turn starting switch ON.
V3B (female) _ and Ll35 (female1(6) normal?
wsen 609 (female) .Msx.lR NC - 11).L135 (female) (2) *Turn starting NO and chassis ground switch OFF. normal? . DisconnectV3B and L135 * Max. 1 R * Turn starting NO switch OFF. - Disconnect BO9 and L135.
Disconnection or defective contact in wiring harness between V3B (female) (4) L135 (female) 16) Contact of wiring harness between B69 (female) (1) L135 (female) (2) with GND harness or chassis ground Defective VHMS controller Disconnection or defective contact in wiring harness between L135 (female) (3) chassis ground
Repair or replace
Repair or replace
5 YES
1
From A 0
Replace
Is resistance betwen L135 (female) (3) and chassis ground normal?
11
Max. 1 R *Turn starting switch OFF. . Disconnect L135.
NO
Repair or replace
The related electrical circuit diagram is the same as that for V-21. See V-21.
WA1 ZOO-3
20-851 0
TROUBLESHOOTING
v-25
V-25
*
[E9371 (Abnormal
charge by alternator)
is displayed
the so when disconnecting is carried out when there is still an abnormality, This troubleshooting 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 CGC monitor display, the problem has been removed. Perform the following troubleshooting when fuse 1410) is not broken. If fuse IO is broken, check the wiring harness between the fuse and L152 for short circuit with the chassis ground. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Gotok /ES Disconnection or defective contact in wiring harness between L152 (female) 12) - ERl (female) 6) Disconnection or defective contact in wiring harness between FS2 (male) (9) am L152 (female) (1). (3)
-Max.ln
NI
. Turn starting switch OFF. - Disconnect L152 and ERl IO
._
Repair or replace
Repair or replace
alternator terminal R and chassis .28t2V * Start engine.
NO
Defective alternator signal relay fL152)
Seplace
NO
6 Is resistance YES bstweenV2A r; l-l (female) (4) and
II
Defective alternator
qepair or rplace
YES
Defective VH MS controller Disconnection or defective contact in ti!ing harness between V2A (female) (4) L152 (female) (6) Short circuit with power source in wiring harness between L152 (female) (21- ERl (female) (5)
qeplace
qepair or aplace
1V . Turn starting switch OFF. * Disconnect L152 and ERl.
- Max.
NO
qepair or eplace
V-25 Related
electrical
circuit diagram
srenal
relay
TJW07.537
20-852 0
WA1 200-3
TROUBLESHOOTING
v-10-I
v-101
* * f *
[E8111 (Abnormality in history
in NSVV power source system) is displayed
Perform the following troubleshooting when fuse 1413) is not broken. If fuse I-113) isbroken, check the wiring harness between the fuse and VHMS for short circuit with the chassis ground. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Since the GND line harness of VHMS cannot be disconnected basically (for the multi-pole design), its disconnection is not taken up as a cause.
Cause
Remedy
1 YES Isvoltage
between Vl (6) and chassis around normal? *20-30V * Turn starting switch ON. NO
Defective VHMS controller Disconnection, defective contact, or short circuit with power source in wiring harness between Vl (female) (6) - F63 (5) -fuse - FS3 (6) - battery relay terminal 6 - battery (+)
Replace
Repair or replace
V-101
Related
electrical
circuit diagram
VHMS
controller Fuse (I) Slow blow
Bat terv
Battery
\
ROI R02.B
f
TJWO2538
WA1 200-3
20-853
TROUBLESHOOTING
v-102
V-102 *
*
[E812] (Short circuit with chassis ground sensor power supply)
in 24-V circuit of
Remedy
YES 1 If MT 2,3.4, and 5 are disconnected one by one, does failure code YES
Defect of sensor, disconnection of which turns off failure code Defect of sensor, disconnection of which turns off failure code
-Turn starting
4 YES If JT2 is 1disconnected, does failure code disappear? between pins of JT2
I Short circuit with chassis

ground in wiring harness between JT~ (female) (2). (3). 14). (5) -MT 5 (female) (2). MT4 (female) (2). MT3 (female), (2)) MT2 (female) (2) Go to A. NO Repair or replace
turn starting switch OFF. When disconnecting each connector, turn starting switch ON.
code disappear?
* Turn starting
switch ON. -When connecting each connector, turn starting switch OFF. When disconnecting
i - Turn
,.
startina switch ON. -
I
*Turn starting switch . . ._ON. 1 Eective JT2, JR14, or Replace
Repair or replace Short circuit with chassis ground in wiring harness between JL2 (female) (4) JTZ (female) 11)or between JL2 (female) (5) - JR14 (female) (1) Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (2) JU (female) (3)
Repair or replace
-Turn starting switch ON.
1disconnected. P
11
Replace
1normal7
- Min. 1 MR - Turn starting switch OFF. - Disconnect Vl and JL2.
IU
N
Repair or replace
20-854 0
WA1 200-3
TROUBLESHOOTING
v-102
V-102
Related
electrical
circuit diagram
Transmission main relief Pressure sensor Torque outlet Pressure converter oil sensor
VHMS
Con t ro I ler
v, ~07020~
Torque converter inlet oil Pressure sensor Transmission modulated Pressure

J T2 (DT2)
oil sensor
Front brake oil Pressure sensor Rear brake oil Pressure sensor Work eauipment relief oil Dressure sensor Steering relief oil Pressure sensor
Pressure
sensor
TJW02533
WA1
200-3
20-855 0
TROUBLESHOOTING
v-103
V-103 *
*
[E813] (Short circuit with chassis ground in 12-V circuit of sensor power supply)
Cause
Remedy
YES 1 If F15 is disconnected, _ does failure code disappear? *Turn starting switch ON. NO
Defective wheel rotation sensor
Replace
2 Is resistance betweenV1 (female) (3) and

chassis ground
YES x -
Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (3) F15 (female) (1 J
Replace
normal?
- Min.
l l
1 MQ Turn tiarting switch OFF. Disconnect VI and F15.
NO
Repair or replace
V-103
Related
electrical
circuit
diagram
Wheel VHMS controller )OUtPUt Vl (07020) (t24v)]307/

FL2 (HD-25086) 3 E 307 0.75fG Fl 5 (DT2) 1 307 sensor
rotat
ion
TJW02540
20-856 0
WA1 200-3
TROUBLESHOOTING
v-104
V-104 *
f
[E814] (Short circuit with chassis ground in 5-V circuit of sensor power supply)
Remedy
Y ES
Defective transmission lubricating oil pressure sensor
Replace
YES If R05 is YES disconnected, does failure code disappear? * Turn starting 2 Ne switch ON.
-
Defective fuel level sensor
Replace
disappear? * Turn starting switch ON.
I
Is resisrance
-
Gotok between R05 (female) (1) and

chassis ground
ll0rmal7
between (female) normal? - Min. *
Vl (5) and
ND chassis ground
1 MR Turn starting switch OFF. . Disconnect Vl and MTl.
* Min. 1 MR - Turn starting switch OFF. * Disconnect R05 and RES3.
Nf
Short circuit with chassis ground in wiring harness between R05 (female) (1) - RES3 (female) (2) Short circuit with chassis ground in wiring harness between Vl (female) (5) MT1 (female) (2) Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (4) RES3 (female) 1
Repair or replace
NO
Repair or replace
5 YES between Vl (femaie) (4) and

~&ahaground
Replace
From A
11
NO
Min. 1 MR * Turn starting switch OFF. * Disconnect Vl and AES3

l
Repair or replace
V-104
Related
electrical
circuit diagram
VHMS controller
RT2 (HD-85086)
Transmission oil lubricating sensor Pressure
TJW0254 I
WA1 200-3
20-857 0
TROUBLESHOOTING
V-105
V-105 [E818] (Wrong connection of connector) is displayed in history

Cause
Remedy
1 YES
Is voltage between V2A (9), (12), V3A (9), V3 B (12) and chassis ground as shown in Table 1?
Defective VHMS controller Disconnection, defective contact, short circuit with chassis ground, or short circuit in wiring harness of improper voltage
Replace
NO
Repair or replace
Table 1
V2A (9) chassis ground V2A (12) chassis ground V3A (9) chassis ground V3B (12) chassis ground
Voltage (V)
20 30 V
05V
05V
20 30 V
20-858 20-858
2 (8)
WA1200-3
TROUBLESHOOTING
v-107
V-107 *
*
[E824] (Communication with CGC and engine controller impossible) is displayed in history
is
Cause
Remedy
Defective CGC, engine 4YE! 5 controller, or VHMS I IS voltaae between controller
Ir
Replace
IU
m m.*, wmdcz uem. bmw.3mJL, uamaw, z d 01 Uemde, K m * hllll JL1 Lnmdd II, _._ ween JLl (male) (1) and (2) and (6) and between JLl (3) and
E-II
I
NO
*Min.lMQ * Turn starting nnritch OFF. * Disconnect JLl. C2. Dl, and V4A.
1
NO
Short circuit with power source in wiring harness 1 having abnormal value Short circuit with chassis
Repair or replace
,ground in wiring harness

I having abnormal value Disconnection or defective contact in wiring harness having abnormal value I Defective joint connector , TJLl)
Repair or replace
NO no switch OFF. - Disconnect jL1, C2, Dl, and V4A.
Repair or replace
- Turn starting switch OFF. - Disconnect JLl .
Replace
V-107
Related
electrical
circuit diagram
VH
TJW02543
WA1 200-3
20459 0
TROUBLESHOOTING
V-108
V-108
* * *
fE8251 (Abnormality in S-NET communication between transmission controller) is displayed in history
VHMS -
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. If E826, E827, and E828 occur simultaneously, disconnection, defective contact, short circuit with chassis ground, or short circuit with power source has occurred in the VHMS controller or in the wiring harness between V3A (8) and JL22 (1).
CallSo
Remedy
Go to A.
-. [tWC;;ss~sgrOund 1 1 resistance -Min. 1 MS2 MS betweenV3A Nf . Turn starting (female) (8) and C3B c switch OFF. (female) (4) normal? _ - DisconnectV3A and as. * Max. 2 R - -Turnstarting NO (male) (I) and (8) switch OFF. Disconnect V3A and C3B.
Is
I
l
Short circuitwith chassis ground in wiring harness between V3A (female) (8) - C3B (female) (4) Disconnection or defective contact in wiring harness between WA (female) (8) - C3B (female) (4) Defective joint connector (JL22)
Repair or replace
Repair or replace
Replace
(male) (1) and (2) Disconnect JL22. 1D * Turn starting switch OFF. -Disconnect JL17.
NO
- Max.
I
NO
Defective joint connector (JL17)
Replace
I Is resistance
II
Go to B.
Replace
FromA
i=
- Max.
1V * Disconnect V3A and C3B. *Turn starting switch ON.
1
1
* Turn starting switch OFF. * Disconnect JL18.
NO
Defective joint connector (JL18) Short circuit with power source in wiring harness between V3A (female) (8) - C3B (female) (4) 10 YE: Defective transmission controller
Replace
NO
Repair or replace
Replace
From B -)
Is voltage between YES ~38(female) 112) and chassis 9 ground normal? 1s resrstancebeYES tween VW (female) * Max. 1 V NI - (18). C3B (female) . DisconnectV3A (12) and chassis 8 and US. ground normal? Is resistance *Turn starting switch ON * Min. 1 MR betweenV3A (female) (18) and Turn starting NO r.Z3;.Z;,male)112) switch OFF. Disconnect V3A = Max. 2 R and C3B . Turn starting NO switch OFF. * Disconnect V3A and C3B.
l l
Short circuit with power source in wiring harness between V3A (female) (18) - C3B (female) (12) Short circuit with chassis ground in wiring harness between V3A (female) (18) - C3B (female) (12) Disconnection or defective contact in wiring harness between WA (female) (18) - C3B (female) (12)
Repair or replace
Repair or replace
Repair or replace
20-860 0
WA1 200-3
TROUBLESHOOTING
v-109
V-109
[E826] (Abnormality in S-NET communication between modulated clutch controller) is displayed in history
VHMS -
* * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. If E825, E827, and E828 occur simultaneously, disconnection, defective contact, short circuit with chassis ground, or short circuit with power source has occurred in the VHMS controller or in the wiring harness between V3A (8) and JL22 (I).
Cause
Remedy
4YE! IC Is voltage between YES MO1 (female) It) 3 and chassis ground normal?
Gotok
Short circuit with power
between JU2 (male) (1) and (7) . Disconnect V3A * Turn starting switch OFF. * Disconnect JL22.
Is resistancebetween V3A (female) NC . (81,MO1(female) (1) - -Max.lV . DisconnectV3A and chassisground and Mol. normal? *Turn starting switch ON Min. 1 MD Turn starting NO switch OFF. * Disconnect V3A and Mol.
l l
source in wiring harness

between V3A (female) (8) - MO1 (female) (11 Short circuit with chassis ground in wiring harness between V3A (female) (8) - MO1 (female) (1) Disconnection or defective contact in wiring harness between V3A (female) (8) MO1 (female) (1)
Repair or replace
Repair or replace
Repair or replace
I
NO
Replace
YE 5 Is resistance I between JU3 (male) (1) and (7) normal7 t
From A -I
- Max.
1R -Turn starting switch OFF. . Disconnect JL23.
7 YE: Go to B. Is resistancebetYES ween WA (female) - (18). M01 (female) 6 Short circuit with chassis (12) and chassis Is resistance ground in wiring harness ground normal? between V3A between V3A (female) * Min. 1 MR NC (female) (181and (18) - MO1 (female) (12) . Turn starting MO1(female) (12) switch OFF. normal? * DisconnectWA and MO1 contact in wiring harness sMax.2R betvveen V3A (female) (18) * Turn starting NO - MO1 (female) (12) switch OFF. * Disconnect V3A and Mol. Defective joint connector (JL23) 0
Repair or replace
Repair or replace
Replace
a MS
From 0 between MO1 (female) (12) _ and chassis ground normal? - Max. 1 V Disconnect V3A and Mol. Turn starting switch ON.
l
Isvoltage
Replace
NO
Short circuit with power source in wiring harness between V3A (female) (18) - MO1 (female) (12)
Repair or replace
20-862 0
WA1 200-3
TROUBLESHOOTING
v-109
V-109
Related
electrical
circuit diagram
TWW02601
WA1 200-3
20-863 0
TROUBLESHOOTING
v-110
V-110
between [E8271 (Abnormality in S-NET communication work equipment controller) is displayed in history
VHMS -
* * *
check that all the related connectors are properly inserted. Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. defective contact, short circuit with disconnection, If E825, E826, and E828 occur simultaneously, in the VHMS controller or in the occurred has source power with circuit chassis ground, or short wiring harness between V3A (8) and JL22 (I).
Cause
Remedy
4YE!
6
I
Gotok
Short circuit with chassis ground in wiring harness between V3A (female) (8 - l.26 (female) (1) Disconnaction or defective contact in wiring harness between V3A (female) (8) L26 (female) (1) Disconnaction or defective contact in wiring harness between V3A (female) (8) U6 (female) (1)
$SZ&~H I Is resistancebetI IL y~z ween V3A Ifemale) -Max.lV NC - (8). L26 (female) (1) - DisconnectV3A and chassisground 2 and LZ6. normal? . Turn starting switch ON Is resistance Min. 1 MD * YES betweenV3A NO - (female) (8) and LZ6 - * Turn starting switch OFF. (female) (1) normal? 1 * Disconnect V3A Is resistance *Max.2!.2 and L26. _ *Turn starting between JL22 NO (male) (1) and (2) switch OFF. normal? * Disconnect V3A Repair or replace
Repair or replace
Repair or replace
- Max.
1R . Turn starting switch OFF. . Disconnect JL22.
and L26. NO Defective joint connector (JU2) Replace
From A -I
I Is resistance between JL23 (male) (1) and (2) normal?
I I I
_ Is resistance ; betweenV3A - (female) (18) and L26 (female) (12) onal?
lMax.2R
. Turn starting switch OFF. Disconnect V3A and L26.
7 YE! Is resurtancebetYES wee V3A (female) - (181.L26 (female) 6 (121and chassis ,ground normal? . Min. 1 MQ N( *Turn starting switch OFF. * DisconnectV3A and LZ6
NO
Go to 0.
Short circuit with chassis ground in wiring harness between V3A (female) (18) - L26 (female) (12) Disconnection or defective contact in wiring harness between V3A (female) (181 - L26 (female) (12) Defective joint connector (JK3)
Repair or replace
Repair or replace
- Max.
1R -Turn starting switch OFF. . Disconnect JL23.
IO
Replace
8 YES
From S _ Is voltage between _ L26 (female) (12) and chassis ground normal? *Max.lV Disconnect V3A and L26. -Turn starting switch ON.
l
Defective work equipment controller Short circuit with power source in wiring harness between V3A (female) (18) - L26 (female) (12)
Replace
NO
Repair or replace
20-864 0
WA1 200-3
TROUBLESHOOTING
v-110
V-110
Related
electrical
circuit diagram
II
II
II
TWW02601
WA1 200-3
20-865 0
TROUBLESHOOTING
v-111
V-l 11 [E828] (Abnormality in S-NET communication main monitor) is displayed in history

* * *
between
VHMS -
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. If E825, E826, and E827 occur simultaneously, disconnection, defective contact, short circuit with chassis ground, or short circuit with power source has occurred in the VHMS controller or in the
wiring harness between V3A (8) and JL22 (1).
CaUSS!
Remedy
GotoA.
(female) (8) and LO8 (female) (11 normal? aMax.2R * Turn starting switch OFF. * Disconnect V3A and L08.
Short circuit with chassis ground in wiring harness between V3A (female) (81 - LO8 (female) (1)
Repair or replace
. DisconnectWA and L08.
(male) (1) and (8) normal? between JL17 (male) (1) and (6) .Max.lR *Turn starting switch OFF. . Disconnect JL17. *Max.lR . Turn starting switch OFF. . Disconnect JU2.
NO
Disconnection or defective contact in wiring harness between V3A (female) (8) LO8 (female) (1) Defective joint connector (JL22)
Repair or replace
Replace
NO
Replace
7 YE
YES 6 Is resistance between JL23 (male) (1) and (8) normal?
Go to 8.
From A -c
Is resistance _ * Max. 1 R YES_ between JL18 NC -Turn starting (male) (1) and (6) 5 normal? switch OFF. Is voltage between * Disconnect JU3. - Max. 1 D Lo8 (female) (1) * Turn starting NO and chassis switch OFF. ground normal? - Disconnect JL18. . Max. 1 V * Disconnect V3A NO and L08. * Turn starting switch ON. 10 YE! Is voltage between YES LO8 (female) (3) and chassis 9 ground normal? Is reswance betyes waen WA (female) *Max.lV N( - (181. LO8(female) (3) s DisconnectV3A ground chassis and 8 and L08. normal? * Turn starring switch ON . Min. 1 MR - . Turn starting NO _ switch OFF. * Disconnect V3A and LO8 NO
qeplace
Defective joint connector (JL18) Short circuit with power source in wiring harness between V3A (female) (8) - Lo8 (female) (1)
?eplace
qepair or aplace
Replace
Short circuit with power source in wiring harness between V3A (female) (18) - Lo8 (female) (3) Short circuit with chassis ground in wiring harness betwean V3A (female) (18) - Lo8 (female) (3) Disconnection or defective contact in wiring harness between V3A (female) (18) - Lo8 (female) (3)
Repair or replace
From 6 -)
Is resistance betweenV3A (female) (18) and LO8(female) (3) _normal? * Max. 2 R -Turn starting switch OFF. * Disconnect V3A and L68.
Repair or replace
Repair or replace
20-866 0
WA1 200-3
TROUBLESHOOTING
v-102
V-111 Related
electrical
circuit diagram
Transmission ontroller
TWW02601
WA1 200-3
20-867 0
TROUBLESHOOTING
v-113
V-l 13 [E8411 (Short circuit with power source in buzzer output system) is displayed in history
* f Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step. inserted.
1 YES
voltage between Vl (female) (16) and chassis ground normal?
Is
Defective VHMS controller Short circuit with power source in wiring harness between Vl (female) (16) - I39 (female) (2)
Replace
* Max. 1 V - Turn starting switch OFF. * Disconnect Vl and L9g. Turn starting switch ON.
NO
Repair or rePlace

Emergency Parking brake cancel switch Main monitor LO6 (040 16) 0.5fL VHMS controller Vl FS2 (S12 Blue) Fues (I) L89 (M4)
(07020)
Caution relay
buzzer
Caution buzzer
TJW02518
WA1 200-3
20-869 0
TROUBLESHOOTING
v-114
V-114
* J,
[E843]
(Short circuit with power source in check lamp system) is displayed in history
Cause
Remedy
Is voltage between Vl (female) (14)
Defective VHMS controller Short circuit with power source in wiring harness between Vl (female) (14) - LO6 (female) (10)
Replace
* Max. 1 V -Turn starting switch OFF. . Disconnect VI and L06. * Turn starting switch ON.
NO
Repair or replace
V-l 14 Related
electrical
circuit diagram
VHMS Controller
Main
monitor
TJW02545
20-870 0
WA1 200-3
TROUBLESHOOTING
v-115
V-115
[E844] (Short circuit with power source in flash synchronizing signal system) is displayed in history
connect any disconnected check that all the related connectors are properly connectors before going on to the next step. inserted.
*
Ir
Before carrying out troubleshooting,

Always
Cause
Remedy
1 YES Is voltage between Vl (female) (13) and chassis ground normal? ; Max. 1 V * Turn starting switch OFF. * Disconnect Vl and L07. *Turn starting switch ON. NO
Defective VHMS controller Short circuit with power source in wiring harness between Vl (female) (13) - LO7 (female) (6)
Replace
Repair or replace
V-115
Related
electrical
circuit
diagram
VHMScontroller
Main
monitor
WA1 200-3
20-871 0
TROUBLESHOOTING
V-116
V-116
*
[E861] (Disconnection or short circuit with chassis ground in boom bottom pressure sensor system) is displayed-in history
* *
Perform the following troubleshooting when fuse II-9 is not broken. If fuse II-9 is broken, check the wiring harness between the fuse, VHMS controller, and F06 (female) (2) for short circuit with the chassis ground. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
* YES 3 r
4YES .I Is resistance between JF3 (male) (1) and (4)
Go to A.
Is resistance betYES ween ~06 (female) _ NO Max. 10 (31 and chassis * Turn starting switch 2 _ ground normal? OFF. If F06 (female) (3) is - Disconnect JF3. YES groqded to chassis, * Min. 1 MR _ IS resonancebetween _ Turn starting NO Vl (female1 (1) and switch OFF. 1 ck%?grcd n 1 * Disconnect Vl *Max.10 and F06. Turn starting of boom head NO pressure switch, is switch OFF. * Disconnect Vl and F06. . Turn starting switch ON. NO
l l l
Defective joint connector (JF3) Short circuit with chassis ground in wiring harness between Vl (female) (1) FfE (female) (3) Disconnection or defective contact in wiring harness between Vl (female) (1) F06 (female) (3) Defective boom bottom pressure sensor
Repair or replace
Repair or replace
YES
Defective VHMS controller Disconnection or defective contact in wiring harness between Fo6 (female) (2) - Vl (female) (81, (9)
From A
Max. 1 Q -Turn starting switch OFF. . Disconnect F06 and Vl.
NO
Repair or replace
204372 0
WA1 200-3
TkOUBLESHOOTlNG
V-116
V-116
Related
electrical
circuit diagram
VHMS
Boom bottom pressure sensor
TWW02602
WA1 200-3
20-873 0
TROUBLESHOOTING
v-117
V-117
[E862] (Disconnection or short circuit with chassis ground in boom head pressure sensor system) is displayed in history
* *
Perform the following troubleshooting when fuse II-9 is not broken. If fuse II-9 is broken, check the wiring harness between the fuse, VHMS controller, and F14 (female) (2) for short circuit with the chassis ground. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
Cause
Remedy
4YES ez Is resistance betweenJF3 (male) (1) and (5) normal? .Max.lR NO *Turn starring switch OFF. * Disconnect JF3. NO
Gotok
8
_ & _ If F14 (female) (31 if yES groundedto chasrx _ I* resistancebetween _
Vl (female) (10) and
Defective joint connector (JF3) Short circuit with chassis ground in wiring harness between Vl (female) (10) - F14 (female) (3) Disconnection or defective contact in wiring harness between Vl (female) (10) - F14 (female) (3) Defective boom head pressure sensor
Replace
ground normal? * Min. 1 MD - Turn starting switch OFF. Disconnect Vl and F14. NO
l
Repair or replace
chassisground replaced with that of boom bottom pressure switch, is *Turn starting switch ON.
*Turn starting switch OFF. Disconnect Vl and F14.

l
Repair or replace
Replace
NO
Defective VHMS controller From A
Replace
Max. 1 Q * Turn starting switch OFF. * Disconnect F14 and Vl.
i---NO
Disconnection or defective contact in wiring harness between F14 (female) (2) - Vl (female) (81, (9)
Repair or replace
20-874 0
WA1 200-3
TROUBLESHOOTING
v-102
V-l 17 Related
electrical
circuit diagram
VHMS controller
TJW02548
WA1 200-3
20-875 0
TROUBLESHOOTING
V-118
V-118
[E863] (Disconnection or short circuit with chassis ground in rea.r brake oil pressure sensor system) is displayed in history
* * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. If E864, E865, E867, and E868 occur simultaneously, disconnection, defective contact, or short circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JR14 (female) (1).
Cause
Remedy
1 1 If rear brake oil 1 pressure sensor is

1
I
JR14 (male) (1) and (5). between JL2
Defective rear brake oil pressure sensor
Replace
4YE
Ilf HR16 (female) (2) is
Ir
GotoA.
. Turn starting switch OFF. * Replace pressure

sensor normal -Turn switch with one.
contact in wiring harness between Vl (female) (2) HR16 (female) (2)
Repair or replace
- Max. * Turn
starting ON.
- Max. 1 Q -Turn starting switch OFF. . Disconnect JR14, Jl2, or JR13.
1R starting switch OFF. * Disconnect HR16 and V2k
I Vl.
NO
Disconnection or defective contact in wiring harness between Vi% (female) (8) HR16 (female) (31 Joint connector having improper resistance (JR14, JL2, or JR131
Repair or replace
IO
Replace
7 YE!
I Is resistance bet-
1r
Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (2) HR16 (female) (2) Short circuit with chassis ground in wiring harness between V2A (female) (8) - HR16 (female) (3) Disconnection or defective contact in wiring harness between HR16 (female) (1) -chassis ground
Replace
YI
,~~~
Repair or replace
From
Aie/
lMax.lR
. Turn starting switch OFF. . Disconnect HR16.
* Turn starting switch OFF. * Disconnect V2A and HR16.
NO
Repair or replace
Repair or replace
20-876 0
WA1 200-3
TROUBLESHOOTING
V-118
V-118
Related
electrical
circuit diagram
VH
JRl3tDTlB)
Battery
RAlO
8L
(DTHD4)
TJW02531
WA1 200-3
20-877 0
TROUBLESHOOTING
v-119
V-119
[E864] (Disconnection or short circuit with chassis ground in work equipment relief pressure sensor system) is displayed in history
inserted. +r Before carrying out troubleshooting, check that all the related connectors are properly step. next the to on going before * Always connect any disconnected connectors short If E863, E865; E867, and E878 occur simultaneously, disconnection, defective contact, or * JR14 and (2) (female) VI between harness wiring the in occurred has ground circuit with chassis (I). (female)
Cause
Remedy
MS
sensor is replaced with normal one,
is
system normal?
. Turn starting switch OFF. Replace pressure sensor normal wth one. (steering oil pressure sensor) * Turn starting switch ON.
I r
YI
2
(181 and Ifemale) chassis
Defective work equipment relief pressure sensor
Replace
1If HS2
YES 3
Ifemale)
(2) is
Gotok
If HSZ Ifemale I31 is grounded to chassis, is resistance between WA round normal?
grounded to chassis, is resistance between Vl bnale) (2) and chassis round normal? - Max. 1 R switch starting *Turn OFF. HS2 and * Oisconnect
NI
Disconnection or defective contact in wiring harness between Vl (female) (2) HS2 (female) (2) Disconnection or defective contact in wiring harness behveen V2A (female) (18) - HS2 (female) (3) Joint connector having improper resistance fJR14, JL2, JR16, or JR13)
Repair or replace
Vl.
NO
Repair or replace
- Max. 1 R * Turn starting switch OFF. * Disconnect JR14, JL2, JRl6, or JR13.
switch OFF. * Disconnect HS2 and WA.
Replace
7 YE!
1 tS
resistanca bet-
ir
Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (2) HS2 (female) (2)
Replace
qepair or .eplace
5
Is resistance 1
I
* Turn starting switch OFF. Disconnect V2A and HS2. NO
A ~~~0{~~ From
*Max.lR * Turn starting switch OFF. D&connect HS2,
l
Short circuit with chassis ground in wiring harness between V2A (female) (18) - HS2 (female) (2) Disconnection or defective contact in wiring harness between HS2 (female) (1) chassis ground
3epair or pplace
IO
qepair or aplace
20-878 0
WA1 200-3
TROUBLESHOOTING
v-119
V-l 19 Related
electrical
circuit diagram
VHMS
ipment ii e sensor
Bat terv
RAlO [DTHDI) 000 I
TJW02550
WA1 ZOO-3
20-879 0
TROUBLESHOOTING
v-120
V-120
[E865] (Disconnection or short circuit with chassis ground in front brake oil pressure sensor system) is displayed in history
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted. Jr Always connect any disconnected connectors before going on to the next step. Ir If E863, E864, E867, and E878 occur simultaneously, disconnection, defective contact, or short circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JR14 (female) (1 I.
Cause
Remedy
Defective front brake oil pressure sensor
Replace
4YES tf HR15 (female) CZ! is

YES _ groupded to chassis, IS resistance between _
GotoA
* Turn starting switch OFF. - Replace pressure sensor with normal one. (rear brake oil pressure sensor) . Turn starting switch ON.
n
2
3 If HR15 (female)(3) is groundedto chassis. is resistance between _ WA (female)(7) and f;~~7ground * Max. 1 R * Turn starting switch OFF. . Disconnect HR15 and V2A. IO
;f;;kNand normal?
aMax.lC.2
NC
~0
I,,,
-Max.1 R -Turn starting switch OFF. Disconnect JR14, JL2, or JR13.
l
Is resistance between JR14 (male) (1) and (6). between JLZ (male) (3) and (51, or betwean JR13 (male) 1 and 6 normal?
* Turn starting switch OFF. - DisconnectHRlS and Vl. NO
Disconnection or defective contact in wiring harness between Vl (female) (2) HRl5 (female) (2) Disconnection or defective contact in wiring harness between VZA (female) (7) HRl5 (female) (3) Joint connector having improper resistance (JR14, JL2, or JR131
Repair or replace
Repair or replace
Replace
7 YES
1IS resistance bat-
1r
Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (2) HR15 (female) (2) Short circuit with chassis ground in wiring harness between VZA (female) (7) - HR15 (female) (3) Disconnection or defective contact in wiring harness between HR15 (female) (1) -chassis ground
Replace
M 5
Repair or replace
I Isresistance
From A dig::;
I
1 - Turn starting switch OFF. * Disconnect V2A and HR15. NO
Repair or replace
* Max. 1 R Turn starting switch OFF. * Disconnect HR15.

l
Repair or replace
20-880 0
WA1 200-3
TROUBLESHOOTING
v-120
V-120
Related
electrical
circuit diagram
VHMS
JR13tDTIB1
Fran t brake oi I Pressure
TJW07.530
WA1 200-3
20-881 0
TROUBLESHOOTING
v-121
V-121
[E866] (Disconnection or short circuit with chassis ground in transmission main relief pressure sensor system) is displayed history
in
* * +
Before carrying out troubleshooting, check that ail the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. If E868, E871, and E884 occur simultaneously, disconnection, defective contact, or short circuit with chassis ground has occurred in the wiring harness between Vl (female) (2) and JT2 (female) (1).
Cause
Remedy
Defective transmission main relief pressure sensor
Replace
sensor is replaced
* Turn starting switch OFF. . Replace pressure sensor with normal one. - Turn starting switch ON.
l
Yl
Imale) (1)and 12). kwaen JLZ ImaW (31and (0.
* Max. 1 n Turn starting switch OFF. * Disconnect JTZ, JL2, JT3, or JLll.
4YEI If MT2 (female)(2) is MS groundedto chassis, _ 1sresistance between _ Vl (female)(2) and 3 chassisground If MT2 (female)(3) is normal? , grounded to chassis, NC is resistance between _ .Max.lQ *Turn starting switch OFF. , * DisconnectMT2 and Vl. * Max. 1 Q *Turn starting NO switch OFF. . Disconnect MT2 and WA.
Go to A.
Disconnection or defective contact in wiring harness between Vl (female) (2) MT2 (female) (2) Disconnsction or defective contact in wiring harness between V2A (female) (6) MT2 (female) (3) Joint connector having improper resistance (JTZ, JK, JT3, or JLll)
Repair or replace
Repair or replace
0
7 YES Yl
6
Replace
Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (2) MT2 (female) (2) Short circuit with chassis ground in wiring harness between VZA (female) (6) - MT2 (female) (3) Disconnection or dsfsctive contact in wiring harness between MT2 (female) (1) chassis ground
Replace
iS[
1Is resistancebetYE 6
I Is resistance 1 . Min. 1 MR - Turn starting switch OFF. . Disconnect VZA and MTZ.
1 . Min. 1 MQ NO *Turn starting switch OFF. - DisconneciVl and
Repair or replace
From A
-f%$%~
.Max.lR * Turn starting switch OFF. Disconnect MT2.
l
Repair or replace
Repair or replace
20-882 0
WA1 200-3
TROUBLESHOOTING
v-121
V-121
Related
electrical
circuit diagram
VHMS .._
Transmission
main relief ensor
TJWO2552
WA1 200-3
20-883 0
TROUBLESHOOTING
V-122
V-122
[E8671 (Disconnection or short circuit with chassis ground in steering relief pressure sensor system) is displayed in history
* f *
Cause
Remedy
ES
Defective steering relief pressure sensor
1 1 If steering relief
GotoA.
contact in wiring harness between Vl (female) (2) HS3 (female) (2) switch OFF. - Replace pressure sensor with normal one. switch ON. Max. 1 R * Turn starting switch OFF. * Disconnect JR14, JU, JR16, or JR13.
l
Repair or replace
between (1)ad (41. (male) (5). Bland JU Imale) 121 (male1 JR16 berwem JR13 (41.orand
1R *Turn starting switch OFF. * Disconnect HS3 and V2k
- Mar
1
NO
Vl.
Disconnection or defective contact in wiring harness between WA (female) (16) - HS3 (female) (3) Joint connector having improper resistance (JR14, JU, JR16, or JR13)
Repair or replace
7 YES
I IS resistancebet(21, HS3 (female) (2) and chassisground
Ir
IL
NC
Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (2). HS3 (female) (2) Short circuit with chassis ground in wiring harness between V2A (female) (16) - HS3 (female) (3) Disconnection or defective contact in wiring harness between HS3 (female) (1) chassis ground
Replace
YE
ween VZA (female) (16). HS3 (female)
normal
. _. -MI2
Repair or replace
-Turn starting switch
From
Ai61
- Max. 1 R - Turn starting switch OFF. * Disconnect HS3.
* Min. 1 MD * Turn startino switch OFF.. Disconnect V2A and HS3. IO
- DisconnectVI and HS3.
NO
Repair or replace
Repair or replace
20-884 0
WA1 200-3
TROUBLESHOOTING
v-122
V-122
Related
electrical
circuit diagram
VHMS
Steering relief
oil sensor
TJW02553
WA1 200-3
20-885 0
TROUBLESHOOTING
v-123
V-123
[E8681 (Disconnection or short circuit with chassis ground in torque converter outlet oil pressure sensor system) is displayed in history
* * *
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. If E868, E871, and E884 occur simultaneously, disconnection, defective contact, or short circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JT2 (female) (1).
Cause
Remedy
YES
Defective torque converter outlet oil pressure sensor
Replace
1
rlf tOmu
000v.3-ter
outlet oil pressure

sensor is replaced
* Turn starting switch OFF. * Replace pressure sensor with normal one. - Turn starting switch ON.
(4). betwen and fllaed(41, JKlmabJ ImaId
lMax.lR *Turn starting switch OFF. Disconnect JT2, Jl.2, JT3, or JLl 1.
l
4YE! (2) is If MT3 Wemale) chassis, to YES grounded between _ _ ts resistance Vl (female)(2) and 3 chassis,ground If MT3 (female)(3) is ; gmundedto chassis, -gfUMf. NC between _ * Max. 1 n . ISresistance *Turn starting switch WA (female)(5) and OFF. &&siiTground - DisconnectMT3 and Vl. . Max. 1R *Turn starting NO switch OFF. . Disconnect MT3 and V2k
Gotok
Disconnection or defective contact in wiring harness between Vl (female) (2) MT3 (female) (2) Disconnection or defective contact in wiring harness between &!A (female) (5) MT3 (female) (3) Joint connector having improper resistance (JT2, JU, JT3, or JLll)
Repair or replace
Repair or replace
Replace
IO
7 YE!
Is resistance betyEs ween Vl (female) - (2). MT3 (female) (2) 6 and chassis ground Is resistancebetnormal? wean WA (female) -Min. 1 MS2 NC (female) (31 - * Turn starting switch MT3 (5). and chassisground OFF. normal? * DisconnectVl and MT3. * Min. 1 MR NO * Turn starting switch OFF. * Disconnect WA and MT3.
Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (2) MT3 (female) (2) Short circuit with chassis ground in wiring harness between V2A (female) (5) - MT3 (female) (3) Disconnection or defective contact in wiring harness between MT3 (female) (1) chassis ground
Replace
YI 5
I Is resistance From A ~~~rr?.~~
Repair or replace
Repair or replace
*MaxlR * Turn starting switch OFF. - Disconnect MT3.
Repair or replace
20-886 0
WA1 200-3
TROUBLESHOOTING
v-123
V-123
Related
electrical
circuit diagram
VHMS
Tome outlet
converter oil ensor
TJW02554
WA1 200-3
20-887 0
TROUBLESHOOTING
V-124
V-124
[E8711 (Disconnection or short circuit with chassis ground in transmission modulation pressure sensor system) is displayed in history
f * *
check that all the related connectors are properly inserted. Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next step. defective contact, or short disconnection, if E864, E865, E867, and E878 occur simultaneously, VI (female) (2) and JT2 between circuit with chassis ground has occurred in the wiring harness
(female) (I 1.
Cause
Remedy
YES
Defective transmission modulation pressure sensor
Replace
4YE
yEs _ 3 If MT5 (femalejob If MT5 (female) (2) is to chassis, gryded IS resistance between Vl (female) (2) and ~o~$ground _
* Turn starting switch OFF. - Replace pressure sensor with normal one. Turn starting switch ON.
n i I
JL2 (male) 13)and(4). bshwnJT3lmakl~1lad U. orbetwen JLll ImaW
; groundedto chassis, resistancebetween . IS v2A (female)(151and FoEi&ground
- Max. 1 Q starting switch N $

- Disconnact Vl. MT5 and
Disconnection or defective contact in wiring harness between Vl (female) (2) MT5 (female) (2) Disconnection or defective contact in wiring harness between V2A (female) (15) - MT5 (female) (3) Joint connector having improper resistance (JT2, JL2, JT3, or JLll)
Repair or replace
.Max.lR . Turn starting switch OFF. mDisconnect JT2, JL2, JT3, or JLll.
Max. 1 R - Turn starting switch OFF. * Disconnect MT5 and WA.

-
NO
Repair or replace
Replace
JO
7 YE
Is resistance bet-
fr
Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (2) MT5 (female) (2)
Replace
Repair or replace
From A
-jz;?tt -
I Is resistance
I
* Turn starting switch OFF. . Disconnect V2A and MT5 NO
Short circuit with chassis ground in wiring harness between V2A (female) (15) - MT5 (female) (3) Disconnection or defective contact in wiring harness between MT5 (female) (1) chassis ground
Repair or replace
Max. 1 R * Turn starting switch OFF. . Disconnect MT5.
Repair or replace
20-888 0
WA1 200-3
TROUBLESHOOTING
v-124
V-124 Related
electrical
circuit diagram
I
sor
TJW02555
WA 1200-3
20-889 0
TROUBLESHOOTING
v-125
V-125
[ES721 (Disconnection or short circuit with chassis ground in transmission lubricating oil pressure sensor system) is displayed in history
*
*
Cause
Remedy
Defective transmission lubricating oil pressure sensor
Replace
4YE! 1 If MT1 (female) (2) is transmlsslon yEs younded to chassis, lubricatingoil _ u.resistancebetween_ pressure sensor is Vl (female1 (5) and 3 replaced with chassis gmund normal one, is It MT1 &zmale)(3) is em normal? YES youndedtochassis, RQRMR 1:. _ 1sresisrance benueen _ -Max.lQ NC * Turn starting *Turn starting switch VZA (female)(14) and switch OFF. 2 r;h%&s$ground OFF. - DisconnectMT1 and * Replace pressure Is resistance betVl. * Max. 1 R ween .JT5 (male) (1) sensor with and (5) and between Turn starting normal one. NO NIO JLll (male) (1) and switch OFF. * Turn starting r4) orraL . Disconnect MT1 switch ON. * Max. 1 R and VZA. * Turn starting NO switch OFF.
l
Gotok
Diaconnaction or defective contact in wiring harness between Vl (female) (5) MT1 (female) (2) Disconnection or defective contact in wiring harness between V2A (female) (14) - MT1 (female) (3) Joint connector having improper resistance (JT3 orJRl1)
Repair or replace
Repair or replace
Replace
* Disconnect JT3 and JR11 BYE: Defective VHMS controller Short circuit with power source in wiring harness between V2A (female) (14) - MT1 (female) (3) Short circuit with chassis ground in wiring harness between Vl (female) (5) MT1 (female) (2) Short circuit with chassis ground in wiring harness between V2A (female) (14) - MT1 (female) (3) Disconnection or defective contact in wiring harness betwean MT1 (female) (1) chassis ground Replace
YI 6
Is resistance yes wen V2A bet-
Repair or replace
(female) * Turn starting switch OFF. + Disconnect Vl and MTl. uo NO
- (14). MT1 (female)

Is resistance 5
Repair or replace
, ground
-
(3) and chassis normal?
From A betwee MT1 (female) (1) and chassisground normal? . Max. 1 R * Turn starting switch OFF. * Disconnect MTl.
- Min. 1 MD -Turn starting switch OFF. * Disconnect V2A and MTI. NO
Repair or replace
Reoair or
20-890 0
WA1 ZOO-3
TROUBLESHOOTING
v-125
V-125
Related
electrical
circuit diagram
VHMS
Transmission lubricating oil pressure sensor
rb7
TJW02556
WA 1ZOO-3
20-891 0
TROUBLESHOOTING
V-126
V-126
[E874] (Short circuit with chassis ground in torque converter temperature sensor system) is displayed in history
oil
Ir -k
,_ Is resistance between T24 _ (male) (1) and 12) normal? - 40 kf2 at normal temperature (25C) -Turn starting switch OFF. * Disconnect T24.
2 Is reGstanc8 between YES WA (female) (3). T24 - (female) (1) and 1 chassis ground IlOmMl?
YES
Replace
NO *Min.lMR *Turn starting switch OFF. . Disconnect V2A and T24. NO
Short circuit with chassis ground in wiring harness between V2A (female) (3) - T24 (female) (1) Defective torque converter oil temperature sensor
Repair or replace
Replace
V-126 Related electrical circuit diagram VHMS
Torque convert er oil temperatur e I_--.__ sensor unon I Ior) kUKl
controller
20-892 0
WA1 200-3
TROUBLESHOOTING
V-127
V-127
[E8751 (Short circuit with chassis ground and with power

source in hydraulic oil temperature in history sensor system) is displayed
inserted.
*
*
check that all the related connectors are orooerly Before carrying out troubleshooting, Always connect any disconnected connectors before going on to the next stei.
Cause
Remedy
3 YES Ez 2 PIs rasisIaGce belwaan y~z

VZAifemale) IllI. (female) (1) and HSl
Is voltage between V2A (female) (11) and chassis ground normal?

-Max.lV
Defective VHMS controller Short circuit with power
Replace
1 _ Is resistance between HSl (male) (1) and (2) normal?
chassisground
_normal? * Min. 1 MR * Turn starting NO switch OFF. * Disconnect V2A and HSl. NO
NO * Turn startingswitch OFF. - DisconnectWA and HSl. *Turn startingswitch ON.
source in wiring harness

between V2A (female) (7 1) - HSl (female) (1) Short circuit with chassis ground in wiring harness between V2A (female) (female)(l) (ll)-HSl Defective hydraulic oil temperature sensor
Replace
Repair or replace
- 3.5 - 4.0 M at normal temperature (25C) * Turn starting switch OFF. * Disconnect HSl.
Seplace
V-127 Related
electrical
circuit diagram
VHMS roller
V2A(07018)
LR2 (HO-85086) 8 2801
Hrdraul ic oi I sensor
TJW02528
WA1 200-3
20-893 0
TROUBLESHOOTING
V-128
V-128 *
J,
[E875] (Short circuit with chassis ground in ambient temperature sensor system) is displayed in history
inserted.
Cause
Remedy
4YE: YES 3 r - Is resistanoe between ; VZAIfemale) (10).PHl -- Max. 1 v - (female1 (1) and - -Turn starting switch Is voltage between VIA (female) (10) and chassis ground normal?
Defective VHMS controller Short circuit with chassis ground in wiring harness between V2A (female) (10) - PHl (female) (1) Short circuit with chassis ground in wiring harness between V2A (female) (10) - PHl (female) (1) Disconnection or defective contact in wiring harness between V2A (female) (10) - PHl (female) (1) Defective ambient temperature sensor
Replace
NC
Repair or replace
dwsis ground
nonal?
<
OFF. - Disconnect
V2A and PHl
Is resistance between PH 1 (male) (1) and (2) normal? * Approx. 12 kf2 at normal temperature (25C) *Turn starting switch OFF. - Disconnect PHl.
* Max. 1 R * Turn starting switch OFF. * Disconnect V2A and PHI.
Min. 1 MR - Turn starting switch OFF. Disconnect V2A and PHl.
Turn Rarting switch ON.
NO
Repair or replace
IO
Repair or replace
I
NO
V-128
Related
electrical
circuit diagram
VHMS rol ler
VZA (070
I81
.
temperature
LR2 (~~-85086) 0.76fE
TJWO2557
20-894 0
WA1 200-3
TBQUBLESHOOTING
v-129
V-129
[E878] (Disconnection or short circuit with chassis ground in PPC relief pressure sensor system) is displayed in history
* * Ir
Cause
Remedy
YES
Defective PPC relief pressure sensor
Replace
1 If PPC relief pressure sensor is replaced with normal one, is system normal? El * Turn starting switch OFF. Replace pressure sensor with normal one. -Turn starting switch ON.
l
YI
2
1R * Turn starting switch OFF. * Disconnect JR14 JL2, or JR7.
-Max.
4 YE? If HS4 (female)(2) is MS groundedto chassrs, rsresotance between _ 3 - Vl (female)(2) and ;has$ground If HS4 (female)(3) is o a groundedto chassis, N( is r&stance betwean _ - Max. 1 Q -Turnstarting switch V2A (female)(11and chassisground OFF. normal? * Disconnect HS4 and Vl. * Max. 1 R * Turn Starting NO switch OFF. * Disconnect HS4 and V2A.
IO
Gotok
Disconnection or defective contact in wiring harness between Vl (female) (2) HS4 (female) (2) contact in wiring harness between V2A (female) (1) HS4 (female) 13) Joint connector having improper resistance (JR14, JU, or JR71
Repair or replace
Repair or replace
Replace
From A
Is resistance between HS4 - (female) (1) and chassisground normal?
7 YE: Is resistance betyfzs ween Vl (female) - (2). HS4 (female) 12) _ 6 and chassis ground Is resistancebetnormal? YES ween VZALfemale) P * Min. 1 MR NC - (1). HS4Jfemale) (3) - *Turn starting switch and chassisground 5 OFF. ~ normal? . DisconnectVl and * Min. 1 MR I - -Turn NO
Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (2) HS4 (female) (2) Short circuit with chassis ground in wiring harness between V2A (female) (1) - HS4 (female) (3) Disconnection or defective contact in wiring harness between HS4 (female) (1) chassis ground
Replace
Repair or replace
starting
Repair or replace
- Max. 1 Q . Turn starting switch OFF. . Disconnect HS4.
Switch ncF _. . . *Discon lnect V2A and HS4. NO
Repair or replace
20-896 0
WA1 200-3
TROUBLESHOOTING
v-129
V-129
Related
electrical
circuit diagram
VHMS
JR14tDT2)
RA5 (DTt)
RAlO(DTHD4) 000
WA1 200-3
20-897 0
TROUBLESHOOTING
v-130
V-130
[E884] (Disconnection or short circuit with chassis ground in torque converter inlet oil pressure sensor system) is displayed in history
* * +
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. If E866, E868, and E871 occur simultaneously, disconnection, defective contact, or short circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JT2 (female) (1).
Cause
Remedy
YES
Defective torque converter inlet oil pressure sensor
Replace
iS
1
YES _
tc chassis, ground&d
IS reststance between Vl (female) (2) and _
.~.
Gotok
3
svstem
normal?.
If YES gmu?ded to chassis, IS resmance between _ VZB (female) (10) and
_ - Turn starting switch OFF. 2 ;has$is,ground _ a - o - Replace pressure kresatancebetwenJT2 between (3). ard (1) (male) Max. 1 Q sensor with _ JK Imale) Ill and (3). normal one. NO bSweenJT3Imale)~l)and - -Turnstarting JLll (male) switch OFF. orbetween (3). - Turn starting (11and I21normal? - Disconnect MT4 switch ON. - Max. 1 R and V2B. Turn starting NO switch OFF. * Disconnect JT2, JL2, JT3, or JLll.
l
VI.
NO
chassis wod .normal) - Max. 1 R N IO * Turn starting switch OFF. MT4 and *Disconnect
Disconnection or defective contact in wiring harness between Vl (female) (2) MT4 (female) (2) Disconnection or defective contact in wiring harness between V2B (female) (10) - MT4 (female) (3) Joint connector having improper resistance (JT2 JL2, JT3, or JLll)
Repair or replace
Repair or replace
Replace
7YE 1 Is resistance bet-
II
Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (2) MT4 (female) (2) Short circuit with chassis ground in wiring harness between V2B (female) (10) - MT4 (female) (3) Disconnection or defective
Replace
3 5
qepair or peplace
I Is resistance
FromAdgCt%;
I
1 - Turn starting switch OFF. - Disconnect V2B and MT4. IO NO
qepair or .eplace
Max. 1 R - Turn starting switch OFF. - Disconnect MT4.

l
, contact in wiring harness

MT4 (female) (1) ,chassis ground
1 between
Iepair or ,eplace
20-898 0
WA1 200-3
TROUBLESHOOTING
v-130
V-130
Related
VHMS
electrical
circuit diagram
Tome inlet sensor
oi
t:onverter I Dressure
Cl
TJW02559
WA1 200-3
20-899 0
TROUBLESHOOTING
v-201
V-201
* k *
Disconnection or short circuit with power source in 24-V system of sensor power supply
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Since the GND line harness of VHMS cannot be disconnected basically (for the multi-pole design), its disconnection is not taken up as a cause.
CaUSe
Remedy
2 YES Is voltage between YES Vl (female) 12) and _ 1 r chassis around I normal?II
lfcmalsl I21 and hrrl, 2, 3.4,5 Ifemale) (21, and between V1 Ifemale) (2) and HR15. 16 (female) (2). HS2.3.4, (female)
Defective VHMS controller Short circuitwith power source in wiring harness between Vl (female) (2) and MTI, 2,3,4,5 (female) (2). and berween Vl (female) (2) and HR15.16 (female) (2). HS2,3,4, (female) (21 and HS2 - 4. Disconnectionor defective contact in wiring harness between Vl (female) (2) and MTl. 2.3,4,5 (female) (2). and between Vl (femaie) (2) and HR15, 16 (female) (2), HS2,3,4, (female) (2)
Replace
NO Min. 1 V *Turn starting switch OFF. * Disconnect Vl, MT1 - 5, HR15.16, . Turn sartina switch ON.
l
Repair or replace
1R * Turn starting switch OFF. * Disconnect Vl, MT1 - 5, HR15, 16, and HS2 - 4.
* Max.
Repair or replace
20-900 0
WA1 ZOO-3
TROUBLESHOOTING
v-201
V-201
Related
electrical
circuit diagram
Transmission main relief Pressure sensor Toraue outlet Pressure converter oil sensor
Torque converter inlet oil Pressure sensor Transmission modulated Pressure
FRZIHD-46082)
RT2 (HD-85086)
oil sensor
LR2(HD-85086)
A 5OOC o'75f8
JRl4tOT2)
Front brake oil Pressure sensor Rear brake oil Pressure sensor Work equipment relief oil Pressure sensor Steering relief oil Pressure sensor
Pressure
sensor
TJW02539
WA1
200-3
20-901 0
TROUBLESHOOTING
v-202
V-202
* f f
Disconnection or short circuit with power source in 12-V system of sensor power supply
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Since the GND line harness of VHMS cannot be disconnected basically (for the multi-pole design), its disconnection is not taken up as a cause.
I
2
YES 1
If Vl (female) (3) is gmundedtochassis.
IS resistance between _
CaUSe
Remedy
YES
Is voltage between Vl (female) (3). F15 (female) Ill and chassis ground normal? *
Defective VHMS controller Short circuit with power source in wiring harness between Vl (female) 13) FlS (female) (1) Disconnection or defective contact in wiring harness between Vl (female) (3) - F15 (female) (1)
Max. 1 V
NO
Repair or replace
F15 @male) (1) and &E;,ground
-Max.lQ NO *Turn starting switch OFF. * Disconnect Vl and F15
Turn starting switch OFF. Disconnect Vl and F15. *Turn starting switch ON.
l
Repair or replace
V-202 Related electrical
circuit diagram
Wheel VHMS controller

VI (07020) FL2 (HD-25086) 3
B
rotation
F 15 (DT2) 1 307
sensor
)OfPf
(f24V)j307(
307
TJW02540
20-902 0
WA1 200-3
TROUBLESHOOTING
V-203
V-203 Disconnection
or short circuit with power source in 5-V system of sensor power supply
* Before carrying out troubleshooting, check that all the related connectors are properly inserted. -k Always connect any disconnected connectors before going on to the next step. * Since the GND line harness of VHMS cannot be disconnected b its disconnection is not taken up as a cause.
4YEs rk voltage between
fA
GotoA.
Short circuit with power source in wiring harness between R05 (female) (1) RES3 (female) (2)
1 normal?
Repair or replace
RES3 (female) (1) and chassis ground Is resistance between Vl

(female) (4) and REs3 (female) (1)
normal? s Max. 1 Q * Turn starting switch OFF. * Disconnect Vl and RESJ.
l-l
l
.Max.lV . Turn starting NO switch OFF. Disconnect Vl and RES3. * Turn starting switch ON.
Max. 1 R * Turn starting switch OFF. - Disconnect R05 and RES3.

*
Disconnection or defective contact in wiring harness between R05 (female) 11) RES3 (female) (2)
Repair or replace
Short circuit with power source in wiring harness between Vl (female) (4) RES3 (female) (1) Disconnection or defective contact in wiring harness between Vl (female) (4) FiES3 (female) (1) Defective VHMS controller Short circuit with power source in wiring harness between Vl (female) (5) MT1 (female) (2) Disconnection or defective contact in wiring harness between Vl (female) 6) - MT1 (female) (2)
Repair or replace
NO
Repair or replace
Replace
~ha&sground
11
1normal?
* Max. 1 R * Turn starting switch OFF. * Disconnect Vl and MTl.
- Max. 1V NC *Turn staning switch OFF. - DisconnectVl and MTl. -Turn Sartina switch ON.
Repair or replace
NO
Repair or replace
V-203 Related
electrical
circuit diagram
VHMS controller
Transmi lubrica Dressur
ss ion tina oil e sensor
TJW02541
WA1 200-3
20-903 0
TROUBLESHOOTING
w-204
V-204 Disconnection
output
Ir *
or short circuit with chassis ground in buzzer
system
*
2 Is resistance betMS Wee Vl (female) (16). LSS (female1
YES
Defective VHMS controller ~ Short circuit with chassis ground in wiring harness between Vl (female) (16) - L99 (female) (2) Disconnection or defective contact in wiring harness between Vl (female) (16) - L99 (female) (2)
Replace
1
If Vl (female)
(2) -
grounded to
is resiRance
(16) is _ chassis, between _
ad chassis ground normal? *

l
L99 @male) (2) and ckzssztground * Max. 1 R * Turn starting switch OFF. . Disconnect Vl and L99.
Min. 1 MC? NO Turn starting switch OFF. Disconnect Vl and L99.
Repair or replace
NO
Repair or replace

Emergency parking brake cancel switch Main monitor LO6 (040 16) L89 0.5fL
(M4)
I Blue) Fues (11
I 8
I
i>
1
0.. t
I
3 124AC
FS: - ! (S12
VHMS controller
Vl
(07020)
I I
ion er
TJW02516
20-904 0
WA1 200-3
TROUBLESHOOTING
v-205
V-205
Disconnection lamp system

connect
or shot-t circuit with chassis ground in check
Before carrying out troubleshooting,

any disconnected
Jc Always
check that all the related connectors are properly connectors before going on to the next step.
inserted.
2 YES I Is resistance betII YES ween VI (female) - (14).LO6 (female) _ 1 (10) and chassis If Vl (female)(14) is ground normal? ground&to chassis, NO is resistance between _ . Min. 1 MQ LO6(female) (10) and *Turn starting chassisground switch OFF. normal? * Disconnect Vl and L06. Max. 1 R . Turn starting NO switch OFF. * Disconnect Vl and LO&
l
Defective VHMS controller Short circuit with chassis ground in wiring harness between Vl (female) (14) - LO6 (female) (10) Disconnection or defective contact in wiring harness between Vl (female) (14) - LO6 (female) (10)
Replace
Repair or replace
Repair or replace
Main
monitor
TJW02545
WA1 ZOO-3
20-905 0
TROUBLESHOOTING
V-206
V-206
Disconnection synchronizing
or short circuit with chassis ground in flash signal system

inserted.
* *
Cause
Remedy
YES
1
~~;za;;ssis grounded to chassis, is resistance between LO7 (female) (61 and ground f
Replace
1Q -Turn starting switch OFF. . Disconnect Vl and L07.
- Max.
NO Min. 1 MQ *Turn startina switch OFF.* Disconnact Vl and L07.

-
Short circuit with chassis ground in wiring harness between Vl (female) (13) - LO7 (female) (6) Disconnection or defective contact in wiring harness between Vl (female) (13) - LO7 (female) (6)
Repair or replace
NO
Repair or replace
V-206
Related
electrical
circuit diagram
VHMS controller
LO7 (04012)
Main
monitor
TJW02546
20-906 0
WA1 200-3
TROUBLESHOOTING
V-207
V-207 Short circuit with power source in boom bottom sensor system
f *
pressure
Cause
Remedy
1 YES
Is voltage between VI (female) (1) and chassis ground normal? - Max. 1 V * Turn starting switch OFF. * Disconnect Vl and F06. * Turn starting switch ON. NO
Defective VHMS controller Short circuit with power source in wiring harness between Vl (female) (1) F06 (female) (3)
Replace
Repair or replace
TJW0.2547
WA1 200-3
20-907 0
TROUBLESHOOTING
V-208
V-208 *
j,
Short circuit with power source in boom head pressure sensor system
inserted.
Cause
Remedy
1 YES
Is voltage between Vl (female) (10) and chassis ground normal? Max. 1 V * Turn starting switch OFF. mDisconnect Vl and F14. * Turn starting switch ON.
l
Defective VHMS controller Short circuit with power source in wiring harness between Vl (female) (10) - F74 (female) (3)
NO
Repair or replace
V-208
Related
electrical
circuit diagram
VHMS
TJW02548
20-908 0
WA1 200-3
TROUBLESHOOTING
v-209
V-209 Ir
f
Short circuit with power source in rear brake oil pressure sensor system
inserted.
I
1 YES
Is
cause
Remedy
voltage between
-
Defective VHMS controller Short circuit with power source in wiring harness between V2A (female) (8) - HR16 (female) (3)
Replace
V2A (male) (8). HR16 (female) (3) and chassis ground normal?
.Max.lV *Turn starting switch OFF. Disconnect V2A and HR16. *Turn starting switch ON.
l
NO
Repair or replace
V-209 Related electrical
circuit diagram
JR13 (DTlB)
JR14 (DT2)
oil
e wessure
RA5 CDT11
Bat terv
RAt 0 (DTHD4)
OL
TJW02531
WA1 200-3
20-909 0
TROUBLESHOOTING
v-210
V-210 Short circuit with power source in front brake oil pressure sensor system Sr
* Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
1 YES
Is
VZA (female) (7). HR15 (female) (3) and chassisground normal?

l l
voltage beMeen
Defective VHMS controller ~ Short circuit with power source in wiring harness ~between V2A (female) (7) - HR15 (female) (3)
Replace
Max. 1 V Turn starting switch OFF. Disconnect WA and HR15. Turn starting switch ON.
NO
Repair or replace
JR13
(DTIB)
LR7 (DTI)
RAI 0 (DTHD4) 000 I
TJW02530
20-910 0
WA1 200-3
TROUBLESHOOTING
v-21 1
V-211 Ir
+
Short circuit with power source in work equipment pressure sensor system
relief
inserted.
Remedy
t-=
1 ISvoltage between V2A (female) (18). HS2 (female) (3) and chassis ground IllJmlal? * Max. 1 V * Turn starting switch OFF. . Disconnect V2A and HS2. -Turn starting switch ON. NO YES Defective VHMS controller Short circuit with power source in wiring harness between V2A (female) (18) - HS2 (female) (3) Replace
Repair or replace
V-211
Related VHMS con
electrical
circuit diagram
JR/6
(DTII
Work esuiment relief oil .e sensor
TJW02550
WA1 200-3
20-911
0
TROUBLESHOOTiNG
v-212
V-212 *
+
Short circuit with power source in transmission sensor system
relief pressure
Cause
Remedy
Defective VHMS controller MT2 (female)(3) and chassisground nO~~l7 * Max. 1 V -Turn starting switch OFF.* Disconnect WA and MT2. *Turn starting switch ON. NO
Replace
I
Short circuit with power source in wiring harness between WA (female) (6) - MT2 (female) (3) Repair or replace
V-212
Related
electrical
circuit diagram
Transmission nain relief cvessure sensor l-l
VHMS
TJWO2552
20-912 0
WA1 200-3
TROUBLESHOOTING
V-213
V-213 *
*
Short circuit with power source in steering relief pressure sensor system
Cause
--I
Repair or replace
Remedy
1 YES Is voltage between VZA (female) (16). HS3 (female) (3) and chassis ground nOrf?l~l? * Max. 1 V -Turn starting switch OFF. * Disconnect V2A and HS3. - Turn starting switch ON. NO
Defective VHMS controller Short circuit with power source in wiring harness between V2A (female) (16) - HS3 (female) (3)
V-123
Related
VHMS
con
electrical
circuit diagram
ol ler
VI (07020)
il sensor
TJW02553
WA1 ZOO-3
TROUBLESHOOTING
v-214
V-214 *
It
Short circuit with power source in torque converter pressure sensor system
outlet oil
Cause
Remedy
I Is voltase
between V2A (f&ale) (5). MT3 (female) (3) and chassis ground tl0iTllal7
1 YES I I
-
Defective VHMS controller Short circuit with power source in wiring harness between V2A (female) (5) - MT3 (female) (3)
Replace
Max. 1 V Turn starting switch OFF. . Disconnect WA and MT3. * Turn starting switch ON.
l
NO
Repair or replace

VHMS
lortoe converter outlet oil Dressure sen t.or
20-914 0
WA1 200-3
TROUBLESHOOTING
V-215
V-215 *
*
Short circuit with power source in transmission pressure sensor system
modulation
Cause
Remedy
1 YES
Is voltage between V2A (female) (151, MT5 (female) (3) and chassis ground normal? * Max. 1 V * Turn starting switch OFF.. * Disconnect V2A and MT5. Turn starting switch ON.
l
Defective VHMS controller Short circuit with power source in wiring harness between V2A (female) (15) - MT5 (female) (3)
Replace
NO
Repair or replace
V-215
Related
VHMS &roller
electrical
circuit diagram
Transmission modulated oil wassure sensor
VI fO70201
TJWO2555
WA1 200-3
20-915 0
TROUBLESHOOTING
V-216
V-216 *
*
Disconnection or short circuit with power source in torque converter oil temperature sensor
CallSe
Remedy
3 YES
Is voltage between YES T24 (female) (1) and chassis 2 ground normal? If V2A Wemale) (3) is _ MS groundedto chassis, NO _ ISresistancebetween _ - Max. 1 V T24 (female)(1) and . Turn starting switch OFF. 1 chassisground * Disconnect V2A and T24. y normal? Is resistance * Turn starting switch ON. -Max. IQ between T24 NO *Turn startina (male) (1) and (2) switch OFF.normal? I * Disconnect V2A - 40 kC2at normal and T24. temperature NO (25C) * Turn starting switch OFF. Disconnect T24.
l
Defective VHMS controller Short circuit with power source in wiring harness between V2A (female) (3) - T24 (female) (1) Disconnection or defective contact in wiring harness between V2A (female) (3) - T24 (female) (1) Defective torque converter oil temperature sensor
Replace
Repair or replace
Repair or replace
Replace
V-216
Related
electrical
circuit diagram
Torsue converter oil temperature or)
VHMS
JL.21 (DTIB
III
-44 J4 aa aa
41
TJW02527
20-916 0
WA1 200-3
TROUBLESHOOTING
V-217
V-217 t
f
Disconnection
in hydraulic oil temperature
sensor system
Cause
Remedy
Defective VHMS controller Disconnection or defective contact in wiring harness between V2A (female) (11) - HSl (female) 11) Defective hydraulic oil temperature sensor
Replace
No
* 3.5 - 4.0 kQ at normal temperature (25C) *Turn narting switch OFF. * Disconnect HSl. - Disconnect V2A and HSI. NO
I
I
Repair or replace
Replace
V-217
Related
electrical
circuit
diagram
VHMS
TJW02528
WA1 ZOO-3
20-917 0
TROUBLESHOOTING
V-218
V-218 *
*
Disconnection
in ambient temperature
sensor system
inserted.
Cause
Remedy
2 If V2A (female) (lo! is Y,-s

_
YES
Defective VHMS controller Disconnection or defective contact in wiring harness between VZA (female) (10) - PHl (female) (1) Defective ambient temperature sensor
Replace
y
Is
1 resistance between PHl _ (male) (1) and (2) normal?
grounded to chess% 15 resistance between PHl (female) (1) and &a3ass~Tground
Approx. 12 kS2at normal temperature (25C) *Turn starting switch OFF. Disconnect PHl.
l l
. Max. 1 R Turn starting switch OFF. . Disconnect V2A and PHl. NO

l l
k NO
Repair or replace
Replace
V-218 Related VHMS
electrical
circuit diagram
JR13 (DTIB)
TJW02557
20-918 0
WA1 200-3
TROUBLESHOOTING
v-219
V-219 Short circuit with power source in PPC relief sensor system
or
* Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step. inserted.
ReDlace
Repair or replace
switch OFF.- Disconnect V2A and HS4. - Turn starting switch ON.

VHMS
JR7 (DTl)
LR7 (DTI) B
TJW02558
WA1 200-3
20-919 0
TROUBLESHOOTING
v-220
V-220
*
Short circuit with chassis ground in fuel level sensor system
CaUSe
Remedy
2 If VZA (female) (2) is

Es 1 r gcouqded to chasss. IS resistance belween R05 (female) (1) and _
YES
Defective VHMS controller Short circuit with chassis ground in wiring harness between V2A (female) (2) - R05 (female) (1) Defective fuel level sensor
Replace
-I*r&sancebetween R05 (male) _ (1) and (2) as shown in Table 11 * See Table 1. * Disconnect RO5
II ~Ft%t~~d
NO .Min.lMQ *Turn starting switch OFF. - Disconnect V2A and RO5.
Repair or replace
NO
Table
1 Resistance Between (1) - (2) Between (1) - chassis grouncI
FULL (100%) l/2 (50%) l/4 (25%)

1 EMPTY (0%)
Approx. 10 Q Approx. 32 R Approx. 49.5 Q Min. 1 MP
Approx.
85 R
V-220
Related
electrical
circuit diagram
VHM
LR2 (HD-85086)
TlW02526
20-920 0
WA1 200-3
TROUBLESHOOTING
V-221
V-221 *
* Always
Short circuit with power source in battery fluid level sensor 1

connect out troubleshooting, check that all the related connectors are properly any disconnected connectors before going on to the next step. inserted.
Before carrying
Cause
Remedy
1 YES Is voltage between V2B (female) (1). RA7 (female) 11) and chassisground normal? NO * Max. 1 V *Turn starting switch OFF. - Disconnect V2B and RA7. *Turn starting switch ON.
Defective VHMS controller Short circuit with power source in wiring harness betweenV2B (female)(1) - RA7 (female) (1)
Replace
Repair or replace
VHMS
controller
LR~(HD-85086)
RA3 (DT21
1
RAl (DTZ/DTl)
Bat terv
TJW02532
WA1 200-3
20-92
0
TROUBLESHOOTING
V-222
V-222 Short circuit with power source in battery fluid level sensor 2
*
Cause
Remedy
1 YES IS voltage between V26 (female) (2). RAE (female1(1) and chassis ground lXXfT#el? . Max. 1 V *Turn starting switch OFF. * Disconnect V2A and RA8. Turn starting switch ON.
l
Defective VHMS controller Short circuit with power source in wiring harness between V2B (female) (2) - RA8 (female) (11
Replace
NO
Repair or replace
V-222 Related
electrical
circuit diagram
VHMS
RA2 (DT2/DTI)
RA7 (DTl)
Battery Jevel sensor
TJW02532
20-922
WA1 200-3
TROUBLESHOOTING
V-223
V-223 Short circuit with power source in battery fluid level sensor 3
* * Before carrying Always connect out troubleshooting, check that all the related connectors are properly any disconnected connectors before going on to the next step. inserted.
Cause
Remedy
1 YES Is voltage between V28 (female) (3). RAS (female) (1) and chassis ground IlO~al? *Max.lV . Turn starting switch OFF. . Disconnect V2B and RA9. * Turn starting switch ON. NO
Defective VHMS controller Short circuit with power source in wiring harness between V2B (female) (3) - RA9 (female) (1)
qeplace
qepair or ,eplace
V-223
Related
electrical
circuit diagram
VHMS controller
LR2 (HD-85086)
RA3 CDT21
RAl(DTZ/DTl)
TJW02532
WA1 ZOO-3
20-923 0
TROUBLESHOOTING
V-224
V-224 Short circuit with chassis ground or power source in brake fluid
level sensor *
cause
Remedy
Defective front brake level sensor
Replace
ween HRlO (male) (1) and chassis . Turn starting switch OFF. * Disconnect HRlO. . Measure resistance when front brake tank is empty.
ES
Defective rear brake level sensor
Replace
ween HR6 (female)
4YE vccl ween V3A (female) I I 1 A IS). HR6 (female) (1) I-l
1Isresktance bet-
1r
Gotok
Short circuit with chassis ground in wiring harness between V3A (female) (5) - HR6 (female) (1) Short circuit with chassis ground in wiring harness between V3B (female) (5) -HRlO (female) (1) Defective VHMS controller 5hort circuit with power ;ource in wiring harness cetween V3A (female) (5) - HR6 (female) (1) Short circuit with power source in wiring harness setween V3B (female) (5) - HRlO (female) (1)
. Turn starting switch OFF. * Disconnect HR6 h (female). * Measure resistance when rear brake tank is empty.
1and chassis ?I? II * Min. 1 MQ * Turn starting switch OFF.- Disconnect V3B and HRIO.
*Turn
Repair or replace
stanina switch OFF. * DisconnectV3A and
_6 YES
Repair or replace
_1Is voltage
between 1 1
Replace
From A -
Repair or replace
-Turn starting switch OFF. * Disconnect V3B and HAlO. - Turn starting switch ON.
NO
Repair or replace
V-224
Related
electrical
circuit diagram Front brake oil level
VHMS controller ake el
-n%-
TJW02533
20-924 0
WA1 200-3
TROUBLESHOOTING
V-225
V-225 *
+
Short circuit with power source in coolant level sensor

inserted.
Cause
1 YES IS voltage between

V3B ~fermle) 110). GO6 (female) (1) and chassis ground -
Defective VHMS controller Short circuit with power source in wiring harness between V3B (female) (10) - GO6 (female) (1)
*Max. 1 V * Turn starting switch OFF. * Disconnect V36 and G06. * Turn starting switch ON.
NO
I
Replace Repair or replace
V-225
Related
VHMS
electrical
circuit diagram
RAlO
(DTHD4)
Coolant
level
TJW02534
WA1 200-3
20-925 0
TROUBLESHOOTING
V-226
V-226
Short circuit with chassis ground or power source in transmission oil filter clogging sensor
* *
ChJSt?
Remedy
2 YES
MS , r _ Is resistancebatween V3A (female) (111, R02 (female) (1) and chassis around normal? Min. 1 MR - Turn starting switch OFF. - Disconnect V3A and R02.
l
Is voltage between V3A (female) (11). R02 (female) (1) and chassisground normal?
NO Max* *Turn starting switch OFF. . Disconnect V3A and R02. - Turn starting switch ON.
Defective transmission oil filter or VHMS controller Short circuit with power source in wiring harness
Replace
between V3A (female) (11) - R02 (female) (1) Short circuit with chassis ground in wiring harness between v3A (female) (11) - R02 (female) (1)
Repair or replace
NO
Repair or replace
V-226
Related
electrical
circuit diagram
VHMS
Transmission
TJW02535
20-926 0
WA1 200-3
TROUBLESHOOTING
v-227
V-227
Short circuit with power source in air cleaner clogging (1) relay system
inserted.
* *
Cause
Remedy
1 YES
Is voltage between _ V3B (female) (1) and L132 (female) (6) normal? 1V * Turn starting switch OFF. * Disconnect V3B and L132. -Turn starting switch ON.
Defective VHMS controller Short circuit with power source in wiring harness between V3B (female) (1) - L132 (female) (6)
Fieoair or
- Max.
NO
V-227
Related VHMS controller
electrical
circuit diagram
DUS t
I r clay
ind icator
Dus t ind icator 2 r clay
-vindicator
31
-vindicator
-IDust 141
TJW02536
WA1 200-3
20-927 0
TROUBLESHOOTING
V-228.229
V-228 *
*
Short circuit with power source in air cleaner clogging system
(2) relay
Cause
Remedy
1 YES
Is voltage between V3B (female) (2) and L133 (female) (61 normal? . Max. 1 V * Turn starting switch OFF. - Disconnect V36 and L133. -Turn starting switch ON. NO
Defective VHMS controller Short circuit with power source in wiring harness between V3B (female) (2) L133 (female) (6)
hplace
aepair or replace
See V-227.
V-229 *
*
Short circuit with power source in air cleaner clogging system
(3) relay
Cause
Remedy
1 YES Is voltage between V3B (female) (3) and L134 (female) (6) normal? - Max. 1 V - Turn starting switch OFF. . Disconnect V3B and L134. * Turn starting switch ON.
Defective VHMS controller Short circuit with power source in wiring harness between V3B (female) (3) - Ll34 (female) (6)
Replace
NO
Repair or replace
See V-227.
20-928 0
WA1 200-3
TROUBLESHOOTING
v-230
V-230
Short circuit with power source in air cleaner clogging (4) relay system
* *
Cause
Remedy
1 MS Is voltage between V3B (female) (4) and L135 (female) (6) normal? * Max. 1 V * Turn starting switch OFF. mDisconnect V36 and L135. * Turn starting switch ON. NO
Defective VHMS controller Short circuit with power source in wiring harness between V3B (female) (4) - L135 (female) (6)
Replace
Repair or replace
The related electrical circuit diagram is the same as that for V-227. See V-227.
WA1 200-3
20-929 0
TROUBLESHOOTING
V-231
V-231 j,
*
Abnormal
charge by alternator
inserted.
1 YES
( 1 Is resistance bet1ween WA (female) I (4). L152 (female) 16) and chassis ground n0l-nlal?
l
1 I
t-=--v=
I
Short circuit with chassis ground in wiring harness between V2A (female) (4) - L152 (female) (6) - El4 (female) (2), El5 (female) I?\ ,L,
I I
Replace
Repairor
replace
Min. 1 MR -Turn starting switch OFF. Disconnect V2A. L152, and JE3.
NO
V-231
Related
electrical
circuit diagram
VHM
Alternator signal relay Fuse (I) FS2 (SlZBlue) -___ m--l

TJWO7.537
20-930 0
WA1 ZOO-3
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
H- 1 Machine does not move ........................................................................................................... H- 2 H- 3 Machine lacks power or speed (every speed range). ........................................................... Excessive time lag when starting machine or shifting gear ................................................
20-I 002 .20-1003 20-l 004 20-1005 20-l 006 20-I 007 20-1008 20-I 009
H- 4 Torque converter oil temperature is high ............................................................................... H- 5 Steering does not turn .............................................................................................................. H- 6 Turning, response of steering is poor .................................................................................... H- 7 H- 8 Joystick lever is heavy.. ............................................................................................................ Steering wheel shakes or jerks ................................................................................................
H- 9 Turning radius is different between left and right at maximum steering ......................... 20-1010 H-10 Wheel brakes do not work or braking effect is poor ............................................................ H-II H-12 H-13 Wheel brakes are not released or brakes drag ...................................................................... Boom does not rise.. ................................................................................................................. Boom moves slowly or does not have sufficient lifting power .......................................... Boom cylinder cannot hold down bucket ............................................................................... Boom has large amount of hydraulic drift ............................................................................. Boom fluctuates while working ............................................................................................... Bucket does not tilt ................................................................................................................... Bucket is moves slowly or has insufficient tilt back power.. ............................................... Bucket movement becomes slow during tilt back.. .............................................................. Bucket cylinder cannot hold down bucket.. ............................................................................ Bucket has large amount of hydraulic drift ............................................................................ Bucket dumps momentarily when lever is operated from HOLD to TILT .......................... Boom and bucket levers do not move smoothly .................................................................. 20-1010 20-1011 20-1012 .20-1013 20-1014 20-1014 20-1014 20-1015
H-14 When raising boom, becomes slow at certain height .......................................................... H-15 H-16 H-17 H-18 H-19 H-20 H-21 H-22 H-23 H-24 H-25 H-26
Boom drops momentarily when lever is operated from HOLD to RAISE.. ........................ 20-1015 20-1016 .20-1017 .20-1018 20-1018 20-1018
Bucket fluctuates while traveling under load (work equipment valve HOLD). .................. 20-1019 20-1019 20-l 020
WA1 200-3
20-1001 0
TROUBLESHOOTING
H-l
H-l Machine does not move

points Ask the operator the following . Did the machine suddenly stop moving?
Yes = Component seized or damaged Was there any abnormal noise when the machine stopped moving? Yes = Component broken.
Checks before troubleshooting . Is oil level in transmission
case correct?
. .
Is monitor display normal? Is drive shaft broken?
Transmission
No.
Problems
6)
- 8
9 10 11
Low at every speed range. Transmission Low at certain speed ranges. modulating pressure too low Indicator fluctuates violently. Pilot pressure defective Torpue converter relief valve pressur- --- ---Torpue converter regulator valve pressure IOO m
IololoTOl
Note
1: If the solenoid valve and hydraulic pres-
sure are normal, the m in the Causes column indicates that the valve spool
does not work.

Note 2: If the transmission
The following symbols are used to indicate the action to be taken when a cause of failure is located. 0: Repair X: Replace C: Clean A: Adjust
clutch pressure is low, but the cause cannot be found in the above table, a possible cause is cracks in the valve or transmission.
20- 1002 0
WA1 200-3
iROUBLESHOOTlNG
H-2
H-2 Machine
lacks power or speed (every speed range)
Checks before troubleshooting . Is oil level transmission case correct?
. .
Is there any leakage of oil from joints of piping or valves? Is parking brake or wheel brake dragged?
for abnormalities
Checking
l l
.
l
. .
Engine high idling speed Torque converter stall speed Machine travel speed Transmission clutch pressure (both high pressure and low pressure) Pressure at outlet port of torque converter pump Pilot reducing pressure
Relief pressure at torque converter too low (Items 5 and 7 normal) Torque converter regulator valve pressure (outlet port low pressure) too Iron or alumimum case. Modulating particles stuck to strainer of transmission
0 0 0 0
9 ,. 11
pressure drops when oil temperature
rises.
WA1 200-3
20- 1003
0
TROUBLESHOOTING
H-3
H-3 Excessive time lag when starting machine or shifting gear

case correct? Is there any leakage of oil from joints of piping or valves?
4
6 6
Transmission range
modulating pressure too low in every speed
0000
As in Items 4; indicator fluctuates violently Torque converter oil temperature is above operating range.
0
0 0
20- 1004 0
WA1 200-3
TROUBLESHOOTING
H-4
H-4 Torque converter
oil temperature
is high
I
I I I I I /
Ask the operator the following points . Does torque converter oil temperature
go up during torque converter stall, and down when the torque converter is not installed? Yes = Normal (incorrect selection of gear speed)
Is transmission
case correct? filter clogged?
Checking for abnormalities Ir If the oil temperature is normal but the
oil temperature gauge is outside the operating range, the oil temperature gauge is defective.
1 2 3 4
Pump makes abnormal noise when oil temperature High idling and low idling speeds are too low.
is low.
0 0 0
Hvdraulic oressure at inlet oort of torque converter too low Transmission modulating pressure too low lolo/
0
1 1 I
WA1 200-3
zo1005
0
TROUBLESHOOTING
H-5
H-5 Steering
does not turn
Ask the operator the following points Did the problem suddenly start?
l
Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?
Checks before troubleshooting

l
. . .
Is the oil level in the hydraulic tank correct? Is the type of oil correct? Is the steering shaft broken? Has the safety bar been removed from the frame? is steering valve open?
2 3 4 5 6 7
Steering wheel turns only in one direction (left or right)
1Steering 1Work
wheel is heavy in both directions (left and right) moves does not move
equipment
I
00 00
Inl
Work equipment Abnormal
noise comes from around PTO
Abnormal noise comes from around PPC pump or hydraulic tank
I
When steering relief pressure is measured Oil pressure is low or there is no pressure in both directions (left and right) Oil pressure is low or there is no pressure in one direction (left or right) 0000
,9
When steering pilot valve output pressure is measured, oil pressure is found to be low or there is no oil pressure When PPC valve (Orbit-roll) basic pressure iS measured Oil pressure is low There is no oil oressure
lololol lo101 lolol
Ir
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- 1006 0
WA1 200-3
TROUBLESHOOTING
H-6
H-6 Turning,
response of steering is poor
Ask the operator the following points . Did the problem suddenly start?
Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Was there previously any symptom, such as difficulty in steering? Yes = Wear of related equipments, defective seal
Checks before troubleshooting . Is the oil level in the hydraulic tank cor-
rect? Is the type of oil correct?
No. Problems
Turning, response of steering is poor in both directions (left and right)
.. ..
I I I IO/O 10 10 I()( 0 /
5
6
. . _ . worn equipment
( Work equipment moves also speed IS slow Abnormal noise comes from around PTO Abnormal noise comes from around steering pump or hydraulictank Abnormal noise comes from around switch pump or hydraulictank
oww
10101 l0l0l0J --- I I I 0 0 00 0
8
9
--I
10
11 12 13
When steering relief pressure is measured
Oil pressure is low or there is no pressure in both directions (left and right) Oil pressure is low or there is no pressure in one direction (left or right)
o(-j(-Jooonlnl
I InI
I0 I I
When steering pilot valve output pressure is measured, oil pressure is found to be low When PPC valve (Orbit-roll) basic pressure is measured, oil pressure is found to be low
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.
WA1 200-3
20- 1007 0
TROUBLESHOOTING
H-7
H-7 Joystick
lever is heavy
Checking for abnormalities . Is the steering difficult to turn? Yes = Go to H-6 . Measure the operating effort and turning speed, and check the STANDARD VALUE TABLE to see if they are abnormal. Ask the operator the following points Did the problem suddenly start? Yes = Related equipment broken Was there previously any symptom, such as heavy steering? Yes = Wear of related equipment, defective seal
Checks before troubleshooting . Is the oil level in the hydraulic tank correct? Is the type of oil correct? Is the tire inflation pressure correct?
l
Remedy/+/
No. Problems
1 2 S Steering is heavy when turned in both directions (left and right) Steering is heavy when turned in one direction (left or right) Steering is heavy even when joint between steering shaft and Orbit-roil is disconnected When s=adng relief pressure is measured 6 Oil pressure is low in both directions (left and right) Oil nressure is low in one direction (left or riaht)
/x/x
000
I
0
I
0
101
1 1 1
When steering pilot valve output pressure is found to be low
20- 1008 0
WA1 200-3
TROUBLESHOOTING
H-8
H-8 Steering
wheel shakes or jerks
Checking for abnormalities . Is the steering difficult to turn?

. Yes = Go to H-6 Is there any abnormal noise from around the steering equipment?
Checks before troubleshooting . Is the steering wheel play correct?

. in the connecIs there any abnormality tion between the steering shaft and the steering pilot valve? Is the tire inflation pressure correct?
No. Problems
1 2 S Steering wheel shakes or jerks in both directions (left and right) Steering wheel shakes or jerks in one directions (left or right) During operations or when traveling (when steering is neutral), steering wheel shakes or jerks in both directions (left and right) During operations or when traveling (when steering is neutral), steering wheel shakes or jerks in one direction Cleftor right) Steering wheel jerks or there is excessive shock when steering is operated to end of its stroke Work equipment also jerks Oil pressure is unstable in both directions (left and right) Oil pressure is unstable in one direction (left or right) Oil pressure is unstable in both directions (left and right) Oil pressure is unstable in one direction (left or right) 000 lO[OlOj~
6 7 8
When steering relief pressure is measured
10
When steering pilot valve output pressure is measured
11
When PPC valve (steering pilot valve) basic pressure is measured, oil pressure is found to be unstable
WA1 200-3
20-l 009 0
TROUBLESHOOTING
H-9, H-10
H-9 Turning radius is different between steering

Causes and Remedy Defective adjustment stopper (4
l
left and right at maximum
of joystick lever
H-10
Wheel brakes do not work or braking effect is poor
Checking for abnormalities . Measure the actual brake performance, and check if there is actually an abnormality or whether it is just the feeling of the operator. For details, see TESTING AND ADJUSTING, Measuring brake performance. Ask the operator the following points. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? . Did the problem gradually appear? Yes = Wear of related equipments, defective seal
l l
Checks before troubleshooting . Is the oil level in the hydraulic tank correct? Is the type of oil correct? Is the brake pedal play correct? Is there any leakage of oil from the brake tube? Is there any deformation of the tube? . Is the tire inflation pressure and tread pattern correct?
l l
20-1010
0
WA1 200-3
TROUBLESHOOTING
H-l 1
H-11 Wheel brakes are not released or brakes drag

Ask the operator the following points. . Did the problem suddenly start?
Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?
Checks before troubleshooting

l
Does the brake pedal come back fully? Is the parking brake still applied (ON)?
No
1 2 3
I
When remaining pressure is released from brake accumulator circuit with left brake pedal only, brake is released When remaining pressure is released from brake accumulator circuit with right brake pedal only, brake is released When air bleed plug in wheel poeion is loosened, oil flows out and brake is released When air bleed plug is loosened, a large amount of oil flows out When brake disc wear is measured and brake pedal is released, piston returns 0
0 0
()
5 6 7 8 -
When brake disc wear is measured and brake pedal is released, piston does not return
00
WA1 200-3
20-l 011 0
TROUBLESHOOTING
H-12
H-12
Boom does not rise
Ask the operator the following points . Did the problem suddenly fail to rise?
l
+ Seizure or damage to various units. Was unusual noise produced? (Where did it emanate from?) Were there previous signs of the boom slowing down? + Wear of parts of flattening of spring.
Checks before troubleshooting . Is oil level in hydraulic tank correct?
Is travel of lift arm control lever and spool correct?
unable to rise. Or, the bucket operates but the boom is
20-1012 0
WA1 200-3
TROUBLESHOOTING
H-13
H-13
Boom moves slowly or does not have sufficient lifting power
Checks before troubleshooting . Is the travel of the boom control lever
and also the spool of the work equipment control valve correct? Seizure of work equipment linkage bushing. (Does emits abnormal noise) If the boom speed lowers when it is loaded, it must be overloaded. Check the load meter in this case.
Fault check
There is a strong relationship between faults involving lifting force and lifting speed. Such faults appear initially in the from of insufficient lifting speed. Measure the lifting speed of the lift arm when loaded and refer to the standard value table to determine whether or not there is a fault.
Ming speed is low. 2 Bucket tilt back force and speed are normal but boom lifting speed is slow. Some as Item 1 except that boom lifting speed becomes particularly low when oil temperature 4 6 rises. 00
00
Hydraulic pump emits abnormal noise. When the engine is at full, steering action is light and excessively fast. When the engine is at full, steering action is heavy and slow. Cylinder has a large amount of hydraulic drift. The relief pressure of relief valve of work equipment control valve.
0
0 00 0 000
6 7 6
WA1 ZOO-3
20-1013 0
TROUBLESHOOTING
H-14, H-15, H-16
H-14
When raising boom, becomes slow at certain height
Checks before troubleshooting 0. External deformation of boom cylinder. Cause Swollen or internally damaged boom cylinder tube. * Regarding other faults occurring during boom rise, refer to item H-13 Boom moves slowly or does not have sufficient lifting power.
l
H-15
Boom cylinder cannot hold down bucket
Refer to item H-13 Boom moves slowly or does not have sufficient lifting power. Checks before troubleshooting . Is travel of boom spool of work equipment control valve correct? Cause . Defective boom cylinder rod side suction valve seat of work equipment control valve . Oil leakage from boom cylinder piston seal
H-16
Boom has large amount of hydraulic drift
Ask the operator the following points Did the hydraulic drift suddenly become large? + Dirt lodged in valve or damaged parts. . Did the hydraulic drift gradually become large? + Worn parts.
l
Checks before troubleshooting Is the boom spool in the hold position? + Seized ring bushing, defective spool detent.
l
Troubleshooting and cause When measuring hydraulic drift, internal leakage of boom cylinder makes oil leakage noise. -_j Damaged cylinder packing. . When measuring hydraulic drift, boom cylinder does not make oil leakage noise. -_j Defective oil sealing of boom spool. + Defective check valve between pipings.
l
20-1014 0
WA1 200-3
TROUBLESHOOTING
H-17, H-18
H-17
Boom fluctuates
while working
During excavation or ground leveling when the boom control lever is in the HOLD position, the bucket and boom move up and down in accordance with the terrain. Troubleshooting and cause Check the amount of hydraulic drift and whether or not the machine body can be lifted up by the boom cylinder. 1. If the amount of hydraulic drift is greater than the standard value, refer to item H-16 Boom has large amount of hydraulic drift. 2. If the machine body can not be lifted up by the boom cylinder, refer to item H-15 Boom cylinder cannot hold down bucket. 3. If the amount of hydraulic drift is normal and the machine body can be lifted up by the boom cylinder after the boom is moved several times to cause the boom cylinder to move through its entire stroke -+ the trouble is due to the generation of a vacuum in the cylinder. * If a vacuum is generated frequently + defective suction valve on boom cylinder rod side.
H-18
Boom drops momentarily RAISE
when lever is operated
from HOLD to
The boom drops momentarily under its own weight when the boom control lever is gradually shifted from the HOLD position to the RAISE position while the engine is at low idling. When the control lever is put completely into the RAISE position, the boom moves normally. Cause Defective seating of work equipment control valve or boom spool check valve.
l
WA1 200-3
20-l 015
TROUBLESHOOTING
H-19
H-19
l
Bucket does not tilt back

the following points
Ask the operator
Did the bucket suddenly cease to move? + Seized or damaged equipment. Was any abnormal noise emitted (where did it emanate from?) Was there previous signs of the bucket slowing down? + Worn parts or flattening of spring.
Checks before troubleshooting . Is the travel of the bucket control lever
and spool correct?
20-1016 0
WA1 200-3
TROUBLESHOOTING
H-20
H-20
Bucket moves slowly or has insufficient
tilt back power
Checks before troubleshooting . Is the travel of the bucket control lever
and the work equipment control valve spool correct? Seizure of bushing in bucket linkage? (Does emits abnormal noise?)
Fault checks
l
Check deficient tilt back force by performing actual work. Measure the operating speed of the bucket and check it against the standard value table to determine whether or not it is normal.
Boom lifting force and lifting speed are abnormal and also bucket tilt force and tilt speed are abnormal. Boom lifting force and lifting speed are normal but bucket tilt force and tilt speed are abnormal. Phenomena temperature of item 1 become particularly bad when the oil increases. 00 0000 0
ooc
3 4
The hydraulic pump emits an abnormal noise. action is light and excessively fast when the engine
WA1 200-3
20-1017
TROUBLESHOOTING
H-21, H-22, H-23
H-21
Bucket movement
becomes slow during tilt back
Checks before troubleshooting External deformation of bucket cylinder.

l
Cause
l l
Swollen or internally damaged bucket cylinder tube. As to other faults which occur when operating bucket, refer to item H-20 Bucket moves slowly or has insufficient tilt back power.
H-22
Bucket cylinder cannot hold down bucket

or has insufficient tilt back power.
Refer to item H-20 Bucket moves slowly
Checks before troubleshooting . Is the travel of bucket spool of work equipment control valve correct? Cause
l
Defective seat of safety valve (with suction valve) of the rod side of bucket cylinder of work equipment valve. Oil leakage from seal of bucket cylinder piston.
H-23
Bucket has large amount

the following points
of hydraulic drift
Ask the operator

l
Did the hydraulic drift suddenly become large? + Dirt lodged in valve or damaged parts. Did the hydraulic drift gradually become large? + Worn parts.
Checks before troubleshooting . Is the bucket spool in the hold position? + Seized ring bushing, faulty spool detent. Fault check . Use the standard value table to check whether or not the hydraulic drift of the bucket is actually large.
Cause
l l
Oil leakage in bucket cylinder Defective seating of safety valve (with suction valve) at bottom side. Defective oil sealing of bucket spool. Defective check valve between pipings.
20-1018 0
WA1 ZOO-3
TROUBLESHOOTING
H-24. H-25
H-24
Bucket fluctuates (work equipment
while traveling valve HOLD)
under load
Checks before troubleshooting Excessive play in pin and bushing of work equipment produced?)
linkage.
(Was an abnormal noise
Cause Defective piston seal of bucket cylinder. . Defective safety valve (with suction valve) for the head side of bucket cylinder. If the above symptoms occur together, refer to the troubleshooting items corresponding to each fault. _ .
l
H-25
Bucket dumps momentarily to TILT
when lever is operated
from HOLD
The bucket dumps momentarily under its own weight when the bucket control lever is gradually shifted from the HOLD position to the TILT position while the engine is at low idling. When the control lever is put completely into the TILT position, the bucket moves normally. Cause . Defective seating of bucket spool check valve of work equipment valve.
WA1 200-3
20-1019 0
TROUBLESHOOTING
H-26
H-26
Boom and bucket levers do not move smoothly
Fault check Using the standard value table, check whether or not the operating effort of the lever is large.
20-1020 0
WA1 200-3
DISASSEMBLY AND ASSEMBLY

30-002 STANDARD TIGHTENING TORQUE 30-003 PRECAUTIONS WHEN CARRYING OUT OPERATION 30-005 COATING MATERIALS 30-006 SPECIAL TOOL LIST 30-007 SKETCHES OF SPECIAL TOOLS DT 30-050 REMOVAL AND INSTALLATION OF DT CONNECTOR PIN HD 30-051 REMOVAL AND INSTALLATION OF HD CONNECTOR PIN 30-051 REPAIR PROCEDURE OF HARNESS Assy 30-052 ENGINE MOUNT Assy Assy 30-055 COOLING SYSTEM Assy Assy 30-058 FUEL TANK Assy Assy 30-062 AIR CONDITIONER Assy 30-064 AIR CONDITIONER PIPING Assy Assy 30-066 DAMPER Assy Assy 30-068 CONTROL VALVE Assy Assy 30-069 TORQFLOW Assy Assy 30-071 CONVERTER Assy Assy 30-077 TRANSMISSION Assy Assy 30-080 VALVE Assy Assy 30-081 T/C, T/M LINE Assy Assy 30-086 PROPELLER SHAFT Assy Assy 30-086-1 DISASSEMBLY AND ASSEMBLY OF CENTER SUPPORT Assy Assy 30-087 FRONT AXLE Assy Assy 30-089 REAR AXLE Assy Assy 30-091 DIFFERENTIAL CARRIER Assy Assy 30-096 FINAL & BRAKE Assy J/S & Ass y 30-100 J/S & ARM-REST Assy Assy 30-103 BRAKE SYSTEM Assy Assy 30-105 LOADER CONTROL Assy Assy 30-106 FRAME Assy Assy 30-110 GUARD & HOOD Assy A/C Assy 30-112 FLOOR/PLATFORM SUPPORT, A/C COVER Assy Assy 30-113 CONSOLE/DASH Assy Assy 30-115 HYDRAULIC TANK Assy Assy 30-116 STEERING HYDRAULIC LINE Assy Assy 30-117 LOADER LINKAGE Assy Assy 30-120 KICKOUT POSITIONER Assy Assy 30-121 ROPS CANOPY Assy Assy 30-122 EMERGENCY STEERING Assy Assy 30-124 STEERING CYLINDER Assy 30-126 LIFT CYLINDER Assy Assy 30-128 DUMP CYLINDER Assy MESABI Assy 30-131 MESABI OIL COOLER Assy
WA1200-3
30-001
(9)

1. STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the table below. 3. TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS Unless there are special instructions, tighten the O-ring boss piping joints to the torque below. Nominal No.
02 03, 04 05, 06 10, 12 14
Thread diameter mm
14 20 24 33 42

Varies depending on type of connector.
Tightening torque (Nm{kgm}) Range

35 63 84 132 128 186 363 480 746 1010 {3.5 6.5} {8.5 13.5} {13.0 19.0} {37.0 49.0} {76.0 103}
Target
44 103 157 422 883 {4.5} {10.5} {16.0} {43.0} {90.0}
Thread diameter of bolt
Width across flats
4. TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS Unless there are special instructions, tighten the O-ring boss plugs to the torque below. mm
6 8 10 12 14 16 18 20 22 24 27 30 33 36 39
mm
10 13 17 19 22 24 27 30 32 36 41 46 50 55 60 11.8 27 59 98 153 235 320 455 610 785 1,150 1,520 1,960 2,450 2,890
Nm 14.7 34 74 123 190 285 400 565 765 980 1,440 1,910 2,450 3,040 3,630 1.2 2.8 6 10 15.5 23.5 33 46.5 62.5 80 118 155 200 250 295
kgm 1.5 3.5 7.5 12.5 19.5
Nominal No.
08 10 12 14 16 18 20 24 30 33 36 42 52
Thread diameter mm
8 10 12 14 16 18 20 24 30 33 36 42 52

14 17 19 22 24 27 30 32 32 36
Tightening torque (Nm{kgm}) Range

5.88 8.82 9.8 12.74 14.7 19.6 19.6 24.5 24.5 34.3 34.3 44.1 44.1 53.9 58.8 78.4 93.1 122.5 107.8 147.0 127.4 176.4 181.3 240.1 274.4 367.5 {0.6 0.9} {1.0 1.3} {1.5 2.0} {2.0 2.5} {2.5 3.5} {3.5 4.5} {4.5 5.5} {6.0 8.0} {9.5 12.5} {11.0 15.0} {13.0 18.0} {18.5 24.5} {28.0 37.5}
Target
7.35 11.27 17.64 22.54 29.4 39.2 49.0 68.6 107.8 124.4 151.9 210.7 323.4 {0.75} {1.15} {1.8} {2.3} {3.0} {4.0} {5.0} {7.0} {11.0} {13.0} {15.5} {21.5} {33.0}
29.5 41 58 78 100 147 195 250 310 370
Thread diameter of bolt mm

6 8 10 12
Width across flats mm

10 13 14 27 5.9 13.7 34.3 74.5 Nm 9.8 23.5 46.1 90.2 0.6 1.4 3.5 7.6 kgm 1.0 2.4 4.7 9.2
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified. Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {kgm}) Nominal size Width across of hose flats Range Target Taper seal type Face seal type Root diameter (mm) (Reference) 14.3 17.5 20.6 25.4 30.2
Nominal thread Thread size size - Threads per (mm) inch, Thread series 14 18 22 24 30 33 36 42 9 16 18UN 11 16UN 16 13 16UN 16 1 14UNS 1 3 12UN 16
34 54 {3.5 5.5} 02 19 34 63 {3.5 6.5}
44 {4.5} 44 {4.5} 74 {7.5} 78 {8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
2. TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the table below. Thread diameter mm
10 12 16
22 03 24 04 27 32 36 41 46 55
54 93 {5.5 9.5} 59 98 {6.0 10.0} 84 132 {8.5 13.5} 128 186 {13.0 19.0} 177 245 {18.0 25.0} 177 245 {18.0 25.0} 197 294 {20.0 30.0} 246 343 {25.0 35.0}

14 17 22 Nm 59 74 98 123 235 285
Tightening torque
kgm 6 7.5 10 12.5 23.5 29.5
05 06 (10) (12) (14)
30-002
(9)
WA1200-3
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using face seal type
Nominal number 02 03 04 05 06 Plug (nut end) 07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 Nut (elbow end) 02789-00210 02789-00315 02789-00422 02789-00522 02789-00628
2.
Precautions when carrying out installation work Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the cylinder 100 mm from the end of its stroke. 3. Next, operate the hydraulic cylinder 3 4 times to the end of its stroke. 4. After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure. 3. Method of disassembling, connecting push-pull type coupler There are 2 types of push-pull type coupler. The method of disassembling and connecting is different, so see the following page when disassembling and connecting the coupler.
2) Split flange type hoses and tubes

Nominal number 04 05 Flange (hose end) 07379-00400 07379-00500 Sleeve head (tube end) 07378-10400 07378-10500 Split flange 07371-30400 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal number 06 08 10 12 14 16 18 20 22 24 27 Part Number 07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430 07049-02734 Dimensions D d L 6 5 8 8 6.5 11 10 8.5 12 12 10 15 14 11.5 18 16 13.5 20 18 15 22 20 17 25 22 18.5 28 24 20 30 27 22.5 34
4. Precautions when completing the operation If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
L
DEW00401
Taper 1/8
WA1200-3
30-003
(9)
Before
carrying out the following work, release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
Even
Disconnection 1) Release the residual pressure from the hydraulic tank. For details, see TESTING AND ADJUSTING, Releasing residual pressure from hydraulic tank. 2) Hold adapter (1) and push hose joint (2) into mating adapter (3). (See Fig. 1) The adapter can be pushed in about 3.5 mm. Do not hold rubber cap portion (4). After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against (3) until it clicks. (See Fig. 2) Hold hose adapter (1) or hose (5) and pull it out. (See Fig. 3) Since some hydraulic oil flows out, prepare an oil receiving container. 3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it. 3) Hold in the condition in Steps 1) and 2), and pull out whole body (2) to disconnect it. 2) Hold in the condition in Step 1), and turn lever (4) to the right (clockwise). 2) Hold in the condition in Step 1), and push until cover (3) contacts contact surface a of the hexagonal portion at the male end.
3)
4)
Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (See Fig. 4) Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (See Fig. 5) When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
Disassembly
30-004
(9)
Connection
WA1200-3
COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code LT-1A Part No. 790-129-9030 Qty 150 g Container Tube Main applications, features Category Molybdenum disulphide lubricant Komatsu code LM-G LM-P Part No. 09940-00051 09940-00040 SYG2-400LI SYG2-350LI SYG2-400LI-A SYG2-160LI SYGA-160CNLI SYG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-160CNCA SYG2-400M SYG2-400M-A SYGA-16CNM SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) SYG0-16CNT (*) SYG2-400B SYGA-16CNB SYG2-400BT (*) SYGA-16CNBT (*) Qty 60 g 200 g Container Can Tube Main applications, features Used as lubricant for sliding portion (to prevent from squeaking). Used to prevent seizure or scuffling of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc. General purpose type
LT-1B
LT-2
LT-3 Adhesives LT-4 Holtz MH 705 Three bond 1735
Aron-alpha 201 Loctite 648-50 LG-1
LG-5
Gasket sealant
LG-6
LG-7 Three bond 1211 Three bond 1207B
Used to prevent rubber gaskets, rubber cushions, and cock plug from coming out. Used in places requiring an immediately effective, strong adhesive. Used for plas20 g Polyethylene 790-129-9050 tics (except polyethylene, polyprophylene, container (2 pcs.) tetrafluoroethlene and vinyl chloride), rubber, metal and non-metal. Features: Resistance to heat and chemicals Polyethylene 09940-00030 50 g Used for anti-loosening and sealant purcontainer pose for bolts and plugs. Adhesive: Used as adhesive or sealant for metal, 790-129-9060 1 kg glass and plastic. (Set of adhesive Hardening Can and hardening agent: agent) 500 g Polyethylene Used as sealant for machined holes. 790-129-9040 250 g container Used as heat-resisting sealant for repairing 790-126-9120 75 g Tube engine. Quick hardening type adhesive Polyethylene Cure time: within 5 sec. to 3 min. 790-129-9140 50 g container Used mainly for adhesion of metals, rubbers, plastics and woods. Quick hardening type adhesive Polyethylene Quick cure type (max. strength after 30 minutes) 790-129-9130 2 g container Used mainly for adhesion of rubbers, plastics and metals. Polyethylene Resistance to heat, chemicals 79A-129-9110 50 cc Used at joint portions subject to high container temperatures. Used as adhesive or sealant for gaskets 790-129-9010 200 g Tube and packing of power train case, etc. Used as sealant for various threads, pipe joints, flanges. 790-129-9080 1 kg Can Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. Features: Silicon based, resistance to heat, cold Used as sealant for flange surface, tread. 790-129-9020 200 g Tube Used as sealant for oil pan, final drive case, etc. Features: Silicon based, quick hardening type 790-129-9070 1 kg Tube Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc. Used as heat-resisting sealant for repairing 790-129-9090 100 g Tube engine. Features: Silicone type, heat resistant, vibration resistant, and impact resistant 419-15-18131 100 g Tube sealing material Used as sealing material for transfer case
G2-LI
Various
Various
G2-CA
Various
Various
Used for normal temperature, light load bearing at places in contact with water or steam.
Molybdenum disulphide Grease grease LM-G (G2-M) Hyper White Grease G2-T G0-T (*) *: For use in cold district Biogrease G2B G2-BT (*) *: For high temperature and large load SUNSTAR PAINT PRIMER 580 SUPER Primer SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PENGUINE SEAL 580 Adhesive SUPER S or W Sika Japan, Sikaflex 256HV SUNSTAR PENGUINE Caulking SEAL No. 2505 material SEKISUI SILICONE SEALANT
400 g 10 Bellows type 400 g 20 Bellows type 16 kg Can
Used for heavy load portion
400 g 16 kg
Seizure resistance and heat resistance higher than molybdenum disulfide grease Bellows type Since this grease is white, it does not Can stand out against machine body. Since this grease is decomposed by bacteria in short period, it has less effects on Bellows type microorganisms, animals, and plants. Can Used as primer for cab side (Using limit: 4 months) Used as primer for glass side (Using limit: 4 months) S is used for high-temperature season (April - October) and W for low-temperature season (November - April) as adhesive for glass. (Using limit: 4 months) Used as adhesive for glass. (Using limit: 6 months) Used to seal joints of glass parts. (Using limit: 4 months) Used to seal front window. (Using limit: 6 months)
400 g 16 kg
20 ml
Glass container Glass container
417-926-3910
320 ml
Polyethylene container Polyethylene container Polyethylene container Polyethylene container
20Y-54-39850 417-926-3920
310 ml 320 ml
20Y-54-55130
333 ml
Adhesive for cab glass
20 ml
WA1200-3
30-005
(9)
SPECIAL TOOL LIST
SPECIAL TOOL LIST

Tools with part number 79 Tcannot be supplied (they are items to be locally manufactured). Necessity: s: Cannot be substituted, should always be installed (used). q: Extremely useful if available, can be substituted with commercially available part. New/remodel: N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from items already available for other models. Blank: Tools already available for other models, used without any modification. Tools marked in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS). Tools having Nos. SMT-- are shown for manufacture in the field and are not set as special tools (their prices are not set). Accordingly, they cannot be supplied.
Component Symbol Part No.
790-314-1000 790-101-4000 790-101-1102 SMT-890-2100
Part Name
Puller Puller Pump Push tool
Necessity
Qty
1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1
New/ re Sketch model
Nature of work, remarks
s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s
N N N N N N N
SMT-890-2110 Guide SMT-890-2120 Guide SMT-890-2150 Guide SMT-890-2160 Guide
Component
Symbol
Part No.
SMT-890-1700
Part Name
Push tool
Necessity
Qty
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 Press fitting of bearing
SMT-890-2170 Plate SMT-890-2180 Bolt 01643-33690 01580-03629 Washer Nut
s s s s s s s s s s s s s s s s s s s s s
N N N N N N N N N N N N N N N N N N N N
Disassembly, assembly of damper cover assembly
1 B 2 3
SMT-890-1710 Sleeve SMT-890-1720 Spacer SMT-890-1810 SMT-890-1820 SMT-890-1200 Push tool Push tool AssyDraw
1 Disassembly, assembly of torque converter assembly
SMT-890-1210 Socket SMT-890-1220 Guide
2 3
SMT-890-1230
Socket
SMT-890-1240 Test/J SMT-890-1250 Test/J
4 1
SMT-890-1310 SMT-890-1410 SMT-890-1500
Wrench Socket AssyDraw
2 Disassembly, assembly of transmisD sion assembly
SMT-890-1510 Socket SMT-890-1520 Guide
3 4 5 6 7
SMT-890-1530 SMT-890-1540 SMT-890-1550 SMT-890-1560 790-302-1280
Socket Socket Socket Socket

Socket (Width across flats: 55 mm)
Press fitting of bearing
SMT-890-2130 Guide Press fitting of dust seal SMT-890-2140 Guide SMT-890-2210 Guide Press fitting of retainer and oil seal Disassembly, assembly of center hinge SMT-890-2220 Guide K 791-775-1140 01643-33080 Press fitting of bearing 01580-03024 AdjuSMTent pre-load on input gear bearing
Removal, installation of modulated clutch piston nut Press fitting of transmission front housing bearing
N N N N N
Bolt Washer Nut Puller Pump Push tool
790-101-4000 790-101-1102 SMT-890-2300
N N N N N N N
SMT-890-2310 Sleeve SMT-890-2320 Sleeve 2 SMT-890-2330 Plate SMT-890-2210 Guide SMT-890-2220 Guide 791-775-1140 01643-33080 01580-03024 SMT-890-2410 SMT-890-2420 3 SMT-890-2430 SMT-890-2440 Push tool Push tool Bolt Washer Nut Push tool Push tool
Press fitting of transfer output shaft oil seal
Press fitting of transfer output shaft dust seal Press fitting of transfer output shaft coupling cover Press fitting of transfer output shaft bearing
Press fitting of bushing
Support of transfer output shaft

Removal, installation of transfer coupling bolt
N N N N
Press fitting of dust seal
30-006
(9)
WA1200-3
SPECIAL TOOL LIST
Component
Symbol
Part No.
793-890-2500 793-890-2510 793-890-2520 793-890-2530 793-890-2540 793-890-2550 793-890-2560
Part Name
Push tool Shaft Nut Sleeve Sleeve Plate Plate Spring Guide Ring Bolt Nut Screw Eyebolt Eyebolt Push tool Sleeve Sleeve Shaft Nut Guide Ring Bolt Nut Eyebolt Nut wrench Wrench Micrometer Adapter Wrench Tool assembly Cylinder Piston Shaft Plate
Necessity
Qty
1 1 1 1 1 1 1 4 1 1 6 6 6 2 2 1 1 1 1 1 1 1 4 4 2 1 1 1 1 1 1
s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s
N N N N N N N N N N N Press fitting of boom bushing
793-890-2570 793-890-2580 793-890-2590 793-890-2610
Removal, installation, disassembly, assembly of work equipment assembly
01580-02016 V 01236-40512 04530-12030 04530-11222 793-890-2700 793-890-2710 793-890-2720 793-890-2730 2 793-890-2740 793-890-2750 793-890-2760 793-890-2770 01580-02016 04530-11222 792-340-1120 1 796-550-1310 792-525-3000 2 790-425-1670 790-425-1660 W SMT-890-3100 SMT-890-3110 3 SMT-890-3120 SMT-890-3130 SMT-890-3140
N N N N N N N N Press fitting of ring bushing
Removal, installation of sleeve nut
Disassembly, assembly of axle final drive brake assembly
Adjustment of side bearing preload
Adjustment of hub bearing preload
WA1200-3
30-006-1
(9)
!J3B*sm
!#33lca~~
SKETCHES OF SPECIAL TOOLS
OF SPECIAL TOOLS
.w *~t~k~~~~~~~~l~t~~~~~~~(~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
$~a-~y~~i~~~Bl St AJ-U70-007 #3 k&T&, lii8CMli co.5tm R0.64.2mIo:tl

Thisspaceris eauivalent to one in jigdrawing No. AJ-U70-007 #3 of Komatsu EC . Chamfer outside corners to CO.5and roundinside corners to R0.6 - RI.2 unless otherwise specified. #AmI 1 V mWll?fA Rl?
1
pI,;mj1
; HEAT TREATMENT 1 CASE DEPTH MATERIAL
ss4cJo PART NAME

PAMT CM SJFACE mAT.arz
MASS (kg1 SCALE
SPACER
NONE
ThissPaceris euuivalent to one in jigdrawing No. AJ470-007#2 of Komatsu MEC . Chamfer outside corners to CO.5and roundinside corners to R0.6 - RI.2 unless otherwise specified. V
I
WA1200 (31
HEAT TREATMENT CASE DEPTH I . I . p(AT& MASS (kg) PART NAME
APPLICATION QTY MATERIAL
/
sJ?=da TREIT.lm
tiIOl!
CASE DEPTH MATEATAL HEAT TREATMENT HRC26-32 s45c #A#WL /Idenim and tmerinn PAMT (R PART NAME MASS (kg)
RDJTOFI
12
SCALE
SLEEVE
PUSH
TOOL
SJmcE TE4r.coK
NONE
WA1 200-3
30-007 0
53i$T*$!Rz
!+35kJX!sr$H
:d) *~t=~~~~~~~~~~Wt~~~~~~~~~-~~~~~~~~~~.
B2/B3
NOTE:
Komatsu cannot accept any responsibility
for special tools manufactured
according
to these sketches.
$38
$3
$jJ
Detail of "A"
Detail of "A"
r-;-5-----y-+_
=Q
\::\,_
_---ti ----._---
111 1.4,ik,
t-4 I I III I
L I . .
____
#lBA
LF-~j-------
ThissDaceris eauivalent to one in jig drawing No. AJ-D70-008-B of Komatsu MEC . Chamfer outside corners to CO.5and round inside corners to R0.6 - R0.8unless otherwise smified.
WA 1200 (31
APPLICATION
Thismater is equivalent to one in jig drawing No. AJ-U70-008-A of Komatsu MEC . Chamfer outside corners to CO.5and roundinside corners to R0.6 -R0.8unless otherwise specified.
1
WA1200 (31
APPLICATION I Fmii MASS [kg) PART NAME HEAT TREATMENT CASE DEPTH MATER IAL
1
BTY
QTY
I
I
HEAT
TREATMENT
CASE
OEPTH
MATERIAL
PmTrti
MASS [kg) PART NAME
ss400
,
ss400 4.8
SCALE
8.5
SCALE
PUSH
TOOL
PAINT WI SUFFACE TFEATXOM
PUSH
TOOL
PAINT OR SWACE TREAT.CXJE
NONE
142,o,A
NONE
30-008 0
WA1 200-3
53l?e*uL
4-33sE!s#iH
NOTE:
Komatsu
cannot accept any responsibility
according
to these sketches.
-- -:p q.$
co
0
oocc;
a*
;f
0-J
8 / .
--
.----------
1,
:
I
I q I r-7-Y
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i
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I I
I.
86. 67
\
.
I
l I
I
,
I
I
a------: I
WA1200131 1 1
$~l;tZ~I&%Q!~ooi
I I I ( --f r i -7 i
I
40-85155-OOA
#l3i~t16.
[. ;
KflTICti!
HEAT TREATMENT
CASE DEPTH
APPLICATION 1 QTY MATERIAL PAMT (R
i-
Thissocketis equivalent to one in ii9drawing No. 40-85155-OOA AwazuPlant.
MASS Ik g)
PART NAME
I
8.8
SCALE
ASS'Y-DRAW
SURFACE TREAT.coDE
I
NONE
WA1 200-3
33l#*%l2t
mIE!81$m
1 Cl (2/3)
NOTE:
according
to these sketches.
It) 7
1.4 7
0.15
77
WAi200131 1 175
.. I
HEAT TREATMENT 1 CASE DEPTH
APPLICATIONQTY
MATERIAL
&423295311301
MASS (kg1
HRC5863
PART NAME
SCM415H
PAINT OR SURFACE lREAT.cooE
Thissocketis eauivalent to one in jigdrawing No. 40-85t55-001 AwazuPlant.
5.7
SCALE
SOCKET
NONE
30-010 0
WA1 200-3
53##-wi
!l333kIB%H
-&I *~t~kb~~~~~~~~Wt~~l~~~~~~-~~~ff~~~~~~.
Cl (3/3)
NOTE:Komatsu
cannot accept any responsibility for special tools manufactured according to these sketches.
_ 8 -9 _ 170 6 7v 1
o2
W 00 /
I 66 * _,4 ~ z (r0
n1wJ J5,driIled
hole
G 0 as
44 g
g
---
__&__-_-___
Thissocketis ecmivalent to one in iio drawing No. 40-85155-002 AwazuPlant.
PLATE
PART NAME
YC
.I.
s43c / i ii :
MATER I AL jUY/nr y@ REMARKS
3.1
SCALE
GUIDE
SUEFACE TREU.CODE
NONE
WA1 200-3
11
5H#*mi
!fs33cm~~
-w *iTlcd:
t3~~~~-fi~~ll~~-~~~-C~~f;flt-Wlo)~ff~~~~~1.
accept any responsibility for special tools manufactured
c2
NOTE: Komatsu cannot
according to these sketches.
------__-_ ------
Thissocketis eauivalent to one in jig drawing No. 40-85161-001 AwazuPlant.
30-012 0
WA1 200-3
m#*%m
!#3mZao
w
1 C3(1/2) 1
*lzlt-.k
~~~~~~~~LWl~~~~~~~~~-~~~~~~~~~~.
for special tools manufactured according to these sketches.
NOTE:
T$;I~ wjjP$#i4m&#
40-85227-001
BtI~&P;hbc
Awazu Plant.
I
This Socket is ealiivalent

!3
to one in jig drawing No. 40-85227~001
01
SYM.
PIPE BOSS GEAR
STKM13A 1 1 10.5 c SS4OP n f 543

I
HEAT TREATMENT
PART
NAME 1 CASE DEPTH IAPPLICATIONI QTY
rIIJNi
TJ fi 4 A
u
jij .
ss
42C-.13-15120
- SAE~~;lr"h-En?fdd
DETAIL OF SAE I NVOLUTE
(NONE)
SH,AT
! Thermal %/!t!of __. . . MASS (kg1
material,
PA-RT
/ HRC20-30
NAME
I
m
1
SPL I NE
1.56
SCALE
T!~I/~J
-p-t-/
PAINT Cfl SWFACE,,IREAT.COE
NONE
WA1 200-3
?!S,MT,89.0:
11
PART
NO.
124,O.d
30-013
%#*%I3
CINCH
2s:) *~t~~~~~~~~~~l~t~~~~~~~~~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility
Thissocketis euuivalent to one in jigdrawing No. 40-85228-001 AwazuPlant.
inioiutespline 60X22X2. 5
I 1
_iHAt
20 00
I
I-
!iiOo1 1 0.19;
s43c 1 1 '$.
MATERIAL UV!3$ffs~ REMARKS
Pressure angle
E3lA
PART NAME
4/;r;Jr
Detail
Ex774/ti3Yk
involute spline
f Thermal refining of material

SWACE TiEAT.CODE
of
shaft
125.o.L
30-O 14 0
WA1 200-3
53l!#*+Jlz
DIZZY
NOTE:
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
d -
-A
-------_--_
c
,=
y _-co.5 co.5
z
),
z
i
/\ /'
-22-l -
218 (240) d
++ \ &
\
00
A-A
03
WM.
PIPF
PART NAME
$TKMM I s43c
i 1
4.8 +127xt8 2.2t22

qAsp REMARKS
I
1MATERIAL ewi3
SCALE
NONE
WA1 200-3
!&%*a2
~71~~H
l__!L-l
NOTE:
according
to these sketches.
------
-----
--------
--&________
100
This socket is equivalent to one in jig drawing No. 40-85159-001 Awazu Plant.
WdPOO131 1
04 02
SYM.
BAR PI ATF PiPE

PART NAME
/SS4OOP I s53c
2 10.051. 1 I 1.5 I. ~TKMI~A i l6.1 i$lOOXt6 I s53c 1 i-2.2 I.

j MATER[AL[UY~~f;~j REMARKS
HEAT
TREATMENT
CASE
DEPTH
AIlTmi I
7 b-L#i.hh
APPLICATION OTY MATERIAL
j I
]
I Flame hardening PART NAME MASS (kg1 9.9

SCALE
s53c
PAINT L-R SURFACE TAEAT.WOE
SOCKET
NONE 30-016 0
WAl200-3
33fR*$m
6v.%IE%H
1 D2(1/3)
-1
NOTE:
120 204
* 1
HEAT I . I FumB! MASS (kg) TREATMENT CASE DEPTH
WAlXtO131
$o"old I$!l&WBirsbti 40-85154-OOA
ME&H,
PART
NAME
PAINT (R
Thissocketis eauivalent to one in jigdrawing No. 40-85154-OOA AwazuPlant.
13.2
SCALE
ASS'Y-DRAW
SUR?Q TREAT.COOE
NONE
WA1 200-3
30-017 0
53-fe*%i&
t%3?kIWer$H
%&I *~t~~d~~~~~~~~Wt~~~~7~~~~-~~~~~~~~~~.
1 D2 (2/3)
NOTE:
according
to these sketches.
Harden, turn with lathe, then finish with sandpaper
Surface must be sharp and free
-25.
5_ 44. I-
5kO. I__ I-
120
w
HEAT TREATMENT CASE PART NAME DEPTH
WAi200 131 1 1
APPLICATION B'TY MATERIAL
,;,:232953
*g/i W~I~~WB~B~ 40-85154-001 #%P~3I
MASS(kg)
1130
HF?C58-63
SCM415H
PAIN3 OF! SURFACE TREAT.CUOE
This socket is euuivalent
to one in jigdrawing No. 40-85154-001 AwazuPlant.
8.3
SCALE
SOCKET
NONE
WA1 200-3
30-018 0
53s*at
$34WX@El
m
1 D2(3/3) 1
*Iat-k
bQ~:~~M~~~FG-~,t~~~~~b-Wlo)~~~~~~~~.
NOTE:
154 27. 5 16. 5 E 66
r m
C-
S%
7v
4: OD
_---
-----
r u
145
__J
02 01
SYM.
BAR PLATE
PART NAME
.s43c s43c
10,5. 1 4.4 .
REMARKS
MATER I AL ffJY/Wyczp
WAlX)O I31 I
1
QJY
4
RTM[ m'
I
ztiy$igzk I
after f inishiw PART
HRC30-36
NAME
APPLICATION MATERIAL
Thissocketis euuivalent to one in jig drawing NO. 40-85154-002 AwazuPlant.
MASS (kg)
4.9
SCALE
GUIDE
PAINT (El SUFFACE TREAT.COoE
NONE
WA1 200-3
30-019 0
fpt#*%m
!i33#IW%H
-82 *iat-h
NOTE:
~~~~~~~~~Wt~~~~~~~~~-~~~~~~~~~~.
t
Y
40
I
83 5
93. 5 * 196.
N r ;
131 ) 1 f WA1200
/APPLICATION I ~17
afterf inishim
MdSS (kg) PART NAME
s53c
FAINT OR
Thissocketis euuivalent to one in jig drawing No. 51-85154-003 AwazuPlant.
7.6
SCALE
SOCKET
SWFACf TREAT.COOE
NONE 30-020 0
WA1 200-3
m#*4!m
!f33ZkIWls$B
rl) *Faclt-k ~~~~~~~~LWt~9l~~~~~~-~~~~~~~~~~.

$o,IL! WI#%WBrnSI 40-85153-001
I!ama.
Thissocketis eouivalent to one in jig drawing No. 40-85153-001 AwazuPlant.
q@@ ,li\
~#ll~ltf~
May be finished with lathe afterheattreatment

t HEAT TREATMENT CASE DEPTH %&~XF? L K&N; Hardening and tefiwering ! after finishing MASS (kg) PART REMARKS
.___
,_.
HRC36w42 SEE
NAME
WAlZCU 131 I 1 APPLICATION OTY MATERIAL
DWG
03
1
GUIDF OCKFT
PART NAME
WM.
I s53c II 12.2 . I s53c II 16.9.

1MATER I AL ]UlY/j@$~
9.1 NONE
SCALE
SOCKET
PAINT OR WIFACE lFEAT.cooE
WA1 200-3
30-02 0
53-#+*#i42
!4+3s#IE?sl$rn
,&) *~lt-~13~~:~~~~~~tt-7~~~~~~t-Wle>-ff~~~~~~.
-__
,d /,A
&;.L
i, \.--._ f----i \
-3
i
I
/
8
j
/
I
I,
j
t---
q.k===J= j
a-/
c__-__-__-__-__-ji_ ~_______________~
\
c
5 drilled
hole $I@ Stamp
U70-OP/TF-85156-2
/
/ /
/
40 20 z:_:
5-T-=----,I ii
1
/ii /
---_--
_---
I I
I;\ /I I
---__
III __-__-__-__
I .
I!I !I
I__-__-__-__-__-_i
ii i_______________J May be finished wi th lathe after heat tr eatment
1 WAiZOO(3) 1 I
*naM\
%:+Ig%WHm&f
40-85 equivalent to
156-00 one in jis
1 @ii,766,
drawing No.40-85156-001 Awazu Plant.
NUNt t
This
socket
is
SKR?"" 8 9 0 - 1 5 5 0 n
WA1 200-3
30-022 0
33%*s!m
$39?kIE?BI$B
is..) *~t~~$~~~~~~~~Wt~~L~7~~~~-~~~ff~~~~L~.
D6
for special
tools
manufactured
according
to these
sketches.
6-13. 5Zfy 6-13.5. drilled hole
INI
I A Hole
H7*.01*
-_-
j /
I
I/,
40- ,85157-00
This socket is ewivalent
to onein ii47 drawing No.

v
40-85157-001 AwazuPlant.
1 WA1200 I31 ( CASE

DEPTH APPLICATION
-I
01353-32335 i
02
SYM.
j
/
/
BOLT BAR BAR

PART NAME
$%i
Standard oart
ss4ooi3 s53c s53c

MATER I AL
!. , 2 ! 0.02!. 1 Qm. ! 1 I koi.

if1y/91j rcsy , REMARKS
6 1
I I ! I
j
02 I 01 ; 7z&itARiz L poRrrar, Harden1 ng andtenwer i rig : after finishing PART MASS (kg)
HEAT
TREATMENT
QTY
HRC36-42
NAME
MATERIAL
SEE DWG
PRINT ari SURFACE TREAT.CODE
8.4
SCALE
SOCKET
NONE
WA1 200-3
30-023 0
53-~*sRZ
!i3E%Js%H
:A) Milt-~
NOTE:
ul1~~:~~~~~t-~~~-cr~~~~-31~39rff~~~~~~.
JLL-1
-_,rj
_ $228.6
t;
yyIck;I:p
31 I -clYu
2150
07-k/:j
Upperh irwe
Lower hinge
SCALE
NONE 30-024 0
WA1 200-3
53s*wi
$333aw3~
1 Kl(Wi) 1
*,,I% %Yc/ZS%%WHrn
I@3 AJ-lJ70-004 #Z $?lS&:ap&a. ~~Xit$%$Plt CO. 5 3-?%!YtRO. 6-l. Zlz-c~nra,L I:
NOTE:
Thismater is euuivalerrt to one in jig drawing No. AJ-U70-004 #2 of Komatsu MEC Chamfer outside corners to CO.5and round inside corners to R0.6 -Rf.2unless
Thismater is euuivalent to one in iio drawing No. AJ-U70-004 #I of Komatsu MC . Chamfer outside corners to CO.5and round inside corners to R0.6 -RI.2unless
FllRiItq
I
-_. .. _
I HEAT
I I
TREATMENT
1 CASE DEPTH
I-
BA#lut
and tempering
Hardening
HRC26+32
NAME NO.
KlRTrow~ &A#;RJ
Hardening
MASS (kg)
23.4
SCALE
I
;
PART
GUIDE
PART
PAINT al SURFACE ilEAT.CUIE
MASS (kg)
16
SCALE
NONE
WA1 200-3
- 2 1,2Q ,A - 9,0, I I$M,T, tj
-MA&ii HRC26-32 and tempering s45c PAINT OR PART Ntd4E !iUFAIX lEAT.COE GUIDE I
I
I I
NONE
-2 $M,T, - Ej 9,0,
30-025 0
PART
NO.
!iMf+*BE
DISASSEMBLY
+$3zKls~~
AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
*w *~t~~~~~~~~~~IWt~~t~~~~~~-~~~~~~~~~~.
This spacer is equivalent to one in jig drawing No. AJ-U70-004 #4 of Komatsu MEC _
I \/
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R1.2 unless otherwise specified. This spacer is equivalent to one in jig drawing No. AJ-U70-004 #3 of Komatsu MEC .
I .
WAiZOO I31 1
R~PUCA~~ QT~
; HEAT
TREATMENT
1 CASE DEPTH 1 mum
1QTY
I
II-IEAT
TREATMENT
-CASE DEPTH
Klmf
wRi1a; IkAwzL H/q--J+32MATERIAi ~~~26-32 MATERIAL I Hardening I Hardening and tempering and tempering S45C' s45c 1 L PAINT OR PAINT OR PART NAME MASS (kg) ; PART NAME MASS (kg) SlFHCE TEAT. COPE SIK-AGE rnbT.COoE 6 i GUIDE . GUIDE 16 .
#t;ARWl/
SCALE
NONE
30-026 0
I ISM,T
PART
-, Ej 9,0, - 2
NO,
SCALE NONE
-; 1
$M,T,E)9,0,21,3Q
PART
NO.
tA
WA1200-3
53l!l8*24Em
!f33?kIEfiH
-El *~t~~~~~~~~~~l~t~~~~~~~l~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured
accordingto these sketches.
MIN
MIN 4
WA1200 (31
I . I PuITrm HEAT TREATMENT CASE DEPTH
1
. I P@llI@lf MASS (kg)
v
!
HEAT TREATMENT CASE DEPTH
ss400
PART NAME FAINT 08
MASS (kg)
HRC30*36
PART NAME
1.2
SCALE
PLATE
SURAIX lFFAT.CWE
17.5
SCALE
GUIDE
PAINT OR SUIFACZ TlEAT.CCOE
NONE
WA1 200-3
NONE 30-027 0
53f$3*llai
$-333cEEBa
*&I *Eat-k ~~~~~fi~~~~t~~~~~~~~~-~~~~~~~~~~.

NOTE: Komatsu
cannot accept any responsibility
according
to these sketches.
Q9
02
01
MIN MIN -----+
0-W
---_-
R z -82
A
++
I
-C _
_c1
t-
80 v<4 PLACES
18.54
SCALE
GUIDE
SURFACE TFlEAT.CC#lE
NONE 30-028 0
WA1 200-3
M#*%l~
!f3BcLE@B
iz) *Elt-h
~~~~~~~~~Wt~~t~~~~~~-~~~~~~~~~~.
1 K1(6/7)
NOTE:
MIN
36X3
\ WAi2ooI31 1 I
HEAT TREATMENT
Hardening and tempering PART
1 CASE
DEPTH
1 APPLICATION O'TY
MATERIAL
Fal;lolj E$Ai%c;R L
M&S (kg)
HB248~285
NAME
s45c
PllINl OR SWdCE ~~.CODE
I
I
WA1 200-3
6
SCALE
GUIDE
II
NONE
I~;S,MT:Q9,0:222,O,fi
PART NO.
/\
SCALE
NONE 30-029 0
53B*4m
!#33%a@H
1 K1(7/7)
NOTE:
according
to these sketches.
PLACES
01I
RlFmq
HEAT #iAm
TREATMENT
CASE
DEPTH
L
I
Hardening and tempering lkgl

SCALE
O?
SYM.
BAR
PART NAME
SS4OOB s45c
MATERIAL
2
1
0.07 .
11 .
GEMARKS
M&S
PART NAME
11.14; NONE
GUIDE
PAINT OR SWACE TREAT.CME \
BlYIsEI q@y
30-030 0
WA1 200-3
5MR*sm
#S#IJSE4
*~t~~~~~rh~~~l~t~~~~~~~~~-~~~ff~~~~~~.
NOTE:
---y-----
I_---
--
l__-Ll-_____
II ::
I _-_-u-__ t-I I MASS . SCALE HEAT TREATMENT
ii
:
HA1200 (31
APPLICATION
1
QTY
CASE
DEPTH
MATERIAL
. PmTl
(kg)
PART
NAME
PUSH
TOOL
PAINT WI lHEAT.COOE
WFACI
NONE
WA1 200-3
230.0.A
30-03 1 0
1 Q(N)
NOTE:
Komatsu
cannot
accept any responsibility
according
to these sketches.
This spacer is equivalent to one in jig drawing No. AJ-U70-011 #l of Komatsu MEC .
This spacer is equivalent to one in jig drawing No. AJ-U70-011 #12 of Komatsu MEC .
f&ruw~ co.5 U#li R0.64.2 mwl:t-~

Chamfer outside corners to CO.5 and round inside corners to R0.6 - R1.2 unless otherwise specified. \-
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R1.2 unless otherwise specified.
IHEAT
P&q
TREATMENT #iAM% L
and tempering
CASE DEPTH RIGTIM-
QTY
. ; HEAT I ~~~
I
TREATMENT
and tempering
/ CASE DEPTH 1 m[n~r(,g 1QTY
I 7.2
Hardening
HRC26-32
NAME
MA;E;FL
PAINT IJA
p[RTIoN~ #khf&RL
I
Hardening
HRC26-32
NAME
I
aMA;;;FL
PAINT OR S&FACE TREAT.=
MASS (kg) SCALE ;
PART
SLEEVE
SUFACE TREAT.COOE , .
MASS (kg)
\
PART
I
13.3
SCALE
SLEEVE
1 PART NO.
NONE
30-032 0
1 SM,T, ,
PApT
-2 8 9,0,
NO.
NONE
-2 I ZjM,T '3,1Q ,A ; E) 9,0, I

WA1 200-3
53l%*ai
!#3sIE!lsis~
NOTE:
according
to these sketches.
Finish
corners
smoothly
with
grinder
t
I
This
spacer
is equivalent
to one in jig drawing No. AJ-U70-011 #3
of Komatsu MEC
Kf?iIoN~ .
MASS (kg)
I HEAT
TREATMENT PART ;
1 CASE
DEPTH
1 MATERIAL
ss400
NAME NO.
FAINT IJR SURFACE TEAT.CCXE
22
SCALE
PLATE I I
NONE
WA1200-3
SjM,T, L 8 9,0,- ;i
30-033 0
PART
53l?B*%l~
434xcNm
.&I *~t~~~~~~~~~~~~c~~~~~~~~~-~~~ff~~~~~~. NOTE: Komatsu cannot accept any responsibility

'his spacer is equivalent to one in jig Irawing No. AJ-U70-006-C of Komatsu MEC
This spacer is equivalent to one in jig drawing No. AJ-U70-006-B of Komatsu MEC
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R0.8 unless
S/ii
f YBX~~#JZ
t3
AJ-U70-006-D
&,TbL
.
f ~3J%k%&b
I$ AJ-U70-006-A
I%Taii;t
.
This spacer is equivalent to one in jig drawing No. AJ-U70-006-D of Komatsu MEC
This spacer is equivalent to one in jig drawing No. AJ-U70-006-A of Komatsu MEC
A +j-jFJ$@
Detai I of A !5U!w Detai I of A
CO.5 lk#ia R0.6w0.8
i;mm:te
#ji$,!~~#.i CO.5 tm
RO.bO.8
mlIm~t.
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R0.8
30-034 0
WA1200-3
5m*mc
433?DxBH
m
1 Vl (l/8) 1
*ixllt:k
~~~~~~~~~Wt~~/l~~~l~-~~~~~~~~~~.
NOTE:
---2
1 tlA1200 (31 1
. , I HEAT TREATMENT CASE DEPTH NAME
APPLICATION 1 QTY MATERIAL PAINT OR
mum!
MASS (kg)
I
PART
PUSH
TOOL
SIBFACE TREAT.CCllE
I
SCALE
NONE
WA1 200-3
30-035 0
53lYF*%It
!l3%kIIE@H
:d) *lzlr-1
NOTE:
d3~~~~~~~L~tt_3~~T~~I~.-~~Wff~~~~~1.
for special tools manufactured according -1 to these sketches.
8V m40
Thread depth: 40
$$I! ~73$~~$%lli l!i

This spacer
AJ-U70-001 #I&i?i3~ I;-tbm~:t~
is equivalentto one in jig drawing No. AJ-U70-001 #l of Komatsu MEC
I HEAT TREATMENT ;pw11~~1 ImtWL

I
CASE
,
DEPTH
mang!j
QTY
&i#Wi
CO.,5 tidli R0.64.2
1 Hardening and MASS (kg)
tempering
HRC26-32
NAME
MA;;;FL
PAINTOR mAT.COOE
PART
Chamfer o&side corners to CO.5 and round inside corners to RO.6 - Rj.2 unless otherwise swcif ied.
98
SCALE
SHAFT
SWAE
NONE
30-036 0
WA1 200-3
alt#*%m
Oxfam
*~jl-~:13~~~;ht;~~~~t-31,~~~~t~.-wl~a~~~~~~~.
NOTE:
Actually positioned on part No. 793-890-2510
#2 ill3~rrnai
This spacer is equivalent to one in jig drawing No. AJ-U70-001 #2 of Komatsu MEC
v
. . I
idEAT
TREATMENT
CASE XJEPTH
Chamfer outside corners to CO.5and roundinside corners to R0.6 - RI.2 unless otherwise smcified.
wRTrar;
!
Hardening and tempering
&A&EL
HRC26*32
NAME NO.
MATERIAL
s45c
PAINT OR SlFAcE TFEAT . COE .
PART SCALE
NUT
PART
NONE
WA1200-3
1 z9,3,Ej9,0,25,2Q
,A
30-037 0
53R*wL
!l+iSKLEsl$B
VI
(4/8)
NOTE:
ItAJ-U70-001 #4~~ir;b3t
.
.
mI@(
I I HEAT. TREATMENT %ma L I

Hardening and tempering
AMIWIM CASE DEPTH
0 TY
MATERIAL
I
MiI@(
I I HEAT
I
MPLIWIJN
QTY
TREATMENT PART
I
1 CASE
1
DEPTH
MATERIAL
HRC26*32
NAME
s45c
PAINT OR WFKETREAT. COOE
Harder?$%kempering
HRC26?32
NAME NO.
s45c
PAINT OR
MASS (kg)
PART,
MASS (kg)
SWFACE
TEAT.CUE
9
SCAiE
SLEEVE
17.5
SCALE
SLEEVE
PART
NONE
30-038 0
NONE
WA1 200-3
53-#f*wi
DISASSEMBLY AND ASSEMBLY SKETCHES
+-3+%.IE@R
OF SPECIAL TOOLS
.&I *~t~k$~~~~~~~I~~~~1~~~~~~-~~~~~~~~~~.
$ g@$lo This spacer is equiva I ent to one in j ig drawing No. AJ-U70-001 #6 of Komatsu MEC 639
Thread depth : 10 Make 6 holes at equal intervals
This spacer
is equivalent
to one in j ig drawing
No. AJ-U70-001
#5
of Komatsu MEC .
EM?li co.5 w
lHEAT PQRiroW! MASS (kg)
Chamfer outside corners to CO.5 and round inside corners to RO. 6 - Rl. 2 un I ess
R0.64.2 trfIa~t.
CASE DEPTH NAME
WA1200 131 1
APfINXIoN
1Fii8hftdii
OTY
Chamfer outside corners to CO.5 and round inside corners to RO. 6 - Rl. 2 unless
co.5 tm R0.6~1.2 mlIfJ~L
biAl200 131 1
APPLIUm
TREATMENT . PART
MATERIAL
I I HEATBAi;FATMENT
OTY
CASE DEPTH
MATERIAL
ss4go
PAINT OR SIRWE TEAT.COCE
FURiiQJ! Hardening MASS (kg)
and tempering
HRC26*32
NAME
PAINT
S45G SWACE TREAT-COLE

OR
PART
2.6
SCALE
PLATE
7.8
SCALE
PLATE
NONE
WA1 200-3
NONE
30-039 0
53B*$IE
m?u~~~
%B.i) mls-bc ~~~~~fi~~I~c~7ts~~~m-~~~ff~~~~~~.

(Equa I I Y spaced)
41
[ 9% Outside 1 ojB@
IdbarOER
Specifications
of spring
diameter
Cm) Cum)
1 1
1
32
3 46
/ 1 1
Wire diameter
1 I&X*
Freeheight W
/.x5-
A-A
8&U
?f~x;ctf$ H#i!$~1bUla $!;8$
A32-03
~~,",~~a.
$88~TNM#J~ hl# AJ-801-024 tr3 I%tbh

This spacer is equivalent to one in jig drawing No. AJ-801-024 #3 of Komatsu MEC
This spring is equivalent to compressivecoil spring,product No. A32-03, manufacturedby SANESU Co.,Ltd.
v (wAi200131 _
, HEAT wirm~ TREATMENT wmz L
and tempering
WAl200(31
APPLICATION 1 I FaiLor HEAT TREATMENT PART CASE NAME DEPTH MATERIAL
4
QTY
CASE
OEPTH
~~UTIM
0.n
~~~30-36
PART NAME
MATERIAL
s45c
PAM
SEE
DWG
1 Hardening
MASS (kg1
MASS (kg)
SCALE
39.9
SCALE
GUIDE
SIFUI TR5AT.W
IBI
SPRING
PART NO.
PUNT [R TIBT.wDE
SRdCE
NONE
NONE
WA1200-3
30-040 0
53lB-ala
!f?3?#IE!sr$B
:w *Ht-k
NOTE:
~~~~~fi~~~~t~~~~~~~l~-~~~~~~~~~~.
accept any responsibility for special tools manufactured according to these sketches.
Komatsu cannot
WAVOOi31 1
MlICllTIM Q TY
,HEAT
A-A
,mim~ MASStkg) Iii

to one
TREATMENT . PART
CASE DEPTH MATERIAL . ss400 PAINT OR NAME

SW&E .
$8
This
bi3SfAitWl~
spacer is equivalent
AJ-801-024 #4 131~&3,
in jig drawing No.
7.8
SCALE
RING
PART NO.
TREAT .COOE
AJ-801-024 #4 of Komatsu
MEC
NONE
WA1 200-3
7y9,3,89,0,25,90
,A
30-04 1 0
53?#*$Im
%3%7IE@O
22) *~c~k~~~~h~~~LW~~~1~~~~~~-~~~ff~~~~~~.
Q/5
This
spacer
is equivalent
to one in j ig drawing
No. AJ-801-024 #7 of Komatsu MEC .
MAi
TREATMENT . PART CASE DEPTH . NAME NO. MATERIAL
APRI@TION 0 TY I HEAT F&U%! MASS (kg)
SS40OB
PAINT OR SWXE TFWT.W
1.1
SCALE
BOLT.
PART
NONE
30-042 0
WA1 200-3
5m*wi
!f34zkIE@H
.&Ii)*l.ac-k
NOTE:
~~~~~~~~I~l~~/l~~~~~-~~~~~~~~~~.
WA1200 131
I HEAT TREATMENT CASE DEPTH
AfJFtICATI~ QTY MATERIAL
lxlli,i MASS (kg)
PART
NAME
PUNTIIF!
SWACE TWJ.CWE
PUSH
SCALE
TOOL
NONE
WA1 200-3
30-043 0
%f#*wi
$-3-3i#IE!sl$H
m *~t~~~~~~~~~~~Wt~~l~~~~~~-~~~~~~~~~~.
RO.5QT / RO. 5 max.
Chamfer corners to C0.5, unless otherwise specified.
MATERIAL
s45c
PAINT OA SIRFdCE TREAT.UXE
This spacer is ivalent to one in jig drawing No. AJ-801-002#501 of Komatsu MEC
SCALE
-.-..
. .._ -_
NONE
WA1200-3
30-044 0
33lB*sm
$-333=W~~
1 V2(3n) 1
NOTE:
Chamfer corners to C0.5, unless otherwise specified.
I
i!
This spacer is equivalent to one in jig drawing No. AJ-801-002 #502 of Komatsu MEC .
&EAT
TFIEATMENTI CASE DEPTH 1 MATERIAL
WRiIoN! W&R
MhCC~l/rl~I 7.8
SCALE
t
PART
]HRC26-32
NAME
I
s45c
PdINT SWACE IIA
TEAT
.
-CUE
SLEEVE
PART NO.
NONE
WA1200-3
30-045 0
33lR*sIlz
!$3-EkIE!sl$B
*ia *iziJt-kl b~~~~~~~~~t~~~S~~~~~-~~~~~~~~~~. NOTE: Komatsu cannot accept any responsibility

hT?l\tsPhdld CO.5
Chamfer
tmi%Pld R0.6-1.2
k~~oIo:t,
outside corners to CO.5 and round inside corners to R0.6 - R0.8 unless
This spacer is equivalent to one in jig drawing No. AJ-801-002 #401
of Komatsu MEC
SCALE
NONE
WA1200-3
30-046 0
33-$T*sm
!#+!s?kiI~~rn
m
I v2(5/7) I
*~t~kb~~~~~~~~Wt~~l~~~~~~-~~~~~~~~~~.
NOTE:
t-lb
tually positioned on part
of Komatsu MEG
&4188ll
co.5 SkdiR0.6*1.2 tmn:tt
v
TREATMENT
$$iu ;r~318$Z%iB6 It AJ-801-002#402 RiirQh
lHEAT
f Hardening
I
CASE DEPTH
of Komatsu MEC
Riq
MASS (kg)
&ABE t
and tempering of material
I
HRC24*30
NAME
.MATERIAL
s45.c
PAINT OR SWFAE TiEAT.COE .
PART
I o-9
WA1200-3
BOLT
2.5
SCALE
NlJT
I silkci
Tml.cm
NONE 30-047 0
*Bll-dr $~~~~~~~~~t~~l~~~nl~-~~~~~~~~~~.
A-A
v
of Komatsu MEC
13;WWL AJ-801-002 l!ii 1lr3WSMlii Spit This equivalent to one RROIKtl R0.64.2 co.5Mlud tiwffi#lii corners to outside Chamfer
spacer is in jig drawing No. AJ-801-002 a3
TREATMENT !$iA#Wt &KN! PART MASS (kg) lHEAT
CASE .NAME
DEPTt(
MATERlAL
HRC30+36
s45c
PAINTOR SWACE TfE~T.COlE
20
SCALE ;
GUIDE
PART NO.
CO.5 and round inside corners to R0.6 - R1.2 unless
-NONE
WA1 200-3
30-048 0
m#*%l*
#$4?ax!88$B
-83 ~~t-~c3~~:~;pl_fi~~~~t-~,1~~~~~zS-~Je)~it~~~~~~.
--
4 - ZZ+'J
A-A
\
SiItrr38fiMMi 110 AJ-801-002#4 lll%M

This spacer is equivalent to one in jig drawing No. AJ-801-002 #4 of Komatsu MEC
. IHEAT
. ~RiHM!
V
TREATMENT
.
I CASE DEPTH
.
WA 12Oi[31 1
APWUfIa( Q TY MATERIAL
ss400
PAINTOR SWACE TEAT. CmlE
.
~dM#t
CO. 5 MN
R0.6d.2 M114):ts
MASS (kg)
PART
NAME NO.
13
SCALE
RING
PART
NONE
WA1200-3
I7,9,3,@9,0, 7,6Q tA
30-049 0
53s*$!E
!f33?kIErs$H
-&I *~t~~~~~~~~~~~~r~~t~~~~l~-~~~ff~~~~~~.
*&a, This
EAI%;$E~f@6nf tool assembly is
A J -0 equivalent
0 1 9 3 P to
@%,,Tdj~, one in jig drawing No.AJ-00193P Mooka Plant.
Length
of
bolt
is
Processed
io
24mm.
cLq=\ \ -__-__-__---
\
(,
1 @p\__
--
__I;:
0 8
J-fiiilb
t.
1 J IS
1
I
07
I~dd3ld
JIS
~1s
06 I~-Y-P~JC~
1 1 1 - If?01 6, 39ifEa24mm 1 2 1 - IMlOxl.5, L=65 I 4 I - 1~16x2, ~=50
08 IEye bolt 07 IC~P bolt bolt 06 iCa~ bolt 05 IHexagon
1 J ,s 1 JIS I JIS 1 J IS
I , ) _
1 2
[Nominal size :6.

Thread length
74mm
01
SYM.
tiEtJ29
PART NAME
%lMB#
rT!;t Rl-30
REMARKS CASE DEPTH
cwwo4994
1 - IMlOxl.5, L=65 I 4 I - 1~16x2. L=~O 1 3 1 - jM3Ox3. L=l65
MATERIAL R'TVSET ;;;; HEAT TREATMENT
WA1200 (31
MATERIAL
APPLICATION Q'TY
30-049-l 0
WA1 200-3
w#*sm
!l-sscLE&H
2%) *~t~~~~~~~fi~~LWI~~L~~~~~~-~~~ff~~~~~~.
5-11 drilled ($fiEx!iic)

(DISP DWG) 4-M16x2330
hole
3-1011
79115
20. 5
3-10 drilled hole seat hole I5
*n"nlX, +iRI%;iW@m;f
This WA1 200-3 cylinder is
AJ-00193P-02
to one in jig
8%&7.660
drawing
MASS (kg)
PART NAME
52. 0 No.AJ-00193P-02 Mooka Plant.

SCALE
CYLINDER t szi";"" 8 !4 0 -?I
PAINT OR SURFACE TREAT. CODE
equivalent
NONE
1 1 0
n 30-049-2 0
53#f*%B
~1~~~
*&) *~t~kd~~~h~~~LWt~~t~~~~~~-~~~~~~~~~~.
3-52fJ
240
This
Piston
is
equivalent
to
one
in
jig
drawing
No.AJ-00193P-01
Mooka
Plant.
SCALE
NONE
S;";"" 8 9 0 - 3 1 2 0 A
WA1 200-3
30-049-3 0
53-?%*4!m
+33?kIE%El
-83 *~t~~~~~~~~~~r~t~~t~~~~l~-~~~~~~~~~~.
This Mooka
shaft Plant.
is
esuivalent
to
one
in
.iis
drawing
No.AJ-00193P-04
This Mooka
WAI200 (3) 2
Plate Plant.
is
equivalent
to
one
in
jig
drawing
No.AJ-00193P-03
cwwo4997
WA1200 (31
HEAT TREATMENT
PORTION
APPLICATION Q'TY HEAT TREATMENT PORTION MASS (kg) SCALE PART NAME CASE DEPTH MATERIAL CASE DEPTH
APPLICATION Q'TY MATERIAL
ss400 SHAFT
PAINT OR SURFACE TREAT. COOE
ss400
PART NAME
MASS (kg) SCALE
PLATE NONE f
PAINT OR SURFACE TREAT. CODE
NONE
WA1 200-3
SIR;""' 8 9 0 - 3 13 0 n
Spei";"" 8 9 0 - 3 14 0 n
30-049-4 0
53l%*wz
DISASSEMBLY AND ASSEMBLY DT CONNECTOR PIN
REMOVAL
1.
OF DT CONNECTOR
PIN
INSTALLATION OF DT CONNECTOR PIN

1.
Xl
Using needle-nose pliers, tweezers, or pulling tool from DT connector, pull out wedge (I). (Photo shows male side)
Hold wire (4) at 30 mm on rear side of crimped of contact.
part
i
2. Separating contact fixing claw (2) in connector from contact with flat-head screwdriver, tweezers, or pulling tool Xl, pull out wire to reset fixing claw. 2. Insert wire (4) on grommet side of connector. Ir Insert contact at end of wire (4) straight in grommet hole until it clicks. * Insert the wire until you catch a click (a sound made when the contact passes the fixing claw) and feel the contact collide with the end wall. Ir Pull the wire a little in the pull-out direction to confirm that the contact at the end of the wire is not removed.
__
3.
Holding (4).
shield rubber
(grommet)
(3), pull out wire
3.
After inserting
all wires, install wedge (1).
30-050 0
WA1 200-3
53FB*~&
DISASSEMBLY AND ASSEMBLY HD CONNECTOR PIN, REPAIR PROCEDURE OF HARNESS
REMOVAL
1.
OF HD CONNECTOR
PIN
REPAIR
PROCEDURE
OF HARNESS
Select tool matched to wire size of pin to be removed from Special Tools List, and install it to wire.
Remove cover of wire. * For the length of cover to be removed, following table. Wire JIS 0.5 0.5 - 0.85 1.25 - 2.0 2.0 - 3.0 8.0 size
see the
SAE
Length of cover to beremoved (mm) 3.96 - 5.54 6.35 - 7.92 6.35 - 7.92 5.64 - 7.21 10.9 - 12.5 1 10.9 - 12.5
2 - 24AWG 16 - POAWG 14 - IGAWG 12 - 14AWG 8 - IOAWG / 6AWG
2
@Vi04861
2.
Insert tool Xl in clearance between wire and connector seal driver (1) until it is stopped by contact. t Use a tool a little larger than the wire. * Take care not to break the wire and connector pin. Pull out wire (2) together with tool Xl.
15.0
Remove
pin (1) of crimping
tool X2.
3.
Raise and turn knob (2) to select a size matched to wire size. (AWG sizes in above table are indicated on tool X2.) Loosen locknut (3) and turn adjustment screw (4).
INSTALLATION OF HD CONNECTOR PIN

1. Hold wire (2) at 30 mm on rear side of crimped of contact. part Insert contact (5) in crimping tool X2. * Turn adjustment screw (4) so that the top of contact (5) will be flush with upper end a of the tool hole, then tighten locknut (3).
2.
Insert wire on grommet side of connector. * Insert contact straight in grommet hole until it clicks. * Insert the wire until you catch a click (a sound made when the contact passes the fixing claw) and feel the contact collide with the end wall. t Pull the wire a little in the pull-out direction to confirm that the contact at the end of the wire is not removed.
6. 7.
Insert wire
(6) in contact
(5).
Grip handles to crimp contact. * Grip the handles to the stroke open automatically.
end,
and they
WA1 200-3
aE#*mi
ri-;;iT?i bAssy ENGINE MOUNT Assy
,
/'
nzz+Y t 12)
LT-ZA@bKt
WA1 200-3
mR*sm
r>-;iiT9i bAssy ENGINE MOUNT Assy
Ii-);iTrfi ENGINE MOUNT
t+Assy(2/3) Assy (2/3)
16.2-6.
9kom
llGHTEN,Nt TORDf
il%Lh7
45-49.5Nm (4. 6-5. Okom)
fi -
C 'I 7 :j
TlGniEWlltTORPUE IffIJI 24-28Nm (2. 5-2. 6kom)
(33.1-37.
Okomi
_-.-__-__-_.-__-__---I
--. \
l-
CWW04867
WA1 200-3
30-053 0
33fl3+*%3
IIj-;i;Y+ i bAssy ENGINE MOUNT Assv
Ii-;;>?3 ENGINE
1.
i MOUNT
bAssy(3/3) Assy(3/3)
i-JL3wctzha. Unspecified tightening torque shall be as follows. (1) Bolts: Conform to KES 04. 123. 1 Impact wrench (2) Hose clamps: Conform to KES D 07281, D 07289 (3) PT thread: Conform to KES 04. 123. 3 Change direction of hose clamp 180 each for double clamp portion. Engine oil Total volume: 290 .r? Exchange volume: 260 e Oil grade: E015-40CD Meet API CE or CF grade For muffler stack installation follow steps below. a. Prepare pattern as shown and fit the pattern to the muffler outlet pipe. Mark lines along the pattern outside 4 places with unelasable pen. b. Assemble muffler stack with matching its flange to the mark. If adjustment at hole on muffler stack is not enough, max. 5 mm shifting is permitted.
#%?Q)&LGGVX#Wlrf-t? (1)%x. b
KES 04. 123. 1 4 >I\3 b L>f D 07281, D 07289 KES 04. 123. 3
(2)*-X:3427 (3)Fr;taC
PATTERN MUFFLER OUTLET cwwo4931
30-054 0
WA1 200-3
53lF#*%lz
/I-j;~--i;;:P&Assy COOLING SYSTEM Assy
3-Y
i9
-i ;ifLsAssy(l/3) SYSTEM Assy (l/3)
COOLING
-__-k:=::
-----__-__
WA1 200-3
33%*siil~
3-J ig>X?&Assy COOLING SYSTEM Assy
3-11
i?-iX5-&Assy(2/3)
COOLING SYSTEM Assy (213)
-_ -
;Nm
Skem)
X--
CWWO4869
30-056
WA1 200-3
53##-%li~
3 - J i$%-i;(&Assy COOLING SYSTEM Assy
3 - / i 9-i Xf&Assy(3/3) COOLING SYSTEM Assy (3/3)

~-ii__
,i_~~~+Ig$LI~~ -__-_____-
=ii=i=
------
,______------
____-----
________------j-----
,fL&$
___ __
&A
(I :z)
-_-
(FROM
Ctwo4868~ 77%. (2)
HTC?P'1-SIN RADIATOR
/ v (FROM ~~~04868) (FROM ~~~048681 '_'
CWWO4870
WA1 200-3
30-057 0
3Mf-ii!s
7z~-IIL9>3Assy FUEL TANK Assy
7 ZL--JI~
i?Assy(1/4)
FUEL TANK Assy(l/4)
A 1
-__-_____-_____-______-----z:
----__
I
4
---_
@____ lb-4ib
\ -3
-
%\ --_
-_
+_x (TO CWWO4874)
--_-_/i
,,,,F
A-
=-+!
CWW04871
30-058 0
WA1 200-3
33fR*siEl
7 LL-IIL~ i3Assy FUEL TANK Assy
7.1--MO~Assy(2/4) FUEL TANK Assy (2/4)
Z(G2-Ll)XttKt.
:%?-I.,, II ATICED AREA
J-J GG
[If:61
11:s)
I-I IFROM
(1 :5) CWWO4871)
/
i -1 1
cwwo4872
WA1 200-3
30-059 0
M+*$m
7~-IW~~9Assy FUEL TANK Assy
7 ~--~l&i3Assy(3/4) FUEL TANK Assy (3/4)
(25-31.
5kem)
H-H
II :2.
5)
30-060 0
WA1 200-3
53~*slZ
7x-IlbSi3Assy FUEL TANK Assv
7 x--h9
'~77-Pi~17owx4
i?Assy(4/4)
'1?3>t'i'/l REARCOYBINITIOH LAYP
FUEL TANK Assy (4/4)

FULL 3681.9L
(FROM
CWWO4871) c-c t1:2. 5) (FROM ~~~04873)
D-D (1:2) (FROM ~~~04873)
E-E (1:2. 51 (FROM ~~~04873)
B-B (1:2. 5) (FROM CWWO4872)
F-F
(1:2. 51
PTl/2
P (1:2. 5) (FROM CWWO4872)
&_________ __-__-__;________ ________-)) -_____&-------i------n__ /

CWWO4874
WA1 200-3
30-061 0
53@-3m
IP=I iAssy AIR CONDITIONER Assy
7171
iAssy(V2) Assy(l/2)
AIR CONDITIONER
TltHTEYinG
TOPDUE
fi#Ek9
3.43~4.4lNm (0. 35-O. 45kam)
B-B
(FROM CWWO4876)
F-F
/PH
:2.5)
J-J
(TO (FROM
D-D
CWWO4876)
30-062 0
WA1 200-3
53%*$&t
171 iAssy AIR CONDITIONER Assy
17=1
iAssy(2/2) Assy (212)
AIR CONDITIONER
B (TO CWWO4875)
~~&_-+L-~~~!l~
I
___-i-________________
c i
i--B
mi
CWW04876
WA1 200-3
30-063 0
5383*wE
IP=I ;f \+ e>gAssy AIR CONDITIONER PIPING Assy
17=I
if\4
tsi9Assy(l/2) PIPING Assy(V2)
AIR CONDITIONER
ii/
,_-----*
r-7
--<__ ._>
______L_L________L
____-__Ld_-______
: i
, ii__ -_-
______-__-__T_
Yy._ _-__-__-________
4
.
_ ---____
- -____
30-064 0
WA1 200-3
fpB83*$43~
173
>/\I
AIR CONDITIONER
I?> 9Assy PIPING Assy
17=I
il\q
l?i9Assy(2/2) PIPING Assy(2/2)

2. Precautions for filling air conditioner with refrigerant
AIR CONDITIONER
1.
Attention to connection of piping (1) Coat ND-OIL8 (Compressor oil for non-freon) on O-ring. Be sure not to use oil of sniso base and liquid lubricants of CRC (mineral oil).
(1) Keep the ambient temperature above 3C (since the system does not work if the ambient temperature
is below 3C).
(2) Use Freon gas (R134a) as refrigerant.

(3) Before filling the air conditioner with refrigerant, be sure to evacuate the air conditioner by repetitive evacuation method. (The degree of vacuum must be above 750 mmHg.1 (4) The standard quantity of refrigerant to be supplied is 1.3 - 1.5 kg. (5) Take care not to supply liquid Freon to the refrigerant system by holding the refrigerant can upside down or handling it wrongly. (6) Do not operate the compressor before filling the air conditioner with refrigerant. 3. Inspection after assembly (I) Check that proper quantity of refrigerant was supplied to the air conditioner. Judge and adjust the quantity of refrigerant by the following method. Operating pressure of compressor 0.1 MPa Il.0 kg/cm*} Proper 0.06 - 0.1 MPa IO.6 - 1.0 kg/cm*) 0.06 MPa to.6 kg/cm*} Number of bubbles passing through receiver sight glass Bubbles pass sometimes or do not pass at all. Bubbles pass continuously. Bubbles pass continuously. Remedy Discharge refrigerant through pressure valve to proper level. Connect charging hose to compressor and supply refrigerant to proper level.
(2) Remove the plugs of the air conditioner parts (devices and hoses) just before connecting those parts
(to prevent dust and water from entering those parts). (3) Connect each hose securely by using two spanners. (Hold the device side with one spanner and tighten only the flare nut of the hose with another spanner.) (4) Do not connect the ports of receiver conversely. (5) Tightening torques of the following 1) Bolt: Conform to KES 2) Taper thread: Conform to KES 3) Nut: Conform to KES 4) Pipe connecting parts parts must be as shown, unless other specified. 04. 123. 1 Impact wrench 04. 123. 3 DO1597
0
Nut type D l/2 G 24
Ml6 x 1.5
12 - 15 {I18 1471 20 - 25 I196 - 2451 30 - 35 (294 - 343)
CONDI out CONDZ out ret to unit in CONDl in CONDZ in Unit out
Insufficient
M22 x 1.5
b 4.
(2) Check the air conditioner starting normally. Precautions for discharging gas
D 518
0
27
M24 x 1.5
(1) Before discharging gas, perform the oil return work (work to return compressor oil in the piping to the
compressor). . Oil return procedure: Set the fan switch to the MAX position and run the engine at low idling and operate the air conditioner for 5 minutes.
Block joint
~~ 5.
(2) Be sure to discharge the gas through the high-pressure valve. Precautions for repair work
(1) If a defective part is installed and the refrigerant needs to be discharged to repair that part, perform
After tighten up, if the gas shall leak, clean and apply ND-OIL8 to the flares. And tighten as mentioned above.
the oil return work, then discharge the refrigerant gradually through the valve rubbers installed to the high-pressure and low-pressure valves of the compressor. (It is very dangerous to disconnect the piping without reducing the pressure in the cooling system. Never do that.) (2) When repairing the air conditioner, be sure to put on protective goggles. eyes, you may lose your eyesight.) (3) Do not repair the air conditioner in a dusty or damp place. (4) Once refrigerant is discharged and supplied again for a repair work, check the compressor (Specified quantity of oil: 130~* cc, ND-OIL81 6.
Never leave the machine outdoors without installing the cab.
6)
Tube joint to click as assembly.
(If refrigerant enters your
oil.
When it is obliged to do so, take measures to protect the air conditioner (indoor unit) from rainwater.
WA1 200-3
30-065 0
53+#*2m
"iif fAssy DAM PER Ass' y
9kfAssy(l/2) DAMPER Ass y (l/2)

TlCTENlNG
TOROUE
ti#bJid 245-309Nm
16x2 \/
TlGTENlHG TORPUE
P#bh9
5.9--ll.8Nm (0. 6-l. 2Ksm)
TIGHTENING Pbkhl
98-123Nm (10~12.5Ks.m)
TORPUE
cwwo487a
30-066 0
WA1 200-3
53E#*sR~
ZI ; b J3--IL/ \JldAssy CONTROL VALVE Assy
3 =/ I- II
--/LI\/I,
j'Ass'y
CONTROL VALVE Assy

,,GHTEHlG TDlOE
f#bh3
294-314Nm {30-32komI
E-E
TlGHTEnIYG TOlO
OQik5
Zll-240Nm (?.I.+24.5komI
Ok81
30-068 0
53%*%lZ
b IL3 7 El -Assy TORQFLOW Assv
b/L?
7 q -Assy(l/2) Assy(1
TORQFLOW
Y
(TO CWWO
WA1 200-3
mf#*mz
b IL3 7 II -Assy TORQFLOW Assy
F /td 7 q -Assy(2/2) TORQFLOW Assy (2/2)
P (1 :2.
5)
(FROM cwwo4879)
CWWO4880
30-070 0
WA1 200-3
TORQFLOW ASSEMBLY
GENERAL
DISASSEMBLY,
ASSEMBLY
OF TORQFLOW
ASSEMBLY
Disassembly procedure 1. Preparation work Support the vehicle body with wood blocks, etc. so that the TORQFLOW assembly will be horizontal. A Support the transmission securely, too, so that it will not fall down when the TORQFLOW assembly is disconnected. 2. Wiring harness Remove wiring harness (1). Ir Remove the wiring clamp, too. 3. Tubes 1) Remove the clamp, 2 mounting bolts, and remove bracket (2). 2) Remove the 6 mounting bolts and drain tube (3). 3) Remove the 6 mounting bolts and drain tube (4). 4) Remove the 6 mounting bolts and drain tube (5). 5) Remove the 8 mounting bolts and drain tube (6). 6) Remove the 8 mounting bolts and lubrication tube (7). 4. Lubrication hose Remove lubrication hose (8). * Remove the hose clamp, too. 5. Removal of TORQFLOW assembly 1) Sling converter assembly (9) temporarily and remove the 25 mounting bolts. 2) Disconnect converter assembly (9) and transmission assembly (IO) from each other. Ir Pull out the torque converter horizontally until the input shaft of the transmission is disconnected. r+lkg assembly: Approx. 1,450 kg Transmission assembly: r+ kg Approx. 3,750 kg * For the disassembly procedure of the converter assembly, see CONVERTER ASSEMBLY. * For the disassembly procedure of the transmission assembly, see TRANSMISSION ASSEMBLY. Converter Assembly procedure 1. Preparation work Support the vehicle body with wood blocks, etc. so that the transmission assembly will be horizontal. 2. Connection of TORQFLOW assembly 1) Fit the O-ring to the connecting parts of converter assembly (9) and transmission assembly (IO). & O-ring: Grease (G2-LI) 2) Sling converter assembly (9) and install it to transmission assembly (IO) with the 25 mounting bolts. assembly: Approx. 1,450 kg Transmission assembly: r+ kg Approx. 3,750 kg Lubrication hose Install lubrication hose (8). * Secure the lubrication hose with the hose clamp. Tubes 1) Fit the O-ring and install lubrication tube (7) with the 8 bolts. 2) Fit the O-ring and install drain tube (6) with the 8 bolts. 3) Fit the O-ring and install drain tube (5) with the 6 bolts. 4) Fit the O-ring and install drain tube (4) with the 6 bolts. 5) Fit the O-ring and install drain tube (3) with the 6 bolts. 6) Install bracket (2) with the 2 bolts and clamp. Wiring harness Install wiring harness (I). * Secure the wiring harness with the wiring clamp. 6 kg Converter
3.
4.
5.
cwwo4950
WA1 200-3
30-070- 1 0
53l!R-$m
=I if
f-
SAss'y
CONVERTER Assy
3 x\-
9Assy(l/6)
CONVERTER Assy (l/6)
K-K
(TO CWWO4883) (TO CWWO4883)
(TO
CWWO4883)
i _+,q
f=fl
GG(i:i)
E-E (I : I)
T/Clild-t PDRT PF T/C EXlT
TlGHTENlWC
TDROUE
913th944.1553.9Nm
(4. 5--5. 5 kern)
\\I?4
'ti (TO CWWO4884)
1 1.
N-N
;/ AC- AC
CWWO4881
WA1 200-3
30-071 0
H#*$m
Zl iJ<-9Assy CONVERTER Assy
=I id-
9Assy(3/6) Assy (3/6)
CONVERTER
(FROM
cwwo48811 LT-2@b
TlGiENlNG
TOROUE
h?lb9
58.6-73. 5Nm (6-7. Skeml
A-A
(FROM CWWO4881) (FROM cwwo4881)
cwwo4883
WA1 200-3
30-073 0
53~*mk
J j/tSAssy CONVERTER Assy
1 id-
gAssy(4/6)
CONVERTER Assy (4/6)

LT-PM
(2%31.5koml
3uat1'I WC- 1
(42C-13-172603 Ilctxt. SEE NOTE I
J-J
(FROM CWWO4881)
LT-Ptt
LT-2ltle
(FROM
c-c CWWO4881)
CWW04884
30-074 0
WA1 200-3
mB*sHz
1 idSAssy CONVERTER Assy
=I id
- 9Assy (5/6)
CONVERTER Assy (5/6)
(TO 214)
z-
--_ -I+!
,CWWO4866.
CWWO466;)
CWW04885
WA1 200-3
30-075 0
53~*w45
3 iJ\- SAssy CONVERTER Assy
ZI
id-
9Assy(6/6) Assy (6/6)

_
When assembling oil seal (07012-50110), coat with LG5 on fitting face of the housing (42G13-15250) lightly and after assembling, wipe off the rest completely. Shim is 2 division type. Right and left shims shall be same thickness and pieces. When adjusting preload for input transfer taper roller bearing, do as follows. (11 Obtain as preload of 0 - 1.08 Nm (0 - 0.11 kgm} from single shaft A, B, C, D, E. [When setting orderly do as follows] After setting shaft A and E, obtain the combined preload 0 - 2.16 Nm IO - 0.22 kgm1 from shaft B. Further when setting shaft C, obtain the combined preload 0 - 3.24 Nm (0 - 0.33 kgm1 from shaft C. Further when setting all of gears after setting D, obtain the combined preload 0 - 5.40 Nm {O - 0.55 kgm} from shaft D. (2) After preloads have been adjusted, check all gears that there are no plays. Gear A-B A-C A-D I A-E Speed reduction ratio 68/74=0.919 68/74=0.919 68/74=0.9 19 58/74=0.784
VIEW tt!fi&t9L6 FROM OUTPUT SIDE cwwo4934
CONVERTER
42C-15-15150
Following right and left assemble position about PTO gear 42C-13-15140 and 42C-13-15150.
30-076 0
WA1 200-3
CONVERTER ASSEMBLY
GENERAL
DISASSEMBLY,
ASSEMBLY
OF CONVERTER
ASSEMBLY
Disassembly procedure 1. Breather and breather hose I) Remove breather hose (I 1. 2) Remove the 2 mounting bolts, then remove breather (2) and the block as one unit. 3) Remove elbow (3). 2. Lubrication hoses and block I) Remove lubrication hoses (4) and (5). * Remove the hose clamps, too. 2) Remove the 4 mounting bolts, flange, and remove lubrication hose (6). * Remove the hose clamp, too. 3) Remove the 4 mounting bolts and block (7). 4) Remove lubrication hose (8). Lubrication tubes and blocks I) Remove the 3 joints and lubrication tube (9). 2) Remove the 2 joints each from lubrication tubes (IO), (II), (121, and (131, then remove those tubes. 3) Remove the 2 mounting bolts, block (141, and bracket (15). 4) Remove the 3 mounting bolts and block (16). Main relief valve and torque converter relief valve assembly Remove the 7 mounting bolts and main relief valve and torque converter relief valve assembly (17). Torque converter regulator valve assembly I) Remove the 4 mounting bolts and block (18). 2) Remove sleeve (19). 3) Remove the 4 mounting bolts, cover (201, and block (21). 4) Remove the 4 mounting bolts and torque converter regulator valve assembly (22). 5) Remove valve block assembly (23). Modulated clutch ECMV assembly I) Remove the 3 mounting bolts and cover (24). Remove the 4 mounting bolts and modulated clutch ECMV assembly (25). Rotation sensor Loosen the locknut and remove rotation sensor (26). Modulated clutch assembly Remove the 10 mounting bolts and modulated clutch assembly (27). * Since the hexagon socket head bolt is not used for mounting, do not remove it. 2) 9.
* *
Pull out the modulated clutch assembly with forcing screws (12 mm). Pull out the modulated clutch assembly horizontally so that the inner race and outer race of the roller bearing will not be tilted when they are disconnected from each other.
kg
lel
f
Modulated
clutch assembly:
220 kg
3.
For the disassembly procedure of the modulated clutch assembly, see DISASSEMBLY, ASSEMBLY OF MODULATED CLUTCH ASSEMBLY. Torque converter assembly and PTO and transfer assembly 1) Remove the 19 mounting bolts, then remove torque converter assembly (28) from PTO and transfer assembly (29). assembly: 430 kg PTO and transfer assembly: &I kg 800 kg * For the disassembly procedure of the torque converter assembly, see DISASSEMBLY, ASSEMBLY OF TORQUE CONVERTER ASSEMBLY. * For the disassembly procedure of the torque converter assembly, see DISASSEMBLY, ASSEMBLY OF PTO AND TRANSFER ASSEMBLY. Remove coupling (30) from torque converter assembly (28). I+ kg Torque converter
4.
5.
2)
6.
7.
8.
WA1 200-3
30-0760
CONVERTER ASSEMBLY
Assembly procedure 1. Torque converter assembly and PTO and transfer assembly I) Install coupling (30) to torque converter assembly (28). 2) Fit the O-ring to the connecting parts of torque converter assembly (28) and PTO and transfer assembly (29). & O-ring: Grease (G2-LI) 3) Install torque converter assembly (28) to PTO and transfer assembly (29) with the 19 bolts. * Since the outer race and inner race of the tapered roller bearing are coupled with each other, drop about 6 cc of engine oil (E030-CD or EOIOCD) onto the sliding surfaces of the rollers. 63ks !I+ks 2. Torque converter assembly: 430 kg assembly: 800 kg
4.
Modulated clutch ECMV assembly I) Fit the O-ring and install modulated clutch ECMV assembly (25) with the 4 bolts. Mounting bolt: 27.4 - 34.3 Nm f2.8 - 3.5 kgm} 2) Install cover (24) with the 3 bolts. Torque converter regulator valve assembly I) Fit the O-ring and install valve block assembly (23) with the 4 bolts. w Mounting bolt: 44.1 - 53.9 Nm (4.5 - 5.5 kgm1 2) Fit the O-ring and install torque converter regulator valve assembly (22) with the 4 bolts. w Mounting bolt: 44.1 - 53.9 Nm 14.5 - 5.5 kgml 3) Fit the O-ring and install block (21) and cover (20) with the 4 bolts. 4) Fit the O-ring and install sleeve (19). & O-ring: Grease (G2-LI) 5) Fit the O-ring and install block (18) with 4 bolts. Main relief valve and torque converter relief valve assembly Fit the gasket and install main relief valve and torque converter relief valve assembly (17) with the 9 bolts. m Mounting bolt: 58.8 - 73.5 Nm j6.0 - 7.5 kgm} Lubrication tubes and blocks 1) Fit the O-ring and install block (16) with the 3 bolts. 2) Install bracket (15) and block (14) with the 2 bolts. 3) Fit the gasket and install lubrication tubes (131, (121, (II), and (IO) with the 2 joints each. w Joint: 44.1 - 53.9 Nm 14.5 - 5.5 kgm1 4) Fit the gasket and install lubrication tube (9) with the 3 joints. w Joint: 44.1 - 53.9 Nm 14.5 - 5.5 kgm1 Lubrication hoses and block Install lubrication hose (8). * Secure the hose with the hose clamp. Install block (7) with the 4 bolts. Fit the O-ring and install lubrication hose (6) with the 4 bolts and the flange. Install lubrication hoses (5) and (4). * Secure the hoses with the hose clamps. &I ks
9.
Breather and breather hose 1) Install elbow (3). 2) Install breather (2) with the 2 bolts. 3) Install breather hose (I). * Secure the hose with the hose clamp.
5.
PTO and transfer
Modulated clutch assembly Fit the O-ring and install modulated clutch assembly (27) with the 10 bolts. 6 O-ring: Grease (G2-LB * Since the outer race and inner race of the roller bearing are coupled with each other, drop about 6 cc of engine oil (E030-CD or EOIO-CD) onto the sliding surfaces of the rollers and insert the modulated clutch assembly horizontally, taking care not to tilt it. r+lkg Modulated clutch assembly: 220 kg
6.
7.
3.
Rotation sensor Install rotation sensor (26) and secure it with the locknut. & Threaded part of sensor: Gasket sealant (LG-51 Put the rotation sensor tip lightly against * the gear tooth tip in the modulated clutch and return by l/2 - 1 turn and secure with the locknut. m Locknut: 49.0 - 68.6 Nm (5 - 7 kgm1
8.
30-076-Z 0
WA1 200-3
CONVERTER ASSEMBLY
DISASSEMBLY,
ASSEMBLY
OF MODULATED
CLUTCH ASSEMBLY
Disassembly procedure 1. Cage I) Remove the 4 mounting Assembly procedure 1. Shaft I) Press fit the inner race of roller bearing (33) to shaft (31). * Using a press, fit the bearing until the end of its inner race touches the shoulder of the shaft. 2) Install seal ring (32) to shaft (31). 6 Seal ring: Grease (G2-LI) 3) Install seal rings (30) and (29) to shaft (31). & Seal ring: Grease (G2-LI) * Install the seal rings as shown in the following figure.
bolts and cage
2.
3.
(I). * Pull out the cage with forcing screws (12 mm). 2) Remove snap ring (2), then remove bushing (3) and ball (4) from cage (I). Case 1) Remove snap ring (5). 2) Remove the 2 mounting bolts and case (6). 3) Remove ball bearing (7) from case (6). * Use a press to remove the ball bearing. Cover and input drum assembly 1) Remove cover and input drum assembly 2) 3) 4) 5) (34). Remove snap ring (81, plate (9), and ball
(IO). Remove snap ring (II), cover (121, and ball (13). Remove input drum (17) from cover (14). Remove snap ring (15) and ball bearing
4.
5.
6.
(16). * Use a press to pull out the ball bearing. Discs and plates 1) Remove snap ring (18) and plate (19). 2) Remove damper (20). 3) Remove 19 discs (21) and 18 plates (22) alternately. 4) Remove damper (23). Piston 1) Using tool C4, remove nut (24). 2) Remove plate (25). 3) Remove seal ring (26) from plate (25). 4) Remove piston (27). Ir Push out the piston from the shaft side with forcing screws (12 mm). Output drum Remove the 12 mounting bolts and drum (28). Ir Push out the drum from the shaft side with forcing screws (12 mm). Shaft 1) Remove seal rings (29) and (30) from shaft (31). 2) Remove 2 seal rings (32) from shaft (31). 3) Remove the inner race of roller bearing (33) from shaft (31). * Use a bearing puller to pull out the bearing.
cwwo4953
Output drum Install drum (28) with the 12 bolts. 6 Threaded parts: Liquid adhesive (LT-2) m Mounting bolt: 98 - 123 Nm IlO. - 12.5 kgm1 Piston I) Install piston (27). 2) Install seal ring (26) to plate (25). 6 Seal ring: Grease (G2-LI) j, Install the seal ring as shown in the following figure.
7.
WA1 200-3
30-076-3 0
CONVERTER ASSEMBLY
4.
5.
Install plate (25). Using tool C4, install nut (24). & Threaded parts of nut: Liquid adhesive (LT-2) * Install the nut with the chamfered periphery to plate (25). w Nut: 313.8 - 392.3 Nm I32 - 40 kgm} . . Discs and plates I) Install damper (23). * install the damper with the cork side to the piston. 2) Install 19 discs (21) and 18 plates (22) alternately. f Soak the discs in clean engine oil (E030-CD or EOIO-CD) for at least 2 minutes before installing them. 3) Install damper (20). * Install the damper with the cork side to plate (19). 4) Install plate (19) and secure it with snap ring (18). Cover and input drum assembly 1) Using tool C2, install ball bearing (16) to cover (14) and secure it with snap ring (15). * Press fit the bearing until the end of its outer race touches the shoulder of the cover. * After press fitting the bearing, drop about 6 cc of engine oil (EOSO-CD or EOIO-CD) onto the sliding parts and rotate the bearing 10 turns to spread the oil. 3) 4)
2) 3)
4)
5) 6.
Install input drum (17) to cover (14). Install ball (13) and cover (12) and secure them with snap ring (II). * Put the ball in the ball hole of the drum, then install the cover, matching its ball groove to the ball. Install ball (IO) and plate (9) and secure them with snap ring (8). * Put the ball in the ball hole of the cover, then install the plate, matching its ball groove to the ball. Install cover and input drum assembly
7.
(34). Case I) Install ball bearing (7) to case (6). Using a press, fit the bearing until the end of its outer race touches the shoulder of the cover. After press fitting the bearing, drop about 6 cc of engine oil (E030-CD or EOIO-CD) onto the sliding parts and rotate the bearing 10 turns to spread the oil. 2) Fit the O-ring to the cover and install case (6) to shaft (31) and secure them with the 2 bolts. & O-ring: Grease (G2-LI) * Push the inner race of ball bearing (7) with a press until its end touches the shoulder of the shaft. * Check that the ball bearing is fitted perfectly, then tighten the 2 bolts. 3) Install snap ring (5). Cage I) Install ball (4) and bushing (3) to cage (I) and secure them with snap ring (2). * Put the ball in the ball hole of the bushing, then install the cage, matching its ball groove to the ball. 2) Fit the O-ring and install cage (I) with the 4 bolts. 6 O-ring: Grease (G2-LI)
cwwo4955
30-076-4 0
WA1 200-3
CONVERTER ASSEMBLY
DISASSEMBLY,
ASSEMBLY
OF TORQUE
CONVERTER
ASSEMBLY
Disassembly procedure 1. Preparation work Set the torque converter assembly vertically with the input shaft side up. * Adjust the height of the torque converter assembly so that the mounting bolts can be removed from the underside of the case. 2. Case Remove the 13 mounting bolts, then remove the torque converter from case (I). * Install a hanging bolt (12 mm) to the input shaft end and lift off the torque converter vertically with the all internal parts of the case assembled. * Place the removed torque converter with the input shaft side up on a work table. 3. input shaft 1) Remove the 20 mounting bolts and shaft (2). 2) Remove the inner race of tapered roller bearing (3) from shaft (2). * Use a bearing puller to pull out the inner race. 4. Case and turbine assembly I) Remove 36 mounting bolts and case and turbine assembly (4). 2) Remove snap ring (5) and wire (6). 3) Remove snap ring (7) and cover (8). 4) Remove turbine (9). * Pull out the turbine with forcing screws (IO mm). 5) Remove ball bearing (IO) from case (II). * When removing the ball bearing with a press, do not push its snap ring side. 5. Stator 1) Remove snap ring (12) and stator (13). 2) Remove spacer (14). 6. Pump assembly Remove pump assembly (15). Ir Remove the pump assembly vertically so that the inner race and outer race of the roller bearing will not be tilted when they are disconnected from each other. Remove 16 mounting bolts, retainer (161, and guide (17) from pump (18). Remove the outer race of roller bearing (19) from guide (17). * Use a press to remove the outer race. Remove drain plug (20) from pump (18).
CWWO4956
7.
Shaft I) Remove the 4 mounting bolts and plate (21) from shaft (22). 2) Remove seal ring (23) from shaft (22). 3) Remove the inner race of roller bearing (19) from shaft (22). * Use a bearing puller to pull out the inner race. 4) Remove sleeve (24) from shaft (22).
WA1 200-3
30-076-5 0
CONVERTER ASSEMBLY
Assembly procedure 1. Shaft Install sleeve (24) to shaft (22). * Install the sleeve by expansion fit. Press fit the inner race of roller bearing (19) to shaft (22). f Push the inner race with a press until its end touches the shoulder of the shaft. Install plate (21) to shaft (22) with the 4 bolts. Install seal ring (23) to shaft (22). & Seal ring: Grease (GZ-LI) 2. Pump assembly 1) Install drain plug (20) to pump (18). w Drain plug: 9.8 - 12.7 Nm Il.0 - 1.3 kgm} 2) Press fit the outer race of roller bearing (19) to guide (17). Ir Apply bearing compound to 4 places of the periphery of the bearing. After installing the outer race, wipe off the projected compound so that it will not enter the bearing.
C_
i lO--20mm
cwwo4957
3)
4)
Push the outer race with a press until its end touches the shoulder of the guide. Install guide (17) and retainer (16) to pump (18) with 16 bolts. 6 Threaded parts of mounting bolt: Liquid adhesive (LT-21 m Mounting bolt: 59 - 74 Nm IS.0 - 7.5 kgml Install pump assembly (15) to shat (22). Ir Since the outer race and inner race of the roller bearing are coupled with each other, lower the pump assembly vertically, taking care not to tilt it.
Stator 1) Install spacer (14). 2) Install stator (13) and secure it with snap ring (12). 4. Case and turbine assembly 1) Install ball bearing (IO) to case (11). * Push the ball bearing with a press until its snap ring touches the shoulder of the case. * After press fitting the bearing, drop about 6 cc of engine oil (E030-CD or EOIO-CD) onto the sliding parts and rotate the bearing 10 turns to spread the oil. Install turbine (9). * Support the inner race of the ball bearing and push the turbine with a press until the shoulder of the turbine touches the end of the inner race. Install cover (8) and secure it with snap ring (7). Install wire (6) and secure it with snap ring (5). Install case and turbine assembly (4) with the 36 bolts. * Match the internal oil groove on case to the drain plug of the pump. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 49 - 59 Nm 15 - 6 kgm1 5. Input shaft 1) Install the inner race of tapered roller bearing (3) to shaft (2). * Push the inner race with a press until its end touches the shoulder of the shaft. 2) Install shaft (2) with the 20 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 245 - 309 Nm (25.0 - 31.5 kgml 6. Case Install the torque converter to case (I) with the 13 bolts. * Install a hanging bolt (12 mm) to the input shaft end, then sling and install the torque converter vertically. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 245 - 309 Nm (25.0 - 31.5 kgml 3.
30-076-6 0
WA1 200-3
CONVERTER ASSEMBLY
DISASSEMBLY,
ASSEMBLY
OF PTO AND TRANSFER
ASSEMBLY
20 \ /
CWWO4982
WA1 200-3
30-076-7 0
DISASSEMBLY
AND
ASSEMBLY
CONVERTER
ASSEMBLY
Disassembly procedure Rotation sensor Loosen the locknut and remove rotation sensor (1). Cover Remove the 12 mounting bolts and cover (2). PTO gear 1 (Gear D) 1) Remove the 6 mounting bolts, cage (31, and shims (4). Ir Check the thickness and quantity of the shims. 2) Remove the outer race of tapered roller bearing (5) from cage (3). * Use a bearing puller to pull out the outer race. 3) Remove coupling (6). 4) Remove snap ring (7) from coupling (6). 5) Remove gear (8). 6) Remove snap ring (9) from gear (8). 7) Remove the inner races of tapered roller bearings (5) and (IO) from gear (8). * Use a bearing puller to pull out the inner races. PTO gear 2 (Gear C) I) Remove the 8 mounting bolts, cage (1 I), and shims (12). + Check the thickness and quantity of the shims. 2) Remove the outer race of tapered roller bearing (13) from cage (1 I). + Use a bearing puller to pull out the outer race. 3) Remove gear (14) 4) Remove the inner races of tapered roller bearings (13) and (15) from gear (14). * Use a bearing puller to pull out the inner races. 5. PTO gear 3 (Gear BI I) Remove the 8 mounting bolts, cage (161, and shims (17). Ir Check the thickness and quantity of the shims. 2) Remove the outer race of tapered roller bearing (18) from cage (16). Ir Use a bearing puller to pull out the outer race. 3) Remove gear (19) 4) Remove the inner races of tapered roller bearings (18) and (20) from gear (19). f Use a bearing puller to pull out the inner races.
Modulated clutch gear (Gear E) 1) Remove the 8 mounting bolts, cage (211, and shims (22). * Check the thickness and quantity of the shims. 2) Remove the outer races of tapered roller bearings (23) and (24) from cage (21). * Use a bearing puller and a press to pull out the outer races. 3) Remove gear (25). 4) Remove snap ring (26), then remove the outer race of roller bearing (27) from gear (25). * Use a bearing puller to pull out the outer race. 5) Remove the inner races of tapered roller bearings (23) and (28) from gear (25). * Use a bearing puller to pull out the inner races. Input gear (Gear Al I) Remove the mounting bolts and holder (29). 2) Remove coupling (30). 3) Remove the 17 mounting bolts and cage (31). Remove oil seal (32) from cage (31). Remove the outer race of tapered roller bearing (33) from cage (31). * Use a bearing puller to pull out the outer race. 6) Remove spacer (34). 7) Lift off gear (35). 8) Remove the inner races of tapered roller bearings (33) and (36) from gear (35). * Use a bearing puller to pull out the inner races. 9) Remove the 8 mounting bolts, cage (37), and shims (38). * Check the thickness and quantity of the shims. IO) Remove the outer race of tapered roller bearing (36) from cage (37). * Use a bearing puller to pull out the outer race. Case Remove the outer races of tapered roller bearings (IO), (15), and (20) from case (39). * Use a bearing puller to pull out the outer races. 4) 5)
Assembly procedure 1. Case Install the outer races of tapered roller bearings (201, (151, and (IO) to case (39). f Push each outer race with a press until its end touches the shoulder of the case. 2. Input gear (Gear A) I) Install the outer race of tapered roller bearing (36) to cage (37). * Push the outer race with a press until its end touches the shoulder of the cage. 2) Fit the O-ring and install shims (38) and cage (37) with the 8 bolts. + The shims are of 2-piece split type. Set them to the standard thickness temporarily on each side. * Standard thickness of shims: 2.0 mm 3) Install the inner races of tapered roller bearings (36) and (33) to gear (35). * Push each inner race with a press until its end touches the shoulder of the gear. 4) Install gear (35). 5) Install spacer (34). 6) Install the outer race of tapered roller bearing (33) to cage (31). * Push the outer race with a press until its end touches the shoulder of the cage. 7) Using tool Cl, press fit oil seal (32) to cage (31). * Thinly apply gasket sealant (LG-5) to the oil seal fitting part of the cage. After fitting the oil seal, wipe off the projected sealant. f Press fit the oil seal until the flange of tool Cl touches the cage. & Oil seal lip: Grease (G2-LI)
3.
CWWO4958
Install cage (31) with the 17 bolts. A Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 245 - 309 Nm (25.0 - 31.5 kgm1 Using a push-pull scale, check that the rotational force at the gear tooth tip is within the standard range. j, Rotational force of gear: 0 - 1.08 N (0 - 0.11 kg} Ir If the rotational force is out of the standard range, adjust it by changing the shim thickness. * Adjustment range of shim thickness: 1.3 - 2.7 mm * Types of shims: 0.15 mm, 0.2 mm, 0.5 mm IO) Fit the O-ring and install coupling (30). 11) Install holder (29) with the mounting bolts. a Threaded parts of mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 824 - 1,030 Nm I84 - 105 kgm1 Modulated clutch gear (Gear El 1) Install the inner races of tapered roller bearings (28) and (23) to gear (25). * Push each inner race with a press until its end touches the shoulder of the gear. 2) Install the outer race of roller bearing (27) to gear (25) and secure it with snap ring (261. Ir Push the outer race with a press until its end touches the shoulder of the gear. 3) Install gear (25). * Drop about 6 cc of engine oil tE030CD or EOIO-CD) onto the sliding parts of the bearing and rotate the bearing 10 turns to spread the oil. 4) Install the outer races of tapered roller bearings (24) and (23) to cage (21). j, Push each outer race with a press until its end touches the shoulder of the cage. 5) Install shims (22) and cage (21) with the 8 bolts. * Drop about 6 cc of engine oil (E030CD or EOIO-CD) onto the sliding parts of the bearing and rotate the bearing 10 turns to spread the oil.
30-076-8 0
WA1 200-3
CONVERTER ASSEMBLY
4.
The shims are of 2-piece split type. Set them to the standard thickness temporarily on each side. * Standard thickness of shims: 2.0 mm 6) Using a push-pull scale, check that the rotational force at the gear tooth tip is within the standard range. * Rotational force of gear: 0 - 1.08 N (0 - 0.11 kg} * If the rotational force is out of the standard range, adjust it by changing the shim thickness. * Adjustment range of shim thickness: 1.3 - 2.7 mm * Types of shims: 0.15 mm, 0.2 mm, 0.5 mm PTO gear 3 (Gear BI I) Install the inner races of tapered roller bearings (20) and (19) to gear (19). * Push each inner race with a press until its end touches the shoulder of the gear. 2) Install gear (19). * PTO gear 2 and PTO gear 3 are different parts and they must be installed in the correct directions respectively. There are 2 identification grooves on the end of gear (19). Install gear (19) with those identification grooves on the cage side (torque converter side). (The following figure is the gear seen from the torque converter side.)
4)
5)
Fit the O-ring and install shims (17) and cage (16) with the 8 bolts. * The shims are of 2-piece split type. Set them to the standard thickness temporarily on each side. * Standard thickness of shims: 2.0 mm Using tool C3 (2/2), check that the rotational force at the center of the gear is within the standard range. * Rotational force of gear: 0 - 2.16 Nm IO - 0.22 kgm} * If the rotational force is out of the standard range, adjust it by changing the shim thickness. * Adjustment range of shim thickness: 1.3 - 2.7 mm * Types of shims: 0.15 mm, 0.2 mm, 0.5 mm
6.
3)
4)
c312 /2) \ 5)
CWWO4960
5.
PTO gear 2 (Gear Cl

1) Install the inner races of tapered roller bearings (15) and (13) to gear (14). f Push each inner race with a press until its end touches the shoulder of the gear. Install gear (14). * PTO gear 2 and PTO gear 3 are different parts and they must be installed in the correct directions respectively. There is 1 identification groove on the end of gear (14). Install gear (14) with those identification grooves on the cage side (torque converter side). (The following figure is the gear seen from the torque converter side.)
Ii
14
Install the outer race of tapered roller bearing (13) to cage (II). * Push the outer race with a press until its end touches the shoulder of the cage. Fit the O-ring and install shims (12) and cage (I I) with the 8 bolts. * The shims are of 2-piece split type. Set them to the standard thickness temporarily on each side. Ir Standard thickness of shims: 2.0 mm Using tool C3 (2/2), check that the rotational force at the center of the gear is within the standard range. Rotational force of gear: 0 - 3.24 Nm (0 - 0.33 kgm) If the rotational force is out of the standard range, adjust it by changing the shim thickness. Adjustment range of shim thickness: 1.3 - 2.7 mm Types of shims: 0.15 mm, 0.2 mm, 0.5 mm
PTO gear 1 (Gear D) I) Install the inner races of tapered roller bearings (IO) and (5) to gear (8). * Push each inner race with a press until its end touches the shoulder of the gear. 2) Install snap ring (9) to gear (8). 3) Install gear (8). 4) Install snap ring (7) to coupling (6). 5) Install coupling (6). 6) Press fit the outer race of tapered roller bearing (5) to cage (3). + Push the outer race with a press until its end touches the shoulder of the cage. 7) Fit the O-ring and install shims (4) and cage (3) with the 6 bolts. & O-ring: Grease (G2-LII Ir The shims are of 2-piece split type. Set them to the standard thickness temporarily on each side. * Standard thickness of shims: 2.0 mm 8) Using tool C3 (l/2), check that the rotational force at the center of the gear is within the standard range. * Rotational force of gear: 0 - 5.40 Nm 10 - 0.55 kgm) * If the rotational force is out of the standard range, adjust it by changing the shim thickness. * Adjustment range of shim thickness: 1.3 - 2.7 mm * Types of shims: 0.15 mm, 0.2 mm, 0.5 mm
2)
CWWO4961
3)
Install the outer race of tapered roller bearing (18) to cage (16). * Push the outer race with a press until its end touches the shoulder of the cage.
:WWO4960
WA1 200-3
30-076-9 0
DISASSEMBLY
AND
ASSEMBLY
CONVERTER
ASSEMBLY
7.
8.
Cover Fit the gasket and install cover (2) with the 12 bolts. Rotation sensor Install rotation sensor (I) and secure it with the locknut. & Threaded parts of sensor: Gasket sealant (LG-5) Put the rotation sensor tip lightly against * the side of the input gear in the PTO and transfer assembly and return by l/2 - 3/ 4 turns and secure with the locknut. m Locknut: 49.0 - 68.6 Nm (5 - 7 kgml
30-076-10 0
WA1 200-3
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CWWO4686
WA1 200-3
30-077 0
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CWWO4887
30-078 0
WA1 200-3
m#*smk
b5>iX*~_jsiAssy TRANSMISSION
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b 3 i it : Y -i EI i Assy (3/3) TRANSMISSION
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WA1 200-3
30-079 0
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
ASSEMBLY
GENERAL
DISASSEMBLY,
ASSEMBLY
OF TRANSMISSION
ASSEMBLY
Disassembly procedure 1. Preparation work Raise the transfer section vertically and support it with wood blocks, etc. so that the transmission will be horizontal. 2. Lubrication tubes 1) Remove the 2 joints each from lubrication tubes (I), (21, (31, (4) and (51, then remove those tubes. * Remove the tube clamps, too. 2) Remove the 2 mounting bolts and block (6). 3) Remove the 2 mounting bolts and block 3. (7). Oil filter assembly 1) Remove the 1 mounting bolt and 3 sets of 1 nut and 1 stud bolt, then remove cover (8) and 4 spacers (9). 2) Remove 3 mounting bolts, oil filter assembly (IO), and cover (I 1). Forward-reverse control valve assembly I) Remove the 4 mounting bolts, reverse clutch ECMV assembly (121, and bypass fill and drain valve assembly (13). * The mounting bolts are classified into 2 lengths. Make match marks on them to indicate their respective locations. 2) Remove the 4 mounting bolts, forward clutch ECMV assembly (141, and bypass fill valve assembly (15). * The mounting bolts are classified into 2 lengths. Make match marks on them to indicate their respective locations. Gear speed control valve assembly I) Remove the 4 mounting bolts, 1st clutch ECMV assembly (16), and bypass fill valve assembly (17). * The mounting bolts are classified into 2 lengths. Make match marks on them to indicate their respective locations. 2) Remove the 4 mounting bolts and 2 sets of the 2nd clutch ECMV assembly and 3rd clutch ECMV assembly (18). Ir The mounting bolts are classified into 2 lengths. Make match marks on them to indicate their respective locations. Lubrication relief valve assembly Remove the 3 mounting bolts and lubrication relief valve assembly (19). The mounting bolts are classified into 3 lengths. Make match marks on them to indicate their respective locations. Valve seats I) Remove the 4 mounting bolts and valve seat (20). * The mounting bolts are classified into 2 lengths. Make match marks on them to indicate their respective locations. 2) Remove valve seat (21). 3) Remove 14 mounting bolts and valve seat (22). Breathers I) Remove 2 breathers (23) and 2 elbows (24). 2) Remove the 4 mounting bolts and flange *
7.
8.
4.
I .:_
5.
(25). Transmission assembly and transfer and parking brake assembly I) Sling transmission assembly (26) temporarily. 2) Remove the 23 mounting bolts and disconnect the transmission assembly (26) and transfer and parking brake assembly (27) from each other. A When removing the transmission, take care extremely so that the transfer and parking brake assembly will not fall down. Shift the transmission toward the input shaft until its output shaft comes out of the transfer. Place the removed transmission assembly on blocks with the input shaft side up. For the disassembly procedure of the transmission assembly, see DISASSEMBLY, ASSEMBLY OF TRANSMISSION ASSEMBLY. For the disassembly procedure of the transfer and parking brake assembly, see DISASSEMBLY, ASSEMBLY OF TRANSFER AND PARKING BRAKE ASSEMBLY. 10. Strainer I) Remove the 2 mounting bolts and drain 9. 2) 3) 4) plug (28). Remove the 4 mounting bolts and 4 covers (29). Remove the 4 springs (30) and 4 magnets (31). Remove 4 cases (32).
6.
CWWO4962
WA1 ZOO-3
TRANSMISSION
ASSEMBLY
Assembly procedure 1. Preparation work Support the transfer with blocks, etc. so that it will be vertical. 2. Strainer 1) Fit the O-ring and install 4 cases (32). & Periphery of O-ring: Grease (G2-LI) 2) Install 4 magnets (31) and 4 springs (30). 3) Fit the O-ring and secure 4 covers (29) with 4 bolts each. 4) Fit the O-ring and install drain plug (28) with the 2 bolts. & O-ring: Grease (G2-LI) 3. Transmission assembly and transfer and parking brake assembly 1) Fit the O-ring to the connecting parts of transmission assembly (26) and transfer and parking brake assembly (27). 6 O-ring: Grease (G2-LI) 2) Sling transmission assembly (26) and install it to transfer assembly (27) with the 23 bolts. A When installing the transmission, take care extremely so that the transfer and parking brake assembly will not fall down. * After installing the transmission, support it with blocks, etc. 4. Breathers 1) Install flange (25) with the 4 bolts. & Mating faces of flange and case: Gasket sealant (LG-51 2) Install 2 elbows (24) and 2 breathers (23). & Elbow and breather: Gasket sealant (LG-5) 5. Valve seat 1) Fit the O-ring and install valve seat (22) with 14 bolts. w Hexagon socket head bolts (6 pieces): 58.8 - 73.5 Nm IS.0 - 7.5 kgm} 2) Fit the O-ring and install valve seat (21). 3) Fit the O-ring and install valve seat (20) with the 4 bolts. * The mounting bolts are classified into 2 lengths. When installing them, check their respective locations by the match marks made when they were removed. w Mounting bolt: 58.8 - 73.5 Nm IS.0 - 7.5 kgm} 6. Lubrication relief valve assembly Fit the O-ring and install lubrication valve
7.
8.
assembly (19) with the 3 bolts. * The mounting bolts are classified into 3 lengths. When installing them, check their respective locations by the match marks made when they were removed. w Mounting bolt: 58.8 - 73.5 Nm 16.0 - 7.5 kgml Gear speed control valve assembly f The ECMV assembly for gear speed control and that for forward-reverse control are different from each other. The cover of the ECMV assembly for gear speed control is secured with hexagon bolts. 1) Fit the O-rings and install the 2 sets of the 3rd clutch ECMV assembly and 2nd clutch ECMV (18) with the 4 bolts each. * The mounting bolts are classified into 2 lengths. When installing them, check their respective locations by the match marks made when they were removed. w Mounting bolt: 27.4 - 34.3 Nm 12.8 - 3.5 kgm) 2) Fit the O-ring and install bypass fill valve assembly (17) and 1st clutch ECMV assembly (16) with the 4 bolts. * The mounting bolts are classified into 2 lengths. When installing them, check their respective locations by the match marks made when they were removed. w Mounting bolt: 27.4 - 34.3 Nm (2.8 - 3.5 kgm} Forward-reverse control valve assembly The ECMV assembly for forward-reverse control and that for gear speed control are different from each other. The cover of the ECMV assembly for forward-reverse control is secured with hexagon socket head bolts. Fit the O-rings and install the bypass fill valve assembly (15) and forward clutch ECMV assembly (14) with the 4 bolts. + The mounting bolts are classified into 2 lengths. When installing them, check their respective locations by the match marks made when they were removed. m Mounting bolt: 27.4 - 34.3 Nm {2.8 - 3.5 kgm} Fit the O-ring and install bypass fill and drain valve assembly (13) and reverse clutch ECMV assembly (12) with the 4 bolts.
w 9.
The mounting bolts are classified into 2 lengths. When installing them, check their respective locations by the match marks made when they were removed. Mounting bolt: 27.4 - 34.3 Nm 12.8 - 3.5 kgm}
Oil filter 1) Fit the O-ring and install cover (11) and oil filter assembly (IO) with the 3 bolts. m Mounting bolt: 58.8 - 73.5 Nm IS.0 - 7.5 kgml 2) Install the 3 stud bolts, then install the 4 spacers (9) and cover (8) with the 1 bolt and 3 nuts. 10. Lubrication tube I) Install block (7) with the 2 bolts. 2) Install block (6) with the 2 bolts. 3) Fit the gasket and install lubrication tubes (51, (41, (31, (21, and (I) with 2 joints each. w Joint: 44.1 - 53.9 Nm I4.5 - 5.5 kgm}
WA1 200-3
30-079-Z 0
TRANSMISSION
ASSEMBLY
DISASSEMBLY,
ASSEMBLY
OF TRANSMISSION
ASSEMBLY
Il/2
40 27 Lk
\
54
-55
30-079-3
0
WA1 200-3
TRANSMISSION
ASSEMBLY
WA1 200-3
30-079-4 0
TRANSMISSION
ASSEMBLY
Disassembly procedure 1. Preparation work Set the transmission assembly on blocks, etc. with the input shaft side up. 2. Case 1) Remove 7 sleeves (1). * Apply a bearing puller, etc. to the groove on the inside wall of the sleeve to pull out the sleeve. 2) Remove the 3 mounting bolts and case 3. (2). Housing Remove the 24 long bolts, 6 short bolts, and housing (3). Input shaft, reverse clutch carrier and reverse sun gear assembly 1) Sling the input shaft end and remove the input shaft, reverse clutch carrier and reverse sun gear assembly (4). * Sling the input shaft vertically so that the inner race and outer race of the taper roller bearing under the carrier will not be tilted when they are disconnected from each other. 2) Remove snap ring (5) and spacer (6). 3) Remove cage (7). Ir Use a puller to remove the cage. 4) Remove ball bearings (8) and (9) from cage (7). Jr Use bearing puller to pull out the bearings. 5) Remove the 8 mounting bolts and cage (IO). * Pull out the cage with forcing screws. 6) Remove 2 seal rings (11) from cage (IO). 7) Remove snap ring (12) and gar (13). 8) Remove snap ring (14). 9) Remove shaft (15). + Use a press to pull out the shaft. 10) Remove seal ring (16) from shaft (15). 11) Remove snap ring (17) and gear (18). 12) Remove ball bearing (19) from shaft (15). * Use a press to pull out the ball bearing. 13) Remove shaft (20) and ball (21) from carrier (22). * Remove the 4 sets. 14) Remove gear (23), 2 needle bearings (24) each, and 2 thrust washers (25) each. * Remove the 4 sets. 15) Remove the inner race of roller bearing (26). * Use a bearing inner race. puller to remove the
5.
6. 7.
4.
8.
Reverse clutch plates and discs 1) Remove 6 springs (27). * The length of the springs depends on the clutch. Put tags, etc. to the springs to indicate their respective locations. 2) Remove 8 plates (28), 7 discs (29), and 48 springs (30) alternately. Reverse clutch ring gear Remove ring gear (31). Reverse clutch housing and piston 1) Remove housing (32). * Remove the housing and piston as 1 unit. 2) Remove piston (33) from housing (32). 3) Remove seal ring (34) from housing (32). 4) Remove seal ring (35) from piston (33). Connecting ring gear 1) Remove the 8 mounting bolts and plate (36). 2) Remove ring gear (37). 3) Remove snap ring (38) from ring gear
13. Forward clutch and 3rd clutch carrier assembly 1) Remove the 4 mounting bolts and collar
9.
(37). Forward clutch plates and discs 1) Remove 6 pins (39) and 12 pins (40). Ir The length of the pins depends on the clutch. Put tags, etc. to the pins to indicate their respective locations. 2) Remove 6 springs (41). * The length of the springs depends on the clutch. Put tags, etc. to the springs to indicate their respective locations. 3) Remove 9 plates (42), 8 discs (43), and 72 springs (44). _ 10. Forward clutch ring gear Remove ring gear (45). 11. Forward clutch housing and piston 1) Remove housing (46). * Remove the housing and piston as 1 unit. 2) Remove piston (47) from housing (46). 3) Remove seal ring (48) from housing (46). 4) Remove seal ring (49) from piston (47). 12. 3rd clutch plates and discs 1) Remove 6 springs (50). f The length of the springs depends on the clutch. Put tags, etc. to the springs to indicate their respective locations. 2) Remove 5 plates (51), 4 discs (52), and 30 springs (53) alternately.
(54). 2) Remove 2 seal rings (55) from collar (54). 3) Lift off forward clutch and 3rd clutch carrier assembly (56). 4) Remove snap ring (57), ball bearing (58), and gear (59). * Use a press to pull out above parts. 5) Remove collar (60) from ball bearing (61). * Use a press to pull out the bearing. 6) Remove shaft (62) and ball (63) from carrier (64). * Remove the 4 sets. 7) Remove 2 gears (65) each, 4 needle roller bearings (66) each, and 4 thrust washers (67) each. * Remove the 4 sets. 8) Remove the outer race of roller bearing (26) from carrier (64). * Use a bearing puller to pull out the outer race. 14. 3rd clutch ring gear 1) Remove the 8 mounting bolts and plate (68). 2) Remove ring gear (69). 3) Remove snap ring (70) from ring gear (69). 15. 3rd clutch housing and piston 1) Remove housing (71). * Remove the housing and piston as 1 unit. 2) Remove piston (72) from housing (71). 3) Remove seal ring (73) from housing (71). 4) Remove seal ring (74) from piston (72). 16. 2nd clutch plates and discs 1) Remove 6 springs (75). * The length of the springs depends on the clutch. Put tags, etc. to the springs to indicate their respective locations. 2) Remove 6 pins (76) and 12 pins (77). Ir The length of the pins depends on the clutch. Put tags, etc. to the pins to indicate their respective locations. 3) Remove 4 plates (78), 3 discs (79), and 24 springs (80). 17. 2nd clutch ring gear Remove ring gear (81). 18. 2nd clutch housing I) Remove housing (82). * Remove the housing and piston as 1 unit.
2) Remove piston (83) from housing (82). 3) Remove seal ring (84) from housing (82). 4) Remove seal ring (85) from piston (83). lg. 2nd clutch sun gear Remove gear (86). 20. 2nd clutch carrier and 1st clutch assembly 1) Remove 2nd clutch carrier and 1st clutch assembly (87). * Utilizing the bolt holes of the carrier, pull out the assembly with a puller. 2) Remove the 30 mounting bolts and cage (88). Remove snap ring (89) and spacer (90) from cage (88). * Remove the snap ring, compressing the spring with a press. 4) Remove 3 springs (91) from cage (88). 5) Remove piston (92) from cage (88). 6) Remove seal ring (93) from piston (92). 7) Remove snap ring (94) and ball bearing (95) from cage (88). * Use a bearing puller to pull out the ball bearing. 8) Remove snap ring (96) and collar (97) from cage (88). 9) Remove ball bearing (98) from cage (88). * Use a bearing puller to pull out the ball bearing. 10) Remove seal rings (99) and (100) from cage (88). 11) Remove hub (101). 12) Remove 2 seal rings (102) from hub (101). 13) Remove 9 discs (103), 8 plates (104), and 9 springs (105) alternately. 14) Remove snap ring (106) from carrier (107). 15) Remove shaft (108) and ball (109) from carrier (107). * Remove the 4 sets. 16) Remove gear (IIO), 2 needle bearings (111) each, and 2 thrust washers (I 12) each. * Remove the 4 sets. 21. Output shaft assembly and housing 1) Remove 6 mounting bolts and output shaft assembly (113) from housing (114). * Pull out the output shaft with forcing screws. 2) Remove snap ring (115) and cage (116) from shaft (I 17). * Use a press to pull out the cage. 3) Remove seal ring (I 18) from cage (I 16). 4) Remove snap ring (119) and ball bearing (120) from shaft (I 17). 3)
30-079-5 0
WA1 200-3
TRANSMISSION
ASSEMBLY
5)
Use a press to pull out the ball bearing. Remove seal ring (121) from shaft (117).
7)
Install seal rings (100) and (99) to cage 038). & Seal ring: Grease (G2-LI) * Install seal ring (100) as shown low.
be-
3. Assembly procedure 1. Output shaft assembly and housing 1) Install seal ring (121) to shaft (117). 6 Seal ring: Grease (G2-LI) 2) Install ball bearing (120) to shaft (117) and secure it with snap ring (119). J, Push the bearing with a press until the end of its inner race touches the shoulder of the shaft. 3) Install seal ring (118) to cage (116). 6 Seal ring: Grease (G2-LI) 4) Install cage (116) to shaft (117) and secure it with snap ring (115). * Push the outer race of the bearing with a press until it touches the shoulder of the cage. 5) Install output shaft assembly (113) to housing (114) with the 6 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 98 - 123 Nm (10.0 - 12.5 kgml 2. 2nd clutch carrier and 1st clutch assembly I) Set 2 thrust washers (112) each and 2 needle bearings (I 1 I) each to gear (I IO), then install them to carrier (107). * When installing, take care not to bruise the thrust washers. * Install the 4 sets. 2) Set ball (109) to shaft (1081, then install them to carrier (107). * Match the ball to the cut of the carrier and push the shaft with a press until it is flush with the carrier. * Install the 4 sets. 3) Install snap ring (106) to carrier (107). 4) Install 9 discs (103), 8 plates (1041, and 9 springs (105) to carrier (107) alternately. 5) Install 2 seal rings (102) to hub (101). 6 Seal ring: Grease (G2-LI) 6) Install hub (101) to carrier (107). 4.
15) Install cage (88) to carrier (107) with the 30 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 98 - 123 Nm (IO.0 - 12.5 kgml 16) Install 2nd clutch carrier and 1st clutch assembly (87) to the output shaft. Ir Push the assembly with a press until the end of the inner race of the ball bearing touches the shoulder of the shaft. 2nd clutch sun gear Install gear (86). 2nd clutch housing I) Install seal ring (85) to piston (83). & Seal ring: Grease (G2-LI) * Install the seal ring as shown below.
7.
8)
Install ball bearing (98) to cage (88). * Push the ball bearing with a press until the end of its outer race touches the shoulder of the cage. 9) Install collar (97) to cage (88) and secure it with snap ring (96). IO) Install ball bearing (95) to cage (88) and secure it with snap ring (94). * Push the ball bearing with a press until the end of its outer race touches the shoulder of the cage. 11) Install seal ring (93) to piston (92). & Seal ring: Grease (G2-LI) * Install the seal ring as shown below.
8.
CWWO4967
2)
Install seal ring (84) to housing (82). a Seal ring: Grease (G2-LI) f Install the seal ring as shown below. 9.
Install 12 pins (77) and 6 pins (76). * The length of the pins depends on the clutch. Before installing each pin, check its length. * Pin length: (77); 208 mm, (76); 223 mm 3) Install 6 springs (75). * The length of the springs depends on the clutch. Before installing each spring, check its length. * Free length of spring: 56.9 mm 3rd clutch housing and piston 1) Install seal ring (74) to piston (72). & Seal ring: Grease (G2-LI) * The seal ring must be installed in the correct direction. When installing it, check its direction (Install it as in the 2nd clutch). 2) Install seal ring (73) to housing (71). & Seal ring: Grease (G2-LII f The seal ring must be installed in the correct direction. When installing it, check its direction (Install it as in the 2nd clutch). 3) Install piston (72) to housing (71). 4) Install housing (71). 3rd clutch ring gear 1) Install snap ring (70) to ring gear (69). 2) Install ring gear (69). 3) Install plate (68) with 8 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 98 - 123 Nm (IO.0 - 12.5 kgml Forward clutch and 3rd clutch carrier assembly Install the outer race of roller bearing (26) to carrier (64). j, Push the outer race with a press until its end touches the shoulder of the carrier. Set 2 thrust washers (67) each and 2 needle bearings (66) to gear (65), then install them to carrier (64). * When installing, take care not to bruise the thrust washers. * Install the 4 sets. Install ball (63) to shaft (62), then install them to carrier (64). * Match the ball to the cut of the carrier and push the shaft with a press until it is flush with the carrier. * Install the 4 sets. Install gear (59) to carrier (64).
2)
CWW04966 CWW04968
12) Install piston (92) to cage (88). 13) Install 3 springs (91) to cage (88). 14) Install spacer (90) and secure it with snap ring (89). * Install the snap ring, compressing the spring with a press. * Installed load of spring: 1,697 N {I73 kg1
5. 6.
3) Install piston (83) to housing (82). 4) Install housing (82). 2nd clutch ring gear Install ring gear (81). 2nd clutch plates and discs 1) Install 4 plates (781, 3 discs (791, and 24 springs (80) alternately.
WA1 200-3
30-079-6
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
ASSEMBLY
10.
11.
12. 13.
Press fit collar (60) to ball bearing (58). * Push the collar with a press until its shoulder touches the end of the inner race. 6) Install bearing (58) to carrier (64) and secure it with snap ring (57). Ir Push the bearing with a press until the end of its outer race touches the shoulder of the carrier. 7) Install forward clutch and 3rd clutch carrier assembly (56). 8) Install 2 seal rings (55) to collar (54). & Seal ring: Grease (G2-LII 9) Install collars (54) with 4 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 98 - 123 Nm I10.0 - 12.5 kgm} 3rd clutch plates and discs I) Install 5 plates (511,. 4 discs (521, and 30 springs (53) alternately. 2) Install 6 springs (50). * The length of the springs depends on the clutch. Before installing each spring, check its length. * Free length of spring: 68.8 mm Forward clutch housing and piston 1) Install seal ring (49) to piston (47). & Seal ring: Grease (G2-LI) * The seal ring must be installed in the correct direction. When installing it, check its direction (Install it as in the 2nd clutch). 2) Install seal ring (48) to housing (46). & Seal ring: Grease (G2-LI) * The seal ring must be installed in the correct direction. When installing it, check its direction (Install it as in the 2nd clutch). 3) Install piston (47) to housing (46). 4) Install housing (46). Forward clutch ring gear Install ring gear (45). Forward clutch plates and discs I) Install 9 plates (421, 8 discs (431, and 72 springs (44) alternately. 2) Install 6 springs (41). * The length of the springs depends on the clutch. Before installing each spring, check its length. * Free length of spring: 168 mm
5)
14.
15.
16. 17.
18.
Install 12 pins (40) and 6 pins (39). j, The length of the pins depends on the clutch. Before installing each pin, check its length. * Pin length: (40); 315 mm, (39); 315 mm Connecting ring gear 1) Install snap ring (38) to ring gear (37). 2) Install ring gear (37). 3) Install plate (36) with 8 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 98 - 123 Nm {IO.0 - 12.5 kgm} Reverse clutch housing and piston 1) Install seal ring (35) to piston (33). 6 Seal ring: Grease (G2-LI) * The seal ring must be installed in the correct direction. When installing it, check its direction (Install it as in the 2nd clutch). 2) Install seal ring (34) to housing (32). 6 Seal ring: Grease (G2-LI) * The seal ring must be installed in the correct direction. When installing it, check its direction (Install it as in the 2nd clutch). 3) Install piston (33) to housing (32). 4) Install housing (32). Reverse clutch ring gear Install ring gear (31). Reverse clutch plates and discs I) Install 8 plates (281, 7 discs (291, and 48 springs (30) alternately. 2) Install 6 springs (27). * The length of the springs depends on the clutch. Before installing each spring, check its length. * Free length of spring: 133 mm Input shaft, reverse clutch carrier and reverse sun gear assembly I) Install the inner race of roller bearing (26) to carrier (22). * Push the inner race with a press until its end touches the shoulder of the carrier. 2) Set 2 thrust washers (25) and 2 needle bearings (24) to gear (231, then install them to carrier (22). * When installing, take care not to bruise the thrust washers. Ir Install the 4 sets.
3)
Set ball (21) to shaft (201, then install them to carrier (22). * Match the ball to the cut of the carrier and push the shaft with a press until it is flush with the carrier. * Install the 4 sets. 4) Install ball bearing (19) to shaft (15). * Push the ball bearing with a press until the end of its inner race touches the shoulder of the shaft. 5) Install gear (18) and secure it with snap ring (17). 6) Install shaft (15) to carrier (22). + Push the outer race of the ball bearing with a press until its end touches the shoulder of the carrier. 7) Install snap ring (14). 8) Install gear (13) and secure it with snap ring (12). 9) Install 2 seal rings (I I) to cage (IO). & Seal ring: Grease (G2-LI) IO) Install cage (IO) to carrier (20) with the 8 bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 98 - 123 Nm {IO.0 - 12.5 kgm} 11) Install ball bearing (9) to cage (7). * Push the ball bearing with a press until the end of its inner race touches the shoulder of the cage. 12) Install cage (7) to cage (IO). * Push the cage with a press until the end of the inner race touches the shoulder of the cage. 13) Install ball bearing (8) to cage (7). * Push the inner race and outer race of the ball bearing simultaneously with a press until the end of the outer race touches the shoulder of the cage. 14) Install spacer (6) and secure it with snap ring (5). 15) Install seal ring (16) to shaft (15). & Seal ring: Grease (G2-LII 16) Sling the input shaft end and install the input shaft, reverse clutch carrier and reverse sun gear assembly (4). * Sling the input shaft vertically so that the inner race and outer race of the taper roller bearing under the carrier will not be tilted when they are coupled with each other.
3)
19. Housing Install housing (3) with 24 long bolts and 6 short bolts. 6 Threaded parts of short mounting bolt: Liquid adhesive (LT-2) w Long bolt: 353 - 392 Nm I36 - 40 kgm1 Short bolt: 98 - 123 Nm {IO.0 - 12.5 kgml 20. Case 1) Install case (2) with the 3 bolts. m Mounting bolt: 490 - 608 Nm (50 - 62 kgml 2) Fit the O-ring and install 7 sleeves (I).
30-079-7 0
WA1 200-3
TRANSMISSION
ASSEMBLY
DISASSEMBLY,
ASSEMBLY
OF TRANSFER
AND PARKING
BRAKE ASSEMBLY
29
27
28 \ 32
WA1 200-3
30-079-8 0
TRANSMISSION
ASSEMBLY
Disassembly procedure Ir When removing only the parking brake assembly from the TORQFLOW assembly or vehicle body, see REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY. 1. Front coupling I) Remove the mounting bolts and holder (I). 2) Remove coupling (2). 2. Cage 1) Remove the 6 mounting bolts, cage (31, and shims (4). * Check the thickness and quantity of the shims. 2) Remove dust seal (5) from cage (4). 3) Remove oil seal (6) from cage (4). 3. Rear coupling I) Remove the bolts and holder (7). 2) Remove coupling (8). 4. Parking brake assembly I) Remove 2 mounting bolts and flange (9). 2) Remove sleeve (IO). * Screw a hanging bolt (12 mm) in the sleeve to pull out the sleeve. 3) Remove 2 plugs (11) and 2 sets of bolt and washer (12). * Any bolts and washers may be removed, since they will be used to secure the parking brake. Do not remove any of the 4 hexagon socket head bolts. 4) Install the removed 2 sets of bolt and washer (12) in the plug holes. * Screw in the 2 sets of bolt and washer alternately and slowly to pull the piston in the packing brake toward the housing. 5.
Pull out the assembly evenly with forcing screws. After it is pulled out to the shaft end, lift it off. For the disassembly procedure of the parking brake assembly, see DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY. Output shaft and gear assembly I) Remove the 8 mounting bolts and cover (14). Remove output shaft and gear assembly (15). 3) Remove spacer (16) and gear (17) from shaft (IS). * Use a press to pull out the spacer and gear simultaneously. Idler gear I) Remove the 2 mounting bolts and plate (19). 2) Remove the 18 mounting bolts and cage 2) (20). * Pull out the cage with forcing screws (12 mm). * Pull out the cage straight so that the inner race and outer race of the roller bearing will not be tilted when they are disconnected from each other. 3) Remove the outer race of roller bearing (21) from cage (20). * Use a bearing puller to pull out the outer race. 4) Remove gear (22). * Pull out the gear straight so that the inner race and outer race of the roller bearing will not be tilted when they are disconnected from each other. 5) Remove the 4 mounting bolts and joint (23) from gear (22). 6) Remove the inner races of roller bearings (21) and (24) from gear (22). * Use a bearing puller to pull out the inner races. Input gear Remove the 2 mounting bolts and plate (25). Remove the 6 mounting bolts and cage (26). * Pull out the cage straight so that the inner race and outer race of the roller bearing will not be tilted when they are disconnected from each other. Remove snap ring (27) and joint (28). Remove the 18 mounting bolts and cage (29).
8.
6.
Remove the outer race of roller bearing (30) from cage (29). * Use a bearing puller to pull out the out races. Remove gear (31). * Pull out the gear straight so that the inner race and outer race of the roller bearing will not be tilted when they are disconnected from each other. Remove the inner races of roller bearings (30) and (32) from gear (31). * Use a bearing puller to pull out the inner races. Case 1) Remove the outer races of roller bearings (24) and (32) from case (33). * Use a bearing puller to pull out the outer races. 2) Remove tapered roller bearing (34) from case (33). Ir Use a bearing puller to pull out the bearing.
7.
5)
Remove the remaining 10 mounting bolts and parking brake assembly (13). * Do not remove the 4 hexagon socket head bolts.
Assembly procedure * When installing only the parking brake assembly to the TORQFLOW assembly or vehicle body, see REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY. 1. Case Install the outer races of roller bearings (24) and (32) to case (33). * Push each outer race with a press until its end touches the shoulder of the case. 2. Input gear 1) It-&all the inner races of roller bearing (32) and (30) to gear (31). * Push each inner race with a press until its end touches the shoulder of the case. 2) Install gear (31). * Insert the gear straight so that the inner race and outer race of the roller bearing will not be tilted when they are coupled with each other. 3) Install the outer race of roller bearing (30) to cage (29). * Push the outer race with a press until its end touches the shoulder of the cage. 4) Install cage (29) with the 18 bolts. * Insert the cage straight so that the inner race and outer race of the roller bearing will not be tilted when they are coupled with each other. 5) Install joint (28) and secure it with snap ring (27). 6) Fit the O-ring and install cage (26) with the 6 bolts. & O-ring: Grease (G2-LI) 7) Fit the O-ring and install plate (25) with the 2 bolts. 3. Idler gear Press fit the inner races of roller bearings (24) and (21) to gear (22). -Lr Push each inner race with a press until its end touches the shoulder of the gear. Install joint (23) to gear (22) with the 4 bolts. Install gear (22). * Insert the gear straight so that the inner race and outer race of the roller bearing will not be tilted when they are coupled with each other.
30-079-9 0
WA1 200-3
TRANSMISSION
ASSEMBLY
Install the outer race of roller bearing (21) to cage (20). * Push the outer race with a press until its end touches the shoulder of the cage. 5) Fit the O-ring and install cage (20) with the 18 bolts. 6 O-ring: Grease (G2-LI) * Insert the cage straight so that the inner race and outer race of the roller bearing will not be tilted when they are coupled with each other. w Mounting bolt: 245.0 - 308.7 Nm I25.0 - 31.5 kgm} 6) Fit the O-ring and install plate (19) with the 2 bolts. 4. Output shaft and gear assembly I) Install tool D6 to case (31).
4)
5.
Parking brake assembly 1) Fit the O-ring and set the parking brake assembly (13) in position, then tighten the 10 bolts temporarily. 2) Remove the 2 sets of bolt and washer (12) from parking brake assembly (131, then install parking brake assembly (13) with the 12 bolts in total. * Loosen the bolts and washers alternately and slowly so that the piston in the parking brake will not be tilted. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 205.9 - 269.7 Nm I21.0 - 27.5 kgml
6.
7.
Rear coupling I) Install coupling (8). 2) Install holder (7) with the bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 2,059 - 2,354 Nm (210 - 240 kgml Cage 1) Using tool D2, press fit oil seal (6) to cage (3). Sr Thinly apply gasket sealant (LG-5) to the oil seal fitting part of the cage. After fitting the oil seal, wipe off the projected sealant. f Push the oil seal until the flange of the tool touches the cage. & Oil seal lip: Grease (G2-Lll
iii) Calculate shim thickness c. c = (a -b) - (0.05 to 0.10) * The bearing is pushed in by 0.05 to 0.10 mm with the cage. * Standard shim thickness (Reference): 0.8 to 2.0 mm * Types of shims: 0.15, 0.20 mm
l
cwwo4974
.D6
3)
Install selected shim (4) and cage (3) with the 6 bolts. * Since the shims are of 2-piece split type, be sure to set them to the same thickness on both sides. 4) Using tool D3, install dust seal (5) to cage (3). * Push the dust seal until the flange of the tool touches the cage. & Dust seal lip: Grease (G2-LII
a
3) 4) 2) Install gear (17) and spacer (16) to shaft (18). * After installing the gear, push it with a press until the end of the spacer touches the shoulder of the shaft. Install output shaft and gear assembly (15). Install cover (14) with the 8 bolts. 5) 6) 7)
3) 4)
Install 2 plugs (11) to parking brake assembly (13). Fit the O-ring and install sleeve (IO). & Sleeve: Grease (G2-LI) Fit the O-ring and install flange (9) with the 2 bolts. Remove tool D6. Using tool D5, install tapered roller bearing (34) to case (33). Ir Since the bearing is an assembly, handle it as one unit, when replacing. * Press fit the bearing one side by one and insert the ring without fail.
cwwo4973
2)
Select the shim thickness according to the following procedure. i) Install cage (3) to case (33) temporarily and measure distance a between the cage end and case end. * Do not install any shim at this time. ii) Remove cage (3) and measure cage thickness b.
8.
Front coupling I) Install coupling (2). 2) Install holder (1) with the bolts. & Threaded parts of mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 2,059 - 2,354 Nm 1210 - 240 kgm1
WA1 200-3
30-079- 10 0
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
ASSEMBLY
REMOVAL,
INSTALLATION
OF PARKING
BRAKE ASSEMBLY
(FROM VEHICLE
BODY)
Preparation of tools * Prepare the tools used for removal and stallation work. @ Shackle (2 pieces) * If the shackles are not manufactured the specified dimensions, they may terfere with some parts and may not usable.
45Lt ,Min. 45 30
in-
to inbe
Removal procedure 1. Remove the mounting bolts and holder (I). f When using a booster wrench to loosen the mounting bolts, hold it securely with a rope or a band from above so that it, bolts, and wrench adapter will not come
Off.
2. 3. 4.
Remove Remove
coupling (2). the 2 mounting
bolts and flange
30M
Max.
30MT
,
? -_
, j r
Max.
30
18M Min. 18
5.
6.
Guide bolt (3 pieces)
(3). Remove sleeve (4). f Screw a hanging bolt (12 mm) in the sleeve to pull out the sleeve. Remove 2 plugs (5) and 2 sets of bolt and washer (6). * Any bolts and washers may be removed, since they will be used to secure the parking brake. Do not remove any of the 4 hexagon socket head bolts. Install the removed 2 sets of bolt and washer (6) in the plug holes. Sr Screw in the 2 sets of bolt and washer alternately and slowly to pull the piston in the parking brake toward the housing.
MR : S43C-D MateriaI:S43C-D
CWWO4984
I 7.
CWWO4986
Remove the parking brake assembly (7) accordina to the following procedure. Remove the remaining 10 mounting bolts. * Do not remove the 4 hexagon socket head bolts. Using forcing screws, pull out parking brake assembly (7) to a position where 2 shackles @ can be installed. Install 2 shackles @ as shown in the figure. Sling parking brake assembly (7) from both sides of the transmission.
CWW04983
30-079-11 0
WA1 200-3
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
ASSEMBLY
5)
Using output shaft (8) as a guide, slide off parking brake assembly (7) to the rear of the vehicle body.
Installation procedure 1. Install parking brake assembly (7) according to the following procedure and tighten the IO mounting bolts temporarily. 1) Install shackles @ as shown in the figure. 2) Sling parking brake assembly (7) from both sides of the transmission and slide it toward the transfer until it is placed on output shaft (8) perfectly.
Mounting bolt: 205.9 - 269.7 Nm (21.0 - 27.5 kgm}
CWW04986
CWW04987
3. 4. 5.
CWW04988
6. 7.
3) 4)
5)
Remove shackles @ and install 3 guide bolts @ as shown in the figure. Push parking brake assembly (7) toward the transfer to set it to the position for installation. Tighten the 10 bolts temporarily and remove guide bolts 0.
Install 2 plugs (5) to parking brake assembly (13). Fit the O-ring and install sleeve (4). & Sleeve: Grease (G2-LI) Fit the O-ring and install flange (3) with 2 bolts. Install coupling (2). Install holder (1) with the bolts. f When using a booster wrench to tighten the mounting bolts, hold it securely with a rope or a band from above so that it, bolts, and wrench adapter will not come
Off. &
Threaded
parts of mounting bolt: Liquid adhesive (LT-2) Mounting bolt: 2,059 - 2,354 Nm I210 - 240 kgm)
CWW04989
2.
Remove 2 sets of bolt and washer (6) from parking brake assembly (7), then install parking brake assembly (13) with the 12 bolts in total. Sr Loosen the bolts and washers alternately and slowly so that the piston in the parking brake will not be tilted. & Threaded parts of mounting bolt: Liquid adhesive (LT-2)
WA1 200-3
30-079-12 0
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
ASSEMBLY
DISASSEMBLY,
ASSEMBLY
OF PARKING
BRAKE ASSEMBLY
IO
Disassembly procedure 1. Plate Remove snap ring (1) and plate (2). 2. Plates and discs Remove 9 plates (3),8 discs (41, and 8 springs 3. 4. 5. (5). Drum 1 Remove drum (6). Spacer Remove spacer (7). Drum 2 I) Remove 2 sets of bolt and washer (8). * These are the bolts moved when the parking brake assembly was removed. + Loosen the 2 sets alternately and slowly, checking that the piston is coming out toward the drum. 2) Remove the 4 bolts and drum (9). 3) Remove snap ring (IO) from drum (9). Piston I) Remove piston (II). 2) Remove seal rings (12) and (13) from piston (11). Springs Remove 14 springs (14) and 14 springs (15). Bearing Remove snap ring (16) and bearing (17). * Use a bearing puller to pull out the bearing. Housing 1) Remove dust seal (18) from housing (19). 2) Remove oil seal (20) from housing (19).
Assembly procedure 1. Housing 1) Using tool D2, install oil seal (20) to housing (19). + Thinly apply gasket sealant (LG-5) to the oil seal fitting part of the housing. After fitting the oil seal, wipe off the projected sealant. * Press fit the oil seal until the flange of the tool touches the housing. & Oil seal lip: Grease (G2-LI)
6.
7. 8.
2)
Using tool D3, install dust seal (18) to housing (19). * Press fit the dust seal until the flange of the tool touches the housing. & Dust seal lip: Grease (G2-LI)
9.
Ii
CWW04978
2. Bearing Install bearing (17) and secure it with snap ring (16). * Push the bearing with a press until its end touches the shoulder of the housing.
CWWO4976
30-079- 13 0
WA1 200-3
TRANSMISSION
ASSEMBLY
3. 4.
Springs Install 14 springs (15) and 14 springs (14). Piston I) Install seal rings (13) and (12) to piston (II). * Install the seal rings as shown in the following figure. I 1 I
6.
7. 8.
Spacer Install spacer (7). Jr Insert the spacer vertically, since it is used as the inner race of the roller bearing, too. Drum 2 Install drum (6). Plates and discs Remove 9 plates (3), 8 discs (41, and 8 springs (5) alternately. Plate Install plate (2) and secure it with snap ring (I).
I
2)
cwwo4979
5.
Place piston (I 1) on the spring. * Match the dowel pin of the housing to the pin hole of the piston. Drum 2 I) Install snap ring (IO) to drum (9). 2) Place drum (9) over piston (11) and secure it with the 4 bolts. * Tighten the bolts slowly so that the piston will not be tilted in the housing. 3) Tighten the 2 sets of bolt and washer (8) in the plug holes. * Use the bolts and washers for the parking brake assembly temporarily. Do not remove them until the parking brake assembly is installed to the transfer. * Tighten the 2 sets alternately and slowly, checking that the piston is moving toward the housing.
WA1 200-3
30-079-14 0
5M*i#m
lW7Assy
VALVE Ass?
I\ /I/
j'Ass'y
VALVE Assy
_-_-_-_-_ _________--_-_-_-_ _________-__
L-J
AA
f?l
ll7-h
1i
I
30-080 0
WA1 200-3
mB*$m
t-/l/~;,
bSiX2
y-i~1>i5-fiAs.sy T/C, T/M LINE Assy
bIL=Ii, T/C, T/M
b?i7(:
~jaiffiAssy(V5)
LINE Assy(V5)
D-D
-__r__-__7____
d-_________!_______-_____-__.-~_-._-__r__-__-_-
___--- _-----_-____ --__ _------_______ >.:---
B-B(1
:2)
F-F
-_--__-__-___ -__-__-__-__-__-__
._-__3
_-__
I ,/
Y<
3 0
5,
,,,
0
_&_
CWW04889
WA1 200-3
30-081 0
!im*@3
bJI*=Ii,
b5i5Z:s~-i~i~-fiAssy T/C, T/M LINE Assy
IdLO,
~~jsc~8~~~i~~iAssy(2/5)
T/C, T/M LINE Assy(2/5)
/--1 --_,
\
\ \
(TO CW'w;892)
A__-_
_Ip-__
r\
L--r_ ___-;_-__-__h_ -________ __-__-__-__ I I:0 CWWO48921 r
. ,'
'\\ \ '\\ \( \
CWWO4890
30-082 0
WA1 200-3
5M#*%l3
bJtXi,
bYi;c<
~-iai5i>Assy T/C, T/M LINE Assy
bAai,
b3i;c-i
~_jai5OAssy(3/5)
___-______
1 it-
-------.
AIR BLEEOIHG PLUG
(FROM
c-c (1 :2) CWWO48921
E-E
Y
(FROM CWWO4889)
CWW0489 1
WA1 200-3
30-083 0
33B+*?im
t+Jb=I>,
b?iX<-~_iz;5_I;Assy T/C, T/M LINE Assy
bl1,=Ii,
bPii:
~_j~1=/3-IiAss'y(4/5)
(FROM
CtWO4890)
PC1 2)
CWW04892
30-084 0
WA1 200-3
53@f*sm
bILzli,
b~iX.*~-ia>i4>Assy T/C, T/M LINE Assv
T/C, T/M
LINE Assy
(5/5)
1.
Bolt tightening torque per KES 04. 123. 1 impact wrench (Table 2). Install hoses free from twisting. KES 00. 258. 1 (Contaminant inspection method and contaminant limit in hydraulic circuit) and KES 00. 248. 1 (Contaminant removing method during manufacturing hydraulic parts and contaminant defecting method of finished parts and contaminant limit) shall be satisfied. Tightening 123. 3. torque of pipe thread per KES 04.
2. 3.
4.
5.
Adjust number of shims so that of parallelism within 0.15 between center pin and matching surface of output yoke of transmission front end. Use oil E03@CD . .. Atmospheric temperature 0C Min. EOIO-CD . ..Atmospheric temperature +lOC Max. Oil capacity 360 Q At oil change 280 Q Oil inlet and air extract method at 1st oil inletting (At 1st time, oil level is not stabirized because the air was into oil circuit. So check oil level as follows) (I) Pour oil 300 Q into oil filler. (2) Run the engine. Then add oil 60 Q when oil level gauge starts to move downward. (3) Check oil level to be oil level of engine idle after idling engine 5 minutes. (4) Leave half a day as engine stop. Bleed air of torque converter oil cooler after loosening air bleeding plug of torque converter oil cooler. (5) Then run the engine and keep idle 5 minutes or more. So confirm oil level in regulated area.
6.
6.
7.
8.
8.
WA1 200-3
30-085 0
53l%*%l2
7UV -i t 7 bAssy PROPELLER SHAFT Ass%
Tn4?-i
-tt 7
bAssy Assy
PROPELLER
SHAFT
I
L__~~______I_~__-__-__-_; TlGWTEHlWG TDLPUE
i
I
L_~I_-___-LI__I_-__-__-_~
ilGTEYlYG
8fiClb9
343-427Nm
iiIth7
(35-43.
343-427Nm
5kaml
TORPUE
CWW04893
30-086 0
WA1 200-3
CENTER SUPPORT
DISASSEMBLY, ASSEMBLY OF CENTER SUPPORT

DISASSEMBLY
1. Retainer Remove 3 mounting bolts (2) of retainer (1). 4. Shaft 1) Set shaft and housing assembly (8) on press stand. 2) Remove shaft (9) with press. Receive the shaft so that it will not fall onto the floor. 5. Oil seal Remove oil seal (11) from retainers (1) and (7).
6. 2. Coupling 1) Turn over the center support assembly. 2) Remove bolt (3), then remove holder (4), coupling (5), and shim (6). Check the number and thickness of the shims.
Housing Remove outer race (12) from housing
3)
Remove bearing (10) and retainer (1) from shaft.
3.
Retainer Remove retainer (7).
WA1200-3
30-086-1
(9)
CENTER SUPPORT
ASSEMBLY
1. Housing 1) Install outer race (12) to the housing. 2) Install the O-rings to both ends of the housing.
3.
Shaft 1) Install retainer (1) to the shaft. 2) Using the push tool, install bearing (10) to the shaft.
4.
Retainer 1) Install retainer (7). Fill internal space (c) with grease (G2-LI). 3 Mounting bolt: 98 123 Nm {10 12.5 kgm}
7)
Using dial gauge [1], check that the end play is within the standard range. End play: 0.05 0.15 mm
2.
Oil seal Using the push tool, install oil seal (11) to retainers (1) and (7). Press fit oil seal (11) until it comes in contact with the retainer. Reference Dimension (a) = 2 0.5 mm 2 Oil seal lip: Grease (G2-LI)
3) 4)
5)
Install housing (13) to the shaft. Fill internal space (b) with grease (G2-LI). Tighten mounting bolt (2) of retainer (1). 3 Mounting bolt: 98 123 Nm {10 12.5 kgm} Using the push tool, install bearing (14).
5.
Adjusting shim 1) Install coupling (5), holder (4), and bolt (3). Measure the thickness of the holder. Do not install the shim. 2) While rotating housing (13), tighten bolt (3) so that the starting torque of the housing will be 8 12 Nm {0.8 1.2 kgm}. 3) Measure clearance (d) between holder (4) and shaft (9) at 3 places in holder hole (e). 4) Calculate average (f) of clearance (d). 5) Select and install some of the set shims so that their total thickness will be as follows and the standard end play will be obtained. Set shims: 0.05, 0.1, 0.3 mm Total thickness of shims = (f) + 0.1 to (f) + 0.15 mm 6) While rotating housing (13), tighten bolt (3) to the following torque. 3 Bolt: 2,450 3,040 Nm {250 310 kgm}
30-086-2
(9)
WA1200-3
53lB*Bl3
7Ui bP//XlLAssy FRONT AXLE ASSY
7 q i I\ ;i7// XIbAssy(l/Z) FRONT AXLE Assy (l/2)
(31 P6(425-22-13520. 425-22-13540) + (0. 610.
1)taikicti.
41.7.
425-22-13530. ~/r\lbf(btL)
CWW04894
WA1 200-3
30-087 0
FRONT AXLE Ass;
7ni
b73JWAssy(2/2)
FRONT AXLE As&y (2/2)
NW04895
30-088 0
WA1 200-3
DISASSEMBLY
AND
ASSEMBLY
FRONT
AXLE
ASSEMBLY
DISASSEMBLY,
ASSEMBLY
OF FRONT AXLE ASSEMBLY
Disassembly procedure 1. Draining oil 1) Remove 3 level plugs (I ). 2) Remove 3 drain plugs (2) and drain the oil from the axle. : Quantity of drained oil: 670 e
Axle assembly: 16,100 kg (Without oil) Sensor assembly 1) Remove the mounting bolts and clip (5). 2) Remove the 2 mounting bolts, sensor assembly (61, and shims (7). * Check the thickness and quantity of the shims. Shaft Remove the 2 mounting bolts and shaft (8), Tubes Remove tubes (91, (IO), and (11) and 6 connectors (12). Remove breather (13). &I kg
Assembly procedure 1. Breather Install breather (13). 2. Tubes 1) Install 6 connectors (12). 2) Install tubes (II), (IO), and (9). w Tube nut: 15.7 - 23.5 Nm (1.6 - 2.4 kgm} 3. Shaft Fit the O-ring and install shaft (8) with the 2 bolts. 4. Sensor assembly I) Assemble the sensor assembly according to the following procedure. i) Insert the sensor until its tip touches the flange of the axle. ii) Measure the clearance between the sensor fitting faces of the flange and housing. iii) Adjust the shims so that the clearance between the sensor tip and the housing in the axle will be as follows. * Clearance at sensor tip: 0.6 -C 0.1 mm * Types of shims: 0.2, 0.3, 1.0 mm * Combine the shims so that the number of them will be minimized. 2) Fit selected shims (7) and the O-ring and install sensor assembly (6) with the 2 bolts. w Bolt: 98 - 123 Nm {IO - 12.5 kgml 3) Install clip (5) with the bolts. 5. Supplying oil, I) Fit the O-ring and install 3 drain plugs Drain plug: 127 - 176 Nm I13 - 18 kgm) Fit the O-ring and supply oil into the axle and install 3 level plugs (1). G w Oil: 670 L? (AX0751 Level plug: 127 - 176 Nm (13 - 18 kgml (2). w
2)
CWW02772
WA1 200-3
30-088-l 0
53f%*%lilz
/ P - 7 3 X JbAssy REAR AXLE Assy
H-P%WAssy(l/2) REAR AXLE Assy (l/2)
I. M94fV4l.
94f
IL\V4l
STD. OPT.
ttll 165/65-57155.5/80-57 1 52x57 1 44x57
'11.441
J7lfid4JL
/AKO75li.KES.90.751 )I 670Q/
cwwo4902
WA1 200-3
30-089 0
53fE*%Z
IT-J3XJbAssy REAR AXLE ASSY
/ +--B3XJLAssy(2/2) REAR AXLE Assy (2/2)
WA1 200-3
fffR*wi
REAR
AXLE
ASSEMBLY
DISASSEMBLY,
ASSEMBLY
OF REAR AXLE ASSEMBLY

Disassembly procedure 1. Draining oil I) Remove 3 level plugs (I). 2) Remove 3 drain plugs (2) and drain the oil from the axle. : Quantity of drained oil: 670 .4 Assembly procedure 1. Breather Install breather (11). 2. Tubes 1) Install 6 connectors (IO). 2) Install tubes (91, (81, and (7). m Tube nut: 15.7 - 23.5 Nm Il.6 - 2.4 kgml 3. Shaft Fit the 2 O-rings and install 2 shafts (6) with the 2 bolts each. 4. support Install support (5) with the 30 bolts. m Mounting bolt: 1,520 - 1,910 Nm I155 - 195 kgml 5. Supplying oil 1) Fit the O-ring and install 3 drain plugs (2). m 2) Drain plug: 127 - 176 Nm I13 - 18 kgml Supply oil into the axle and install 3 level plugs (I). G# w Oil: 670 .@. (AX0751 Level plug: 127 - 176 Nm I13 - 18 kgm}
& kg
Axle assembly: 16,100 kg (Without
oil)
support Remove the 30 mounting
bolts and support
(5). Shaft Remove the 2 mounting bolts each and 2 shafts (6). Tubes Remove tubes (71, (81, and (9) and 6 connectors (IO). Breather Remove breather (I I).
cwwo2773
WA1 200-3
30-090-l 0
a~*%!43
? 7 3 f I PAssy DIFFERENTIAL CARRIER Assy
?7
+ -v I PAssy(F)
(l/5) Assy (F) (l/5)
DIFFERENTIAL
CARRIER
CWWO4896
WA1 200-3
30-09 1 0
53fiff-sm
DISASSEMBLY ANti ASSEMBLY
77 + t I 7Assy DIFFERENTIAL CARRIER Assy
?7+
+ J JAssy(F)
(2/5) Assy (F)
DIFFERENTIAL
CARRIER
@/5)
CLEARANCE
COAT
GREASE
G2-Ll
i LT-2Lf
APPLY LT-2 ON THREAD
A-A
(FROM
cwwo4896)
CWWO4897
30-092 0
WA1 200-3
a$E*mi
%3-v IPAssy DIFFERENTIAL CARRIER Assy
? 7 + -r I 7Assy DIFFERENTIAL
(R) (315) Assy (R) (315)
CARRIER
Z-2413
4-24X3 I
c1w04904
WA1 200-3
30-093 0
53-?s*$Im
77 + P 'I JAssy DIFFERENTIAL CARRIER Assy
?7
+ -v I PAssy(R)
(4/5)
to.2 to.3 t1.0
DIFFERENTIAL CARRIER Assy (R) (4/5)
CLEARANCE
A-A
(FROM
cwwo4904)
30-094 0
WA1 200-3
aBE*%l.a
F-7 3 P I PAssy DIFFERENTIAL CARRIER Assy
1.
Adjustment of differential side bearing. Tighten nut (568-22-11611) to obtain pre-load as follows. Pre-load: 15.7 - 31.4 kN 11,600 - 3,200 kg1 Adjustment of bevel pinion Select shims (427-22-11460, 22-11480, 427-22-11490) to shown. Pre-load: 7.8 - 35.3 kN bearing. 427-22-l 1470, 427obtain pre-load as I800 - 3,600 kg}
2.
3.
Installation of bevel pinion and gear (I) Select shims (42C-22-11371, 42C-22-11381, 42C-22-11390) to obtain specified mounting distance on the end face of pinion (42G2211211). (2) Install gear assy and adjust bearing preload. See item 1. (3) Adjust backlash to 0.43 - 0.61 mm by using nut (568-22-I 1611). Oil seal (428-22-11780) and dust seal (428-22. .. . . 11790) installatron posmon and greasrng 1s as shown. Other to be per KES 83. 271. 2.
4.
WA1 200-3
30-095 0
DIFFERENTIAL CARRIER ASSEMBLY
REMOVAL,
INSTALLATION,
DISASSEMBLY,
ASSEMBLY
OF DIFFERENTIAL
CARRIER ASSEMBLY
3 4 5
\ \
\
13
-1
\.(J
.\
Ii -_-.-_
j
cwwo2774
so-095 1
0
WA1 200-3
Removal procedure 1. Differential carrier assemblv
1) Remove the 13 mounting bolts and cover

assembly 3) 4) 5) (3).
2) Remove gear (4).

Remove shaft assembly (5). Remove the mounting bolts and t-piece (7). Remove 23 mounting bolts and differential carrier assembly (6). kg &?I Differential carrier assembly: 1,570 kg
Disassembly procedure 2. Cover Remove the 2 mounting bolts and cover (8). Ir Front differential carrier only 3. Flange Remove snap ring (9) and flange (IO). * Front differential carrier only 4. Lock plate Remove the 4 mounting bolts and 2 lock plates (I I). 5. Cage assembly bolts and 1) Remove the 2 mounting bracket (12). 2) Remove the 22 mounting bolts and cage assembly (13). 3) Remove shims (14) from cage (15). * Check the thickness and quantity of the shims. 4) Remove the mounting bolts, holder (16), and shims (17). * Check the thickness and quantity of the shims. 5) Remove coupling (18). 6) Remove the 4 mounting bolts and cage (19). 7) Remove dust seal (20) from cage (19). 8) Remove oil seal (21) from cage (19). 9) Remove pinion (22) from cage (15). IO) Remove the inner race of roller bearing (23) from cage (15). 11) Remove the inner race of roller bearing (24) from pinion (22). * Use a press to pull out the inner race. 12) Remove the outer races of roller bearings (23) and (24) from cage (15). + Use a bearing puller to pull out the outer races. 6. Differential assembly I) Remove the 4 mounting bolts and 2 caps (25). 2) Remove 2 nuts (26). 3) Remove differential assembly (28) and 2 outer races of bearing (27) from carrier 4) 5) 6) (29). Remove the 8 mounting bolts and case
8)
Disassemble the pinion gear assembly according to the following procedure. i) Secure pinion gear assembly (34) with a press and remove locknut (35) with wrench WI. ii) Using a press, remove sleeve (37) from pinion gear (36). iii) Remove inner race (38A) from pinion gear (36). iv) Remove spacer (38B) and inner race (38C) from sleeve (37).
Using a press, remove outer race (38D) from pinion gear (36). vi) Using a press, remove collar (38E) and outer race (38F) from pinion gear (36).
v)
Assembly procedure 1. Differential assembly I) Install bevel gear (44) to case (41) with the 20 bolts. & Mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 824 - 1,030 Nm (84 - 105 kgml 2) Install 2 bushings (43) to case (41). * Front differential carrier only 3) Install tube (42) to case (41). * Front differential carrier only 4) Install the inner race of bearing (27) and thrust washer (40) to case (41). & Contact faces of thrust washer (40) and side gear (39): Axle oil (AX075). 5) Install side gear (39) to case (41). 6) Assemble the pinion gear assembly according to the following procedure. i) Using a press, install collar (38E) and outer race (38F) to pinion gear (36). * Push the outer race until its end touches the pinion gear. ii) Using a press, install outer race (38D) to pinion gear (36). * Push the outer race until its end touches the pinion gear.
I
9) Remove side gear (39). IO) Remove the inner race of bearing
(27) and thrust washer (40) from case (41). 11) Remove tube (42) and 2 bushings (43). Ir Front differential carrier only 12) Remove the 20 bolts and bevel gear (44).
cwwo4991
iii) install inner race (38C) and spacer (38B) to sleeve (37). iv) Install sleeve (37) to pinion gear (36). VI Install inner race (38A) to pinion gear (36).
7)
(30). Remove the inner race of bearing (27) and thrust washer (31) from case (30). Remove side gear (321, then remove spider shaft (33) and pinion gear assembly (34) as one unit. Remove 4 pinion gear assembly (34) from spider shaft (33).
WA1 200-3
30-095-2 0
DISASSEMBLY
AND ASSEMBLY
vi) Secure
pinion gear assembly (34) with a press and tighten nut (35) with wrench WI.
Nut: 882 - 1,080
Nm I90 - 110 kgn

35 / ,38A
just it into the following range with the adjustment nut. * Rotational force: 20.6 - 23.5 N (2.1 - 2.4 kg} f The rotational force may be measured by winding a string onto plane half part b. (79.4 - 95.1 N I8.1 - 9.7 kg))
7)
8)
9)
IO)
11)
12)
13)
14) 15)
Install the assembly of 4 pinion gear assemblies (34) and spider shaft (33) to case (41). Install side gear (32). * Move the side gear to check that the pinion gear rotates lightly. Install the inner race of bearing (27) and thrust washer (31) to case (30). & Contact faces of thrust washer (31) and side gear (32): Axle oil (AX075). Install case (30) to case (41) with the 8 bolts. m Mounting bolt: 824 - 1,030 Nm (84 - 105 kgml Install the 2 outer races of bearing (27) to cases (41) and (30). Install differential assembly (28) to carrier (29). Tighten 2 nuts (26) onto carrier (29) temporarily. * Check that the carrier can be rotated lightly with the hand. Install 2 caps (25) to carrier (29) with the 4 bolts. Adjust the preload on the differential side bearing according to the following procedure. i) Bring the lock groove of the nut on the bevel gear side to the position where the lock plate is inserted. ii) Rotate the bevel gear until it rotates smoothly. iii) Measure the rotational force of the bevel gear at large end a, then ad-
becomes 15.7 Nm Il.6 kgml. iv) Measure distance b between the holder and pinion end. v) Calculate shim thickness c. . c = (b - a) - (0 to 0.04) * Select shims so that their thickness will be 0 to -0.04 mm less than the clearance. * Types of shims: 0.05, 0.2, 0.3, 1.0 mm * Combine the shims so that the number of them will be minimized. vi) Install the selected shims and tighten the bolt. vii) Rotate cage (15) to fit the bearing, then check that the starting torque is 15.7 - 52.0 Nm (I.6 - 5.3 kgm). * If the starting torque is out of the above range, adjust the shims again.
b a
9)
10)
11)
12) 13)
2.
iv) After adjusting, check that the adjustment nut groove on the plain half side is at the position where the lock plate is inserted. Cage assembly 1) Install the outer races of roller bearings (24) and (23) to cage (15). * Push each outer race until its end touches the shoulder of the cage. 2) Install the inner race of roller bearing (24) to pinion (22). * Push the inner race until its end touches the pinion. 3) Install pinion (22) to cage (15). & Bearing: Axle oil (AX0751 * Press fit the bearing, rotating the cage. Stop press fitting when a load is applied. * Limit the press fitting force to the minimum load to insert the bearing. 4) Install the inner race of roller bearing (23) to pinion (22). 5) Adjust the thickness of the shim for the input bearing according to the following procedure. i) Measure thickness a of the holder. ii) Install coupling (18) to pinion (22), then install holder (16) temporarily with the bolts. Sr Do not install the shims at this time. iii) Fitting the bearing, loosen the bolt gradually until the starting torque
Install cage (19) to cage (15) with the 4 bolts. w Mounting bolt: 157 - 196 Nm (16 - 20 kgml Install coupling (18) to pinion (22), then fit the O-ring. 6 Yoke end, shaft spline: Lubricant (LM-G) Install the selected shims and holder (16) with the bolts. & Mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 2,450 - 3,040 Nm (250 - 310 kgml Fit the O-ring to cage (15). Adjust the shim thickness for the differential carrier according to the following procedure. * After the bearing, pinion gear, bevel gear, etc. is replaced, adjust the shims. i) Measure distance a between carrier (29) and pinion gear (22).
CWW02777
6) 7) 8)
Fit the O-ring to cage (19). Install oil seal (21) to cage (19). Install dust seal (20) to cage (19). * Fitting dimension c of dust seal: 4 mm from cage end & Fitting part of oil seal: Gasket sealant (LG-I) or (LG-5) & Seal lip: Grease (G2-LI)
cwwo2778
ii)
Calculate standard value b. b=(427+c)-(121.69id) * Dimensions c and d are indicated at the end of the pinion shaft on the unit of l/100 mm. (Take care of plus and minus.)
CWWO7776
cwwo2787
30-095-3 0
WA1 200-3
DISASSEMBLY
AND
ASSEMBLY
DIFFERENTIAL
CARRIER
ASSEMBLY
iii) Calculate shim thickness e. . e=b-a * Types of shims: 0.2, 0.3, 1.0 mm * Combine the shims so that the number of them will be minimized. 14) Install selected shims (14) to cage (15) and install it to cage (29) with the 22 bolts. w Mounting bolt: 1,520 - 1,910 Nm 1155 - 195 kgml 15) Install bracket (12) to cage (15) with the 2 bolts. m Mounting bolt: 1,520 - 1,910 Nm I155 - 195 kgml 16) Adjust the backlash of the bevel pinion according to the following procedure. 1: Adjust movement of the bevel gear with the adjustment nuts. When moving the bevel gear, turn the nuts on both sides in the same direction by the same angle so that the preload on the bearing will not change. i) Apply dial gauge W2 to the outer end of the bevel gear. ii) Adjust the backlash into the specified range with the adjustment nuts. Ir Backlash: 0.43 - 0.61 mm * Fix the pinion gear and measure at 3 - 4 places. iii) Thinly apply minium to the tooth surfaces of the bevel gear and check the tooth contact. * Rotate the bevel gear and check that the convex and concave faces are in the following ranges respectively.
(146) mm
3.
4.
5.
Lock plate Install 2 lock plates (11) with the 4 bolts. m Mounting bolt: 245 - 309 Nm (25 - 31.5 kgml Flange Install flange (IO) and snap ring (9). Ir Front differential carrier only Cover Install cover (8) with 2 bolts. * Front differential carrier only m Mounting bolt: 98 - 123 Nm {IO - 12.5 kgml
Installation procedure 6. Differential carrier assembly 1) Fit the O-ring to differential carrier sembly (6). 2) Install differential carrier assembly with the 23 bolts. r+lkg w 3) Install w Install Install Install bolts. w Differential
as(6)
4) 5) 6)
carrier assembly: 1,570 kg Mounting bolt: 1,520 - 1,910 Nm (155 - 195 kgm} t-piece (7) with the bolt. Mounting bolt: 1,520 - 1,910 Nm 1155 - 195 kgml shaft assembly (5). gear (4). cover assembly (3) with the 16 Mounting bolt: 245 - 309 Nm I25 - 31.5 kgm)
I-_
kg--63mml
169~83mA
I3
CII
cwwo2779
WA1 200-3
30-095-4 0
53s*%I2
7 ~-ffJlr& jk+Assy FINAL & BRAKE Assy
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30-096 0
WA1 200-3
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WA1 200-3
30-097 0
53f#s*~Z
TdTJlr&?L/-+Assy FINAL & BRAKE Assy
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30-098 0
WA1 200-3
%%*%3
7p4flL&?L-+Assy FINAL & BRAKE ASSY
7 57+ $-Jr, & i I/ - +Assy (414) FINAL & BRAKE Assy(4/4)

9 + 7 b (42C-22-12820)@hj$j 1. Floating seal installation (1) To install floating seals, put tube (42C-2213231) upright. (2) O-ring (562-33-I 1922, 428-33-l 1650) to be clean with EOIO-CD. (3) Coat with EOIO-CD on O-ring contact faces of retainer (42G33-113223, cylinder (42C-33112531, retainer (42C-33-11331) and hub (42C-22-12710). (4) Coat with EOlO-CD on O-ring contact surfaces of seal (42G33-11410), and install Oring (562-33-11922) into these seals without twisting. (5) Coat with EOIO-CD on O-ring contact surfaces of seal (42C-33-115103, and install Oring (428-33-11650) into these seals without twisting. (6) Install half of seal assy (O-ring and seal) into hub, retainer and cylinder by pressing O-ring with cylindrical tool as shown. (Fig. 1) (7) Mating faces a of seal (42C-33-11410, 42C-33-11510) to be clean and free of dust. Coat with EOIO-CD on surface a before assembling. (Fig. 2) Adjustment of wheel bearing. Select shims (42C-22-12230, 42G22-12240, 42C22-12250) to obtain pre-load as shown. Pre-load: 11.8 - 70.6 kN 0,200 - 7,200 kg} When assembling carrier assy (42C-22-12201) and hub (42C-22-12710), thru screw hole Y to be met with drill hole Z under drain plug. Disc wear indicator installation
. .
5.
1.2 F7 L -g .x 2 F7t -f
brD7?ti
: 0.306-0.564mm
: 0.089-0.346mm >YQIl)lr> F;pL-g(-tr .:,
L t 7 b (42C-22-12820) #iA@
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L t 7 P (42C-22-12830)#Ai$
1. Y P7L - 8 : 0.175-0.445nlIn
(1) When assembling 9 plates (562-33-21231)

from tube (42C-22-132311, the center of tooth lack to be met with the center of tooth lack of gear (42C-33-11231). When assembling one plate (562-33-21231) from piston (42G33-11121), tooth must exist on the tooth lack of gear (42C-33-11231). Brake without cap (42C-33-12140). Push shaft (42C-33-12110) and adjust guide (42C-33-12130) until mating the surface of shaft (42C-33-12110) and the surface of guide (42C-33-12130), and fix with nut. Install cap (42C-33-12140).
L t 7 b (42C-22-12830) $$A$$
(2)
(3) (4)
6.
441-883Nm 7. ;f;l-JL<7
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9 4 (42C-22-12230,42C-22-12240, 426-22-12250) +% z LT -t%SsG%;ilei+s.
(5)
3E%f-S? : 11.8-70.6kN I1,200-7,200kgI

8. 3 t J 7Assy(42C-22-12201) &/\7*(42C-22-12710) t-$ij.sl;f-~?~k$ /\10BL 9 :, 7RY &+-P I 70) 3. 2. Degrease mating surface of seal (562-33-11941) and cylinder (42C-33-112531, and apply Loctite #648 before assembling. Brake testing procedure (1) Bleed air from brake cylinder with bleeder (566-32-I 1430). (2) Brake oil to be pressurized to 175 MPa 1178 kg/cm*} and left for 5 minutes. Pressure drop to be Max. 2.94 MPa 13 kg/cm*). End play of No. 1 planetary bearing (adjustment not to be required) Before inserting planetary shaft (42C-22-12820) . End play: 0.306 - 0.564 mm After inserting planetan/ shaft (42G22-12820) . End play: 0.089 - 0.346 mm Endplay of No. 2 planetary bearing (adjustment not to be required) Before inserting planetan/ shaft (42C-22-12830) . End play: 0.175 - 0.445 mm After inserting planetary shaft (42C-22-12830) . End play: 0.103 - 0.392 mm Studs (01145-93045) to be sunk to incomplete thread. Tightening torque to 441 - 883 Nm I45 - 90 kgm1
~L-~i~~~~~iJftz~Q~~ar~~~~~ &oIZk. 9.
4.
( 2 ) y;z I- Y (42C-33-11121)f$Q 7L - b (562-3321231) 1 f%zi. 4-V (42C-33-11231)a 4 9 j\T s!ss&wQ~EiW13rttr. btif&ati t-i%loL 5.
6.
WA1 200-3
30-099 0
FINAL DRIVE AND BRAKE ASSEMBLY
DISASSEMBLY,
ASSEMBLY
OF FINAL DRIVE AND BRAKE ASSEMBLY
36
,------
---.-__
/I
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30-099- 1 0
, / -L -i____/-
80
CWWO2780 )
WA1 200-3
DISASSEMBLY
AND ASSEMBLY
FINAL
DRIVE
AND
BRAKE
ASSEMBLY
Disassembly &I kg
procedure
Final drive and brake assembly: 5,450 kg
1. Cover assembly I) Install the 16 mounting bolts and cover assembly (3). 2) Remove the O-ring from cover (4). 3) Remove spacer (5). 4) Remove the 3 mounting bolts and shaft 2. 3. (6). Sun gear Remove gear (7). Carrier assembly (Large) 1) Remove the 4 cap bolts and carrier assembly (8). 2) Remove the O-ring from carrier assembly (8). Remove 4 shafts (10) from carrier (9), then remove 4 balls. (11). -k Remove the 4 sets. 4) Remove 4 gears (12) from carrier (9). * Remove the 4 sets. 5) Remove the bearing (13) from gear (12). Jr Remove the 4 sets. 6) Remove snap ring (14) from gear (12). * Remove the 4 sets. Ring gear I) Remove the 16 mounting bolts and 8 plates (15). 2) Remove ring gear (16). Shaft assembly I) Remove shaft assembly (17). 2) Remove snap ring (19) and gear (20). 3) Remove spacer (21) from shaft (18). Carrier assembly (Small) I) Remove carrier assembly (22). 2) Remove spacer (24) from carrier (23). 3) Remove snap ring (25) and pin (26). * Remove the 3 sets. 4) Remove 3 balls (27). 5) Remove 3 gears (28) from carrier (23). 6) Remove 2 bearings (29) and spacer (30). * Remove the 3 sets. 7) Remove snap ring (31) from gear (28). * Remove the 3 sets. Hub and brake assembly 1) Sling hub and brake assembly (32) temporarily, then remove the 36 mounting bolts and the assembly. 2) Remove the O-ring and plate (33). 3)
4.
5.
6.
Hub ring -- gear assembly 1) Remove the 8 mounting bolts, retainer (34), and shims (35). * Check the thickness and quantity of the shims. 2) Remove hub ring gear assembly (36). 3) Remove the O-ring from tube (74). bolts and 2 4) Remove the 2 mounting plates (37). 5) Remove retainer (38) and O-ring. 6) Remove seal (39) and O-ring. 7) Remove ball (40). 8) Remove the inner race of roller bearing (41) from hub (42). bolts and 8 9) Remove the 16 mounting plates (43). 10) Remove ring gear (44) from hub (42). 9. Wheel hub assembly 1) Remove 61 stud bolts (45) from wheel hub assembly (46). 2) Remove the outer race of roller bearing (41) from hub (51). 3) Remove seal (47) and O-ring. 4) Remove retainer (48) and seal (49). 5) Remove the O-ring from seal (49). 6) Remove the O-ring from hub (51). 7) Remove the outer race of roller bearing (50) from hub (51). 10. Cylinder and piston assembly 1) Remove the 16 mounting bolts and cylinder (52). 2) Remove the O-ring from cylinder (52). 3) Remove oil seal (53) and seal (54). 4) Remove the O-ring from seal (54). 5) Remove plug (55) and O-ring. 6) Remove bleeder (56). 7) Remove plug (57) and O-ring. 8) Remove 3 plugs (58). 9) Remove 2 plugs (59) and 2 O-rings. 10) Remove 2 plugs (60) and 2 O-rings. 11) Push in guide (61) and remove 8 dowel pins (62) and 8 plates (63). 12) Remove 8 guides (61) and 8 springs (64). 13) Remove piston (65) from cylinder (52). 14) Remove seals (66) and (67) from piston (65). 11. Discs and plates 1) Remove 10 plates (68) and 9 discs (69) alternately. 2) Remove gear (71).
8.
12. Tube 1) Remove (74). Remove ing (50). 3) Remove 4) Remove (75). 13. Gear 1) Remove 2) Remove 3) Remove 4) Remove 5) Remove 2)
plug (70) and O-ring from tube the inner race from roller bearretainer (72) and 3 washers (73). the 34 mounting bolts and gear
plugs (76) and (77) and O-rings. plugs (78) and (79) and O-rings. spring pin (80). cap (81) and guide (82). lever (83) and shaft (84).
Assembly procedur 1. Gear 1) Fit the O-ring and install guide (82) to gear (75). 2) Fit the O-ring to shaft (84). 3) Insert shaft (84) in gear (75). Pass guide (82) and lever (83) onto the shaft in order, then install spring pin (80). 4) Fit the O-ring and install plug (79). w Plug: 58.8 - 78.4 Nm 16 - 8 kgm) 5) Install plug (78). 6) Fit the O-ring and plug (77). 7) Fit the O-ring and install plug (76) to gear (75). w Plug: 44.1 - 53.9 Nm 14.5 - 5.5 kgm) 2. Tube 1) Fit the O-ring to tube (74). & Fitting part of O-ring: Grease (G2-LI) 2) Install gear (75) to tube (74) with the 34 bolts. m Mounting bolt: 824 - 1,030 Nm (84 - 105 kgml 3) Fit 3 washers (73) and install retainer (72). Install the inner race of roller bearing (50) to tube (74). 5) Fit the O-ring and install plug (70). Wheel hub assembly 1) Press fit the outer races of roller bearings (41) and (50) to hub (51). * Press fit each outer race until its end touches the shoulder of the hub. 2) Fit the O-ring to hub (51). a O-ring: Grease (G2-LI) 3) Install retainer (48) to hub (51). 4) Fit the O-ring to seal (49). a Seal: Engine oil (EOIO-CD) * Before fitting the O-ring, remove the blooming white powder from its surface with engine oil (EOIO-CD). * Before fitting the O-ring, check that it is not skewed. 4)
3.
7.
WA1 200-Z
30-099-2 0
DISASSEMBLY
AND
ASSEMBLY
FINAL
DRIVE
AND
BRAKE
ASSEMBLY
5)
Install seal (49) to retainer (48). & Retainer: Engine oil (EOIO-CD) * Check the O-ring contact face of the retainer is free from flaw, dust, etc. * Use a push jig to install the seal. * After installing the seal, check that the O-ring is not skewed. * After installing the seal, measure dimension a at 4 places on the periphery and reduce the dimensional difference below 1 mm.
8)
Install 61 stud bolts (45) to hub (51). * Tighten each stud bolt to the incomplete thread portion. * Check that each stud bolt has an identification mark. * Tightening dimension (Reference): 139 mm w Stud bolt: 441 - 883 Nm I45 - 90 kgm}
* *
After installing the seal, check that the O-ring is not skewed. After installing the seal, measure dimension a at 4 places on the periphery and reduce the dimensional difference below 1 mm (similarly to seal
8)
Remove wheel hub assembly hub rina aear assembly (36).
(46) and
5.
CWW02784
cwwo4993
4.
6)
7)
Fit the O-ring to seal (47). & Seal: Engine oil (EOIO-CD) t Before fitting the O-ring, remove the blooming white powder from its surface with engine oil (EOIO-CD). * Before fitting the O-ring, check that it is not skewed. Install seal (47) to hub (51). & Hub: Engine oil (EOIO-CD) Check the O-ring contact face of the hub is free from flaw, dust, etc. Use a push jig to install the seal. After installing the seal, check that the O-ring is not skewed. After installing the seal, measure dimension a at 4 places on the periphery and reduce the dimensional difference below 1 mm (similarly to seal (49)).
Hub ring gear assembly I) Press fit the inner race of roller bearing (41) to hub (42). 2) Install ring gear (44) to hub (42). 3) Install 8 plates (43) with the 16 bolts. & Mounting bolt: Liquid adhesive (LT-21 w Mounting bolt: 245 - 309 Nm 125 - 31.5 kgm} 4) Install ball (40). 5) Fit the O-ring to retainer (38). 6) Install retainer (38) to hub (42). 6 Retainer fitting part: Grease (G2-LI) 71 Install 2 plates (37) with 2 bolts. & Mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 98 - 123 Nm {IO - 12.5 kgm} 8) Fit the O-ring to seal (39). 6 Seal: Engine oil (EOIO-CD) * Before fitting the O-ring, remove the blooming white powder from its surface with engine oil (EOIO-CD). Sr Before fitting the O-ring, check that it is not skewed. 9) Fit the O-ring and seal (39) to retainer (38). 6 Retainer: Engine oil (EOIO-CD) * Check the O-ring contact face of the retainer is free from flaw, dust, etc. * Use a push jig to install the seal.
(49)). IO) Fit the O-ring to tube (74). & O-ring: Grease (G2-LI) II) Install hub ring gear assembly (36). & Fitting face of bearing seal: Engine oil (EOIO-CD) Adjustment of preload on wheel bearing 1) Install wheel hub assembly (46) and hub ring gear assembly (36). & Bearing: Axle oil (AX075) 2) Install preload adjustment jig W3 with the 3 bolts. 3) Checking the oil pressure with oil pressure gauge 0, apply the following specified hydraulic pressure to preload adjustment jig W3 with a hydraulic pressure pump. * Specified hydraulic pressure: 40.8 MPa (400 kg/cm*) 4) Close needle valve @ and remove the coupler. suffi5) Rotate the hub wheel assembly ciently to fit the bearing. * Check that the hydraulic pressure is about 38.8 MPa (380 kg/cm*}. If it is below that level, raise it again according to step 3). 6) Measure dimension b between cylinder upper face and piston upper face with a depth micrometer. * Measure the dimension at 3 places and obtain the average. 7) Calculate shim thickness d. d = (a - b - c) + (0 to 0.1) * a: 86.99 mm, c: 40.09 mm * Types of shims: 0.2, 0.3, 1.0 mm * Combine the shims so that the number of them will be minimized.
l
6.
7.
Discs and plates Remove gear (71). Install 10 plates (68) and 9 discs (69) alternately. Install the 9 plates from the tube side, matching the centers of their cuts to the centers of the cuts of the indicator mounting part of the gear. Install the 1 plate from the piston side, matching its tooth to the cut of the indicator mounting part of the gear. Cylinder and piston assembly 1) Install seals (67) and (66) to piston (65). & Periphery of seal: Grease (G2-LB * Before installing the seals, check the piston grooves for flaw and foreign matter. 2) Install piston (65) to cylinder (52). & Piston surface: Grease (G2-LI) 3) Install 8 springs (64) and 8 guides (61). 4) Push in guide (61) and install 8 dowel pins (62) and 8 plates (63). 5) Fit the O-ring to cylinder (52).
30-099-3 0
WA1 200-3
FINAL DRIVE AND BRAKE ASSEMBLY
6)
7)
8)
9)
IO) 11)
12)
13)
Install cylinder (52) to gear (75) with the 16 bolts. w Mounting bolt: 824 - 1,030 Nm (84 - 105 kgml Fit the 2 O-rings and install 2 plugs (60) to cylinder (52). m Plug: 58.8 - 78.4 Nm (6 - 8 kgm) Fit the 2 O-rings and install 2 plugs (59) to cylinder (52). w Plug: 9.8 - 12.7 Nm Il.0 - 1.3 kgm1 Install 3 plugs (58). Fit the O-ring and install plug (57). Install breather (56) to cylinder (52). & Threaded parts of breather: Gasket sealant (LG-51 Fit the O-ring and install plug (55) to cylinder (52). m Plug: 34.3 - 44.1 Nm I3.5 - 4.5 kgml Check the brake seal according to the following procedure. i) Install an oil pressurizing connector to pressurizing port a. ii) Supply oil through pressurizing port a and bleed air through bleeder b. iii) Keep the piston operating hydraulic pressure at 175 MPa (178 kg/cm*] and close the hand valve. iv) Check that the pressure does not fall more 0.29 MPa (3 kg/cm*) in 5 minutes.
b
iii) Install cap (81) to guide (82). m Cap: 117.6 - 161.7 Nm (12 - 16.5 kgm)
10. Carrier assembly (Small) I) Install snap ring (31) to gear (28). * Install the 3 sets. 2) Install spacer (30) and 2 bearings (29). * Install the 3 sets. 3) Install 3 gears (28) to carrier (23) with 3 balls (27) and 3 pins (26). 4) Install 3 snap rings (25). 5) Install spacer (24) and carrier assembly (22). 11. Shaft assembly I) Install spacer (21) to shaft (18). 2) Install gear (20) and snap ring (19) to shaft (18). 3) Install shaft assembly (17). 12. Ring gear 1) Install ring gear (16) to ring gear (44). 2) Install 8 plates (15) with the 16 bolts. & Mounting bolt: Liquid adhesive (LT-2) m Mounting bolt: 245 - 309 Nm 125 - 31.5 kgml 13. Carrier assembly (Large) I) Install snap ring (14) to gear (12). * Install the 4 sets. 2) Install bearing (13) to gear (12). * Install the 4 sets. 3) Install 4 gears (12) to carrier (9) with 4 balls (II) and 4 shafts (IO). 4) Fit the O-ring to carrier assembly (81, then install them with the 4 cap bolts. m Mounting bolt: 123 - 157 Nm I12.5 - 16 kgm} Ir When installing the carrier assembly to the hub, match through tap hole a of the hub to hole b under the drain plug of the carrier.
14. Sun gear Install gear (7). 15. Cover assembly Install shaft (6) with the 6 Mounting bolt: Liquid m Mounting bolt: 245 - 309 Nm Install spacer (5). Fit the O-ring and install (3) with the 16 bolts. w Mounting bolt: 245 - 309 Nm
3 bolts. adhesive (LT-2)
(25 - 31.5 kgml cover assembly
I25 - 31.5 kgm}
15) Fit the O-ring to seal (54). 6 Seal: Engine oil (EOIO-CD) * Before fitting the O-ring, remove the blooming white powder from its surface with engine oil (EOIO-CD). f Before fitting the O-ring, check that it is not skewed. 16) Install seal (54) to cylinder (52). & Cylinder: Engine oil (EOIO-CD) * Check the O-ring contact face of the cylinder is free from flaw, dust, etc. * Use a push jig to install the seal. * After installing the seal, measure dimension a at 4 places on the periphery and reduce the dimensional difference below 1 mm (similarly to seal (49)). 17) Install oil seal (53) to cylinder (52). & Oil seal fitting part: LOCTITE 648 & Oil seal lip: Grease (G2-LI) Wheel hub assembly and hub ring gear assem-
CWWO.2781
14) Adjust the disc wear indicator according to the following procedure. i) Apply pressure to the brake. ii) Rotate guide (82) with shaft (84) pushed in and adjust the shaft end flush with the guide end, then secure the shaft with the nut. w Nut: 237.7 - 321 Nm I24 - 33 kgm}
bly I) Install wheel hub assembly (46). 6 Bearing: Axle oil (AX0751 2) Install hub ring gear assembly (36). & Bearing: Axle oil (AX0751 3) Install the selected shims (35) and retainer (34) with the 8 bolts. & Mounting bolt: Liquid adhesive (LT-2) w Mounting bolt: 1,520 - 1,910 Nm I155 - 195 kgm} Hub and brake assembly Fit the O-ring and plate (33) to tube (74). Install hub and brake assembly (32) with the 36 bolts. w Mounting bolt: 2,450 - 3,040 Nm (250 - 310 kgm}
CWWO2785
WA1 200-3
30-099-4 0
53l?B*%l~
J/S & P--4L/iC bAssy J/S & ARM-REST Assy
J/S & 7-LaLL/ J/S & ARM-REST
bAssy(V3) Assy(V3)
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(1~2)
CWWO4906
WA1 200-3
53lE*sm
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OF FRAME ANGLE
DIRECT TOWARD
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Z(l:l) 7b-b%KT>L3P@ DETAILS OF POTENT10 OF FRANE ANGLE METER
CWWO4906 cwwoh4g06
cwwo4907
WA1 200-3
30-101 0
%!#*%I2
J/S & 7-h L X b Assy J/S & ARM-REST Assv
J/S & Y--bit
bAssy(3/3)
1.
J/S & ARM-REST Assy(3/3)
Method of assembling joint (Cf. Q, A-A): I-l) Assemble lever (42C-40-12310) in the same direction (as shown) of slit of upper joint assy (42C-40-123201, and install lever to the top limit of serration. I-PITurn lever toward fore-and-aft of vehicle. Assemble, joint assy (42C-40-12480) so that grease nipple turn in the direction as shown. Adjustment of slide rail in the direction of foreand-aft (Cf. A-A, D-D): Before assembling cover etc. tighten + marked bolt (01435-00814/direction for up-and-down) and [XI marked bolt (01435-OlOPOldirection for right-and-left) temporarily so that bracket (42C40-12160) can slide smoothly, and then tighten them firmly. Adjustment of slide rail of joint cover (Cf. P): When assembling cover (42G40-12350, 42C-4012360) and slide rail (42C-40-123401, tighten bolt (01435-00620) for slide rail, bracket (42C-4012380) temporarily and adjust them so that two slide rails parallel each other. And then tighten them firmly. Adjustment of stopper bolt for J/S (Cf. Q, and below): When turning vehicle on low-idling, adjust length of bolt for adjustment of steering angle bX_ marked/ 01010-80620) so that gap of frameend stopper can be almost 37 - 40 mm. Lever for fore-and aft adjustment of J/S and lever for up and down adjustment of arm-rest and assembling stopper plate (Cf. S, T, B-B D-D): 5-I) Before assembling cover etc. assemble lever (42C-40-122403 as shown without handle part. 5-2)After assembling cover etc. assemble handle part at an angle of 30 clockwise from vertical upper position. 5-3)And then adjust the position of plate (42C40-12250) so that plate touches stopper bolt at an angle of 60 on turning back counterclockwise from LOCK position. Unless otherwise specified, tightening torque of bolt-nut to conform to KES 04.123. l/ Method of assembling U-joint. (Cf. 2): 7-1)Assemble lever (42C-40-12450) at right angle from direction of slit of pilot valve (42C-40-12550). 7-2)Turn lever toward fore-and-aft and assemble U-joint assy (42G40-12470) so that grease-nipple turn in the direction as shown.
8.
2.
3.
Method of auto correction of offset angle of lever and frame potentio (0 & *) (Calibration): 8-1)Straighten vehicle and J/S lever (42C-4012310). (Direction may be desided at a guess.) 8-2) Put steering lock lever on LOCK position (Lower side). When arm-rest situated at storage position (most backward), slide arm-rest at forward optional position. 8-3) Start engine and keep low-idling. 8-4)Slide J/S console in the storage position (most backward). Switch (42A-06-15140) go on. (Cf. A-A) 8-5) Put steering lock lever on FREE position (Upper). 8-6)Calibration ends normally if it sounds PiPi-Pi after 1 second. Note: During operation 1 to 6, do not move steering lever. If calibration ends abnormally, check assembling angle of potentio (0 & Ir). And, restart calibration.
4.
5.
6.
7.
WA1 200-3
53s*%I&
ik3XZf~Assy BRAKE SYSTEM Assy
ik-+>X%Assy(1/2) BRAKE SYSTEM Assy (l/2)
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pin head 3 to 5 times with copper head ham16. To assure contact on each contact surface, repeat step 15 three times. Then, tighten bolts @ and @ with torque M36: 2,450 - 3,040 Nm {250 - 310 kgm} and M45: 4,510 - 5,490 Nm I460 - 560 kgm} again. 17. Remove all bolts @,. Measure clearance between retainer and frame at 3 positions on circumference using thickness gauge and calculate average clearance value. Use shims so that average clearance is 0.08 to 0.18 mm. In this case, total thickness of shims must not exceed any measured clearance. 18. Keeping rear frame not to slide. Remove bolts @ and @ and set shim adjusted in step 17. 19. Perform steps 15 and 16. 20. Remove bolts @ and @ one after the other, apply Locktite #262 and tighten them with specified torque. (Degrease fully the tapped thread.) 21. Perform steps 15, 16 and 20 for upper pin bolts (01010-62485). In this case use tightening torque for M20 in steps 15 and 16. 22. Remove jack from under rear frame lower hinge. . Apply sufficient grease inside of bearing when assembling. . Supply grease into upper hinge and lower hinge shafts and steering hinge until grease exude from dust seal after assembling. Adhesion procedure (rear axle support bushing assembling procedtire.) 1. Remove dirt and oil with cleaning liquid etc. 2. Clean bushing contact surface with cloth soaked with primer (428-99-80080). 3. After coating primer, apply instant adhesive (428-99-80070). within 5 minutes. (Primer will dry instantly.) * Apply adhesive of about 18 g to each bushing (42C-46-17140). (Slightly smaller than 0.01 g per contact area of 1 cm*) * Set time of adhesive is 30 to 60 seconds. Set time: Time from starting of adhesive to end of assembling bushing to axle support. 4. Press bushing quickly onto axle support. (Caution) Never mix adhesive and primer. 0 Rear axle support bushing disassembling procedure. 1. Insert blade end of knife and remove bushing and support throughout circumference. In this case, if it is difficult to peel them, handy torch to about 100C. 2. After removing bushing, apply peeling liquid (427-46-11890) to remained adhesive and wipe with cloth after 2 or 3 minutes. Unspecified tightening of bolts and nuts shall be in accordance with KES 04.123. 1 Impact wrench.
FRAME Assy(4/4) 0 t>sk>5sl&a7z%%m

16.
6.
Center hinge assembling procedure 1. Attach-seal to front and rear frames and retainer (42C-46-13210, 42C-46-13230) so that seal lip faces outside. (See section A-A) Lock front and rear frame seals with plate (42C-46-13340, 427-46-11330). 2. Press fit bearing cup (One side). Make sure that bearing cup contacts tightly to bottom. 3. Install a set of bearing cone and spacer. (Bearing is adjusted as a set. Never change combination) 4. Press fit bearing cup. 5. Install retainer with 6 retaining bolts placed equally at 60 for upper side and 10 bolts at 36O for lower side. Tighten bolts uniformly with the following torque. . Upper hinge bearing retainer: 137 Nm {14 kgm] + 10 % . Lower hinge bearing retainer: 441 Nm I45 kgm} f 10 % 6. Loosen bolts once. Then tighten them uniformly to torque specified in step 5. Measure clearance between retainer and front and rear frames at 4 positions equally places on circumference. And calculate average clearance value. Use shims so that average clearance is 0.08 to 0.18 mm. In this case, total thickness of shims must be not exceed any measured clearance. 7. Add shims adjusted in step 6 and install retainer with the following torque. . Upper hinge 824 - 1,030 Nm (84 - 105 kgm) for each of 6 bolts . Lower hinge 2,450 - 3,040 Nm {250 - 310 kgm) for each of 10 bolts 8. Press fit bushing (42C-46-13320, 42C-46-13330) to front frame. 9. Install bushing @ into rear frame lower hinge. 10. Install bushing (42C-46-13120) into rear frame upper hinge. 11. Install retainer (42C-46-13110) onto upper pin. Bolt @: Tightening torque: 824 - 1,030 Nm {84 - 105 kgm) 12. Install front frame between rear frame hinge and insert upper pin. Bolt 0: Tightening torque: 824 - 1,030 Nm I84 - 105 kgm} 13 Insert lower pin and bushing into lower hinge and install retainer. (See view Y) 14. Place jack under rear frame lower hinge. Keep front frame to contact firmly to bushing @ without clearance. 15. After tightening retainer bolts @ and @ of lower hinge with torque M36: 2,450 - 3,040 Nm (250 - 310 kgm) and M45: 4,510 - 5,490 Nm I460 - 560 kgm) respectively, tap lower
WA1 200-3
53?%#*mi
fj:- F&7FAssy GUARD & HOOD Assy
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WA1 200-3
30-l 11 0
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CWWO4918
WA1 200-3
30-113 0
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WA1 200-3
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79-93Nm (8. l-9.5kgn) BREATHER SET PRESS I'l-7FYb.E 0.14MPa (I. 4ke/cm')
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WA1 200-3
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30-l 16 0
WA1 200-3
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cwwo4922
WA1 200-3
30-117 0
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30-l 21 0
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cwwo4927
WA1 200-3
30-123 0
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7
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(16~20kgml
CWWO4928
30- 124 0
WA1 200-3
53f#*%Z
'I 7 I---i J i9Assy LIFT CYLINDER Assy
J 7 F -i I iYAssy(l/2) LIFT CYLINDER Assy(l/2)
cwwo4929
30- 126 0
WA1 200-3
T)l%*aE
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1.
Install U-packing, piston seal, rod dust seal, and O-ring, taking care not to damage them. Before assembling, clean each part. After assembling, cover piping ports and holes for pin to prevent entrance of dust. When inserting back-up rings for O-ring, warm them in water of approx. 50 to 60C and install under due pressure. Tighten bolts to conform to KES 04. 123. 1. Ensure that threaded portion of piston (707-3630013) and nut (01010-61670) are completely clean of all oil (grease). Apply hardener (Primer T manufactured by LOCTITE JAPAN CORP.) to each 6 places of threaded portion. Then apply 0.5 cc - 0.7 cc bonding agent (LOCTITE No. 262 manufactured by LOCTITE JAPAN CORP. or equiv.) on to T 6 places of piston screws and tighten bolt at torque of 245 - 309 Nm 125 - 31.5 kgm1. Then leave them for about 30 minutes (for the time of hardening the bonding agent). In the first operation after assembling the cylinder (including reassembling), deaeration of the cylinder shall be completely performed, particularly for the first 3 to 5 strokes, (extension and retraction) shall not load the set pressure of relief valve at the stroke ends. In transit, keep the assembly in most retracted condition.
2.
3.
4. 5.
6.
7.
WA1 200-3
30-127 0
53$3*4m
Sflli7i J i$Assy DUMP CYLINDER Assy
gi7j DUMP
J XfAssy(l/2) CYLINDER Assy(V2)
cwwo4930
30-128 0
WA1 200-3
DISASSEMBLY
AND ASSEMBLY
DUMP CYLINDER As.9
1.
Install U-packing, piston seal, rod dust seal, and O-ring, taking care not to damage them. Before assembling, clean each part. After assembling, cover piping ports and holes for pin to prevent entrance of dust. When inserting back-up rings for O-ring, warm them in water of approx. 50 to 60C and install under due pressure. Tighten bolts to conform to KES 04. 123. 1. Ensure that threaded portion of piston (707-3636030) and nut (01010-62085) are completely clean of all oil (grease). Apply hardener (Primer T manufactured by LOCTITE JAPAN CORP.) to each 6 places of threaded portion. Then apply 0.5 cc - 0.7 cc bonding agent (LOCTITE No. 262 manufactured by LOCTITE JAPAN CORP. or equiv.) on to T 6 places of piston screws and tighten bolt at torque of 490 - 608 Nm {50 - 62 kgm1. Then leave them for about 30 minutes (for the time of hardening the bonding agent). In the first operation after assembling the cylinder (including reassembling), deaeration of the cylinder shall be completely performed, particularly for the first 3 to 5 strokes, (extension and retraction) shall not load the set pressure of relief valve at the stroke ends. In transit, keep the assembly in most retracted condition.
2.
3.
4. 5.
6.
7.
WA1 200-3
30-129 0
OIL COOLER
PROCEDURE FOR DISASSEMBLY AND ASSEMBLY OF MESABI OIL COOLER ASSEMBLY

Outline
1. General locations of oil cooler assembly
WA1200-3
30-131
6
OIL COOLER
30-132
6
W1200-3
OIL COOLER
2. Specifications, points The overall dimensions are extremely large: approximately length 2162 mm x width 2880 mm x depth 143 mm. The total number of tubes is 912. The tubes have a top-bottom two- stage structure and there are four tubes to each line. 1) When mounted on the machine, it is difficult to pinpoint the location of any leakage. It is only possible at the front face at places where there are no ribs. 2) There is a top-bottom two-stage structure. To remove the tubes at the bottom (bottom core), first remove the tubes at the top (top core), then remove the tubes at the bottom. (Even if the top retainer clip is removed, it is still difficult to move.) When assembling, assemble the tubes at the bottom first, then assemble the tubes at the top. For the above reasons, carry out repairs or replacement when mounted on the machine only at the front where it easy. For other locations, take the machine to the repair shop and set the machine horizontal.
3. Tool list for disassembly and assembly Component Symbol A B Disassembly and assembly of oil cooler assembly C D E F Part No. 793-803-1110 793-803-1130 793-803-1120 799-301-1600 793-803-1150 793-803-1160 Part name Support installer Tube installer Breaker tool Air leak checker Flange Flange Qty 1 1 1 1 1 1 Checking for leakage of air from core Removal, installation of core Details of operation
4. Supply parts list No. 1 2 3 4 5 6 Note: Part No. LM35780 LM63377 LM33567 LM33083-107 LM123-10-4200 LM48622 Part name Rubber seal Copper washer Tube retainer Air baffle ITS tube Tube support Qty 1,824 2,736 912 2 912 912 Remarks
The pressure is high, so a blind plug cannot be used. For this reason, no blind plug is available as a supply part.
WA1200-3
30-133
6
OIL COOLER
DISASSEMBLY OF MESABI OIL COOLER ASSEMBLY

Preparatory work 1) Wash the oil cooler assembly with a hot water washing machine. Turn it over and wash it from the opposite side also. Pressure: Max. 1200 PSI, 8.3 MPa {Max. 84.4 kg/cm2} Water temperature: Max. 180 F {Max. 82 C} Do not use steam.
2) After completing the washing, blow with air to completely remove any water.
3) Set the oil cooler assembly on a horizontal workstand. To make it possible to put objects on top of the oil cooler, spread cardboard or a wooden board on top of the oil cooler. If it is necessary for a worker to get on top when carrying out the work, put a strong wooden board on top of the oil cooler to prevent any excessive force from being applied to the tubes or fins.
Disassembly
When removing all the tubes, first remove the two lines at the front face, then turn the oil cooler assembly over and remove the two lines from the rear face. 1. Remove the support bars. Before removing the support bars, make counter marks to show the position when assembling.
30-134
6
W1200-3
BOTTOM DUMP OIL CYLINDER COOLER
2. Removal of tubes When removing the tubes, start from the top core. 1) Use pliers to grip the tubes in the retainer clip.
2) To clean, blow with air and wipe off any dirt.
3) When removing the tubes, move the copper washer down towards the fins to prevent any resistance.
4) To make it easier to remove the tubes, coat the top seal, bottom seal, and area around the tube support with lubricating oil.
WA1200-3
30-135
6
OIL COOLER
5) If the tube and rubber seal have stuck together and the tube is difficult to remove, use breaker tool C to move the tube and make it easier to remove.
6) Using tube installer B, remove the tube from the bottom seal. Set the round portion of the tube installer parallel to the tube fins, put the lower jaw in contact with the plate of the center tank, and tighten the handle. 1: Position to put round portion in contact at first (after pushing the fins with the round portion and removing slightly)
7) The tube cannot be removed in the one movement, so insert the round portion of the tube installer at the side of the copper seal and tighten the handle until the tube end is removed. 2: Position to put round portion in contact for second time
After carrying out the procedure in Steps 6) and 7), check that the connection of the tube support has been completely removed.
30-136
6
W1200-3
OIL COOLER
8) If the tube is stiff and does not move, use tube installer B and support installer A together when removing. When the spigot joint portion comes out completely, stop pushing. If it moves too much, the tube support may contact fins and bend them, so be careful not to push too much.
9) Remove the tube. When removing the tubes from the top seal, be sure to remove in a parallel direction and be careful not to damage the tube end or cause kinks.
10) In the places where the square rib of the oil cooler is, it is not possible to use the tool properly as it is, so use breaker tool C to change the angle of the tube fins 90 before removing.
11) Grasp of the tip of the rubber seal with finenosed pincers and pull out.
3. After completing disassembly of the top two stages, turn over and repeat the procedure to disassemble the bottom two stages.
WA1200-3
30-137
6
OIL COOLER
ASSEMBLY OF MESABI OIL COOLER ASSEMBLY

Preparatory work Wipe with a cloth or blow with air to clean the surface and inside of the holes of all parts.
Assembly
1. Installation of tubes 1) Install the rubber seal by hand. If it is cold and the rubber seal is stiff, warm it up in hot water before installing. An oil film will cause leakage of oil, so do not use lubricating oil on the seal. Tap with a flat hammer to bring portion a of the rubber seal into tight contact.
If the rubber seal is concave as shown in the figure on the right after it is inserted, it has been inserted too far and the inside diameter has become smaller. When the tube is inserted, force will be brought to bear on the seal and it will be damaged, so be extremely careful not to insert it too far when installing.
2) Coat the inside surface of the rubber seal and end of the tube thoroughly with oil.
30-138
6
W1200-3
OIL COOLER
3) Coat the tube support thoroughly with oil also. 4) Check that the copper washer has entered both ends of the tube. Top end: 2 Bottom end: 1 When inserting vertically on the machine, to prevent the copper washer at the bottom end from falling out, insert just before inserting the tube into the bottom seal.
5) Align the top end of the tube with the position of the hole in the rubber seal, then insert.
6) Check the position of the tube support.
7) Align the bottom end of the tube with the position of the hole in the rubber seal and insert it slightly by hand.
WA1200-3
30-139
6
OIL COOLER
8) Insert the tube support by hand until just before the meshing part enters. If the tool is used to insert when the tube and rubber seal hole are not aligned, the rubber seal will be in the same condition as when it is pushed and inserted too far. This will cause damage to the rubber seal, so do not push it in by force.
9) Using tube installer B and support installer A, insert the tube until the copper washer is seated completely against the end face of the rubber seal.
10) Using pliers, install the retainer clip between the copper washers.
Align the position of the tabs of the retainer clip to prevent the air from escaping. (To prevent reduction of the cooling effect) When disassembling partially, if the position of the air buffer is moved, return it to its original position when assembling.
30-140
6
W1200-3
OIL COOLER
11) If the position of the tube support is not correct, the support bar cannot be assembled, so use breaker tool C to align the position of the tube support.
12) If the tube is bent for some reason, use breaker tool C to straighten it.
13) At the corner portion, if there is a rib, it is extremely difficult to carry out the work, so be extremely careful when aligning the position of the holes and inserting. Always carry out the work with two workers and use bright lighting.
14) At the corner portion, assemble four lines of tubes together. After completing the assembly of the bottom tubes, assemble the top tubes.
WA1200-3
30-141
6
OIL COOLER
2. Installing support bar After installing at the front face, align the counter marks made during disassembly and install the support bars. 3. Using the lifting hook, turn the oil cooler over and repeat the same procedure to assemble the two lines on the opposite side.
Pressurizing test
1. Install flange E to the oil cooler outlet port. 2. Fit flange F to the oil cooler inlet port, then install air leak checker D. 3. Apply air pressure and maintain it. Air pressure: 0.88 1.03 MPa {9.0 10.5 kg/cm2} Coat with soapy water to check that there is no leakage of air at the jig portion. 4. Disconnect the basic pressure hose for the air. 5. Check that there is no drop in the air pressure for one hour. If the air pressure goes down, coat with soapy water and check for the sound of air leakage, or use a bath with clean water to pinpoint the location of the air leakage.
30-142
6
W1200-3
40
MAINTENANCE
STANDARD
Engine mount ............................................... 40- 2 Transmission mount.. ................................. 40- 4 Damper.. ....................................................... 40- 6 Torque converter, transmission, brake cooling and brake pump .......... 40- 7 Input transfer . PTO ..................................... 40- 8 Modulated clutch ......................................... 40-10 Torque converter.. ...................................... 40-I 1 Transmission ............................................... 40-12 Transfer ........................................................ 40-16 Main relief, torque converter relief valve ............................................ 40-18 Torque converter regulator valve ............... 40-20 By-pass fill valve .......................................... 40-21 By-pass fill valve and by-pass drain valve .............................. .40-22 ECMV ............................................................. 40-23 Lubricating oil relief valve.. ........................ .40-25 Drive shaft.. .................................................. 40-26 Center support.. .......................................... 40-27 Differential.. .................................................. 40-28 Final drive .................................................... 40-32
Axle mount .................................................. 40-34 Center hinge pin.. ....................................... 40-36 Steering pump.. .......................................... 40-38 Switch pump ................................................ 40-39 Steering demand valve .............................. .40-40 Diverter valve ............................................. 40-42 Steering cylinder mount.. .......................... 40-43 Emergency steering pump ........................ 40-44 Brake valve .................................................. 40-45 Slack adjuster ............................................. 40-47 Brake.. ........................................................... 40-48 Parking brake ............................................... 40-50 Work euipment pump No. 1 ...................... .40-52 Work euipment pump No. 2 ....................... 40-53 PPC valve ..................................................... 40-54 PPC relief valve ........................................... .40-56 Pump control relief valve .......................... 40-57 Main control valve ....................................... 40-58 Hydraulic cylinder ........................................ 40-60 Bucket positioner and remote positioner .................................. 40-63 Bucket linkage .............................................. 40-64
WA1 200-3
40-l
MAINTENANCE
STANDARD
ENGINE MOUNT
ENGINE MOUNT
n n
i56* 6koml
SWWO4865
40-2
WA1 200-3
MAINTENANCE STANDARD
TRANSMISSION MOUNT
TRANSMISSION
MOUNT
__ zB-0
A-A SWWO4666
40-4
WA1 200-3
MAINTENANCE
STANDARD
TRANSMISSION
MOUNT
--r---r------ ,---,-=jqpqy
A3~_.____________
SWW04667
Unit: mm
No.
Check item
Criteria
Remedy
Clearance between trunnion torque converter case
and
Standard size Shaft 320 -0.125 -0.214 0 -0.035 +0.123 +0.083
Tolerance Standard clearance Hole +0.089 0 +0.035 0 +0.089 0 0.125 0.303 0 - 0.070 -0.123 -0.006 Clearance limit
Replace
Clearance between O.D. of shaft and I.D. of rubber cushion Clearance between O.D. of rubber cushion and I.D. of bracket hole Thickness of mount shim
90
125
Standard shim thickness: 1.5 mm (parallelism of coupling mating joint of transmission output shaft and sensor of sensor pin: Max. 0.5 mm)
WA1 200-3
40-5
MAINTENANCE
STANDARD
DAMPER
DAMPER
~0.45*0.15ksnl
4.4* 1.4Nm 1.4 * 2.4Nm I0.75*0.25kPml
279*29Nm
~28.5*3.0kml
279*29Nm {28.5h 3.0kml
__j__-_ ,i_-_
, c ii
/
112*9.8Nm 111.5* l.Okrrml
il
1 ____ __i
111.5* l.Okoml SJWO4868
Unit: mm
No. -
Check item
Criteria
Remedy
I
Clearance shaft between bearing and
120 Clearance housing Clearance and shaft between bearing and 215 between inner body
+0.018 +0.003 0 -0.030 +0.018 +0.003 size
0 -0.020 -0.008 -0.037 +0.077 +0.047 Tolerance 0 -0.100 0 -0.100 0.091 - 0.261
-0.038 -6.003 -0.037 0.022 0.029 0.074 Repair
2 3
0.025 Replace
120 Standard
0.1
limit
Wear
of surface
in shaft and oil seal 150 I I -0.160
5 6
Wear seal
of surface
in sleeve and oil 180
-0.160
Backlash
of spline
WA1 200-3
MAINTENANCE
STANDARD
TORQUE CONVERTER, TRANSMISSION, BRAKE COOLING AND BRAKE PUMP
TORQUE CONVERTER, AND BRAKE PUMP 4 2
TRANSMISSION,
BRAKE COOLING
SWWO3285 Unit: mm No. Check item Model SARl4) 200 1 Side clearance SARl4) 200 SAR(3) 71 SAR(2) 28 SARl4) 200 Clearance between inside diameter of plain bearing and outside diameter of gear shaft SARI41 200 SARl3) 71 SARl2) 28 Model SARl4) 200 3 Insertion depth of pin SAR(4) 200 SARl3) 71 4 Model Revolution tram) Rotating torque of spline shaft SAR(2) 28 1 I
I
Criteria Standard clearance Clearance limit
Remedy
0.14 - 0.19 0.14 - 0.19 0.10 - 0.15 0.10 - 0.15 0.06 - 0.14 0.06 - 0.14 0.06 - 0.149 0.06 - 0.125
I
0.22 0.22 0.19 0.19 0.20 0.20
Replace 0.20 I
I
0.20
( Standard size 1
14 I3 13 -
Tolerance l.5 0 -0.5
1 Repair limit
1
I
I
1
4.5 O
-
I-l
I
29.4 - 48.1 Nm f3.0 - 4.9 kgm}
Discharge Oil: EOlO-CD Temperature: 45 - 55C
2,000
SAR(2) 28
20.6 {210)
49
43
WA1 200-3
40-7
MAINTENANCE
STANDARD
INPUT TRANSFER - PTO
INPUT TRANSFER
. PTO
All IHt
9JBOO110
40-8
WA1 200-3
MAINTENANCE
STANDARD
INPUT TRANSFER - PTO
Unit: mm
Standard size
0.15 - 0.32
WA1 200-3
40-9
MAINTENANCE
STANDARD
MODULATED CLUTCH
MODULATED
CLUTCH
110.3*12.3Nm II
1,l)cI 1 rlEl,__l
,*c,,,
353*39.2Nm
93800111
Unit: mm
No
seal ring contact
Total assembly
thickness
of 19 discs
WA1 200-3
MAINTENANCE
STANDARD
TORQUE CONVERTER
TORQUE CONVERTER
277* 31. 9Nm (26.25 i3.25ko.I \
53.5*4.9Nm (5.5*0.5knml I i
277* 31. 9Nm (26.25 * 3.25 kom)
66.2* 7.35Nm (6.75* 0.75kom 1
9JBOO112
Unit: mm
No.
Check item
Criteria
Remedy
I
Standard 1 inside diameter of seal ring contact surface of retainer 0180 2 Inside diameter of seal ring contact surface of sleeve Width size Tolerance +0.040 0 +0.035 0 0 -0.1 *o.
I
Repair limit Plate with hard chromium or replace.
180.5
085
85.1
Wear of seal ring of retainer
5.95
5.45
Thickness 4 5 Thickness of retainer Thickness of plate
6.3
5.67 Replace
20.1
8.5
32
eo.1
31.5
WA1 200-3
40-l 1
MAINTENANCE
STANDARD
TRANSMISSION
TRANSMISSION
--_-------_
110.3*12.3Nm ~ll.25*1.25knmI
110.3*~2.3Nm 1.25*1.25kaml (1
110.3~12.3Nm (11.25*1.25kPml 9JBOO113
40-12
WA1 200-3
MAINTENANCE
STANDARD
TRANSMISSION
Unit: mm
No.
Check item
Criteria
Remedy Repair limit Installation load 322.6 N (32.9 kg} 456.0 N l46.5 kg} 304.0 N t31.0 kg} 358.9 N l36.6 kg}
I
Standard Free length 133
size Installation load 379.5 N 138.7 kg} 536.4 N 154.7 kg) 357.9 N 136.5 kg} 42.7 N t43.0 kg}
I I
No. 1 clutch spring
(6 PCS.)
Installation length 94
Free length 125.02
No. 2 clutch spring
(6 PCS.)
168
106
157.92
No. 3 clutch spring (6 PCS.)
68.8
55
64.67 53.49
No. 4 clutch spring
(6 PCS.)
56.9
!
43 8.5
No. 5 clutch spring
(3 PCS.)
9.5
1,697 N 1173.0 kg} Tolerance
8.93 Repair
1.443 N 1147.1 kg} limit
Standard Total assembly thickness of 8 discs and 7 plates for No. 1 clutch
size
83.8
kO.39
+0.41
79.5
Total assembly thickness of 9 discs and 8 plates for No. 2 clutch Total assembly thickness of 5 discs and 4 plates for No. 3 clutch Total assembly thickness of 4 discs and 3 plates for No. 4 clutch I Total assembly thickness of 9 discs and 8 plates for No. 5 clutch
95.0
90.2
50.2
kO.30
47.5 Replace
9
10 11 12
39.0
~0.26
36.9
77.6
20.41
72.8
Thickness
of No. 1 - 4 clutch disc
5.4
kO.1
4.87
Thickness
of No. 5 clutch disc
4.8
ao. 1
4.27
13
Thickness
of No. 1 - 4 clutch plate
5.8
+o. 1
5.22
14
Thickness
of No. 5 clutch plate
4.3
+O.l
3.87
Wear 15
of seal ring of input shaft
Width
-0.01 -0.03 20.1 -0.01 -0.03 eo.12
2.7
transmission
Thickness
3.5
3.35
Wear 16
of seal ring of output
Width
3.6
transmission shaft
Thickness
4.6
4.45
Wear 17
of seal ring of
Width
-0.01 -0.03 +0.15
5.5
No. 5 clutch Thickness 6.8 6.65
WA1 200-3
40-l 3
MAINTENANCE
STANDARD
TRANSMISSION
Unit: mm No. 18
19
Check item Backlash between No. 1, 2, 3 gear and planetary pinion sun
Criteria 0.16 - 0.40 0.18 - 0.43 0.19 - 0.47 0.17 - 0.39 0.18 - 0.44 0.35 - 0.80 (Both sides)
Remedy
I
I
Backlash between No. 1 planetary pinion and inside teeth of ring gear Backlash between No. 2, 3 planetary pinion and inside teeth of ring gear
I
I
I I Replace
20 21 22 23
Backlash between No. and planetary pinion
sun gear
Backlash between No. 4 planetary pinion and inside teeth of ring gear Side clearance of planetary pinion
40-14
WA1 200-3
MAINTENANCE
STANDARD
TRANSFER
TRANSFER
277 *31.%m -{Z&25* 3.25kml
17*147.lNm 1u5f15 km1
2207*147.lNm {225*15 kern1
,_*,.
(24.;
9JBOO114
40-l 6
WA1 200-3
MAINTENANCE
STANDARD
TRANSFER
Unit: mm
No.
Check item
Criteria
Remedy
Standard 1 2 3 Outside diameter of oil seal contact surface of rear coupling Backlash between idler gear Backlash between put gear input gear and 0140 Outside diameter of oil seal contact surface of front coupling 0140
size
Tolerance +0.052 +0.027 +0.052 +0.027 0.20 - 0.44
Repair
limit
139.8
139.8
4 -
idler gear and outI Standard size fii
0.20 - 0.44
I
i:ta$dr;e
I
1nte;znce
Interference bearing
between
input gear and
0140
+0.078 +0.060
0 -0.025
0.060 0.103
0.060 0.103
Replace
Interference between input bearing and transfer case Interference bearing between
gear
idler gear and
Interference between idler bear bearing and transfer case Interference and bearing between output shaft 0120 +0.045 +0.023 0 -0.030 +0.052 +0.027 0 -0.030 0.023 0.065 -0.016 0.060 0.027 0.077 -0.016 0.060 0.023 0.065 -0.016 0.060 0.027 0.077 -0.016 0.060
9 10
Jo20 -0.014 -0.060 0 -0.025 -0.014 -0.060
Interference between front bearing and transfer case Interference bearing between
output
0215 0140
spacer
and
Interference between rear output bearing and parking brake cover
0210
WA1 200-3
40-17
MAINTENANCE
STANDARD
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
MAIN
RELIEF, TORQUE CONVERTER
RELIEF VALVE
4
A-A
66.2*7.35Nm *0.75koml (6.75

\
9JB00115
40-l 8
WA1 200-3
MAINTENANCE
STANDARD
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
Unit: mm
No -
Check item
Criteria
Remedy
Clearance between main relief valve spool and valve body
2 3 4
Clearance between spool and piston
main relief valve
Clearance between torque converter relief valve spool and valve body Clearance between torque converter relief valve spool and piston
Valve spring of main relief valve (Outside)
Valve spring of main relief valve (Inside) 7 Piston spring Valve spring lief valve Piston spring lief valve of main relief valve of torque converter re-
a
9
of torque
converter
re-
WA1 200-3
40-19
MAINTENANCE
STANDARD
TORQUE CONVERTER
REGULATOR
VALVE
49*4.9Nm 5 * 0.5 kern)
A-A
Unit: mm
No -
Check item
Criteria
Remedy
I
Tolerance Clearance between torque converter regulator valve spool and valve body Standard size Shaft Hole 0.035 0.061 0.020 0.051 Repair Installation load Free length 155.6 Valve spring of torque converter reguStandard clearance
I
Clearance limit
040 Clearance between torque converter regulator valve spool and piston
-0.035 -0.045 -0.020 -0.030 Standard size
+0.016 0 +0.021 0
0.081
022
0.071
limit Installation load 156.9 N 116.0 kg}
Replace
Valve spring of torque converter lator valve (Outside)
regu-
Free length
Installation length
4 5
~
Piston spring of torque converter
40-20
WA1 200-3
MAINTENANCE
STANDARD
BY-PASS FILL VALVE
BY-PASS FILL VALVE

(For forward clutch and 1st speed clutch)
39. 2 * 9.6 Nm (4 f lkoml
4. 9 f INm {O. 5 f 0. lkom) 9JB00117
No.
Check item
Criteria
T
~;Z Clearance limit 0.035 0.056 0.076
Unit: mm Remedy
Clearance between by-pass fill valve spool and valve body
Standard size
&I
040
-0.035 -0.045 Standard size
+O.Oll 0
I
Installation load 63.7 N (6.5 kg} 33.3 N (3.4 kg}
Repair Free length 32.4
limit Installation load 60.8 N f6.2 ka} 31.4 N 13.2 kg}
Replace
Return spring (Outside)
of by-pass
fill valve
Free length 33.4
Installation length 17.3
Return spring of by-pass fill valve (Inside)
38.2
17.3
37.1
WA1 200-3
40-21
MAINTENANCE
STANDARD
BY-PASS FILL VALVE AND BY-PASS DRAIN VALVE
BY-PASS FILL VALVE AND BY-PASS DRAIN VALVE

(For reverse clutch)
4.9 f 1 Nm (0.5*0.1 koml
? t1;
tL,8,b
4.9 * f 1 Nm (0. 5 0. I knm1
9JBOOl18
Unit: mm
No. -
Check item
Criteria
Remedy
Clearance between by-pass spool and valve body
fill valve
2 -
Clearance between by-pass valve spool and valve body
drain
Replace 3 Return spring (Outside) of by-pass fill valve
Return spring of by-pass fill valve (Inside) Return spring of by-pass drain valve
40-22
#Al 200-3
MAINTENANCE
STANDARD
ECMV
ECMV
(For modulated clutch)
30. 9 *3. 43 Nm 13. 15 *O. 35kam)
9JBOOl 19
No
Check item Criteria
Unit: mm Remedy
Standard 1 Clearance between flow sensor valve spool and valve body
3 Replace
Spring
for fill switch
5 6
WA1 200-3
40-23
MAINTENANCE
STANDARD
ECMV
(For transmission)
30. 9 *3. 43 Nm (3. 15 *O. 35komI
9JBOO120
Unit: mm
No. -
Check item
Criteria
Remedy
Clearance between flow sensor valve spool and valve body 019 -0.035 -0.045 -0.035 -0.045 -0.035 -0.045 Standard Free length 15 size Installation load 41.7 N (4.25 kg} 4.9 N (0.5 kg} 10.6 N Il.08 kg} +0.013 0 +O.Oll 0 +0.012 0 0.035 0.058 0.035 0.056 0.035 0.057 0.064
2 Clearance between oressure valve spool and valve body Clearance between pressure valve SDOOI and oiston contra 014 contra 05.7
0.062
0.063 Replace
Repair Free length 14.7
limit Installation load 37.6 N c3.83 kg} 4.4 N CO.45 kg} 9.5 N IO.97 kg}
Spring
for fill switch
Return spring of flow sensor valve Return valve spring of pressure control
33.5
29.5
32.8
16.2
11.7
15.9
40-24
WA1 200-3
MAINTENANCE
STANDARD
LUBRICATING OIL RELIEF VALVE
LUBRICATING
OIL RELIEF VALVE
66.2*7.35Nm 1 6.75i 0.75 kam]
A-A
SJBOO121
Unit: mm
No.
Check item
Criteria
Remedy
Clearance between lubricating oil relief valve spool and valve body
Standard size Shaft
Tolerance
Standard clearance Hole

I
Clearance limit
I
022
+0.013 0
0.035 0.058
0.078 Replace
Repair
limit
Valve valve
spring
of lubricating
oil relief
,I:
40-25
WA1 200-3
MAINTENANCE
STANDARD
DRIVE SHAFT
DRIVE SHAFT
385.4*41.2Nm (39.3*4.2koml
'277*31.4Nm t28.3*3.2bd
176.5*19.6Nm (18.0*2.0ksm) 176.5*19.6Nm ~l8.0*2.0hl
1 I I
fl
367.8*24.5Nm {37.5*2.5kPmI 367.8*24.5Nm (37.5*2.5ksml 367.8*24.5Nm ~37.5~2.5knml
367.8*24.5Nm
385.4*41.2Nm (39.3+4.2kml
213.8*6.9Nm (21.8*0.7ksml SJWO4869
40-26
WA1 200-3
MAINTENANCE
STANDARD
CENTER SUPPORT
CENTER SUPPORT
Unit: mm
No.
Clearance bearing
between
case and
2 3 4
Wear
of oil seal surface
WA1 200-3
40-27
MAINTENANCE
STANDARD
DIFFERENTIAL
DIFFERENTIAL
(I/Z)
A-A
40-28
WA1 200-3
MAINTENANCE
STANDARD
DIFFERENTIAL
No
Unit: mm
Clearance of bearing outer race in differential gear assembly
shaft bearing
6 7 _ 8
11 12 13 14 15 16 17 18 Standard thickness of shims for differential cage 1.3 Backlash of differential gear Preload of pinion bearing Preload of side bearing Rear face runout of bevel gear 0.31- 0.40 7.8 - 35.3 N {800 - 3,600 kg} Adjust 15.7 - 31.4 N {l,SOO - 3,200 kg1 0.13
WA1 200-3
MAINTENANCE
STANDARD
DIFFERENTIAL
DIFFERENTIAL
(2/2)
176.5* 19.6Nm (18.0+2.0koml
1715*195Nm (175*20kPml
277*31.4Nm (28.3* 3.2bmJ
927* 103Nm (94.5* 10.5koml
2746 i294Nm ~260-t30ko.1
1715 *195Nm il75i20kml
927* 103Nm 194.5* IO.5kPml SJWO4872
Unit:
mm
No.
Check
item
Criteria
Remedy
Standard 1 Thickness of side gear washer 9.0 2 3 Thickness sleeve Wear of pinion gear washer
size
Tolerance
Repair
limit
8.5 Replace
10.8 0 -0.100
10.3
of oil seal surface
160
159.84
40-30
WA1 200-3
MAINTENANCE
STANDARD
FINAL DRIVE
FINAL DRIVE
277131.4Nm ~28.3~3.2ksmI
277*31.4Nm (28.3*3.2ksml
277*31.4Nm ,(28.3*3.2bml
1715*195Nm -~175*2Okaml
12
152*24.5Nm ~15.5~2.5kivnl
i5
IO
II
13
4
SJWO4873
40-32
WA1 200-3
MAINTENANCE
STANDARD
FINAL DRIVE
Unit: mm
No.
Check item
I
Standard size Shaft +0.018 0 0 -0.025 +0.041 +0.026 +0.025 0 +0.127 +0.076 +0.076 0 -0.020 -0.060 +0.051 0 size
Criteria
Remedy
Tolerance , Clearance between and bearing planetary shaft
Standard clearance Hole 0 -0.020 -0.035 -0.075 +0.025 0 -0.005 -0.051 +0.051 0 -0.050 -0.130 +0.051 0 -0.044 -0.114
Clearanc limit
90 2 3
-0.038-0.075 -0.010 -0.041 -0.001 -0.076 -0.005 -0.127 -0.025 -0.206 -0.050 -0.020 0.111
Clearance between and bearing
planetary
gear
155
Clearance between I and bearing
planetary
shaft I
99.982
Clearance between 4 I and bearing 5 Clearance between I and bearing
planetary
gear
190.5
ring gear hub I wheel hub and
479.425
Clearance bearing
between
679.45
Clearance between and bearing Clearance bearing between
axle
housing hub and
409.575
Replace wheel * 546.1 -0.165 -0.044 Repair limit
Standard 9 Thickness of retainer hub mount at ring gear 40
Tolerance
to.1
39.6
Standard IO Backlash between sun gear planet gear and
clearance
Clearance
limit
0.25 - 0.66 planet gear and
11 12
Backlash between ring gear Backlash between sun gear Backlash between ring gear
0.28 - 0.83
planet
gear and
I
13 ,4
0.27 - 0.72
I I
2.4
planet
gear and
I
shim for
0.30 - 0.91
Thickness of standard wheel hub
WA1 200-3
40-33
MAINTENANCE
STANDARD
AXLE MOUNT
AXLE MOUNT
5000*490Nm ~510*50ksm~
5000*490Nm (510*50id
5000*490Nm ~510*50koml
19.6Nm 176.5-t ~l8.0*2.0hl
2746*294Nm (280~30koml
2746*294Nm (280~3Okp.l B-B SJW04874
40-34
WA1 200-3
MAINTENANCE
STANDARD
AXLE MOUNT
No Check item Criteria
Unit: mm
1
~ Remedy
Tolerance Standard size Shaft Hole Standard clearance Clearance limit
Clearance of shaft and hole (Front support side) (Before press-fit bushing)
540 2
Clearance of shaft and hole (Front support side)
+4.000 0 -0.076 -0.185
+0.175 0 +0.522 -0.345
-4.000 +0.175 0.270 0.707
530
1.6
(After press-fit bushing)

3
Clearance of shaft and hole (Rear support side) (Before press-fit bushing) Clearance of shaft and hole (Rear SUDDO~~ side) (After p&s-fit bushing)
540
+4.000 0 -0.076 -0.185
+0.175 0 +0.522 -0.345
-4.000 +0.175 -0.270 0.707 Replace 1.6
530
Standard Thickness of thrust washer 8
size
Tolerance
Repair
limit
kO.2
6 7
Thickness
of thrust
plate
53
-0.21 -0.35
Thickness
of rear bushing
-to.1
a -
Thickness
of front bushing
I I
20.1
WA1 200-3
40-35
MAINTENANCE
STANDARD
CENTER HINGE PIN
CENTER HINGE PIN
927*103Nm {94.5*10.5kml
(When adiustinQ with shim) 927*103Nm 194.5*10.5kml (Final value)
441*44Nm 145*4.5bml (When adjusting 'with shim) 2746 *294Nm 18 {260* 30koml (Fina I value)
53.9 15.52 A-A
17
Ii
B - B
5000*4QONm (510*50kaml
'2746*294Nm
(280*3Okml
sxwo4935
40-36
WA1 200-3
MAINTENANCE
STANDARD
CENTER HINGE PIN
No.
Check item
Unit: mm Criteria Remedy
Clearance between and bushing
lower
hinge pin
I
2 Clearance between and (small) spacer lower hinge pin 3 4 _ 5 and bearingbetween Clearance and (large) spacer between Clearance lower hinge pin
228.6 228.6
-0.079 -0.050 -0.050 -0.079
+0.078 0 +0.072 0
0.050 0.1570.050 0.151 1.0
I I I
228.6 228.6
-0.079 -0.050 -0.079 -0.050 -0.137 -0.056 +0.025 0
0 +0.025 0 +0.072 0 +o.oss -0.074 -0.126
0.1040.050 0.151 0.050 0.2360.056 -0.151 -0.074 1.0
I I I
lower
hinge pin
spacer (large) and bushing Clearance between lower hinge Clearance between front frame upper hinge bearing upper and rear frame Clearance between Clearance between and bearing hinge pin and
305.0
269.875
187.325
-0.079 -0.050 -0.050 -0.079 +0.025 0
0 +0.072 +0.025 0 -0.093 -0.150
0.1510.050 0.050 0.129
upper hinge pin 187.325 and 355.6
8 9 10 11
Replace Clearance between front frame lower hinge bearing -0.175 -0.093
bushing Clearance
between
rear frame
and
248 210
-0.079 -0.050 +0.26 +0.16 +0.260 +0.160 +0.242 +0.196 +0.325 +0.268 size
0 +0.072 +0.072 0 +0.081 0 +0.072 0 +0.089 0 Tolerance
0.1510.050 -0.260 -0.088 -0.260 -0.079 -0.242 -0.124 -0.325 -0.179 Repair limit
Clearance at press-fitted of upper hinge pin Clearance at press-fitted of lower hinge pin Clearance between bushing and frame Clearance between bushing and frame
part of seal
12
part of seal
310
13 14
lower hinge (upper) lower hinge (lower)
I I
250
I I
325
Standard 15 Height of lower hinge spacer (small) 177.2
*o. 1
16
Height of lower Thickness retainer
hinge spacer
(large)
220
to. 1
17
for lower hinge and
I
for lower hinge and
45
kO.8
I I
Adjust
18 19
Shim thickness retainer Shim thickness retainer Shim thickness retainer
I
for lower hinge and
3.0
I
for upper hinge and
2.52
2.62
WA1 200-3
40-37
MAINTENANCE
STANDARD
STEERING PUMP
STEERING PUMP
(HPF160 + 160)
66*6.9Nm {6.73~0.7kml
68.j* 9.81Nm i7.0* l.Obd
9JYOO286
40-38
WA1 200-3
MAINTENANCE
STANDARD
SWITCH PUMP
SWITCH PUMP
(HPV160 + HPF160)
34.3*4.9Nm ~3.5*0.5l@ml
24.5*4.9Nm ~2.5*0.5koml \
66*6.9Nm {6.73*0.7bml
l-----l
9JYOO287
WA1 200-3
40-39
MAINTENANCE
STANDARD
STEERING DEMAND
VALVE
--I
I
svwo3soo
A-A
40-40
WA1 200-3
MAINTENANCE
STANDARD
Unit: mm Remedy
Standard
size
Repair
limit
WA1 200-3
MAINTENANCE
STANDARD
DIVERTER VALVE
DIVERTER VALVE
A-A
SEW01614
Unit: mm
No.
Check item
Criteria
Remedy
Clearance
between
body and spool

I I I
I
40
+0.015 +0.007
0.020 0.030 Repair limit Replace
Spool spring
Free length 122.6
Installation length a4 54.5 57.5
Installation load 216.7 N 122.1 kg} 5.6 N IO.57 kg} 4.9 N {0.50 ka)
Free length 120.7 77.9 77.9
Installation load 205.9 N I21.0 kg} 5.3 N fO.54 kg} 4.6 N IO.47 kg)
3
4 Check valve spring
79.2 79.2
Check valve spring
40-42
WA1 200-3
MAINTENANCE
STANDARD
STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
A-A
SJWO4876
No.
Check item Criteria
Unit: mm Remedy
I
1 Clearance between mounting pin and bushing connection of steering cylinder rod and frame 160 Clearance between mounting pin and bushing at connection of steering cylinder bottom and frame
Tolerance
-0.043 -0.106
+0.025 0
0.131 0.043
1.0
Replace 3 Connection front frame of steering cylinder and 120 -0.25 O

I
135 +;
0 - 3.25
Connection of steering snd rear frame
cylinder
rod
120:.25
135+:,
Standard
size
Tolerance
Repair
limit
width
of spacer 7.0 to.5
WA1 200-3
40-43
MAINTENANCE
STANDARD
EMERGENCY STEERING PUMP
EMERGENCY STEERING PUMP

Model SAM131100 + 100
A-A
SWWO3661
Unit:
mm
No.
1
Clearance side plate
Check
item
Criteria
Remedy
Pump 1 between gear gear case and
model
Standard
clearance
Clearance
limit Replace
SAM(3)lOO I Clarance between inside diameter of plain bearing and outside diameter of gear shaft SAM(3)lOO size
0.10 - 0.15
I
0.19
0.020 - 0.043
0.075
Standard
Tolerance Replace
1 Rotating
torque
of spline
shaft
I
Pump model
13.7 - 23.5 Nm Il.4 Rerrtf:on .I-..., 2000
- 2.4 kgm} Standard discharge IO,,;\ lLilllllli 352 ltmlt cepalr '. F discharge Wmin) 312
Discharge Oil: EOlO-CD Temperature:
Pressure
45 to 55C
SAM(3)lOO
+ 100
1 ?0.6
MPa kg/cm? 210
WA1 200-3
MAINTENANCE
STANDARD
BRAKE VALVE
(RIGHT)
SWWO4877
Unit: mm
No. -
Check item
Criteria
Remedy
Clearance between pedal hole and bracket hole 10 10
!
-0.025 -0.075 -0.025 -0.075 size
I
+O.l 0 +O.l 0 Tolerance 0 -0.5
I
0.175 0.025 0.175 0.025
!
0.25
2 -
Clearance
between
roller and pin
0.25
Standard 3 Outside diameter of roller 30
Repair
limit
29.2 I Repair Free length 33 limit Installation load
Standard Free length 34 5 Control spring 46.3 46.0
size Installation load 4.6 N IO.47 kg) 11.8 N Il.2 kg} 60.8 N 16.2 ka1 17.7 N (1.8 kg} 16.7 N (1.7 kg}
Replace
Control
spring
Installation height 33.5
45.3
Return spring
86.2
58
78
7 8 -
Spring
17
16.5
16.2
Return
spring
31.5
19.5
28
WA1 200-3
40-45
MAINTENANCE
STANDARD
BRAKE VALVE
(LEFT)
7.3Nm 0.75kom
152*24.5Nm
~15.5*'2.5koml
Unit: mm
No. -
Check item
Criteria
Remedy
/
1 Clearance between pedal mount hole and bracket hole
St;$xd
shafoferHo,e
1 $eyici~
Clsa;;ce
10 2 Clearance between roller and pin 10
-0.025 -0.075 -0.025 -0.075 size
+O.l 0 +O.l 0 Tolerance 0 -0.5
0.175 0.025 0.175 0.025
0.25
0.25
Standard 3 Outside diameter of roller 30
Repair limit
29.2
Replace
Control
spring
Control
spring
46.3
34.3
45.9 N (4.7 kg} N 60.8 (6.2 kg} 16.7 N (1.7 kg1
45.3
Return
spring
86.2
58
78
Return spring
31.5
19.5
28
WA1 200-3
MAINTENANCE
STANDARD
SLACK ADJUSTER
SLACK ADJUSTER
55.9* 6.9Nm (5.7*0.7kml
1 I2*9.8Nm (1 1.5* l.Okml

SXW04878
No.
Check item Criteria
Unit: mm Remedy
Tolerance Standard size 1 Clearance between body and piston 55 Shaft -0.030 -0.076 Standard Free length 246 size Installation load 117.7 N I12 kg} 123.6 N 112.6 kg} Hole +0.074 0
Standard clearance
Clearance limit
0.030 0.150
0.250
Repair limit Free length Installation load
Slack adjuster
spring
3 -
Check valve spring
44.8
38
WA1 200-3
40-47
MAINTENANCE
STANDARD
BRAKE
BRAKE
i
I_------%_/
927i-98
Nm
SXWO4879
194.5* IO km1
40-48
WA1 200-3
MAINTENANCE
STANDARD
BRAKE
Unit: mm
No.
Check item Standard Free length 124.9 size
Criteria Repair Installation load 1,600 N 1163 kg) Tolerance Free length 123.0 limit Installation load 1,520 N f154.9 kg} Repair limit
Remedy
Return spring
Standard 2 Thickness of plate 3.1
size
kO.1
2.85
Thickness
of disc
6.7
eo.3
I I
6.2 Replace
Wear
of contact
surface
of oil seal
Wear of surface piston seal Wear of surface piston seal
in contact with 839.5 in contact with 864
I I
0
-0.230
+0.140 0
+0.140 0
I
Repair limit
I
Deformation plate of friction surface of Standard
Max. 0.5 Deformation disc of friction surface of Max. 0.7

L
WA1 200-3
40-49
MAINTENANCE
STANDARD
PARKING BRAKE
PARKING BRAKE
2207 f 147.INm (225 *I5 ken I
1 I
2207 * 147.1Nm (225 ~15 kernI
237. 8 f 31.9 Nm (24.25 f 3.25 kern)
9JBOO122
40-50
WA1 200-3
MAINTENANCE
STANDARD
PARKING BRAKE
Unit: mm
No
Check item Standard Free lenoth 113 size
Criteria Repair Installation load 2,444 N I249.2 kg} 1,313 N 1133.9 kg} Tolerance Free lenath 101.7 limit Installation load 2,200 N 1224.3 kg} 1,182 N 1120.5 kg} Repair limit
Remedy
No. 1 Clutch spring
(14 PCS.)
Installation lenath 77.4
No. 2 Clutch spring
(14 PCS.)
111
77.4
99.9
3 -
Total assembly thickness of 8 brake discs and 9 separator plates
Standard
size
61.6
-co.41
56.8 Replace
Thickness 4 Separator plate Distortion
4.0
kO.05
3.9
0.20
0.6
Thickness Lining groove depth (One side) Lining thickness (One side) 6 Load on wave spring (Height: 3.2 mm)
3.2
+0.08 +0.7 0 20.16 ~176.5 N {*I8 kg)
2.77
Brake disc
0.45
I
I
0.235
0.7 626.6 N 163.9 kg}
405 N 141.3 kg}
WA1 200-3
40-51
MAINTENANCE
STANDARD
WORK EQUIPMENT
HPV160 + 160
PUMP No. 1
66* 6.9Nm (6.73*0.7kp.l 24.5i4.9Nm ~2.5*0.5kPml
3.5Nm 30.5* ~3.11*0.36bml 4.9Nm 34.3* ~3.5*0.5lwnI
9JYOO288
40-52
WA1 200-3
MAINTENANCE
STANDARD
WORK EQUIPMENT
PUMP No. 2
WORK EQUIPMENT
HPV95 + 95
PUMP No. 2
24.554.9Nm
(3.5*0.5kp.l
34.3i4.9Nm
30.9*3.43Nm {3.15*0.35bml
66.2*7.35Nm 16.75*0.75kml
66.7*9.81Nm (7.0* l.O!all

9JYooza9
WA1 200-3
40-53
MAINTENANCE
STANDARD
PPC VALVE
PPC VALVE
SVWO3605
40-54
WA1 200-3
MAINTENANCE
STANDARD
PPC VALVE
Unit: mm
No.
Check item
I
Standard size
Criteria
Remedy
I
Installation load 5.4 N iO.55 kg} 21.1 N i2.15 kg} 33.3 N c3.4 kg) 14.7 N (1.5 kg} -
Repair Free length
limit Installation load
Centering spring (Bucket dump, boom
lower)
Free length 39.9
Centering spring (Bucket tilt, boom
raise)
56.7
34.5
Replace if damaged or deformed
Metering
spring
33.5
29.4
Return spring
26.2
17.5
WA1 200-3
40-55
MAINTENANCE
STANDARD
PPC RELIEF VALVE
PPC RELIEF VALVE
152 *24.5Nm ~l5.5*2.5k.m1
108 f 14.7Nm 1 2
i 11.0*1.5koml
39.2* l.ONm (4* lkml
34.3ik.SNm 13.5*0.5kml
SJWO4897
Unit: No. Check item Standard size Free length 44.5 2 Poppet spring 31.0 Installation length 32.5 25.5 Installation load 17.6 N Il.79 kg} 46.9 N c4.78 kg) Criteria Repair limit Free length Installation load
mm
Remedy
Main valve spring
Replace 13.7 N (1.4 kg} 37.4 N 6.8 kg1
WA1 200-3
MAINTENANCE
STANDARD
PUMP CONTROL RELIEF VALVE
PUMP CONTROL RELIEF VALVE
I 52 f 24.5Nm {15.5*2.5bml
108 f 14.7Nm (1 l.O* 1.5koml
39.2* l.ONm (4* Ibml
34.3+4.9Nm 13.5*0.5!Qml
SJW04897
No Check item Standard Free length 44.5 size Criteria Repair limit
Unit: mm Remedy
Installation load 17.6 N f1.79 kg} 36.9 N 13.77 kg}
Free length
Installation load 13.7 N il.4 kg} 29.5 N i3.0 kg}
I
Replace
Poppet spring
31.0
26.7
WA1 200-3
MAINTENANCE
STANDARD
MAIN CONTROL VALVE
MAIN CONTROL VALVE
152.0*24.5Nm
A-A
c-c
68.7*9.8Nm (7.0*I.Okaml
304+9.8lNm 131.0*I.Obml
B-B
D-D
E-E
9JYOO290
40-58
WA1 200-3
MAINTENANCE
STANDARD
MAIN CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Remedy
Spool return spring
2 3 4 5 6 7 6 Relief valve poppet spring Unloader valve spring Float selector valve spring Check valve spring Main valve spring Spool return spring Replace Spool return spring
WA1 200-3
40-59
MAINTENANCE
STANDARD
HYDRAULIC CYLINDER
HYDRAULIC
BOOM CYLINDER
CYLINDER
2450*250Nm (250*25kml SJWO4898
Unit: mm
No.
Check item
Criteria
Remedy
Clearance between rod and bushing
boom cylinder 0.084 0.369 0.471 0.641 0.471 0.641 Repair
240 Clearance mounting Clearance mounting between piston rod pin and bushing between cylinder pin and bushing bottom 240
-0.050 -0.122 -0.050 -0.122 -0.050 -0.122 size
+0.247 +0.034 +0.519 +0.421 +0.519 +0.421 Tolerance +0.2 0
0.669 Replace 1.0
240
1.0 limit
I I
Cylinder
bore
Standard
360
40-60
WA1 200-3
MAINTENANCE
STANDARD
HYDRAULIC CYLINDER
BUCKET
CYLINDER
2450*250Nm 1250*25kml
277* 32Nm (28.25*3.25kPml

SJW04899
No.
Check item
Criteria
I
Clearance between rod and bushing bucket cylinder Clearance limit
T
0.622
Unit: mm Remedy
2 Clearance mounting Clearance mounting between piston rod oin and bushing between cylinder pin and bushing bottom 1.0
Replace
3 -
1.0
Standard 4 Cylinder bore 300
size
Tolerance +0.2 n
Repair
limit
1
40-61
WA1 200-3
MAINTENANCE
STANDARD
HYDRAULIC CYLINDER
STEERING
CYLINDER
1150*120Nm ~117.5~12.5kem1
~18*2kml
176.5* 19.6Nm
SJWO4900
Unit: mm
Clearance between steering cylinder rod and bushing
Standard 4 Cylinder bore 225
size
Tolerance +0.20 0
Repair
limit
40-62
WA1 200-3
MAINTENANCE
STANDARD
BUCKET POSITIONER AND REMOTE POSITIONER
BUCKET POSITIONER AND REMOTE POSITIONER
2
17.2*2.5Nm (1.75*0.25kPml
A-A
-1
SJWO4901
Unit: mm No. Check item Criteria Remedy
Clearance of bucket positioner Clearance switch Clearance positioner of remote positoner
switch
3-5
3-5
Adjust
between bucket protector and switch
0.5 - 1
WA1 200-3
40-63
MAINTENANCE
STANDARD
BUCKET LINKAGE
BUCKET LINKAGE
20 II
20 18
I!
SJWO4902
40-64
WA1 200-3
MAINTENANCE
STANDARD
BUCKET LINKAGE
e d b I7 c-c c
A-A
B-0
d d d 14
D-D
e b b
E-E
F-F
d b
13 G-G a
b la
I2
H-H
b
J-J
SJWO4903
WA1 200-3
40-65
MAINTENANCE
STANDARD
BUCKET LINKAGE
Unit:
mm
No.
Check
item
Criteria
Remedy
Clearance between bushing each end of bucket link
and pin at
180
-0.043 -0.106 -0.050 -0.122 -0.056 -0.137 -0.043 -0.106 -0.043 -0.106 -0.052 -0.122 -0.050 -0.122 -0.050 -0.122 of pin
+0.401 +0.309 +0.519 +0.421 +0.605 +0.493 +0.401 +0.309 +0.401 +0.309 +0.519 +0.421 +0.519 +0.421 +0.519 +0.421 Width
0.352 0.507 0.471 0.641 0.549 0.742 0.352 0.507 0.352 0.507 0.471 0.641 0.471 0.641 0.471 0.641 of collar b Width
1.0
andbucket pin at Clearance boom and connecting between parts of bushing and pin at Clearance between boom and frame connecting parts of bushing Clearance betweenbushingand pin at connecting parts of bucketcylinder rod and bellcrank Clearancebstwas~ bushing and pin at connecting parts of bucket cylinder bottom and frame Clearance between bushing and pin at connecting parts of bellcrank and boom
240
1.0 Replace (Replace when pin has scuff mark, too)
3 4 5
280 180 180
1.0 1.0
1.0 1.0 1.0
240
Clearance betweenbushingand pin at connecting parts of boom cylinder bottom and frame Clearance between bushing and pin at connecting parts of boom cylinder rod and boom
240
240 Length
1.0 of color
C
Connecting parts of bucket cylinder and bellcrank 393 20.3 IO Connecting parts of boom and frame
Width of bushing a 209.5 t 0.1
91.3 f 0.1
91.3 f 0.1
I
I
655 2 0.3
304.5
+ 0.1
174.7+0.1-
II I2
Connecting Connecting bucket
parts of boom parts of bucket
and bucket link and
594 -c 0.3
349.4 t 0.1
121.8 + 0.1
121.8 f 0.1
461 f 0.3
259.5 f 0.1
91.3 + 0.1
109.3 f 0.1
I3 I4
Connecting bucket link Connecting and frame
parts of bellcrank parts of boom parts
and
443 f 0.3
259.5
f 0.1
91.3 * 0.1
91.3 f 0.1
If clearance ofd+e becomes 2.5 mm, replace bushing and collar.
cylinder and I
580.5 * 0.3
274.4 + 0.1
121.8 + 0.1
183.3 + 0.1
I5 I6
Connecting boom Connecting and frame
of bellcrank
594 * 0.3
349.4 * 0.1
121.8 + 0.1
121.8 * 0.1
parts of bucket cylinder
411 * 0.3
209.5 + 0.1
109.3 + 0.1
91.3 + 0.1
,7
Connecting cylinder
parts of boom
and boom
479 f 0.3
274.4 + 0.1
101.8 * 0.1
101.8 + 0.1
Standard I8 Wear of bucket tooth 504 Ig Wear of wear plate
size
Repair
limit
340
I
I
I
I
70
I
I
12
Replace
20
Wear of edge protector
189
40
21
Wear of side edge protector
83
30
WA1 200-3
90
OTHERS
Transmission hydraulic circuit diagram ................................................... Brake circuit diagram .................................................................................. Work euipment hydraulic circuit diagram (l/2) ....................................... Work euipment hydraulic circuit diagram (2/2) ....................................... Electrical circuit diagram (I/i) ................................................................... Electrical circuit diagram (2/i) ................................................................... Electrical circuit diagram (3/i) ................................................................... Electrical circuit diagram (4i7) ................................................................... Electrical circuit diagram (5/7) ................................................................... Electrical circuit diagram (6/7) ................................................................... Electrical circuit diagram (7/7) ...................................................................
90- 2 90- 4 90- 7 90- 9 90-I 1 90-13 90-15 90-17 90-19 90-21 90-23
WA1 200-3
90-l
OTHERS
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
90-2
6
WA1200-3
OTHERS
1. Transmission case 2. Strainer 3. Transmission and torque converter charging pumps 4. Torque converter charging pump 5. Oil filter 6. Main relief valve 7. Torque converter relief valve 8. Torque converter 9. Torque converter regulator valve 10. Oil cooler 11. Transmission lubricating circuit 12. Transfer lubricating circuit 13. PTO and input transfer lubricating circuits 14. Modulated clutch lubricating circuit 15. Lubricating oil relief valve 16. Brake circuit (see brake circuit diagram) 17. Parking brake pilot lamp switch 18. Parking brake (Builtin transmission) 19. Clutch No. 1 (Reverse) ECMV 20. Clutch No. 1 (Reverse) by-pass fill valve and by-pass drain valve 21. Clutch No. 1 (Reverse) 22. Clutch No. 2 (Forward) ECMV 23. Clutch No. 2 (Forward) by-pass fill valve 24. Clutch No. 2 (Forward) 25. Clutch No. 3 (3rd speed) ECMV 26. Clutch No. 3 (3rd speed) 27. Clutch No. 4 (2nd speed) ECMV 28. Clutch No. 4 (2nd speed) 29. Clutch No. 5 (1st speed) ECMV 30. Clutch No. 5 (1st speed) by-pass fill valve 31. Clutch No. 5 (1st speed) 32. Pilot oil filter 33. Modulated clutch ECMV 34. Modulated clutch 35. Transmission control valve oil temperature sensor a. From parking brake emergency actuation valve port A b. To parking brake solenoid valve port P c. From parking brake solenoid valve port T
WA1200-3
90-3
6
OTHERS
BRAKE CIRCUIT DIAGRAM
90-4
6
WA1200-3
OTHERS
1. Torque converter, transmission, brake cooling and brake pump 1A. Torque converter pump 1B. Transmission pump 1C. Brake cooling pump 1D. Brake pump 2. Strainer 3. Accumulator charge valve 3A. Safety relief valve 3B. Relief valve 3C. Strainer 4. Check valve 5. Low pressure sensor 6. Rear brake accumulator 7. Front brake accumulator 8. Emergency brake switch 9. Brake valve (left) 10. Transmission cut-off switch 11. Brake valve (right) 12. Stop lamp switch 13. Rear slack adjuster 14. Front slack adjuster 15. Parking brake solenoid valve 16. Parking brake switch 17. Parking brake (Built in transmission) 18. Parking brake pilot lamp switch 19. Brake oil tank 20. Parking brake emergency actuation valve 21. Transmission (see transmission hydraulic circuit diagram) A. From transmission main circuit
WA1200-3
90-5
6
ELECTRIC CIRCUIT DIAGRAM (1/7)
WA1200-3
90-11
(7)
90-13
(7)
WA1200-3
90-15
(7)
WA1200-3
90-17
(7)
WA1200-3
90-19
(7)
WA1200-3
90-21
(7)
WA1200-3
90-23
(7)
DataKom Publishing Corporation

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03 WA1200-3 Shop Manual

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SEBM018209

SERIAL NO. 50001 and up

2004 1 All Rights Reserved Printed in Japan 10-04(01)

LIST OF REVISED PAGES

Indication Page to be newly added Page to be replaced

Action required Add Replace Discard

Pages having no marks are those previously revised or made additions.

LIST OF REVISED PAGE

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LIST OF REVISED PAGES

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LIST OF REVISED PAGES

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30-086-1 (9) 30-086-2 (9) 30-087 30-088 (5) (5)

30-088-1 (5) 30-089 30-090 (5) (5)

90- 1 90- 2 90- 3 90- 4 90- 5 (6) (6) (6) (6)

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

2) Sling wire ropes from the middle portion of the hook.

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

50 g Adhesive: 1 kg Hardening agent: 500 g 250 g 75 g

LT-3 Adhesives LT-4 Holtz MH 705 Three bond 1735

790-129-9060 (Set of adhesive and hardening agent) 790-129-9040 790-126-9120

Polyethylene container Tube Polyethylene container

Aron-alpha 201 Loctite 648-50 LG-1

Polyethylene container Polyethylene container Tube

LG-6 Gasket sealant LG-7

Three bond 1211 Three bond 1207B

Komatsu code LM-G

Part No. 09940-00051

Molybdenum disulphide lubricant

400 g 10 Bellows type 400 g 20 Bellows type 16 kg Can

Used for heavy load portion

Glass container Glass container

Polyethylene container Polyethylene container Polyethylene container

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

kgm 2.5 0.5 52 82 14 3 18 3 20 5 25 5 30 5

STANDARD TIGHTENING TORQUE

Width across flat mm 14 17 22 Nm 59 74 98 123 235 285

Tightening torque kgm 6 7.5 10 12.5 23.5 29.5